Composite structures containing finite length tapes and methods for manufacturing and using the same

A composite laminate structure comprising:

• a grid component having a plurality of ply layers, each one of the plurality of ply layers comprising a plurality of first elongate tapes oriented in a first direction and a plurality of second elongate tapes oriented in a second direction, the second direction being offset from the first direction by a first angle of at least 20 degrees;
• and
• a skin component, comprising a plurality of third elongate tapes oriented in a third direction and a plurality of fourth elongate tapes oriented in a fourth direction, the fourth direction being offset from the third direction by a second angle of at least 20 degrees, the second angle being different than the first angle,
• wherein:
• each of the plurality of first elongate tapes in one of the plurality of ply layers has a first length extending between opposing ends of each of the plurality of first elongate tapes and a first midpoint intermediate the opposing ends;
• each of the plurality of second elongate tapes in the one of the plurality of ply layers has a second length extending between opposing ends of each of the plurality of second elongate tapes and a second midpoint intermediate the opposing ends;
• opposing ends of each one of the plurality of first elongate tapes are positioned adjacent opposite sides of the second midpoint of adjacently positioned ones of the plurality of second elongate tapes to define first joint locations, each of the first joint locations being defined by only two ends of two adjacently positioned ones of the plurality of first elongate tapes and no ends of the plurality of second elongate tapes;
• opposing ends of each one of the plurality of second elongate tapes are positioned adjacent opposite sides of the first midpoint of adjacently positioned ones of the plurality of first elongate tapes, so as to define second joint locations, each of the second joint locations being defined by only two ends of two adjacently positioned ones of the plurality of second elongate tapes and no ends of the plurality of first elongate tapes;
• each of the first and second elongate tapes has a longitudinal axis extending between the opposing ends of each of the first and second elongate tapes and along the length thereof, the opposing ends of each of the first and second elongate tapes having a semi-circular rounded shape relative to the longitudinal axis of the first and second elongate tapes;
• and
• the skin component is positioned adjacent one exterior ply layer of the plurality of ply layers of the grid component.

A grid structure for use in a composite laminate structure, the grid structure comprising:

• a single ply layer comprising a set of first elongate tapes oriented in a first direction and a set of second elongate tapes oriented in a second direction, the second direction being offset from the first direction by an angle of at least 25 degrees,
• wherein:
• each of the first elongate tapes has a first length extending between opposing ends of each of first elongate tapes and a first midpoint intermediate the opposing ends;
• each of the second elongate tapes has a second length extending between opposing ends of the second elongate tapes and a second midpoint intermediate the opposing ends;
• the first length is the same as the second length;
• opposing ends of the first elongate tapes are positioned adjacent opposite sides of the second midpoint of adjacently positioned ones of the second elongate tapes to define first joint locations, each of the first joint locations being defined by only two ends of two adjacently positioned ones of the plurality of first elongate tapes and no ends of the plurality of second elongate tapes;
• opposing ends of the second elongate tapes are positioned adjacent opposite sides of the first midpoint of adjacently positioned ones of the first elongate tapes, so as to define second joint locations, each of the second joint locations being defined by only two ends of two adjacently positioned ones of the plurality of second elongate tapes and no ends of the plurality of first elongate tapes;
• and
• each of the first and second elongate tapes has a longitudinal axis extending between the opposing ends of each of the first and second elongate tapes and along the length thereof, the opposing ends of each of the first and second elongate tapes having a semi-circular rounded shape relative to the longitudinal axis of the first and second elongate tapes.