The present invention is generally directed to prepreg composites, typically in the form of unidirectional tapes, which contain at least one reinforcing fiber and a thermoplastic polyester matrix. The prepreg composites can be thermally bonded to a mineral-containing substrate in order to improve the performance characteristics of the substrate without requiring adhesives and without significantly increasing the mass or thickness of the substrate. The prepreg composite of the present invention can be applied to a wide range of mineral-containing substrates, including structural panels, gypsum wallboards, plasterboard, drywall, cement boards, or ceiling tiles.

The present invention is directed to a gypsum panel with enhanced hail resistance and a method of making such gypsum panel. For instance, in one aspect, the gypsum panel comprises a gypsum core and a first facing material and a second facing material, the first facing material and the second facing material sandwiching the gypsum core, the first facing material, the second facing material, or both comprising glass fibers and one or more binders, the glass fibers being bound by the one or more binders. The methods of the present invention are directed to making the aforementioned gypsum panels by providing the first facing material, providing a gypsum slurry comprising gypsum and water onto the first facing material, and providing a second facing material on the gypsum slurry.

A bonded optical assembly comprising infrared-transparent materials. The assembly comprises two or more infrared transparent optical elements and a polymer comprising at least one chalcogenide element and crosslinking moieties between the infrared-transparent optical elements. The crosslinking moieties may be organic, inorganic, or both.

Gypsum boards formed from synthetic gypsum and other gypsum sources having high chloride salt concentrations. Gypsum boards may include a board core including set gypsum between a front cover sheet and a back cover sheet. A total concentration of the chloride anion in the board core ranges from about 150 to 4000 parts by weight (pbw) chloride, typically about 300 to about 3000 pbw, more typically from about 400 to about 2000 pbw, further typically from about 1000 to about 2000 pbw, and further typically from about 600 to about 1000 pbw, per 1,000,000 pbw calcium sulfate dihydrate. A polymer layer contacts an inner surface of the back cover sheet. A densified gypsum layer contacts an inner surface of the front cover sheet. Methods of making the gypsum board, and a wall system for employing the gypsum boards, are also provided.

The present invention is directed to a gypsum panel with enhanced fire resistance properties and a method of making such gypsum panel. In one embodiment, the gypsum panel comprises a gypsum core, a fire resistance composition, a first facing material, and a second facing material. The fire resistance composition may include phosphorus, nitrogen, boron, or a combination thereof. The weight ratio of phosphorus to nitrogen may be 40-95:0-50. The weight ratio of phosphorus to boron may be 40-95:0-10. The methods of the present invention are directed to making the aforementioned gypsum panels.

Embodiments relate to a flame barrier that may be adhered or mechanically fastened to a substrate to provide fire resistance and/or an outer protective surface. The flame barrier may alternatively be adhered or mechanically fastened to an existing flame barrier to provide increased fire resistance and/or increased protective ability. The flame barrier is configured to protect against high temperature flames, prevent flame penetration, and contain aggressive flames to reduce the severity of the flame's impact, heat, and velocity.