METHOD OF OBTAINING INFORMATION ON THE RECYCLABILITY OF AT LEAST ONE FLEXIBLE FOAM MADE AT LEAST PARTIALLY OF AT LEAST ONE POLYURETHANE

Abstract

Disclosed herein is a computer-implemented method of obtaining information on the recyclability of at least one flexible foam made at least partially of at least one polyurethane.

Further disclosed herein are a computer program and a computer-readable storage medium for performing the method, a method of treatment of the flexible foam, a device for obtaining information on the recyclability of the flexible foam and a system for treatment of the flexible foam.

Claims

1. A computer-implemented method of obtaining information on the recyclability of at least one flexible foam made at least partially of at least one polyurethane, the method comprising: i. at least one first determination step, comprising automatically determining, by evaluating spectral data of the flexible foam, whether at least one first chemical compound of a predetermined first list of recyclable candidate components for a first class of monomers of polyurethane is present in the flexible foam, the first list of recyclable candidate components comprising at least one first recyclable candidate component; and ii. at least one first decision step, comprising automatically deciding, on the basis of the outcome of step i., if a second determination step is required, the second determination step comprising determining whether at least one second chemical compound of a predetermined second list of recyclable candidate components for a second class of monomers of polyurethane is present in the flexible foam, the second list of recyclable candidate components comprising at least one second recyclable candidate component. wherein, if it is determined in the first determination step that the first chemical compound of the first list of recyclable candidate components is not present in the flexible foam, the method comprises generating at least one item of information indicating that the flexible foam is not recyclable, or else, if it is determined that the first chemical compound of the first list of recyclable candidate components is present in the flexible foam, the method further comprises the following step: iii. performing the second determination step.

2. The method according to claim 1, wherein the first class of monomers of polyurethane comprises isocyanate monomers.

3. The method according to claim 1, wherein step i comprises comparing the spectral data of the flexible foam with at least one first reference spectrum of at least one first flexible reference foam made at least partially of at least one polyurethane comprising the at least one first chemical compound of the first list of recyclable candidate components.

4. The method according to claim 1, wherein the second class of monomers of polyurethane comprises polyol monomers.

5. The method according to claim 1, wherein step iii comprises comparing the spectral data of the flexible foam with at least one second reference spectrum of at least one second flexible reference foam made at least partially of at least one polyurethane comprising the at least one second chemical compound of the second list of recyclable candidate components.

6. The method according to claim 3, further comprising: iv. at least one second decision step, comprising automatically deciding, after performing step iii., on the basis of the outcome of step iii., if a third determination step is required, the third determination step comprising determining whether at least one flame retardant compound of a predetermined third list of candidate flame retardant components is present in the flexible foam, the third list of candidate flame retardant components comprising at least one flame retardant candidate component.

7. The method according to claim 6, wherein, if it is determined in the second decision step that the second chemical compound of the second list of recyclable candidate components is not present in the flexible foam, the method comprises generating at least one item of information indicating that the flexible foam is not recyclable, or else, if it is determined that the second chemical compound of the second list of recyclable candidate components is present in the flexible foam, the method further comprises the following step: v. performing the third determination step.

8. The method according to claim 7, wherein the third list of candidate flame retardant components comprises at least one flame retardant component selected from the group consisting of: melamine derivatives, phosphates, derivatives of phosphoric acid, derivatives of phosphonic acid and derivatives of phosphinic acid.

9. The method according to claim 7, wherein step v. comprises comparing the spectral data of the flexible foam (112) with at least one third reference spectrum of at least one third flexible reference foam comprising at least one candidate flame retardant component of the third list of candidate flame retardant components.

10. The method according to claim 7, further comprising: vi. at least one third decision step, comprising automatically deciding, after performing step v., on the basis of the outcome of step v., if a fourth determination step is required, the fourth determination step comprising determining the content of at least one filler compound of a predetermined fourth list of candidate filler compounds in the flexible foam, the fourth list of candidate filler compounds comprising at least one candidate filler compound.

