Recycling polyols produced from seat cover materials

Abstract

The present application relates to a method for producing a molded recycled polyurethane foam for a seat element, from seat cover material.

Description

Description Title: Recycling of polyols produced from seat cover materials. technical field

[0001] This disclosure relates to the field of polyurethane foams for automotive seats. Specifically, this disclosure relates to the recycling of seat cover materials to produce new polyurethane foams. Previous technique

[0002] The synthesis of polyurethane materials (rigid and flexible foams, elastomers, adhesives, etc.) relies on the polyaddition reaction between a polyol, for example, a polyphenol, and a polyisocyanate compound. A polyol must possess specific properties to be used in the manufacture of polyurethane materials. For example, a polyol intended for the manufacture of molded polyurethane foam for automotive seats preferably has a viscosity at 25°C between 800 mPa·s and 1200 mPa·s, and a hydroxyl value between 26 mg (KOH) / g 1 and 35 mg (KOH).g 1and a water content of less than 0.1%. Indeed, a polyol with such viscosity is liquid and mixes easily with the polyisocyanate compound and any additives during the conventional manufacturing of polyurethane foam at room temperature or in a mold heated between 50 and 75°C. Furthermore, the range of hydroxyl values ​​indicated above allows for the formation of a three-dimensional cross-linked network, giving the foam, among other things, mechanical properties suitable for use in automotive seating.

[0003] Polyols and polyisocyanate compounds are petrochemical-derived polymers whose production generates significant amounts of CO2. In order to reduce dependence on oil, and also decrease the amount of CO2 emitted, it is necessary to use polyols and polyisocyanate compounds of non-petrochemical origin or recycled.

[0004] Automotive seat covers classically include a charmeuse made of poly(ethylene terephthalate) or polyamide, a look material made of poly(ethylene terephthalate) and a split block polyurethane foam between the charmeuse and the look material.

[0005] Currently, materials from end-of-life automotive seat covers or those left over from seat production are incinerated or landfilled; they are not recycled. Yet, they represent an alternative source to petroleum for the production of polyols, which can then be used to produce recycled polyurethane foam for seats, creating a virtuous cycle of material recycling.

[0006] However, producing a polyol with the desired properties for manufacturing polyurethane seat foam from headwear materials is not straightforward because headwear materials are complex, composed of materials of different natures: poly(ethylene terephthalate)-based textiles, polyamide-based textiles, and foam. polyurethane. Indeed, to produce a molded recycled polyurethane foam with comfort properties that meets the requirements of automotive seats, it is necessary that the depolymerization of the headrest materials allows for the precise cutting of the material structure in order to produce small molecules containing hydroxyl groups capable of subsequently reacting with isocyanates. It is therefore to the credit of the inventors that they have found a process that meets this need. Summary

[0007] A process is proposed for the production of recycled polyurethane foam, particularly for seats, mattresses or sofas, more particularly for vehicle seats such as automobiles or aircraft seats, for furniture seating, especially for automobile seat headrests, for automobile seat lateral support, said process comprising the following steps: a) treating a seat cover material, particularly for automobile seats, aircraft seats, or furniture seats, by glycolysis to obtain a liquid mixture of polyols, and b) contacting the liquid mixture of polyols with a polyol, a surfactant, a polyisocyanate compound and optionally an additive to produce the recycled polyurethane foam, wherein the seat cover material is selected from polyester, polyurethane foam, poly(ethylene terephthalate), polyamide and mixtures thereof,characterized in that the mass ratio of liquid mixture of polyols: polyol at step b) is greater than or equal to 1:99 and less than 40:60, in particular is between 10:90 and 30:70, most particularly is between 15:85 and 20:80, and the surfactant is selected from an anionic surfactant, a cationic surfactant, a zwitterionic surfactant, a nonionic surfactant and mixtures thereof, more particularly from a nonionic surfactant.

[0008] During step a) of glycolysis treatment, which is a conventional step known to those skilled in the art, the seat cover material will depolymerize to form the liquid mixture of polyols. The polyols in this liquid mixture then react with the polyisocyanate compound during step b) of the process of the present invention to produce recycled polyurethane foam, particularly for seating, which may comprise up to 6% by mass of the seat cover material.

