Isocyanate emissions from pyrolysis of mattresses containing polyurethane foam

- Pyrolysis of flexible and viscoelastic memory foams was performed.
- At 350-450 °C, diisocyanates are formed (around 0.1 μg/gsample).
- At 850 °C, the emission factors of ICA and PHI 1 and 0.01 μg/gsample, respectively.
- Isocyanate profiles observed agree with kinetic models proposed previously.
- Six new aminoisocyanates have been found in the evolved gases from FPUF pyrolysis.

This study examined the emissions of powerful asthmatic agents called isocyanates from small-scale pyrolysis experiments of two common foams employed in mattress production such as flexible polyurethane foam (FPUF) and viscoelastic memory foam (VMF). A nitrogen atmosphere and five different temperatures, 300, 350, 400, 450 and 850 °C, were selected to carry out the experiments in order to evaluate the worst possible conditions for thermal degradation.A similar trend for both materials was found. At lower temperatures, diisocyanates were the most important products whereas at 850 °C monoisocyanates, and mainly isocyanic acid released mainly from the thermal cracking of diisocyanates evolved directly from the polymer chains.The total yields of isocyanates were in the range of 1.43-11.95 mg/m3 for FPUF at 300-850 °C and 0.05-6.13 mg/m3 for VMF, 300-850 °C. This difference could be a consequence of the lower amount of isocyanates employed in the VMF production which was confirmed by the nitrogen content of the foams, 5.95% FPUF vs. 3.34% in VMF.Additionally, a qualitative search for so far unknown isocyanates was performed in samples from the pyrolysis of FPUF at 300, 400 and 850 °C. It was confirmed that six different aminoisocyanates at 300 °C were evolved, whereas at 400 and 850 °C only five of them were detected. The general trend observed was a decrease of the aminoisocyanate levels with increasing pyrolysis temperature.

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