MONTREAL (RecyclingMonster): Houston-based Edge Global Innovation Inc. has secured a U.S. patent for a thermochemical process that converts discarded polyurethane mattress foam into high-value recycled materials, opening the door to new end uses such as wallets, phone cases, footwear components, and synthetic leather products.

Patent Advances Foam Recycling

The newly patented process uses a method known as vitrimerization to transform polyurethane foam waste into reusable materials. Edge Global Innovation is commercializing the technology through its subsidiary, VitriCycle LLC.

The development marks a notable step forward for mattress and foam recycling, particularly as the industry looks for scalable ways to convert post-consumer and industrial scrap into higher-value products.

Process Targets Efficiency and Material Reuse

According to CEO Vahid Serajian, the VitriCycle process is designed to be energy-efficient and does not require added solvents or catalysts. The company says the technology can turn old mattress foam into products including shoe soles, phone cases, key rings, bumpers, gaskets, and other everyday items.

MRC-Backed Research Reaches Patent Stage

The Mattress Recycling Council funded an early stage of the research as part of its effort to expand end markets for post-consumer polyurethane mattress foam. The organization said VitriCycle is the first MRC-supported research project to receive a patent, with six additional patent applications still pending from MRC-backed work.

From Pellets to Synthetic Leather

VitriCycle said its core technology can produce pellets from scrap foam for injection molding, making the material suitable for rubber-like applications such as soft plastic parts, footwear items, industrial gaskets, and automotive accessories.

The same process can also be used to create synthetic leather sheets for wallets, purses, furniture, accessories, promotional items, and craft applications. The company is marketing this synthetic leather product line as “KindHide.”

Domestic Supply Chain Could Be a Selling Point

VitriCycle believes the U.S.-made recycled materials could appeal to manufacturers, designers, and brands seeking circular inputs and alternatives to conventional leather and virgin resin-based materials. The company also said domestic production may help reduce exposure to virgin resin pricing, oil price volatility, tariffs, and overseas supply-chain disruptions.

Serajian added that VitriCycle has already held exploratory talks with a national furniture manufacturer about potential circular applications for upholstery and related products.

Courtesy: www.wasteadvantagemag.com