Patent ID: 7754120

Claim:
A process of forming a composite panel from recycled polyurethanes along with other materials incidental to at least one recycled component comprising the steps of: a. forming a core layer comprising the steps of: cutting and milling said recycled polyurethanes along with said other materials incidental to said at least one recycled component; passing the milled polyurethanes and said other materials incidental to said at least one recycled component through a screen to ensure all particles are not larger than about 3 millimeters in diameter; blending said recycled polyurethanes and said other materials incidental to said at least one recycled component with isocyanate and water, wherein a volume of said isocyanate is approximately 3% to 10% by weight and a volume of said water is approximately 1% to 9% by weight; cleaning said recycled polyurethanes and said other materials incidental to said at least one recycled component in a wind sifter; b. forming surface layers comprising the steps of: cutting and milling said recycled polyurethanes along with said other materials incidental to said at least one recycled component; blending said recycled polyurethanes and said other materials incidental to said at least one recycled component with isocyanate and water; cleaning said recycled polyurethanes and said other materials incidental to said at least one recycled component in a wind sifter; passing said milled polyurethane and said other materials incidental to said at least one recycled component through a screen to ensure all particles are not larger than about 1.5 millimeters in diameter; c. forming a three layer mat with said blended core layer and said blended surface layers wherein said core layer is between said surface layers; and d. pressing said mat with a press system at temperatures from about 40° C. to about 185° C. at a speed of about 1 to about 16 seconds per millimeter of panel thickness with a pressure of about 5 kg/cm 2 to about 45 kg/cm 2 .