Methods for manufacturing sublaminate modules and forming composite laminated structures from the same

A method of manufacturing a sub-laminate module for use in forming a composite laminate, said method consisting of the steps of:

• spreading a first tow comprising a plurality of fibers to form a first ply layer;
• spreading a second tow comprising a plurality of fibers to form a second ply layer;
• positioning the plurality of fibers of the first tow in a first orientation, such that the first ply layer is aligned with a primary longitudinal axis that corresponds to a primary load-bearing axis of the sub-laminate module;
• positioning the plurality of fibers of the second tow in a second orientation, the second orientation being offset relative to the first orientation and the primary longitudinal axis such that the relative offset corresponds to and defines an acute angle there between, the acute angle being less than 90°;
• stacking the second ply layer and the first ply layer adjacent one another, the stacking forming an unbalanced structure of the sub-laminate module due to the relative offset of the second ply layer;
• and
• stitching the first ply layer and the second ply layer relative to one another in a non-crimped configuration,
• wherein the first ply and the second ply are opposing outer ply layers of the sub-laminate module.

A method of manufacturing a composite laminated structure, said method comprising the steps of:

• forming a plurality of sub-laminate modules, each module consisting of:
• a first ply comprising fibers extending in a first orientation such that the first ply is aligned with a primary longitudinal axis that corresponds to a primary load-bearing axis of each of the plurality of sub-laminate module;
• a second ply comprising fibers extending in a second orientation, the second orientation being offset relative to the first orientation and the primary longitudinal axis;
• and
• an acute angle defined by the relative offset between the first orientation and the second orientation, the acute angle being less than 90° and defining an unbalanced structure of the sub-laminate module;
• stacking the plurality of sub-laminate modules adjacent one another;
• securing respective ones of the plurality of sub-laminate layers relative to one another in a substantially non-crimped configuration;
• and
• sequentially laying up each of the respectively secured plurality of sub-laminate layers so as to form the composite laminated structure,
• wherein the first ply and the second ply of each of the plurality of sub-laminate modules are opposing outer ply layers of their respective sub-laminate module.