Disclosed is a composite gypsum board comprising a board core and a concentrated layer of substantial thickness (e.g., at least about 0.02 inches). The concentrated layer includes a higher weight percentage of an enhancing additive than the board core. The board core has a thickness greater than the thickness of the concentrated layer and forms the bulk of the board volume. The concentrated layer has a higher density (e.g., at least about 1.1 times greater) than the density of the board core. Also disclosed is a method of preparing a composite gypsum board.

Disclosed is a composite gypsum board comprising a board core and a concentrated layer of substantial thickness (e.g., at least about 0.02 inches). The concentrated layer includes a higher weight percentage of an enhancing additive than the board core. The board core has a thickness greater than the thickness of the concentrated layer and forms the bulk of the board volume. The concentrated layer has a higher density (e.g., at least about 1.1 times greater) than the density of the board core. Also disclosed is a method of preparing a composite gypsum board.

The present disclosure is generally directed to a mold inhibiting composition. The mold inhibiting composition can be used to treat various different substrates, including building material products, such as facing layers for wallboard. In general, any suitable paper product may be treated with the composition. The composition contains a mold inhibiting agent in combination with a defoamer. The mold inhibiting agent may comprise a pyrithione. The defoamer, on the other hand, may comprise an oil based defoamer containing metal oxide particles, such as silica particles. The mold inhibiting composition can be combined with a water repellent and applied to a substrate without excessive amounts of foam or froth being formed. The defoamer is selected so as to not interfere with the resulting water absorption properties of the product.

The present disclosure is generally directed to a mold inhibiting composition. The mold inhibiting composition can be used to treat various different substrates, including building material products, such as facing layers for wallboard. In general, any suitable paper product may be treated with the composition. The composition contains a mold inhibiting agent in combination with a defoamer. The mold inhibiting agent may comprise a pyrithione. The defoamer, on the other hand, may comprise an oil based defoamer containing metal oxide particles, such as silica particles. The mold inhibiting composition can be combined with a water repellent and applied to a substrate without excessive amounts of foam or froth being formed. The defoamer is selected so as to not interfere with the resulting water absorption properties of the product.

Composite panels and methods of preparation are described herein. In some embodiments, the composite panel can include a first fiber reinforcement, a polyurethane composite having a first surface and a second surface opposite the first surface, wherein the first surface is in contact with the first fiber reinforcement; and a cementitious material adjacent the first fiber reinforcement opposite the polyurethane composite. The polyurethane composite can be formed from (i) one or more isocyanates selected from the group consisting of diisocyanates, polyisocyanates, and mixtures thereof, (ii) one or more polyols, and (iii) a particulate filler. The fiber reinforcement can be formed from a woven or non-woven material, such as glass fibers. The composite panel can further include a material, such as a second fiber reinforcement and a cementitious layer, in contact with the second surface of the polyurethane composite. Articles comprising the composite panels are also disclosed.

A method to produce a veneered element, the method including applying a first layer on a substrate, applying a second layer on a veneer layer, applying the veneer layer with the second layer applied thereto on the first layer, such that the second layer is facing the first layer, pressing the first layer, the second layer and the veneer layer together to form a veneered element, thereby material originating from the second layer permeates into the veneer layer, and wherein, after pressing, the first layer is visible through a crack, cavity, hole and/or knot of the veneer layer. Also, a veneered element.

A base paper (6), a picture pattern layer (7) provided on a surface (6a) side of the base paper (6), and foaming agents (8) arranged on a surface (7a) of the picture pattern layer (7) or in the picture pattern layer (7) are provided. In the foaming agents (8), the average particle diameter after foaming is set to 15 μm or more and 250 μm or less and the foaming start temperature is set to 100° C. or more and 220° C. or less.

Disclosed is a composite gypsum board comprising a board core comprising set gypsum sandwiched between face and back cover sheets. The composite gypsum board also comprises an intermediate sheet between the board core and the face cover sheet, with a thin, dense gypsum layer disposed between the intermediate sheet and the face cover sheet. Optionally, a second dense gypsum layer can be disposed between a first major side of the board core and the back cover sheet. Also disclosed is a method of preparing a composite gypsum board in which an intermediate sheet is applied over a dense gypsum layer disposed on a face cover sheet. A back cover sheet is applied to the other major side of the board core, with a second dense gypsum layer optionally disposed therebetween.

Disclosed is a composite gypsum board comprising a board core comprising set gypsum sandwiched between face and back cover sheets. The composite gypsum board also comprises an intermediate sheet between the board core and the face cover sheet, with a thin, dense gypsum layer disposed between the intermediate sheet and the face cover sheet. Optionally, a second dense gypsum layer can be disposed between a first major side of the board core and the back cover sheet. Also disclosed is a method of preparing a composite gypsum board in which an intermediate sheet is applied over a dense gypsum layer disposed on a face cover sheet. A back cover sheet is applied to the other major side of the board core, with a second dense gypsum layer optionally disposed therebetween.

Provided are wallboard panels that include a foam material layer and a core material, with one or more sheets of facer material and/or one or more sheets of backing material. The foam material layer may include one or more pores having an open pore geometry. Additionally, provided are methods of manufacturing such wallboard panels.