A method of manufacturing a noodle of a structural joint that comprises pulling a first composite sheet through a first splitting station to cut the first composite sheet into a plurality of first composite plies, pulling the plurality of first composite plies through a first alignment station to stack the plurality of first composite plies on top of each other to form a first stacked composite layup, pulling the first stacked composite layup through a first heating station to heat the first stacked composite layup to form a first heated composite layup, pulling the first heated composite layup through a first forming station to shape the first heated composite layup into a first pre-selected cross-sectional shape to form at least a first portion of a continuous noodle, and pulling at least the first portion of the continuous noodle through a cutting station to cut at least the first portion of the continuous noodle to a pre-selected length.

A method and apparatus for manufacturing a filler for a composite structure. The apparatus may comprise a filler. The filler may comprise a fiber matrix that is uniform in all directions. The fiber matrix may comprise a first plurality of discontinuous filaments and a second plurality of discontinuous filaments. Each filament of the first plurality of discontinuous filaments may be comprised of a stiffening material. Each filament of the second plurality of discontinuous filaments may be comprised of a binding material. Discontinuous filaments of both the first plurality of discontinuous filaments and the second plurality of discontinuous filaments may be randomly oriented and entangled with each other.

A method and apparatus is presented. A layer of composite material is laid up on a forming tool. A bend is formed in the layer on the forming tool to form a bent layer. A laminate stack and the bent layer are assembled to form the composite filler.

This pultrusion material that is a composite material member comprises: a plurality of fiber sheets that extend along a lengthwise direction; and a gap material that is provided to a gap formed by the plurality of fiber sheets, wherein the gap material has a gap fiber sheet including reinforcement fibers that are oriented in a different fiber direction than the lengthwise direction, and has gap reinforcement fibers that are oriented in the same fiber direction as the lengthwise direction. Additionally, the gap reinforcement fibers are provided evenly distributed in a cross-section of the gap material, said cross-section being perpendicular to the lengthwise direction.

This structure is provided with a first composite material 11, a second composite material 12 joined to the first composite material 11 by a film adhesive 21 provided between the first composite material 11 and the second composite material 12, and a corner fillet part 13 provided on a corner part 15 formed by the first composite material 11 and the second composite material 12. The shape of the corner fillet part 13 is a design shape P designed in advance, and the corner fillet part 13 is formed by curing the film adhesive 21 after arranging the film adhesive 21 on the corner part 15 so as to fit into the design shape P.

Systems and methods for forming radius fillers for composite structures are disclosed herein. The systems include a sheet-locating structure that has a support surface and a support surface edge. The systems further include a separation device, a conveyance structure, and a layup surface. The methods include locating a sheet of composite material on a first support surface and translating the sheet of composite material such that a first portion of the sheet is supported by the first support surface and a second portion of the sheet extends past the support surface edge. The methods also include separating the second portion of the sheet from the first portion of the sheet to form a strip of composite material. The methods further include conveying the strip of composite material onto a layup surface and repeating the methods to form the radius filler from a plurality of strips of composite material.

A composite structure includes a first composite material, a second composite material bonded to the first composite material, and a corner fillet part provided at a corner part formed by the first composite material and the second composite material. In the composite structure, the rigidity of the corner fillet part is adjustable, and a pull-off stress to be applied to the corner part is adjusted by adjusting the rigidity of the corner fillet part. The pull-off stress to be applied to the corner part is adjusted to be decreased by adjusting the rigidity of the corner fillet part to be decreased.

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 over-arching systems connected to the one or more conductive radius fillers, via one or more conductive radius filler connections, forming one or more current handling systems of the system. The one or more current handling systems include one or more of an edge glow handling system configured to handle edge glow, a static dissipation handling system configured to handle static dissipation, and a current return handling system configured to handle current return.

A filler preform in a wedge form includes reinforcing fiber bundles consisting of reinforcing fiber filaments, wherein the filaments are directed parallel to each other within the fiber bundle, wherein the fiber bundle contains a first resin composition in a concentration in the range from 1 to 10 wt. % relative to the fiber weight, wherein the fiber bundles have a length in the range from 2 to 20 mm and at least 60% of the fiber bundles are reversibly fixed in a curved form within the wedge filler preform whereby flanks of the curved fiber bundles create an opening angle of less than 120° and the opening angle of the curved fiber bundles relates with an opening angle of the wedge form of the wedge filler preform. A method for producing the wedge filler preform and a method for producing a reinforcing fiber composite include a filler perform.

A braided radius filler, including at least three carbon yarns wherein at least one carbon yarn is a continuous carbon filament yarn and at least two carbon yarns are braided together with each other, wherein at least one continuous carbon filament yarn contains a resin composition in a concentration in the range from 1 to 10 wt. % relative to the fiber weight of the continuous carbon filament yarn and the total amount of resin in the radius filler is less than 10 wt. % relative to the total fiber weight of the radius filler and the braided radius filler is braided according a formula. A further object pertains to a method for producing the radius filler and a composite comprising the radius filler.