Method for recycling polymeric material from vehicle shredder residue

Abstract

A method for recycling polymeric material selected from the group consisting of polyurethane, polyurethane urea, polyisocyanurate and mixtures of two or more thereof, the method comprising the steps of: (a) providing a shredded material obtained by shredding a vehicle, and / or shredding a vehicle and obtaining a shredded material, the shredded material comprising one or more foamed pieces made of polymeric material; (b) performing a first sorting step for selecting target foamed pieces comprising polymeric material from the shredded material; (c) subjecting the target foamed pieces to a mechanical treatment to obtain target foamed flakes having a maximum dimension of less than 120 mm, wherein the first sorting step comprises a sorting step using one or more of optical sorting methods to sort the target foamed pieces based on the type of isocyanate and / or the type of polyol used to produce the target foamed pieces.

Description

Technical Field

[0001] The present invention relates to a method for recycling polymeric materials from shredded material obtained by a crushing vehicle, the polymeric material being selected from the group consisting of polyurethane, polyurethane urea, polyisocyanurate, and mixtures of two or more thereof. Background Technology

[0002] Solid waste disposal presents significant challenges both now and in the future. Since ongoing landfilling is not a sustainable solution, alternatives such as solid waste sorting and recycling systems are being developed.

[0003] In the field of plastic foam recycling, one option is mechanical recycling. In mechanical recycling, foam sheets are typically mixed with a binder, and the mixture is steamed and pressed, for example, in a roller press, a process that is antibacterial and activates the binder. After the pressed cylinders dry, they can be peeled to the desired thickness. The rolls are eventually cut to specific dimensions to become recycled foam products, such as fall-absorbing plates or sound or heat insulation materials.

[0004] Currently, innovative alternatives to mechanical recycling processes are being developed and deployed, which are categorized as chemical recycling. These processes aim to depolymerize plastic foam to obtain components from which polymers have been produced. For example, polystyrene foam (PS foam) can be depolymerized to obtain the monomer styrene. As another example, polyurethane foam (PU foam) can be depolymerized to obtain polyols and aromatic amines (such as TDA or MDA) for use in the production of corresponding aromatic diisocyanates (such as TDI or MDI).

[0005] Polyurethane (PU) is one of the most important materials in a broad and diverse family of polymers and plastics. It can be solid or have an open-cell structure. In this case, it is called foam. Foam can further be soft or rigid. Polyurethane is typically manufactured by reacting polyols and diisocyanates, both of which are derived from crude oil. A series of additives are then added to produce high-quality PU foam products. The nature of the additives depends on the application the foam will be used for, which in particular includes bedding, furniture, and automobiles.

[0006] Products containing polyurethane materials are widely used in industrial and everyday applications. Due to the immense and ever-increasing prevalence of polyurethane materials, a significant amount of polyurethane waste exists, such as from old mattresses, furniture, insulation panels, building materials, or vehicle interior parts like car seats. This polyurethane waste should be used appropriately and as eco-friendly as possible. One way to utilize polyurethane materials in this way is by recycling raw materials from polyurethane.

[0007] Aside from household waste, the disposal of end-of-life or scrapped vehicles is of particular concern, as millions of passenger cars, trucks, and buses continue to age or become unusable. To recycle many components from such vehicles, shredders have been designed that mechanically tear the vehicles apart and separate them into two products: metal scrap and automotive shredder residue (ASR). The metal scrap is transported to metal reprocessing centers, while the ASR material is sent to landfills or landfills. However, given that automobiles are designed to reduce the amount of metallic components and increase the amount of non-metallic components, it is desirable to develop systems for sorting and recycling as many reusable components as possible from the ASR material.

[0008] The recycling of automotive waste (ASR) faces several challenges that hinder its efficient and effective recycling. ASR is typically a complex mixture of materials, including metals, plastics, rubber, glass, and various organic and inorganic compounds. This diverse composition makes it difficult to separate and recycle the individual components, resulting in suboptimal recycling rates. Without proper separation, valuable resources remain trapped within the ASR, limiting its recycling potential. Addressing these issues is crucial for improving the recycling of ASR and maximizing its potential as a valuable resource. Developing efficient methods and systems that can effectively separate and recycle the multiple components of ASR while safely managing and disposing of hazardous materials will play a vital role in promoting sustainability and the circular economy.

[0009] Several ASR sorting and recycling systems have been developed. For example, document EP 0692356 A2 suggests recycling automotive debris by preparing composite materials containing ASR and virgin polymers.

[0010] Vijayan, SK; Kibria, MA; Uddin, MH; Bhattacharya, S. “Pretreatment of Automotive Shredder Residues, Their Chemical Characterization, and Pyrolysis Kinetics.” Sustainability 2021, 13, 10549. The study recommends recycling automotive shredder residues through pyrolysis.

[0011] Ezzat El Halabi, Mike Third, and Matthew Doolan, “Machine-based disismantling of end-of-life vehicles: A life cycle perspective,” Procedia, 29 (2015) 651-655, recommend recycling automotive shredder residues through machine-based dismantling.

[0012] Juliana Argente Caetano, Valdir Schalch, Javier Mazariegos Pablos, “Characterization and recycling of the fine fraction of automotive shredder residue (ASR) for concrete paving blocks production”, Clean Technologies and Environmental Policy (2020) 22:835-847, recommends recycling ASR by solidifying it with cement, gravel, and sand used in paving block production.

[0013] Won-Seok Yang et al., “Utilization of automobile shredder residue (ASR) as a reducing agent for the recovery of black copper”, Korean J. Chem. Eng., 33(4), 1267-1277 (2016), suggested recycling ASR by using it instead of lump coal as a reducing agent in copper production.

[0014] Document US 8,985,487 B2 discloses an apparatus for selectively separating polyurethane foam and fibers from automotive debris. The apparatus comprises three main separators: the first separator primarily separates fine particles (like dirt and glass) from larger polyurethane foam and fibers, using a combination of vibration and magnetic separation to remove fine particles and metals, while a rake-shaped fiber separator processes the larger polyurethane foam and fibers. The second separator employs a grinder to further process the remaining material. The third separator utilizes a roller fiber separator, along with airflow and mesh separators, to sort the material based on size and weight, thereby separating medium-sized polyurethane foam and fibers from plastics, rubber, and other materials.

[0015] Document JP 2003-236837 A discloses a method for recycling shredded materials from end-of-life vehicles by dismantling and shredding them to remove hazardous and valuable materials, and by subjecting the resulting shredded material to a series of processing steps. The method includes various stages of separation processing utilizing the material's resilience and specific gravity differences. The recycled foamed plastic is then shredded, mixed with thermoplastic resin, and granulated for use as a raw material in blast furnaces.

[0016] However, an improved system is still needed where waste can be processed into usable products. Compared to treatment methods used for other (non-foam) recyclable materials, foam presents unique challenges due to its low density and large size, making efficient treatment essential for economic success.

[0017] The purpose of this invention is to provide an optimized method for obtaining target foam sheets from waste, which enables a reduction in overall recycling costs and, particularly in the case of chemical recycling, produces higher yields and higher product quality.

[0018] According to the invention, these tasks are accomplished by the method for recycling polymer materials as described in claim 1. Advantageous variations of the method are presented in the dependent claims. Summary of the Invention

[0019] As used herein, the terms “have,” “include,” or “contain,” or any of their grammatical variations, are used in a non-exclusive manner. Thus, these terms can refer either to a situation where no other features exist in the entity described in the context besides those introduced by these terms, or to a situation where one or more other features exist. For example, the statements “A has B,” “A includes B,” and “A contains B” can refer either to a situation where no other elements exist in A besides B (i.e., A consists solely of B), or to a situation where entity A contains one or more other elements besides B (such as element C, elements C and D, or other elements).

[0020] Furthermore, it should be noted that the terms "at least one," "one or more," or similar expressions indicating a feature or element may appear once or more, but are typically used only once when the corresponding feature or element is introduced. In most cases, the expressions "at least one" or "one or more" are not repeated when referring to the corresponding feature or element, but in fact, the corresponding feature or element may appear once or more.

[0021] Furthermore, as used herein, the terms “preferredly,” “more preferably,” “particularly,” “more particularly,” “specifically,” “more specifically,” or similar terms are used in combination with optional features without limiting the possibility of alternatives. Therefore, the features introduced by these terms are optional features and are not intended to limit the scope of the claims in any way. As those skilled in the art will recognize, the invention can be carried out by using alternative features. Similarly, features introduced by phrases such as “in embodiments of the invention” are intended to be optional features and do not limit any alternative embodiments of the invention, nor the scope of the invention, nor the possibility of combining features introduced in this way with other optional or non-optional features of the invention.

[0022] In a first aspect of the invention, a method for recycling a polymer material selected from the group consisting of polyurethane, polyurethane urea, polyisocyanurate, and mixtures of two or more thereof is disclosed. The method includes the following steps:

[0023] a) Providing scrap material obtained by a crushing vehicle, and / or crushing vehicle and obtaining scrap material, the scrap material comprising one or more foam sheets made of polymeric material;

[0024] b) Perform a first sorting step to select target foam sheets containing polymer materials from the scrap;

[0025] c) subject the target foam sheet to mechanical processing to obtain a target foam sheet with a maximum size of less than 120 mm, preferably less than 90 mm, and more preferably less than 70 mm.

[0026] The first sorting step includes a sorting step that uses one or more optical sorting methods to sort the target foam sheets based on the type of isocyanate used to produce the target foam sheets, the type of polyol, or both the type of isocyanate and the type of polyol.

[0027] It has been found that sorting and subsequently pulverizing the shredded foam sheets obtained from a crushing vehicle for target foam sheets containing polymer materials enables the collection of more uniform target foam sheets, which are easier to handle during the recycling process and transportation. The shredded material comprises one or more, preferably multiple, pulverized foam sheets that are processed in the first sorting step to remove unwanted material unsuitable for the intended recycling process. Those unselected foam sheets are separated and no longer participate in the pre-processing methods of the first aspect, and the associated transportation costs are reduced, especially when transportation involves transporting the target foam sheets from the material recycling facility to another recycling plant by truck, rail, air, or sea. Furthermore, the more uniform size distribution of the target foam sheets improves the efficiency of subsequent chemical recycling processes and thus results in lower overall recycling costs.

