GB2588603A

GB2588603A - Noodle

Info

Publication number: GB2588603A
Application number: GB1915574.6A
Authority: GB
Inventors: Nicholas Parkes Philip; Queeney Laurence; Norman Woolcock John; Mcmahon Andrew
Original assignee: Airbus Operations Ltd
Current assignee: Airbus Operations Ltd
Priority date: 2019-10-28
Filing date: 2019-10-28
Publication date: 2021-05-05
Also published as: GB201915574D0; WO2021083699A1

Abstract

A noodle 20 for filling a void in a composite assembly comprises pins 28 on at least one surface. The noodle may be of unitary construction or comprise a pin carrier plate (52, fig 5; 72, fig 6) having pins and a noodle body. The pin carrier plate may comprise a recess for receiving the noodle body and/or a mesh region; the noodle body may comprise holes through which the pins pass. A T-shaped joint assembly is provided wherein a linear cavity runs along between first and second L-shaped members and base layer with a noodle occupying the cavity, wherein the noodle comprises pins which penetrate into at least one of the base layers and L-shaped members. A method of assembling a T-shaped assembly comprises pressing a web part of two L-shaped members together; inserting a noodle having pins into a gap between the members; placing a base layer on top of the flange parts of the L-shaped members and the noodle and curing the assembly. A pin carrier plate for use with a noodle body in a composite assembly comprising reinforcing pins on top and bottom for insertion into the composite assembly. The pins on the surface of the noodle enhance the connection between the parts and strengthen the assembly. Such an assembly may be suitable for introducing out-of-plane loads to a composite panel for use as a rib or stiffener in an aircraft skin section. The plate or noodle may be formed of Titanium and obtained by additive manufacturing.

Description

NOODLE

TECHNICAL FIELD

[0001] The present invention relates to noodles for filling voids in composite assemblies, as well as pin carrier plates for use in such noodles and methods for assembling composite assemblies.

BACKGROUND

[0002] Aircraft structures are increasingly made using composite materials due to the high strength and low weight offered by such materials. With reference to Figure la, one such use in fixed wing aircraft 2 is in the wings 4. One disadvantage of composite materials is their anisotropy. In particular composite materials tend to be strong within the plane of their reinforcement, but weak in out-of-plane directions. Accordingly, large composite panels, such as those used in the skin of the wings or fuselage, may require reinforcement to provide appropriate rigidity.

[0003] Figure lb shows the inner surface of such a composite panel 6, such as might be used on the wings. One reinforcement approach is to provide a plurality of stringers 8 formed integrally with the panel 6 to increase its stiffness. A further reinforcement approach is to provide one or more ribs, 10, perpendicular to and larger than the stringers. The rib 10 provides an appropriate place to secure other aircraft components to the panel 6. Similar features may be found on the internal surface of curved panels, such as the skin of the fuselage of the aircraft.

[0004] Since the rib 10 may be secured to other components of the aircraft, it can introduce significant out-of-plane loads to the composite panel 6. Accordingly, the rib 10 is secured to the panel 6 via fasteners such as bolts rather than being integrally formed with panel 6.

[0005] With reference to Figure 2, a prior art T-shaped composite assembly 10 is shown in schematic cross section. The T-shaped composite assembly 10 comprises three pieces of composite material: a base layer 12, a first L-shaped member 14 and second L-shaped member 16. Typical composite materials used in such structures are one or more sheets of woven carbon-fibre reinforcement with a resin matrix. The woven carbon-fibre reinforcement sheet( s) impose a minimum radius on curves that may be adopted by the material. Accordingly, there is a cavity where the L-shaped members 14, 16 meet created by the local curvature of the members. This cavity is filled with a -noodle" 18 (also known as a -radius filler") to avoid air gaps in the composite structure.

[0006] The noodle 18 may be formed of a plastic material or be formed of a composite material itself The noodle 18 may serve to help form the curves in the L-shaped members 14, 16 but remains in place in the finished composite component. In the case of a composite assembly made using pre-impregnated (prepreg) carbon fibre sheets with resin already included the finishing is achieved by simply curing the resulting assembly. In the case of a composite assembly with reinforcement sheets or tape not pre-impregnated with resin, the resin will be infused throughout the assembly before it can be cured.

