Structural fiber composite systems and methods to make them

Abstract

An assembly that includes two or more longitudinal members comprising a continuous fiber composite material. The two or more longitudinal members are interconnected by a connector that includes a receptacle in which a portion of the two or more longitudinal members are inserted.

Description

Attorney Docket No. CFS-100-B-WOSTRUCTURAL FIBER COMPOSITE SYSTEMS AND METHODS TO MAKE THEMCROSS-REFERENCE TO RELATED APPLICATION(S)

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 714,934, filed on November 1, 2024, and U.S. Provisional Patent Application No. 63 / 679,431, filed on August 5, 2024, the entire disclosures of which are hereby incorporated by reference.FIELD

[0002] The disclosure is directed to structural systems, and more particularly, to structural fiber composite systems.BACKGROUND

[0003] The building construction industry and various other industries continue to shift from use of natural materials (e.g., wood) to metal and engineered wood products for structural applications. Similarly, there has been a desire in the building construction industry and various other industries to replace conventionally metal (e.g., steel) structures with lighter weight materials, such as aluminum, fiber glass / polymer composites, and carbon fiber polymer composites. For example, in the building construction industry, conventional steel structural components (e.g., structural beams, columns, and other load-bearing components) may be replaced with fiber-reinforced polymer composites, which may exhibit a higher strength-to- weight ratio when compared to the conventional steel structural components. Likewise, metal roofing and siding often employed for residential and / or commercial buildings may be replaced with aluminum composite panels (e.g., a non-aluminum core material bonded between opposing aluminum sheets) to provide a lightweight and durable alternative.

[0004] These alternative materials may, however, be less cost-effective when compared to the natural or metal materials conventionally utilized. Moreover, fiber glass / polymer composites and / or carbon fiber polymer composites may also be difficult to manufacture. For example, processing the aforementioned fiber composites and curing of the polymer may be difficult to accomplish free of defects, which may often be undesirable for visible structures (e.g., an exterior of a home).14857-5085-0654, v. 1Attorney Docket No. CFS-100-B-WO

[0005] Additionally, the natural and metal structural materials and the aforementioned alternative materials may be difficult to install. By way of example, structural systems that include one or more structural support members may often be complex or difficult to install. For example, installation of conventional structural support members used for load-bearing applications may be labor intensive and require significant modifications to ensure proper mounting and / or positioning of the structural support members. Moreover, such structural support members may be complex to achieve one or more desired physical properties (e.g., a desired load-bearing capability), resulting in even further complexity and / or difficulty when installing. Thus, such structural support members may require significant labor for installation and / or may be difficult to properly align (e.g., level) and / or mount, thereby resulting in undesirable final installation results. Moreover, due to such difficulty when installing, nonprofessional contractors (e.g., homeowners) may be unable or unwilling to complete the installation themselves.

[0006] Accordingly, it would be desirable to further decrease the weight and / or cost of structural materials, such as structural load bearing materials for use in various industries, such as the construction industry. It would also be desirable to provide alternative structural materials that improve on conventional installation techniques used for installing structural materials. Moreover, it would be desirable to provide alternative structural materials that may provide improved structural performance (e.g., stronger structural materials that may achieve improved load-bearing capabilities).SUMMARY OF THE INVENTION

[0007] In one aspect of the present teachings, an assembly is disclosed. The assembly includes two or more longitudinal members comprising a continuous fiber composite material and interconnected by a connector comprised of a receptacle in which a portion of the two or more longitudinal members are inserted.

[0008] In some configurations, the continuous fiber composite material is comprised of synthetic fibers.

[0009] In some configurations, the continuous fiber composite material is comprised of carbon fibers.24857-5085-0654, v. 1Attorney Docket No. CFS-100-B-WO

[0010] In some configurations, the continuous fiber composite material traverses all or a portion of a length of the two or more longitudinal members, the length being measured along or parallel to a longitudinal axis of the two or more longitudinal members.

[0011] In some configurations, the two or more longitudinal members are a laminate that include the continuous fiber composite material.

[0012] In some configurations, the continuous fiber composite material has a density of about 2 g / cc or less.

[0013] In some configurations, the two or more longitudinal members have an axial tensile strength of about 250 Ksi or more.

[0014] In some configurations, the two or more longitudinal members have a flex modulus of about 19,000 Ksi or more.

[0015] In some configurations, the connector receives a terminal end of each of the two or more longitudinal members.

[0016] In some configurations, the connector receives a central portion of each of the two or more longitudinal members, the central portion being a portion of the two or more longitudinal members that is located between terminal ends of the two or more longitudinal members.

[0017] In some configurations, the two or more longitudinal members are inserted into the connector, and an insertion force to insert the two or more longitudinal members is less than a force required to remove the two or more longitudinal members from the connector.

[0018] In some configurations, the force required to remove the two or more longitudinal members from the connector is about 200% greater than the insertion force.

[0019] In some configurations, the two or more longitudinal members are inserted into the connector and coupled to the connector free of any additional fasteners.

[0020] In some configurations, the two or more longitudinal members are inserted into the connector and coupled to the connector by an adhesive.

[0021] In some configurations, at least about 5 centimeters or more of a length of each of the two or more longitudinal members is inserted into the connector, the length being measured along or parallel to a longitudinal axis of the two or more longitudinal members.

[0022] In some configurations, the adhesive is comprised of one or more of an epoxy resin, an acrylate adhesive, and a polyurethane adhesive.34857-5085-0654, v. 1Attorney Docket No. CFS-100-B-WO

[0023] In some configurations, the adhesive abuts a longitudinal surface of each of the two or more longitudinal members to form an adhesive layer between the two or more longitudinal members and the connector.

[0024] In some configurations, the two or more longitudinal members have a length that is parallel to a direction of fibers of the continuous fiber composite material, a width that is perpendicular to the direction of the fibers of the continuous fiber composite material, and a thickness that is perpendicular to the direction of the fibers of the continuous fiber composite material.