[0028] Foam (also known as expanded polystyrene) is a synthetic resin that has been converted into a sponge-like substance with a closed-cell or open-cell structure, either of which can be soft or rigid. Foams are used in a wide variety of products, including cushioning materials, air filters, furniture, toys, thermal insulation materials, sponges, plastic boats, building panels, lightweight beams, and many automotive applications. Almost every thermosetting or thermoplastic resin can be converted into foam under suitable conditions. Commonly foamed plastics include vinyl plastics, polystyrene, polyethylene, phenolic plastics, silicone, cellulose acetate, and urethanes such as polyurethane (PU). PU foam is typically used in the manufacture of mattresses and padding. Different types of PU foam include, for example, standard PU foam, high-elasticity PU foam, viscoelastic PU foam, etc. Depending on foam parameters such as density, elasticity, or chemical composition, PU foam can be obtained, for example and not limited to, charcoal foam, quick-drying foam, high-density foam, lux foam (evlon foam), latex-rubber foam, rebonded foam, etc., all of which are open-cell polyurethane foams.

[0029] In the following sections, embodiments of the method of the first aspect of the present invention will be disclosed.

[0030] In the first step, a shredded material obtained by a crushing vehicle is provided, the shredded material comprising one or more foam sheets made of a polymeric material selected from the group consisting of polyurethane, polyurethane urea, polyisocyanurate, and mixtures of two or more thereof.

[0031] Typically, polyurethane foam is produced through a reaction between a polyisocyanate component and a polyol component. Additional materials, particularly additives, such as flame retardants (e.g., phosphorus-based), polymerization catalysts (e.g., tertiary amines), fillers, and surfactants like siloxanes, can be added during the polymer production process.

[0032] The properties of polyurethane foam are influenced by the chemical properties of the polyisocyanate and polyol components used, as well as the formulation applied during polymerization. For example, starting materials can affect the crosslinking density of the polymer in a three-dimensional network. Rigid polyurethanes are typically obtained from monomers with relatively low molecular weight and high functionality, resulting in a highly crosslinked, dense network.

[0033] Industrially, and therefore extensively, methylene di(phenyl isocyanate) (MDI) or its polymeric form, or toluene 2,4- and 2,6-diisocyanates (TDI), are used as polyisocyanate components for the production of rigid and flexible polyurethane foams. For representative compositions of these PU foams, see, for example, US 9,023,907 B2, WO 2015 / 121057 A1, and WO2013 / 139781 A1.

[0034] The organic polyisocyanates that can be used to prepare polyurethanes are any of the known organic diisocyanates and polyisocyanates, preferably aromatic polyfunctional isocyanates.

[0035] Suitable polyisocyanate components for the production of polyurethanes or polyisocyanates include any of the polyisocyanates known for the production of polyurethanes or polyisocyanates. These include aliphatic, alicyclic, and aromatic bifunctional or polyfunctional isocyanates known from the art, as well as any desired mixtures thereof. Examples are diphenylmethane 2,2'-, 2,4'-, and 4,4'-diisocyanates, mixtures of monomeric diphenylmethane diisocyanates with diphenylmethane diisocyanate homologues (polymer MDI) having a greater number of rings, isophorone diisocyanate (IPDI) and its oligomers, toluene 2,4- and 2,6-diisocyanates (TDI) and mixtures thereof, tetramethylene diisocyanate and its oligomers, hexamethylene diisocyanate (HDI) and its oligomers, naphthylene diisocyanate (NDI), and mixtures thereof.

[0036] Preferably, toluene 2,4- and / or 2,6-diisocyanate (TDI) or mixtures thereof, monomeric diphenylmethane diisocyanate, and / or diphenylmethane diisocyanate homologues having a greater number of rings (polymer MDI), and mixtures thereof. Other possible isocyanates are mentioned, for example, in “Kunststoffhandbuch [Plastics handbook], Volume 7, Polyurethane [Polyure-thanes]”, Carl Hanser Verlag, 3rd edition, 1993, Chapters 3.2 and 3.3.2.

[0037] Organic diisocyanates and polyisocyanates can be used alone or in mixtures.

[0038] Commonly used polyols include those selected from the group consisting of: polyether polyols, polyester polyols, polyether ester polyols, and mixtures thereof.

[0039] Polyether alcohols are produced, for example, from epoxides (e.g., propylene oxide and / or ethylene oxide) or from tetrahydrofuran with a starting compound exhibiting hydrogen activity, such as fatty alcohols, phenols, amines, carboxylic acids, water, or compounds based on natural substances (e.g., sucrose, sorbitol, or mannitol), in the presence of a catalyst. Basic catalysts and bimetallic cyanide catalysts may be mentioned herein, as exemplified by those described in WO 2006 / 034800 A1, EP 0090444 A1, or WO 2005 / 090440 A1.

[0040] Polyester alcohols, for example, are produced from aliphatic or aromatic dicarboxylic acids and polyols, polysulfide polyols, polyesteramides, hydroxylated polyacetals and / or hydroxylated aliphatic polycarbonates, preferably in the presence of an esterification catalyst. Other possible polyols are mentioned, for example, in "Kunststoffhandbuch [Plastics handbook], Volume 7, Polyurethane [Polyurethanes]", Karl Hansel, 3rd edition, 1993, Chapter 3.1.

[0041] The first sorting step includes a sorting step that sorts the target foam sheets based on the type of isocyanate used to produce the target foam sheets, the type of polyol, or both the type of isocyanate and the type of polyol. In an embodiment, the first sorting step includes a pre-sorting step to remove non-plastic contaminants from the scrap.

[0042] Preferably, in the pre-sorting step, solid parts such as metal or wooden parts are removed, thereby reducing the amount of pulverized material to be processed in further processing. Separation may include suitable methods, such as visual or tactile assessment, sorting by color, pore size distribution, elasticity, or using spectroscopic methods (such as NIR methods).

[0043] The sorting step, which involves separating the target foam sheet based on the type of isocyanate and / or polyol used in its production, may include suitable methods, such as spectroscopic methods. Furthermore, sorting may include additional separation steps, such as removing foam material containing large amounts of additives or grafted polyols.

[0044] For example, the method may include a sorting step based on optical methods (such as NIR spectroscopy). In this method, optical sorting may be used, for example, to determine the grafted polyol content of the polyurethane foam. Preferably, the method may further include a step of adjusting the grafted polyol content of the mixture within a predetermined range, for example, separating foams having less than 5% grafted polyol content by weight from foams having more than 5% grafted polyol content by weight, or further separating foams having a grafted polyol content in the range of 5% to 10% by weight from foams having more than 10% grafted polyol content by weight. Furthermore, the sorting may be based on the content of additives (such as flame retardants) or the chemical properties of isocyanates present in the polyurethane material.

[0045] In an embodiment, the method further includes a second sorting step for removing impurities from the target foam sheet to obtain a purified target foam sheet.

[0046] The second sorting step may include sieving or separation by density ratio, i.e., separation by air, liquid, or magnetic force. Optionally, the fragments may also undergo processes to remove impurities (such as paper labels, metal parts, or wooden parts). Suitable methods include, for example, spectroscopic methods, such as NIR spectroscopy.

[0047] In the embodiments, one or more optical sorting methods, particularly one or more optical sorting methods selected from the group consisting of: near-infrared spectroscopy, mid-infrared spectroscopy, UV-VIS spectroscopy, optical camera-based methods, Raman spectroscopy, THz spectroscopy, laser-induced breakdown spectroscopy, and X-ray fluorescence-based methods are used for one or more sorting steps.

[0048] Infrared spectroscopy (IR spectroscopy or vibrational spectroscopy) measures the interaction between infrared radiation and matter through absorption, emission, or reflection. Infrared spectroscopy is used to study and identify chemical substances or functional groups in solid, liquid, or gaseous states. It can be used to characterize new materials or to identify and verify known and unknown samples.

[0049] The infrared portion of the electromagnetic spectrum is typically divided into three regions: near-infrared, mid-infrared, and far-infrared (named according to their relationship to the visible spectrum). The higher energies of the near-IR region (approximately 14,000–4,000 cm⁻¹) further contribute to this spectrum. -1 (0.7-2.5 μm wavelength) can excite overtone or combination modes of molecular vibrations. The mid-infrared (approximately 4,000-400 cm⁻¹) -1 (2.5-25 μm) is commonly used to study fundamental vibrations and associated rotational-vibrational structures. For example, near-infrared spectroscopy (NIRS) is a spectroscopic method that uses the near-infrared region of the electromagnetic spectrum (approximately 700 nm to 2500 nm). Typical applications include medical and physiological diagnostics and quality control. Near-infrared spectroscopy is not a particularly sensitive technique, but it can be very useful for probing dispersed materials with minimal sample preparation. Instruments used for NIRS include sources, detectors, and dispersive elements (such as prisms or, more commonly, diffraction gratings) to allow recording of intensities at different wavelengths. The instrument is very similar to those used for the UV-visible and mid-infrared ranges.

[0050] UV-VIS spectroscopy refers to absorption or reflectance spectroscopy in a portion of the ultraviolet region and the entire adjacent visible region of the electromagnetic spectrum. This method is relatively inexpensive and easy to implement, and is widely used in a variety of applications and fundamental research. The only requirement is that the sample absorbs in the UV-VIS region, i.e., it contains chromophores. Absorption spectroscopy is complementary to fluorescence spectroscopy. Besides the measurement wavelength, parameters of interest are absorbance (A), transmittance (%T), or reflectance (%R), and their changes over time. UV-VIS spectroscopy is routinely used in analytical chemistry for the quantitative determination of a wide variety of analytes or samples, such as transition metal ions, highly conjugated organic compounds, and biomacromolecules.

