Closed-Loop Recycled Polyurethane Foam, Methods Of Manufacture And Products Therefrom

A method for forming a polyurethane foam for a vehicle headliner comprising:

• providing a mixture of 75-95 parts by weight of a polyol that has a viscosity range of 1760 cps at 15° C. to 218 cps at 45° C. in combination with chemolysis polyol products of a polyurethane foam wherein said chemolysis polyol has an average equivalent weight in the range of 100-500 and wherein said glycolysis polyol product has a viscosity range of 40,000 cps at 20° C. to 2000 cps at 50° C.;
• adding to said mixture a viscosity reducer comprising a dibasic ester wherein said dibasic ester is present at a level of 1-10 parts by weight wherein said mixture has a viscosity in the range of 1,100 to 1300 cps at 20° C.;
• adding a polymerization catalyst to said mixture wherein said mixture including said viscosity reducer is combined with isocyanate compounds to form a foam wherein said catalyst is present at a level of 0.1 to 1.0 part by weight and wherein said foam formation is characterized by a gel time of 220 seconds or longer and/or a rise time of 345 seconds or longer.