Structural Composite Panel and Method of Construction Thereof

1 . A structural composite panel, comprising:

a scrim layer;

a drywall sheet;

a nonwoven matt sandwiched between said scrim layer and said drywall sheet, said nonwoven matter having comminuted cardboard and heat bondable textile fibers thermally bonded together to a desired thickness.

2 . The structural composite panel of claim 10 further including a paper layer bonded to a side of said drywall sheet, said drywall sheet being sandwiched between said paper layer and said matt.

3 . The structural composite panel of claim 2 wherein said paper layer is formed from recycled waste paper.

4 . The structural composite panel of claim 3 wherein said paper layer is formed from recycled newsprint.

5 . The structural composite panel of claim 1 wherein said matt has a thickness substantially retained as initially produced.

6 . The structural composite panel of claim 1 further including a chemical mixture applied, dried and cured to at least one outer surface of said matt, said chemical mixture including at least one of a flame retardant, a biocide and a binder.

7 . The structural composite panel of claim 6 wherein said chemical mixture includes each of said flame retardant, biocide and binder.

8 . The structural composite panel of claim 6 wherein said chemical mixture is applied at least to the side of said matt attached to said scrim layer.

9 . A method of constructing a structural composite panel, comprising:

providing a nonwoven matt;

laminating a scrim layer to one side of the nonwoven matt;

providing a sheet of drywall;

laminating a paper layer to one side of the sheet of drywall; and

bonding one side of the nonwoven matt directly to one side of the sheet of drywall.

10 . The method of claim 9 further including constructing the nonwoven matt comprising cardboard and heat bondable textile fibers.

11 . The method of claim 10 further comprising:

comminuting the cardboard into predetermined reduced sized pieces and combining the reduced sized pieces with the heat bondable textile fibers to form a substantially homogenous mixture;

forming a web from the mixture; and

thermally bonding the constituent ingredients of the web to produce the matt of a desired thickness.

12 . The method of claim 11 further comprising laminating the scrim layer to the matt without substantially reducing the thickness of the matt.

13 . The method of claim 9 further including applying a chemical mixture including at least one of a flame retardant, a biocide and a binder to at least one surface of the matt.

14 . The method of claim 13 further including providing the chemical mixture including a flame retardant, a biocide and a binder.

15 . The method of claim 13 further including applying the chemical mixture to the side of the matt opposite the scrim layer.

16 . The method of claim 13 further including drying and curing the chemical mixture before laminating the scrim layer to the matt.

17 . The method of claim 9 further including providing the scrim layer as an impervious layer.

18 . The method of claim 9 further including laminating the scrim layer to the nonwoven matt to form a first laminated sheet and laminating the paper layer to the sheet of drywall to form a second laminated sheet and then laminating the first laminated sheet to the second laminated sheet.