[0051] Raman spectroscopy is a typical spectroscopic technique used to determine the vibrational modes of molecules, although rotational modes and other low-frequency modes can also be observed. Raman spectroscopy is commonly used in chemistry to provide structural fingerprints, which can be used to identify molecules. Typically, a laser beam illuminates the sample. Electromagnetic radiation from the illuminated point is collected by a lens and transmitted through a monochromator. Elastic scattered radiation (Rayleigh scattering) corresponding to the wavelength of the laser line is filtered out by a notch filter, edge-pass filter, or band-pass filter, while the remaining collected light is dispersed onto a detector.

[0052] Laser-induced breakdown spectroscopy (LAS) is a type of atomic emission spectroscopy that uses high-energy laser pulses as the excitation source. The laser is focused to form a plasma, which atomizes and excites the sample. Plasma formation begins only when the focused laser reaches a certain threshold for optical breakdown, which typically depends on the environment and the target material.

[0053] X-ray fluorescence (XRF) refers to the emission of characteristic "secondary" (or fluorescent) X-rays from materials excited by bombardment with high-energy X-rays or gamma rays. This phenomenon is widely used in elemental and chemical analysis.

[0054] Terahertz spectroscopy uses electromagnetic fields in the frequency range of several hundred gigahertz (THz) to detect and control the properties of matter. In many-body systems, the energy difference between several related states matches the energy of a THz photon. Therefore, THz spectroscopy provides a particularly powerful method for resolving and controlling individual transitions between different many-body states.

[0055] In one embodiment, a handheld near-infrared spectroscopy device is used for the first sorting step. In another embodiment, a handheld near-infrared spectroscopy device is used for the second sorting step.

[0056] In this embodiment, at least one sorting step includes:

[0057] - Perform a first analytical step to determine first composition data of the foam sample being analyzed, which indicates the composition of the foam sample;

[0058] - Perform a second analytical step to determine second compositional data for the same sample foam sheet, which indicates the composition of the sample foam sheet; and

[0059] - When determining the first and second composition data to indicate the polymer material, the sample foam sheet is selected as the target foam sheet.

[0060] Composition data is data indicating the composition of the foam sheet being analyzed. From this data, information about the type of foam material and / or additives contained can be inferred. Based on this information, the suitability of the foam sheet for a predetermined recycling process can be determined, i.e., whether the foam sheet contains polymer materials.

[0061] In this embodiment, different analytical methods are used for a first analytical step to determine first composition data and a second analytical step to determine second composition data. This allows for a better identification or even quantification of the composition of the analyzed foam sheet (i.e., the current sample foam sheet), which is typically impossible when only one analytical method is applied. For example, the first composition data indicates the type of polyurethane foam in the sample foam sheet, and the second composition data indicates the type of additives and / or impurities in the sample foam sheet, particularly the type of additives selected from the group consisting of: water, inorganic fillers, flame retardants, styrene (especially styrene-acrylonitrile), silicone stabilizers, crosslinking agents, chain extenders, monohydric alcohols, antioxidants, defoamers, catalysts, and dyes. Alternatively or additionally, the second composition data may indicate dust, dirt, moisture, microbial contaminants, or fungal contaminants. In another embodiment, the first composition data indicates the type of additives and / or impurities, and the second composition data indicates the type of foam.

[0062] In an embodiment, the method further includes performing at least a third analytical step to determine at least third compositional data indicating the composition of the sample foam sheet, and selecting the sample foam sheet as a target foam sheet when it is determined that all determined compositional data indicate a polymer material. In an alternative embodiment, the sample foam sheet is selected as the target foam sheet when at least a predetermined percentage of the determined compositional data indicates a polymer material. For example, in an exemplary and non-limiting embodiment, four different analytical steps are performed, and the sample foam sheet is selected as the target foam sheet when at least 75%, i.e., three out of the four determined compositional data indicate a polymer material, is selected.

[0063] Alternatively or alternatively, in another embodiment of the method of the first aspect of the invention, the first sorting step, the second sorting step, or both the first sorting step and the second sorting step include:

[0064] - Determine the composition of the sample foam sheet at a first location, thereby obtaining first composition data indicating the composition of the sample foam sheet at the first location;

[0065] - Determine the composition of the sample foam sheet at a non-overlapping second location different from the first location, thereby obtaining second composition data indicating the composition of the sample foam sheet at the second location; and

[0066] - When determining that the compositional data obtained at the first and second positions indicate the polymer material, the sample foam sheet is selected as the target foam sheet.

[0067] This is particularly advantageous in the case of foams with a mixed composition, which includes segments made of polymeric materials and other segments of non-target substances.

[0068] In an embodiment, the method further includes determining corresponding compositional data indicating the composition of a sample foam sheet at three or more distinct non-overlapping locations, and selecting the sample foam sheet as a target foam sheet when at least a predetermined percentage of the determined compositional data indicates polymeric material. For example, in an exemplary and non-limiting development, the sample foam sheet is analyzed at four distinct non-overlapping locations, and the sample foam sheet is selected as a target foam sheet when at least 75%, i.e., three out of the four determined compositional data, indicates polymeric material. In a more preferred development, the sample foam sheet is selected as a target foam sheet when at least 80%, at least 85%, at least 90%, or at least 95% of the determined compositional data indicates polymeric material. In the most preferred development, the sample foam sheet is selected as a target foam sheet when all determined compositional data indicates polymeric material.

[0069] In an embodiment, the mechanical treatment according to step (c) is selected from the group consisting of: grinding, beating, crushing, tearing, and a combination of two or more of these treatments.

[0070] Crushing can be carried out, for example, in a rotary mill or rotary grinder. In an embodiment, the step of crushing the selected target foam sheet produces crushed foam sheets with a maximum size ranging from 100 mm to 500 mm. Alternatively or alternatively, in another development, the step of grinding the selected target foam sheet produces ground target foam sheets with a maximum size of less than 120 mm, preferably less than 90 mm, more preferably less than 70 mm.

[0071] In an embodiment, the method further includes the steps of: pressing the target foam sheet to form a pressed target foam sheet before subjecting the target foam sheet to mechanical processing, and / or pressing the target foam sheet to form a pressed target foam sheet.

[0072] This is particularly advantageous in developments requiring the transport of the target foam sheet between two different locations, for example, by truck, rail, plane, or ship. Alternatively or additionally, the method includes pressing the target foam sheet already obtained by pulverizing the target foam sheet. This is particularly advantageous in developments of preprocessing methods requiring the transport of the target foam sheet, for example, from a preprocessing unit (e.g., by road, rail, air, or sea) to a recycling reactor. In a particular embodiment, the method includes pressing the target foam sheet using an extruder. This is particularly advantageous for controlling the dosage of the target foam sheet entering the reactor, especially when the reactor vessel is pressurized.

[0073] The debris, comprising one or more foam sheets, preferably multiple foam sheets, is obtained from the shredding of a vehicle, with or without prior dismantling. Dismantling of the vehicle may include the selective removal of parts such as engines, transmissions, tires, glass, and plastics for reuse as spare parts in the second-hand market. Dismantling may also include the removal of larger plastic components. Given the inventive method for selecting target foam sheets, plastic components made of soft or rigid foam are of particular interest.

[0074] In an embodiment, the shredded material includes vehicle seats, headliners, dashboards, interior trim panels, automotive shredded residue, shredded light fraction (SLF) separated from automotive shredded residue, shredded heavy fraction (SHF) separated from automotive shredded residue, or any combination thereof.

[0075] As used herein, the term “automobile debris residue” (also known as “ASR”) is a broad term and should be given its common and conventional meaning to those skilled in the art and is not limited to any particular or custom meaning.

[0076] Automotive debris can be obtained through vehicle crushing, preferably through such methods. More preferably, automotive debris can be obtained through vehicle decontamination, vehicle dismantling, vehicle crushing, and separation of metal particles from the crushed vehicle.

[0077] The vehicle is typically an end-of-life vehicle (also known as an "ELV"), typically at least 15 years old. The vehicle can be a passenger car, light or heavy-duty truck, motorcycle, multi-purpose vehicle, agricultural vehicle, or recreational vehicle. The vehicle can be an electric vehicle, such as a pure electric vehicle or a hybrid electric vehicle.

[0078] In vehicle decontamination, harmful liquids (such as fuel, lubricating oil, coolant, brake fluid) and batteries can be removed from the vehicle before crushing.

[0079] Vehicle dismantling can include the selective removal of parts such as engines, transmissions, tires, glass, and plastics for reuse as spare parts in the second-hand market. Dismantling can also include the removal of larger plastic components, such as bumpers, dashboards, and fluid containers, for individual recycling of the plastics.

[0080] ASR (Automatic Recycling Refrigeration) can include additional waste from other sources. For example, trash from a previous owner may be left in the trunk or inside the vehicle. An advantage of the method of this invention is that it can handle ASRs with a wide variety of compositions.

[0081] Crushing can be done using a vehicle crusher. Vehicle crushers are manufactured in various sizes. Typically, a vehicle crusher includes a heavy-duty, high-speed rotating rotor that can rotate in a vertical or horizontal plane and is usually equipped with a swing hammer. The vehicle crusher tears and crushes the vehicle wreckage until its parts are reduced to fragments with the desired size (e.g., up to 30 cm, preferably 1 mm to 15 cm). The fragments can then pass through a grid and exit the rotor housing.

[0082] After crushing, metal fragments (such as ferrous and non-ferrous metal fragments) can be separated from the crushed vehicle. Ferrous metal fragments can be removed using a magnetic separator. Non-ferrous metal fragments can be separated from the crushed vehicle using an eddy current separator, a density-based heavy media flotation device, or manual sorting. Typically, 60-90 wt% of the vehicle's weight is metal, which can be separated from the crushed vehicle.

[0083] The automotive debris can account for approximately 10-40 wt%, preferably 15-35 wt%, and especially 20-30 wt% of the original vehicle weight.

