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

The present application is a continuation of U.S. patent application Ser. No. 16/408,410, filed May 9, 2019, the contents of which is hereby incorporated by reference in its entirety.

The present disclosure generally relates to composite structures and, more specifically, to composite structures and methods for forming composite structures having a variable gage.

Composite structures are used in a wide variety of applications, including in the manufacture of aircraft, spacecraft, rotorcraft, watercraft, automobiles, trucks, and other vehicles and structures, due to their high strength-to-weight ratios, corrosion resistance, and other favorable properties. In general, a composite structure is a structure that is formed from two or more constituent component materials with different physical and/or chemical properties that, when combined, produce a composite material having characteristics that are different than the characteristics of the individual components materials.

As an example, one type of composite material is carbon fiber reinforced plastic (“CFRP”). CFRP generally includes one or more composite layers or plies laminated together to form a sheet, laminate or layup. Each of the composite layers or plies can include a reinforcement material and a matrix material. The matrix material surrounds, binds and supports the reinforcement material. The reinforcement material provides structural strength to the matrix material and the CFRP. The matrix material is generally a non-conductive polymer such as an epoxy resin. The reinforcement material generally consists of strands of carbon fiber, which are electrically conductive.

In an example, a composite structure having a variable gage is described. The composite structure includes a first end having a first gage, a second end having a second gage, which is less than the first 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.

The plurality of plies include a plurality of continuous plies and a plurality of drop-off plies. Each continuous ply extends from the first end to the second end. Each drop-off ply includes a tip having a tapered shape. 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 subset of the plurality of drop-off plies are between the first outer surface and a central portion of the stack and a second subset of the plurality of drop-off plies are between the central portion and the second outer surface. The tips of the plurality of drop-off plies are arranged in a monotonically-inward pattern including: (a) in a first order of the first subset of the plurality of drop-off plies from the first outer surface toward the central portion, with each successive drop-off ply in the first order, a relative distance between the tip of the drop-off ply and the second end decreases, and (b) in a second order of the second subset of the plurality of drop-off plies from the second outer surface toward the central portion, with each successive drop-off ply in the second order, a relative distance between the tip of the drop-off ply and the second end decreases.

In another example, a method of forming a composite structure having a variable gage is described. The method includes forming a plurality of continuous plies and forming a plurality of drop-off plies. Forming the plurality of drop-off plies includes forming, for each drop-off ply, a tip of the drop-off ply having a tapered shape. The method also includes positioning the plurality of continuous plies and the plurality of drop-off plies in a stack having (i) a first end, (ii) a second end, (iii) a first outer surface extending from the first end to the second end, and (iv) a second outer surface extending from the first end to the second end. The first end has a first gage and the second end has a second gage, which is less than the first gage.

Positioning the plurality of continuous plies and the plurality of drop-off plies includes 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 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 subset of the plurality of drop-off plies are between the first outer surface and a central portion of the stack and a second subset of the plurality of drop-off plies are between the central portion and the second outer surface.

Positioning the plurality of continuous plies and the plurality of drop-off plies in the stack further comprises arranging the plurality of drop-off plies in a monotonically-inward pattern including: (a) in a first order of the first subset of the plurality of drop-off plies from the first outer surface toward the central portion, with each successive drop-off ply in the first order, a relative distance between the tip of the drop-off ply and the second end decreases, and (b) in a second order of the second subset of the plurality of drop-off plies from the second outer surface toward the central portion, with each successive drop-off ply in the second order, a relative distance between the tip of the drop-off ply and the second end decreases.

In another example, a composite structure having a variable gage is described. The composite structure includes 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. The transition segment includes 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.

The plurality of plies include a plurality of continuous plies and a plurality of drop-off plies. Each continuous ply extends from the first end to the second end. Each drop-off ply includes a tip having a tapered shape. 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 subset of the plurality of drop-off plies are between the first outer surface and a central portion of the stack and a second subset of the plurality of drop-off plies are between the central portion and the second outer surface. The tips of the plurality of drop-off plies are arranged in a monotonically-inward pattern including: (a) in a first order of the first subset of the plurality of drop-off plies from the first outer surface toward the central portion, with each successive drop-off ply in the first order, a relative distance between the tip of the drop-off ply and the second end decreases, and (b) in a second order of the second subset of the plurality of drop-off plies from the second outer surface toward the central portion, with each successive drop-off ply in the second order, a relative distance between the tip of the drop-off ply and the second end decreases.

The features, functions, and advantages that have been discussed can be achieved independently in various examples or may be combined in yet other examples further details of which can be seen with reference to the following description and drawings.

The novel features believed characteristic of the illustrative examples are set forth in the appended claims. The illustrative examples, however, as well as a preferred mode of use, further objectives and descriptions thereof, will best be understood by reference to the following detailed description of an illustrative example of the present disclosure when read in conjunction with the accompanying drawings, wherein:

FIG. 1 depicts a composite structure, according to an example.

FIG. 2 depicts a composite structure, according to another example.

FIG. 3 depicts a composite structure, according to another example.

FIG. 4 depicts a simplified block diagram of a composite structure, according to another example.

FIG. 5A depicts a side view of a composite stringer including the composite structure of FIG. 1 , according to another example.

FIG. 5B depicts a side view of a composite stringer including the composite structure of FIG. 3 , according to another example.

FIG. 6 illustrates a flow chart of an example process for forming a composite structure having a variable gage, according to an example.

FIG. 7 illustrates a flow chart of an example process for forming a composite structure having a variable gage that can be used with the process shown in FIG. 6 .

FIG. 8 illustrates a flow chart of an example process for forming a composite structure having a variable gage that can be used with the process shown in FIG. 6 .

FIG. 9 illustrates a flow chart of an example process for forming a composite structure having a variable gage that can be used with the process shown in FIG. 8 .

FIG. 10 illustrates a flow chart of an example process for forming a composite structure having a variable gage that can be used with the process shown in FIG. 9 .

FIG. 11 illustrates a flow chart of an example process for forming a composite structure having a variable gage that can be used with the process shown in FIG. 9 .

FIG. 12 illustrates a flow chart of an example process for forming a composite structure having a variable gage that can be used with the process shown in FIG. 11 .

FIG. 13 illustrates a flow chart of an example process for forming a composite structure having a variable gage that can be used with the process shown in FIG. 6 .

FIG. 14 illustrates a flow chart of an example process for forming a composite structure having a variable gage that can be used with the process shown in FIG. 6 .

FIG. 15 illustrates a flow chart of an example process for forming a composite structure having a variable gage, according to an example.

FIG. 16 illustrates a flow chart of an example process for forming a composite structure having a variable gage that can be used with the process shown in FIG. 15 .

FIG. 17 illustrates a flow chart of an example process for forming a composite structure having a variable gage that can be used with the process shown in FIG. 16 .

FIG. 18 illustrates a flow chart of an example process for forming a composite structure having a variable gage that can be used with the process shown in FIG. 16 .

FIG. 19 illustrates a flow chart of an example process for forming a composite structure having a variable gage that can be used with the process shown in FIG. 16 .

FIG. 20 illustrates a flow chart of an example process for forming a composite structure having a variable gage that can be used with the process shown in FIG. 16 .

FIG. 21 illustrates a flow chart of an example process for forming a composite structure having a variable gage that can be used with the process shown in FIG. 16 .

Disclosed examples will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all of the disclosed examples are shown. Indeed, several different examples may be described and should not be construed as limited to the examples set forth herein. Rather, these examples are described so that this disclosure will be thorough and complete and will fully convey the scope of the disclosure to those skilled in the art.

By the term “approximately” or “substantially” with reference to amounts or measurement values described herein, it is meant that the recited characteristic, parameter, or value need not be achieved exactly, but that deviations or variations, including for example, tolerances, measurement error, measurement accuracy limitations and other factors known to those of skill in the art, may occur in amounts that do not preclude the effect the characteristic was intended to provide.

As used herein, the terms “greater than” and “less than” are intended to have their common meaning. Thus, a first value is greater than a second value if the first value is greater than the second value by any amount. Similarly, a first value is less than a second value if the first value is less than the second value by any amount.

As used herein, the term “composite structure” means a structure that is manufactured, fabricated or assembled, in whole or in part, from one or more composite materials.

As noted above, a composite structure can be used in a wide variety of applications, including in the manufacture of aircraft, spacecraft, rotorcraft, watercraft, flying taxis, trains, automobiles, trucks, and other vehicles (e.g., passenger capsules or cargo containers) due to their high strength-to-weight ratios, corrosion resistance, and other favorable properties. Additionally or alternatively, a composite structure can be used in buildings, bridges, swimming pools, storage tanks, robotic frame structures, energy structures (e.g., wind blades, turbine blades, propulsion blades, and/or solar panels), sporting goods (e.g., bicycle frames, skis, snow boards, surfing boards, paddies), residential houses, office buildings, and/or medical board frames.

In some implementations, different portions of a composite structure may have different gages. As used herein, the term “gage” means a thickness between two opposing sides of the composite structure. It may be desirable to vary the gage from one portion of the composite structure relative to another portion of the composite structure for a variety of reasons. For example, a stiffness and/or a strength of the composite structure may be related to the gage of the composite structure. In some instances, it may be desirable to vary the stiffness and/or the strength of the composite structure from a first portion of the composite structure to a second portion of the composite structure. For instance, the first portion of the composite structure may be expected to experience a relatively greater amount of loading and/or applied force than the second portion of the composite structure. As such, it may be desirable for the first portion of the composite structure to have a gage that is greater than a gage of the second portion of the composite structure.

In other examples, it may be desirable to vary the gage of the composite structure additionally or alternatively based on other design criteria such as, for example, aesthetics, weight distribution, space constraints, load variation, and/or damage protection.

One approach to transitioning from one gage to another gage involves forming the composite structure from a plurality of plies of composite material, which include a plurality of continuous plies and one or more drop-off plies. In general, each continuous ply extends from a first end to a second end of the composite structure. By contrast, each drop-off ply extends from the first end to a respective position of a tip of the drop-off ply between the first end and the second end. In this arrangement, there are fewer plies at the second end relative to the first end. Thus, by positioning the tips of the drop-off plies between the first end and the second end, the gage decreases from the first end to the second end so as to transition from one gage to another gage.

Existing approaches to transitioning from one gage to another gage suffer from some drawbacks. For example, in existing composite structuring having a variable gage, the tips of the drop-off plies have a blunt-end shape and are arranged immediately adjacent to each other in a cluster. This can result in a relatively large resin pocket in a region at or near the tips of the drop-off plies. In some instances, the relatively large resin pocket may lead to delamination in the region under certain thermal and/or mechanical loads. Additionally, for example, arranging the tips of the drop-off plies in a cluster may increase a risk of ply kinks and/or wrinkles, which may reduce laminate strength.

As an example, FIG. 1 depicts an example composite structure 100 having a variable gage, according to an example. As shown in FIG. 1 , the composite structure 100 includes a first end 110 A having a first gage 112 A and a second end 110 B having a second gage 112 B, which is less than the first gage 112 A of the first end 110 A. The composite structure 100 also includes a first outer surface 114 extending from the first end 110 A to the second end 110 B, and a second outer surface 116 extending from the first end 110 A to the second end 110 B.

As also shown in FIG. 1 , the composite structure 100 includes a plurality of plies 118 i=1 to 118 i=n of composite material (hereinafter collectively referred to as “plies 118 i ”) arranged in a stack between the second outer surface 116 and the first outer surface 114 , where n is an integer value that is greater than or equal to two. In FIG. 1 , the composite structure 100 includes a total of 18 plies 118 i (i.e., n=18). However, in other examples, the composite structure 100 can include a lesser quantity or a greater quantity of plies 118 i .

In this arrangement, the first gage 112 A of the first end 110 A and the second gage 112 B of the second end 110 B are respective thicknesses between the first outer surface 114 and the second outer surface 116 at the first end 110 A and the second end 110 B, respectively. Further, the first gage 112 A is related to a quantity of the plies 118 i at the first end 110 A and the second gage 112 B is related to a quantity of the plies 118 i at the second end 110 B. For instance, in FIG. 1 , the quantity of the plies 118 i at the first end 110 A is greater than the quantity of the plies 118 i at the second end 110 B such that the first gage 112 A is greater than the second gage 112 B.