[0007] Such a T-shaped composite assembly is not a suitable integrally formed rib since it is not suitable for introducing significant loads to a panel. Any significant out-of-plane load or twisting moment would lead to delamination of the assembly at the base of noodle 18 or between base layer 12 and one or both of the L-shaped members 14, 16. Accordingly ribs in aircraft, even when formed from composite materials, are separately made to the panel they are to be fitted to and then secured by fasteners.

[0008] It would be desirable to provide a T-shaped composite assembly that is suitable for introducing significant out-of-plane loads to a panel and could be used as an integrally formed rib.

[0009] W02011131995A1 describes a type of composite joint known as "Hybrid Penetrative Reinforcement joint" (HYPER joint) which enhances the bond between metal and CFRP components by the use of pins or spikes on the metal part to penetrate and become embedded in the matrix of the CFRP component.

SUMMARY

[0010] A first aspect of the present disclosure provides an elongate noodle for filling a linear cavity in a composite assembly, the noodle having a generally triangular cross-section compiising a base and first and second concave faces, the noodle further comprising pins on at least one of the base, first concave face and second concave face.

[0011] Such a noodle can be used in a T-shaped assembly that is integrally formed with a wider panel that is suitable for introducing out-of-plane loads into the panel as the pins on the noodle can reinforce the connection between the different parts of the assembly. The pins may penetrate one of the parts, increasing the bond between the noodle and that part and reduce the chance of delamination under load in that area. The concave faces can help to define the shapes of the surrounding parts in a manner similar to tooling used for forming parts and also by achieving a snug fit the contact and bonding between the noodle and parts is improved (and the amount of resin that is used to bond the noodle to the parts is reduced by avoiding any gaps).

[0012] Preferably, the noodle comprises a first. row of pins along an edge of the first.

concave face; a second row of pins along an edge of the second concave face; and a third and fourth rows of pins respectively along each outer edge of the base. By having pins on each face each part of a T-shaped assembly will be penetrated by the pins and the bond between every part. of the assembly is improved. Furthermore the forces will typically be concentrated at the edges of the noodle and therefore this is an ideal place to locate the pins. The pins on the two concave faces would ideally be parallel for easy installation and may point in the same direction or opposite directions.

[0013] Alternatively, the noodle may comprise a pin carrier plate having a base and a top, at least one of base and the top having protruding pins; and a noodle body, complementary to the pin carrier plate, for filling the linear cavity in the composite assembly in combination with the pin carrier plate. Such a noodle construction reduces the size of the part that has pins. This may reduce the weight of the noodle or simplify its manufacture. A noodle body may be formed of a more flexible material than the pin carrier plate and make its insertion into a cavity easier. For example, for a T-shaped assembly that traverses an uneven surface, a single flexible noodle body could he used in the cavity that follows the contours of the surface, supplemented by a series of straight pin carrier plates on appropriately flat sections of the assembly.

[0014] Preferably, the pin carrier plate comprises a mesh region. This can further reduce the weight of the assembly and by increasing the surface area of the pin carrier plate its bond to the assembly may be improved.

[0015] Optionally, the pin carrier plate has pins on the top and the noodle body comprises gaps through which the pins pass and project beyond the edge of the noodle body. This eases inserting the pin carrier plate into the assembly since the pins do not need to penetrate the noodle body.

[0016] Alternatively, the pin carrier plate comprises a recess on the top in which the noodle body is received. This allows the pin carrier plate and noodle body to cooperate to form the sides of the overall noodle.

[0017] A further aspect of the present disclosure provides a noodle body as described above. Such a noodle body may be used with a variety of different pin carrier plates.