[0025] In some configurations, the continuous fiber composite material is comprised of at least one of natural fibers and synthetic fibers.

[0026] In some configurations, the continuous fiber composite material is a continuous fiber polymer composite material.

[0027] In some configurations, the continuous fiber polymer composite material is a pultruded or extruded continuous polymer composite material.

[0028] In some configurations, a polymer of the continuous fiber polymer composite material is comprised of one or more of an epoxy, polyurethane, or poly urea.

[0029] In some configurations, the two or more longitudinal members define one or more apertures that extend through a thickness of the two or more longitudinal members.

[0030] In some configurations, the one or more apertures are pre-drilled holes that are configured to receive a fastener to secure the two or more longitudinal members to a structure.

[0031] In another aspect of the present disclosure, a method of assembling a reinforcement structure is disclosed. The method includes connecting a first longitudinal member to a connector and connecting a second longitudinal member to the connector to interconnect the first longitudinal member to the second longitudinal member. The connector is an intermediary component that mechanically connects the first longitudinal member to the second longitudinal member. The first longitudinal member and the second longitudinal member are a continuous fiber composite material comprised of carbon fibers.

[0032] In some configurations, the connector includes a first connecting portion and a second connecting portion, the first longitudinal member is connected to the first connecting portion, and the second longitudinal member is connected to the second connecting portion.44857-5085-0654, v. 1Attorney Docket No. CFS-100-B-WO

[0033] In some configurations, the connector includes a connecting portion, and the first longitudinal member and the second longitudinal member arc both inserted into the connecting portion.

[0034] In some configurations, the first longitudinal member abuts the second longitudinal member after insertion into the connecting portion.

[0035] In some configurations, the first connecting portion and the second connecting portion are a channel or a cavity defined by the connector.

[0036] In some configurations, the connecting portion is a channel or a cavity defined by the connector, and a cross-section of the cavity is complementary in shape to a cross-section of the first longitudinal member and the second longitudinal member when the first longitudinal member and the second longitudinal member abut one another.

[0037] In some configurations, the first longitudinal member and the second longitudinal member are inserted into the connector, and an insertion force required to insert the first longitudinal member and the second longitudinal member into the connector is less than a force required to remove the first longitudinal member and the second longitudinal member from the connector.

[0038] In some configurations, an adhesive is disposed between the first longitudinal member and the connector and between the second longitudinal member and the connector.

[0039] In some configurations, the method includes activating the adhesive after inserting the first longitudinal member and the second longitudinal member into the connector.

[0040] In some configurations, a foaming material is disposed between the first longitudinal member and the connector and between the second longitudinal member and the connector.

[0041] In some configurations, the method further includes activating the foaming material after inserting the first longitudinal member and the second longitudinal member into the connector to expand the foaming material and fill a gap between the first longitudinal member and the connector, a gap between the second longitudinal member and the connector, and a gap between the first longitudinal member and the second longitudinal member.

[0042] In another aspect of the present disclosure, a connector is disclosed. The connector is configured to receive two or more longitudinal members therein. An insertion force to insert the two or more longitudinal members is less than a force required to remove the two or more54857-5085-0654, v. 1Attorney Docket No. CFS-100-B-WO longitudinal members from the connector. The two or more longitudinal members are configured to be inserted into the connector and coupled to the connector free of any additional fasteners.

[0043] In some configurations, the two or more longitudinal members comprise a continuous fiber composite material, and the connector comprises a receptacle that is configured to receive a portion of the two or more longitudinal members.

[0044] In some configurations, the force required to remove the two or more longitudinal members from the connector is about 200% greater than the insertion force.BRIEF DESCRIPTION OF THE DRAWINGS

[0045] The disclosed non-limiting embodiments are discussed in relation to the drawings appended hereto and forming part hereof, wherein like numerals indicate like elements, and in which:

[0046] FIG. 1A illustrates a side view of a structural support system prior to assembly in accordance with the present teachings.

[0047] FIG. IB illustrates a cross-sectional view of the structural support system shown in FIG. 1A after assembly.

[0048] FIG. 2 illustrates a side view of a second example of a structural support system in accordance with the present teachings.

[0049] FIG. 3 illustrates a side view of a third example of a structural support system in accordance with the present teachings.

[0050] FIG. 4A illustrates a perspective view of a longitudinal member of a structural support system in accordance with the present teachings.

[0051] FIG. 4B illustrates a top-down view of a longitudinal member in accordance with the present teachings.

[0052] FIG. 4C illustrates a top-down view of a longitudinal member in accordance with the present teachings.

[0053] FIG. 4D illustrates a top-down view of a longitudinal member in accordance with the present teachings.

[0054] FIG. 5 illustrates a side view of a fourth example of a structural support system in accordance with the present teachings.64857-5085-0654, v. 1Attorney Docket No. CFS-100-B-WO

[0055] FIG. 6 illustrates a cross-sectional view of another example of a longitudinal member of a structural support system in accordance with the present teachings.

[0056] FIG. 7A illustrates a top-down view of a fifth example of a structural support system in accordance with the present teachings.

[0057] FIG. 7B illustrates a side view of the structural support system shown in FIG. 7A.

[0058] FIG. 7C illustrates a side view of another example of the structural support system shown in FIGS. 7 A and 7B.

[0059] FIG. 8A illustrates a side view of a sixth example of a structural support system in accordance with the present teachings.

[0060] FIG. 8B illustrates a top-down view of the structural support system shown in FIG. 8A.

[0061] FIG. 9 illustrates a side view of a connector of the structural support system shown in FIGS. 8 A and 8B.

[0062] FIG. 10A illustrates a side view of a seventh example of a structural support system in accordance with the present teachings.

[0063] FIG. 10B illustrates another side view of the structural support system shown in FIG. 10A.

[0064] FIG. 10C illustrates a top-down view of another example of the structural support system shown in FIGS. 10A and 10B.