[0084] Automotive debris can include fragments of various polymer vehicle parts, such as bumpers, interior trim panels, dashboards, cable insulation, fuel tanks, electrical insulation materials, soft foam seats, foam insulation panels, automotive suspension bushings, electrical potting compounds, body parts, pillar covers, polymer spoiler parts coated with automotive paint, wheel covers, gears, bushings, cams, bearings, weather-resistant coatings, interior and exterior trim, fuel systems, gear housings, headlight retainers, engine hoods, connector housings, door handles, carburetor components, exterior mirror components, windshield wiper components, windshield wiper protection housings, decorative grilles, hood strips, roof rails, window frames, sliding roof frames, antenna covers, headlights and taillights, radiator grilles and exterior body parts, engine hoods, cylinder head covers, intake manifolds, engine hoods, turbocharger housings, and fragments of turbocharger valves.

[0085] Automotive debris can contain fragments of various polymer vehicle parts, such as the following:

[0086] - Bumpers, interior panels, dashboards, cable insulation, and other components, which are typically made of polypropylene;

[0087] - Fuel tanks, electrical insulation materials, where these fragments are typically made of polyethylene;

[0088] - Soft foam seats, foam insulation panels, automotive suspension bushings, electrical potting compounds, rigid plastic parts, transmission mounts, engine mounts, seals, and impact-resistant foam parts, among which these components are typically made of polyurethane;

[0089] - Body parts, dashboards, wheel covers, where these components are typically made of acrylonitrile-butadiene-styrene;

[0090] - Gears, bushings, cams, bearings, turbocharged air coolers, cylinder head covers, oil pans, engine cooling systems, thermostat and heater housings, exhaust systems including muffler and catalytic converter housings, intake manifolds, timing chain belt covers, where these components are typically made of nylon 6 or nylon 6.6.

[0091] - Interior and exterior trim, fuel systems, small gears, where these components are typically made of polyoxymethylene;

[0092] - Wiper arm and gear housings, headlight retainers, connector housings, where these components are typically made of polyethylene terephthalate; and

[0093] Door handles, bumpers, carburetor parts, and other components, among which these parts are typically made of polybutylene terephthalate (PET).

[0094] Automotive debris may contain at least 30 wt%, preferably at least 40 wt%, and particularly at least 50 wt% of fragments of polymer vehicle parts.

[0095] Automotive debris may contain at least 20 wt%, preferably at least 30 wt%, and particularly at least 40 wt% of fragments of polymer vehicle parts, which are black polymer vehicle parts. Black polymer vehicle parts typically contain carbon black pigment.

[0096] Automotive debris may contain up to 15 wt%, preferably up to 10 wt%, and particularly up to 5 wt% of metal fragments, such as ferrous and nonferrous metal particles.

[0097] Automotive debris may contain up to 15 wt%, preferably up to 10 wt%, and particularly up to 5 wt% of wood and cardboard.

[0098] Automotive debris may contain up to 15 wt%, preferably up to 10 wt%, and particularly up to 5 wt% of glass fragments, such as broken window glass fragments.

[0099] Vehicle debris can be separated into light fraction (SLF) and heavy fraction (SHF). The separation of SLF and SHF can be achieved through air classification. Another form of air classification is achieved by the rotational motion of the vehicle crusher, which generates a fan-like effect that blows out the light fraction, while the heavy fraction exits the vehicle crusher through a grille.

[0100] SLF can be present in an amount of 55-90 wt%, preferably 65-85 wt%, and particularly 70-80 wt% of automotive crushing residue. SHF can represent a balance to be made up to 100 wt%.

[0101] SHF can be present in amounts of 10-45 wt%, preferably 15-35 wt%, and particularly 20-30 wt% of automotive crushing residue. SLF can represent a remainder made up to 100 wt%.

[0102] SLF typically contains a lower weight percentage of rubber particles than SHF. SLF typically contains a lower weight percentage of glass particles than SHF. SLF typically contains a lower weight percentage of metal particles than SHF. SLF typically contains a higher weight percentage of polyurethane foam particles than SHF. SLF typically contains a lower weight percentage of solids and sand than SHF.

[0103] In an embodiment, the method further includes the following steps:

[0104] - Feed the target foam sheet, compressed target foam sheet, target foam film, and / or compressed target foam film into the reactor, and

[0105] -A reaction mixture is obtained by depolymerizing the target foam sheet, the pressed target foam sheet, the target foam film and / or the pressed target foam film by hydrolysis, acid hydrolysis, alcohol hydrolysis, aqueous alcohol hydrolysis, aqueous ammonolysis, aqueous ammonolysis, ammonolysis or any combination thereof.

[0106] Depending on the initial scrap material used, the depolymerization process can, for example, produce polyamines containing amino groups attached to the carbon atoms bonded to the isocyanate groups in the initial polyisocyanate, such as methylene diphenyl diamine (MDA), oligomerized and polymerized methylene phenyleneamine and toluene diamine (TDA) (especially 2,4-toluene diamine or 2,6-toluene diamine), hexamethylene diamine (HDA), and naphthyl diamine (NDA). The polymerization process can further produce, for example, polyester polyols, fragments of polyester polyols, low molecular weight polyols such as ethylene glycol or propylene glycol, or high molecular weight polyether polyols. Typically, depolymerization yields both polyol and amine components.

[0107] Suitable methods for depolymerization are known in principle to those skilled in the art. According to the invention, depolymerization is preferably achieved by hydrolysis, acidolysis, alcohololysis (e.g., diololysis), hydro-alcohololysis (e.g., hydrodiololysis), hydroammonolysis, hydroamineolysis, or via ammonolysis. Preferably, depolymerization is achieved by hydrolysis, diololysis, and / or hydrodiololysis.

[0108] According to the present invention, the hydrolysis step can be performed separately from or in combination with the alcoholysis, ammonolysis, or aminolysis steps. Typically, the amine corresponding to the isocyanate component used in the polymer material is obtained by applying a depolymerization process that includes a hydrolysis step, which may optionally be performed together with or after, for example, alcoholysis, ammonolysis, or aminolysis. Generally, depolymerization produces a mixture of components that can be separated using suitable separation techniques.

[0109] Methods for depolymerization via diol hydrolysis are known in principle. Preferably, diol hydrolysis is carried out in the presence of a base. Therefore, according to other embodiments, the present invention also relates to the methods disclosed above, wherein diol hydrolysis is carried out in the presence of a catalyst, such as an alkali metal hydroxide (e.g., potassium hydroxide) or an amine.

[0110] Suitable methods for depolymerization via hydrogenation include hydrogenation in the presence of a hydrogenation catalyst. Therefore, according to another embodiment, the invention also relates to a method as disclosed above, wherein hydrogenation is carried out in the presence of a hydrogenation catalyst.

[0111] Another possibility is to depolymerize the polymer material by hydrolysis with water in the presence of a reusable organic nitrogen base (such as 1-alkylimidazole) in combination with water (as described in WO 2010 / 130652 A2), or pyridine / water, or a combination of nitrogen-containing ionic liquid and water, to allow hydrolysis at lower temperatures and shorter reaction times.

[0112] In particular, for the recovery of amine substances, it is advantageous to alcoholize the polyurethane material by contacting it with an alcoholizing substance, wherein the amount of water added is such that the water content of the resulting mixture is about 0.2 eq. to about 30 eq. water, particularly about 1 eq. to about 20 eq., particularly about 1.15 eq. to about 10 eq., for example about 1.3 eq. to about 5 eq., for example about 1.4 eq. to about 2 eq. water, based on the amount of cleavable bonds in the polyurethane material. During the hydroalcoholization (i.e., hydrolysis) of the polyurethane material, amine substances and polyol substances are formed.

[0113] Eq. (equivalent) refers to the equivalent number of breakable bonds relative to the polyurethane material. Breakable bonds are defined as urethane and urea bonds within the polyurethane material, and include segments in the polyurethane material linked by urethane units and via biuret groups. Essentially, the amount of breakable bonds is equal to the amount of isocyanate groups in the original polyurethane material.

[0114] According to the present invention, in embodiments, depolymerization is carried out via aqueous glycololysis. Suitable conditions for aqueous glycololysis are known in principle to those skilled in the art. The aqueous glycololysis reaction can be carried out, for example, in a stirred reactor at a temperature in the range of 170°C to 250°C and a pressure in the range of 1 to 50 bar.

[0115] Additional additives, including solvents or other catalytically active components, may be added during the depolymerization step. Preferably, depolymerization is carried out without the addition of an additional catalyst. After the depolymerization step, a mixture of reaction products is typically obtained. The depolymerized products can be separated using suitable separation techniques, which are known in principle to those skilled in the art.

[0116] In an embodiment, the method further includes the step of separating the reaction mixture into a polyol-rich phase and an amine-rich phase.

[0117] In embodiments, the method further includes allowing the mixture to stand, wherein one or more phases are formed, or the mixture can be extracted via an anhydrous organic solvent that is immiscible with or partially miscible with water. Furthermore, particularly for the recovery of components, the method preferably includes a post-treatment that may include one or more of the following:

[0118] -filter;

[0119] - Centrifugation;

[0120] -Analysis;

[0121] -extraction;

[0122] - Distillation;

[0123] - The phase is completely or partially evaporated in one or more evaporators;

[0124] - To bring the phase into contact with the ion exchange material;

[0125] - To bring the phase into contact with one or more adsorbents.

[0126] According to a preferred embodiment, phase separation is performed after the mixture has been allowed to settle. Preferably, phase separation is performed in a phase separation apparatus. For improved phase separation, it may be advantageous to remove water contained in the mixture, for example, by flash evaporation. Water removal can also be accomplished by applying a vacuum to the mixture or simply distilling the mixture at atmospheric pressure. In principle, phase separation can also be improved by adding salt or by using specific internals in the phase separation apparatus. Suitable methods are known in principle to those skilled in the art.

