Reinforced structural assembly having a tee joint and method for forming the same

Abstract

Reinforced structural assemblies and methods for forming such assemblies are disclosed. In one embodiment, a ribbed portion includes rib segments having a vertical height that extend laterally between junctions to form a network coupled to a supporting substrate. The rib segments include a plurality of flanged portions coupled to a lateral edge of the rib segments. In another embodiment, the ribbed portion includes rib segments having flanged portions on opposing lateral edges that receive opposing substrates. Similarly, a method includes forming a ribbed portion having a plurality of rib segments extending laterally between junctions. The rib segments include a plurality of flanged portions on at least one of the first and second lateral edges. First and second substrates are coupled to opposing sides of the ribbed portion.

1 . A reinforced structural assembly, comprising: 
 a ribbed portion that includes rib segments having a predetermined vertical height and that extend laterally between junctions to form a network of the rib segments fixedly coupled to a supporting substrate;    a plurality of flanged portions fixedly coupled to at least one of the lateral edges of the rib segments; and    a second substrate configured to be fixedly coupled to the flanged portions.    
   
   
       2 . The reinforced structural assembly of  claim 1 , wherein each flanged portion extends at least partially along each lateral edge of the rib segment.  
   
   
       3 . The reinforced structural assembly of  claim 1 , wherein each flanged portion extends along each lateral edge of the rib segment and into the junction.  
   
   
       4 . The reinforced structural assembly of  claim 1 , wherein each flanged portion further comprises at least one recess that extends along a length of the flanged portion.  
   
   
       5 . The reinforced structural assembly of  claim 1 , wherein the network of the rib segments further comprises a closed network having a regular polygonal shape.  
   
   
       6 . The reinforced structural assembly of  claim 5 , wherein the network of the rib segments further comprises a closed network having a rectangular shape.  
   
   
       7 . The reinforced structural assembly of  claim 5 , wherein the network of the rib segments further comprises a closed network having a triangular shape.  
   
   
       8 . The reinforced structural assembly of  claim 1 , wherein the substrate is fixedly coupled to the flanged portions using an adhesive material.  
   
   
       9 . The reinforced structural assembly of  claim 1 , wherein the substrate is fixedly coupled to the flanged portions using a fusion process.  
   
   
       10 . The reinforced structural assembly of  claim 1 , wherein the assembly is comprised of a non-ferrous material.  
   
   
       11 . The reinforced structural assembly of  claim 10 , wherein the non-ferrous material comprises aluminum and titanium.  
   
   
       12 . The reinforced structural assembly of  claim 1 , wherein the assembly is comprised of a polymeric material.  
   
   
       13 . A reinforced structural assembly, comprising: 
 a ribbed portion that includes rib segments having a predetermined vertical height and that extend laterally between junctions to form a network of the rib segments, at least some of the rib segments having flanged portions on opposed lateral edges; and    a pair of opposing substrates fixedly coupled to the flanged portions.    
   
   
       14 . The reinforced structural assembly of  claim 13 , wherein each flanged portion extends at least partially along each lateral edge of the rib segment.  
   
   
       15 . The reinforced structural assembly of  claim 13 , wherein each flanged portion extends along each lateral edge of the rib segment and into the junction.  
   
   
       16 . The reinforced structural assembly of  claim 13 , wherein each flanged portion further comprises at least one recess that extends along a length of the flanged portion.  
   
   
       17 . The reinforced structural assembly of  claim 13 , wherein the network of the rib segments further comprises a network having a regular polygonal shape.  
   
   
       18 . The reinforced structural assembly of  claim 17 , wherein the network of the rib segments further comprises a network having a rectangular shape.  
   
   
       19 . The reinforced structural assembly of  claim 17 , wherein the network of the rib segments further comprises a network having a triangular shape.  
   
   
       20 . The reinforced structural assembly of  claim 13 , wherein the substrate is fixedly coupled to the flanged portions using an adhesive material.  
   
   
       21 . The reinforced structural assembly of  claim 13 , wherein the substrate is fixedly coupled to the flanged portions using a fusion process.  
   
   
       22 . The reinforced structural assembly of  claim 13 , wherein the assembly is comprised of a non-ferrous material.  
   
   
       23 . The reinforced structural assembly of  claim 22 , wherein the non-ferrous material comprises aluminum and titanium.  
   
   
       24 . The reinforced structural assembly of  claim 13 , wherein the assembly is comprised of a polymeric material.  
   
