A method to produce a building panel, including: providing a substrate, applying a thermosetting binder in dry form on the substrate for forming a sub-layer, applying a sheet on the sub-layer, and pressing the substrate, the sub-layer and the sheet together to form a building panel, thereby the thermosetting binder of the sub-layer impregnates the sheet from below. Also, a semi-finished product.

A building board, particularly a gypsum board, can include a first cover sheet, a second cover sheet, a first layer with gypsum disposed between the first and second cover sheets, a second layer with gypsum disposed between the first cover sheet and the first layer, and an interlayer between the first and second sheets. The board can have a TC4 failure timethe time to reach 140 plus room temperature on the cold face of the boardof greater than 73 minutes. The board can have a TC4 failure improvement timethe amount of time longer the board lasted in a TC4 failure time test compared to the standard boardof at least about 3 minutes or TC4 failure improvement percentage time of at least 1.5%. The board can have at least 15% expansion improvement-a percentage the board expanded over expansion of a standard board-over a standard board.

Composite door systems that are configured for providing safety, security, and resistance to physical impacts or threats (natural and man-caused), and which can be utilized in barrier structures, such as for doors. The composite door systems may include one or more layers, each of which may have one or more fiber layers, such as fabric layers or plastic layers. The composite door systems may further include one or more additional layers of a sheet material, a fill material, or the like. The composite door systems are infinitely customizable and configured to be adapted to a variety of applications, and scalable levels of protection.

A method of manufacturing a building element, including applying a first layer on a first surface of a substrate, the first layer including a mixture of a binder, at least one filler and fine non-pigment cohesive particles, wherein an amount of the fine non-pigment cohesive particles in the mixture may be between 0.05 wt % and 9 wt % of the mixture, and applying heat and/or pressure to the first layer and/or the substrate thereby forming the building element. The disclosure further relates to such a building element.

A method to produce a building panel, including: providing a substrate, applying a thermosetting binder in dry form on the substrate for forming a sub-layer, applying a sheet on the sub-layer, and pressing the substrate, the sub-layer and the sheet together to form a building panel, thereby the thermosetting binder of the sub-layer impregnates the sheet from below. Also, a semi-finished product.

Composite door systems that are configured for providing safety, security, and resistance to physical impacts or threats (natural and man-caused), and which can be utilized in barrier structures, such as for doors. The composite door systems may include one or more layers, each of which may have one or more fiber layers, such as fabric layers or plastic layers. The composite door systems may further include one or more additional layers of a sheet material, a fill material, or the like. The composite door systems are infinitely customizable and configured to be adapted to a variety of applications, and scalable levels of protection.

Described herein is a building panel and related building systems, the building panel having a first major surface opposite a second major surface, the building panel comprising a core comprising a first body comprising a first fibrous material; and a second body comprising a second fibrous material, a veneer facing layer coupled to the core, the veneer facing layer comprising a plurality of perforations.

The embodiments of the present invention generally relate to i) paper and paperboard or molded products with improved abrasion resistance and/or taber stiffness, ii) methods for making paper and paperboard or molded products with improved abrasion resistance and/or taber stiffness, and iii) methods for improving abrasion resistance and/or taber stiffness paper and paperboard or molded products, by using a metal chelate, such as, Ammonium Zirconium Carbonate (AZC) or Potassium Zirconium Carbonate (PZC). Further advantages of the embodiments of the present invention will be readily apparent to the reader from this disclosure.