[0018] A further aspect of the present disclosure provides a T-shaped assembly comprising a base layer and first and second L-shaped members, coupled to the base layer and to each other to form the T-shaped assembly; a linear cavity that runs along the T-shaped assembly between the L-shaped members and base layer; and a noodle occupying the cavity, the noodle comprising pins which penetrate into at least one of the base layer and first and second L-shaped members. Such a T-shaped assembly is reinforced by the pins and can handle increased loads before delam 'nation compared to a T-shaped assembly which does not have a noodle comprising pins.

[0019] A further aspect of the present disclosure provides a method of assembling a T-shaped assembly, the assembly having a web and a flange, comprising: providing first and second L-shapcd members, each L-shaped member having a flange part and a web part, the flange part and web part being at right angles to each other and connected by a curved part; pressing the web part of the first and second L-shaped members together to form the web of the assembly and a gap between the curved parts; inserting a noodle having pins into the gap between the curved parts, providing a base layer and placing it on top of the flange parts of the L-shaped members and the noodle; mid curing the resulting T-shaped assembly.

[0020] Such a method provides a T-shaped assembly which is reinforced by the pins on the noodle and is therefore more resistant to delamination. The curing step may involve first introducing a resin if resin infusion is to be used, and in that or the prepreg case activates the resin present and binds the assembly together.

[0021] Preferably, the step of inserting Further comprises pressing die noodle into the web so the pins penetrate at least one of the L-shaped members. This provides a simple way to aid penetration of the pins. hi the event that the base of the noodle also features pins, pressing may be achieved via a block that fits on the noodle with cut outs for the pins that are present.

[0022] Preferably, the method further comprises pressing the base layer and the web together to aid penetration of pins on the noodle into at least one of the first L-shaped member, second L-shaped member and base layer. This aids penetration of all appropriately aligned pins in the assembly and the pressing may be achieved manually, with a press or by vacuum pressure.

[0023] Optionally, when the noodle comprises a noodle body and pin carrier plate, the step of inserting the noodle comprising first inserting the noodle body and debulking the resulting assembly before inserting the pin carrier plate. By debulking the assembly of the noodle body with the L-shaped members the noodle body will be firmly pressed into the gap between the L-shaped members which helps avoid any gaps in the assembly. Furthermore it ensures that any pins on the pin carrier plate appropriately oriented can optimally penetrate the L-shaped members when the pin carrier plate is introduced.

[0024] A further aspect of the present disclosure provides a pin carrier plate for use with a noodle body in a composite assembly, the pin carrier plate having a top and a bottom and comprising reinforcing pins for insertion into the composite assembly on both the top and bottom. Such a pin carrier plate may be formed of titanium or any other appropriate material that can form sufficiently strong pins. Titanium has the advantage of needing no further processing to avoid corrosion when used with carbon fibre composite materials.

[0025] A further aspect of the present disclosure provides a noodle for use in a composite assembly, the composite assembly having at least two composite members, at least one of the composite members being curved such that there is a cavity between the members, the noodle being shaped to occupy the cavity; the noodle comprises pins on its surface for penetrating a least one or the composite members.

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Embodiments of the invent-ion will now be described, by way of example only, with reference to the accompanying drawings, in which: [0027] Figure la is perspective view of an aircraft. according to the prior art; [0028] Figure lb is a perspective view of an aircraft wing skin according to the prior art; [0029] Figure 2 is a schematic cross section of a composite rib according to the prior art; [0030] Figure 3a is a schematic cross section view of a noodle according to a first

embodiment of the present disclosure;

[0031] Figure 3b is a perspective view of a noodle according to the first embodiment of

the present disclosure;

[0032] Figures 4a-f are a sequence of schematic cross sections of a T-shaped composite assembly being assembled according to an embodiment of the present disclosure; [0033] Figure 5a is a dorsal perspective view of a two-part noodle according to a second

embodiment of the present disclosure;

[0034] Figure 5b is a ventral perspective view of a two-part noodle according to the

second embodiment of the present disclosure;

[0035] Figure Sc is a perspective view of a Pin Carrier Plate (PCP) according to the

second embodiment of the present disclosure;

[0036] Figure 5d is a ventral perspective view of a noodle body according to the second

embodiment of the present disclosure.

