The RAMPF Group developed a pioneering upcycling approach for the manufacture of customized polymer aerogels. This new technology enables the processing of mixed polyurethane-based production scraps into eco-friendly and ultralight materials for use in thermal insulation, lightweight fillers, rheology additives and oil binding agents.

Conventional chemical recycling involves costly sorting and separating processes. RAMPF groundbreaking chemical solution allows direct upcycling of unsorted polyurethane (PU) scraps into customized polymer aerogels.

Schematic flowchart of the new upcycling approach to transfer mixed PU scraps to aerogel. (source: Journal of Sol-Gel Science and Technology)

The pioneering solution includes:

1. Glycolysis of mixed polyurethane scraps to obtain a recycled polyol,

2. Synthesis of a polyurethane-based gel, and

3. Supercritical drying of the wet gel to obtain an aerogel.

Dr. Gerd-Sebastian Beyerlein, Director of New Business Development and Technology Lead, explained that technical properties of aerogels are highly dependent on physical microstructure, with less significant on purity of feedstock.

The aerogels synthesized by RAMPF’s team possess a well-defined and adjustable mesoporous microstructure as well as very low thermal conductivity in the range of comparable high-performance insulation materials.

“The transfer of this newly developed approach to other polymers as well as bio-based precursors could significantly accelerate the development of holistic circular economies,” added Dr. Beyerlein.

This unique combination of aerogel and recycling technology is also promising for the industrialization of aerogels.

The RAMPF Group developed a pioneering upcycling approach for the manufacture of customized polymer aerogels. This new technology enables the processing of mixed polyurethane-based production scraps into eco-friendly and ultralight materials for use in thermal insulation, lightweight fillers, rheology additives and oil binding agents.

Conventional chemical recycling involves costly sorting and separating processes. RAMPF groundbreaking chemical solution allows direct upcycling of unsorted polyurethane (PU) scraps into customized polymer aerogels.

Schematic flowchart of the new upcycling approach to transfer mixed PU scraps to aerogel. (source: Journal of Sol-Gel Science and Technology)

The pioneering solution includes:

1. Glycolysis of mixed polyurethane scraps to obtain a recycled polyol,

2. Synthesis of a polyurethane-based gel, and

3. Supercritical drying of the wet gel to obtain an aerogel.

Dr. Gerd-Sebastian Beyerlein, Director of New Business Development and Technology Lead, explained that technical properties of aerogels are highly dependent on physical microstructure, with less significant on purity of feedstock.

The aerogels synthesized by RAMPF’s team possess a well-defined and adjustable mesoporous microstructure as well as very low thermal conductivity in the range of comparable high-performance insulation materials.

“The transfer of this newly developed approach to other polymers as well as bio-based precursors could significantly accelerate the development of holistic circular economies,” added Dr. Beyerlein.

This unique combination of aerogel and recycling technology is also promising for the industrialization of aerogels.