Double-double composite sub-laminate structures and methods for manufacturing and using the same

A composite laminate structure comprising:

• a plurality of sub-laminate modules each comprising:
• a first ply set containing a first ply layer oriented at a first angle and a second ply layer oriented at a second angle, the second angle being equal and opposite the first angle;
• a second ply set containing a third ply layer oriented at a third angle and a fourth ply layer oriented at a fourth angle, the fourth angle being equal and opposite the third angle;
• a first acute angle defined by a difference between the first angle and the third angle;
• and
• a second acute angle defined by a difference between the second angle and the fourth angle,
• wherein:
• the second ply layer is positioned adjacent the third ply layer and the second and third ply layers are both positioned intermediate the first and fourth ply layers, thereby defining a double-double helix arrangement of the respective ply layers,
• the plurality of sub-laminate modules are sequentially stacked relative to one another so as to define a homogenized composite laminate structure,
• the first and second angles of at least one of the plurality of sub-laminate modules are one of:
• ±32°, ±13°, or ±22.5°, and
• the third and fourth angles of at least one of the plurality of sub-laminate modules are one of:
• ±58°, ±73°, or ±67.5°.

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

• positioning a first ply set in a first orientation, the first ply set consisting of a first ply layer oriented at a first angle and a second ply layer oriented at a second angle, the second angle being equal and opposite the first angle;
• positioning a second ply set in a second orientation different from the first orientation, the second ply set consisting of a third ply layer oriented at a third angle and a fourth ply layer oriented at a fourth angle, the fourth angle being equal and opposite the third angle, a difference between the third angle and the first angle defining an acute angle there-between;
• and
• stacking the second ply set adjacent the first ply set so as to define a double-double helix arrangement of the respective layers,
• wherein, when stacked, the second ply layer is positioned adjacent the third ply layer and the second and third ply layers are both positioned intermediate the first and fourth ply layers.