Imagine it: Recycled mattress foam transformed into in-demand products including synthetic leather products, shoe soles, or phone cases.
It’s become a reality, as the U.S. Patent and Trademark Office has issued a patent for a thermochemical conversion process developed by Houston-based Edge Global Innovation Inc., marking a major step toward converting discarded and industrial scrap foam into high-value recycled materials.
The newly patented process uses a method known as “vitrimerization” to convert polyurethane foam waste into reusable materials. Edge Global Innovation is commercializing the process through a subsidiary, VitriCycle LLC.
Unlike chemical recycling approaches, CEO Vahid Serajian says 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,” says Serajian.
The Mattress Recycling Council—a nonprofit organization created by the International Sleep Products Association—funded an early portion of the research as part of its mission to develop new markets for post-consumer polyurethane mattress foam. The VitriCycle process is the first MRC-backed research project to earn a patent. Six other patent applications are pending based on MRC research.
“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,” says Mike O’Donnell, MRC’s chief operating officer.
VitriCycle’s core technology uses scrap foam to produce pellets for injection molding, 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 used to create synthetic leather sheets for wallets, purses, furniture, accessories, promotional products, craft projects, and other sustainable design applications. VitriCycle is marketing this product line as “KindHide,” Serajian explains, a kinder alternative to cowhide.
VitriCycle says it sees strong market potential from manufacturers, brands, and designers seeking U.S.-made recycled materials, sustainable leather alternatives, recycled polyurethane sheets, and circular materials for consumer and industrial products.
Because the materials are produced from recycled foam in the United States, VitriCycle products may also help manufacturers reduce risks caused by virgin resin pricing, oil price volatility, tariffs, and overseas supply chain issues.
VitriCycle has had exploratory discussions with a national furniture manufacturer about circular applications, Serajian says. Furniture companies could potentially convert their leftover polyurethane scrap foam into synthetic leather sheets for use in chairs, sofas, or other upholstery components to create new product lines focused on sustainability and circularity.
The VitriCycle technology is available to manufacturers through licensing agreements as well, offering a way for foam manufacturers, mattress producers, furniture manufacturers, automotive suppliers, and mattress recyclers to create value from scrap polyurethane foam.
VitriCycle’s pioneering technology also could unlock global markets for post-consumer mattress foam and industrial scrap foam.
To learn more, visit vitricycle.com or follow its social pages at linkedin.com/showcase/vitricycle or tiktok.com/@kindhide.
