Composite structure having a variable gage and methods for forming a composite structure having a variable gage

1. A composite structure having a variable gage, comprising:

a first end having a first gage;

a second end having a second gage, which is less than the first gage;

a plurality of continuous plies, wherein each continuous ply extends from the first end to the second end; and

a plurality of drop-off plies, wherein each drop-off ply comprises a tip having a blunt-end shape, wherein each drop-off ply extends from the first end to a respective position of the tip of the drop-off ply between the first end and the second end,

a first outer surface extending from the first end to the second end; and

a second outer surface extending from the first end to the second end,

wherein the plurality of drop-off plies are separated from each other by at least one of the plurality of continuous plies,

wherein the plurality of continuous plies and the plurality of drop-off plies are arranged in a stack between the first outer surface and the second outer surface, and

wherein the first gage and the second gage are respective thicknesses between the first outer surface and the second outer surface at the first end and the second end, respectively,

wherein a first subset of the plurality of drop-off plies are between the first outer surface and a central portion,

wherein the central portion (i) is between the first outer surface and the second outer surface and (ii) extends from the first end to the second end,

wherein a second subset of the plurality of drop-off plies are between the central portion and the second outer surface, and

wherein the tips of the first subset of the plurality of drop-off plies are arranged in a pattern that substantially mirrors a pattern of the tips of the second subset of the plurality of drop-off plies,

wherein the central portion comprises a single drop-off ply of the plurality of drop-off plies, and

wherein the respective position of the tip of the single drop-off ply is offset from the respective positions of the tips of the first subset of the plurality of drop-off plies and the respective positions of the tips of the second subset of the plurality of drop-off plies.

2. The composite structure of claim 1 , wherein the respective positions of the tips of the plurality of drop-off plies of the first subset are staggered with the respective positions of the tips of the plurality of drop off plies of the second subset from the first end to the second end.

3. The composite structure of claim 2 , wherein the first subset of the plurality of drop-off plies are in an order from a drop-off ply closest to the first outer surface to a drop-off ply closest to the central portion,

wherein the pattern of the tips of the first subset of the plurality of drop-off plies comprises, with each successive drop-off ply in the order, a relative distance between the tip of the drop-off ply and the second end decreases,

wherein the second subset of the plurality of drop-off plies are in an order from a drop-off ply closest to the second outer surface to a drop-off ply closest to the central portion, and

wherein the pattern of the tips of the second subset of the plurality of drop-off plies comprises, with each successive drop-off ply in the order, a relative distance between the tip of the drop-off ply and the second end decreases.

4. The composite structure of claim 2 , wherein the first subset of the plurality of drop-off plies are in an order from a drop-off ply closest to the central portion to a drop-off ply closest to the first outer surface,

wherein the pattern of the tips of the first subset of the plurality of drop-off plies comprises, with each successive drop-off ply in the order, a relative distance between the tip of the drop-off ply and the second end decreases,

wherein the second subset of the plurality of drop-off plies are in an order from a drop-off ply closest to the central portion to a drop-off ply closest to the second outer surface, and

wherein the pattern of the tips of the second subset of the plurality of drop-off plies comprises, with each successive drop-off ply in the order, a relative distance between the tip of the drop-off ply and the second end decreases.

5. The composite structure of claim 1 , wherein, for each drop-off ply, a distance between the tip of the drop-off ply and the tip of an adjacent one of the plurality of drop-off plies is at least ten times greater than a thickness of the drop-off ply, and

wherein, for each drop-off ply, the adjacent one of the plurality of drop-off plies is adjacent to the drop-off ply in a dimension extending between the first outer surface and the second outer surface.

6. The composite structure of claim 1 , wherein a distance between non-adjacent ones of the plurality of drop-off plies is at least three times greater than a thickness of each drop-off ply.

7. The composite structure of claim 1 , wherein each drop-off ply has a ply angle, relative to a longitudinal axis of the composite structure, which is between approximately −30 degrees and +30 degrees.

