Global Innovation Edge Secures Patent for the Conversion of Mattress Foam

The U.S. Patent and Trademark Office recently granted a patent to Edge Global Innovation Inc., a Houston-based company that has developed a thermochemical conversion process. This patent represents a substantial improvement in the process of transforming discarded and industrial scrap foam into high-value recycled materials.

A technique called "vitrimerization" is used by the recently patented process to transform polyurethane foam waste into reusable materials. The process is being commercialised by VitriCycle LLC, a subsidiary of Edge Global Innovation.

Unlike chemical recycling approaches, CEO Vahid Serajian said the VitriCycle process is designed to be energy-efficient and does not require additional solvents or catalysts.

“Turning old mattress foam into synthetic leather products, shoe soles, phone cases, key rings, bumpers, gaskets, and other everyday products is the future we are building with VitriCycle,” said Serajian.

As part of its objective to establish new markets for post-consumer polyurethane mattress foam, the Mattress Recycling Council provided funding for an initial phase of the research. It is the first research project supported by the MRC to receive a patent, which is the VitriCycle process. There are six additional patent applications that are currently pending, which are based on research conducted by the MRC.

“We are excited to have played a supporting role in developing this technology at an early stage and are thrilled to see it advancing to adoption in new markets,” said Mike O’Donnell, Chief Operating Officer of the Mattress Recycling Council.

The core technology of VitriCycle generates pellets from scrap foam for injection moulding, which are suitable for rubber-like applications such as soft plastic components, footwear products, phone cases, industrial gaskets, and automotive accessories.

The same process can also be employed to produce synthetic leather sheets for a variety of sustainable design applications, including promotional products, craft projects, furniture, accessories, and wallets. VitriCycle is promoting this product line under the name "KindHide.

Manufacturers, brands, and designers are actively seeking U.S.-made recycled materials, circular materials for industrial and consumer products, sustainable leather alternatives, and recycled polyurethane sheets. VitriCycle anticipates a robust market potential. VitriCycle products may also assist manufacturers in mitigating their exposure to virgin resin pricing, oil price volatility, tariffs, and overseas supply-chain risks, as the materials are manufactured from recycled foam in the United States.

VitriCycle has engaged in exploratory discussions with a national furniture manufacturer regarding circular applications. Furniture manufacturers have the potential to develop a new product line that emphasises circularity and sustainability by converting their excess polyurethane scrap foam into synthetic leather sheets for use in chairs, sofas or other upholstery components.

The VitriCycle technology is also accessible to manufacturers through licensing agreements, providing a means for foam manufacturers, mattress producers, furniture manufacturers, automotive suppliers, and mattress recyclers to generate value from scrap polyurethane foam.

Vitricycle's innovative technology has the potential to open up global markets for industrial scrap foam and post-consumer mattress foam.

Source: BedTimes Magazine