[0065] FIG. 11 illustrates a perspective view a connector of the structural support system shown in FIGS. 10A-10C.

[0066] FIG. 12 illustrates a close-up view of the connector shown in FIG. 11.

[0067] FIG. 13 illustrates a side view of an eight example of a structural support system in accordance with the present teachings.

[0068] FIG. 14 illustrates a perspective view of a connector of the structural support system shown in FIG. 13.

[0069] FIG. 15 illustrates a perspective view of another example of a connector of the structural support system shown in FIG. 13.

[0070] FIG. 16 illustrates a side view of a ninth example of a structural support system in accordance with the present teachings.

[0071] FIG. 17 illustrates a perspective view of a connector of the structural support system shown in FIG. 16.74857-5085-0654, v. 1Attorney Docket No. CFS-100-B-WO

[0072] FIG. 18 illustrates a front view of the connector shown in FIG. 16.DETAILED DESCRIPTION

[0073] The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the invention, its principles, and its practical application. The specific embodiments of the present disclosure as set forth are not intended to be exhaustive or limit the scope of the disclosure. It is understood that any reference to a property or characteristic of a material may be determined by any suitable methods such as commonly used methods and standards for such characteristics.

[0074] One or more as used herein means that at least one, or more than one, of the recited components may be used as disclosed. It is understood that the functionality of any ingredient or component may be an average functionality due to imperfections in raw materials, incomplete conversion of the reactants and formation of by-products.

[0075] Conventional structural support systems (e.g., any structural system that includes one or more mounts, brackets, support members, connectors, or other components that may be secured to a primary structure to thereby couple a secondary component or structure to the primary structure) may create significant installation challenges. By way of example, when installing traditional structural support systems, it may be difficult to properly align the components thereof to the structure (e.g., the wall) during and / or after installation. For example, it may be difficult to ensure that the support structure is level and / or flush along the wall, thereby resulting in the installed secondary component or secondary structure being visually displeasing, unusable (e.g., unlevel surface), or insecure. Similarly, due to such difficulties with properly installing the a conventional structural support system, non-contractors (e.g., non-professionals such as homeowners) may be unable to, or otherwise dissuaded from, installing the structural support systems themselves.

[0076] The present teachings provide a structural support system (hereinafter a structural support assembly) that may include one or more brackets that are mounted to a wall or other structure to thereby couple and / or support one or more secondary structures or items to the wall or other structure. By way of example, the structural support system may include one or more longitudinal members that may be secured to the wall or other structure, whereby the longitudinal members may be configured to support the one or more secondary structures or84857-5085-0654, v. 1Attorney Docket No. CFS-100-B-WO items and couple (e.g., directly or indirectly) the one or more secondary structures or items to the wall or other structure. As such, the structural support system may require structural integrity sufficient to both support (e.g., load-bearing) the secondary structures or items and secure the secondary structures or items to the wall or other structure. That is, once the longitudinal members are secured to the wall, the longitudinal members may continuously support and connect the secondary structures or items to the wall. Such secondary structures or items may be a countertop, cabinet, appliance, shelf, other furniture, wall hanging (e.g., painting), electronics (e.g., television), other structural construction items (e.g., the longitudinal members may be loadbearing for structural supports of a building), or a combination thereof.

[0077] The present teachings provide a structural support assembly which address the aforementioned challenges as described in further detail below. The structural support assembly as described herein may advantageously provide a quicker and easier method of installation. For example, the structural support assembly may facilitate quicker and easier installation of the structural support assembly such that installation may be done by an installer (e.g., a contractor or a non-contractor, such as a homeowner) in less time and with little difficulty when compared to installing conventional structural support systems. Additionally, the structural support assembly may ensure that a secondary component or secondary item is secured mounted to a structure (e.g., a wall) in a level and flush manner. Moreover, the structural support assembly described herein may provide a lightweight alternative to conventional structural support systems without sacrificing structural integrity, thereby improving load-bearing capabilities of the structural support systems while simultaneously decreasing the overall weight of the structural support assembly.

[0078] It should be noted that the teachings herein are not particularly limited to any one structural support assembly. For example, all or a portion of the structural support assembly described herein may include, or be used with, bracing, brackets, support members, cabinetry, appliances, decking, other construction applications, or a combination thereof. Moreover, the present teachings may also be used in industries other than the construction industry, such as but not limited to, automative, marine, food and beverage, furniture, other industries, or a combination thereof.

[0079] Turning now to the figures, FIGS. 1A and IB illustrate a side view and a cross-sectional view, respectively, of an example of a structural support assembly 100. FIG. 1A illustrates the94857-5085-0654, v. 1Attorney Docket No. CFS-100-B-WO structural support assembly 100 prior to installation of a first longitudinal member 102 and a second longitudinal member 104 into a connector 106. FIG. IB illustrates the structural support assembly 100 after installation of the first longitudinal member 102 and the second longitudinal member 104 into the connector 106.

[0080] As shown in FIGS. 1A and IB, the connector 106 may define a channel 108 therein that may receive all or a portion of the first longitudinal member 102 and the second longitudinal member 104. The channel 108 may be any size and / or shape. For example, the channel 108 may be complementary in shape to a cross-sectional shape of the first longitudinal member 102 and the second longitudinal member 104. The channel 108 may be any cavity, aperture, through- hole, or other void in the connector 106 that may receive the first longitudinal member 102 and the second longitudinal member 104 therein. For example, the channel may be a receptacle in which a portion of the first longitudinal member 102 and the second longitudinal member 104 is inserted (e.g., the receptacle receives a portion of the first longitudinal member 102 and the second longitudinal member 104), thereby structurally connecting the first longitudinal member 102 to the second longitudinal member 104 and facilitating a transference of load (e.g., mechanical load) between the first longitudinal member 102 and the second longitudinal member 104, and vice versa. As such, the connector 106 may couple the first longitudinal member 102 and the second longitudinal member 104 to each other to form the structural support assembly 100. For example, the structural support assembly 100 may be a structural frame or support system that may be coupled to one or more structures (e.g., walls, studs, other structures, etc.), whereby the structural support assembly 100 may support one or more secondary structures or components (e.g., the first longitudinal member 102 and the second longitudinal member 104 and / or the connector 106 may support the secondary structures or components), such as those described above.

