U.S. Company Wins Mattress Recycling Patent

The U.S. Patent and Trademark Office has granted a patent to Houston-based Edge Global Innovation Inc. for its thermochemical conversion technology, a significant advancement in recycling discarded and industrial foam waste into high-value materials. The patented vitrimerization process transforms polyurethane foam waste into reusable products and is being commercialized through the company’s subsidiary, VitriCycle LLC.

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

CEO Vahid Serajian said, "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."

The Mattress Recycling Council supported the early-stage research behind VitriCycle’s technology, which converts post-consumer and industrial polyurethane foam waste into high-value recycled materials. The company’s patented process produces reusable pellets for injection molding and synthetic leather sheets, serving applications across footwear, consumer goods, furniture, automotive components, and industrial products.

VitriCycle sees strong demand from manufacturers and brands seeking U.S.-made recycled materials and sustainable alternatives to conventional plastics and leather. By utilizing recycled foam sourced domestically, the technology can also help reduce dependence on virgin resins and mitigate supply-chain and pricing risks.

The company is exploring circular-economy applications with furniture manufacturers and is offering the technology through licensing agreements to foam producers, mattress manufacturers, recyclers, furniture makers, and automotive suppliers. VitriCycle believes its innovation has the potential to create new global markets for post-consumer mattress foam and industrial scrap foam.

Source: Mattress Recycling Council