Patent ID: 9662841
Date: 2017-05-30
CPC Classifications: B29C,B64C,Y02T,Y10T

Claim:
1. A composite structure produced by an at least partially automated layup process, the composite structure comprising: a cylindrical portion extending in an axial direction around a centerline; at least one flange portion exhibiting a substantially elliptical shape, the at least one flange portion extending and positioned radially outward from one side portion of the cylindrical portion in a direction along an axis substantially perpendicular to the centerline of the cylindrical portion, the cylindrical portion having a different geometry than the at least one flange portion; and at least one continuous ply layer comprising a plurality of flags each comprising fibers and a matrix material, the plurality of flags each being positioned adjacent another flag of the plurality of flags to define the at least one continuous ply layer having the fibers oriented at an angle offset from an edge of the at least one continuous ply layer, wherein the fibers of each flag of the plurality of flags of the at least one continuous ply layer are oriented at the same angle, the fibers of the at least one continuous ply layer being substantially evenly placed relative to adjacent fibers along a length of the fibers on the cylindrical portion, the at least one continuous ply layer extending continuously from the cylindrical portion, over an interface between the cylindrical portion and the at least one flange portion, and along the at least one flange portion.