en.Wedoany.com Reported - Edge Global Innovation, through its subsidiary VitriCycle LLC, has been granted a patent by the United States Patent and Trademark Office for a thermochemical conversion process that transforms post-consumer polyurethane foam into reusable materials.
The Mattress Recycling Council (MRC) disclosed in a press release that this patented process employs a method known as "vitrification." VitriCycle CEO Vahid Serajian stated that, unlike chemical recycling methods, this process is designed to be energy-efficient and does not require additional solvents or catalysts.
Vahid Serajian added that old mattress foam can be converted through this process into synthetic leather products, shoe soles, phone cases, keychains, bumpers, gaskets, and other everyday items. The MRC funded the early stages of this research as part of its mission to develop new markets for post-consumer polyurethane mattress foam. This is the first MRC-supported research project to receive a patent, with six additional patent applications based on MRC research currently under review.
Mike O'Donnell, Chief Operating Officer of the MRC, headquartered in Alexandria, Virginia, stated that the MRC is pleased to have supported the development of this technology in its early stages and to see it being adopted in new markets.
The core technology utilizes waste foam to produce granules for injection molding, suitable for rubber-like applications such as soft plastic components, footwear products, phone cases, industrial gaskets, and automotive parts. The same process can also be used to produce synthetic leather sheets for wallets, handbags, furniture, accessories, promotional products, and crafts. Serajian noted that this product line is being marketed under the KindHide brand, as it is "a friendlier alternative to cowhide."
According to the press release, the company sees strong market potential from manufacturers, brands, and designers seeking US-made recycled materials, sustainable leather alternatives, recycled polyurethane sheets, and circular materials for consumer and industrial products. These products can help manufacturers reduce exposure to virgin resin prices, oil price fluctuations, tariffs, and overseas supply chain risks, as the materials are produced from domestically recycled foam.
Serajian stated that VitriCycle has held exploratory discussions with a domestic furniture manufacturer regarding circular applications. Furniture companies have the potential to convert surplus polyurethane waste foam into synthetic leather sheets for chairs, sofas, or other upholstered components. VitriCycle's technology can also be made available to manufacturers through licensing agreements.
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