11. The method according to claim 10, wherein, if it is determined in the third decision step that the at least one flame retardant compound of the third list of candidate flame retardant components is not present in the flexible foam, the method comprises generating at least one item of information indicating that the flexible foam is not recyclable, or else, if it is determined that the at least one flame retardant compound of the third list of candidate flame retardant components is present in the flexible foam, the method further comprises the following step: vii. performing the fourth determination step.

12. The method according to claim 11, wherein the fourth list of candidate filler compounds comprises at least one filler compound selected from the group consisting of: polymers prepared using one or more olefinic monomers.

13. The method according to, claim 11 wherein step vii. comprises comparing the spectral data of the flexible foam with at least one fourth reference spectrum of at least one fourth flexible reference foam comprising at least one candidate filler compound of the fourth list of candidate filler compounds.

14. A non-transient computer-readable storage medium comprising instructions which, when the instructions are executed by at least one processor, cause the processor to perform the method according to claim 1.

15. A method of treatment of at least one flexible foam made at least partially of at least one polyurethane, the method comprising: I. obtaining spectral data of the flexible foam; II. obtaining information on the recyclability of the flexible foam by using the by using the spectral data and by using the method according to claim 1; and III. determining, on the basis of the information gained in step III., whether or not to recycle the flexible foam and, if the information indicates a recyclability of the flexible foam, at least partially recycling the flexible foam.

16. A device for obtaining information on the recyclability of at least one flexible foam made at least partially of at least one polyurethane, the device comprising at least one processor, the processor being configured for performing the method according to claim 1.

17. A system for treatment of at least one flexible foam made at least partially of at least one polyurethane, the system comprising: A. at least one retrieving device for retrieving spectral data of the flexible foam; B. at least one device according to claim 16; and C. at least one recycling system for at least partially recycling the flexible foam.

18. The method according to claim 11, wherein the fourth list of candidate filler compounds comprises at least one filler compound selected from the group consisting of: polymers prepared using one or more olefinic monomers selected from the group consisting of acrylonitrile, styrene, (meth)acrylates, (meth)acrylic acid, acrylamide, and combinations thereof.

19. A device for obtaining information on the recyclability of at least one flexible foam made at least partially of at least one polyurethane, the device comprising at least one processor, the processor being configured for performing the method according to claim 15.

20. A system for treatment of at least one flexible foam made at least partially of at least one polyurethane, the system comprising: A. at least one retrieving device for retrieving spectral data of the flexible foam; B. at least one device according to claim 19; and C. at least one recycling system for at least partially recycling the flexible foam.

Description

SHORT DESCRIPTION OF THE FIGURES

[0144] Further optional features and embodiments will be disclosed in more detail in the subsequent description of embodiments, preferably in conjunction with the dependent claims. Therein, the respective optional features may be realized in an isolated fashion as well as in any arbitrary feasible combination, as the skilled person will realize. The scope of the invention is not restricted by the preferred embodiments. The embodiments are schematically depicted in the Figures. Therein, identical reference numbers in these Figures refer to identical or functionally comparable elements.

[0145] In the Figures:

[0146] FIG. 1 shows embodiments of a device for obtaining information on the recyclability of at least one flexible foam made at least partially of at least one polyurethane and of a system for treatment of at least one flexible foam made at least partially of at least one polyurethane in a schematic view;

[0147] FIG. 2 shows a flow chart of an embodiment of a computer-implemented method of obtaining information on the recyclability of at least one flexible foam made at least partially of at least one polyurethane;

[0148] FIGS. 3A and 3B show exemplary spectral data; and

[0149] FIG. 4 shows a flow chart of an embodiment of a method of treatment of at least one flexible foam made at least partially of at least one polyurethane.

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0150] FIG. 1 shows exemplary embodiments of a device 110 for obtaining information on the recyclability of at least one flexible foam 112 made at least partially of at least one polyurethane and of a system 114 for treatment of the at least one flexible foam 112 made at least partially of the at least one polyurethane in a schematic view. In the example of FIG. 1, the flexible foam 112 may comprise at least one mattress 116. However, the flexible foam 112 may also comprise other foam material, such as upholstered furniture or the like.

[0151] The system 114 comprises at least one retrieving device 118 for retrieving spectral data of the flexible foam 112. The retrieving device 118 may specifically comprise at least one spectrometer device 120, in particular for retrieving spectral data in the near infrared spectral range. Thus, as schematically shown in FIG. 1, the retrieving device 118 may be configured for optically interacting with the flexible foam 112 for generating the spectral data.

