Three layer composite panel from recycled polyurethanes

Abstract

A process for the manufacture of a three layer composite panel with improved moisture resistance, minimal thickness swell, thermal stability, and a smooth hard surface suitable for direct lamination. The composite panel is produced utilizing recycled polyurethanes, preferably obtained from vehicle headliners, insulated foam panels, foam insulation, energy absorbent panels, and polyisocyanurate foams along with materials incidental to at least one recycled component including composite resins, cloth, adhesives, fiberglass, and plastics. The composite panel is composed of a core layer pressed between two surface layers.

1 . A composite panel comprising: 
 a core composed of recycled polyurethanes along with other materials incidental to at least one recycled component; and    two surface layers on either side of said core composed of said recycled polyurethanes along with said other materials incidental to said at least one recycled component, wherein said core and said surface layers are each blended with a binding agent and water and compressed together to form a three layer composite panel.    
   
   
       2 . The composite panel of  claim 1 , wherein said recycled polyurethanes are recycled polyisocyanurate foams.  
   
   
       3 . The composite panel of  claim 1 , wherein said recycled polyurethanes are recycled insulated foam panels.  
   
   
       4 . The composite panel of  claim 1 , wherein said recycled polyurethanes are recycled energy absorbent panels.  
   
   
       5 . The composite panel of  claim 1 , wherein said recycled polyurethanes and said materials incidental to said at least one recycled component are from a vehicle.  
   
   
       6 . The composite panel of  claim 1 , wherein said recycled polyurethanes and said materials incidental to said at least one recycled component are from vehicle headliners.  
   
   
       7 . The composite panel of  claim 1 , wherein said recycled polyurethanes are selected from the group consisting of recycled polyisocyanurate foams, recycled insulated foam panels, recycled energy absorbent panels, recycled vehicle headliners, and mixtures thereof.  
   
   
       8 . The composite panel of  claim 1 , wherein said materials incidental to said at least one recycled component are selected from the group consisting of composite resins, cloth, adhesives, fiberglass, plastics, and mixtures thereof.  
   
   
       9 . The composite panel of  claim 1 , wherein said surface layers are composed of particles about 1.5 millimeters or less in diameter.  
   
   
       10 . The composite panel of  claim 1 , wherein said core is composed of particles about 3 millimeters or less in diameter.  
   
   
       11 . The composite panel of  claim 1 , wherein said binding agent is isocyanate.  
   
   
       12 . The composite panel of  claim 1 , wherein said binding agent is diphenylmethane diisocyanate.  
   
   
       13 . The composite panel of  claim 1 , wherein said core and said surface layers are compressed together either by a pre-press and a main press utilizing temperatures ranging from 40° C. to 185° C., at a speed of 10 to 16 seconds per millimeter thickness of the panel, and at a pressure range of about 5 kg per sq. cm. to about 45 kg per sq. cm, or a continuous belt press system with similar temperatures, pressures, and speeds.  
   
   
       14 . 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 polyurethane 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 polyurethane 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 polyurethane along with said other materials incidental to said at least one recycled component; blending said recycled polyurethane and said other materials incidental to said at least one recycled component with isocyanate and water; cleaning said recycled polyurethane 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 10-16 seconds per millimeter of panel thickness with a pressure of about 5 kg/cm 2  to about 45 kg/cm 2 .    
   
   
       15 . The process of  claim 14 , wherein said recycled polyurethanes are recycled polyisocyanurate foams.  
   
   
       16 . The process of  claim 14 , wherein said recycled polyurethanes are recycled insulated foam panels.  
   
   
       17 . The process of  claim 14 , wherein said recycled polyurethanes are recycled energy absorbent panels.  
   
   
       18 . The process of  claim 14 , wherein said recycled polyurethanes and other materials incidental to said at least one recycled component are from a vehicle.  
   
   
       19 . The process of  claim 14 , wherein said recycled polyurethanes and other materials incidental to said at least one recycled component are vehicle headliners.  
   
   
       20 . The process of  claim 14 , wherein said recycled polyurethanes are selected from the group consisting of recycled polyisocyanurate foam, recycled insulated foam panels, recycled energy absorbent panels, recycled vehicle headliners, and mixtures thereof.  
   
   
       21 . The process of  claim 14 , wherein said materials incidental to said at least one recycled component are selected from the group consisting of composite resins, cloth, adhesives, fiberglass, plastics, and mixtures thereof.  
   
   
       22 . The process of  claim 14 , wherein said mat is pressed at temperatures from about 40° C. to about 185° C.  
   
   
       23 . The process of  claim 14 , wherein said mat is pressed with a pressure of about 5 kg/cm 2  to about 45 kg/cm 2 .  
   
   
       24 . The process of  claim 14 , wherein said surface layers are composed of particles about 1.5 millimeters or less in diameter.  
   
   
       25 . The process of  claim 14 , wherein said core is composed of particles about 3 millimeters or less in diameter.  
   
   
       26 . The process of  claim 14 , wherein said isocyanate is diphenylmethane diisocyanate.  
   
   
       27 . A composite panel comprising: 
 a core composed of approximately 40% to 80% polyurethanes milled to particles not larger than approximately 3 millimeters in diameter; and    two surface layers on the outer surfaces of said core composed of approximately 20% to 60% polyurethanes milled to particles not larger than approximately 1.5 millimeters in diameter, wherein said core and said surface layers are each blended with isocyanate and water, formed into a three layer mat and compressed together.    
   
   
       28 . The composite panel of  claim 27 , wherein said polyurethanes are recycled polyisocyanurate foams.  
   
   
       29 . The composite panel of  claim 27 , wherein said polyurethanes are recycled insulated foam panels.  
   
   
       30 . The composite panel of  claim 27 , wherein said polyurethanes are recycled energy absorbent panels.  
   
   
       31 . The composite panel of  claim 27 , wherein said polyurethanes are from a vehicle.  
   
   
       32 . The composite panel of  claim 27 , wherein said polyurethanes are from vehicle headliners.  
   
   
       33 . The composite panel of  claim 27 , wherein said polyurethanes are selected from the group consisting of recycled polyisocyanurate foams, recycled insulated foam panels, recycled energy absorbent panels, recycled vehicle headliners, and mixtures thereof.  
   
   
       34 . The composite panel of  claim 27 , further comprising other materials incidental to at least one recycled component wherein said other materials are selected from the group consisting of composite resins, cloth, adhesives, fiberglass, plastics, and mixtures thereof.  
   
   
       35 . The composite panel of  claim 27 , wherein said binding agent is isocyanate.  
   
   
       36 . The composite panel of  claim 27 , wherein said binding agent is diphenylmethane diisocyanate.  
   
   
       37 . The composite panel of  claim 27 , wherein said core and said surface layers are compressed together by a pre-press and a main press utilizing temperatures ranging from approximately 40° C. to 185° C., at a speed of approximately 10 to 16 seconds per millimeter thickness of the panel, and at a pressure range of approximately 5 kg per sq. cm. to about 45 kg per sq. cm, or a continuous belt press system with similar temperatures, pressures, and speeds.  
   
   
       38 . The composite panel of  claim 27 , wherein said panel is pressed at temperatures from about 40° C. to about 185° C.  
   
   
       39 . The composite panel of  claim 27 , wherein said panel is pressed with a pressure of about 5 kg/cm 2  to about 45 kg/cm 2 .