Specifically, to vary the quantity of the plies 118 i between the first end 110 A and the second end 110 B, the plies 118 i of composite material include a plurality of continuous plies 118 A and a plurality of drop-off plies 118 B. In FIG. 1 , each continuous ply 118 A extends from the first end 110 A to the second end 110 B. Whereas, each drop-off ply 118 B includes a tip 120 , and each drop-off ply 118 B extends from the first end 110 A to a respective position of the tip 120 of the drop-off ply 118 B between the first end 110 A and the second end 110 B.

Accordingly, while the continuous plies 118 A are present at the first end 110 A and the second end 110 B, the drop-off plies 118 B are present at the first end 110 A and absent at the second end 110 B. In this way, the drop-off plies 118 B can contribute to the first gage 112 A at the first end 110 A, whereas the drop-off plies 118 B do not contribute to the second gage 112 B at the second end 110 B due to the drop-off plies 118 B terminating prior to the second end 110 B (i.e., the tips 120 being located at the respective positions between the first end 110 A and the second end 110 B).

For clarity of illustration, in FIG. 1 , a representative subset of the continuous plies 118 A are labeled with reference number 118 A and a representative subset of the drop-off plies 118 B are labeled with reference number 118 B. However, each of the plies 118 i that extends entirely from the first end 110 A to the second end 110 B is one of the continuous plies 118 A, and each of the plies 118 i that terminates between the first end 110 A and the second end 110 B is one of the drop-off plies 118 B. Specifically, in FIG. 1 , the plies 118 i=1-3, 9-18 are the continuous plies 118 A, and the plies 118 i=4-8 are the drop-off plies 118 B.

As shown in FIG. 1 , the tip 120 of each drop-off ply 118 B has a blunt-end shape, and the drop-off plies 118 B are arranged immediately next to each other in the stack (e.g., in a cluster). In general, this approach to transitioning from one gage to another gage can be effective. However, it has been found that the performance of the composite structure 100 can be improved using one or more of the techniques described in detail below with respect to FIGS. 2-3 .

For example, using drop-off plies 118 B with blunt-end shaped tips 120 and/or arranging the drop-off plies 118 B in a cluster can result in a relatively large resin pocket in a region 122 at or near the tips 120 of the drop-off plies 118 B. In some instances, the relatively large resin pocket in the region 122 may lead to delamination in the region 122 under certain thermal and/or mechanical loads. Additionally, for example, arranging the tips 120 of the drop-off plies 118 B in a cluster may increase a risk of ply kinks and/or wrinkles, which may reduce laminate strength. Further, in some instances, arranging the tips 120 of the drop-off plies at an off-center location (e.g., closer to the first outer surface 114 than the second outer surface 116 ) can also increase a risk of ply kinks and/or wrinkles, which can have a reduced static strength and/or a reduced fatigue strength due to potential distortion under thermal and/or mechanical loads.

Within examples, composite structures having variable gages are described, which can improve upon the composite structure 100 in one or more respects. For instance, in some examples, the tips 120 of the drop-off plies 118 B can have a tapered shape and/or the plies 118 i can be arranged according to one or more patterns that can, among other things, enhance the load bearing properties of a composite structure, reduce re-curing, simplify tooling requirements for forming the composite structure, reduce material handling costs, and/or reduce a weight of the composite structure.

Referring now to FIG. 2 , a composite structure 200 having a variable gage is depicted according to an example. As shown in FIG. 2 , the composite structure 200 includes a first end 210 A having a first gage 212 A and a second end 210 B having a second gage 212 B, which is less than the first gage 212 A of the first end 210 A. Additionally, as shown in FIG. 2 , the composite structure 200 includes a first outer surface 214 extending from the first end 210 A to the second end 210 B, and a second outer surface 216 extending from the first end 210 A to the second end 210 B.

As also shown in FIG. 2 , the composite structure 200 includes a plurality of plies 218 i=1 to 218 i=n of composite material (hereinafter collectively referred to as “plies 218 i ”) arranged in a stack between the second outer surface 216 and the first outer surface 214 , where n is an integer value that is greater than or equal to two. In FIG. 2 , the composite structure 200 includes a total of 28 plies 218 i (i.e., n=28). However, in other examples, the composite structure 200 can include a lesser quantity or a greater quantity of plies 218 i .

In this arrangement, the first gage 212 A of the first end 210 A and the second gage 212 B of the second end 210 B are respective thicknesses between the first outer surface 214 and the second outer surface 216 at the first end 210 A and the second end 210 B, respectively. Further, as described above, the first gage 212 A is related to a quantity of the plies 218 i at the first end 210 A and the second gage 212 B is related to a quantity of the plies 218 i at the second end 210 B. For instance, in FIG. 2 , the quantity of the plies 218 i at the first end 210 A is greater than the quantity of the plies 218 i at the second end 210 B such that the first gage 212 A is greater than the second gage 212 B.

As described above, the variable gage of the composite structure 200 results from the plies 218 i of composite material including a plurality of continuous plies 218 A and a plurality of drop-off plies 218 B arranged in the stack between the second outer surface 216 and the first outer surface 214 . In FIG. 2 , each continuous ply 218 A extends from the first end 210 A to the second end 210 B. Whereas, each drop-off ply 218 B extends from the first end 210 A to a respective position of a tip 220 of the drop-off ply 218 B between the first end 210 A and the second end 210 B. Thus, the first gage 212 A is based on a quantity of the continuous plies 218 A and a quantity of the drop-off plies 218 B, and the second gage 212 B is based on the quantity of the continuous plies 218 A (and not the quantity of the drop-off plies 218 B).

For clarity of illustration, in FIG. 2 , a representative subset of the continuous plies 218 A are labeled with reference number 218 A and a representative subset of the drop-off plies 218 B are labeled with reference number 218 B. However, each of the plies 218 i that extends entirely from the first end 210 A to the second end 210 B is one of the continuous plies 218 A, and each of the plies 218 i that terminates between the first end 210 A and the second end 210 B is one of the drop-off plies 218 B. Specifically, in FIG. 2 , the plies 218 i=1-6, 8, 10, 12, 14, 15, 17, 19, 21, 23, 25-28 are the continuous plies 218 A, and the plies 218 i=7, 9, 11, 13, 16, 18, 20, 22, 24 are the drop-off plies 218 B.

As shown in FIG. 2 , the tip 220 of each drop-off ply 218 B has a tapered shape. More particularly, for example, the tip 220 of each drop-off ply 218 B can gradually reduce in thickness in a direction along the tip 220 from the first end 210 A toward the second end 210 B. Because the tip 220 has the tapered shape, the tip 220 can more closely abut against adjacent ones of the plies 218 i (e.g., as compared to the blunt-end shaped tips 120 in FIG. 1 , which terminate relatively abruptly). As such, the tips 220 having the tapered shape can reduce (or may minimize) resin pockets at the tips 220 of the drop-off plies 218 B, which can help to improve (or may maximize) interlaminar strength of the composite structure 200 . Accordingly, the tapered shape of the tips 220 of the drop-off plies 218 B can help to improve a load bearing performance of the composite structure 200 having the variable gage for transitioning from a section having the first gage 212 A to a section having the second gage 212 B.

Within examples, the tapered shape of the tips 220 of the drop-off plies 218 B can be formed by cutting each drop-off ply 218 B at an angle less than approximately 85 degrees relative to a longitudinal axis of the drop-off ply 218 B. By contrast, the blunt-end shape of the tips 120 of the drop-off plies 118 B shown in FIG. 1 can be formed, for example, by cutting each drop-off ply 118 B at an angle of approximately 90 degrees relative to a longitudinal axis of the drop-off ply 118 B.

As noted above, the load bearing performance of the composite structure 200 can be enhanced, additionally or alternatively, based on a pattern in which the plies 218 i are arranged in the composite structure 200 . For example, in FIG. 2 , the drop-off plies 218 B are separated from each other by at least one of the continuous plies 218 A. More particularly, in FIG. 2 , each drop-off ply 218 B is sandwiched between and abuts against a respective two continuous plies 218 A of the plurality of continuous plies 218 A. By separating the drop-off plies 218 B from each other and/or sandwiching the drop-off plies 218 B between the continuous plies 218 A, the drop-off plies 218 B can be more uniformly distributed between the second outer surface 216 and the first outer surface 214 (as compared to the clustered arrangement of the drop-off plies 118 B shown in FIG. 1 ). This can help to reduce (or may prevent) ply kinks and/or wrinkles, reduce (or may prevent) resin pockets, and/or increase (or may maximize) interlaminar strength of the composite structure 200 .

As noted above, in FIG. 2 , the plies 218 i=1-6, 8, 10, 12, 14, 15, 17, 19, 21, 23, 25-28 are the continuous plies 218 A, and the plies 218 i=7, 9, 11, 13, 16, 18, 20, 22, 24 are the drop-off plies 218 B. Accordingly, in FIG. 2 , each of the plies 218 i=7, 9, 11, 13, 16, 18, 20, 22, 24 is separated from each other by at least one of the plies 218 i=1-6, 8, 10, 12, 14, 15, 17, 19, 21, 23, 25-28 , and each of the plies 218 i=7, 9, 11, 13, 16, 18, 20, 22, 24 is sandwiched between and abuts against a respective two of the plies 218 i=1-6, 8, 10, 12, 14, 15, 17, 19, 21, 23, 25-28 . For instance, in FIG. 2 , the ply 218 i=7 is separated from the ply 218 i=9 by the ply 218 i=8 , and the ply 218 i=7 is sandwiched between the ply 218 i=6 and the ply 218 i=8 . Additionally, for instance, the ply 218 i=9 is separated from the ply 218 i=11 by the ply 218 i=10 , separated from the ply 218 i=9 by the ply 218 i=8 , and sandwiched between the ply 218 i=8 and the ply 218 i=10 . Further, for instance, the ply 218 i=16 is separated from the ply 218 i=13 by the plies 218 i=14, 15 , separated from the ply 218 i=18 by the ply 218 i=17 , and sandwiched between the ply 218 i=15 and the ply 218 i=17 . Similar relationships exist for a remainder of the drop-off plies 218 B in FIG. 2 (i.e., the plies 218 i=11, 13, 18, 20, 22, 24 ). As noted above, arranging the plies 218 i in a pattern having a characteristic of the drop-off plies 218 B interleaved with the continuous plies 218 A (e.g., as shown in FIG. 2 ) can help to reduce (or may prevent) ply kinks and/or wrinkles, reduce (or may prevent) resin pockets, and/or increase (or may maximize) interlaminar strength of the composite structure 200 .

Within examples, the pattern of the tips 220 of the drop-off plies 218 B can additionally or alternatively include one or more of the following characteristics: (i) an arrangement of the tips 220 in a first half of the composite structure 200 in a pattern that substantially mirrors or mirrors a pattern of the tips 220 in a second half of the composite structure 200 , (ii) a staggered arrangement of the tips 220 relative to each other, and/or (iii) spacing the tips 220 relative to each other by at least one threshold distance (e.g., at least one distance related to respective positions and/or respective thicknesses of one or more of the plies 218 ). Each of these characteristics alone or in combination can contribute to arranging the drop-off plies 218 B in a pattern that can reduce (or may prevent) ply kinks and/or wrinkles, reduce (or may prevent) resin pockets, and/or increase (or may maximize) interlaminar strength.

FIG. 2 shows the tips 220 arranged in substantially mirror or mirror patterns relative to a central portion 224 of the composite structure 200 according to one example. The central portion 224 can include one or more of the plies 218 i that provide a frame of reference for characterizing patterns of the tips 220 of the drop-off plies 218 B on opposing sides of the central portion 224 . In general, the central portion 224 ( i ) is between the second outer surface 216 and the first outer surface 214 and (ii) extends from the first end 210 A to the second end 210 B.