[0009] However, the inventors found that the liquid polyol mixture could not be used as such in step b) because of its very high hydroxyl number. This hydroxyl number increases the hardness of the foams produced, decreases the open cell count in the foam, and increases its shrinkage. Foams produced with a High hydroxyl index polyols are therefore not suitable foams for car seats.

[0010] Without being bound by any theory, the inventors are of the opinion that this high hydroxyl index is due to the implementation of the cap material in step a). Indeed, the glycolysis of the cap material, in particular poly(ethylene terephthalate) and polyamide, leads to the obtaining of polyols with a high hydroxyl index.

[0011] On the other hand, the introduction of polyols obtained by depolymerizing headgear materials into molded seat foam formulations disrupts the foaming process by destabilizing the foam, which collapses during the molding process. Without being bound by any theory, the inventors are of the opinion that this destabilizing effect is due to the implementation of the material for the cap in step a) because it contains pollutants such as sizing oils, dyes, fillers likely to disrupt the foaming processes.

[0012] It is to the credit of the inventors that they found that the use of the polyol and the surfactant in step b) of the process of the invention makes it possible to solve these problems.

[0013] Thus, thanks to steps a) and b), the process of the present invention creates a virtuous circle of recycling a significant amount of material for head coverings, whereas this material is not normally recycled.

[0014] Thanks to this virtuous circle, the process of the present invention makes it possible to reduce the pollution generated by the incineration of these materials, to reduce the environmental impact and the amount of CO2 produced by the polyurethane foam production chain for seats.

[0015] The process of the present invention also makes it possible to reduce and limit the volatility of the production costs of polyurethane seat foam by limiting the amount of petroleum-based polyol incorporated into this foam.

[0016] Furthermore, the foam produced by the process of the present invention exhibits a rise profile comparable to that of an industrial foam produced from a petrochemical-derived polyol and commonly used in seating. Thus, the foam produced by the process of the present invention can be used in a seat component and does not require modification of the conventional industrial process for producing polyurethane foam.

[0017] According to another aspect, a polyurethane foam is proposed, in particular for seats, seat elements, mattresses or sofas, more particularly for vehicle seats such as automobiles or airplanes, for seating for furniture, which can be obtained by the process of the present invention. Brief description of the drawings

[0018] Other features, details, and advantages will become apparent upon reading the detailed description below and analyzing the attached drawings, on which: Fig. 1

[0019] [Fig. 1] shows a foam rise profile according to the invention (mass ratio liquid mixture of polyols:polyol of 20:80 and mass ratio liquid mixture of polyols:polyol of 30:70) and comparative foams (Reference). Fig. 2

[0020] [Fig. 2] shows different photos of foams according to the invention and comparative foams. Description of the implementation methods

[0021] A process is proposed for the production of recycled polyurethane foam, particularly for seats, mattresses or sofas, more particularly for vehicle seats such as automobiles or aircraft seats, for furniture seating, especially for automobile seat headrests, for automobile seat lateral support, comprising the following steps: a) glycolytic treatment of a seat cover material, particularly for automobile seats, aircraft seats, furniture seats, to obtain a liquid mixture of polyols, and b) contacting the liquid mixture of polyols with a polyol, a surfactant, a polyisocyanate compound and optionally an additive to produce the recycled polyurethane foam, wherein the seat cover material is selected from polyester, polyurethane foam, poly(ethylene terephthalate), polyamide and mixtures thereof,characterized in that the mass ratio of liquid mixture of polyols: polyol at step b) is greater than or equal to 1:99 and less than 40:60, in particular is between 10:90 and 30:70, most particularly is between 15:85 and 20:80, and the surfactant is selected from an anionic surfactant, a cationic surfactant, a zwitterionic surfactant, a nonionic surfactant and mixtures thereof, more particularly from a nonionic surfactant.

[0022] For the purposes of this invention, the term "foam," as used, for example, in the expression "polyurethane foam," refers to a compound with a three-dimensional, expanded, cellular structure. The foam may be rigid or flexible, with open or closed cells.

[0023] For the purposes of this invention, "seat foam" means a foam whose mechanical properties are suitable for a seat element, in particular an automotive seat element, an aircraft seat element, or a furniture seat element.

[0024] For the purposes of the present invention, "seat element" means a headrest, an armrest, a side part and combinations thereof.

