Composite Hollow Body Ply Staggering to Prevent Curing Wrinkles

The patent applies asymmetry by deliberately misaligning course edges between adjacent ply layers in a controlled staggered pattern. Instead of symmetric alignment that causes wrapping, the course edges are offset by specific distances in different directions, creating an asymmetric distribution that eliminates the wrapping phenomenon while maintaining manufacturing feasibility through computer-controlled positioning.

The patent transitions from one-dimensional alignment (edges directly above each other) to two-dimensional staggered positioning by introducing offset distances in both radial and circumferential directions. This dimensional change allows course edges to be distributed across different spatial positions between ply layers, preventing the concentration of stress that causes wrapping while preserving ease of manufacture.

The patent implements preliminary action by calculating and determining the optimal staggered positioning of course edges between ply layers before the actual manufacturing process begins. The computer system pre-computes the offset distances and positions based on the desired surface smoothness requirements, then guides the manufacturing equipment to place courses at these predetermined locations, thereby achieving high precision without real-time complexity.

The patent uses copying by creating a digital model or pattern of the desired staggered course edge distribution. Once the optimal staggered arrangement is calculated for one ply layer, this pattern can be replicated and adapted for subsequent ply layers, maintaining consistency and surface smoothness while reducing the computational complexity required for each individual layer placement.