# US 2019/0168497 A1 · Splices comprising honeycomb cores supported by tie clips and methods of forming thereof

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- Number: US 2019/0168497 A1
- Document ID: US20190168497A1
- Status: Published application
- Kind: A1
- Application number: 16/267,305
- Filed: 2019-02-04
- Published: 2019-06-06
- Earliest claimed: 2017-01-18
- Assignees: The Boeing Company
- Applicants: The Boeing Company
- Inventors: Evan F. Pierce; Mikel D. Marty; Francis W. Moore; Roger A. Bown; Megan E. Bliss
- Web page: https://patentgrep.com/patent/US20190168497A1

## CPC

- B32B 37/146: {whereby one or more of the layers is a honeycomb structure}
- B29C 65/48: using adhesives {, i.e. using supplementary joining material; solvent bonding}
- B29C 65/562: {using extra joining elements, i.e. which are not integral with the parts to be joined (using plastic snap elements B29C65/58; using plastic rivets B29C65/601)}
- B29D 99/0089: {Producing honeycomb structures (consisting of porous ceramic ware C04B38/0006)}
- B32B 3/12: characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 37/12: characterised by using adhesives
- F16B 5/0064: {and using C-shaped clamps}
- F16B 11/006: {by gluing (gluing of plastics material B29C65/48)}
- B29L 2031/608: {Honeycomb structures}
- B32B 2305/72: Cured, e.g. vulcanised, cross-linked
- B32B 2605/18: Aircraft
- B64F 5/40: Maintaining or repairing aircraft
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00)
- F16B: DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING (couplings for transmitting rotation F16D)
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B64F: GROUND OR AIRCRAFT-CARRIER-DECK INSTALLATIONS SPECIALLY ADAPTED FOR USE IN CONNECTION WITH AIRCRAFT; DESIGNING, MANUFACTURING, ASSEMBLING, CLEANING, MAINTAINING OR REPAIRING AIRCRAFT, NOT OTHERWISE PROVIDED FOR; HANDLING, TRANSPORTING, TESTING OR INSPECTING AIRCRAFT COMPONENTS, NOT OTHERWISE PROVIDED FOR

## Abstract

Provided are splices, comprising honeycomb cores and adhesive layers with tie clips supporting the honeycomb cores. Also provided are methods of forming such splices. Each tie clip includes two legs and a bridging portion joining the legs. When forming a splice, an adhesive layer is positioned between two honeycomb cores. One leg of the tie clip is inserted into the full cell of one honeycomb core, while the other leg is inserted into the full cell of the other honeycomb core. The bridging portion extends across the adhesive layer. While curing the adhesive layer, the tie clip supports the honeycomb cores with respect to each other and maintains their orientation. The tie clip becomes a part of the splice. The tie clip may be buried in the honeycomb cores without extending above the first face of the splice.

## Claims

### Claim 1

A splice comprising:
a first honeycomb core, comprising a first face;
a second honeycomb core; and
a first tie clip, comprising:
a first leg inserted into the first honeycomb core,
a second leg inserted into the second honeycomb core, and
a bridging portion, connecting the first leg and the second leg.

### Claim 2 (depends on 1)

The splice of claim 1, further comprising an adhesive layer, disposed between and directly interfacing the first honeycomb core and the second honeycomb core.

### Claim 3 (depends on 2)

The splice of claim 2, wherein the bridging portion of each of the first tie clip protrudes through the adhesive layer.

### Claim 4 (depends on 1)

The splice of claim 1, wherein the bridging portion comprises a top edge, the top edge being flush with the first face of the first honeycomb core.

### Claim 5 (depends on 1)

The splice of claim 1, wherein the bridging portion protrudes through a cell wall of the first honeycomb core.

### Claim 6 (depends on 1)

The splice of claim 1, wherein the splice is an aircraft structure.

### Claim 7

A sandwich panel splice comprising:
a first honeycomb core, comprising a full cell, having a wall;
a second honeycomb core, having a full cell, having a wall; and
a first tie clip, comprising a first leg, a second leg, and a bridging portion,
the first leg being inserted into the full cell of the first honeycomb core and adjacent to the wall of the full cell of the first honeycomb core,
the second leg being inserted into the full cell of the second honeycomb core and adjacent to the wall of the full cell of the second honeycomb core, and
the bridging portion attaching the first leg and the second leg across a gap between the full cell of the first honeycomb core and the full cell of the second honeycomb core.

### Claim 8 (depends on 7)

The sandwich panel splice of claim 7, wherein the first leg contacts the wall of the full cell of the first honeycomb core.

### Claim 9 (depends on 7)

The sandwich panel splice of claim 7, wherein the second leg contacts the wall of the full cell of the second honeycomb core.

### Claim 10 (depends on 7)

The sandwich panel splice of claim 7, wherein the bridging portion protrudes through the wall of the full cell of the first honeycomb and the wall of the full cell of the second honeycomb.

### Claim 11

A method of forming a splice, the method comprising:
placing a first leg of a tie clip into a full cell of a first honeycomb core;
placing a second leg of a tie clip into a full cell of a second honeycomb core, different from the first honeycomb core; and
bridging between the first leg and the second leg.

### Claim 12 (depends on 11)

The method of claim 11, wherein bridging between the first leg and the second leg comprises bridging across a gap between the first honeycomb core and the second honeycomb core using a bridging portion of the tie clip connected to each of the first leg and the second leg.

### Claim 13 (depends on 12)

The method of claim 12, further comprising protruding the bridging portion into an adhesive layer disposed between the first honeycomb core and the second honeycomb core.

### Claim 14 (depends on 12)

The method of claim 12, further comprising protruding the bridging portion into a wall of the full cell of a first honeycomb core and a wall of the full cell of a second honeycomb core thereby making a top edge of the bridging portion flush with a first surface of the first honeycomb core.

### Claim 15 (depends on 11)

The method of claim 11, further comprising positioning a face sheet over the first honeycomb core and the second honeycomb core.

### Claim 16 (depends on 15)

The method of claim 15, wherein the face sheet directly interfaces each of the first honeycomb core and the second honeycomb core.

### Claim 17 (depends on 15)

The method of claim 15, further comprising positioning an additional face sheet over the first honeycomb core and the second honeycomb core, such that the first honeycomb core and the second honeycomb core are positioned between the face sheet and the additional face sheet.

### Claim 18 (depends on 11)

The method of claim 11, further comprising, after bridging, changing shape of the splice.

### Claim 19 (depends on 11)

The method of claim 11, further comprising contacting a wall of the full cell of the first honeycomb core with the first leg of the tie clip while placing the first leg of the tie clip into the full cell of the first honeycomb core.

### Claim 20 (depends on 11)

The method of claim 11, further comprising contacting a wall of the full cell of the second honeycomb core with the second leg of the tie clip while placing the second leg of the tie clip into the full cell of the second honeycomb core.