[0025] For the purposes of the present invention, the term "seat cover" refers to an element covering the padding of a seat.

[0026] According to the invention, the seat cover material is selected from polyurethane foam, poly(ethylene terephthalate), polyamide, and mixtures thereof. Typically, the poly(ethylene terephthalate) can be derived from the seat cover's appearance material and / or the charmeuse material, the polyamide can be derived from the charmeuse material, and the polyurethane foam can be the foam between the appearance material and the charmeuse material.

[0027] Typically, seat cover material can come from all or part of the cover, waste from cover production, waste from cover cutting, waste from the end of life of an automotive seat, or combinations thereof.

[0028] Step a) of glycolysis treatment is a standard step known to those skilled in the art. It is described, for example, in: The chemical recycling of polyurethane (review), Behrendt & Naber, Journal of the University of Chemical Technology and Metallurgy, 44, 1, 2009, 3-23 (January 2009). Those skilled in the art will know how to implement it to obtain the liquid polyol mixture, in particular the liquid polyol mixture exhibiting the following properties: - a hydroxyl value between 200 mg (KOH).g 1 and 700 mg (KOH).g 1 , more specifically between 300 mg (KOH).g 1 and 500 mg (KOH).g 1 , And - a viscosity at 25°C between 500 mPa.s and 5000 mPa.s more particularly between 750 mPa.s and 2000 mPa.s, more particularly still between 1000 mPa.s and 1500 mPa.s.

[0029] For the purposes of the present invention, "viscosity" means Brookfield viscosity and / or viscosity measured by a cone-plate viscometer at 25°C.

[0030] The viscosity of the liquid polyol mixture facilitates its implementation in step b). Indeed, it is advantageously liquid at 25°C and mixes easily with the polyol, the surfactant, the polyisocyanate compound and the possible additive during step b) to produce the polyurethane foam.

[0031] For the purposes of the present invention, "hydroxyl index" means the content of free hydroxyl groups in a chemical substance expressed in milligrams of potassium hydroxide equivalent to the hydroxyl content of one gram of the chemical substance.

[0032] The implementation of the seat cover material in step a) results in obtaining the liquid mixture of polyols exhibiting a high hydroxyl number, in particular a hydroxyl number within the ranges above. This high index does not allow the liquid mixture of polyols to be implemented, as such, in step b) of the process of the present invention.

[0033] The inventors noted that the polyurethane foam formed from the liquid mixture of polyols, polyol, surfactant and possible additive under the conditions of the process of the invention has mechanical properties suitable for use in a seat component. In particular, the three-dimensional reticulated network of the foam gives it, among other things, mechanical properties suitable for its use in an automotive seat component.

[0034] The polyol used in step b) of the process of the present invention is of petrochemical or bio-based origin. For example, it can be chosen from alkoxylated glycerol, alkoxylated sorbitol, alkoxylated diethyltriamine, alkoxylated sucrose, polyoxypropylene glycol-based polyols and mixtures thereof, in particular from alkoxylated diethyltriamine, polyoxypropylene glycol-based polyols and mixtures thereof, more particularly from polyoxypropylene glycol-based polyols and mixtures thereof.

[0035] Caradol SA34-05, Wanol F3135, Lupranol 2095, Lupranol 2090, Nextyol Y-3322N and Rokopol 6010 are examples of commercial polyols suitable for use alone or in mixtures as a second polyol in the process of the present invention.

[0036] The mass ratio of liquid mixture of polyols:surfactant during step b) can be between 100:1 and 100:10, in particular between 100:3 and 100:5, more particularly is 100:5.

[0037] Advantageously, such a mass ratio of liquid mixture of polyols:surfactant helps to prevent the collapse of the foam during the foaming process.

[0038] According to the invention, the surfactant is chosen from an anionic surfactant, a cationic surfactant, a zwitterionic surfactant, a non-ionic surfactant and mixtures thereof, more particularly from a non-ionic surfactant.

[0039] For the purposes of the present invention, "non-ionic surfactant" means a surfactant whose lipophilic part and hydrophilic part are not charged.

[0040] For the purposes of the present invention, "zwitterionic surfactant" means a surfactant in which one of the lipophilic and hydrophilic parts is positively charged, the other being negatively charged.

