Microcellular Polyurethane Flexible Foam Performance Benefits Using Closed-Loop Recycled Content Polyol

Transcription

1 Microcellular Polyurethane Flexible Foam Performance Benefits Using Closed-Loop Recycled Content Polyol Michael E. Brooks, Ph.D. Cody W. Shepperd Greg C. Hunt, MBA Emery leochemicals LLC Cincinnati, hio

2 Introduction Recycled content polyols are of interest due to polyurethane wastes that can be generated by foam manufacturing and fabrication. Production and fabrication of technical foam grades can have yield losses greater than 50% depending upon the application. The primary method for recycling polyurethane scrap foam is rebonding (e.g. carpet underlayment). Not all scrap foam is amenable to rebond applications resulting in a significant amount of polyurethane being landfilled every year. Page 2 2

3 Chemical Recycling: Aminolysis Chemical recycling of scrap polyurethane has been investigated over several decades. ne of these recycling processes is Aminolysis: R H N R' + R R" R" NH N N + R' H 2 H H Amines Ureas Polyol Depolymerization with ammonia or amines to yield ureas and polyols Page 3 3

4 Chemical Recycling: Acidolysis Another chemical recycling process is Acidolysis: R H N R' + H " R H R" = alkyl or alkenyl H H N N + R R R + + R - - " R' H RN N N H 3 2 H H Amine Salts Amides Polyols Ureas R Depolymerization with inorganic or organic acids to yield amides, amine salts, ureas, and polyols Page 4 4

5 Chemical Recycling: Glycolysis Another chemical recycling process is Glycolysis: R H N R' + H R" H Glycol, R" = alkyl, alkyl ether H N R RNH 2 + R + R'(H) n + R N H Amines Amides Polyols Ureas N H R Depolymerization with glycols yielding amides, ureas, and polyols Page 5 5

6 Chemical Recycling Historically, chemical recycling has been challenged with multiphase products where the soft and hard segments tended to separate. A secondary issue has been polyol product variability which can be caused by variable scrap foam sources. INFIGREEN chemical recycling is designed to address these and other concerns. Page 6 6

7 Recycled Content Polyols Emery leochemicals INFIGREEN technology utilizes glycolysis, but includes a second step to rebuild the recycled content polyol for the target application. Issues of variability and formulation changes are minimized since the foam producer s materials are returned back to them via closed-loop processing. Page 7 7

8 Collaboration Rubberlite Inc. and Emery leochemicals LLC partnered to develop a closed-loop INFIGREEN recycled content polyol for one of Rubberlite s Visco-cel foam formulations. Rubberlite provided Emery leochemicals with several scrap foam samples for glycolysis investigations and both companies reviewed the results and agreed upon the polyol composition specifications (hydroxyl value, acid value, moisture, viscosity, etc.). Page 8 8

9 Closed-Loop Recycled Content Polyol Development Process Page 9 9

10 Collaborative Development & Corresponding Production Trials Initial bench experiments indicated a closed-loop INFIGREEN recycled content polyol provided a workable and predictable system. Rubberlite s laboratory data suggested adding recycled material may actually boost some microcellular foam performance properties. Therefore, a series of production trials were conducted at Rubberlite s manufacturing facility to: Evaluate process responses and levels of closed-loop INFIGREEN recycled content polyol Assess resultant microcellular foam physical properties Page 10 10

11 Rubberlite Production Trial Processing Notes Initial microcellular foam processing results with 2% and 5% closedloop INFIGREEN recycled content polyol supplement: Initial minor formulation adjustments Shows potential for reduced catalyst demand Indications observed for better foam cell opening Indications for reduced foam shrinkage are also observed Page 11 11

12 Rubberlite Production Trials Foam Density Page 12 12

13 Rubberlite Production Trials Indentation Force 25%/65% Page 13 13

14 Rubberlite Production Trials Rate Sensitivity Page 14 14

15 Rubberlite Production Trials Resiliency Page 15 15

16 Rubberlite Production Trials Tensile Strength Page 16 16

17 Rubberlite Production Trials Tear Strength Page 17 17

18 Rubberlite Production Trials Elongation Page 18 18

19 Rubberlite Production Trials Microcellular Foam Structures Visco-cel Visco-cel with closed-loop INFIGREEN recycled content polyol Page 19 19

20 Conclusions Through industry collaboration, Rubberlite and Emery leochemicals have demonstrated that a closed-loop INFIGREEN recycled content polyol can be successfully reintroduced into a flexible foam pouring process. Additionally, empirical data suggests performance enhancements may be realized for foam processing and finished properties: Reduced catalyst requirements and better cell opening Increased microcellular foam surface firmness and increased tensile / tear strength Page 20 20

21 Acknowledgements Jamie Durham Technical Director, Polyurethanes at Rubberlite Inc. Jeff Goad Vice President of Technology at Rubberlite Inc. Rubberlite manufactures several types and a multitude of engineered foam solutions under the trademarks HyPUR-cel and Visco-cel. Their Visco-cel product line features slow recovery visco-elastic (memory) performance microcellular polyurethane flexible foam for mattress pads, wheelchair seating, footwear, and many more pressure distribution or shock-attenuation applications. Page 21 21

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