   
       25 . A method for constructing a reinforced structural assembly, comprising: 
 forming a ribbed portion including a plurality of rib segments extending laterally between junctions to form a network of the rib segments, the rib segments having first lateral edges and opposing second lateral edges defining respective first and second sides of the ribbed portion;    forming a plurality of flanged portions on at least one of the first and second lateral edges of at least some of the rib segments that extend along at least a portion of the lateral edges;    fixably coupling a first substrate to the first side; and    fixably coupling a second substrate to the second side.    
   
   
       26 . The method of  claim 25 , wherein forming a ribbed portion including a plurality of rib segments extending laterally between junctions to form a network of the rib segments further comprises forming a ribbed portion having a regular polygonal shape.  
   
   
       27 . The method of  claim 26 , wherein forming a ribbed portion having a regular polygonal shape further comprises forming a ribbed portion having a rectangular shape.  
   
   
       28 . The method of  claim 26 , wherein forming a ribbed portion having a regular polygonal shape further comprises forming a~ribbed portion having a triangular shape.  
   
   
       29 . The method of  claim 26 , wherein forming a plurality of flanged portions on at least one of the first and second lateral edges further comprises forming a plurality of flanged portions on at least one of the first and second lateral edges that extend at least partially along each lateral edge of the rib segment.  
   
   
       30 . The method of  claim 26 , wherein forming a plurality of flanged portions on at least one of the first and second lateral edges further comprises forming a plurality of flanged portions on at least one of the first and second lateral edges that extend along lateral edge of the rib segment and into the junction.  
   
   
       31 . The method of  claim 26 , wherein forming a plurality of flanged portions further comprises forming at least one recess in each of the plurality of flanged portions.  
   
   
       32 . The method of  claim 26 , wherein forming a plurality of flanged portions further comprises forming flanged portions on the first and the second lateral edges.  
   
   
       33 . The method of  claim 26 , wherein fixably coupling a first substrate further comprises adhesively coupling the first substrate.  
   
   
       34 . The method of  claim 26 , wherein fixably coupling a first substrate further comprises fusing the first substrate to the first side.  
   
   
       35 . The method of  claim 26 , wherein fixably coupling a second substrate further comprises adhesively coupling the second substrate.  
   
   
       36 . The method of  claim 26 , wherein fixably coupling a second substrate further comprises fusing the second substrate to the second side.  
   
   
       37 . An aerospace vehicle, comprising: 
 a fuselage;    wing assemblies and an empennage operatively coupled to the fuselage; and    a reinforced structural assembly comprising at least a portion of the fuselage, the wing assemblies and the empennage, the reinforced structural assembly further comprising: 
 a ribbed portion that includes rib segments having a predetermined vertical height and that extend laterally between junctions to form a network of the rib segments fixedly coupled to a supporting substrate;  
 a plurality of flanged portions fixedly coupled to at least one of the lateral edges of the rib segments; and  
 a substrate configured to be fixedly coupled to the flanged portions.  
   
   
   
       38 . The aerospace vehicle of  claim 37 , wherein each flanged portion extends at least partially along each lateral edge of the rib segment.  
   
   
       39 . The aerospace vehicle of  claim 37 , wherein each flanged portion extends along each lateral edge of the rib segment and into the junction.  
   
   
       40 . The aerospace vehicle of  claim 37 , wherein each flanged portion further comprises at least one recess that extends along a length of the flanged portion.  
   
   
       41 . The aerospace vehicle of  claim 37 , wherein the network of the rib segments further comprises a closed network having a regular polygonal shape.  
   
   
       42 . The aerospace vehicle of  claim 41 , wherein the network of the rib segments further comprises a closed network having a rectangular shape.  
   
   
       43 . The aerospace vehicle of  claim 41 , wherein the network of the rib segments further comprises a closed network having a triangular shape.  
   
   
       44 . The aerospace vehicle of  claim 37 , wherein the substrate is fixedly coupled to the flanged portions using an adhesive material.  
   
   
       45 . The aerospace vehicle of  claim 37 , wherein the substrate is fixedly coupled to the flanged portions using a fusion process.  
   
   
       46 . The aerospace vehicle of  claim 37 , wherein the assembly is comprised of a non-ferrous material.  
   
   
       47 . The aerospace vehicle of  claim 46 , wherein the non-ferrous material comprises aluminum and titanium.  
   
   
       48 . The aerospace vehicle of  claim 37 , wherein the assembly is comprised of a polymeric material.