[0081] The first longitudinal member 102 and the second longitudinal member 104 may be secured in the connector 106 in any desired manner. For example, the first longitudinal member 102 and the second longitudinal member 104 may be secured within (e.g., coupled to) the channel 108 of the connector 106 using one or more mechanical fasteners (e.g., screws, bolts, nails, etc.), one or more mechanical interlocks (e.g., compression fittings, mechanical latches, pins, abrasive surfaces, teeth, etc.), one or more adhesives, or a combination thereof. Thus, it is envisioned that a force to insert the first longitudinal member 102 and the second longitudinal104857-5085-0654, v. 1Attorney Docket No. CFS-100-B-WO member 104 into the connector 106 may be less than a force required to remove the first longitudinal member 102 and the second longitudinal member 104 from the connector 106. For example, a pull-out force to remove the first longitudinal member 102 and the second longitudinal member 104 from the connector 106 may be about 50% greater, about 100% greater, about 200% greater, or about 300% greater than the force required to insert the first longitudinal member 102 and the second longitudinal member 104 into the channel 108 of the connector 106. For example, the pull-out force may be about 100 N to about 1,000 N, about 250 N to about 750 N, or about 400 N to about 600 N.

[0082] If an adhesive is used to connect the first longitudinal member 102 and the second longitudinal member 104 to the connector, such as the adhesive 110, the adhesive 110 may be disposed in the channel 108 and / or along an outer surface of one or both of the first longitudinal member 102 and the second longitudinal member 104 to couple (e.g., adhere or bond) the first longitudinal member 102 and the second longitudinal member 104 to the connector 106 and / or to each other (e.g., the first longitudinal member 102 may be bonded directly to the second longitudinal member 104 within the channel 108. The adhesive 110 may be any desired adhesive. The adhesive 110 may have any thickness (e.g., shortest distance between members through the adhesive 110) may be any useful thickness, such as from about 0.025 mm or 0.05 mm to about 1 mm or 3 mm. The adhesive 110 may have one or more fillers. The fillers may be particulate ceramics, such as inorganic glass (e.g., beads and hollow beads), silicates (e.g., talc), clays, alumino- silicates (e.g., mullite), oxides (e.g., titanium dioxide, silica, calcium oxide, magnesium oxide and alumina), carbon (e.g., amorphous and graphitic), and metal powders. When the materials have polar groups at their surface, the adhesive may be comprised of, for example, an epoxy, urethan, urea, formaldehyde, acrylate, silicone, or a combination thereof. In some instances, to achieve the desired load properties of the structural support assembly 100, the adhesive 110 may have a lap shear of at least about 5 N / mm2, about 10 N / mm2, or about 20 N / mm2at 20 °C or 40 °C, whereby the lap shear is measured in accordance with ISO-4587.

[0083] By way of example, the adhesive 110 may be or may include an epoxy. The epoxy may be comprised of an epoxy resin and a curing agent. The epoxy adhesive may be one that has a latent curing agent (e.g., a hardener) or may be a two-part epoxy where the curing agent and epoxy resin are mixed upon application. The epoxy resin may be saturated or unsaturated, aliphatic, cycloaliphatic, aromatic, or heterocyclic and may be substituted. The epoxy resin may114857-5085-0654, v. 1Attorney Docket No. CFS-100-B-WO also be monomeric or polymeric. An extensive enumeration of epoxy resins useful in the present invention is found in Lee, H. and Neville, K., "Handbook of Epoxy Resins." McGraw-Hill Book Company, New York, 1967, Chapter 2, pages 257-307; incorporated herein by reference.

[0084] By way of example, the adhesive 110 may be or may include a polyurethane. The polyurethane adhesive may be any known in the art and may include those commercially available. In some instances, the polyurethane is further comprised of urea linkages due to the substitution of some of the polyols with a polyamine.

[0085] The adhesive 110 may be or may include a foam. The foam may be separate from the adhesive 110 such that both the adhesive 110 and a foam may be disposed in the channel 108. For simplicity, the adhesive 110 shown in FIG. IB may illustrate both the adhesive 110 and the foam as described herein. However, the structural support assembly 100 may include the adhesive 110, the foam, neither, or both.

[0086] The foam may be commonly understood as meaning a body that is cellular. Cellular (foam) herein means the body has a substantially lowered apparent density compared to the density of the body's material (e.g., polymer, ceramic or metal) and the body is comprised of cells that are closed or open. Closed cell means that the gas within that cell is isolated from another cell by the polymer walls forming the cell. Open cell means that the gas in that cell is not so restricted and is able to flow to another cell without passing through any polymer cell walls to the atmosphere.

[0087] The size of the cells may be any useful size depending on the characteristics desired. Illustratively, the cells of the foam may have an average size (largest dimension) of 0.05 to 5.0 mm, especially from about 0.1 to about 3.0 mm, as measured by ASTM D-3576-98. Foams having larger average cell sizes, of especially about 1.0 to about 3.0 mm or about 1.0 to about 2.0 mm in the largest dimension, may be of particular use in load bearing application, such as those described herein.

[0088] The foam may have a density from about 16 kg / m3to about 100 kg / m3or more. The foam density, typically, is selected depending on the particular application. For example, for an exterior building facade panel, the density may desirably be about 24 kg / m3to about 64 kg / m3.

