Multi-axial laminate composite structures and methods of forming the same

A method of forming a composite laminate structure, comprising:

• forming a first bidirectional layer by positioning a first reinforcement layer adjacent to a second reinforcement layer, the first layer including a plurality of parallel reinforcement fibers oriented at a first selected shallow angle relative to a first selected direction and the second layer including a plurality of approximately parallel reinforcement fibers oriented at a second selected shallow angle relative to the first direction;
• forming a second bidirectional layer by positioning a third reinforcement layer adjacent to a fourth reinforcement layer, the third layer including a plurality of parallel reinforcement fibers oriented at a third selected broad angle relative to the first selected direction and the fourth layer including a plurality of approximately parallel reinforcement fibers oriented at a fourth selected broad angle relative to the first direction;
• and
• coupling the first bidirectional layer to the second bidirectional layer.

An aerospace vehicle, comprising:

• a fuselage;
• wing assemblies and an empennage operatively coupled to the fuselage;
• and
• a composite laminate structure incorporated into a selected portion of at least one of the fuselage, the wing assemblies and the empennage, further comprising:
• a first bidirectional layer having a first portion that includes a plurality of parallel reinforcement fibers oriented at a first selected shallow angle relative to a first selected direction and a second adjacent portion that includes approximately parallel reinforcement fibers oriented at a second selected shallow angle relative to the first direction;
• a second bidirectional layer having a first portion that includes a plurality of parallel reinforcement fibers oriented at a third selected broad angle relative to the first selected direction and a second adjacent portion that includes approximately parallel reinforcement fibers oriented at a fourth selected broad angle relative to the first direction;
• and
• at least one unidirectional layer having a plurality of parallel reinforcement fibers and coupled to at least one of the first bidirectional layer and the second bidirectional layer.