In FIG. 2 , the central portion 224 can include the plies 218 i=15, 16 . Thus, in FIG. 2 , the central portion 224 can include a single drop-off ply 218 B (i.e., the ply 218 i=16 ) and a single continuous ply 218 A (i.e., the ply 218 i=15 ). However, in another example, the central portion 224 can include two drop-off plies 218 B and at least one continuous ply 218 A. In yet another example, the central portion 224 can consist of only a single drop-off ply 218 B. In another example, the central portion 224 can consist of one or more continuous plies 218 A and omit the drop-off plies 218 B. More generally, the central portion 224 can include one or more of the continuous plies 218 A and/or one or more of the drop-off plies 218 B.

As noted above, the tips 220 of the drop-off plies 218 B can be arranged in substantially mirror or mirror patterns relative to the central portion 224 . For instance, a first subset of the drop-off plies 218 B can be between the first outer surface 214 and the central portion 224 , and a second subset of the drop-off plies 218 B can be between the central portion 224 and the second outer surface 216 . In this arrangement, the tips 220 of the first subset of the drop-off plies 218 B are arranged in a pattern that substantially mirrors a pattern of the tips 220 of the second subset of the drop-off plies 218 B. In other words, with reference to the central portion 224 , the respective positions of the tips 220 of the first subset of the drop-off plies 218 B are (i) reversely and (ii) similarly (or identically) arranged in comparison to the respective positions of the tips 220 of the second subset of the drop-off plies 218 B.

For example, in FIG. 2 , the central portion 224 can include the plies 218 i=15, 16 , the first subset of the drop-off plies 218 B can include the plies 218 i=7, 9, 11, 13 , and the second subset of the drop-off plies 218 B can include the plies 218 i=18, 20, 22, 24 . As shown in FIG. 2 , the pattern of the tips 220 of the first subset of the drop-off plies 218 B substantially mirrors the pattern of the tips 220 of the second subset of the drop-off plies 218 B. For instance, with reference to the central portion 224 , the respective positions of the tips 220 of the first subset are reversely and similarly arranged in comparison to the respective positions of the tips 220 of the second subset.

Additionally, as shown in FIG. 2 , the pattern of the tips 220 of the drop-off plies 218 B can be a monotonically-outward pattern. For instance, in FIG. 2 , the first subset of the drop-off plies 218 B can be in an order from a drop-off ply 218 B closest to the central portion 224 (e.g., the ply 218 i=13 ) to a drop-off ply 218 B closest to the first outer surface 214 (i.e., the ply 218 i=7 ). The pattern of the tips 220 of the first subset of the drop-off plies 218 B can include, with each successive drop-off ply 218 B in the order, a relative distance between the tip 220 of the drop-off ply 218 B and the second end 210 B decreases. As such, in FIG. 2 , (i) the tip 220 of the ply 218 i=13 is at a first distance from the second end 210 B, (ii) the tip 220 of the ply 218 i=11 is at a second distance from the second end 210 B, which is less than the first distance, (iii) the tip 220 of the ply 218 i=9 is at a third distance from the second end 210 B, which is less than the second distance, and (iv) the tip 220 of the ply 218 i=7 is at a fourth distance from the second end 210 B, which is less than the third distance.

Similarly, the second subset of the drop-off plies 218 B can be in an order from a drop-off ply 218 B closest to the central portion 224 (e.g., the ply 218 i=18 ) to a drop-off ply 218 B closest to the second outer surface 216 (e.g., the ply 218 i=24 ). The pattern of the tips 220 of the second subset of the drop-off plies 218 B includes, with each successive drop-off ply 218 B in the order, a relative distance between the tip 220 of the drop-off ply 218 B and the second end 210 B decreases. As such, in FIG. 2 , (v) the tip 220 of the ply 218 i=18 is at a fifth distance from the second end 210 B, (vi) the tip 220 of the ply 218 i=20 is at a sixth distance from the second end 210 B, which is less than the fifth distance, (vii) the tip 220 of the ply 218 i=22 is at a seventh distance from the second end 210 B, which is less than the sixth distance, and (viii) the tip 220 of the ply 218 i=24 is at an eighth distance from the second end 210 B, which is less than the seventh distance.

Accordingly, in the monotonically-outward pattern of the tips 220 shown in FIG. 2 , the tips 220 of the drop-off plies 218 B generally appear to be spread outward from the central portion 224 in a direction from the first end 210 A to the second end 210 B. The monotonically-outward pattern of the tips 220 can help to more gradually and/or smoothly transition from the first gage 212 A at the first end 210 A to the second gage 212 B at the second end 210 B. Additionally, for example, the monotonically-outward pattern of the tips 220 can help to achieve a relatively greater degree of symmetry relative to, for instance, the arrangement of the tips 120 in FIG. 1 (which are clustered near the first outer surface 114 ).

According to an additional or alternative aspect of the monotonically-outward pattern shown in FIG. 2 , the drop-off plies 218 B can be arranged in a plurality of pairs of drop-off plies 218 B that define an order in which the drop-off plies 218 B drop off in a direction from the first end 210 A toward the second end 210 B (i.e., an order of the respective positions of the tips 220 in the direction from the first end 210 A toward the second end 210 B). In particular, each pair of drop-off plies 218 B can include a respective one drop-off ply 218 B of the first subset and a respective one drop-off ply 218 B of the second subset.

For example, in FIG. 2 , a first pair includes the plies 218 i=13, 18 , a second pair includes the plies 218 i=11, 20 , a third pair includes the plies 218 i=9, 22 , and a fourth pair includes the plies 218 i=7, 24 . As shown in FIG. 2 , in the direction from the first end 210 A to the second end 210 B, the drop-off plies 218 B drop off in an order from the first pair to the fourth pair. In other words, the tips 220 of the first pair of the drop-off plies 218 B are closest to the first end 210 A, the tips 220 of the second pair of the drop-off plies 218 B are second closest to the first end 210 A, the tips 220 of the third pair of the drop-off plies 218 B are third closest to the first end 210 A, and the tips 220 of the fourth pair of the drop-off plies 218 B are farthest from the first end 210 A.

Additionally, for example, for each pair of drop-off plies 218 B, the respective one drop-off ply 218 B of the first subset and the respective one drop-off ply 218 B of the second subset can be substantially equidistant from the central portion 224 in a dimension between the first outer surface 214 and the second outer surface 216 . For instance, as shown in FIG. 2 , the first pair of the drop-off plies 218 B are each spaced from the central portion 224 by a distance equal to a ply thickness 226 of a single ply 218 i , the second pair of the drop-off plies 218 B are each spaced from the central portion 224 by a distance equal to three times the ply thickness 226 , the third pair of the drop-off plies 218 B are each spaced from the central portion 224 by a distance equal to five times the ply thickness 226 , and the fourth pair of the drop-off plies 218 B are each spaced from the central portion 224 by a distance equal to seven times the ply thickness 226 . Arranging the drop-off plies 218 B in pairs that (i) drop off, pair-by-pair, in an order from the first end 210 A to the second end 210 B, and/or (ii) are equidistant relative to the central portion 224 can additionally help to more gradually and/or smoothly transition from the first gage 212 A at the first end 210 A to the second gage 212 B at the second end 210 B, and/or achieve a relatively greater degree of symmetry relative to, for instance, the arrangement of the tips 120 in FIG. 1 (which are clustered near the first outer surface 114 ).

Within examples, each drop-off ply 218 B can have a ply angle, relative to a longitudinal axis of the composite structure 200 (e.g., the longitudinal axis 348 ), which is between approximately −30 degrees and +30 degrees. This can help to achieve a desired stiffness with a relatively few (or minimal) quantity of plies 218 i and, thus, reduce (or may minimize) a weight and/or cost of fabricating the composite structure 200 . In an example, for each pair, the ply angle is approximately the same for the drop-off plies 218 B of the pair. This can help to improve (or may maximize) a symmetry of the composite structure 200 .

According to an additional or alternative aspect of the monotonically-outward pattern shown in FIG. 2 , the monotonically-outward pattern can include, along a direction from the first end 210 A to the second end 210 B, the tips 220 of the first subset of the drop-off plies 218 B alternating with the tips 220 of the second subset of the drop-off plies 218 B. For example, in FIG. 2 , the tips 220 of the drop-off plies 218 B are in the following order from the first end 210 A to the second end 210 B: (i) the tip 220 of the ply 218 i=18 from the second subset, (ii) the tip 220 of the ply 218 i=13 from the first subset, (iii) the tip 220 of the ply 218 i=20 from the second subset, (iv) the tip 220 of the ply 218 i=11 from the first subset, (v) the tip 220 of the ply 218 i=22 from the second subset, (vi) the tip 220 of the ply 218 i=9 from the first subset, (vii) the tip 220 of the ply 218 i=24 from the second subset, and (viii) the tip 220 of the ply 218 i=7 from the first subset. Alternating the respective positions of the tips 220 of the drop-off plies 218 B can additionally or alternatively help to help to more gradually and/or smoothly transition from the first gage 212 A at the first end 210 A to the second gage 212 B at the second end 210 B.

As noted above, arranging the drop-off plies 218 B such that the tips 220 of the drop-off plies 218 B are staggered relative to each other can additionally or alternatively help to reduce (or may prevent) ply kinks and/or wrinkles, reduce (or may prevent) resin pockets, and/or increase (or may maximize) interlaminar strength. As an example, in FIG. 2 , the respective positions of the tips 220 of the drop-off plies 218 B can be staggered from the first end 210 A to the second end 210 B. By “staggered”, it is meant that the tips 220 of the drop-off plies 218 B are each at a respective distance from the second end 210 B, and the respective distances between the tips 220 and the second end 210 B are all different from each other (i.e., the tips of no two drop-off plies are equidistant from the second end 210 B). Staggering the tips 220 of the drop-off plies 218 B can help to mitigate some or all of the challenges associated with a clustered arrangement of drop-off plies described above.

Also, as noted above, spacing the tips 220 relative to each other by at least one threshold distance can additionally or alternatively help to reduce (or may prevent) ply kinks and/or wrinkles, reduce (or may prevent) resin pockets, and/or increase (or may maximize) interlaminar strength. In an example, for each drop-off ply 218 B, a distance 228 between the tip 220 of the drop-off ply 218 B and the tip 220 of an adjacent one of the drop-off plies 218 B can be at least ten times greater than the ply thickness 226 of the drop-off ply 218 B. In this example, for each drop-off ply 218 B, the adjacent one of the drop-off plies 218 B is adjacent to the drop-off ply 218 B in a dimension extending between the first outer surface 214 and the second outer surface 216 . That is, two of the drop-off plies 218 B are adjacent to each other only if there is not another one of the drop-off plies 218 B between the two of the drop-off plies 218 B in the dimension extending between the first outer surface 214 and the second outer surface 216 . Thus, for example, the ply 218 i=18 is adjacent to the ply 218 i=16 and the ply 218 i=20 , and non-adjacent to the other drop-off plies 218 B (i.e., plies 218 i=7, 9, 11, 13, 22, 24 ).

A representative one of the distances 228 is depicted in FIG. 2 between the tips 220 of the ply 218 i=18 and the ply 218 i=16 , which are adjacent to each other. As shown in FIG. 2 , the distance 228 between the tip 220 of the ply 218 i=18 and the tip of the ply 218 i=16 is at least ten times greater than the ply thickness 226 of the ply 218 i=18 . Similarly, in FIG. 2 , the tips 220 of the other adjacent ones of the drop-off plies 218 B are separated by respective distances 228 that are at least ten times greater than the ply thickness 226 . As described above, arranging the drop-off plies 218 B such that the tips 220 of adjacent ones of the drop-off plies 218 B are separated by the distance 228 of at least ten times the ply thickness 226 can help to reduce (or may prevent) ply kinks and/or wrinkles, reduce (or may prevent) resin pockets, and/or increase (or may maximize) interlaminar strength.