[0037] Figure 6a is a dorsal perspective view of a two-part noodle according to a third

embodiment of the present disclosure;

[0038] Figure 6b is a perspective view of a Pin Carrier Plate (PCP) according to the

third embodiment of the present disclosure;

[0039] Figure 6c is a dorsal perspective view of a noodle body according to the third

embodiment of the present disclosure; and

[0040] Figures 7a-d are a sequence of schematic cross sections of a T-shaped composite assembly being assembled according to another embodiment of the present disclosure

DETAILED DESCRIPTION

[0041] Figure 3a shows a schematic cross-section or a HYPER noodle 20 in accordance with a first embodiment of the present disclosure. The noodle 20 has a flat base 22 for placing on base layer 12, and first and second concave faces 24, 26 for interfacing with the curved parts of L-shaped members 14, 16. The noodle 20 has pins 28 in rows parallel to the length of the noodle. In this embodiment, the noodle 20 has three rows of pins 28 along the bottom of base 22-one row close to each edge and one row along the middle. The noodle of this embodiment further has one row of pins 28 at the lower edge of each concave face 24, 26 oriented perpendicular to the base 22.

[00421 The pins 28 allow the joint between the noodle 20 and the various parts of a T-shaped composite assembly 10 to be HYPER joints, strengthening the joint and improving the resilience of the bond between the various parts of the T-shaped composite assembly 10. In particular they create a direct mechanical linkage between the composite layers of the assembly 10 which substantially increases the strength of the joint. Various HYPER techniques can be used to further improve the strength of the bond such as using pins 28 of different lengths in combination with each other to vary penetration depth. These different lengths could be used alternately along the noodle 20 (so that the pins of different lengths are evenly spread along the noodle 20) or concentrated in areas subject to increased or reduced load forces. A further HYPER technique suitable for use with the noodle 20 is using pins with a flared tip for better pin retention. The pins could have a round or non-round cross section.

[00431 Alternative pin arrangements may also be suitable for different applications, with pins 28 being in rows perpendicular to the long axis of the noodle 20, for example, or evenly distributed across any of its surfaces. A random or pseudo-random pattern may be appropriate in some applications. Furthermore, it may not be necessary to have as many pins 28 depending on the desired characteristics of the bond, with pins 28 on some surfaces being removed for easier insertion of the noodle 20.

[0044] A further alternative pin arrangement would be to have pins 28 oriented in direction other than perpendicular to the base 22. This might be particularly appropriate on the concave faces 24, 26, where the pins 32 could be parallel to base 22 or at a 45° angle, for example. Although insertion of the pins might be more difficult the strength of the assemhly may he improved in different directions with differently angled pins which may be desirable. In the case of pins parallel to base 22 on the concave faces 24, 26 a row located along the upper edge of the concave faces 24, 26 (near the apex) might he particularly appropriate.

[0045] An approprthte way to make such a noodle 20 would be via additive manufacturing (also known as 3D printing). In particular, in order to realise a high strength of the part with a minimal risk of corrosion when combined with CFRP composite, Titanium would be a particularly suitable substance to form the part from, which is amenable to a variety of additive manufacturing techniques. . Alternatively, it may be possible to add the pins 28 to an already machined noodle via additive manufacturing.

[0046] Figure 3h shows a perspective view of a variant noodle 20 with only two rows of pins 28 on base layer 22. The pins have a circular cross-section, alternate in length and feature a flared tip for better retention within a composite member. Figure 3b makes clear that the noodle 20 has a significant volume. The noodle 20 could be solid all the way through. However, if the noodle is made using additive manufacturing the noodle 20 may not actually be solid as such, but feature internal cavities to reduce the weight and cost of the noodle 20. In that case internal struts or support may be used to increase the strength of the noodle 20. Such struts might he contiguous across the cross section of noodle 20.

