A closed loop recycling process of manufacturing a foam part includes dispersing a filler material recycled from an additive manufacturing (AM) process in at least one foam reactant and pouring or injecting the at least one foam reactant with the filler material into a mold and forming the foam part. The foam part has a foam matrix with between 2.5 wt. % and 30 wt. % of the filler material. The filler material can be a recycled powder from a selective laser sintering process that is not graded (i.e., sized) before being dispersed in the at least one foam reactant. For example, the recycled powder can be a recycled polyamide 12 (rPA12) powder with an average particle diameter of less than 100 micrometers. Also, the least one foam reactant can be a polyol reactant and an isocyanate reactant such that a polyurethane foam matrix with recycled rPA12 filler material is formed.

Foam wall structures and methods for making them are described. The wall structures include a frame, a foam panel overlying a front surface of the frame, and a polyurethane foam layer disposed in a cavity of the wall structure. The polyurethane foam layer has a density, as determined by ASTM D1622-14, of at least 44 kg/m.sup.3 and exhibits ASTM E84-16 Class A flame spread and smoke development characteristics. The polyurethane foam layer is the cured reaction product of a polyurethane foam-forming composition that includes a polyisocyanate, an aromatic polyester polyol having a functionality of greater than 2.5 and an OH number of at least 300 mg KOH/g, which is present in an amount of at least 50% by weight, based on the total weight of the polyurethane foam-forming composition less the weight of the polyisocyanate, a catalyst, and a blowing agent composition. The blowing agent composition includes water and a hydrofluoroolefin.

Isocyanate-reactive compositions that include a hydrofluoroolefin blowing agent, polyurethane foam-forming compositions, as well as spray-applied polyurethane foams formed therefrom that can provide structural support to wall structures and can also exhibit ASTM E84-16 Class A flame spread and smoke development characteristics at a foam thickness of 4 inches.

An amorphous polyester or copolyester composition comprises the reaction product of a crystalline or semicrystalline polyester or copolyester, optionally derived from a recycled waste stream, at least one diol or aromatic diacid or an ester of a diacid or a hydroxycarboxylic acid or a lactone or a dianhydride, and a catalyst, wherein the amorphous composition has a weight average molecular weight of at least 10,000 g/mol (polystyrene equivalent molecular weight) as measured by gel permeation chromatography.

The present invention relates to a method for preparing a foamed thermoplastic polyurethane elastomer product, comprising the steps of: 1) coating a binder: coating the binder on the surfaces of expandable thermoplastic polyurethane elastomer particles; 2) curing and molding: adding the product obtained from step 1) to a mold and then placing it in a vulcanizing machine for curing and molding; and 3) cooling and setting: cooling the mold after the molding in step 2) to obtain the product of the present invention. By means of pre-coating the binder on the surfaces of expanded thermoplastic polyurethane elastomer particles according to the present invention, the weight of the binder can be reduced, and the properties of the expanded thermoplastic polyurethane elastomer particles can be utilized to the maximum extent.

The present disclosure relates to a foam layer that may include a silicone based matrix component, a flame retardant filler component, and an insulation filler component. The foam layer may have a thickness of at least about 0.5 mm and no greater than about 10 mm. The foam layer may further have a compression force deflection at 25% of at least about 5 kPa and not greater than about 500 kPa. The foam layer may also have a HBF flammability rating as measured according to ASTM D4986.

To provide a polyether polyol having a high degree of freedom in the design of a polyurethane foam, and capable of providing a polyol system solution excellent in storage stability. A polyether polyol having a polyoxyalkylene chain consisting of oxyalkylene units, and having a degree of unsaturation of at most 0.020 meq/g, a hydroxy value of from 1 to 80 mgKOH/g, a content of oxyethylene units of from 0 to 50 mass %, and a content of ultra-high molecular weight components which have molecular weights of from 12 to 46 times the number average molecular weight of at most 1,000 mass ppm. The number average molecular weight is a molecular weight as calculated as polystyrene measured by gel permeation chromatography (GPC) method, and the content of ultra-high molecular weight components is a value measured by high performance liquid chromatography (HPLC) method using a charged aerosol detector (CAD).

A process includes calcining a high potassium carbonaceous waste product to form potassium oxide and carbon dioxide and reacting the potassium oxide and carbon dioxide to yield bio-based potassium carbonate. The process also includes catalyzing a reaction of a lignocellulosic biomass with abundant hydroxyl groups into a biopolyol using the bio-based potassium carbonate and brominating using a brominating agent a triglyceride to form a bio-isocyanate. In addition, the process includes reacting the biopolyol and the bio-isocyanate to form a polyurethane foam.

Polyurethane foams that are hydrophilic but nonetheless have low compression sets are made from a combination of MDI and TDI prepolymers, water, and a polymer polyol. The foams optionally are made incorporating a phase change material in the foam formulation. The phase change material does not require encapsulation.

A reactive mixture and method for making a thermoplastic polyurethane (TPU) flexible foam having a predominantly open-cell structure (open-cell content of ≥50% by volume calculated on the total volume of the foam and measured according to ASTM D6226-10) and an apparent density below 200 kg/m.sup.3.