[0089] The foam may adhere the first longitudinal member 102 and the second longitudinal member 104 to the connector 106 and / or to each other (e.g., the foam is or is part of the adhesive 110). The foam may be isolated in the channel 108. In other configurations, where the connector124857-5085-0654, v. 1Attorney Docket No. CFS-100-B-WO106 includes more than one channel, (e.g., the connector 106 includes a plurality of the channel 108, whereby the channels may be spaced spart or connected), the foam may be isolated in each channel or may flow through all of the channels. For example, the foam may be in communication between two or more of the channels (e.g., cavities) via a throughway traversing the thickness of the connector 106 or extending between the channels. The throughway may be a notch or hole of any geometry or configuration (e.g. rectangular notch or hole). The foam may form a continuous matrix (foam in and between throughways connecting the channels).

[0090] The foam may be a polymer foam, but need not be. The foam may have a porosity of about 30% or 50% to any practically useful porosity, such as about 95%. The foam may, for example, be an inorganic (metal or ceramic) foam, cement, aerogel or porous body. An adhesive (e.g., the adhesive 110) may be used to bond those foams having insufficient adhesion to the first longitudinal member 102 and the second longitudinal member 104 and / or the connector 106. The adhesive may be any suitable adhesive such as any one or more of those described herein.

[0091] The foam may have any amount of open or closed cells. Even so, for some applications a portion of the cells may be closed, for example, when absorption of water is deleterious to the function of the final product. Even though open or closed foams may be used, when the application desired benefits from lack of water absorption, the foam is preferably closed cell. For such applications, at least about 55%, at least about 60%, at least about 75%, or at least about 90% of the cells of the foam are closed cells.

[0092] The foam may be a thermoplastic or thermoset polymer foam. Any polymer that may be made into a foam may be used. Illustratively, the foam may be a polyurethane, polyurea, polyolefin, polyester, polycarbonate, polyacrylate, polyether, polyvinyl (e.g., polystyrene), polyvinylidene, polyetherester or any combination thereof. An illustration is the use of a polyurethane foam that is foamed into the channel 108 and allowed to expand to the channel 108 desired to be filled (e.g., an entirety of the space in the channel 108 not filled by the first longitudinal member 102 and the second longitudinal member 104.

[0093] As shown in FIGS. 1A and IB, the first longitudinal member 102 and the second longitudinal member 104 may be substantially coaxial with each other and the connector 106 along a longitudinal axis of the structural support assembly 100. However, any orientation of the first longitudinal member 102 and the second longitudinal member 104 with respect to each other and / or the connector 106 may be possible. For example, the first longitudinal member 102134857-5085-0654, v. 1Attorney Docket No. CFS-100-B-WO and the second longitudinal member 104 may be positioned parallel or non-parallel (e.g., skewed or perpendicular) to one another, as dictated by the connector 106 (e.g., by the channel 108 or other cavities of the connector 106 that receive and secure the first longitudinal member 102 and the second longitudinal member 104.

[0094] The first longitudinal member 102 and the second longitudinal member 104 and / or the connector 106 may be made of any material and may be made of the same or different materials. However, it is envisioned that the first longitudinal member 102 and the second longitudinal member 104 and / or the connector 106 may be made of a material that is substantially lighter weight when compared to conventional metal (e.g., steel) or wood materials conventionally used in structural support systems. Additionally, such materials as described herein may improve structural integrity of the structural support assembly 100. For example, the materials described herein, when compared to the conventional materials described above, may exhibit improved load-bearing capabilities, tensile strength, tensile modulus, compressive strength, compressive modulus, flex modulus, or a combination thereof based upon the desired properties of the structural support assembly 100.

[0095] By way of example, the first longitudinal member 102, the second longitudinal member 104, the connector 106, or a combination thereof may be a composite material. For example, the first longitudinal member 102 and the second longitudinal member 104 and / or the connector 106 may be a continuous fiber composite material (CFCM). The CFCM may traverse all or a portion of a length of the first longitudinal member 102 and / or the second longitudinal member 104. For example, the CFCM may traverse substantially all of the length of the first longitudinal member 102 and / or the second longitudinal member 104, whereby the length may be measured along or parallel to a longitudinal axis of the first longitudinal member 102 and / or the second longitudinal member 104. The CFCM may provide improved structural integrity (e.g., improved load-bearing capabilities, flexural strength, etc.) when compared to conventional structural materials. The CFCM may be comprised of fibers, such as carbon fibers. For example, the CFCM may be a continuous carbon fiber polymer (CCFP) composite. The CFCM may be further comprised of fibers other than carbon fibers. Other useful fibers that may be used in the CFCM may include any suitable fibers, such as naturally occurring fibers (e.g., hemp, bamboo, jute sisal, coconut, etc.), metal fibers, and glass fibers. When present, such other fibers may be present in any suitable amount depending on the desired characteristics but may typically be present in an144857-5085-0654, v. 1Attorney Docket No. CFS-100-B-WO amount of about 1 %, about 5%, about 10%, or about 20% to about 99%, about 95%, about 75%, or about 50% by volume of the fibers present in the CFCM composite with the balance being carbon fibers.

[0096] The CFCM may comprise one or more polymers. The polymers may enable the desired weight, cost, and mechanical characteristics of the structural support assembly 100. The CFCM or the fibers thereof may be woven (e.g., bidirectional) or unidirectional. For example, unidirectional continuous carbon fibers may be pultruded into ribbons or sheets with a thermoset or thermoplastic resin to form one or more of the components of the structural support assembly 100. The use or ribbons or sheets with the carbon fibers parallel to the pultrusion direction may allow for the formation of lattices, which may provide simple and / or complex shapes when formed.

[0097] The CFCM may be any suitable material for the structural support assembly 100. For example, the carbon fiber may be one that is derived from any material that may be processed into a filament of desired size and carbonized. For carbon fibers, petroleum-based pitches, polyamide, or polyacrylonitrile may be used. The fibers may be any useful diameter and may be from about 1 micrometer to about 20 micrometers, about 50 micrometers, or about 100 micrometers in diameter.

