A method and apparatus for forming a radius filler. A lattice is formed of connecting elongate members having a three-dimensional shape of the radius filler. A resin is placed within the lattice.

The present invention relates to a method of manufacturing a wind turbine rotor blade, to a wind turbine rotor blade obtainable by said method, to a pultrusion process for producing an elongated preform (97) for embedment in a wind turbine rotor blade and to an elongated preform (97) obtainable by said process. The blade manufacturing process involves a pultrusion process to obtain the preform (97), embedding the preform (97) within one or more parts of the blade, infusing a resin into said one or more blade parts containing the preform (97), and assembling the rotor blade including said one or more blade parts.

The present disclosure relates to a part made from composite material that includes a base and a T-shaped reinforcement. The T-shaped reinforcement includes a first L-shaped element having a first right-angled connection portion and a second L-shaped element having a second right-angled connection portion. The part further includes a plurality of needles, each connecting the base to the T-shaped reinforcement of the part, close to the connection portions and extending in multiple directions so as to oppose, in particular, the separation of the base from the T-shaped reinforcement.

Methods for manufacturing elongated structural elements are provided. Such methods provide composite material having optimal properties such as weight and strength which can be produced at much lower costs compared to conventional methods. Composite materials including such elements are also provided. In addition, commercial products incorporating such structural elements are provided.

A method for forming a composite structure includes the steps of: forming a fiber-reinforced polymer paste to a shape of a cavity of a dry fiber preform structure; heating said dry fiber preform structure having said fiber-reinforced polymer in said cavity to an infusion temperature; infusing resin into said dry fiber preform structure and around said fiber-reinforced polymer; and curing said resin-infused fiber preform structure and said fiber-reinforced polymer at a cure temperature higher than said infusion temperature.

A solid laminate stringer includes a base segment that forms a first generally trapezoidal cross section. The solid laminate stringer also includes a transition segment abutting the base segment, with concave sides that are continuous with the sides of the base segment. The solid laminate stringer also includes a top segment abutting the transition segment, where the top segment forms a second generally trapezoidal cross section with sides that are continuous with the concave sides of the transition segment. The solid laminate stringer also includes a first overwrap layer covering the top segment, the transition segment, and at least a portion of the base segment. The solid laminate stringer also includes a second overwrap layer overlapping at least a portion of the first overwrap layer covering the base segment.

A floor panel for installation in an aircraft includes a plurality of thermoplastic C-shaped stringers, a consolidated thermoplastic deltoid filler, a thermoplastic upper facing sheet, and a thermoplastic lower facing sheet. The stringers are disposed in a parallel arrangement with one another. The deltoid filler is disposed within a longitudinally-extending notch defined by a pair of adjacent stringers. The upper facing sheet covers an upper surface of the stringers and the deltoid filler. The lower facing sheet covers a lower surface of the stringers and the deltoid filler. The stringers, the deltoid filler, and the upper and lower facing sheets are integrally consolidated forming a unitary construction.

Composite components having a T or L-shaped configuration that include features that reduce void defects between abutting laminate portions and provide improved mechanical properties are provided. Methods for forming such components are also provided. In one exemplary aspect, a composite component defines a first direction and a second direction and includes a wedged-shaped noodle at a joint interface between an abutting first laminate portion extending along the first direction and a second laminate portion extending along the second direction. The noodle has a first surface that is angled with respect to the second direction. At least one of the plies of the second laminate portion terminate and attach to the angled first surface of the noodle.

A deformable, coated radius filler composed of a continuous or elongated fibrous structure and a tacky, resin surface coating formed by pulling a dry, continuous or elongated fibrous structure through a heated resin bath. The coated radius filler has an inner portion that is substantially free of resin and the resin surface coating has a substantially uniform thickness.

There is provided a conductive radius filler system and method. The system has a composite assembly with one or more composite structures having one or more radius filler regions. The system further has one or more conductive radius fillers filling the one or more radius filler regions. Each of the conductive radius fillers has a conductive element of electrically conductive material. The system further has one or more conductive radius filler connections connecting the conductive radius fillers to one of, a fastener system, a fuel tank system, and a current generating system, to form one or more current handling systems of the system. The one or more current handling systems provide one of, edge glow mitigation of edge glow as a secondary effect of lightning strikes, electrostatic discharge mitigation of electrostatic discharge caused by refueling electrification and fuel slosh, and current return handling to provide a minimized dedicated conductive system.