720470Development of novel PU binder and processing plant technology for use in PU foam recyclingClosedGRD Development of PrototypeInnovate UKFlexible polyurethane (PU) foam is used extensively in the manufacture of durable goods (e.g. vehicles & furniture). Despite continuous improvements in production methods, up to 20% of all PU foam becomes scrap after cutting and shaping. Additionally, once products such as mattresses and chairs reach their end-of-life stage, the disposal of the PU foam content must be addressed. Rebonded PU foam carpet underlay is one highly successful product developed to deal with waste foam. Although the benefits of recycled foam are numerous, the recycling process itself is slow, lengthy and requires significant energy input due to the use of steam, a necessary component of the binding process. Currently the production of underlay from waste foam involves bonding the foam “chippings” into large blocks with PU binders, using a steam curing process. The use of steam in the processing of recycled PU foam has many disadvantages. Generating steam is extremely expensive and non-environmentally friendly. Furthermore, the foam blocks produced have a high moisture content meaning they must be dried for up to 3-4 days in large storage sheds before slitting. Pollutants trapped within the steam can also escape into the environment during evaporation. The Foam-Bind project proposes to transfer and develop technology used in the rubber recycling industry and apply it to PU foam recycling applications in order to eliminate the need for steam and thereby address the issues outlined above. Rosehill Polymers (RP) has already undertaken successful laboratory developmental work for the binding agent. We plan to further develop the specialist polyurethane (PU) binder and also the dosing/mixing plant required to apply the binder to the chip foam.