System and method for securely connecting portions of a composite structure together

Abstract

A composite component assembly may include a composite core including a plurality of core cells between first and second ends. A connection joint is formed between the first and second ends. An adhesive layer is disposed within the connection joint between the first and second ends. The adhesive layer is configured to bond the first and second ends through a curing process. A peg splice securing joint securely connects the first and second ends together before and during the curing process.

What is claimed is: 
     
         1 . A method of forming a composite component assembly, comprising:
 disposing an adhesive layer within a connection joint between first and second ends of a composite core having a plurality of core cells;   securely connecting the first and second ends together with a peg splice securing joint; and   curing the composite component assembly, wherein the securely connecting securely fastens and stabilizes the first and second ends together before and during the curing process, and wherein the curing causes the adhesive layer to securely bond the first and second ends together.   
     
     
         2 . The method of  claim 1 , further comprising laying-up the composite core having the plurality of core cells in relation to a mandrel before the disposing. 
     
     
         3 . The method of  claim 1 , wherein the composite core has a first height, wherein the peg splice securing joint has a second height that is less than the first height. 
     
     
         4 . The method of  claim 1 , wherein the second height is less than 50% of the first height. 
     
     
         5 . The method of  claim 1 , wherein the securely connecting comprises urging the peg splice securing joint into outer surfaces of the first and second ends until an outer surface of the peg splice securing joint is flush with the outer surfaces of the first and second ends. 
     
     
         6 . The method of  claim 5 , wherein the securely connecting comprises spacing the adhesive layer apart from the peg splice securing joint. 
     
     
         7 . The method of  claim 1 , wherein the curing comprises causing the adhesive layer to adhere to portions of the first and second ends. 
     
     
         8 . The method of  claim 1 , wherein each of the plurality of core cells comprises a septum having acoustic properties. 
     
     
         9 . The method of  claim 8 , wherein the securely connecting comprises spacing the peg splice securing joint apart from the septum of each of the plurality of core cells. 
     
     
         10 . The method of  claim 1 , further comprising forming the composite core and the peg splice securing joint of the same material. 
     
     
         11 . A method of forming a composite component assembly, comprising:
 laying-up a composite core having a plurality of core cells in relation to a mandrel;   disposing an adhesive layer within a connection joint between first and second ends of the composite core; and   securely connecting the first and second ends together with a peg splice securing joint, wherein the securely connecting comprises urging the peg splice securing joint into outer surfaces of the first and second ends until an outer surface of the peg splice securing joint is flush with the outer surfaces of the first and second ends.   
     
     
         12 . The method of  claim 11 , further comprising curing the composite component assembly, wherein the securely connecting securely fastens and stabilizes the first and second ends together before and during the curing process, and wherein the curing causes the adhesive layer to securely bond the first and second ends together. 
     
     
         13 . The method of  claim 11 , wherein the composite core has a first height, wherein the peg splice securing joint has a second height that is less than the first height. 
     
     
         14 . The method of  claim 11 , wherein the second height is less than 50% of the first height. 
     
     
         15 . The method of  claim 11 , wherein the securely connecting comprises spacing the adhesive layer apart from the peg splice securing joint. 
     
     
         16 . The method of  claim 11 , wherein the curing operation comprises causing the adhesive layer to adhere to portions of the first and second ends. 
     
     
         17 . The method of  claim 11 , wherein each of the plurality of core cells comprises a septum having acoustic properties. 
     
     
         18 . The method of  claim 17 , wherein the securely connecting comprises spacing the peg splice securing joint apart from the septum of each of the plurality of core cells. 
     
     
         19 . The method of  claim 11 , further comprising forming the composite core and the peg splice securing joint of the same material. 
     
     
         20 . A method of forming a composite component assembly, comprising:
 laying-up a composite core having a plurality of core cells in relation to a mandrel;   disposing an adhesive layer within a connection joint between first and second ends of the composite core; and   securely connecting the first and second ends together with a peg splice securing joint, wherein the securely connecting comprises spacing the adhesive layer apart from the peg splice securing joint.