Composite bi-angle and thin-ply laminate tapes and methods for manufacturing and using the same

A quasi-isotropic composite laminate structure, said structure comprising:

• at least three bi-angle tapes, each tape comprising:
• a first ply layer comprising fibers extending in a first orientation;
• and
• a second ply layer comprising fibers extending in a second orientation, the second orientation being offset relative to the first orientation;
• and
• wherein each of the at least three tapes of the composite laminate structure are rotationally oriented relative to one another such that corresponding ply layers are substantially uniformly distributed across a 360° angle at an incremental angle of less than or equal to 30°.

A method of forming a quasi-isotropic composite laminate structure, the method comprising the steps of:

• forming at least three tapes, each tape comprising a first ply layer comprising fibers oriented in a first direction and a second ply layer comprising fibers oriented in a second direction, the second direction being offset relative to the first direction by a ply angle of less than or equal to 30°;
• positioning a first of said at least three tapes such that fibers of said second ply layer of said first tape extend in a first orientation;
• stacking a second of said at least three tapes relative to said first of the at least three tapes such that fibers of said first ply layer of said second of the at least three tapes extend in a second orientation, said second orientation being offset relative to said first orientation by an incremental angle of less than or equal to 45°;
• and
• stacking a third of said at least three tapes relative to said second of the at least three tapes such that said fibers of said first ply layer of said third of the at least three tapes extend in a third orientation, said third orientation being offset relative to said second orientation by said incremental angle,
• wherein said fibers of said second ply layer of said third of the at least three tapes extend in a fourth orientation, said fourth orientation being offset relative to fibers of said first ply layer of said first tape by said incremental angle, such that said at least three tapes are substantially uniformly distributed across a 360° angle so as to form the composite laminate structure.

A method of forming a composite laminate integrated bulkhead structure, said method comprising the steps of:

• forming at least three tapes, each tape comprising a first ply layer comprising fibers oriented in a first direction and a second ply layer comprising fibers oriented in a second direction, the second direction being offset relative to the first direction by an angle of less than or equal to 30′;
• positioning a first of said at least three tapes such that fibers of said second ply layer of said first tape extend in a first orientation, said first of said at least three tapes defining a first portion of a surface of said bulkhead structure;
• stacking a second of said at least three tapes relative to said first of the at least three tapes such that fibers of said first ply layer of said second of the at least three tapes extend in a second orientation, said second orientation being offset relative to said first orientation by an incremental angle of less than or equal to 45°, said second of said at least three tapes defining a second portion of said surface of said bulkhead structure, said second portion at least in part overlapping said first portion;
• and
• stacking a third of said at least three tapes relative to said second of the at least three tapes such that said fibers of said first ply layer of said third of the at least three tapes extend in a third orientation, said third orientation being offset relative to said second orientation by said incremental angle, said third of said at least three tapes defining a third portion of said surface of said bulkhead structure, said third portion at least in part overlapping said first and second portions,
• wherein said fibers of said second ply layer of said third of the at least three tapes extend in a fourth orientation, said fourth orientation being offset relative to fibers of said first ply layer of said first tape by said incremental angle, such that said at least three tapes are substantially uniformly distributed across a 360° angle such so as to form the composite laminate integrated bulkhead structure.