Resilient article and method of manufacturing same using recycled material

A method of manufacturing a resilient article using recycled materials, comprising the steps of:

• mixing respective predetermined amounts of a binder comprised of recycled material and a thermoset comprised of ground vehicle tire rubber with fabric and metal material having been substantially removed, to provide a mixture having a predetermined density;
• introducing the mixture into a barrel having a rotatable screw and rotating the screw at a predetermined rate to entrap air into the mixture and to extrude the mixture into and through a die, such that the mixture emerges from the die as a sheet having a thickness corresponding to a desired thickness of the resilient article;
• heating the mixture in the barrel and in the die to maintain the mixture substantially at said predetermined density;
• further adjusting the thickness of the sheet after it emerges from the die to more precisely match the desired thickness of the sheet;
• cooling the sheet and passing the sheet through plural rollers to impart a relatively uniform finish to surfaces of the sheet;
• and
• cutting the sheet to provide the resilient article.