8. A method of forming a composite structure having a variable gage, comprising:

forming a plurality of continuous plies;

forming a plurality of drop-off plies, wherein forming the plurality of drop-off plies comprises forming, for each drop-off ply, a tip of the drop-off ply having a blunt-end shape; and

positioning the plurality of continuous plies and the plurality of drop-off plies in a stack having a first end and a second end,

wherein the first end has a first gage,

wherein the second end has a second gage, which is less than the first gage,

wherein positioning the plurality of continuous plies and the plurality of drop-off plies comprises:

positioning the plurality of continuous plies such that each continuous ply extends from the first end to the second end, and

positioning the plurality of drop-off plies such that (i) each drop-off ply extends from the first end to a respective position of the tip of the drop-off ply between the first end and the second end, and (ii) the plurality of drop-off plies are separated from each other by at least one of the plurality of continuous plies,

wherein positioning the plurality of continuous plies and the plurality of drop-off plies in the stack further comprises:

forming a first outer surface extending from the first end to the second end; and

forming a second outer surface extending from the first end to the second end,

wherein the first gage and the second gage are respective thicknesses between the first outer surface and the second outer surface at the first end and the second end, respectively,

wherein positioning the plurality of continuous plies and the plurality of drop-off plies in the stack further comprises:

positioning a first subset of the plurality of drop-off plies between the first outer surface and a central portion, wherein the central portion (i) is between the first outer surface and the second outer surface and (ii) extends from the first end to the second end, and

positioning a second subset of the plurality of drop-off plies between the central portion and the second outer surface,

wherein positioning the first subset of the plurality of drop-off plies and positioning the second subset of the plurality of drop-off plies comprises positioning the plurality of drop-off plies such that the tips of the first subset of the plurality of drop-off plies are arranged in a pattern that substantially mirrors a pattern of the tips of the second subset of the plurality of drop-off plies,

wherein the central portion comprises a single drop-off ply of the plurality of drop-off plies, and

wherein the respective position of the tip of the single drop-off ply is offset from the respective positions of the tips of the first subset of the plurality of drop-off plies and the respective positions of the tips of the second subset of the plurality of drop-off plies.

9. The method of claim 8 , further comprising, after positioning the plurality of continuous plies and the plurality of drop-off plies in the stack, curing the plurality of continuous plies and the plurality of drop-off plies.

10. The method of claim 8 , wherein positioning the plurality of drop-off plies comprises positioning the plurality of drop-off plies such that the respective positions of the tips of the plurality of drop-off plies of the first subset are staggered with the respective positions of the tips of the plurality of drop off plies of the second subset from the first end to the second end.

11. The method of claim 10 , wherein positioning the first subset of the plurality of drop-off plies comprises:

positioning the first subset of the plurality of drop-off plies in an order from a drop-off ply closest to the first outer surface to a drop-off ply closest to the central portion, and

positioning the first subset of the plurality of drop-off plies such that the pattern of the tips of the first subset of the plurality of drop-off plies comprises, with each successive drop-off ply in the order, a relative distance between the tip of the drop-off ply and the second end decreases, and

wherein positioning the second subset of the plurality of drop-off plies comprises:

positioning the second subset of the plurality of drop-off plies comprises positioning the second subset of the plurality of drop-off plies in an order from a drop-off ply closest to the second outer surface to a drop-off ply closest to the central portion, and

positioning the second subset of the plurality of drop-off plies such that the pattern of the tips of the second subset of the plurality of drop-off plies comprises, with each successive drop-off ply in the order, a relative distance between the tip of the drop-off ply and the second end decreases.

12. The method of claim 10 , wherein positioning the first subset of the plurality of drop-off plies comprises:

positioning the first subset of the plurality of drop-off plies in an order from a drop-off ply closest to the central portion to a drop-off ply closest to the first outer surface, and

positioning the first subset of the plurality of drop-off plies such that the pattern of the tips of the first subset of the plurality of drop-off plies comprises, with each successive drop-off ply in the order, a relative distance between the tip of the drop-off ply and the second end decreases, and

wherein positioning the second subset of the plurality of drop-off plies comprises:

positioning the second subset of the plurality of drop-off plies comprises

positioning the second subset of the plurality of drop-off plies in an order from a drop-off ply closest to the central portion to a drop-off ply closest to the second outer surface, and

positioning the second subset of the plurality of drop-off plies such that the pattern of the tips of the second subset of the plurality of drop-off plies comprises, with each successive drop-off ply in the order, a relative distance between the tip of the drop-off ply and the second end decreases.

13. The method of claim 8 , wherein positioning the plurality of drop-off plies comprises positioning the plurality of drop-off plies such that, for each drop-off ply, a distance between the tip of the drop-off ply and the tip of an adjacent one of the plurality of drop-off plies is at least ten times greater than a thickness of the drop-off ply, and

wherein, for each drop-off ply, the adjacent one of the plurality of drop-off plies is adjacent to the drop-off ply in a dimension extending between the first outer surface and the second outer surface.

