Patent ID: 8765871

Claim:
A thermoformable, non-porous, polyurethane material, comprising: a plurality of isocyanates; a plurality of polyols; alumina trihydrate (ATH); a plurality of particulates; and a plurality of molecular sieves; wherein the plurality of isocyanates, the plurality of polyols, the ATH, the plurality of particulates, and the plurality of molecular sieves are mixed in a vacuum mixer to form a mixture, wherein a duration of mixing and a vacuum level of the vacuum mixer are sufficient to induce an exothermic polymerization reaction with a temperature of the exothermic polymerization reaction being maintained at no greater than 10 degrees F. over an ambient temperature to prevent the mixture from boiling, and wherein the mixture is formed into a composite material after said duration of mixing, the composite material being medium-to-high durometer, impact-resistant, fire-retardant, thermoformable, and non-porous due to the exothermic polymerization reaction at the specified temperature.