Additionally or alternatively, for example, a distance 230 between non-adjacent ones of the drop-off plies 218 B can be at least three times greater than the ply thickness 226 of each drop-off ply 218 B. A representative one of the distances 230 is depicted in FIG. 2 between the tips 220 of the ply 218 i=18 and the ply 218 i=13 , which are non-adjacent to each other (e.g., because the ply 218 i=16 is between the ply 218 i=18 and the ply 218 i=13 ). As shown in FIG. 2 , the distance 230 between the tip 220 of the ply 218 i=18 and the tip of the ply 218 i=13 is at least three times greater than the ply thickness 226 of the ply 218 i=18 . Similarly, the tips 220 of the other non-adjacent ones of the drop-off plies 218 B are separated by respective distances 230 that are at least three times greater than the ply thickness 226 . As described above, arranging the drop-off plies 218 B such that the tips 220 of non-adjacent ones of the drop-off plies 218 B are separated by the distance 228 of at least three times the ply thickness 226 can help to reduce (or may prevent) ply kinks and/or wrinkles, reduce (or may prevent) resin pockets, and/or increase (or may maximize) interlaminar strength.

In FIG. 2 , the ply thickness 226 is the same for all of the plies 218 i . However, in another example, one or more of the plies 218 i can have a different ply thickness than another one of the plies 218 i . In some implementations, providing the plies 218 i with different ply thicknesses can help to provide relatively greater flexibility for achieving fabrication quality objectives.

Additionally, in FIG. 2 , the tips 220 of the drop-off plies 218 B all have the tapered shape. However, in another example, one or more of the tips 220 of the drop-off plies 218 B can have the blunt-end shape shown in FIG. 1 . Although the tapered shape can be beneficial for at least the reasons described above, a composite structure including the drop-off plies 218 B having the tips 120 with the blunt-end shape in a pattern having one or more of the characteristics described above with respect to FIG. 2 can provide improvements over the composite structure 100 shown in FIG. 1 . Similarly, a composite structure including the drop-off plies 118 B arranged in the pattern shown in FIG. 1 , but with the tips 220 having the tapered shape can provide improvements over the composite structure 100 shown in FIG. 1 . Accordingly, within examples, the drop-off plies 118 B, 218 B can the tips 220 with the tapered shape and/or the tips 120 with the blunt-end shape, and the drop-off plies 118 B, 218 B can be arranged in a clustered pattern (as shown in FIG. 1 ) and/or a pattern having one or more of the characteristics described above with respect to FIG. 2 .

As described, arranging the tips 220 of the drop-off plies 218 B in a pattern having one or more of the characteristics described above can help to achieve a relatively greater degree of symmetry for the composite structure 200 (e.g., about the central portion 224 ) relative to, for instance, the arrangement of the tips 120 in FIG. 1 . As used herein, the term “symmetry” is intended to be a relative term and does not mean exactly symmetric. For example, as shown in FIG. 2 , the composite structure 200 includes 14 plies 218 i between the central portion 224 and the first outer surface 214 , and 12 plies 218 i between the central portion 224 and the second outer surface 216 . However, in the context of this disclosure, the composite structure 200 shown in FIG. 2 has a greater degree of symmetry relative to the composite structure 100 shown in FIG. 1 .

Within examples, providing the composite structure 200 with a relatively greater degree of symmetry about the central portion 224 can help to increase (or may maximize) interlaminar strength. Additionally or alternatively, providing the composite structure 200 with a relatively greater degree of symmetry about the central portion 224 can help to reduce (or may minimize) re-curing, tooling, material handling costs, and/or weight.

As described above, FIG. 2 shows the composite structure 200 with the drop-off plies 218 B arranged in an example pattern having one or more characteristics that can help to improve performance, reduce re-curing, reduce tooling, reduce material handling costs, and/or reduce a weight of the composite structure 200 . Other example patterns having the one or more characteristics are also possible.

For instance, FIG. 3 shows a composite structure 300 having a variable gage according to another example. As shown in FIG. 3 , the composite structure 300 includes a first end 310 A having a first gage 312 A and a second end 310 B having a second gage 312 B, which is less than the first gage 312 A of the first end 310 A. Additionally, as shown in FIG. 3 , the composite structure 300 includes a first outer surface 314 extending from the first end 310 A to the second end 310 B, and a second outer surface 316 extending from the first end 310 A to the second end 310 B.

As also shown in FIG. 3 , the composite structure 300 includes a plurality of plies 318 i=1 to 318 i=n of composite material (hereinafter collectively referred to as “plies 318 i ”) arranged in a stack between the second outer surface 316 and the first outer surface 314 , where n is an integer value that is greater than or equal to two. In FIG. 3 , the composite structure 300 includes a total of 28 plies 318 i (i.e., n=28). However, in other examples, the composite structure 300 can include a lesser quantity or a greater quantity of plies 318 i .

In this arrangement, the first gage 312 A of the first end 310 A and the second gage 312 B of the second end 310 B are respective thicknesses between the second outer surface 316 and the first outer surface 314 at the first end 310 A and the second end 310 B, respectively. Further, the first gage 312 A is related to a quantity of the plies 318 i at the first end 310 A and the second gage 312 B is related to a quantity of the plies 318 i at the second end 310 B. For instance, in FIG. 3 , the quantity of the plies 318 i at the first end 310 A is greater than the quantity of the plies 318 i at the second end 310 B such that the first gage 312 A is greater than the second gage 312 B.

As described above, the variable gage of the composite structure 300 results from the plies 318 i of composite material including a plurality of continuous plies 318 A and a plurality of drop-off plies 318 B arranged in the stack between the second outer surface 316 and the first outer surface 314 . In FIG. 3 , each continuous ply 318 A extends from the first end 310 A to the second end 310 B. Whereas, each drop-off ply 318 B includes a tip 320 , and each drop-off ply 318 B extends from the first end 310 A to a respective position of the tip 320 of the drop-off ply 318 B between the first end 310 A and the second end 310 B.

For clarity of illustration, in FIG. 3 , a representative subset of the continuous plies 318 A are labeled with reference number 318 A and a representative subset of the drop-off plies 318 B are labeled with reference number 318 B. However, each of the plies 318 i that extends entirely from the first end 310 A to the second end 310 B is one of the continuous plies 318 A, and each of the plies 318 i that terminates between the first end 310 A and the second end 310 B is one of the drop-off plies 318 B. Specifically, in FIG. 3 , the plies 318 i=1-4,6,8,10,12,14,15,17,19,21,23,25-28 are the continuous plies 318 A, and the plies 318 i=5,7,9,11,13,16,18,20,22,24 are the drop-off plies 318 B.

As shown in FIG. 3 , the tip 320 of each drop-off ply 318 B has the tapered shape described above with respect to the tips 220 shown in FIG. 2 . As such, the tips 320 having the tapered shape can reduce (or may minimize) resin pockets at the tips 320 of the drop-off plies 318 B, which can help to improve (or may maximize) interlaminar strength of the composite structure 300 . However, in other examples, one or more of the drop-off plies 318 B can have the blunt-end shape shown in FIG. 1 .

As noted above, the load bearing performance of the composite structure 300 can be enhanced, additionally or alternatively, based on the pattern in which the plies 318 i are arranged in the composite structure 300 . For example, in FIG. 3 , the drop-off plies 218 B can be separated from each other by at least one of the continuous plies 318 A. For instance, each drop-off ply 318 B can be sandwiched between and abut against a respective two continuous plies 318 A of the plurality of continuous plies 318 A. By separating the drop-off plies 318 B from each other and/or sandwiching the drop-off plies 318 B between the continuous plies 318 A, the drop-off plies 318 B can be more uniformly distributed between the second outer surface 316 and the first outer surface 314 (as compared to the clustered arrangement of the drop-off plies 118 B shown in FIG. 1 ). This can help to reduce (or may prevent) ply kinks and/or wrinkles, reduce (or may prevent) resin pockets, and/or increase (or may maximize) interlaminar strength of the composite structure 300 .

Within examples, the pattern of the tips 320 of the drop-off plies 218 B can additionally or alternatively include one or more of the following characteristics: (i) an arrangement of the tips 320 in a first half of the composite structure 300 in a pattern that mirrors a pattern of the tips 320 in a second half of the composite structure 300 , (ii) a staggered arrangement of the tips 320 relative to each other, and/or (iii) spacing the tips 320 relative to each other by at least one threshold distance. As described above, each of these characteristics alone or in combination can contribute to arranging the drop-off plies 318 B in a pattern that can reduce (or may prevent) ply kinks and/or wrinkles, may reduce (or may prevent) resin pockets, and/or increase (or may maximize) interlaminar strength.

FIG. 3 shows the tips 320 arranged in mirror patterns relative to a central portion 324 of the composite structure 300 according to another example. The central portion 324 can include one or more of the plies 318 i that provide a frame of reference for characterizing patterns of the tips 320 of the drop-off plies 318 B on opposing sides of the central portion 324 . As noted above, in general, the central portion 324 ( i ) is between the second outer surface 316 and the first outer surface 314 and (ii) extends from the first end 310 A to the second end 310 B.

In FIG. 3 , the central portion 324 can include the plies 318 i=14, 15 . Thus, in FIG. 3 , the central portion 324 can include two continuous plies 318 A. However, in another example, the central portion 324 can include two drop-off plies 318 B and at least one continuous ply 318 A. In yet another example, the central portion 324 can consist of only a single drop-off ply 318 B. In another example, the central portion 324 can consist of at least one continuous ply 318 A and omit the drop-off plies 318 B. More generally, the central portion 324 can include one or more of the continuous plies 318 A and/or one or more of the drop-off plies 318 B.

Also, as shown in FIG. 3 , the tips 320 of the drop-off plies 318 B can be arranged in substantially mirror or mirror patterns relative to the central portion 324 . For instance, a first subset of the drop-off plies 318 B can be between the first outer surface 314 and the central portion 324 , and a second subset of the drop-off plies 318 B can be between the central portion 324 and the second outer surface 316 . In this arrangement, the tips 320 of the first subset of the drop-off plies 318 B are arranged in a pattern that substantially mirrors a pattern of the tips 320 of the second subset of the drop-off plies 318 B. In other words, with reference to the central portion 324 , the respective positions of the tips 320 of the first subset of the drop-off plies 318 B are (i) reversely and (ii) similarly (or identically) arranged in comparison to the respective positions of the tips 320 of the second subset of the drop-off plies 318 B.

For example, in FIG. 3 , the central portion 324 can include the plies 318 i=14, 15 , the first subset of the drop-off plies 318 B can include the plies 318 i=5, 7, 9, 11, 13 , and the second subset of the drop-off plies 318 B can include the plies 318 i=16, 18, 20, 22, 24 . As shown in FIG. 3 , the pattern of the tips 320 of the first subset of the drop-off plies 318 B substantially mirrors the pattern of the tips 320 of the second subset of the drop-off plies 318 B. For instance, with reference to the central portion 324 , the respective positions of the tips 320 of the first subset are reversely and similarly arranged in comparison to the respective positions of the tips 320 of the second subset.

As described above, FIG. 2 shows the pattern of the tips 220 of the drop-off plies 218 B as a monotonically-outward pattern. FIG. 3 shows the tips 320 of the drop-off plies 318 B arranged in a monotonically-inward pattern, according to an example. In a first order of the first subset of the drop-off plies 318 B from the first outer surface 314 toward the central portion 324 , with each successive drop-off ply 318 B in the first order, a relative distance between the tip 320 of the drop-off ply 318 B and the second end 310 B decreases. Also, in a second order of the second subset of the drop-off plies 318 B from the second outer surface 316 toward the central portion 324 , with each successive drop-off ply 318 B in the second order, a relative distance between the tip 320 of the drop-off ply 318 B and the second end 310 B decreases.

As such, in FIG. 3 , (i) the tip 320 of the ply 218 i=5 is at a first distance from the second end 310 B, (ii) the tip 320 of the ply 318 i=7 is at a second distance from the second end 310 B, which is less than the first distance, (iii) the tip 320 of the ply 318 i=9 is at a third distance from the second end 310 B, which is less than the second distance, (iv) the tip 320 of the ply 318 i=11 is at a fourth distance from the second end 310 B, which is less than the third distance, and (v) the tip 320 of the ply 318 i=13 is at a fifth distance from the second end 310 B, which is less than the fourth distance. Also, in FIG. 3 , (vi) the tip 320 of the ply 318 i=24 is at a sixth distance from the second end 310 B, (vii) the tip 320 of the ply 318 i=22 is at a seventh distance from the second end 310 B, which is less than the sixth distance, (viii) the tip 320 of the ply 318 i=20 is at an eighth distance from the second end 310 B, which is less than the seventh distance, (ix) the tip 320 of the ply 318 i=18 is at a ninth distance from the second end 310 B, which is less than the eighth distance, and (x) the tip 320 of the ply 318 i=16 is at a tenth distance from the second end 310 B, which is less than the ninth distance.