[0041] For the purposes of the present invention, "anionic surfactant" means a surfactant comprising only anionic groups as ionic or ionizable groups.

[0042] For the purposes of the present invention, "cationic surfactant" means a surfactant comprising only cationic groups as ionic or ionizable groups.

[0043] According to one embodiment, the non-ionic surfactant can be a silicone surfactant.

[0044] For the purposes of the present invention, "silicone surfactant" means a non-ionic surfactant comprising at least one silicone atom.

[0045] The silicone surfactant can, for example, be chosen from a polyalkylsiloxane, a dimethylpolysiloxane modified by a polyoxyalkylene polyol, a dimethylpolysiloxane modified by an alkylene glycol and mixtures thereof, in particular be a mixture of polyalkylsiloxane and dimethylpolysiloxane modified by a polyoxyalkylene polyol.

[0046] Typically, the polyisocyanate compound can be chosen from m-phenylene diisocyanate, toluene 2,4-diisocyanate, toluene 2,6-diisocyanate, hexamethylene 1,6-diisocyanate, tetramethylene 1,4-diisocyanate, cyclohexane 1,4-diisocyanate, hexahydrotoluene diisocyanate, naphthylene 1,5-diisocyanate, methoxyphenyl-2,4-diisocyanate, diphenylmethane 4,4'-diisocyanate and their isomers, biphenylene 4,4'-diisocyanate, 3,3'-dimethoxy-4,4'-biphenyl diisocyanate, biphenyl 3,3'-dimethyl-4,4'-diisocyanate, 4,4'-3,3'-dimethyldiphenylmethane diisocyanate, 4,4',4'-triphenylmethane triisocyanate, polymethylene polyphenylisocyanate, polymeric diphenylmethane diisocyanate, isophorone diisocyanate, 2,4,6-toluene triisocyanate, 4,4'-dimethyldiphenylmethane-2,2',5,5'-tetraisocyanate, polymethylenepolyphenyl ester of isocyanic acid and mixtures thereof, in particular among 2,4-Toluene diisocyanate, 2,6-Toluene diisocyanate, 1,6-Hexamethylene diisocyanate, 4,4'-Diphenylmethane diisocyanate, polymethylene polyphenylisocyanate, polymeric diphenylmethane diisocyanate, isophorone diisocyanate and mixtures thereof, particularly among 4,4'-Diphenylmethane diisocyanate, polymethylene polyphenylisocyanate, polymeric diphenylmethane diisocyanate, 2,4-Toluene diisocyanate, 2,6-Toluene diisocyanate and mixtures thereof, particularly again polymeric diphenylmethane diisocyanate.

[0047] The mass ratio of liquid mixture of polyols:polyisocyanate compound can be between 1:100 and 45:100, in particular between 3:100 and 35:100, especially between 20:100 and 30:100.

[0048] In order to modify and / or improve the properties of polyurethane foam, an additive known to those skilled in the art may be added during step b) of the process of the present invention. Typically, this additive may be selected from a crosslinker, a flame retardant, a blowing agent, an antioxidant, an anti-hydrolysis agent, a biocide and mixtures thereof, in particular selected from a crosslinker, a flame retardant, a blowing agent and mixtures thereof, in particular being a crosslinker, a blowing agent or mixtures thereof.

[0049] For the purposes of this invention, "crosslinking agent" means a compound that generates the formation of one or more three-dimensional networks in polyurethane foam. The crosslinking agent may be selected from glycerol, diethanolamine, triethanolamine, glycols with a molecular weight less than 1000 and a functionality greater than or equal to 3, and mixtures thereof, in particular diethanolamine, triethanolamine, and mixtures thereof.

[0050] For the purposes of this invention, "flame retardant (also called flame retardant)" means a compound having the property of reducing or preventing the combustion or heating of the materials it impregnates or coats. The flame retardant may, for example, be antimony, graphite, a silicate, boron, a nitrogenous, halogenated or phosphorus compound such as tris(1-chloro-2-propyl) phosphate (TCPP), triethylene phosphate (TEP), a triaryl phosphate ester, an ammonium polyphosphate, red phosphorus, trishalogenaryl or mixtures thereof.