[0098] The polymer of the CFCM may be formed from a thermoplastic resin or polymer or thermosetting resin. Resin is used herein to denote that further curing or polymerization may occur when forming the CFCM (e.g., by pultruding). The thermoplastic materials as described herein may generally encompass a plastic material or polymer that is reversible in nature. For example, thermoplastic materials typically become pliable or moldable when heated to a certain temperature and return to a more rigid state upon cooling. Further, thermoplastic materials may include amorphous thermoplastic materials and / or semi-crystalline thermoplastic materials. For example, some amorphous thermoplastic materials may generally include, but are not limited to, styrenes, vinyls, cellulosics, polyesters, acrylics, polysulphones, and / or imides.

[0099] The thermoset materials as described herein generally encompass a plastic material or polymer that is non-reversible in nature. For example, thermoset materials, once cured, cannot be easily remolded or returned to a liquid state. As such, after initial forming, thermoset materials are generally resistant to heat, corrosion, and / or creep. Example thermoset materials may154857-5085-0654, v. 1Attorney Docket No. CFS-100-B-WO generally include, but are not limited to, polyesters, polyurethanes including polyurethanes having polyurca, esters, cpoxics, or any other suitable thermoset material.

[0100] The CFCM may typically have an amount of fibers sufficient to realize the load bearing capabilities and weight desired in the structural support assembly 100. For example, the amount of fibers is from about 20%, about 30%, or about 50% to about 70% or about 80% by volume of the CFCM. When utilizing the CFCM, the structural support assembly 100 or any components thereof (e.g., the first longitudinal member 102 and the second longitudinal member 104) may be any size and / or shape (e.g., a sheet, ribbon, tape, tube, slitted tube, rod, etc.), such as those that may be produced by pultrusion, extrusion, molding, or other manufacturing methods.

[0101] The CFCM may also be comprised of other additives for imparting one or more desired characteristics. For example, the additives may one or more fillers. Other additives may also include colorants, flame retardants, lubricants, release agents, compatibilizers, dispersing agents, plasticizers, color protectors, UV stabilizers, antibacterial agents, antifungal agents, vibration dampers, or a combination thereof. The amount of other additives may be any useful amount for imparting a desired characteristic of the CFCM. For example, the amount of other additives may be an amount of about 0.1% or about 1% to about 50%, about 40%, about 30%, or about 20% by volume of the CFCM.

[0102] FIG. 2 illustrates a side view of second example of a structural support assembly 200, which may be similar to the structural support assembly 100 described above. As shown, the structural support assembly 200 may include a first longitudinal member 202 and a second longitudinal member 204 connected to one another via a connector 206 disposed therebetween. The connector 206 may define a channel 208 therein that may receive the first longitudinal member 202 and the second longitudinal member 204 to secure the first longitudinal member 202 and the second longitudinal member 204 to each other and to the connector 206. For example, the connector 206 may include one or more faces 212 that define an opening to receive the first longitudinal member 202 and the second longitudinal member 204 therein such that at least a portion of the first longitudinal member 202 and the second longitudinal member 204 are positioned within the channel 208. As shown in FIG. 2, the size and / or shape of the channel 208 is different than the channel 108 described above such that orientation of the first longitudinal member 202 and the second longitudinal member 204 to one another is different than those shown in the structural support assembly 100.164857-5085-0654, v. 1Attorney Docket No. CFS-100-B-WO

[0103] FIG. 3 illustrates a side view of a third example of a structural support assembly 300. The structural support assembly 300 includes a first longitudinal member 302 and a second longitudinal member 304 stacked on top of one another (e.g., longitudinal surfaces abutting one another). The first longitudinal member 302 and the second longitudinal member 304 are inserted together into a channel 308 defined by a connector 306 to secure the first longitudinal member 302 and the second longitudinal member 304 to each other and to the connector 306. For example, the connector 306 may include one or more engaging features 314 that may secure the first longitudinal member 302 and the second longitudinal member 304 in the channel 308. For example, the one or more engaging features 314 may be a compression fitting, a fastener, an abrasive surface, a mechanical interlock, other feature that may engaging the first longitudinal member 302 and the second longitudinal member 304, or a combination thereof.

[0104] FIG. 4A illustrates a perspective view of a longitudinal member 402 in accordance with the present teachings. The longitudinal member 402 may be similar to any of the longitudinal members described above. As shown, the longitudinal member 402 may have a cross-sectional shape that may be substantially square or rectangular and may linearly extend along a longitudinal axis 404 between a first end 406 and an opposing second end 408. The longitudinal member 402 may also, in certain configurations, have one or more bends, undulations, curves, grooves, or a combination thereof. Moreover, a cross-sectional shape of the longitudinal member 402 may also be round, oval, triangular, asymmetrical, or a combination thereof. Thus, the longitudinal member 402 is only one example of a shape of the longitudinal members that may be used in the structural support assemblies described herein.

[0105] FIGS. 4B-4D illustrate top-down views of the longitudinal member 402. The longitudinal member 402 may include one or more apertures, such as the apertures 410, therein, which may extend through all or a portion of the thickness of the longitudinal member 402 to couple the longitudinal member to a structure (e.g., a wall or stud or other support) and / or to the connector 106. The longitudinal member 402 may include any number of the apertures 410 and the apertures 410 may be disposed anywhere along the longitudinal member 402, such as near the first end 406, the opposing second end 408 (FIG. 4C), or both. Alternatively, the apertures 410 may be disposed centrally along a length of the longitudinal member 402 between the first end 406 and the opposing second end 408, as shown in FIG. 4D. Moreover, in certain configurations,174857-5085-0654, v. 1Attorney Docket No. CFS-100-B-WO such as when using adhesives for mounting, the longitudinal member 402 may be free of the apertures 410 (FIG. 4B).

