Multi-layer plies for improved composite performance

A ply for fabricating composite material, comprising:

• a first tow comprising a plurality of fibers spread to a width dimension in a direction along a width of a cross section of the ply;
• a first sheet of enhanced performance material positioned to overlie the first tow and extends across the width dimension of the first tow;
• and
• a second tow comprising a plurality of fibers wherein:
• the plurality of fibers within the second tow are spread in a direction along the width of the cross section of the ply to overlie the first sheet of enhanced performance material and the first tow, and
• the plurality of fibers of the second tow are spread to a width dimension having substantially the same width dimension as the width dimension of the first tow wherein the width dimension of the first tow and the width dimension of the second tow are positioned coextensive with each other;
• and
• another tow comprising a plurality of fibers spread in the direction along the width of the cross section of the ply positioned laterally from and against the first tow, the second tow, and the first sheet of enhanced performance material, with the plurality of fibers of the another tow extending in substantially the same direction as the plurality of fibers of the first and second tows;
• wherein:
• the another tow has approximately the same width dimension of the width dimension of the first tow and the second tow;
• and
• the first tow and the second tow each have approximately one half of the plurality of fibers of the another tow;
• and
• a top sheet of enhanced performance material positioned to extend along the top of the ply and to overlie the second tow and the another tow.

A ply for fabricating composite material, comprising:

• a first sheet of enhanced performance material which extends along a width of a cross section of the ply;
• a first tow of fibers positioned to underlie the first sheet of enhanced performance material;
• and
• a second tow of fibers positioned on an opposing side of the first sheet of enhanced performance material, wherein at least a portion of fibers of the second tow of fibers overlies at least a portion of fibers of the first tow of fibers, such that a portion of the first sheet of enhanced performance material is positioned between the first and second tows of fibers and extends between a bottom of the cross section of the ply and a top of the cross section of the ply;
• wherein:
• the portion of the first sheet of enhanced performance material positioned at the top of the cross section of the ply has a first portion of first sheet of enhanced performance material which extends in a direction from the portion along the top of the cross section of the ply overlying the first tow;
• and
• the portion of the first sheet of enhanced performance material positioned at the bottom of the cross section of the ply has a second portion of first sheet of enhanced performance material which extends in a direction from the portion along the bottom of the cross section of the ply underlying the second tow.

A ply for fabricating a composite material, comprising:

• a first sub-layer of the ply including a first sheet of enhanced performance material configured in a corrugated shape which defines at least two recesses, wherein:
• the first sheet of enhanced performance material extends across a cross section of the ply;
• and
• at least one tow of plurality of fibers is positioned within each recess;
• and
• a second sub-layer of the ply including a second sheet of enhanced performance material configured in a corrugated shape which defines at least two recesses, wherein:
• the second sheet of enhanced performance material extends across the cross section of the ply;
• at least one tow of plurality of fibers is positioned within each recess;
• and
• the second sub-layer overlies the first sub-layer.