Composite laminated structures and methods for manufacturing and using the same

A sub-laminate module for use in forming a composite laminate, the sub-laminate module consisting of:

• a primary longitudinal axis corresponding to a primary load-bearing axis of the sub-laminate module;
• a first ply comprising fibers extending in a first orientation, the fibers of the first ply comprising a plurality of spread tows lying adjacent to each other;
• a second ply comprising fibers extending in a second orientation, the fibers of the second ply comprising a plurality of spread tows lying adjacent to each other, the second orientation being offset relative to the first orientation;
• and
• an acute angle defined by the relative offset between the first and the second orientations, the acute angle being less than 90° and defining an unbalanced structure of the sub-laminate layer,
• wherein:
• the first orientation is aligned with the primary longitudinal axis of the sub-laminate module such that the first ply is aligned with the primary load-bearing axis of the sub-laminate module;
• the second orientation is offset relative to the first orientation and the primary longitudinal axis such that the relative offset corresponds to the acute angle and defines the unbalanced structure of the sub-laminate module;
• and
• the fibers of the first and the second plies are secured relative to one another via a plurality of stitches.

A composite laminated structure, the composite laminated structure comprising:

• a plurality of sub-laminate modules, each module consisting of:
• a primary longitudinal axis corresponding to a primary load-bearing axis of the sub-laminate module;
• a first ply comprising fibers extending in a first orientation;
• a second ply comprising fibers extending in a second orientation, the second orientation being offset relative to the first orientation;
• and
• an acute angle defined by the relative offset between the first orientation and the second orientation, the acute angle being less than 90° and defining an unbalanced structure of the sub-laminate module,
• wherein;
• the first orientation is aligned with the primary longitudinal axis of the sub-laminate module such that the first ply is aligned with the primary load-bearing axis of the sub-laminate module;
• the second orientation is offset relative to the first orientation and the primary longitudinal axis such that the relative offset corresponds to the acute angle and defines the unbalanced structure of the sub-laminate module;
• and
• the first ply and the second ply are secured relative to one another via a plurality of transversely oriented stitches, the plurality of transverse stitches being oriented substantially perpendicular relative to the primary longitudinal axis of the sub-laminate module so as to at least in part define a non-crimped configuration.

A composite laminated structure, the composite laminated structure comprising:

• a plurality of sub-laminate modules, each module consisting of:
• a primary longitudinal axis corresponding to a primary load-bearing axis of the sub-laminate module;
• a first ply comprising fibers extending in a first orientation, the fibers of the first ply comprising a plurality of spread tows lying adjacent to each other;
• a second ply comprising fibers extending in a second orientation, the fibers of the second ply comprising a plurality of spread tows lying adjacent to each other, the second orientation being offset relative to the first orientation;
• and
• an acute angle defined by the relative offset between the first and the second orientations, the acute angle being less than 90° and defining an unbalanced structure of the sub-laminate layer,
• wherein:
• the first orientation is aligned with the primary longitudinal axis of the sub-laminate module such that the first ply is aligned with the primary load-bearing axis of the sub-laminate module;
• the second orientation is offset relative to the first orientation and the primary longitudinal axis such that the relative offset corresponds to the acute angle and defines the unbalanced structure of the sub-laminate module;
• and
• the fibers of the first and the second plies are secured relative to one another via a plurality of stitches.

A sub-laminate module for use in forming a composite laminated structure, the sub-laminate module consisting of:

• a primary longitudinal axis corresponding to a primary load-bearing axis of the sub-laminate module;
• a first ply comprising fibers extending in a first orientation aligned with the primary load-bearing axis of the sub-laminate module;
• a second ply comprising fibers extending in a second orientation, the second orientation being offset relative to the first orientation;
• and
• an acute angle defined by the relative offset between the first orientation and the second orientation, the acute angle being less than 30°,
• wherein the first ply and the second ply are secured relative to one another via a plurality of transversely oriented stitches, the plurality of transverse stitches being oriented substantially perpendicular relative to the primary longitudinal axis of the sub-laminate module so as to at least in part define a non-crimped configuration.