[0106] FIG. 5 illustrates a side view of fourth example of a structural support assembly 500. The structural support assembly 500 may be similar to the structural support assembly 100, the structural support assembly 200, and the structural support assembly 300 described above. The structural support assembly 500 includes a longitudinal member 502 that may include one or more apertures, such as the apertures 510, therein. The apertures 510 may receive fasteners 512 therein such that the fasteners 512 may extend through the longitudinal member 502 and into a structure 514 (e.g., a wall or stud) to couple the longitudinal member 502 to the structure 514. The longitudinal member may also include a chamfered or tapered surface 516 that may engage a secondary component or structure (e.g., a mounting bracket of a television or cabinetry) to couple the secondary component or structure to the structure 514. The chamfered or tapered surface 516 may be and size and / or contour.

[0107] FIG. 6 illustrates an example of a cross-section of a longitudinal member 602, which may be similar to any of the longitudinal members described above. As shown, the longitudinal member 602 may have a generally rectangular cross-sectional shape and may define a channel 620 therein. The channel 620 may extend along all or a portion of the length of the longitudinal member 602 and may be any size and / or shape.

[0108] FIG. 7A illustrates a top-down view of a fifth example of a structural support assembly 700. FIG. 7B illustrates a side view of the structural support assembly 700. The structural support assembly 700 may be similar to the structural support assembly 100, the structural support assembly 200, the structural support assembly 300, and the structural support assembly 500 described above.

[0109] The structural support assembly 700 may include a longitudinal member 702 that may function as a support portion 704 to support one or more secondary components and / or structures. The support portion 704 (e.g., the longitudinal member 702) may be coupled to or integrally formed with a mounting portion 706 of the structural support assembly 700. The mounting portion 706 may define an opening 708 that may receive a portion or an entirety of a structure 714 (e.g., a wall or stud) therein. As such, the mounting portion 706 may sandwich the structure 714 such that one or more fasteners, such as the fasteners 716, may extend into and / or through the structure 714 to secure the structural support assembly 700 to the structure 714. The184857-5085-0654, v. 1Attorney Docket No. CFS-100-B-WO fasteners 716 may extend through one or more apertures 718 defined by the mounting portion 706.

[0110] As shown in FIG. 7C, the mounting portion 706 may in certain configurations include a different geometry to accommodate additional fasteners therein, which may be similar to the fasteners 716. For example, the mounting portion 706 shown in FIG. 7C may be configured to secure the structural support assembly 700 to only one side of the structure 714. That is, the mounting portion 706 may be free of the opening 708.

[0111] FIG. 8A illustrates a top-down view of a sixth example of a structural support assembly 800. FIG. 8B illustrates a side view of the structural support assembly 800. The structural support assembly 800 may be similar to the structural support assembly 100, the structural support assembly 200, the structural support assembly 300, the structural support assembly 500, and the structural support assembly 700 described above.

[0112] The structural support assembly 800 may include a first longitudinal member 802 and a second longitudinal member 804 disposed adjacent to one another such that the second longitudinal member 804 may support the first longitudinal member 802. That is, the first longitudinal member 802 may be disposed along an upper surface of the second longitudinal member 804. The first longitudinal member 802 and the second longitudinal member 804 may be coupled to a first connector 806 and a second connector 808 on opposing ends (e.g., opposing sides) of the first longitudinal member 802 and the second longitudinal member 804. Thus, the longitudinal members may span a distance or define a distance between the first connector 806 and the second connector 808. Additionally, by stacking the first longitudinal member 802 and the second longitudinal member 804, the structural support assembly 800 may further increase load-bearing capabilities of the structural support assembly 800.

[0113] As shown in FIG. 8B, one or both of the first longitudinal member 802 and the second longitudinal member 804 (e.g., at least the first longitudinal member 802) may define one or more apertures, such as the apertures 810, therein. The apertures 810 may be aligned with one of the first connector 806 and the second connector 808 such that the apertures 810 may receive a fastener (e.g., a screw) and the fastener may extend through the first longitudinal member 802 and the second longitudinal member 804 and into one of the first connector 806 and the second connector 808, to secure the first longitudinal member 802 and the second longitudinal member 804 to the first connector 806 and the second connector 808. For example, a first fastener may194857-5085-0654, v. 1Attorney Docket No. CFS-100-B-WO extend through the first longitudinal member 802 and the second longitudinal member 804 into the first connector 806 and a second fastener may extend through the first longitudinal member 802 and the second longitudinal member 804 into the second connector 808. However, any mounting technique, such as using an adhesive, may be employed to secure the first longitudinal member 802 and the second longitudinal member 804 to the first connector 806 and the second connector 808.

[0114] FIG. 9 illustrates an example of a connector 906 of a structural support assembly, such as the structural support assembly 800. That is, the connector 906 may be similar to the first connector 806 and the second connector 808 described above.

[0115] The connector 906 may define a receiving portion 908 (e.g., a channel) therein that may receive one or more longitudinal members (e.g., the first longitudinal member 802 and the second longitudinal member 804) to secure the longitudinal members to the connector 906. For example, the connector 906 may include one or more fingers 910 that may engage the longitudinal members to secure the longitudinal members in the receiving portion 908. One or more fasteners and / or one or more adhesives may also be used. The connector 906 may also include one or more mounting apertures 912, which may be oriented in any desired orientation with respect to the receiving portion 908, that may receive one or more fasteners therein to secure the connector 906, and thus the longitudinal members therein, to a structure. It should be noted that the connector 906 may also be similar' to any of the connectors described above and may be any size and / or shape.

[0116] FIG. 10A illustrates a side view of a seventh example of a structural support assembly 1000. FIG. 10B illustrates another side view of the structural support assembly 1000. The structural support assembly 1000 may be similar to the structural support assembly 100, the structural support assembly 200, the structural support assembly 300, the structural support assembly 500, the structural support assembly 700, and the structural support assembly 800 described above.