[0047] T-shaped composite assemblies can be formed using a noodle according to any of the above embodiments in a straightforward way, the key issues being ensuring appropriate levels of penetration of the pins 28 into the composite substrate and accounting for the angle of the pins 28. With reference now to figures 4a-4d a simplified assembly method is shown for forming a T-shaped assembly using a noodle 20 with pins perpendicular to the base 22. In all such st.eps the sheets of material used could be any appropriate composite base material, either in the form of prepreg material or "dry" material if resin infusion is to he used later. The material could take the form of woven sheets, non-woven sheets, bonded randomly-oriented short fibres, uni-directional tape, braid, stitched, or any other appropriate composite reinforcement form. Appropriate reinforcement materials might be carbon fibre, glass fibre, carbon nanotubes, cellulose, high-strength polymer Fibre, metal wire or any other appropriate composite reinforcement material.

[0048] Figure 4a shows the formation of one of the L-shaped members 14, 16 by use of a complementary male and female mould 42, 44 which press a sheet into the correct shape. This could involve heat to help form the sheet and a de-bulking step. The L-shaped members 14, 16 may be left on the male mould 42 and then pressed together to form the web of the T-shaped assembly as shown in Figure 4b. Alternatively the L-shaped members 14, 16 may be transferred to another tool before assembly formation. In any case the moulds 42 form a cassette 46 around the T-shaped assembly that is to be assembled. Once the web has been formed Figure 4c shows the noodle 20 being introduced to the gap between the L-shaped members 14, 16 caused by their curvature. The noodle 20 may be inserted with or without additional heating and under simple finger pressure to embed the pins 28 into the L-shaped members 14, 16. Alternatively, to aid penetration of the pins into the L-shaped members 14, 16 the noodle 20 could be pressed in via a press.

[0049] With reference to Figure 4d the cassette 46 containing the L-shaped members 14, 16 and noodle 20 may then be incorporated into a larger tool 48 and then brought into contact with base layer 12. In the case of an aircraft wing skin base layer 12 may be very large and multiple such cassettes 16 could be held within the larger tool 48 for forming T-shaped assemblies on the aircraft wing skin. In any case the larger assembly can be co-cured or resin infused to create the final structural component.

[0050] With reference to figure 4e an alternative T-shaped assembly forming step is shown using a noodle 20 with pins 28 parallel to the base 22 at the apex of the concave surfaces 24, 26. In this case the moulds 42 bearing the L-shaped assemblies 14, 16 are pressed together around the noodle 20 so that the pins can penetrate the sheets during the formation of the web of the T-shaped assembly. Again, heat or additional force may be used to aid penetration of the pins 28 into the L-shaped members 14, 16. The base layer 12 can then be added in the same way as shown in Figure 4d.

TWO-PART NOODLE

[0051] With reference to Figures 5a to 5d, a different noodle construction is shown according to a second embodiment of the present disclosure. In this embodiment, the noodle comprises two parts -a flat Pin Carrier Plate (PCP) 52 on the one part and noodle body 56 on the second part.

[0052] The PCP 52 has pins 54 for insertion into the composite components of the final assembly as before. The role of filling the cavity in this embodiment falls to the noodle body 56, which surrounds the PCP 52 and has concave faces 24, 26 for interfacing with the curved parts of the L-shaped members 14, 16 and in this way fulfils the usual role of a noodle. The noodle body 56 has holes 58 for receiving the pins 54 from the PCP 52 and allowing them to project through the concave faces 24, 26 for penetrating the L-shaped members 14, 16.

[0053] This two-part construction is particularly suitable for use with a PCP 52 formed from metal, such as Titanium, since the size of the metal part is reduced allowing a reduction in costs and also weight. Since the part is largely fiat the PCP 52 could be formed from stamped metal with the pins 54 being formed by bending protrusions along the edge of the PCP.

[0054] As shown in Figure Sc the PCP 52 may have a central mesh region 62 as well as two side rails 64 for supporting the pins 54. The mesh region 62 serves both to reduce the weight of the PCP 52 as well as improve the bond between the PCP 52, the noodle body 56 and the composite parts since the PCP 52 has a large surface area to better receive and adhere to the resin matrix of the composite assembly. Alternatively, the PCP 52 could be skeletonised, for example comprising a central spine with arms supporting each pin or an outer frame supporting the pins with only a few cross-members for rigidity.