Accordingly, in the monotonically-inward pattern of the tips 320 shown in FIG. 3 , the tips 320 of the drop-off plies 318 B generally appear to be converge inward from the first outer surface 314 and the second outer surface 316 toward the central portion 324 in a direction from the first end 310 A to the second end 310 B. The monotonically-inward pattern of the tips 320 can help to more gradually and/or smoothly transition from the first gage 312 A at the first end 310 A to the second gage 312 B at the second end 310 B. Additionally, for example, the monotonically-inward pattern of the tips 320 can help to achieve a relatively greater degree of symmetry relative to, for instance, the arrangement of the tips 120 in FIG. 1 (which are clustered near the first outer surface 114 ).

According to an additional or alternative aspect of the monotonically-inward pattern shown in FIG. 3 , the drop-off plies 318 B can be arranged in a plurality of pairs of drop-off plies 318 B that define an order in which the drop-off plies 318 B drop off in a direction from the first end 310 A toward the second end 310 B (i.e., an order of the respective positions of the tips 320 in the direction from the first end 310 A toward the second end 310 B). In particular, each pair of drop-off plies 318 B can include a respective one drop-off ply 318 B of the first subset and a respective one drop-off ply 318 B of the second subset.

For example, in FIG. 3 , a first pair includes the plies 318 i=5, 24 , a second pair includes the plies 318 i=7, 22 , a third pair includes the plies 318 i=9, 20 , a fourth pair includes the plies 318 i=11, 18 , and a fifth pair includes the plies 318 i=13, 16 . As shown in FIG. 3 , in the direction from the first end 310 A to the second end 310 B, the drop-off plies 318 B drop off in an order from the first pair to the fifth pair. In other words, the tips 320 of the first pair of the drop-off plies 318 B are closest to the first end 310 A, the tips 320 of the second pair of the drop-off plies 318 B are second closest to the first end 310 A, the tips 320 of the third pair of the drop-off plies 318 B are third closest to the first end 310 A, the tips 320 of the fourth pair of the drop-off plies 318 B are second farthest from the first end 310 A, and the tips 320 of the fifth pair of the drop-off plies 318 B are farthest from the first end 310 A.

Additionally, for example, for each pair of drop-off plies 318 B, the respective one drop-off ply 318 B of the first subset and the respective one drop-off ply 318 B of the second subset can be equidistant from the central portion 324 in a dimension between the first outer surface 314 and the second outer surface 316 . For instance, as shown in FIG. 3 , the first pair of the drop-off plies 318 B are each spaced from the central portion 324 by a distance equal to eight times a ply thickness 326 of a single ply 318 i , the second pair of the drop-off plies 318 B are each spaced from the central portion 324 by a distance equal to six times the ply thickness 326 , the third pair of the drop-off plies 318 B are each spaced from the central portion 324 by a distance equal to four times the ply thickness 326 , the fourth pair of the drop-off plies 318 B are each spaced from the central portion 324 by a distance equal to two times the ply thickness 326 , and the fifth pair of the drop-off plies 318 B are each immediately adjacent to and abut against the central portion 324 . Arranging the drop-off plies 318 B in pairs that (i) drop off, pair-by-pair, in an order from the first end 310 A to the second end 310 B, and/or (ii) are equidistant relative to the central portion 324 can additionally help to more gradually and/or smoothly transition from the first gage 312 A at the first end 310 A to the second gage 312 B at the second end 310 B, and/or achieve a relatively greater degree of symmetry relative to, for instance, the arrangement of the tips 120 in FIG. 1 (which are clustered near the first outer surface 114 ).

According to an additional or alternative aspect of the monotonically-inward pattern shown in FIG. 3 , the monotonically-inward pattern can include, along a direction from the first end 310 A to the second end 310 B, the tips 320 of the first subset of the drop-off plies 318 B alternating with the tips 320 of the second subset of the drop-off plies 318 B. For example, in FIG. 3 , the tips 320 of the drop-off plies 318 B are in the following order from the first end 310 A to the second end 310 B: (i) the tip 320 of the ply 318 i=5 from the first subset, (ii) the tip 320 of the ply 318 i=24 from the second subset, (iii) the tip 320 of the ply 318 i=7 from the first subset, (iv) the tip 320 of the ply 318 i=22 from the second subset, (v) the tip 320 of the ply 318 i=9 from the first subset, (vi) the tip 320 of the ply 318 i=20 from the second subset, (vii) the tip 320 of the ply 318 i=11 from the first subset, (viii) the tip 320 of the ply 318 i=18 from the second subset, (ix) the tip 320 of the ply 318 i=13 from the first subset, and (x) the tip 320 of the ply 318 i=16 from the second subset. Alternating the respective positions of the tips 320 of the drop-off plies 318 B can additionally or alternatively help to help to more gradually and/or smoothly transition from the first gage 312 A at the first end 310 A to the second gage 312 B at the second end 310 B.

As noted above, arranging the drop-off plies 318 B such that the tips 320 of the drop-off plies 318 B are staggered relative to each other can additionally or alternatively help to reduce (or may prevent) ply kinks and/or wrinkles, reduce (or may prevent) resin pockets, and/or increase (or may maximize) interlaminar strength. As an example, in FIG. 3 , the respective positions of the tips 320 of the drop-off plies 318 B can be staggered from the first end 310 A to the second end 310 B. By “staggered”, it is meant that the tips 320 of the drop-off plies 318 B are each at a respective distance from the second end 310 B, and the respective distances between the tips 320 and the second end 310 B are all different from each other (i.e., the tips of no two drop-off plies are equidistant from the second end 310 B). Staggering the tips 320 of the drop-off plies 318 B can help to mitigate some or all of the challenges associated with a clustered arrangement of drop-off plies described above.

Also, as noted above, spacing the tips 320 relative to each other by at least one threshold distance can additionally or alternatively help to reduce (or may prevent) ply kinks and/or wrinkles, reduce (or may prevent) resin pockets, and/or increase (or may maximize) interlaminar strength. In an example, for each drop-off ply 318 B, a distance 328 between the tip 320 of the drop-off ply 318 B and the tip 320 of an adjacent one of the drop-off plies 318 B can be at least ten times greater than the ply thickness 326 of the drop-off ply 318 B. In this example, for each drop-off ply 318 B, the adjacent one of the drop-off plies 318 B is adjacent to the drop-off ply 318 B in a dimension extending between the first outer surface 314 and the second outer surface 316 . For instance, as described above, two of the drop-off plies 318 B are adjacent to each other only if there is not another one of the drop-off plies 318 B between the two of the drop-off plies 318 B in the dimension extending between the first outer surface 314 and the second outer surface 316 . Thus, for example, the ply 318 i=7 is adjacent to the ply 318 i=5 and the ply 318 i=9 , and non-adjacent to the other drop-off plies 318 B (i.e., plies 218 i=11, 13, 16, 18, 20, 22, 24 ).

A representative one of the distances 328 is depicted in FIG. 3 between the tips 320 of the ply 318 i=7 and the ply 318 i=5 , which are adjacent to each other. As shown in FIG. 3 , the distance 328 between the tip 320 of the ply 318 i=7 and the tip of the ply 318 i=5 is at least ten times greater than the ply thickness 326 of the ply 318 i=7 . Similarly, in FIG. 3 , the tips 320 of the other adjacent ones of the drop-off plies 318 B are separated by respective distances 328 that are at least ten times greater than the ply thickness 326 . As described above, arranging the drop-off plies 318 B such that the tips 320 of adjacent ones of the drop-off plies 318 B are separated by the distance 328 of at least ten times the ply thickness 326 can help to reduce (or may prevent) ply kinks and/or wrinkles, reduce (or may prevent) resin pockets, and/or increase (or may maximize) interlaminar strength.

Additionally or alternatively, for example, a distance 330 between non-adjacent ones of the drop-off plies 318 B can be at least three times greater than the ply thickness 326 of each drop-off ply 318 B. A representative one of the distances 330 is depicted in FIG. 3 between the tips 320 of the ply 318 i=7 and the ply 318 i=22 , which are non-adjacent to each other (e.g., because the plies 318 i=9, 11, 13, 16, 18, 20 are between the ply 318 i=7 and the ply 318 i=22 ). As shown in FIG. 3 , the distance 330 between the tip 320 of the ply 318 i=7 and the tip of the ply 318 i=22 is at least three times greater than the ply thickness 326 of the ply 318 i=7 . Similarly, the tips 320 of the other non-adjacent ones of the drop-off plies 318 B are separated by respective distances 330 that are at least three times greater than the ply thickness 326 . As described above, arranging the drop-off plies 318 B such that the tips 320 of non-adjacent ones of the drop-off plies 318 B are separated by the distance 328 of at least three times the ply thickness 326 can help to reduce (or may prevent) ply kinks and/or wrinkles, reduce (or may prevent) resin pockets, and/or increase (or may maximize) interlaminar strength.

In FIG. 3 , the ply thickness 326 is the same for all of the plies 318 i . However, in another example, one or more of the plies 318 i can have a different ply thickness than another one of the plies 318 i . In some implementations, providing the plies 318 i with different ply thicknesses can help to provide relatively greater flexibility for achieving fabrication quality objectives.

Additionally, in FIG. 3 , the tips 320 of the drop-off plies 318 B all have the tapered shape. However, in another example, one or more of the tips 320 of the drop-off plies 318 B can have the blunt-end shape of the tips 120 shown in FIG. 1 . Although the tapered shape can be beneficial for at least the reasons described above, a composite structure including the drop-off plies 318 B having the tips 120 with the blunt-end shape in a pattern having one or more of the characteristics described above with respect to FIG. 3 can provide improvements over the composite structure 100 shown in FIG. 1 .

In FIGS. 1-3 , the composite structures 100 , 200 , 300 are shown having a shape that curves between the first end 110 A, 210 A, 310 A and the second end 110 B, 210 B, 310 B. However, in other examples, the composite structures 100 , 200 , 300 can have a different shape such as, for example, a planar shape, a scalloped shape, a corrugated shape, a uniform shape, a non-uniform shape, a polygonal shape, and/or a non-polygonal shape.

In some examples, the first end 110 A, 210 A, 310 A and/or the second end 110 B, 210 B, 310 B can form external surfaces of the composite structure 100 , 200 , 300 . However, in other examples, the first end 110 A, 210 A, 310 A and/or the second end 110 B, 210 B, 310 B can be respective interfaces with other segments of a larger composite structure. For instance, the composite structure 100 , 200 , 300 shown in FIGS. 1-3 can provide a transition segment of a composite structure for transitioning from one gage to another gage within the composite structure.

Referring to FIG. 4 , a simplified block diagram of a composite structure 400 having a variable gage is shown, according to another example. As shown in FIG. 4 , the composite structure 400 includes a first segment 440 , a second segment 442 , and a transition segment 444 between the first segment 440 and the second segment 442 . The first segment 440 has a first gage 412 A and the second segment 442 has a second gage 412 B, which is less than the first gage 412 A. Although FIG. 4 depicts the composite structure 400 having three segments (i.e., the first segment 440 , a transition segment 444 , and a second segment 442 ), the composite structure 400 can include a lesser quantity or a greater quantity of segments in other examples.

The transition segment 444 can have a variable gage for transitioning from between the first gage 412 A and the second gage 412 B. For example, the transition segment 444 can include one or more continuous plies and one or more drop-off plies, which are configured to transition between the first gage 412 A and the second gage 412 B as described above with respect to the composite structures 100 , 200 , 300 shown in FIGS. 1-3 .

