A method for making a composite article comprises securing a layup over a form. The layup including a plurality of dry intermediate reinforcement plies wrapped around an inner reinforcement ply. Resin is infused into the layup under vacuum. The resin-infused layup is consolidated under pressure and cured.

A decorative sheet includes a releasing layer, a pressure-sensitive adhesive layer disposed on a surface of the releasing layer, and a skin layer disposed on a surface of the pressure-sensitive adhesive layer. The releasing layer includes a shape-holding layer, both the shrinkage ratio of the shape-holding layer and the shrinkage ratio of the skin layer are 0/1000 to 9/1000, and both the softening start temperature of the shape-holding layer and the softening start temperature of the skin layer are 60 C. or more and 120 C. or less.

A decorative sheet includes a releasing layer, a pressure-sensitive adhesive layer disposed on a surface of the releasing layer, and a skin layer disposed on a surface of the pressure-sensitive adhesive layer. The releasing layer includes a shape-holding layer, both the shrinkage ratio of the shape-holding layer and the shrinkage ratio of the skin layer are 0/1000 to 9/1000, and both the softening start temperature of the shape-holding layer and the softening start temperature of the skin layer are 60 C. or more and 120 C. or less.

A single-skinned composite lattice sandwich structure includes a face sheet, fiber stringers, and at least one fiber tow arranged in a lattice structure separating the face sheet and fiber stringers. The face sheet and at least the fiber tow(s) forming the lattice may be interfused with a matrix to form a contiguous composite structure. The fiber stringers may be formed of various materials for imparting different structural properties to the sandwich structure, including carbon fiber for tensile strength and lightness, metallic or other rigid material for imparting overall structural rigidity, shape-changing material or actuated material for providing actuated deformation of the structure, and may also include sensors.

A single-skinned composite lattice sandwich structure includes a face sheet, fiber stringers, and at least one fiber tow arranged in a lattice structure separating the face sheet and fiber stringers. The face sheet and at least the fiber tow(s) forming the lattice may be interfused with a matrix to form a contiguous composite structure. The fiber stringers may be formed of various materials for imparting different structural properties to the sandwich structure, including carbon fiber for tensile strength and lightness, metallic or other rigid material for imparting overall structural rigidity, shape-changing material or actuated material for providing actuated deformation of the structure, and may also include sensors.

A method of manufacturing cross-corrugated support structures is provided. A mold having a molding surface with a first plurality and a second plurality of corrugations therein is used to introduce corrugations into a flexible, carbonaceous sheet. Cross-corrugations are introduced into the sheet by placing the sheet onto the molding surface, encapsulating the sheet to form a vacuum chamber, and evacuating the vacuum chamber of air. As air is evacuated from the vacuum chamber, the sheet is drawn upon the molding surface causing the sheet to conform to the shape of the molding surface. Thermosetting resin is infused into the sheet and cured causing the sheet to rigidly retain the shape of the molding surface. The sheet is further reinforced by securing at least one support member to the sheet using thermosetting resin.

A method of manufacturing cross-corrugated support structures is provided. A mold having a molding surface with a first plurality and a second plurality of corrugations therein is used to introduce corrugations into a flexible, carbonaceous sheet. Cross-corrugations are introduced into the sheet by placing the sheet onto the molding surface, encapsulating the sheet to form a vacuum chamber, and evacuating the vacuum chamber of air. As air is evacuated from the vacuum chamber, the sheet is drawn upon the molding surface causing the sheet to conform to the shape of the molding surface. Thermosetting resin is infused into the sheet and cured causing the sheet to rigidly retain the shape of the molding surface. The sheet is further reinforced by securing at least one support member to the sheet using thermosetting resin.

A glass facer for a constructions board includes a first non-woven layer of coarse fibers and a second non-woven layer of coarse fibers and microfibers. The glass facer also includes a binder that simultaneously binds or adheres the coarse fibers of the first non-woven layer together, the coarse fibers and the microfibers of the second non-woven layer together, and the first non-woven layer to the second non-woven layer. The first non-woven layer has a porosity and air permeability that enables the first non-woven layer to absorb a material of the construction board when the glass facer is positioned atop the construction board during manufacture of the construction board. The second non-woven layer is configured to block the material of the construction board from passing through the glass facer to an exterior surface of the second non-woven layer so that the material is not externally visible.

A glass facer for a constructions board includes a first non-woven layer of coarse fibers and a second non-woven layer of coarse fibers and microfibers. The glass facer also includes a binder that simultaneously binds or adheres the coarse fibers of the first non-woven layer together, the coarse fibers and the microfibers of the second non-woven layer together, and the first non-woven layer to the second non-woven layer. The first non-woven layer has a porosity and air permeability that enables the first non-woven layer to absorb a material of the construction board when the glass facer is positioned atop the construction board during manufacture of the construction board. The second non-woven layer is configured to block the material of the construction board from passing through the glass facer to an exterior surface of the second non-woven layer so that the material is not externally visible.

In one version there is provided a test system including a layup tool having a layup surface, and two fairing bars attached to the layup surface. The test system includes the composite laminate having a plurality of stacked plies, and positioned between the two fairing bars. The test system includes fiber distortion initiator(s) positioned at one or more locations under, and adjacent to, one or more plies of the plurality of stacked plies. The test system includes two caul plates with a gap in between, and positioned over the composite laminate. When the test system undergoes a pressurized cure process with a vacuum compaction, a restricted outward expansion of the plurality of stacked plies by the fairing bars, and a pressure differential region formed by the one or more fiber distortion initiators at the one or more locations, create the controlled and repeatable out-of-plane fiber distortion in the composite laminate.