Reprocessing Postconsumer Polyurethane Foam Using Carbamate Exchange Catalysis and Twin-Screw Extrusion

Daylan T. Sheppard, Kailong Jin, Leslie S. Hamachi, William Dean, David J. Fortman, David J. Fortman, Christopher J. Ellison, William R. Dichtel

Research output: Contribution to journalArticlepeer-review

16 Scopus citations

Abstract

Cross-linked polyurethane (PU) is extensively used as thermoset foam; however, methods to directly reprocess PU foam waste derived from commercial sources into similar value materials have not been developed. We demonstrate that introducing dibutyltin dilaurate (DBTDL) into cross-linked PU foams and films enables their reprocessing at elevated temperatures via dynamic carbamate exchange reactions. Both model and commercial cross-linked PU foams were continuously reprocessed using twin-screw extrusion to remove gaseous filler and produce PU filaments or films with elastomeric or rigid thermoset mechanical properties. The properties of microcompounded model PU foam were in excellent agreement with PU film synthesized using the same monomers, indicating that this process occurs efficiently. These findings will enable the bulk reprocessing of commercial thermoset PU waste and inspire the further development of reprocessing methods for other thermosets and the compatibilization of chemically distinct cross-linked materials.

Original languageEnglish (US)
Pages (from-to)921-927
Number of pages7
JournalACS Central Science
Volume6
Issue number6
DOIs
StatePublished - Jun 24 2020

Bibliographical note

Funding Information:
This research was supported by the National Science Foundation (NSF) through the Center for Sustainable Polymers (CHE-1413862). This research made use of the Materials Characterization and Imaging Facility, which receives support from the MRSEC Program (NSF DMR-1121262) of the Materials Research Center at Northwestern University, and the Integrated Molecular Structure Education and Research Center at Northwestern University, which has received support from the Soft and Hybrid Nanotechnology Experimental Resource (NSF NNCI-1542205), the State of Illinois, and the International Institute for Nanotechnology. This work made use of the EPIC facility of Northwestern University’s NUANCE Center, which has received support from the Soft and Hybrid Nanotechnology Experimental (SHyNE) Resource (NSF ECCS-1542205); the MRSEC program (NSF DMR-1720139) at the Materials Research Center; the International Institute for Nanotechnology (IIN); the Keck Foundation; and the State of Illinois, through the IIN. We thank John Beumer for the artistic design of Figure 1.

Publisher Copyright:
© 2020 American Chemical Society.

Copyright:
Copyright 2020 Elsevier B.V., All rights reserved.

PubMed: MeSH publication types

  • Journal Article

Fingerprint Dive into the research topics of 'Reprocessing Postconsumer Polyurethane Foam Using Carbamate Exchange Catalysis and Twin-Screw Extrusion'. Together they form a unique fingerprint.

Cite this