For instance, as shown in FIG. 4 , the transition segment 444 includes a first end 410 A at the first segment 440 and having the first gage 412 A, a second end 410 B at the second segment 442 and having a second gage 412 B, a first outer surface 414 extending from the first end 410 A to the second end 410 B, a second outer surface 416 extending from the first end 410 A to the second end 410 B. The first end 410 A can thus provide an interface between the first segment 440 and the transition segment 444 , and the second end 410 B can provide an interface between the second segment 442 and the transition segment 444 .

The transition segment 444 also includes a plurality of plies 418 (i) extending between the first end 410 A and the second end 410 B and (ii) arranged in a stack between the first outer surface 414 and the second outer surface 416 . As shown in FIG. 4 , the plies 418 include a plurality of continuous plies 418 A and at least one drop-off ply 418 B. As described above, each continuous ply 418 A extends from the first end 410 A to the second end 410 B, each drop-off ply 418 B includes a tip 420 , and each drop-off ply 418 B extends from the first end 410 A to a respective position of the tip 420 of the drop-off ply 418 B between the first end 410 A and the second end 410 B. Within examples, the tips 420 of the drop-off plies 418 B can have a tapered shape (e.g., as shown in FIGS. 2-3 ) and/or a blunt-end shape (e.g., as shown in FIG. 1 ).

In some examples, each drop-off ply 418 B is sandwiched between and abuts against a respective two continuous plies 418 A of the plurality of continuous plies 418 A. Additionally or alternatively, the tips 420 of the drop-off plies 418 B can be arranged in a monotonically-outward pattern (e.g., as shown in FIG. 2 ), a monotonically-inward pattern (e.g., as shown in FIG. 3 ), a staggered pattern (e.g., as shown in FIGS. 2-3 ), and/or a substantially mirrored pattern (e.g., as shown in FIGS. 2-3 ) as described above.

For instance, in an implementation in which the tips 420 are arranged in the monotonically-inward pattern, (i) a first subset of the drop-off plies 418 B are between the first outer surface 414 and a central portion of the stack and a second subset of the drop-off plies 418 B are between the central portion and the second outer surface 416 , (ii) in a first order of the first subset of the drop-off plies 418 B from the first outer surface 414 toward the central portion, with each successive drop-off ply 418 B in the first order, a relative distance between the tip 420 of the drop-off ply 418 B and the second end 410 B decreases, and (iii) in a second order of the second subset of the drop-off plies 418 B from the second outer surface 416 toward the central portion, with each successive drop-off ply 418 B in the second order, a relative distance between the tip 420 of the drop-off ply 418 B and the second end 410 B decreases.

Additionally, for instance, in an implementation in which the tips 420 are arranged in the monotonically-outward pattern, (i) a first subset of the drop-off plies 418 B are between the first outer surface 414 and a central portion of the stack and a second subset of the drop-off plies 418 B are between the central portion and the second outer surface 416 , (ii) in a first order of the first subset of the drop-off plies 418 B from the central portion toward the first outer surface 414 , with each successive drop-off ply 418 B in the first order, a relative distance between the tip 420 of the drop-off ply 418 B and the second end 410 B decreases, and (iii) in a second order of the second subset of the drop-off plies 418 B from the central portion toward the second outer surface 416 , with each successive drop-off ply 418 B in the second order, a relative distance between the tip 420 of the drop-off ply 418 B and the second end 410 B decreases.

Additionally or alternatively, for each drop-off ply 418 B, a distance between the tip 420 of the drop-off ply 418 B and the tip 420 of an adjacent one of the drop-off plies 418 B can be at least ten times greater than a thickness of the drop-off ply 418 B. Additionally or alternatively, a distance between non-adjacent ones of the drop-off plies 418 B can be at least three times greater than a thickness of each drop-off ply 418 B.

Within examples, the composite structures 100 , 200 , 300 , 400 described above with respect to FIGS. 1-4 can be used to form a variety of structures. As examples, an aircraft, a spacecraft, a rotorcraft, a watercraft, an automobile, a truck, and/or another type of vehicle (e.g., passenger capsules or cargo containers) can include the composite structures 100 , 200 , 300 , 400 described above. Additionally, for example, a building, a bridge, a swimming pool, a storage tank, robotic frame structures, energy structures (e.g., wind blades, turbine blades, propulsion blades, and/or solar panels), sporting goods (e.g., bicycle frames, skis, snow boards, surfing boards, paddles), residential houses, office buildings, and/or medical board frames can include the composite structures 100 , 200 , 300 , 400 described above.

As one example, FIGS. 5A-5B depict composite stringers 550 that can include one or more of the composite structures 100 , 200 , 300 , 400 described above with respect to FIGS. 1-4 . In general, the composite stringers 550 are each an elongate member that can be coupled to one or more skin panels to help carry and/or transfer a load from the skin panel to another structure of the aircraft (e.g., a frame, a rib, and/or a spar of the aircraft). In this way, the composite stringers 550 can help to prevent buckling under compression or shear loads on the skin panels, and/or mitigate bending of the skin panels. For these and other reasons, the aircraft typically includes one or more composite stringers 550 in a fuselage, wing assemblies, and/or an empennage of the aircraft.

In general, the composite stringer 550 includes one or more flanges 552 A- 552 C and one or more webs 554 A- 554 B. More particularly, in FIGS. 5A-5B , the composite stringer 550 includes a skin flange 552 A configured to be coupled to the support structure 556 (e.g., a skin panel of an aircraft), a top flange 552 B, and a web 554 A extending between the skin flange 552 A and the top flange 552 B. In FIG. 5 , the composite stringer 550 is in the form of a hat-shaped stringer. As such, the web 554 A can extend from a first side of the top flange 550 B, and the composite stringer 550 can further include a second skin flange 552 C configured to be coupled to the support structure 556 and a second web 554 B extending between the second skin flange 552 C and a second side of the top flange 552 B.

Within examples, the composite stringer 550 can further include one or more corner portions, which each provides a transition segment between two other segments of the composite stringer 550 (i.e., between two of the skin flange 552 A, the web 554 A, the top flange 552 B, the second web 554 B, and the second skin flange 552 C). For instance, in FIG. 5 , the corner portion(s) of the composite stringer 550 can include (i) a first corner portion 558 A extending from the skin flange 552 A to the web 554 A, (ii) an second corner portion 558 B extending from the web 554 A to the top flange 552 B, (iii) a third corner portion 558 C extending from the second skin flange 552 C to the second web 554 B, and/or (iv) a fourth corner portion 558 D extending from the second web 554 B to the top flange 552 B.

Also, in FIG. 5 , the top flange 552 B has a first gage 512 A. The skin flange 552 A, the second skin flange 552 C, the web 554 A, and the second web 554 B all have a second gage 512 B. In this example, the first gage 512 A is greater than the second gage 512 B.

In this arrangement, the second corner portion 558 B and the fourth corner portion 558 D can be a composite structure having a variable gage. For instance, the top flange 552 B can be a first segment (e.g., the first segment 440 ), the web 554 A can be a second segment (e.g., the second segment 442 in FIG. 4 ), and the second corner portion 558 B can be a transition segment (e.g., the transition segment 444 in FIG. 4 ) between the top flange 552 B and the web 554 A. Similarly, for instance, the top flange 552 B can be a first segment (e.g., the first segment 440 ), the second web 554 B can be a second segment (e.g., the second segment 442 in FIG. 4 ), and the fourth corner portion 558 D can be a transition segment (e.g., the transition segment 444 in FIG. 4 ) between the top flange 552 B and the second web 554 B.

In particular, in FIG. 5A , the second corner portion 558 B and the fourth corner portion 558 D each include the composite structure 100 shown in FIG. 1 . Whereas, in FIG. 5B , the second corner portion 558 B and the fourth corner portion 558 D each include the composite structure 300 shown in FIG. 3 . As shown in FIGS. 5A-5B , the composite structure 300 of FIG. 3 , which includes the drop-off plies 318 B having the tips 320 with tapered shapes arranged in the monotonically-inward pattern, provides a smoother and relatively more symmetric transition from the first gage 512 A to the second gage 512 B than the composite structure 100 of FIG. 1 , which includes the drop-off plies 118 B having the tips 120 with blunt-end shapes arranged in a cluster at or near the first outer surface 114 .

As described above, FIGS. 5A-5B depict one example of a structure that can include the composite structures 100 , 200 , 300 , 400 described herein. However, as described above, the composite structures 100 , 200 , 300 , 400 can be incorporated in structures other than the composite stringers 550 shown in FIGS. 5A-5B .

Referring now to FIG. 6 , a flowchart for a process 600 of forming a composite structure having a variable gage is described according to an example. As shown in FIG. 6 , at block 610 , the process 600 includes forming a plurality of continuous plies. At block 612 , the process 600 includes forming a plurality of drop-off plies. Forming the plurality of drop-off plies at block 612 can include forming, for each drop-off ply, a tip of the drop-off ply having a tapered shape at block 612 .

At block 616 , the process 600 includes positioning the plurality of continuous plies and the plurality of drop-off plies in a stack having a first end and a second end. The first end has a first gage. The second end has a second gage, which is less than the first gage. As shown in FIG. 6 , positioning the plurality of continuous plies and the plurality of drop-off plies at block 616 can include positioning the plurality of continuous plies such that each continuous ply extends from the first end to the second end at block 618 . Positioning the plurality of continuous plies and the plurality of drop-off plies at block 616 can also include 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 at block 620 .

FIGS. 7-14 depict additional aspects of the process 600 according to further examples. As shown in FIG. 7 , the process 600 can further include, after positioning the plurality of continuous plies and the plurality of drop-off plies in the stack at block 616 , curing the plurality of continuous plies and the plurality of drop-off plies at block 622 .

As shown in FIG. 8 , positioning the plurality of continuous plies and the plurality of drop-off plies in the stack at block 616 can further include forming a first outer surface extending from the first end to the second end at block 624 , and forming a second outer surface extending from the first end to the second end at block 626 . The first gage and the second gage can be respective thicknesses between the first outer surface and the second outer surface at the first end and the second end, respectively.

As shown in FIG. 9 , positioning the plurality of continuous plies and the plurality of drop-off plies in the stack at block 616 can include positioning a first subset of the plurality of drop-off plies between the first outer surface and a central portion at block 628 . 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. Also, in FIG. 9 , positioning the plurality of continuous plies and the plurality of drop-off plies in the stack at block 616 can include positioning a second subset of the plurality of drop-off plies between the central portion and the second outer surface at block 630 .

As shown in FIG. 10 , positioning the first subset of the plurality of drop-off plies at block 628 and positioning the second subset of the plurality of drop-off plies at block 630 can include 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 at block 632 .

As shown in FIG. 11 , positioning the plurality of drop-off plies at block 620 can include positioning the plurality of drop-off plies such that the respective positions of the tips of the plurality of drop-off plies are staggered from the first end to the second end at block 634 .

As shown in FIG. 12 , positioning the first subset of the plurality of drop-off plies at block 628 can include (i) 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 at block 636 , and (ii) 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 includes, 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 at block 638 .

Also, as shown in FIG. 12 , positioning the second subset of the plurality of drop-off plies at block 630 can include (i) positioning the second subset of the plurality of drop-off plies includes 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 at block 640 , and (ii) 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 includes, 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 at block 642 .

As shown in FIG. 13 , positioning the plurality of drop-off plies at block 620 can include 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 at block 644 . 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.

As shown in FIG. 14 , positioning the plurality of drop-off plies at block 620 can include 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 at block 646 .

Referring now to FIG. 15 , a flowchart for a process 1500 of forming a composite structure having a variable gage is described according to an example. As shown in FIG. 15 , at block 1510 , the process 1500 includes forming a plurality of continuous plies. At block 1512 , the process 1500 includes forming a plurality of drop-off plies. Forming the plurality of drop-off plies at block 1512 can include forming, for each drop-off ply, a tip of the drop-off ply having a tapered shape at block 1514 .

