Composite panels with adhesive and separate fragment layers
A panel including a first layer including fragments from a first blend of paper fragments of a first size and plastic fragments of a second size, a second layer including fragments from a second blend of paper fragments of a third size and plastic fragments of a fourth size, the third size being different from the first size, and the fourth size being different from the second size, and a third layer comprising fragments from the first blend. The second layer is disposed between the first layer and the third layer.
1 . A panel comprising:
a first layer comprising fragments from a first blend of paper fragments of a first size and plastic fragments of a second size;
a second layer comprising fragments from a second blend of paper fragments of a third size and plastic fragments of a fourth size, the third size being different from the first size, and the fourth size being different from the second size; and
a third layer comprising fragments from the first blend,
wherein the second layer is disposed between the first layer and the third layer.
2 . The panel of claim 1 wherein the paper and plastic fragments of the first blend and the second blend comprise recycled waste material.
3 . The panel of claim 1 , wherein each of the first layer and the third layer comprises a thermoplastic binder.
4 . The panel of claim 3 , wherein the second layer comprises a thermosetting resin.
5 . The panel of claim 3 , wherein the thermoplastic binder comprises flexible polyvinyl chloride.
6 . The panel of claim 3 , wherein the thermoplastic binder comprises thermoplastic polyolefin.
7 . The panel of claim 1 , wherein the second layer comprises a thermosetting resin.
8 . The panel of claim 1 wherein the first blend comprises a first paper to plastic ratio and the second blend comprises a second paper to plastic ratio different from the first paper to plastic ratio.
9 . The panel of claim 1 further comprising:
a first surface layer on a first outside surface of the panel; and
a second surface layer on a second outside surface of the panel.
10 . A panel comprising:
a first layer comprising:
fragments from a first blend of paper fragments of a first size and plastic fragments of a second size; and
a thermoplastic binder comprising at least one of flexible polyvinyl chloride or thermoplastic polyolefin;
a second layer comprising fragments from a second blend of paper fragments of a third size and plastic fragments of a fourth size, the third size being different from the first size, and the fourth size being different from the second size; and
a third layer comprising fragments from the first blend and a thermoplastic binder comprising at least one of flexible polyvinyl chloride or thermoplastic polyolefin,
wherein the second layer is disposed between the first layer and the third layer.
11 . The panel of claim 10 , wherein the second layer further comprises a thermosetting resin.