[0127] Particularly in embodiments where amine substances are recovered, it may be advantageous to remove excess water from the mixture before allowing it to stand, preferably by evaporation. Specifically, to evaporate the excess water, the mixture is heated and / or a vacuum is applied to it. For example, excess water is removed by using flash evaporation or by applying a vacuum to an already heated mixture. For example, the dehydration step can be carried out for about 120 minutes or less, particularly about 90 minutes or less, for example about 75 minutes or less, for example about 60 minutes or less. Preferably, the dehydration step is carried out for about 10 minutes or longer, particularly about 30 minutes or longer, for example about 40 minutes or more.

[0128] According to one aspect of the invention, solids may be removed from the mixture, preferably by one or more of the following, before or after allowing the mixture to stand: filtration, centrifugation, decantation.

[0129] Suitable methods for removing particulate solids are known in principle to those skilled in the art. For example, a filter unit or centrifuge can be used. Preferably, according to the invention, the filtration step is performed using a filter unit, more preferably a filter, and even more preferably a bag filter, membrane filter, candle filter, agitated pressure filter, vacuum belt filter, plate and frame filter, or Nutsche filter. For filtration, a cascade filter is preferably used. Alternatively or additionally, centrifugation is a preferred solid-liquid separation method.

[0130] In an embodiment, the method further includes the following steps:

[0131] - Purify the polyol-rich phase in a polyol post-processing setup to obtain a recycled polyol component, and / or

[0132] - The amine-rich phase is purified in an amine post-processing setup to obtain the amine component for recycling.

[0133] Post-treatment of the depolymerization products (especially the separation of polyamines and polyols) can be achieved as appropriate, for example by extraction post-treatment, precipitation of the amine component as hydrochloride, precipitation as urea (in the case of ammonolysis), chromatography, or vacuum distillation. Preferably, the post-treatment includes several steps.

[0134] In the context of this invention, amine components should be understood as components containing isocyanate precursors (such as amines, carbamates, or ureas) obtained during the depolymerization process.

[0135] In post-processing via distillation, compounds are separated according to their volatility, with more volatile compounds being separated first. Additives, water, or solvents used in depolymerization can also be removed by distillation before further post-processing of the polyol-polyamine mixture. Generally, the “volatility” of a liquid can be described by its vapor pressure, with high vapor pressure indicating high volatility and vice versa.

[0136] In cases where polyamines are more volatile than polyols, such as in the case of TDA, monomeric MDA, and NDA, the polyamine is recovered from the depolymerization product by distillation, preferably by distillation under reduced pressure. After distillation of the polyamine, the remaining substrate contains the polyol. Suitable conditions for distillation are known in principle to those skilled in the art and are disclosed, for example, in EP22178796.3 or EP 22178797.1.

[0137] Alternatively, the polyol can be recovered from the depolymerization mixture by extraction using a suitable extractant or a pair of extractants. The polyamine component, in its hydrochloride form, can also be precipitated by adding HCl and extracting the polyol component with a suitable solvent (e.g., as described in DE 2854940 A1), which preferably dissolves the polyol component but not the hydrochloride of the polyamine component. After separation, the hydrochloride of the polyamine component can be converted to free polyamine by adding a base, or it can be used directly for phosgenation to produce new polyisocyanates for polyurethane synthesis. In MDA HCl or PMDA In the case of HCl, the hydrochloride can be directly fed into the MDA synthesis equipment before the neutralization step.

[0138] Furthermore, particularly for the recovery of polyols, the method may include post-treatment of the polyol-rich phase by purifying the polyols. Purification may include one or more of the following:

[0139] -filter;

[0140] - Centrifugation;

[0141] - The phase is partially or completely evaporated in one or more evaporators;

[0142] - To bring the phase into contact with the ion exchange material;

[0143] - Contact the phase with one or more adsorbents.

[0144] After post-treatment, the polyol-rich phase preferably has an acid value of 0.1 mg KOH / g or less. The acid number (corresponding to the acid value) is determined according to DIN EN ISO 4629-2 (with minor variations). A 1:1 mixture of isopropanol and water is used as the solvent mixture instead of a 2:1 mixture of toluene and ethanol. As another variation, NaOH / KOH is dissolved in methanol instead of ethanol.

[0145] Preferably, the method further includes post-treatment of the mixture by purifying the amine substance (e.g., by distillation) to purify the amine substance.

[0146] It should be understood that the separation methods described above can be combined with any of the various embodiments of the methods of the present invention described herein.

[0147] The method of the present invention can release about 70% or more, particularly about 80% or more, preferably about 90% or more, and more preferably about 97% or more of the polyols or monomer fragments that are theoretically recoverable from polymer materials. Therefore, the yield of the released polyols or monomer fragments is about 90% or higher, preferably 97 wt.% or higher, and particularly 99 wt.% or higher.

[0148] According to another aspect, the present invention also relates to polyol compositions obtained or available by the method according to the first aspect of the invention. Preferably, the polyol composition for flexible foam comprises or consists of one or more polyols having a molecular weight of about 2,500 to about 3,700 g / mol, a nominal OH functionality of about 3, and an OH value of about 45 mg KOH / g to about 56 mg KOH / g.

[0149] In an embodiment, the method further includes the step of converting the recycled amine component to obtain a recycled isocyanate component. The advantages and / or features described in conjunction with methods for recovering amine substances are also applicable to methods for producing isocyanate substances.

[0150] Preferably, the amine obtained by the recovery method is fed into the purification section of an amine production facility, an amine storage tank, or an isocyanate production facility, such as the phosgenation section of an isocyanate production facility. For use in isocyanate production, the amine must be substantially free of water, alcohols, polyols, residual metals, and silicon compounds.

[0151] Preferably, the recycled amine component is phosgenated to form a recycled isocyanate component. For example, TDA can be phosgenated to prepare TDI, or MDA can be phosgenated to prepare MDI. Furthermore, pMDA can be phosgenated to prepare pMDI, and NDA can be phosgenated to prepare NDI. Suitable conditions for phosgenation are known in principle to those skilled in the art.

[0152] In the context of this invention, the term "isocyanate component" encompasses all isocyanates known to those skilled in the art in relation to polyurethane chemistry, such particularly toluene diisocyanate (TDI; prepared from toluene diamine (TDA)) or diphenylmethane series diisocyanates and polyisocyanates (MDI; prepared from diphenylmethane series diamines and polyamines (MDA)). The expression "isocyanate component" also encompasses embodiments in which two or more different isocyanates (e.g., mixtures of MDI and TDI) are used in the preparation of the polyurethane material. This also applies within an isocyanate category (i.e., for example, various MDI types). Additional isocyanates, such as hexamethylene diisocyanate (HDI) and its oligomers or naphthylene diisocyanate (NDI), may also be present. The total amount of all isocyanates used in the preparation of the polyurethane material is referred to as the isocyanate component (of the polyurethane material). The isocyanate component comprises at least one isocyanate.

[0153] The conversion of recycled amine components can be achieved, for example, by phosgenation or by non-phosgenation. Suitable methods include, for example, liquid phosgenation, gas-phase phosgenation, or gas-liquid phosgenation, or by salt phosgenation or non-phosgenation (e.g., carbamate cleavage). Suitable conditions for phosgenation are known in principle to those skilled in the art and are disclosed, for example, in the following: Ullmann's Encyclopedia of Industrial Chemistry, 7th edition, Vol. 20, 2012, pp. 63-82, WO 99 / 54289 A, WO 2004 / 056756A (liquid phosgenation); Ullmann's Encyclopedia of Industrial Chemistry, 4th edition, Vol. 13, 2012, p. 353, DE 25 870847 A, EP 1532107 A, EP0570799 A, EP 0289840 A (gas-phase phosgenation); or EP 2044009 A1, WO 2013 / 060836 A, WO 2013 / 079517 A (gas-liquid phosgenation). Examples of gas-liquid phosgenation methods are disclosed in WO 2022 / 106716, examples of gas-phase phosgenation methods are disclosed in EP 1761483 B1, EP 2079684 B1, EP 2188247 B1, EP 2408738 B1 and EP2539314 B1, and examples without phosgenation conversion are disclosed in WO2018 / 185168 and EP 3 250 622 B1.

[0154] Preferably, phosgenation includes mixing a solvent into a recycled amine component and stirring, more preferably at a temperature in the range of 50°C to 180°C, more preferably in the range of 70°C to 140°C, and even more preferably in the range of 80°C to 120°C, to obtain a polyamine mixture; and contacting the polyamine mixture with phosgene in a reactor and heating the obtained mixture to a temperature in the range of 90°C to 140°C, more preferably in the range of 110°C to 130°C, to obtain a mixture containing one or more polyisocyanates.

[0155] This invention also relates to isocyanate components obtained or available according to the methods disclosed above. Furthermore, this invention relates to the use of isocyanate components according to the invention, or isocyanate components obtained or available according to the methods according to the invention, in the preparation of novel polymer materials. For example, TDI or MDI produced according to the invention can be used as an isocyanate component to produce polyurethane foam by reacting it with a recycled polyol component obtained according to the invention or any other suitable polyol component.

[0156] In an embodiment, the method further includes the step of preparing a novel polymer material from a recycled polyol component, a recycled amine component, and / or a recycled isocyanate component. The resulting novel polymer material can be used in any suitable application, preferably in the same application. The polymer material can be used, for example, in automotive parts (like bumpers, dashboards, and car seats), and also in home applications (like mattresses and furniture parts), or in appliance or building applications.

[0157] The recycled amine component obtained by the method according to the invention can also be phosgenated together with virgin MDA or TDA to obtain an isocyanate component containing recycled and virgin isocyanate molecules, which can also be used to produce new polymer materials.

[0158] According to another aspect, the present invention also relates to the use of polyol compositions according to the invention or polyol compositions obtained or available according to the method of the invention for the preparation of polyurethanes. The invention further relates to a method for preparing polyurethane materials by reacting a polyol substance obtained by the method of the invention with an isocyanate substance, preferably an isocyanate substance obtained by the method of the invention. In embodiments in which a polyol substance obtained by the method of the invention is used in the method for preparing polyurethane materials, up to 100% of the virgin polyol can be replaced with recycled polyol substance without significant disadvantage in terms of product quality. All the advantages and / or features described in conjunction with the method for recycling polyol substance also apply to the method for preparing polyurethane materials.