At block 1516 , the process 1500 can include positioning the plurality of continuous plies and the plurality of drop-off plies in a stack having (i) a first end, (ii) a second end, (iii) a first outer surface extending from the first end to the second end, and (iv) a second outer surface extending from the first end to the second end. The first end has a first gage. The second end has a second gage, which is less than the first gage.

In FIG. 15 , positioning the plurality of continuous plies and the plurality of drop-off plies at block 1516 can include positioning the plurality of continuous plies such that each continuous ply extends from the first end to the second end at block 1518 . Additionally, positioning the plurality of continuous plies and the plurality of drop-off plies at block 1516 can also include positioning the plurality of drop-off plies such that 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 at block 1520 . A first subset of the plurality of drop-off plies are between the first outer surface and a central portion of the stack and a second subset of the plurality of drop-off plies are between the central portion and the second outer surface.

FIGS. 16-21 depict additional aspects of the process 1500 according to further examples. As shown in FIG. 16 , positioning the plurality of continuous plies and the plurality of drop-off plies in the stack at block 1516 can further include, at block 1522 , arranging the plurality of drop-off plies in a monotonically-inward pattern including (i) in a first order of the first subset of the plurality of drop-off plies from the first outer surface toward the central portion, with each successive drop-off ply in the first order, a relative distance between the tip of the drop-off ply and the second end decreases, and (ii) in a second order of the second subset of the plurality of drop-off plies from the second outer surface toward the central portion, with each successive drop-off ply in the second order, a relative distance between the tip of the drop-off ply and the second end decreases.

As shown in FIG. 17 , after positioning the plurality of continuous plies and the plurality of drop-off plies in the stack at block 1516 , the process 1500 can include curing the plurality of continuous plies and the plurality of drop-off plies at block 1524 .

As shown in FIG. 18 , positioning the plurality of continuous plies and the plurality of drop-off plies at block 1516 can include positioning the plurality of continuous plies and the plurality of drop-off plies such that the plurality of drop-off plies are separated from each other by at least one of the plurality of continuous plies at block 1526 .

As shown in FIG. 19 , positioning the plurality of drop-off plies at block 1520 can include positioning the plurality of drop-off plies such that the respective positions of the tips of the plurality of drop-off plies are staggered from the first end to the second end at block 1528 .

As shown in FIG. 20 , positioning the plurality of drop-off plies at block 1520 can include 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 at block 1530 . 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.

As shown in FIG. 21 , positioning the plurality of drop-off plies at block 1520 can include 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 at block 1532 .

One or more of the blocks shown in FIGS. 6-21 may represent a module, a segment, or a portion of program code, which includes one or more instructions executable by a processor for implementing specific logical functions or steps in the process. The program code may be stored on any type of computer readable medium or data storage, for example, such as a storage device including a disk or hard drive. Further, the program code can be encoded on a computer-readable storage media in a machine-readable format, or on other non-transitory media or articles of manufacture. The computer readable medium may include non-transitory computer readable medium or memory, for example, such as computer-readable media that stores data for short periods of time like register memory, processor cache and Random Access Memory (RAM). The computer readable medium may also include non-transitory media, such as secondary or persistent long term storage, like read only memory (ROM), optical or magnetic disks, compact-disc read only memory (CD-ROM), for example. The computer readable media may also be any other volatile or non-volatile storage systems. The computer readable medium may be considered a tangible computer readable storage medium, for example.

In some instances, components of the devices and/or systems described herein may be configured to perform the functions such that the components are actually configured and structured (with hardware and/or software) to enable such performance. Example configurations then include one or more processors executing instructions to cause the system to perform the functions. Similarly, components of the devices and/or systems may be configured so as to be arranged or adapted to, capable of, or suited for performing the functions, such as when operated in a specific manner.

Further, the disclosure comprises examples according to the following clauses:

Clause 1: A composite structure having a variable gage including a first end having a first gage, and a second end having a second gage, which is less than the first gage. The composite structure also includes a plurality of continuous plies and a plurality of drop-off plies. Each continuous ply extends from the first end to the second end. Each drop-off ply includes a tip having a tapered shape. 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. The plurality of drop-off plies are separated from each other by at least one of the plurality of continuous plies.

Clause 2: The composite structure of Clause 1, further including 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. 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. 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.

Clause 3: The composite structure of Clause 2, wherein a first subset of the plurality of drop-off plies are between the first outer surface and a central portion. 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. A second subset of the plurality of drop-off plies are between the central portion and the second outer surface. 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.

Clause 4: The composite structure of Clause 3, wherein the central portion includes a single drop-off ply of the plurality of drop-off plies.

Clause 5: The composite structure of Clause 3, wherein the central portion includes two drop-off plies of the plurality of drop-off plies and at least one continuous ply of the plurality of continuous plies between the two drop-off plies.

Clause 6: The composite structure of any one of Clause 1-5, wherein the respective positions of the tips of the plurality of drop-off plies are staggered from the first end to the second end.

Clause 7: The composite structure of Clause 6, 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. The pattern of the tips of the first subset of the plurality of drop-off plies includes, 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. 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. The pattern of the tips of the second subset of the plurality of drop-off plies includes, 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.

Clause 8: The composite structure of any one of Clause 2-7, 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. 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.

Clause 9: The composite structure of any one of Clause 1-8, 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.

Clause 10: A method of forming a composite structure having a variable gage includes forming a plurality of continuous plies and forming a plurality of drop-off plies. Forming the plurality of drop-off plies includes forming, for each drop-off ply, a tip of the drop-off ply having a tapered shape. The method also includes positioning the plurality of continuous plies and the plurality of drop-off plies in a stack having a first end and a second end. The first end has a first gage. The second end has a second gage, which is less than the first gage. Positioning the plurality of continuous plies and the plurality of drop-off plies includes (a) positioning the plurality of continuous plies such that each continuous ply extends from the first end to the second end, and (b) 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.

Clause 11: The method of Clause 10, further including, 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.

Clause 12: The method of any one of Clauses 10-11, wherein positioning the plurality of continuous plies and the plurality of drop-off plies in the stack further includes 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. 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.

Clause 13: The method of Clause 12, wherein positioning the plurality of continuous plies and the plurality of drop-off plies in the stack includes 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. Positioning the plurality of continuous plies and the plurality of drop-off plies in the stack also includes positioning a second subset of the plurality of drop-off plies between the central portion and the second outer surface. Positioning the first subset of the plurality of drop-off plies and positioning the second subset of the plurality of drop-off plies includes 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.

Clause 14: The method of Clause 13, wherein the central portion includes a single drop-off ply of the plurality of drop-off plies.

Clause 15: The method of Clause 13, wherein the central portion includes two drop-off plies of the plurality of drop-off plies and at least one continuous ply of the plurality of continuous plies between the two drop-off plies.

Clause 16: The method of any one of Clauses 10-15, wherein positioning the plurality of drop-off plies includes positioning the plurality of drop-off plies such that the respective positions of the tips of the plurality of drop-off plies are staggered from the first end to the second end.

Clause 17: The method of Clause 16, wherein positioning the first subset of the plurality of drop-off plies includes: (i) 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 (ii) 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 includes, 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. Positioning the second subset of the plurality of drop-off plies includes: (a) positioning the second subset of the plurality of drop-off plies includes 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 (b) 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 includes, 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.

Clause 18: The method of any one of Clauses 10-17, wherein positioning the plurality of drop-off plies includes 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. 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.

Clause 19: The method of any one of Clauses 10-18, wherein positioning the plurality of drop-off plies includes 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.

Clause 20: A composite structure having a variable gage. The composite structure includes a first segment having a first gage and a second segment having a second gage, which is less than the first gage. The composite structure also includes a transition segment between the first segment and the second segment. The transition segment includes 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. The plurality of plies include (a) a plurality of continuous plies, wherein each continuous ply extends from the first end to the second end, and (b) at least one drop-off ply, wherein each drop-off ply comprises a tip having a tapered 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. Each drop-off ply is sandwiched between and abuts against a respective two continuous plies of the plurality of continuous plies.

Clause 21: A composite structure having a variable gage including a first end having a first gage, and a second end having a second gage, which is less than the first gage. The composite structure also includes 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. The plurality of plies include a plurality of continuous plies and a plurality of drop-off plies. Each continuous ply extends from the first end to the second end. Each drop-off ply includes a tip having a tapered shape. 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 subset of the plurality of drop-off plies are between the first outer surface and a central portion of the stack, and a second subset of the plurality of drop-off plies are between the central portion and the second outer surface. The tips of the plurality of drop-off plies are arranged in a monotonically-inward pattern including: (i) in a first order of the first subset of the plurality of drop-off plies from the first outer surface toward the central portion, with each successive drop-off ply in the first order, a relative distance between the tip of the drop-off ply and the second end decreases, and (ii) in a second order of the second subset of the plurality of drop-off plies from the second outer surface toward the central portion, with each successive drop-off ply in the second order, a relative distance between the tip of the drop-off ply and the second end decreases.

Clause 22: The composite structure of Clause 21, wherein the plurality of drop-off plies are separated from each other by at least one of the plurality of continuous plies.

Clause 23: The composite structure of any one of Clauses 21-22, 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.

Clause 24: The composite structure of any one of Clauses 21-23, wherein the central portion consists of at least one continuous ply of the plurality of continuous plies.

Clause 25: The composite structure of any one of Clauses 21-24, wherein the respective positions of the tips of the plurality of drop-off plies are staggered from the first end to the second end.

Clause 26: The composite structure of Clauses 21-25, wherein the monotonically-inward pattern further includes, along a direction from the first end to the second end, the tips of the first subset of the plurality of drop-off plies alternating with the tips of the second subset of the plurality of drop-off plies.

Clause 27: The composite structure of any one of Clauses 21-26, wherein the plurality of drop-off plies are arranged in a plurality of pairs of drop-off plies. Each pair of drop-off plies includes a respective one drop-off ply of the first subset and a respective one drop-off ply of the second subset. For each pair of drop-off plies, the respective one drop-off ply of the first subset and the respective one drop-off ply of the second subset are substantially equidistant from the central portion in a dimension between the first outer surface and the second outer surface.

Clause 28: The composite structure of any one of Clauses 21-27, 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.

Clause 29: The composite structure of Clause 28, wherein, for each pair, the ply angle is approximately the same for the plurality of drop-off plies of the pair.

Clause 30: The composite structure of any one of Clauses 21-29, 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. 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.

Clause 31: The composite structure of any one of Clauses 21-30, 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.

Clause 32: A method of forming a composite structure having a variable gage including forming a plurality of continuous plies and forming a plurality of drop-off plies. Forming the plurality of drop-off plies includes forming, for each drop-off ply, a tip of the drop-off ply having a tapered shape. The method also includes positioning the plurality of continuous plies and the plurality of drop-off plies in a stack having (i) a first end, (ii) a second end, (iii) a first outer surface extending from the first end to the second end, and (iv) a second outer surface extending from the first end to the second end. The first end has a first gage and the second end has a second gage, which is less than the first gage. Positioning the plurality of continuous plies and the plurality of drop-off plies includes 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 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 subset of the plurality of drop-off plies are between the first outer surface and a central portion of the stack, and a second subset of the plurality of drop-off plies are between the central portion and the second outer surface. Positioning the plurality of continuous plies and the plurality of drop-off plies in the stack further includes arranging the plurality of drop-off plies in a monotonically-inward pattern including: (a) in a first order of the first subset of the plurality of drop-off plies from the first outer surface toward the central portion, with each successive drop-off ply in the first order, a relative distance between the tip of the drop-off ply and the second end decreases, and (b) in a second order of the second subset of the plurality of drop-off plies from the second outer surface toward the central portion, with each successive drop-off ply in the second order, a relative distance between the tip of the drop-off ply and the second end decreases.

Clause 33: The method of Clause 32, further including, 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.

Clause 34: The method of any one of Clauses 32-33, wherein positioning the plurality of continuous plies and the plurality of drop-off plies includes positioning the plurality of continuous plies and the plurality of drop-off plies such that the plurality of drop-off plies are separated from each other by at least one of the plurality of continuous plies.

Clause 35: The method of any one of Clauses 32-34, wherein the central portion consists of at least one continuous ply of the plurality of continuous plies.

