Composite board

A composite board, comprising:

• a cover layer having a bottom surface;
• and
• a base layer bonded to said bottom surface of said cover layer, said base layer having a first side and a second side and comprising a mixture of at least 5% magnesium oxide, at least 50% recycled magnesium oxide, at least 40% fibrous chips, and at least 5% chemical additive in an aqueous solution;
• and
• a binding agent for bonding said cover layer to said base layer.

A method of manufacturing a composite board, the steps comprising:

• a. providing a base layer panel having a first and a second side opposite said first side, said base layer panel includes the steps of:
• i. preparing a semi-arid mixture of high purity magnesium oxide, low purity magnesium oxide, fibrous chips, and chemical additive in an aqueous solution;
• ii. pouring said semi-arid mixture through a funnel;
• iii. dispensing said semi-arid mixture from said funnel onto a conveyor belt;
• iv. passing the dispensed semi-arid mixture through a roller, where the roller is configured to press and spread said semi-arid mixture against the conveyor belt to a layer of desired uniform thickness;
• v. pressing the layer through a compressor, where the compressor is configured to remove excess liquid from said layer;
• and
• vi. cutting said compressed layer into panels of predetermined length;
• b. apply a binding agent to said first side of said base layer panel;
• c. providing a cover layer having a top and bottom surface;
• and
• d. connecting the bottom surface of said cover layer to said first surface of said base layer panel.

A system for manufacturing a composite board comprising:

• a. means for providing a base layer panel including:
• i. means for preparing a semi-arid mixture of high purity magnesium oxide, low purity magnesium oxide, fibrous chips, and chemical additive in an aqueous solution;
• ii. means for dispensing said semi-arid mixture onto a conveyor belt;
• iii. means for spreading said semi-arid mixture against said conveyor belt to a layer of desired uniform thickness;
• iv. means for removing excess liquid from said layer;
• v. means for cutting said layer into panels of predetermined length;
• b. means for apply a binding agent to said first side of said base layer panel;
• c. means for providing a cover layer having a top and bottom surface;
• and
• d. means for connecting the bottom surface of said cover layer to said first surface of said base layer panel.