Splices comprising honeycomb cores supported by tie clips and methods of forming thereof

Provided are splices (200) comprising honeycomb cores (210, 220) and adhesive layers (230) with tie clips (250) supporting the honeycomb cores (210, 220). Also provided are methods (100) of forming such splices (200). Each tie clip (250) includes two legs (251, 252) and abridging portion (253) joining the legs (251, 252). When forming a splice (200), an adhesive layer (230) is positioned between two honeycomb cores (210, 220). One leg (251) of the tie clip (250) is inserted into the full cell (212) of one honeycomb core (210), while the other leg (252) is inserted into the full cell (222) of the other honeycomb core (220). The bridging portion (253) extends across the adhesive layer (230). While curing (150) the adhesive layer (230), the tie clip (250) supports the honeycomb cores (210, 220) with respect to each other and maintains their orientation. The tie clip (250) becomes a part of the splice (200). The tie clip (250) may be buried in the honeycomb cores (210, 230) without extending above the first face of the splice (200). Il IC. Apply Adhesive Layer between Two Honeycomb Cores 1_1_0 Form Tie Clips 119 Insert First Plurality of Tie Clips into Splice 120 Bridge Full Cells ofTwolHoneycomb Cores 122 Insert First Leg of Tie Clip into Full Cell of First Honeycomb Core 123 Insert Second Leg of Tie Clip into Full Cell of Second Honeycomb Core124 Position Top Edges of Tie Clips At or Below Top Surface of First Honeycomb Core 125 Protrude Bridging Portion into Adhesive Layer and Walls of Honeycomb Cores i ~Align Tie Clips 127 Distribute Tie Clips 128 Insert Second Plurality of Tie Clips into Splice 130 Form Face Sheet 139 Position FaceS heet over Splice 140 Cure Adhesive Layer 150 Heat Splice 152 Pressurize Splice154 Shape Splice 156 Maintain SetDistance between TwoHoneycomb Cores160 Adhere Tie Clips to Adhesive Layer162 Contact Walls of FullCells with Legs of Tie Clips 164 Done FIG. 1 x x 211 il I 4 A 212 223 222A 213 214 224 230 250b x A-A 250 215 212 251 253 252 222 264 Z 210 213 223 220 230