[0159] The method according to the invention can be advantageously used for preprocessing scrap containing a plastic mixture comprising polymeric materials, and additionally or alternatively comprising other types of non-foamed plastic or non-plastic materials. In various embodiments, the plastic mixture may be a polyurethane mixture or a flexible polyurethane mixture. Preferably, the method of the first aspect of the invention is used for feeding target foam sheets into a reactor of a chemical recycling process, particularly for feeding PU-containing target foam sheets into a reactor to recover TDA and polyols as raw materials for manufacturing recycled PU foam.

[0160] In another aspect, the present invention also relates to a method, preferably a method according to the foregoing aspects of the present invention, comprising the steps of: converting a target foam sheet, a pressed target foam sheet, a target foam film, a pressed target foam film, and / or any chemical material that is available or obtainable by the method according to the present invention to obtain product PRF1.

[0161] In the embodiments, product PRF1 is selected from:

[0162] i) Building blocks or single units; or

[0163] ii) a polymer, preferably polymer A, a polymer composition, preferably polymer composition A, or a polymer product, preferably polymer product A; or

[0164] iii) Industrial polymers, industrial surfactants, scale-removing compounds, industrial biocides, industrial solvents, industrial dispersants, compositions thereof, or formulations thereof; or

[0165] iv) Agricultural chemical compositions, agricultural chemical formulations, adjuvants, or agricultural chemical active ingredients; or

[0166] v) Active pharmaceutical ingredients or intermediates thereof, pharmaceutical excipients, animal feed additives, human food additives, dietary supplements, aromatic chemicals or aromatic compositions; or

[0167] vi) Aqueous polymer dispersions, preferably polyurethane or polyurethane-poly(meth)acrylate hybrid polymer dispersions, emulsions, binders for paper and fiber coatings, UV-curable acrylic polymers for hot melts and coatings, polyisocyanates, hyperbranched polyester polyols, polymer dispersants for inorganic binder compositions, unsaturated polyester polyols, or 100% curable compositions; or

[0168] vii) Cosmetic surfactants, emollients, waxes, cosmetic polymers, UV filters, other cosmetic ingredients, or combinations thereof or formulations thereof; or

[0169] viii) Polymer B, polymer composition B, coating composition, other functional composition, foil, molded body, coating or coated substrate.

[0170] The content of the target foam element in product PRF1 may be 1 wt% or more, preferably 2 wt% or more, more preferably 5 wt% or more, more preferably 15 wt% or more, more preferably 30 wt% or more, more preferably 40 wt% or more, more preferably 60 wt% or more, more preferably 80 wt% or more, more preferably 90 wt% or more, more preferably 95 wt% or more; and / or the content of the target foam element in product PRF1 may be 100 wt% or less, preferably 95 wt% or less, more preferably 90 wt% or less, more preferably 50 wt% or less, more preferably 25 wt% or less, more preferably 10 wt% or less. This content is determined based on the identity maintenance and / or segregation and / or quality balance and / or ledger and declared chain of custody model, preferably based on quality balance, preferably the International Sustainability and Carbon Certification (ISCC) standard.

[0171] The publicly disclosed prior art content; No. 684; paragraphs

[1000] to

[8005] ; ISSN: 2198-4786; publication date: February 12, 2024, shall be regarded as reference RF1, which is incorporated herein by reference in its entirety. Preferably, product PRF1 is the product as described in reference RF1; paragraphs

[1000] to

[8005] . Preferably, the method / process described herein is further a method / process for producing product, preferably product PRF1.

[0172] The conversion step for obtaining product PRF1 preferably includes one or more steps as described below, and can be performed by conventional methods well known to those skilled in the art. The conversion step preferably includes one or more steps selected from the following:

[0173] Recycling, preferably through depolymerization, gasification, pyrolysis and / or steam cracking; and / or

[0174] Purification, preferably crystallization, (solvent) extraction, distillation, evaporation, hydrogenation, absorption, adsorption, and / or ion exchange; and / or assembling, preferably foaming, synthesis, chemical conversion, chemical transformation, polymerization, and / or blending; and / or shaping, preferably foaming, extrusion, and / or molding; and / or finishing, preferably coating and / or smoothing. Furthermore, one or more of these steps are described in detail in reference RF1; paragraphs

[1000] to

[8005] .

[0175] As used herein, the term "building unit" refers to a compound that is in a gaseous or liquid state under standard conditions of 0°C and 0.1 MPa. Building units are typically used in the chemical industry to form secondary products that offer greater structural complexity and / or higher molecular weight than the building unit on which the secondary product is based. Building units are preferably selected from the group consisting of hydrogen, carbon monoxide, carbon dioxide, ethylene oxide, ethylene glycol, syngas containing mixtures of hydrogen and carbon monoxide, alkanes, alkenes, alkynes, and aromatic compounds. Alkanes, alkenes, alkynes, and aromatic compounds particularly contain 1 to 12 carbon atoms, respectively.

[0176] As used herein, the term "monomer" includes molecules that can react with each other to form polymer chains through polymerization. Monomers are preferably selected from the group consisting of: (meth)acrylic acid, salts of (meth)acrylic acid; particularly sodium, potassium, and zinc salts; (meth)acrolein; and (meth)acrylates. (Meth)acrylates containing 1 to 22 carbon atoms, particularly 1 to 8 carbon atoms, are preferred. The terms (meth)acrylic acid, (meth)acrolein, or (meth)acrylate refer to acrylic acid, acrolein, or acrylates, and where applicable, also refer to methacrylic acid, methacrolein, or methacrylates. Furthermore, monomers may be selected from hexamethylenediamine (HMD) and adipic acid.

[0177] The building blocks may further be intermediate compounds. As used herein, the term "intermediate compound" includes organic reagents that are used to form compounds with higher molecular complexity. Intermediate compounds may, for example, be selected from the group consisting of phosgene, polyisocyanates, and propylene oxide. Polyisocyanates are particularly aromatic diisocyanates and polyisocyanates, preferably toluene diisocyanate (TDI) and / or diphenylmethane diisocyanate (MDI).

[0178] The building blocks and monomers, as well as one or more typical transformation steps used to obtain the building blocks or monomers, are described in more detail in paragraphs

[1000] through

[1012] of reference RF1.

[0179] As used herein, the term “polymer A” includes thermoplastics (e.g., polyamides or thermoplastic polyurethanes), thermosettings (e.g., polyurethanes), elastomers (e.g., polybutadiene) or copolymers or mixtures thereof, and is defined in more detail in paragraphs

[2001] through

[2007] of reference RF1.

[0180] As used herein, the term “polymer composition A” includes all compositions comprising the polymers described above and one or more additives (e.g., reinforcing agents, colorants, modifiers and / or flame retardants), and is defined in more detail in paragraph

[2008] of reference RF1.

[0181] As used herein, the term “polymer product A” includes any product comprising polymer A and / or polymer composition A as described above, and is defined in more detail in paragraphs

[2009] and

[2010] of reference RF1.

[0182] One or more steps for obtaining a polymer (preferably polymer A), a polymer composition (preferably polymer composition A), or a polymer product (preferably polymer product A) are described in more detail in paragraph

[2011] of reference RF1.

[0183] As used herein, the term "industrial polymer" includes rheological polymers, polycarboxylate polymers, alkoxylated polyalkyleneamine polymers, alkoxylated polyalkyleneimine polymers, polyether polymers, dye-inhibiting polymers, and dirt-releasing cleaning polymers, as defined in more detail in paragraphs

[3035] through

[3044] of reference RF1. As used herein, the term "industrial surfactant" includes nonionic, anionic, and amphoteric industrial surfactants, as defined in more detail in paragraphs

[3008] through

[3034] of reference RF1. As used herein, the term "industrial descaling compound" includes nonphosphate-based builders (NPBs) and phosphonates (CoPs), as described in more detail in paragraphs

[3001] through

[3005] of reference RF1. As used herein, the term "industrial biocide" refers to compounds that kill or inhibit the growth or reproduction of microorganisms, as defined in more detail in paragraphs

[3006] through

[3007] of reference RF1. As used herein, the term “industrial solvent” includes alkylamides, alkyl lactamides, alkyl esters, lactates, alkyl diesters, cyclic alkyl diesters, cyclic carbonates, aromatic aldehydes, and aromatic esters, as defined in more detail in paragraphs

[3045] through

[3055] of reference RF1. As used herein, the term “industrial dispersant” includes anionic and nonionic industrial dispersants, as defined in more detail in paragraphs

[3056] through

[3058] of reference RF1. The term “compositions and / or formulations thereof” with respect to industrial polymers, industrial surfactants, scale-removing compounds, and / or industrial biocides refers to industrial compositions and / or institutional products and / or textiles, as well as home care products and / or personal care products, as defined in more detail in paragraph

[3059] of reference RF1. One or more conversion steps for obtaining industrial polymers, industrial surfactants, scale-removing compounds, and / or industrial biocides are defined in more detail in paragraph

[3060] of reference RF1. The conversion steps for obtaining industrial compositions or formulations of industrial polymers, industrial surfactants, scale-removing compounds and / or industrial biocides are defined in more detail in paragraph

[3061] of reference RF1.

[0184] As used herein, the term "agricultural chemical composition" typically refers to a composition comprising an agricultural chemical active ingredient and at least one agricultural chemical formulation adjuvant. Examples of agricultural chemical compositions, active ingredients, and adjuvants are described in more detail in paragraph

[4001] of reference RF1.

