Novel robust upcycling approach for the manufacture of value-added polymers based on mixed (poly)urethane scraps

Abstract Plastic pollution undoubtedly is a big global issue for present and future generations. Despite numerous activities in the field, the recycling of thermoset polymers still poses an immense challenge to the chemical industry. The present work proposes a new solution to the plastics pollution issue by developing a novel technology for the transformation of polyurethane (PUR) scraps into value-added polymers. In contrast to conventional methods, which usually involve elaborate but costly methods for sorting and separating different plastics into single-origin material flows, the feasibility of direct upcycling of valueless, mixed PUR-based production scraps into polymer aerogels will be shown. Despite the impurity of the feedstock, the aerogels synthesized in this work possess a well-defined and tuneable meso-porous microstructure and a 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. Graphical Abstract