[0051] For the purposes of this invention, "blowing agent" means a compound that, through chemical and / or physical action, induces the expansion of a composition during a foaming step. Typically, the chemical blowing agent is selected from water, formic acid, phthalic anhydride, and acetic acid. The physical blowing agent can be selected from pentane and pentane isomers, hydrocarbons, hydrofluorocarbons, hydrochlorofluoroolefins, hydrofluoroolefins (HFOs), ethers, and mixtures thereof. Methylal is an example of an ether-type blowing agent. According to the invention, a mixture of chemical and physical blowing agents is, for example, a mixture of water / pentane isomer, formic acid / pentane isomer, water / hydrofluoroolefins, pentane isomer / methylal / water, or water / methylal.

[0052] According to a particular embodiment, the blowing agent is water.

[0053] The polyurethane foam produced by the process of the invention can be molded. Step b) can therefore be implemented in a mold with a shape suitable for a seat element, in particular a car seat, an airplane seat, a seat for furniture, especially a car seat. Step b) can alternatively be carried out in a mold not representing a suitable shape for a seat element to produce a molded polyurethane foam, then this foam is shaped to present a suitable shape for a seat element.

[0054] The polyol, surfactant, polyisocyanate compound and any additive may be pre-mixed and the resulting mixture is introduced into the mold.

[0055] It is possible to heat the mold in which step b) is carried out. Thus, reaction step b) can be carried out at a temperature between 30°C and 100°C, in particular between 40°C and 80°C, especially between 50°C and 65°C.

[0056] A catalyst can be used to accelerate the reaction kinetics between the polyol mixture and the polyisocyanate compound and, optionally, between the polyisocyanate compound and the chemical blowing agent during step b) of the process of the present invention.

[0057] Thus, according to one embodiment, step b) of the process of the present invention can be carried out in the presence of a catalyst.

[0058] The amount of catalyst used in the manufacturing process of the polyurethane foam of the invention depends on the compounds used in said process. A person skilled in the art will be able to adjust this amount.

[0059] Typically, the catalyst can be chosen from among those known to catalyze expansion (water-isocyanate) and gelation (polyol-isocyanate) reactions. The catalysts are essentially based on primary, secondary, or tertiary amines containing primary hydroxyl groups, secondary hydroxyl groups, amides, or ureas. Examples of such catalysts include at least one element chosen from the group consisting of N,N-bis(3-dimethylaminopropyl)-N-(2-hydroxypropyl)amine; N,N-dimethyl-N',N'-bis(2-hydroxypropyl)-1,3- propylenediamine; dimethylaminopropylamine (DMAPA); N-methyl-N-2-hydroxypropylpiperazine, bis-dimethylaminopropylamine (POLYCAT 15), dimethylaminopropyl urea and N,N'-bis(3-dimethylaminopropyl) (DABCO NE1060, DABCO NE1070, DABCO NE 1080 and DABCO NE 1082), 1,3-bis(dimethylamino)-2-propanol, 6-dimethylamino-1-hexanol, N-(3-aminopropyl)imidazole, N-(2-hydroxypropyl)imidazole, N,N'-bis(2-hydroxypropyl)piperazine, N-(2-hydroxypropyl)morpholine and N-(2-hydroxyethylimidazole). Catalytic compositions may also include other components, for example transition metal catalysts such as organotin compounds or bismuth carboxylates, for example.

[0060] According to one embodiment, the process of the present invention may include, before step a) of treatment by glycolysis, a step of grinding the material for seat cover to obtain particles having a diameter between 1 mm and 20 mm, in particular between 3 mm and 10 mm, especially between 4 mm and 6 mm, which are implemented in step a) of contacting.

[0061] The particle size can be determined by sieving.

[0062] The use of particles with a diameter in these ranges makes it easier and faster to depolymerize the material for seat covers.

[0063] Typically, this grinding stage can be carried out by cryogenics, grinding using a vibrating ball mill, a knife mill, a hammer mill, a shredder, a centrifuge, or pulsed energy, or combinations thereof. These methods are familiar to those skilled in the art. They will be able to select and implement the method best suited to the material being ground.

[0064] The liquid polyol mixture obtained at the end of step a) may contain solid impurities such as pieces of foam that have not reacted with the glycol. These solid impurities can affect step b) and thus alter the production process of the polyurethane foam produced.