[0185] Agricultural chemical compositions can be in any conventional formulation form. These agricultural chemical compositions are prepared in known ways, for example, by the following: Mollet and Grubemann, Formulation technology, Wiley VCH, Weinheim, 2001; or Knowles, New developments in crop protection product formulation, Agrow Reports DS243, T&F Informa, London, 2005. One or more conversion steps to obtain agricultural chemical active ingredients and adjuvants can be carried out similarly to one or more production steps of their analogues based on petrochemicals or other precursors not obtained through recycling processes. Additionally, the conversion of compounds mentioned in the sections “Polymers” and “Cosmetic Surfactants, Emollients, Waxes, Cosmetic Polymers, UV Filters, Other Cosmetic Ingredients or Combinations or Formulations thereof” can be carried out as described in those sections and the corresponding paragraphs in reference RF1.

[0186] As used herein, the term "active pharmaceutical ingredient and / or its intermediate" includes substances that provide pharmacological activity or other direct action or influence the structure or any function of the body in the diagnosis, cure, relief, treatment or prevention of a disease. Its intermediates are isolated products produced during the multi-step synthetic route of the active pharmaceutical ingredient. As used herein, the term "drug excipient" includes compounds or mixtures of compounds used in compositions for various pharmaceutical applications that are substantially non-pharmaceutical in themselves. Active pharmaceutical ingredients and / or their intermediates, as well as drug excipients, are defined in more detail in paragraph

[5001] of reference RF1.

[0187] One or more conversion steps for obtaining an active pharmaceutical ingredient and / or its intermediates and pharmaceutical excipients may include one or more synthetic steps and may be carried out by conventional synthesis and techniques well known to those skilled in the art.

[0188] As used herein, the terms "animal feed additives, human food additives, dietary supplements" include vitamins, provitas and their active metabolites, including intermediates and precursors, especially vitamins A, B, E, D, K and their esters (such as acetates, propionates, palmitates) or their alcohols (such as retinol) or their salts or any combination thereof; tetraterpenes, especially isoprene-like substances, such as carotenoids and lutein, including their intermediates and precursors and mixtures and derivatives thereof, especially β-carotene, canthaxanthin, hesperidin, astaxanthin, zeaxanthin, lutein, and astaxanthin. Lycopene, apocarotenoids, and any combination thereof; organic acids, especially formic acid, propionic acid, and their salts (such as sodium, calcium, or ammonium salts), and any combination thereof, such as, but not limited to, formic acid and sodium formate, propionic acid and ammonium propionic acid, formic acid and propionic acid, formic acid and sodium formate, and mixtures of propionic acid, propionic acid and sodium propionic acid, and formic acid and sodium formate; glycerides of carboxylic acids and short- and medium-chain fatty acids, conjugated linoleic acid (such as omega-6 fatty acid (C18:2) methyl ester), and 1,2-propanediol; and beverage stabilizers such as polyvinylpyrrolidone polymers or polyvinylimazole / polyvinylpyrrolidone copolymers. Animal feed additives, human food additives, and dietary supplements are defined in more detail in paragraph

[5002] of reference RF1.

[0189] One or more conversion steps used to obtain animal feed additives, human food additives, or dietary supplements may include one or more synthetic steps and may be carried out by conventional synthesis and techniques well known to those skilled in the art.

[0190] As used herein, the terms "aromatic chemicals" and "aromatic compositions" include volatile organic compounds with a molecular weight between 70 and 250 g / mol that contain functional groups having a carbon skeleton of C5-C16 carbon atoms, including straight-chain, branched, cyclic (e.g., ring size C5-C18), bicyclic, or tricyclic aliphatic chains, but not necessarily containing one or more unsaturated structural elements such as double bonds, triple bonds, aromatic compounds, or heteroaromatic compounds, and preferably, one or more additional functional groups are selected from alcohols, ethers, esters, ketones, aldehydes, acetals, carboxylic acids, nitriles, thiols, and amines. In one aspect, aromatic chemicals are terpene-based aromatic chemicals, such as those selected from monoterpenes and monoterpenoids, sesquiterpenes and sesquiterpenoids, diterpenes, triterpenes, or tetraterpenes. Aromatic chemicals can be combined with other aromatic chemicals to obtain aromatic compositions. Aromatic chemicals and aromatic compositions are defined in more detail in paragraph

[5003] of reference RF1.

[0191] One or more conversion steps for obtaining aromatic chemicals and aromatic compositions may include one or more synthetic steps and may be carried out by conventional synthesis and techniques well known to those skilled in the art.

[0192] As used herein, the term "aqueous polymer dispersion" includes one or more aqueous compositions comprising one or more dispersed polymers, and is defined in more detail in the section entitled "Aqueous Polymer Dispersions" of reference RF1

[6001] . One or more dispersed polymers may be selected from one or more acrylic emulsion polymers, one or more styrene acrylic emulsion polymers, one or more styrene butadiene dispersions, one or more aqueous dispersions comprising composite particles, one or more acrylate-alkyd hybrid dispersions, one or more polyurethanes (including UV-curable polyurethanes), and one or more polyurethane-poly(meth)acrylate hybrid polymers. As used herein, the term "emulsion polymer" includes one or more polymers prepared by free radical emulsion polymerization. One or more aqueous polyurethane dispersions are defined in more detail in the section entitled "Polyurethane Dispersions" of reference RF1

[6002] . One or more UV-curable polyurethanes are defined in more detail in the section entitled "Polyurethane Dispersions" of reference RF1

[6017] . One or more polyurethane-poly(meth)acrylate hybrid polymers are defined in more detail in the section of reference RF1

[6016] .

[0193] As used herein, the term “polymer dispersant” preferably includes one or more polymers comprising polyether side chains, particularly one or more polycarboxylate ether polymers and one or more condensation products as defined in more detail in the paragraph entitled “Polymer Dispersants” in reference RF1

[6020] .

[0194] One or more conversion (polymerization) steps for obtaining one or more aqueous polymer dispersions comprising one or more emulsion polymers are defined in more detail in the section entitled “Emulsion Polymerization” in reference RF1

[6003] .

[0195] One or more conversion (polymerization) steps for obtaining one or more waterborne polyurethane dispersions are defined in more detail in the section entitled “Methods for preparing waterborne polyurethane dispersions”

[6014] and the section entitled “UV-curable waterborne polyurethane dispersions, their preparation and use and compositions containing them”

[6017] of reference RF1.

[0196] Compositions and uses of one or more aqueous polymer dispersions and one or more polymer dispersants are defined in more detail in the following sections of reference RF1:

[0197] The section titled "Applications of Aqueous Polymer Dispersions"

[6004]

[0198] The section titled "Adhesives for Building and Building Coatings"

[6005]

[0199] The section titled "Adhesives for Paper Coatings"

[6006]

[0200] The section titled "Adhesives for Fiber Bonding"

[6007]

[0201] The section titled "Adhesive Polymers and Adhesive Compositions"

[6008]

[0202] The section titled "Aqueous Polyurethane Dispersions Suitable for Coating Compositions"

[6015]

[0203] The section titled "Waterborne polyurethane-poly(meth)acrylate hybrid polymer dispersions suitable for coating compositions"

[6016]

[0204] The section titled "Waterborne UV-curable polyurethane dispersions, their preparation and uses, and compositions containing them"

[6017]

[0205] Section entitled “Inorganic binder compositions containing polymer dispersants and their uses”

[6018]

[6019] 100% curable coating compositions.

[0206] One or more UV-crosslinkable poly(meth)acrylates and their uses are defined in more detail in the section entitled “UV-crosslinkable poly(meth)acrylates for use in UV-curable solvent-free hot melt adhesives and their use in the preparation of pressure-sensitive self-adhesive articles” in reference RF1

[6009] .

[0207] One or more polyisocyanates, one or more compositions comprising them, and their uses are defined in more detail in the section entitled “Polyisocyanates” in reference RF1

[6010] .

[0208] One or more hyperbranched polyester polyols and their uses are defined in more detail in the section entitled "Organic solvent-based hyperbranched polyester polyols suitable for coating compositions" in reference RF1

[6011] . One or more conversion steps for obtaining hyperbranched polyester polyols are defined in more detail in the section entitled "Preparation of organic solvent-based hyperbranched polyester polyols" in reference RF1

[6012] . One or more coating compositions comprising one or more hyperbranched polyester polyols, one or more polyisocyanates and one or more additives, and the substrates coated thereon are defined in more detail in the section entitled "Organic solvent-based two-component coating compositions comprising hyperbranched polyester polyols and polyisocyanates" in reference RF1

[6013] .

[0209] One or more unsaturated polyester polyols, one or more solvent-based coating compositions comprising said unsaturated polyester polyols, and one or more substrates for coating with said one or more coating compositions are defined in more detail in the section entitled “Organic Solvent-Based Coating Compositions Containing Unsaturated Polyester Polyols”

[6018] of reference RF1. One or more 100% curable coating compositions are defined in more detail in the section

[6019] of reference RF1. One or more polymeric dispersants for use in inorganic binder compositions are defined in more detail in the section

[6020] of reference RF1. One or more inorganic binder compositions comprising polymeric dispersants and their uses are defined in more detail in the section

[6021] of reference RF1. One or more conversion steps for obtaining one or more polymeric dispersants are defined in more detail in the section

[6020] of reference RF1. As used herein, the term "inorganic binder composition" comprising one or more polymeric dispersants preferably includes, in particular, hydraulic hardening compositions and compositions comprising calcium sulfate, and is defined in more detail in the section entitled "Inorganic Binder Compositions Containing Polymer Dispersants and Their Use Therein"

[6021] of reference RF1. Specific one or more building material formulations containing one or more polymeric dispersants, or one or more building products produced from building material formulations containing polymeric dispersants, are disclosed in more detail in the section of reference RF1

[6021] .

