Closed-loop recycled polyurethane foam, methods of manufacture and products therefrom

A method for closed-loop recycling of polyurethane foam scrap comprising:

• forming a recycled polyol by subjecting polyurethane foam scrap to glycolysis, wherein said recycled polyol has an average equivalent weight in the range of 100-500 and wherein said recycled polyol has a viscosity range of 40,000 cps at 20° C. to 2,000 cps at 50 ° C.;
• adding at least a portion of said recycled polyol to a virgin polyol to produce a polyol blend, wherein said virgin polyol has a viscosity range of 1,760 cps at 15° C. to 218 cps at 45° C.;
• forming a polyurethane foam from said polyol blend;
• producing said polyurethane foam scrap from said polyurethane foam;
• wherein said polyol blend comprises 65-95 parts by weight of said virgin polyol, 5-25 parts by weight of said recycled polyol and a viscosity reducer comprising a dibasic ester wherein said dibasic ester is present at a level of 1-10 parts by weight of the polyol blend, wherein the viscosity reducer reduces the viscosity of the polyol blend to a range of 1,100 to 1,300 cps at 20° C.;
• 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.