[0055] The noodle body 56 may be formed of a soft plastics material such that the PCP 52 can simply be pressed into it. Alternatively a recess 60 for receiving the PCP 52 may be machined or moulded into the noodle body 56. The holes 58 for receiving the pins 54 can be obtained by pushing the pins 54 through a soft noodle body 46; by holes being drilled or moulded through the noodle body 56 or further alternatively though recesses along the edge of noodle body 56.

[0056] With reference to Figure 6a to 6e, a further alternative noodle 70 is shown.

Again, the noodle comprises a PCP 72 and noodle body 80. In this embodiment. PCP 72 again has a central region 74 having a mesh and pins 76 supported by side rails 78. The side rails 78 are raised above the level of the central region and form part of the concave surfaces 24, 26 of the noodle 70. The noodle body 80 is shaped to fit into the recess formed between the raised side rails 78 and thereby cooperate with the side rails 78 to form the rest of the concave surfaces 24, 26. As a result, no holes or recesses are needed in noodle body 80 to accept the pins 76. As shown most clearly in Figure 6c, the noodle body 80 may extend past an end of PCP 72 and therefore have an extended section 82 where the noodle body 80 forms the entirety of the concave surfaces 24, 26.

[0057] With reference to Figures 7a through 7d the assembly of a T-shaped assembly with a two-part noodle is shown. The web of the T-shaped assembly and cassette 46 are formed in the usual way as described above. Once the web has been formed Figure 7a shows the noodle body 56, 80 being introduced to the gap between the L-shaped members 14, 16 caused by their curvature. The noodle body 56, 80 does not need to be pressed in with any particular force as it has no pins and is already of a complementary shape to the curvature of the L-shaped members 14, 16. The assembly is then de-bulked under vacuum as shown in Figure 7b using a vacuum bag 84 or similar.

[0058] With reference to Figure 7c the cassette 46 containing the L-shaped members 14, 16 and noodle body 56, 80 may be incorporated into a larger tool 48. This may be an appropriate time to add the PCP 52, 72 according to the above-described embodiments to the assembly. In order to help the pins 54, 76 penetrate the composite parts (and possibly the noodle body 56 if required) the PCP may be pressed down with finger pressure or a clamp. This pressure could be direct on the PCP or indirect (relayed by a block of material) to avoid damage to the pins 54.76 by whatever provides the pressure Again, heat may aid penetration of the pins 54, 76.

[00591 With reference to Figure 7d the larger tool 48 (or just the cassette 46) may then brought into contact with base layer 12. Again pressure or heat may be used to help the pins 54, 76 penetrate into base layer 12. The assembly as a whole may then he de-bulked under vacuum once more before curing.

WIDER COMPOSITE STRUCTURE

[00601 The T-shaped assembly described herein could be used to form a rib, stringer or other form of stiffener or load introduction point on an aircraft wing skin or other part of an aircraft structure. Each curved part, of that. T-shaped structure could be called a rib foot. or an L-shaped composite member.

[0061] Although the L-shaped members 14, 16 shown here have been separate objects to each other and to the base layer 12, at least some of them could in some applications be different parts of the same larger composite sheet that doubles back on itself. Furthermore where there are two adjacent T-shaped assemblies the same sheet of composite material may be a first L-shaped member 14 on one T-shaped assembly and the second L-shaped member 16 on an adjacent T-shaped assembly.

[0062] Although base layer 12 and the base of the noodle is generally described as -flat" this surface and interface may be non-flat in many applications; for example on the skin of an aircraft wing which is gently curved. In more extreme cases the T-shaped assembly may traverse a discrete bend in the base layer 12 and the noodle may bent to match, either by being pre-formed or bent around the base layer 12.

[00631 Noodles according to this disclosure can also be used to fill voids in surface features desired on one side of an otherwise flat composite sheet. For example, a ridge may be created on one side of a composite sheet by inserting a noodle having a flat base between the composite reinforcement layers. Such a noodle could have a single convex outer side, or any other appropriate shape. Pins may still be useful in such a case to improve the resilience of the composite feature, especially if the feature is used to introduce load to the composite sheet. Furthermore noodles according to this disclosure could be useful in composite assemblies without a flat base e.g. a Y-shaped assembly to be positioned along the length of a corner in a composite part with an adjusted noodle shape to suit.

