Composite panels with adhesive and separate fragment layers

A method for manufacturing a panel comprising:

• obtaining paper fragments and plastic fragments;
• mixing a first portion of the paper fragments and a first portion of the plastic fragments into a first blend of paper and plastic fragments;
• mixing a second portion of the paper fragments and a second portion of the plastic fragments into a second blend of paper and plastic fragments different from the first blend;
• coating the paper fragments and the plastic fragments of the first blend with a thermoplastic binder;
• coating the paper fragments and the plastic fragments of the second blend with a thermosetting resin;
• forming a first layer comprising the first blend;
• forming a second layer comprising the second blend;
• forming a third layer comprising the first blend,
• wherein the second layer is disposed between the first and third layers;
• and
• consolidating the first layer, the second layer, and the third layer into the panel using heat and pressure,
• wherein the first blend includes paper fragments of a first size and plastic fragments of a second size, and the second blend includes paper fragments of a third size and plastic fragments of a fourth size, wherein the first size is different than the third size and the second size is different than the fourth size.

A panel comprising:

• a first layer comprising a first blend of paper fragments and plastic fragments, wherein the paper fragments and plastic fragments of the first blend are coated with a thermoplastic binder;
• a second layer comprising a second blend of paper fragments and plastic fragments, different from the first blend, wherein the paper fragments and plastic fragments of the second layer are coated with a thermosetting resin;
• and
• a third layer comprising the third blend of paper fragments and plastic fragments, wherein the paper fragments and plastic fragments of the third blend are coated with the thermoplastic binder;
• wherein the second layer is disposed between the first layer and the third layer,
• wherein the first layer, the second layer, and the third layer are combined to form the panel using heat and pressure, and
• wherein the first blend includes paper fragments of a first size and plastic fragments of a second size, and the second blend includes paper fragments of a third size and plastic fragments of a fourth size.