[0152] The system 114 further comprises the device 110 for obtaining information on the recyclability of the flexible foam 112 made at least partially of the at least one polyurethane. The retrieving device 118 and the device 110 may be configured for interacting with each other, specifically for exchanging data or information with each other. Thus, the retrieving device 118 may be configured for providing the retrieved spectral data to the device 110. The retrieving device 118 and the device 110 may fully or partially be separate from each other or, alternatively, may also be fully or partially be integrated into one another. The device 110 may also be fully or partially be embodied as a cloud device.

[0153] The device 110 may comprise at least one processor 122. The processor 122 is configured, specifically by software programming, for performing a method of obtaining information on the recyclability of the flexible foam 112 made at least partially of the at least one polyurethane according to the present invention, such as according to the exemplary embodiment shown in FIG. 2. Thus, for a description of the method, reference may be made to the description of FIG. 2. However, the processor 122 may also be configured for performing the method in any other embodiment disclosed herein.

[0154] The system 114 further comprises at least one recycling system 124 for at least partially recycling the flexible foam 112. The device 110 and the recycling system 124 may be configured for interacting with each other, specifically for exchanging data or information with each other. Thus, the device 110 may be configured for providing the information on the recyclability of the flexible foam 112 to the recycling system 124. The recycling system 124 may be configured for performing at least one recycling process, specifically a chemical recycling process, according the information on the recyclability of the flexible foam 112.

[0155] FIG. 2 shows a flow chart of an exemplary embodiment of a computer-implemented method of obtaining information on the recyclability of the flexible foam 112 made at least partially of the at least one polyurethane. The method comprises: [0156] i. (denoted by reference number 126) at least one first determination step, comprising automatically determining, by evaluating spectral data of the flexible foam 112, whether at least one first chemical compound of a predetermined first list of recyclable candidate components for a first class of monomers of polyurethane is present in the flexible foam 112, the first list of recyclable candidate components comprising at least one first recyclable candidate component; and [0157] ii. (denoted by reference number 128) at least one first decision step, comprising automatically deciding, on the basis of the outcome of step i., if a second determination step is required, the second determination step comprising determining whether at least one second chemical compound of a predetermined second list of recyclable candidate components for a second class of monomers of polyurethane is present in the flexible foam 112, specifically a second list being different from the first list, the second list of recyclable candidate components comprising at least one second recyclable candidate component.

[0158] The first class of monomers of polyurethane may comprise isocyanate monomers. Specifically, the first list of recyclable candidate components for the first class of monomers of polyurethane may comprise at least one toluene diisocyanate isomer.

[0159] As can be seen in FIG. 2, the method may further comprise, if it is determined in the first determination step that the first chemical compound of the first list of recyclable candidate components is not present in the flexible foam 112, generating at least one item of information indicating that the flexible foam 112 is not recyclable (denoted by reference number 130). Alternatively, if it is determined that the first chemical compound of the first list of recyclable candidate components is present in the flexible foam 112, the method may further comprise the following step: [0160] iii. (denoted by reference number 132) performing the second determination step.

[0161] As outlined above, the second determination step comprises determining whether the at least one second chemical compound of the predetermined second list of recyclable candidate components for the second class of monomers of polyurethane is present in the flexible foam 112. The second class of monomers of polyurethane may comprise polyol monomers. Specifically, the second list of recyclable candidate components for the second class of monomers of polyurethane may comprise at least one polyol selected from the group consisting of: polyetherpolyols, polyesterpolyols. For example, the second determination step may comprise determining whether at least one standard polyol monomer is present in the flexible foam 112.

[0162] After performing the second determination step, the method may further comprise: [0163] iv. (denoted by reference number 134) at least one second decision step, comprising automatically deciding, after performing step iii., on the basis of the outcome of step iii., if a third determination step is required, the third determination step comprising determining whether at least one flame retardant compound of a predetermined third list of candidate flame retardant components is present in the flexible foam 112, the third list of candidate flame retardant components comprising at least one flame retardant candidate component.