[0064] In some embodiments, one or more parts of the T-shaped assembly may not comprise a composite material, hut instead a simple material such as plastics or metal. In such cases pins may be present on only some parts of the noodle, since (for example) they are not suited for insertion into many metals.

[0065] Although the invention has been described above with reference to one or more preferred examples or embodiments, it will be appreciated that various changes or modifications may be made without departing from the scope of the invention as defined in the appended claims.

[0066] Although the invention has been described above mainly in the context of a fixed-wing aircraft application, it may also be advantageously applied to various other applications, including but not limited to applications on vehicles such as helicopters, drones, trains, automobiles and spacecraft.

[0067] Where the term 'or" has been used in the preceding description, this term should he understood to mean "and/or", except where explicitly stated otherwise.

Claims

CLAIMS: 1. An elongate noodle for filling a linear cavity in a composite assembly, the noodle having a generally triangular cross-section comprising a base and first and second concave faces; CHARACTERISED IN THAT the noodle comprises pins on at least one of the base, first concave face and second concave face.
2. A noodle according to claim 1, comprising: a first row of pins along Int edge of the first concave face; a second row of pins along an edge of the second concave face; and a third and fourth rows of pins respectively along each outer edge of the base.
3. A noodle according to claim 1, comprising: a pin carrier plate having a base and a top, at least one of base and the top having protruding pins; and a noodle body, complementary to the pin carrier plate, for filling the linear cavity in the composite assembly in combination with the pin carrier plate.
4. A noodle according to claim 3, wherein the pin carrier plate comprises a mesh region.
5. A noodle according to claim 3 or 4, wherein the pin carrier plate has pins on the top and the noodle body comprises gaps through which the pins pass and project beyond the edge of the noodle body.
6. A noodle according to claim 3 or 4, wherein the pin carrier plate comprises a recess on the top in which the noodle body is received.
7. A noodle body as described in any one of claims 3 to 6.
8. A T-shaped assembly comprising: a base layer and first and second L-shaped members, coupled to the base layer and to each other to form the T-shaped assembly; a linear cavity that runs along the T-shaped assembly between the L-shaped members and base layer; and a noodle occupying the cavity, the noodle comprising pins which penetrate into at least one of the base layer and first and second L-shaped members.
9. A method of assembling a T-shaped assembly, the assembly having a web and a flange, comprising: providing first and second L-shaped members, each L-shaped member having a flange part and a web part, the flange part and web part being at right angles to each other and connected by a curved part; pressing the web part of the first and second L-shaped members together to form the web of the assembly and a gap between the curved parts; inserting a noodle having pins into the gap between the curved parts, providing a base layer and placing it on top of the flange parts of the L-shaped members and the noodle; and curing the resulting T-shaped assembly.
10. A method according to claim 9 wherein the step of inserting further comprises pressing the noodle into the web so the pins penetrate at least one of the L-shaped members.
11. A method according to claim 9 or 10 further comprising pressing the base layer and the web together to aid penetration of pins on the noodle into at least. one of the first L-shaped member, second L-shaped member and base layer.
12. A method according to any one of claims 9 to 11 wherein the noodle comprises a noodle body and pin carrier plate, the step of inserting the noodle comprising first inserting the noodle body and deb ulking the resulting assembly before inserting the pin carrier plate.
13. A pin carrier plate for use with a noodle body in a composite assembly, the pin carrier plate having a t.op and a bottom and comprising reinforcing pins for insertion into the composite assembly on both the top and bottom.
14. A noodle for use in a composite assembly, the composite assembly having at least two composite members, at least one of the composite members being curved such that there is a cavity between the members, the noodle being shaped to occupy the cavity; CHARACTERISED IN THAT the noodle comprises pins on its surface for penetrating at least one of the composite members.