[0210] As used herein, the term “cosmetic surfactant” includes nonionic, anionic, cationic, and amphoteric surfactants, and is defined in more detail in paragraph

[7002] of reference RF1. As used herein, the term “emollient” refers to a compound used to protect, moisturize, and / or lubricate the skin, and is defined in more detail in paragraph

[7003] of reference RF1. As used herein, the term “wax” includes pearlescent agents and opacifiers, and is defined in more detail in paragraph

[7004] of reference RF1. As used herein, the term “cosmetic polymer” includes any polymer that can be used as an ingredient in cosmetic formulations, and is defined in more detail in paragraph

[7005] of reference RF1. As used herein, the term “UV filter” refers to a compound that blocks or absorbs ultraviolet light, and is defined in more detail in paragraph

[7006] of reference RF1. As used herein, the term “additional cosmetic ingredient” includes any ingredient suitable for the preparation of cosmetic formulations. Several sources disclose ingredients acceptable for cosmetic use. For example, the Cosing database on the European Commission's website discloses cosmetic ingredients, as does the International Dictionary and Handbook of Cosmetic Ingredients edited by the Personal Care Products Association (PCPC). The term "compositions and / or formulations thereof" in relation to cosmetic surfactants, emollients, waxes, cosmetic polymers, UV filters, and / or other cosmetic ingredients refers to personal care and / or cosmetic compositions or formulations as defined in more detail in paragraph

[7007] of reference RF1. One or more conversion steps used to obtain cosmetic surfactants, emollients, waxes, cosmetic polymers, UV filters, or other cosmetic ingredients are defined in more detail in paragraph

[7008] of reference RF1.

[0211] The terms “polymer B”, “polymer composition B”, “coating composition”, “other functional composition”, “foil”, “molded body”, “coating” and “coated substrate” are well known to those skilled in the art and are defined in more detail from paragraphs

[8000] to

[8005] of reference RF1. Detailed Implementation

[0212] Further details and features of the invention are derived from the following description of preferred embodiments, particularly in conjunction with the dependent claims. Corresponding features may be implemented individually or in combination with each other. The invention is not limited to these embodiments. The drawings are to be understood as illustrative and do not represent limitations on the invention, such as regarding specific dimensions or design variations.

[0213] Figure 1 A schematic block diagram of a recycling arrangement 100 according to an embodiment of the present invention is shown.

[0214] The recycling arrangement 100 includes a sorting unit 114 configured to select target foam sheets containing polymeric materials from the shredded material obtained by the crushing vehicle. The polymeric materials are selected from the group consisting of polyurethane, polyurethane urea, polyisocyanurate, and mixtures of two or more thereof. Figure 1 In the example shown, vehicle 102 is crushed in vehicle crushing unit 104, as is common in the prior art. Typically, vehicle 102 is disassembled before crushing, such that most of the easily removable parts of vehicle 102 are removed before it is fed into vehicle crushing unit 104. The crushed material, containing both metallic and plastic components, is fed into pre-sorting unit 108, where at least the metallic components, as non-plastic contaminants, are removed. The remaining material (also known as automotive crushing residue) is typically separated into so-called crushed light fraction and crushed heavy fraction. Plastic particles of interest for chemical recycling are typically contained in the crushed light fraction. Therefore, in Figure 1 In the example shown, the crushed lightweight fraction of automobile debris is pre-processed material in the recycling arrangement 100 according to this embodiment of the invention.

[0215] The debris includes broken foam sheets 112 containing valuable foam elements and foam material 110 unsuitable for the corresponding recycling process. The foam elements 112 are provided to a sorting unit 114 configured to select target foam sheets 116 containing polymer material from the broken foam sheets 112. Foam material 110 unsuitable for recycling is removed in the sorting unit 114. The sorting unit 114 may include, for example, a near-infrared spectroscopy device 114.1, a mid-infrared spectroscopy device 114.2, a UV-VIS spectroscopy device 114.3, an optical camera 114.4, a laser-induced breakdown spectroscopy device 114.5, a Raman spectroscopy device 114.6, an X-ray fluorescence device 114.7, or a THz spectroscopy device 114.8.

[0216] The selected target foam sheet 116 is fed into a pressing unit 118, which is configured to press the selected target foam sheet 116 to form a pressed target foam sheet 120. This configuration is particularly advantageous when the selected target foam sheet 116 must be transported, for example, from a vehicle dismantling and crushing facility to a chemical production plant, where the polymer material will be depolymerized to produce recycled raw material 130. A transport unit 122 is configured to receive the pressed target foam sheets 120 and transport them to a grinding unit 124. The transport unit 122 is exemplary configured as a conveyor belt, but may also be any transport unit suitable for transporting the pressed target foam sheets 120, for example, by road, rail, air, or sea-based transport units (such as trucks, trains, airplanes, or ships) or by any combination thereof. The grinding unit 124 is an example of a mechanical processing unit and is configured to grind the pressed target foam sheets 120 to form target foam flakes 126, which are suitable in both size and composition for feeding into reactor 128. The milled target foam sheet 126 has a maximum size of less than 120 mm, preferably less than 90 mm, and more preferably less than 70 mm.

[0217] The recycling arrangement 100 is adapted to preprocess the scrap 106 to feed the recycling process reactor 128 for the recovery of raw material 130. Reactor 128 is, but is not necessarily, a chemical reactor for the chemical recycling of PU foam. The recycling arrangement 100 can be configured to preprocess the scrap 106 advantageously obtained from shredder vehicles. The scrap 106 can be, for example, automotive shredder residue, shredded light fractions separated from automotive shredder residue, shredded heavy fractions separated from automotive shredder residue, or any combination thereof.

[0218] In summary, the present invention relates to a method for recycling polymeric materials selected from the group consisting of polyurethane, polyurethane urea, polyisocyanurate, and mixtures of two or more thereof, the method comprising the steps of: (a) providing scrap obtained by a crushing vehicle, and / or crushing the vehicle and obtaining the scrap, the scrap comprising one or more foam sheets made of polymeric material; (b) performing a first sorting step for selecting target foam sheets containing polymeric material from the scrap; and (c) subjecting the target foam sheets to mechanical processing to obtain target foam sheets with a maximum size of less than 120 mm.

[0219] By studying the accompanying drawings, this disclosure, and the appended claims, those skilled in the art can understand and implement other variations of the disclosed embodiments when practicing the claimed invention.

[0220] A single unit or device can perform the functions of several items listed in the claims. The fact that certain measures are listed in different dependent claims does not indicate that combinations of these measures cannot be used advantageously.

[0221] Any reference numerals in the claims should not be construed as limiting the scope.

Claims

1. A method for recycling a polymer material selected from the group consisting of polyurethane, polyurethane urea, polyisocyanurate, and mixtures of two or more thereof, the method comprising the following steps: (a) Providing scrap (106) obtained by a crushing vehicle (102), and / or a crushing vehicle (102) and obtaining scrap (106), the scrap (106) comprising one or more foam sheets made of the polymer material; (b) Perform a first sorting step for selecting target foam sheets (116) containing the polymer material from the scrap (106); (c) subjecting these target foam sheets (116) to mechanical processing to obtain target foam sheets (126) with a maximum size of less than 120 mm, preferably less than 90 mm, more preferably less than 70 mm. The first sorting step is characterized by a sorting step that uses one or more optical sorting methods to sort the target foam sheets (116) based on the type of isocyanate and / or polyol used to produce the target foam sheets (116).

2. The method as described in claim 1, wherein, The first sorting step includes a pre-sorting step for removing non-plastic contaminants from the scrap (106).

3. The method of claim 1 or 2, further comprising a second sorting step for removing impurities from these target foam sheets (126) to obtain purified target foam sheets.

4. The method according to any one of claims 1 to 3, wherein, One or more sorting steps are performed using one or more optical sorting methods, particularly one or more optical sorting methods selected from the group consisting of: near-infrared spectroscopy, mid-infrared spectroscopy, UV-VIS spectroscopy, optical camera-based methods, Raman spectroscopy, THz spectroscopy, laser-induced breakdown spectroscopy, and X-ray fluorescence-based methods.

5. The method according to any one of claims 1 to 4, wherein, The mechanical treatment in step (c) is selected from the group consisting of: grinding, beating, crushing, tearing, and a combination of two or more of these treatments.

6. The method according to any one of claims 1 to 5, further comprising the following steps: The target foam sheets (116) are pressed to form a pressed target foam sheet (120) before being subjected to the mechanical treatment, and / or the target foam sheets (126) are pressed to form a pressed target foam sheet.

7. The method according to any one of claims 1 to 6, wherein, The shredded material (106) includes vehicle seats, headliners, dashboards, interior panels, automotive shredded residue, shredded light fraction (SLF) separated from automotive shredded residue, shredded heavy fraction (SHF) separated from automotive shredded residue, or any combination thereof.

8. The method according to any one of claims 1 to 7, further comprising the following steps: - Feed these target foam sheets (116), these compressed target foam sheets (120), these target foam films (126), and / or these compressed target foam films into reactor (128), and -The reaction mixture is obtained by depolymerizing the target foam sheets (116), the pressed target foam sheets (120), the target foam sheets (126) and / or the pressed target foam sheets by hydrolysis, acid hydrolysis, alcohol hydrolysis, hydroammonolysis, hydroamine hydrolysis, amine hydrolysis or any combination thereof.

9. The method of claim 8, further comprising the step of separating the reaction mixture into a polyol-rich phase and an amine-rich phase.

10. The method of claim 9, further comprising the following steps: - Purify the polyol-rich phase in a polyol post-processing setup to obtain a recycled polyol component, and / or - The amine-rich phase is purified in an amine post-processing setup to obtain the amine component for recycling.

11. The method of claim 10, further comprising the step of converting the recycled amine component to obtain a recycled isocyanate component.

12. The method of claim 10 or 11, further comprising the step of preparing a novel polymer material from the recycled polyol component, the recycled amine component, and / or the recycled isocyanate component.

13. A method, preferably the method of any one of claims 1 to 12, comprising the following steps: - The target foam sheets (116), the pressed target foam sheets (120), the target foam sheets (126) and / or the pressed target foam sheets, and / or the chemical materials that are available or obtainable by any one of claims 1 to 7, and are available or obtainable by any one of claims 8 to 12, are converted to obtain product PRF1.

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