A method is provided for manufacturing a product having a three dimensional surface layer. The method may involve applying a water based resin on an underlying surface of the product. The water based resin may be at least in part thermocurable. A UV-curable liquid may be provided onto at least one portion of the water based resin, when the water based resin is liquid or partially cured. The water based resin may be cured at least by heating. The UV-curable liquid may be optionally UV cured. The UV-curable liquid may be optionally removed. The surface layer and the underlaying surface may be optionally pressed together by a pressing device.

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.

A decorative sheet according to one aspect of the present disclosure comprises a decorative plate and an adhesive layer disposed on a first side of the decorative plate. The decorative plate comprises (A) a decorative layer disposed on a second side from the first side, (B) a core layer made of a prepreg containing a fiber base material, and (C) a balancing layer including mixed paper containing an endothermic metal hydroxide as a base material.

The present invention provides an adhered structure in which members of the same or different materials are adhered to each other with a high adhesive strength and a method for producing the adhered structure. The adhered structure of the present invention comprises a first solid member, a second solid member, and an adhesive member. The first solid member and the second solid member are adhered to each other through the adhesive member. The adhesive member contains a polymer. The polymer is chemically bonded to the first solid member and the second solid member.

Disclosed are layered composite articles comprising: a) a rigid backing portion comprising a rigid core having a first surface and an opposed second surface, wherein the rigid core comprises at least one densified fiber batt and wherein the at least one densified fiber batt is comprised of a first plurality of oriented fibers having a first melting point and a second plurality of oriented fibers having a second melting point different from the first melting point; and b) a decorative portion having a first surface and an opposed second surface, wherein the second surface of the decorative portion is affixed to the first surface of the rigid core. Also disclosed herein are methods of making the same.

A composite flame barrier includes at least one layer of nonwoven flame resistant fibers, and at least one layer of heat absorbing intumescing expandable graphite held together with polymeric binders and fire resistant fibers in a sheet structure. The composite material provides thermal protection that cannot be achieved using the expandable graphite is alone. By mechanically attaching a nonwoven felt or hydro-entangled nonwoven material to the layer containing expandable graphite, the graphite becomes stabilized and is more resistant to forces that may damage the material (wind, high velocity flames etc.) and decrease or eliminate the thermal performance of the expandable graphite. The composite flame barrier is useful in applications where prolonged fire and heat resistance is required, and has an advantage of being flexible and lightweight. The uses for the material include emergency portable fire shelters, structural protection of aircraft, structural steel fire proofing, fire-rated wall assemblies, and other fire-resistant applications.

The present disclosure relates to a method to produce a coating layer, including applying a coating composition on a surface of a carrier, curing the coating composition to a coating layer, and subsequently applying pressure to the coating layer. The disclosure further relates to a method to produce a building panel, and such a building panel, and to a method to produce a coated foil, and such a coated foil.

A multilayer laminate for use as a flame barrier in an aircraft comprising (i) a polymeric film layer capable of withstanding a temperature of at least 200 C for at least 10 min, (ii) an adhesive layer having an areal weight of from 2 to 40 gsm capable of activation at a temperature of from 75 to 200 degrees C., (iii) an inorganic refractory layer, and (iv) aramid paper comprising from 50 to 90 weight percent of aramid fibers and from 10 to 50 weight percent of meta-aramid binder wherein the inorganic refractory layer of (iii) comprises platelets in an amount of at least 85% by weight with a dry areal weight of 15 to 50 gsm and a residual moisture content of no greater than 10 percent by weight.

A floor, wall, or ceiling panel has a base made of a wood material and an upper veneer. The base and the veneer are hot-pressed together while incorporating a resin layer. During the pressing process, pores, cracks, and/or gaps in the veneer are filled with resin. In particular, the pressing process is carried out such that the veneer is saturated with resin, and the resin can be seen on the surface of the veneer after the pressing process The adhesion of the veneer to the base and the smoothing of the veneer are thus carried out in one operation.

A curable composition comprising: i) a glycidyl ether of a novolac, comprising or consisting of moieties having the formula (I), wherein R.sub.a is either always hydrogen or always methyl; B is either always *CH2-** or always formula (A); a fraction of 0.8 to 0.99 of the Y moieties are essentially O-glycidyl, this fraction being designated as x, and the remainder of the Y moieties, this fraction being designated as (1-x), are divalent bridging spacers of the structure *OCH.sub.2CH(OH)CH.sub.2O** connecting two moieties according to above formula (I); andn is a number in the range of 0.1 to 3.0; and wherein said novolac glycidyl ether has an epoxy equivalent weight FEW in the range of 160 to 270 g/eq. and the average number of epoxy groups per molecule of novolac glycidyl ether (I), designated as f, is in the range of 2.1 to 5.0; ii) dicyandiamide; and iii) an urea derivative of the formula (II). This composition is stable upon storage at room temperature and fire-retardant. It can be used for preparation of prepregs and in core filling, particularly in the aerospace field.