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A thermoset composite material that my used in the fabrication of structural components including railroad ties comprise a substantially homogeneous blend of an amount of vulcanized rubber particles including a predetermined ratio of different particles sizes, and a thermoset elastomeric binding age

A thermoset composite material that my used in the fabrication of structural components including railroad ties comprise a substantially homogeneous blend of an amount of vulcanized rubber particles including a predetermined ratio of different particles sizes, and a thermoset elastomeric binding agent added to the vulcanized rubber particles. The blend may comprise about 30% to about 97% by weight of the vulcanized rubber particles, and the blend is subjected to compression molding at a predetermined temperature and pressure for a resident time period forming the composite material. The ratio of different rubber particle sizes is selected so that the composite material has a desired density or is within a range of desired densities.

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1. A thermoset composite material, comprising: a substantially homogeneous blend of an amount of vulcanized recycled rubber particles including a predetermined ratio of different particles sizes, and a thermoset elastomeric polyurea binding agent added to the vulcanized rubber particles; and,a fibro

1. A thermoset composite material, comprising: a substantially homogeneous blend of an amount of vulcanized recycled rubber particles including a predetermined ratio of different particles sizes, and a thermoset elastomeric polyurea binding agent added to the vulcanized rubber particles; and,a fibrous filler material and a granulated silica filler material;the blend comprises about 30% to about 97% by weight of the vulcanized recycled rubber particles, and the blend is subjected to compression molding at a predetermined temperature and pressure for a resident time period forming the composite material; and,wherein the ratio of different rubber particle sizes is selected so that the composite material has a desired density or is within a range of desired densities. 2. The composite material of claim 1, wherein the blend comprises about 30% to 70% by weight of the vulcanized rubber particles. 3. The composite material of claim 2, wherein the blend comprises about 40% to 50% by weight of the vulcanized rubber particles. 4. The composite material of claim 1, wherein the blend further comprises a depolymerized vulcanized rubber material and/or an amorphous carbon material. 5. The composite material of claim 1, wherein the blend comprises about 3% to about 15% by weight of the binding agent and the remainder being the vulcanized rubber particles. 6. The composition material of claim 5, wherein the blend comprises about 5% to about 10% by weight of the thermoplastic elastomer and the remainder being the vulcanized rubber particles. 7. The composite material of claim 1, wherein the blend is subjected to compression molding at about 1,000 psi to about 5,000 psi, at a temperature ranging from about 200° F. to about 350° F. for a resident time of about 3 to 10 minutes. 8. The composite material of claim 7, wherein the blend is subjected to compression molding at about 4,500 psi, at a temperature of about 350° F. for a resident time of about 7 to 10 minutes. 9. The composite material of claim 1, wherein a particle size of the vulcanized rubber particles is about 20 mesh to about 60 mesh. 10. The composite material of claim 9, wherein the particle size of the vulcanized rubber powder is about 30 mesh to about 40 mesh. 11. The composite material of claim 1, wherein the composite material as a density from about 45 lb/ft3 to about 80 lb/ft3. 12. The composite material of claim 11, wherein the composite material has a density from about 60 lb/ft3 to about 70 lb/ft3. 13. The composite material of claim 1, wherein the compression molding of the blend is performed to fabricate a railroad tie. 14. The composite material of claim 1, wherein the ratio of different vulcanized rubber particles includes about 25% of −20 mesh, about 25% of −40 to +60 mesh and about 50% of −80 mesh. 15. A thermoset composite material, comprising: a substantially homogeneous blend of an amount of vulcanized recycled rubber particles produced from comminuting a rubber article at temperatures that do not exceed a glass transition temperature of the rubber article, and a thermoset elastomeric polyurea binding agent added to the vulcanized rubber particles; anda fibrous filler material and a granulated silica filler material;wherein the blend comprises about 30% to about 97% by weight of the vulcanized recycled rubber particles and a particle size of the rubber particles does not exceed 20 mesh; and,the blend is subjected to compression molding at a pressure of at least 1,000 psi and at a temperature of at least 200° F. for a resident time period forming the composite material. 16. The composite material of claim 14, wherein the blend is subjected to compression molding at a pressure of about 4,500 psi at a temperature of about 350° F. 17. A method of making a thermoset composite material according to claim 1, comprising: mixing an amount of vulcanized recycled rubber particles, including a predetermined ratio of different particle sizes, with a thermoset elastomeric polyurea binding agent to generate a substantially, homogeneous blend;providing to the blend a fibrous filler material and a granulated silica filler material; and,applying a compressive molding force to the blend at a predetermined temperature and pressure for a resident time. 18. The method of claim 17 wherein the ratio of different particle sizes includes about 25% of −20 mesh, about 25% of −40 to +60 mesh and about 50% of −80 mesh. 19. A railroad tie fabricated from a thermoset composite material according to claim 1, comprising: a substantially homogeneous blend of an amount of vulcanized recycled rubber particles including a predetermined ratio of different particle sizes, and a thermoset elastomeric polyurea binding agent added to the vulcanized rubber particles; and,a fibrous filler material and a granulated silica filler material;the blend comprises about 30% to about 97% by weight of the vulcanized recycled rubber particles, and the blend is subjected to compression molding at a predetermined temperature of about 350° F. and pressure of about 4,5000 psi for a resident time period forming the composite material; and,wherein the ratio of different rubber particle sizes is selected so that the composite material has a desired density of about 60 lbs/ft3 to about 70 lbs/ft3. 20. The railroad tie of claim 19, further comprising an elongated configuration including a top and bottom parallel surface and two parallel side surfaces wherein grooves are formed in the one or both of the side surfaces and the bottom surface. 21. A thermoset composite material, comprising: a substantially homogeneous blend of an amount of vulcanized recycled rubber particles including a predetermined ratio of different particles sizes, and a thermoset elastomeric polyurea binding agent added to the vulcanized rubber particles; and,a fibrous filler material and a granulated silica filler material;the blend comprises about 30% to about 97% by weight of the vulcanized recycled rubber particles, and the blend is subjected to compression molding at a predetermined temperature and pressure for a resident time period forming the composite material.