Cross-linked polyurethane (PU) is generally used for thermosetting foam applications and is typically only recycled by mechanically down cycling. Methods to reprocess PU foam waste, such as foams used in furniture applications, have not been developed. We demonstrate that diffusing dibutyltin dilaurate (DBTDL) as a Lewis acid catalyst into PU waste induces malleability in cross-linked PU foams and films by catalyzing dynamic carbamate exchange. Model and commercial PU foams can be continuously reprocessed using corotating twin screw extrusion to remove gaseous filler, which produces PU filaments or films with elastomeric or rigid thermosetting mechanical properties respectively. PU materials maintain their cross-link density and tensile strengths while also fundamentally changing material morphology from foam to film by removal of air. We envision that these studies will enable the bulk reprocessing of commercial thermosetting PU foaming materials and inspire development of bulk reprocessing methods for other thermosetting systems using dynamic covalent chemistry.

Recycling cross-linked polyurethane foam using twin screw extrusion

Macromolecular Chemistry: The Second Century

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ACS Spring 2020 National Meeting & Expo

The official archive and repository for all ACS Meetings & Expositions abstracts and select posters or presentations.