[0065] To overcome these problems, the process of the present invention may further include, between step a) and step b): - a filtration step of the liquid mixture of polyols to obtain a liquid mixture of polyols free of solid particles.

[0066] The filtration stage is a standard step familiar to those skilled in the art. They will therefore know how to implement it.

[0067] Amino compounds in the liquid polyol mixture may alter the implementation of step b) of the process of the present invention.

[0068] To overcome this problem, the process of the present invention may further include, between step a) and step b): - a deamination step of the liquid mixture of polyols to obtain a liquid mixture of polyols totally or partially free of amino compounds.

[0069] According to another aspect, the present invention, which relates to a polyurethane foam for seating, in particular for automobile seats, for airplane seats, for furniture seating, is capable of being obtained by the process of the present invention as defined below.

[0070] Advantageously, this polyurethane seat foam exhibits properties, particularly density, of the same order of magnitude as industrial polyurethane foam produced from petrochemical-derived polyols and commonly used in automotive seats. This polyurethane foam can therefore be used in automotive seat components. Examples

[0071] The following examples illustrate the invention without limiting it.

[0072] In these examples, we measure: - the hydroxyl index according to ISO 14900:2017, and - density according to DIN EN ISO 845 (2006).

[0073] In these examples, the foam rise profile is determined according to the following protocol. The polyol, the polyisocyanate compound, and the additives are mixed and then poured into a container for a specified duration (5 seconds). At the end of this time, a device (Universal Foam Qualification System, FORMAT Messtechnik) measures the height of expansion over time.

[0074] Example 1: Obtaining the liquid mixture of polyols

[0075] Flakes of seat cover material obtained from cutting and composed of a poly(ethylene terephthalate) appearance material, a split polyurethane foam and a poly(ethylene terephthalate) charmeuse with a particle size of less than 6 mm are brought into contact with diethylene glycol to obtain a liquid mixture of polyols by glycolysis treatment.

[0076] The liquid mixture of polyols has the following characteristics: - hydroxyl value of 438 mg (KOH).g 1 , And - viscosity at 25°C of 1160 mPa.s. Therefore, it cannot be used, as such, in a reaction to produce a flexible polyurethane foam because the hydroxyl index is too high.

[0077] Example 2: Production of flexible molded polyurethane foams from the liquid mixture of polyols of Example 1.

[0078] The liquid mixture of polyols in Example 1 is mixed, in different proportions, with a polyol, which is Rokopol 6010, to obtain two blended polyols, the 20% polyol and the 30% polyol. In the 20% polyol, the mass ratio of liquid mixture of polyols to polyol is 20:80. In the 30% polyol, the mass ratio of liquid mixture of polyols:polyol is 30:70.

[0079] Example 2a: Polyol 20%.

[0080] The rise profile of a foam obtained by mixing 47% by mass of polyol 20%, 0.5% by mass of surfactant (TEGOSTAB® B 8738 LF), 1.7% by mass of water (blowing agent), 0.3% by mass of Jeffcat ZF-10 (catalyst), 0.3% by mass of Dabco 33LX (catalyst), 0.5% of Dabco NE 1070 (catalyst), 0.4% of diethanolamine (crosslinking agent), 1.3% of triethanolamine (crosslinking agent), and 48% by mass of an isocyanate compound (ISO 135 / 161 (BASF)) is determined.

[0081] The rise profile of a reference foam suitable for use in a seat element obtained by mixing 47% by mass of Rokopol 6010, 0.5% by mass of surfactant (TEGOSTAB® B 8738 LF), 1.7% by mass of water (blowing agent), 0.3% by mass of Jeffcat ZF10 (catalyst), 0.3% by mass of Dabco 33LX (catalyst), 0.5% of Dabco NE 1070 (catalyst), 0.4% of diethanolamine (crosslinking agent), 1.3% of triethanolamine (crosslinking agent), and 48% by mass of an isocyanate compound (ISO 135 / 161 (BASF)), is determined.

[0082] As shown in Figures 1 and 2, the foam obtained from the 20% polyol exhibits a foam rise profile and structure comparable to the reference foam. Therefore, the foam obtained from the 20% polyol can be used in a seat component.

[0083] Example 2b: Polyol 30%.