[0164] Thus, if it is determined in the second decision step that the second chemical compound of the second list of recyclable candidate components is not present in the flexible foam 112, the method may comprise generating at least one item of information indicating that the flexible foam 112 is not recyclable (denoted by reference number 136). Alternatively, if it is determined that the second chemical compound of the second list of recyclable candidate components is present in the flexible foam 112, the method may further comprise the following step: [0165] v. (denoted by reference number 138) performing the third determination step.

[0166] The third list of candidate flame retardant components may specifically comprise at least one flame retardant component selected from the group consisting of: melamine derivatives, phosphates, derivatives of phosphoric acid, derivatives of phosphonic acid and derivatives of phosphinic acid.

[0167] As further shown in FIG. 2, after the third determination step, the method may further comprise: [0168] vi. (denoted by reference number 140) at least one third decision step, comprising automatically deciding, after performing step v., on the basis of the outcome of step v., if a fourth determination step is required, the fourth determination step comprising determining the content of at least one filler compound of a predetermined fourth list of candidate filler compounds in the flexible foam 112, the fourth list of candidate filler compounds comprising at least one candidate filler compound.

[0169] Further, if it is determined in the third decision step that the at least one flame retardant compound of the third list of candidate flame retardant components is not present in the flexible foam 112, the method may comprise generating at least one item of information indicating that the flexible 112 foam is not recyclable (denoted by reference number 142). Alternatively, if it is determined that the at least one flame retardant compound of the third list of candidate flame retardant components is present in the flexible foam 112, the method may further comprise the following step: [0170] vii. (denoted by reference number 144) performing the fourth determination step.

[0171] The fourth list of candidate filler compounds may specifically comprise at least one filler compound selected from the group consisting of: polymers prepared using one or more olefinic monomers such as acrylonitrile, styrene, (meth)acrylates, (meth)acrylic acid and/or acrylamide.

[0172] The content of the at least one filler compound may be compared with at least tolerance level (denoted by reference number 146). The method may comprise, if the content exceeds the tolerance level, generating at least one item of information indicating that the flexible foam 112 is not recyclable (denoted by reference number 148). Alternatively, if the content does not exceed the tolerance level, the method may comprise generating at least one item of information indicating that the flexible foam 112 is recyclable (denoted by reference number 150).

[0173] In FIGS. 3A and 3B, exemplary spectral data of the flexible foam 112 are shown. Specifically, FIG. 3A shows exemplary spectral data of the flexible foam 112 for specific polyol monomers. FIG. 3B shows exemplary spectral data of the flexible foam 112 for specific isocyanate monomers. The spectral data may be obtained using a spectrometer device 120, specifically the spectrometer device 120 as schematically shown in FIG. 1. In the FIGS. 3A and 3B, a preprocessed absorbance 152 of the flexible foam 112 is shown as a function of the wavenumber 154 in units of 1/cm. The pre-processing of the spectral data may specifically comprise one or more of filtering and/or smoothing the spectrum of the flexible foam 112. The spectral data may specifically comprise the spectrum 156 of the flexible foam 112 as shown in the upper diagrams of FIGS. 3A and 3B. Additionally or alternatively, the spectral data of the flexible foam 112 may comprise a first-order derivate of the spectrum 158 (FIG. 3B) and/or a second-order derivative of the spectrum 160 (FIG. 3A).

[0174] FIG. 3A shows specifically spectral data for a flexible foam 112 comprising an HR polyol monomer (denoted by reference number 162) and for a flexible foam 112 comprising a standard polyol monomer (denoted by reference number 164). The spectral data may be compared in an entire measured wavelength range of the spectral data. As can be seen in FIG. 3A, the spectral data of the flexible foams 112 show a pronounced optical difference in a wavenumber range of 5100 to 4600 1/cm. By performing the method, it may be possible to detect these optical differences between flexible foams 112 comprising the different polyol monomers. The spectral data as shown in FIG. 3A may provide reference spectra, specifically second reference spectra of a second flexible reference foam comprising a HR polyol monomer (denoted by reference number 162) and of a second flexible reference foam comprising a standard polyol monomer (denoted by reference number 164), which specifically may be used in step iii. of the method as described with reference to FIG. 2, for comparing the spectral data of the flexible foam 112 with at least one second reference spectrum of at least one second flexible reference foam made at least partially of at least one polyurethane comprising the at least one second chemical compound of the second list of recyclable candidate components.