14. The method of claim 8 , wherein positioning the plurality of drop-off plies comprises positioning the plurality of drop-off plies such that a distance between non-adjacent ones of the plurality of drop-off plies is at least three times greater than a thickness of each drop-off ply.

15. A composite structure having a variable gage, comprising:

a first segment having a first gage;

a second segment having a second gage, which is less than the first gage; and

a transition segment between the first segment and the second segment, wherein the transition segment comprises:

a first end at the first segment and having the first gage,

a second end at the second segment and having a second gage,

a first outer surface extending from the first end to the second end,

a second outer surface extending from the first end to the second end, and

a plurality of plies (i) extending between the first end and the second end and (ii) arranged in a stack between the first outer surface and the second outer surface,

wherein the plurality of plies comprise:

(i) a plurality of continuous plies, wherein each continuous ply extends from the first end to the second end, and

(ii) a plurality of drop-off plies, wherein each drop-off ply comprises a tip having a blunt-end shape, wherein each drop-off ply extends from the first end to a respective position of the tip of the drop-off ply between the first end and the second end,

wherein each drop-off ply is sandwiched between and abuts against a respective two continuous plies of the plurality of continuous plies,

wherein the first gage and the second gage are respective thicknesses between the first outer surface and the second outer surface at the first end and the second end, respectively,

wherein a first subset of the plurality of drop-off plies are between the first outer surface and a central portion,

wherein the central portion (i) is between the first outer surface and the second outer surface and (ii) extends from the first end to the second end,

wherein a second subset of the plurality of drop-off plies are between the central portion and the second outer surface,

wherein the tips of the first subset of the plurality of drop-off plies are arranged in a pattern that substantially mirrors a pattern of the tips of the second subset of the plurality of drop-off plies,

wherein the central portion comprises a single drop-off ply of the plurality of drop-off plies, and

wherein the respective position of the tip of the single drop-off ply is offset from the respective positions of the tips of the first subset of the plurality of drop-off plies and the respective positions of the tips of the second subset of the plurality of drop-off plies.

16. The composite structure of claim 15 , wherein the respective positions of the tips of the plurality of drop-off plies of the first subset are staggered with the respective positions of the tips of the plurality of drop off plies of the second subset from the first end to the second end.

17. The composite structure of claim 16 , wherein the first subset of the plurality of drop-off plies are in an order from a drop-off ply closest to the central portion to a drop-off ply closest to the first outer surface,

wherein the pattern of the tips of the first subset of the plurality of drop-off plies comprises, with each successive drop-off ply in the order, a relative distance between the tip of the drop-off ply and the second end decreases,

wherein the second subset of the plurality of drop-off plies are in an order from a drop-off ply closest to the central portion to a drop-off ply closest to the second outer surface, and

wherein the pattern of the tips of the second subset of the plurality of drop-off plies comprises, with each successive drop-off ply in the order, a relative distance between the tip of the drop-off ply and the second end decreases.

18. The composite structure of claim 16 , wherein the first subset of the plurality of drop-off plies are in an order from a drop-off ply closest to the first outer surface to a drop-off ply closest to the central portion,

wherein the pattern of the tips of the first subset of the plurality of drop-off plies comprises, with each successive drop-off ply in the order, a relative distance between the tip of the drop-off ply and the second end decreases,

wherein the second subset of the plurality of drop-off plies are in an order from a drop-off ply closest to the second outer surface to a drop-off ply closest to the central portion, and

wherein the pattern of the tips of the second subset of the plurality of drop-off plies comprises, with each successive drop-off ply in the order, a relative distance between the tip of the drop-off ply and the second end decreases.

19. The composite structure of claim 15 , wherein, for each drop-off ply, a distance between the tip of the drop-off ply and the tip of an adjacent one of the plurality of drop-off plies is at least ten times greater than a thickness of the drop-off ply, and

wherein, for each drop-off ply, the adjacent one of the plurality of drop-off plies is adjacent to the drop-off ply in a dimension extending between the first outer surface and the second outer surface.

20. The composite structure of claim 15 , wherein a distance between non-adjacent ones of the plurality of drop-off plies is at least three times greater than a thickness of each drop-off ply.