Advances in Low-Density Flexible Polyurethane Foams by Optimized Incorporation of High Amount of Recycled Polyol

Study of Aerogel-Modified Recycled Polyurethane Nanocomposites

In this study, a liquid regenerated polyether polyol was obtained after the degradation of waste PU foam by the two-component decrosslinker agents ethylene glycol and ethanolamine. The regenerated polyol-based polyurethane foam was modified by adding different ratios of SiO2 aerogel through the self-preparation of silica aerogel (SiO2 aerogel) to prepare aerogel/regenerated polyurethane foam nanocomposites of SiO2 aerogel-modified regenerated polyurethane composites. A series of analytical tests on self-prepared silica aerogel and aerogel-modified recycled polyurethane foam composites were performed. The analysis of the test results shows that the regenerated rigid PU foam obtained with SiO2 aerogel addition of 0.3% in the polyurethane degradation material has a small density, low thermal conductivity, and higher compressive strength; hence, the prepared silica aerogel-regenerated polyol-based polyurethane nanocomposite has good thermal insulation and strength support properties. The clean, low-carbon, and high-value utilization of recycled waste polyurethane was achieved.

Chemical Recycling of Flexible Polyurethane Foams by Aminolysis to Recover High-Quality Polyols

Polyurethane foams (PUFs) are widely used commodity materials, but most of them end up in landfills at the end of their life, which is not in line with the circular economy approach. Here, we introduce microwave-assisted aminolysis with amine reagents that contain primary and tertiary amino groups in the structure. These reagents enable complete degradation of the urethane groups in the structure of the flexible PUFs with a much lower amount of degradation reagent than is typically required for solvolysis reactions. The purified, recovered polyols are close equivalents to the corresponding virgin polyols in terms of their structural and molar mass characteristics. Therefore, they can be used for the production of high-quality PUFs without having to adapt the synthesis process. The flexible PUFs made from recovered polyols have comparable mechanical properties to those made from virgin polyols.

Study on Efficient Degradation of Waste PU Foam

In this paper, the high-efficiency degradation and alcoholysis recovery of waste polyurethane foam were realized using a combination of a high-efficiency alkali metal catalyst (CsOH) and two-component mixed alcoholysis agents (glycerol and butanediol) in different proportions, using recycled polyether polyol and one-step foaming to prepare regenerated thermosetting polyurethane hard foam. The foaming agent and catalyst were adjusted experimentally to prepare regenerated polyurethane foam, and a series of tests were conducted on the viscosity, GPC, hydroxyl value, infrared spectrum, foaming time, apparent density, compressive strength, and other properties of the degradation products of the regenerated thermosetting polyurethane rigid foam. The resulting data were analyzed, and the following conclusions were drawn: The optimal conditions of alcoholysis were obtained when the mass ratio of glycerol to butanediol was 3:2, the amount of cesium hydroxide was 0.08%, the reaction temperature was 170 °C, and the reaction time was 2.5 h. Regenerated polyurethane foam with an apparent density of 34.1 kg/m³ and a compressive strength of 0.301 MPa was prepared under these conditions. It had good thermal stability, complete sample pores, and a strong skeleton. At this time, these are the best reaction conditions for the alcoholysis of waste polyurethane foam, and the regenerated polyurethane foam meets various national standards.

Determination of End-Group Functionality of Propylene Oxide-Based Polyether Polyols Recovered from Polyurethane Foams by Chemical Recycling

Chemical recycling of polyurethane foams (PUFs) leads to partially aromatic, amino-functionalized polyol chains when the urethane groups in the PUF structure are incompletely degraded. Since the reactivity of amino and hydroxyl groups with isocyanate groups is significantly different, information on the type of the end-group functionality of recycled polyols is important to adjust the catalyst system accordingly to produce PUFs from recycled polyols of suitable quality. Therefore, we present here a liquid adsorption chromatography (LAC) method using a SHARC 1 column that separates polyol chains according to their end-group functionality based on their ability to form hydrogen bonds with the stationary phase. To correlate end-group functionality of recycled polyol with chain size, LAC was coupled with size-exclusion chromatography (SEC) to form a two-dimensional liquid chromatography system. For accurate identification of peaks in LAC chromatograms, the results were correlated with those obtained by characterization of recycled polyols using nuclear magnetic resonance, matrix-assisted laser desorption/ionization time-of-flight mass spectrometry, and SEC coupled with a multi-detection system. The developed method allows the quantification of fully hydroxyl-functionalized chains in recycled polyols using an evaporative light scattering detector and appropriate calibration curve.

Insight into Chemical Recycling of Flexible Polyurethane Foams by Acidolysis

Acidolysis is emerging as a promising method for recycling polyurethane foam (PUF) waste. Here, we present highly efficient acidolysis of PUFs with adipic acid (AA) by heating the reaction mixtures with microwaves. The influence of experimental conditions, such as reaction temperature, time, and amount of the degradation reagent, on the polyol functionality, molecular weight characteristics, the presence of side products, and the degree of degradation of the remaining PUF hard segments was studied by matrix-assisted laser desorption/ionization time-of-flight mass spectroscopy (MALDI-TOF MS), nuclear magnetic resonance (NMR), size-exclusion chromatography (SEC) coupled to a multidetection system, and Fourier transform infrared (FT-IR) spectroscopy. The purified recycled polyols were used for the synthesis of flexible PUFs. The morphology and mechanical properties of the PUFs show that the degree of functionalization of the polyol by the carboxylic end groups, which is higher for larger amounts of AA used to degrade the PUFs, significantly affects the quality and performance of the flexible PUFs from the recycled polyols.

Reactivity of multi-arm polyols towards isocyanates

In this research, the kinetics of the reaction of various polymer polyol crosslinking agents with phenyl isocyanate is reported.

A Brief Introduction to the Polyurethanes According to the Principles of Green Chemistry

Polyurethanes are most often called “green” when they contain natural, renewable additives in their network or chemical structure, such as mono- and polysaccharides, oils (mainly vegetable oils), polyphenols (e.g., lignins, tannins), or various compounds derived from agro-waste white biotechnology (Principle 7). This usually results in these polyurethanes obtained from less hazardous substrates (Principle 4). Appropriate modification of polyurethanes makes them susceptible to degradation, and the use of appropriate processes allows for their recycling (Principle 10). However, this fulfilment of other principles also predisposes them to be green. As in the production of other polymer materials, the synthesis of polyurethanes is carried out with the use of catalysts (such as biocatalysts) (Principle 9) with full control of the course of the reaction (Principle 11), which allows maximization of the atomic economy (Principle 2) and an increase in energy efficiency (Principle 6) while minimizing the risk of production waste (Principle 1). Moreover, traditional substrates in the synthesis of polyurethanes can be replaced with less toxic ones (e.g., in non-isocyanate polyurethanes), which, at the same time, leads to a non-toxic product (Principle 3, Principle 5). In general, there is no need for blocking compounds to provide intermediates in the synthesis of polyurethanes (Principle 8). Reasonable storage of substrates, their transport, and the synthesis of polyurethanes guarantee the safety and the prevention of uncontrolled reactions (Principle 12). This publication is a summary of the achievements of scientists and technologists who are constantly working to create ideal polyurethanes that do not pollute the environment, and their synthesis and use are consistent with the principles of sustainable economy.