Abstract: A composite mixture for making a thin-layer composite product, such as a door skin, which includes cellulosic fibers, at least 1% by weight noncellulosic fibers, such as glass fibers, and at least 1% by weight of an isocyanate resin, and methods for making them. The noncellulosic fibers may be individualized before they come in contact with the resin.

Abstract: A method to produce a thin-layer lignocellulosic composite having increased resistance to moisture-induced shrinking or swelling is provided. The method includes forming a lignocellulosic composite mixture including at least one type of lignocellulosic fiber having a predetermined moisture content of at least about 4 wt %, at least about 1 wt % of an organic isocyanate resin, at least about 0.1 wt % of a tackifier, and at least about 0.1 wt % release agent, wherein the mixture is substantially free of added wax. The method further includes pre-pressing the mixture into a loose formed mat and pressing the mat between two dies at an elevated temperature and pressure and/or a sufficient time to further reduce the thickness of the mat to form a thin-layer composite of predetermined thickness, and to allow the isocyanate resin to interact with the lignocellulosic fiber such that the resultant thin-layer composite has a predetermined resistance to moisture.

Abstract: Metal doors may be more cost-efficient than wood to manufacture and maintain, but may not be as aesthetically pleasing to the consumer. For example, metal garage doors may only be available in limited color lines and often do not simulate a natural wood grain in a very realistic manner. Also, metal garage doors may be limited in design, in that it may be difficult to add three dimensional shaping, such as trim or paneling, to the outer surface of a metal door. For example, some manufacturers apply extrusive plastic panels to the face of a metal garage door to add a design to the face of the door. The plastic and metal components, however, may exhibit different physical properties in response to changes in temperature and humidity and thus, the door may exhibit warping or other types of deformation upon exposure to weather.