[0175] FIG. 3B shows specifically spectral data for a flexible foam 112 comprising a toluene diisocyanate isomer (denoted by reference number 166) and for a flexible foam 112 comprising a methylene diphenyl diisocyanate isomer (denoted by reference number 168). The spectral data may be compared in an entire measured wavelength range of the spectral data. As can be seen in FIG. 3B, the spectral data of the flexible foams 112 show a pronounced optical difference in a wavenumber range of 4900 to 4500 1/cm. By performing the method, it may be possible to detect these optical differences between flexible foams 112 comprising the different isocyanate monomers. The spectral data as shown in FIG. 3B may provide reference spectra, specifically first reference spectra of a first flexible reference foam comprising a toluene diisocyanate isomer (denoted by reference number 166) and of a first flexible reference foam comprising a methylene diphenyl diisocyanate isomer (denoted by reference number 168), which specifically may be used in step i. of the method as described with reference to FIG. 2, for comparing the spectral data of the flexible foam 112 with at least one first reference spectrum of at least one first flexible reference foam made at least partially of at least one polyurethane comprising the at least one first chemical compound of the first list of recyclable candidate components.

[0176] FIG. 4 shows a flow chart of an exemplary embodiment of a method of treatment of the at least one flexible foam 112 made at least partially of at least one polyurethane. The method may specifically be performed by using the system 114 as described with reference to FIG. 1. The method comprises at least the following steps which, as an example, may be performed in the given order. It shall be noted, however, that a different order is also possible. Further, it is also possible to perform one, more than one or even all of the method steps once or repeatedly. Further, it is possible to perform two or more of the method steps simultaneously or in a timely overlapping fashion. The method may comprise further method steps which are not listed.

[0177] The method comprises: [0178] I. (denoted by reference number 170) obtaining spectral data of the flexible foam 112, specifically in the near infrared spectral range; [0179] II. (denoted by reference number 172) obtaining information on the recyclability of the flexible foam 112 by using the by using the spectral data and by using the method of obtaining information on the recyclability of the at least one flexible foam 112 made at least partially of at least one polyurethane according to the present invention, such as according to the embodiment shown in FIG. 2 and/or according to any other embodiment disclosed herein; and [0180] III. (denoted by reference number 174) determining, on the basis of the information gained in step III., whether or not to recycle the flexible foam 112 and, if the information indicates a recyclability of the flexible foam 112, at least partially recycling the flexible foam 112.

LIST OF REFERENCE NUMBERS

[0181] 110 device for obtaining information on the recyclability [0182] 112 flexible foam [0183] 114 system for treatment of at least one flexible foam [0184] 116 mattress [0185] 118 retrieving device [0186] 120 spectrometer device [0187] 122 processor [0188] 124 recycling system [0189] 126 first determination step [0190] 128 first decision step [0191] 130 flexible foam is not recyclable [0192] 132 second determination step [0193] 134 second decision step [0194] 136 flexible foam is not recyclable [0195] 138 third determination step [0196] 140 third decision step [0197] 142 flexible foam is not recyclable [0198] 144 fourth determination step [0199] 146 comparing the filler compound with at least tolerance level [0200] 148 flexible foam is not recyclable [0201] 150 flexible foam is recyclable [0202] 152 pre-processed absorbance [0203] 154 wavenumber [0204] 156 spectrum [0205] 158 first-order derivate of the spectrum [0206] 160 second-order derivative of the spectrum [0207] 162 spectral data for a flexible foam comprising an HR polyol monomer [0208] 164 spectral data for a flexible foam comprising a standard polyol monomer [0209] 166 spectral data for a flexible foam comprising a toluene diisocyanate isomer [0210] 168 spectral data for a flexible foam comprising a methylene diphenyl diisocyanate isomer [0211] 170 obtaining spectral data of the flexible foam [0212] 172 obtaining information on the recyclability of the flexible foam [0213] 174 determining whether or not to recycle the flexible foam