Clause 36: The method of any one of Clauses 32-35, wherein positioning the plurality of drop-off plies includes positioning the plurality of drop-off plies such that the respective positions of the tips of the plurality of drop-off plies are staggered from the first end to the second end.

Clause 37: The method of any one of Clauses 32-36, wherein positioning the plurality of drop-off plies includes 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. 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.

Clause 38: The method of any one of Clauses 32-37, wherein positioning the plurality of drop-off plies includes 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.

Clause 39: A composite structure having a variable gage. The composite structure includes a first segment having a first gage and a second segment having a second gage, which is less than the first gage. The composite structure also includes a transition segment between the first segment and the second segment. The transition segment includes 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. The plurality of plies include a plurality of continuous plies and a plurality of drop-off plies. Each continuous ply extends from the first end to the second end. Each drop-off ply includes a tip having a tapered shape. 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 subset of the plurality of drop-off plies are between the first outer surface and a central portion of the stack and a second subset of the plurality of drop-off plies are between the central portion and the second outer surface. The tips of the plurality of drop-off plies are arranged in a monotonically-inward pattern comprising: (a) in a first order of the first subset of the plurality of drop-off plies from the first outer surface toward the central portion, with each successive drop-off ply in the first order, a relative distance between the tip of the drop-off ply and the second end decreases, and (b) in a second order of the second subset of the plurality of drop-off plies from the second outer surface toward the central portion, with each successive drop-off ply in the second order, a relative distance between the tip of the drop-off ply and the second end decreases.

Clause 40: The composite structure of Clause 39, wherein the first segment is a flange of a composite stringer and the second segment is a web of the composite stringer.

Clause 41: A composite structure having a variable gage including a first end having a first gage, and a second end having a second gage, which is less than the first gage. The composite structure also includes a plurality of continuous plies and a plurality of drop-off plies. Each continuous ply extends from the first end to the second end. Each drop-off ply includes a tip having a blunt-end shape. 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. The plurality of drop-off plies are separated from each other by at least one of the plurality of continuous plies.

Clause 42: The composite structure of Clause 41, further including 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. 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. 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.

Clause 43: The composite structure of Clause 42, wherein a first subset of the plurality of drop-off plies are between the first outer surface and a central portion. 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. A second subset of the plurality of drop-off plies are between the central portion and the second outer surface. 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.

Clause 44: The composite structure of Clause 43, wherein the central portion includes a single drop-off ply of the plurality of drop-off plies.

Clause 45: The composite structure of Clause 43, wherein the central portion includes two drop-off plies of the plurality of drop-off plies and at least one continuous ply of the plurality of continuous plies between the two drop-off plies.

Clause 46: The composite structure of any one of Clause 41-45, wherein the respective positions of the tips of the plurality of drop-off plies are staggered from the first end to the second end.

Clause 47: The composite structure of Clause 46, 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. The pattern of the tips of the first subset of the plurality of drop-off plies includes, 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. 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. The pattern of the tips of the second subset of the plurality of drop-off plies includes, 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.

Clause 48: The composite structure of any one of Clause 42-47, 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. 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.

Clause 49: The composite structure of any one of Clause 41-48, 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.

Clause 50: A method of forming a composite structure having a variable gage includes forming a plurality of continuous plies and forming a plurality of drop-off plies. Forming the plurality of drop-off plies includes forming, for each drop-off ply, a tip of the drop-off ply having a blunt-end shape. The method also includes positioning the plurality of continuous plies and the plurality of drop-off plies in a stack having a first end and a second end. The first end has a first gage. The second end has a second gage, which is less than the first gage. Positioning the plurality of continuous plies and the plurality of drop-off plies includes (a) positioning the plurality of continuous plies such that each continuous ply extends from the first end to the second end, and (b) 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.

Clause 51: The method of Clauses 50, further including, 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.

Clause 52: The method of any one of Clauses 50-51, wherein positioning the plurality of continuous plies and the plurality of drop-off plies in the stack further includes 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. 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.

Clause 53: The method of Clause 52, wherein positioning the plurality of continuous plies and the plurality of drop-off plies in the stack includes 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. Positioning the plurality of continuous plies and the plurality of drop-off plies in the stack also includes positioning a second subset of the plurality of drop-off plies between the central portion and the second outer surface. Positioning the first subset of the plurality of drop-off plies and positioning the second subset of the plurality of drop-off plies includes 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.

Clause 54: The method of Clause 53, wherein the central portion includes a single drop-off ply of the plurality of drop-off plies.

Clause 55: The method of Clause 53, wherein the central portion includes two drop-off plies of the plurality of drop-off plies and at least one continuous ply of the plurality of continuous plies between the two drop-off plies.

Clause 56: The method of any one of Clauses 50-55, wherein positioning the plurality of drop-off plies includes positioning the plurality of drop-off plies such that the respective positions of the tips of the plurality of drop-off plies are staggered from the first end to the second end.

Clause 57: The method of Clause 56, wherein positioning the first subset of the plurality of drop-off plies includes: (i) 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 (ii) 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 includes, 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. Positioning the second subset of the plurality of drop-off plies includes: (a) positioning the second subset of the plurality of drop-off plies includes 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 (b) 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 includes, 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.

Clause 58: The method of any one of Clauses 50-57, wherein positioning the plurality of drop-off plies includes 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. 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.

Clause 59: The method of any one of Clauses 50-58, wherein positioning the plurality of drop-off plies includes 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.

Clause 60: A composite structure having a variable gage. The composite structure includes a first segment having a first gage and a second segment having a second gage, which is less than the first gage. The composite structure also includes a transition segment between the first segment and the second segment. The transition segment includes 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. The plurality of plies include (a) a plurality of continuous plies, wherein each continuous ply extends from the first end to the second end, and (b) at least one drop-off ply, 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. Each drop-off ply is sandwiched between and abuts against a respective two continuous plies of the plurality of continuous plies.

Clause 61: A composite structure having a variable gage including a first end having a first gage, and a second end having a second gage, which is less than the first gage. The composite structure also includes 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. The plurality of plies include a plurality of continuous plies and a plurality of drop-off plies. Each continuous ply extends from the first end to the second end. Each drop-off ply includes a tip having a blunt-end shape. 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 subset of the plurality of drop-off plies are between the first outer surface and a central portion of the stack, and a second subset of the plurality of drop-off plies are between the central portion and the second outer surface. The tips of the plurality of drop-off plies are arranged in a monotonically-inward pattern including: (i) in a first order of the first subset of the plurality of drop-off plies from the first outer surface toward the central portion, with each successive drop-off ply in the first order, a relative distance between the tip of the drop-off ply and the second end decreases, and (ii) in a second order of the second subset of the plurality of drop-off plies from the second outer surface toward the central portion, with each successive drop-off ply in the second order, a relative distance between the tip of the drop-off ply and the second end decreases.

Clause 62: The composite structure of Clause 61, wherein the plurality of drop-off plies are separated from each other by at least one of the plurality of continuous plies.

Clause 63: The composite structure of any one of Clauses 61-62, 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.

Clause 64: The composite structure of any one of Clauses 61-63, wherein the central portion consists of at least one continuous ply of the plurality of continuous plies.

Clause 65: The composite structure of any one of Clauses 61-64, wherein the respective positions of the tips of the plurality of drop-off plies are staggered from the first end to the second end.

Clause 66: The composite structure of Clauses 61-65, wherein the monotonically-inward pattern further includes, along a direction from the first end to the second end, the tips of the first subset of the plurality of drop-off plies alternating with the tips of the second subset of the plurality of drop-off plies.

Clause 67: The composite structure of any one of Clauses 61-66, wherein the plurality of drop-off plies are arranged in a plurality of pairs of drop-off plies. Each pair of drop-off plies includes a respective one drop-off ply of the first subset and a respective one drop-off ply of the second subset. For each pair of drop-off plies, the respective one drop-off ply of the first subset and the respective one drop-off ply of the second subset are substantially equidistant from the central portion in a dimension between the first outer surface and the second outer surface.

Clause 68: The composite structure of any one of Clauses 61-67, 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.

Clause 69: The composite structure of Clause 68, wherein, for each pair, the ply angle is approximately the same for the plurality of drop-off plies of the pair.

Clause 70: The composite structure of any one of Clauses 61-69, 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. 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.

Clause 71: The composite structure of any one of Clauses 61-70, 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.

Clause 72: A method of forming a composite structure having a variable gage including forming a plurality of continuous plies and forming a plurality of drop-off plies. Forming the plurality of drop-off plies includes forming, for each drop-off ply, a tip of the drop-off ply having a blunt-end shape. The method also includes positioning the plurality of continuous plies and the plurality of drop-off plies in a stack having (i) a first end, (ii) a second end, (iii) a first outer surface extending from the first end to the second end, and (iv) a second outer surface extending from the first end to the second end. The first end has a first gage and the second end has a second gage, which is less than the first gage. Positioning the plurality of continuous plies and the plurality of drop-off plies includes 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 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 subset of the plurality of drop-off plies are between the first outer surface and a central portion of the stack, and a second subset of the plurality of drop-off plies are between the central portion and the second outer surface. Positioning the plurality of continuous plies and the plurality of drop-off plies in the stack further includes arranging the plurality of drop-off plies in a monotonically-inward pattern including: (a) in a first order of the first subset of the plurality of drop-off plies from the first outer surface toward the central portion, with each successive drop-off ply in the first order, a relative distance between the tip of the drop-off ply and the second end decreases, and (b) in a second order of the second subset of the plurality of drop-off plies from the second outer surface toward the central portion, with each successive drop-off ply in the second order, a relative distance between the tip of the drop-off ply and the second end decreases.

Clause 73: The method of Clause 72, further including, 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.

Clause 74: The method of any one of Clauses 72-73, wherein positioning the plurality of continuous plies and the plurality of drop-off plies includes positioning the plurality of continuous plies and the plurality of drop-off plies such that the plurality of drop-off plies are separated from each other by at least one of the plurality of continuous plies.

Clause 75: The method of any one of Clauses 72-74, wherein the central portion consists of at least one continuous ply of the plurality of continuous plies.

Clause 76: The method of any one of Clauses 72-75, wherein positioning the plurality of drop-off plies includes positioning the plurality of drop-off plies such that the respective positions of the tips of the plurality of drop-off plies are staggered from the first end to the second end.

Clause 77: The method of any one of Clauses 72-76, wherein positioning the plurality of drop-off plies includes 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. 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.

Clause 78: The method of any one of Clauses 72-77, wherein positioning the plurality of drop-off plies includes 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.

Clause 79: A composite structure having a variable gage. The composite structure includes a first segment having a first gage and a second segment having a second gage, which is less than the first gage. The composite structure also includes a transition segment between the first segment and the second segment. The transition segment includes 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. The plurality of plies include a plurality of continuous plies and a plurality of drop-off plies. Each continuous ply extends from the first end to the second end. Each drop-off ply includes a tip having a blunt-end shape. 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 subset of the plurality of drop-off plies are between the first outer surface and a central portion of the stack and a second subset of the plurality of drop-off plies are between the central portion and the second outer surface. The tips of the plurality of drop-off plies are arranged in a monotonically-inward pattern comprising: (a) in a first order of the first subset of the plurality of drop-off plies from the first outer surface toward the central portion, with each successive drop-off ply in the first order, a relative distance between the tip of the drop-off ply and the second end decreases, and (b) in a second order of the second subset of the plurality of drop-off plies from the second outer surface toward the central portion, with each successive drop-off ply in the second order, a relative distance between the tip of the drop-off ply and the second end decreases.

Clause 80: The composite structure of Clause 79, wherein the first segment is a flange of a composite stringer and the second segment is a web of the composite stringer.

The description of the different advantageous arrangements has been presented for purposes of illustration and description, and is not intended to be exhaustive or limited to the examples in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. Further, different advantageous examples may describe different advantages as compared to other advantageous examples. The example or examples selected are chosen and described in order to explain the principles of the examples, the practical application, and to enable others of ordinary skill in the art to understand the disclosure for various examples with various modifications as are suited to the particular use contemplated.