Polyurethanes (PUs) are well-known for their numerous uses in everyday products. The PU foam is utilised in beds and shoes for padding, automotive interiors such as elastomeric wheels and tyres, electronic compounds, packaging, and carpet underlays due to its incredible resilience and flexibility. Polyurethanes in construction materials, for example, enable architects to create high-performance, long-lasting products.
However, these devices’ normal wear and tear produce a lot of waste, which negatively influences environmental sustainability. Recycling and recovering PUs is the most obvious way to reduce the amount of trash generated by PU goods. Various recycling procedures, like reusing, particle bonding, and grinding, are available depending on PU type. A foam rebonding machine is the most straightforward and practical technique to recycle and recover PUs to create flexible rebonding foam and protect the environment. It also saves money on materials. In other words, bond restoration is the most popular method of reusing PUs.
What is Rebonded Foam, and how does it work?
New blocks of high density and flexible foam are created when different thicknesses of foam are broken up or shredded, or rebonded under immense mechanical pressure, and combined. After that, they are sliced to the correct width and length for usage in various items. For decades, re-bonded polyurethane has been used.
The gathering and sorting of foam is the first and most crucial phase in the recycling process, proceeding with its shredding into tiny chunks. Foam pieces recovered from manufacturing or post-consumer waste are suitable for the rebonding process. This portion can be completed with the help of an upright quality shredding device such as the foam shredding machine, which will transform the foam into the desired granule sizes. These little bits are collected and coated with a sticky polyurethane binder in a mix tank. The foam is compressed and moulded using a piston to get the expected density and shape. The use of steam in these moulds aids in activating and curing the adhesive binder.
After the curing process is complete, moulds are opened to extract the re-bond and allow it to dry. The re-bond can be turned into various final products using traditional cutting and peeling techniques. The foam rebonding machine was created with this entire process in mind: a mould, a shredder device, a mixer, and a pressing station.
All re-bond foams are not equal in quality. The grade of the adhesion binder used, the size of the foam particles and homogeneity of the shred bits, the types and grades of foams utilised, the density wanted in the product, and the binder/foam ratio are all elements to consider.
As previously said, PU foam rebonding help in the reduction of waste and conservation of natural resources. Furthermore, the procedure aids in the decrease of manufacturing expenses. As a result, PU foam recycling and recovery contribute to ecological sustainability.