[0084] The foam rise profile obtained by mixing 47% by mass of the 30% polyol, 0.5% by mass of surfactant (TEGOSTAB B 8738 LF), 1.7% by mass of water (blowing agent), 0.3% by mass of Jeffcat ZF10 (catalyst), 0.3% by mass of Dabco 33LX (catalyst), 0.5% of Dabco NE 1070 (catalyst), 0.4% of diethanolamine (crosslinking agent), 1.3% of triethanolamine (crosslinking agent), and 48% by mass of an isocyanate compound (ISO 135 / 161 (BASF)) is determined.

[0085] As shown in Figures 1 and 2, the foam obtained from the 30% polyol exhibits a foam rise profile and structure comparable to the reference foam. Therefore, the foam obtained from the 30% polyol can be used in a seat component.

Claims

Demands

1. A process for producing recycled polyurethane foam comprising the following steps: a) treating a seat cover material by glycolysis to obtain a liquid mixture of polyols, and b) contacting the liquid mixture of polyols, a polyol, a surfactant, a polyisocyanate compound and optionally an additive to produce the recycled polyurethane foam, wherein the seat cover material is selected from polyester, polyurethane foam, poly(ethylene terephthalate), polyamide and mixtures thereof, characterized in that the mass ratio of liquid mixture of polyols: polyol at step b) is greater than or equal to 1:99 and less than 40:60, and the surfactant is selected from an anionic surfactant, a cationic surfactant, a zwitterionic surfactant, a nonionic surfactant and mixtures thereof.

2. A method according to claim 1 wherein the recycled polyurethane foam is for seating.

3. A method according to claim 1 wherein the recycled polyurethane foam is for mattress or sofa.

4. A method according to any one of claims 1 to 3 wherein the seat cover material is derived from all or part of the cover, from waste from the production of the cover, from waste from cutting the cover, from waste from the end of life of an automobile seat or combinations thereof.

5. A process according to any one of claims 1 to 4, wherein the liquid mixture of polyols has: - a hydroxyl value between 200 mg (KOH).g 1 and 700 mg (KOH).g 1 , And - a viscosity at 25°C between 500 mPa.s and 5000 mPa.s.

6. A method according to any one of claims 1 to 5 wherein the polyol is selected from alkoxylated glycerol, alkoxylated sorbitol, alkoxylated diethyl triamine, alkoxylated sucrose, polyoxypropylene glycol-based polyols and mixtures thereof.

7. A method according to any one of claims 1 to 6 wherein the surfactant is a silicone surfactant.

8. A method according to any one of claims 1 to 7 wherein the mass ratio of liquid mixture of polyols:surfactant is between 100:1 and 100:

10.

9. A method according to any one of claims 1 to 8 wherein the polyisocyanate compound is selected from m-phenylene diisocyanate, toluene 2,4-diisocyanate, the 2,6-Toluene diisocyanate, hexamethylene diisocyanate, tetramethylene diisocyanate, cyclohexane diisocyanate, hexahydrotoluene diisocyanate, naphthylene diisocyanate, methoxyphenyl-2,4-diisocyanate, diphenylmethane diisocyanate and their isomers, 4,4'-Biphenylene diisocyanate, 3,3'-Dimethoxy-4,4'-Biphenyl diisocyanate, 3,3'-Dimethyl-4,4'-Biphenyl diisocyanate, 3,3'-Dimethyl-4,4'-Biphenyl diisocyanate, 3,3'-Dimethyldiphenylmethane diisocyanate, 4,4'-Triphenylmethane triisocyanate, a polyphenylisocyanate polymethylene, polymeric diphenylmethane diisocyanate, isophorone diisocyanate, 2,4,6- toluene triisocyanate, 4,4'-dimethyldiphenylmethane-2,2',5,5'-tetraisocyanate, polymethylenepolyphenyl ester of isocyanic acid and mixtures thereof.

10. A method according to any one of claims 1 to 9 wherein the mass ratio of liquid mixture of polyols:polyisocyanate compound is between 1:100 and 45:

100.

11. A method according to any one of claims 1 to 10 wherein an additive is added during step b).

12. A method according to claim 11 wherein the additive is selected from a crosslinking agent, a flame retardant, a blowing agent, an antioxidant, an antihydrolysis agent, a biocide, and mixtures thereof

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