[0117] The structural support assembly 1000 may include a longitudinal member 1002 and a connector 1006. The longitudinal member 1002 may be mounted to a structure 1014 (e.g., a wall, stud, ceiling, other structure, etc.) by the connector 1006. That is, the longitudinal member 1002 may be coupled to the connector 1006, and the connector 1006 may be coupled to the structure 1014 to secure the longitudinal member 1002 to the structure 1014. By way of example, the204857-5085-0654, v. 1Attorney Docket No. CFS-100-B-WO connector 1006 may define a receiving portion 1008 (e.g., a channel, groove, recess, etc.) therein that may receive the longitudinal member 1002 to secure the longitudinal member 1002 to the connector 1006. The longitudinal member 1002 may then be directly and / or indirectly coupled to the structure 1014 via the connector 1006.

[0118] For example, as shown in FIG. 10A, the connector 1006 may include a first flange 1020 and a second flange 1022. The first flange 1020 and the second flange 1022 may be located on opposing sides of the receiving portion 1008 and may extend away from the receiving portion 1008. In some implementations, the first flange 1020, the second flange 1022, and the receiving portion 1008 may be integrally (e.g., monolithically) formed as a single piece. For example, during manufacturing, the connector 1006 may be stamped to form the receiving portion 1008 therein, thereby also defining the first flange 1020 and / or the second flange 1022.

[0119] The first flange 1020 and / or the second flange 1022 may be configured to secure the connector 1006 - and thus the longitudinal member 1002 - to the structure 1014. For example, the first flange 1020 and / or the second flange 1022 may define one or more apertures, such as the apertures 1016. The apertures 1016 may be configured to receive a fastener, such as the fasteners 1018, therein such that the fasteners 1018 may extend through the connector 1006 (e.g., through the apertures 1016 defined by the first flange 1020 and / or the second flange 1022) and into the structure 1014. The apertures 1016 may be any size and / or shape. For example, the apertures 1016 may be round, square (e.g., to prevent rotation of the connector 1006 when mounting the connector 1006 to the structure 1014 via the fasteners 1018), tapered, threaded, or a combination thereof. As such, the first flange 1020 and the second flange 1022 may abut a surface of the structure 1014 such that the receiving portion 1008 and the surface of the structure 1014 define a cavity therein (e.g., a cavity that receives the longitudinal member 1002). Therefore, the connector 1006 may facilitate inserting the longitudinal member 1002 into the receiving portion 1008 after the connector 1006 is coupled to the structure 1014.

[0120] Alternatively, or additionally, the connector 1006 may also facilitate positioning the longitudinal member 1002 in the receiving portion 1008 prior to coupling the connector 1006 to the structure 1014. For example, one of the apertures 1016 defined by the connector 1006, such as the aperture 1016A, may be defined by a portion of the connector 1006 that defines the receiving portion 1008 (e.g., a central region of the connector 1006 located between the first flange 1020 and the second flange 1022). A portion of the longitudinal member 1002 (e.g., an214857-5085-0654, v. 1Attorney Docket No. CFS-100-B-WO end portion and / or a central portion of the longitudinal member 1002) may be positioned within the receiving portion 1008 such that one of the fasteners 1018, such as the fastener 1018A, may extend through the aperture 1016A and into the longitudinal member 1002 to secure the longitudinal member 1002 to the connector 1006. Thus, the connector 1006 may provide an ability to mount the connector 1006 and the longitudinal member 1002 to the structure 1014 in any desired sequence.

[0121] FIG. 10B illustrates another side view of the structural support assembly 1000 shown in FIG. 10A. As shown in FIG 10A, the connector 1006 may be mounted to the structure 1014 such that the receiving portion 1008 extends along a width of the structure 1014. That is, the connector 1006 may be oriented and coupled to the structure 1014 such that the longitudinal member 1002 extends laterally along a width of the structure 1014 (e.g., in a lateral (e.g., side to side) direction transverse to an elevational direction (e.g., an up / down direction). Additionally, as shown in FIG. 10B, the connector 1006 may also be mounted to the structure 1014 such that the receiving portion 1008 extends along a height of the structure 1014. That is, the connector 1006 may also be oriented and coupled to the structure 1014 such that the longitudinal member 1002 extends along a height of the structure 1014 (e.g., in the elevational direction). It should also be noted that an orientation of the connector 1006 with respect to the structure 1014 may be possible. As such, the longitudinal member 1002 may be coupled to the structure 1014 at an desired orientation.

[0122] Furthermore, as shown in FIG. 10C, the structural support assembly 1000 may include a plurality of connectors, such as the connector 1006 (i.e., a first connector) and a second connector 1024. As described above, the connector 1006 may couple the longitudinal member 1002 in any desired manner (e.g., with any desired orientation, angle, position, etc.) to the structure 1014. For example, as shown in FIG. 10C, the connector 1006 and the second connector 1024 may be configured to couple the longitudinal member 1002 to the structure such that the longitudinal member is located below the structure 1014 in the elevational direction. That is, the longitudinal member 1002 may be suspended from the structure 1014 via the connector 1006 and the second connector 1024. The longitudinal member 1002 may extend through the receiving portion 1008 of the connector 1006 and a receiving portion 1026 defined by the second connector 1024 such that the connector 1006 and the second connector 1024 may sufficiently support the longitudinal member 1002.224857-5085-0654, v. 1Attorney Docket No. CFS-100-B-WO

[0123] Additionally, in some implementations, a single connector, such as the connector 1006, may be configured to support more than one longitudinal member. For example, the receiving portion 1008 of the connector 1006 may receive an end portion of a first longitudinal member and an end portion of a second longitudinal member such that the end portion of the first longitudinal member abuts the end portion of the second longitudinal member within the receiving portion 1008. Alternatively, or additionally, the first longitudinal member and the second longitudinal member may be stacked. That is, a depth of the receiving portion 1008 may be substantially the same or greater than a combined thickness of the first longitudinal member and the second longitudinal member.

[0124] FIG. 11 illustrates a perspective view of the connector 1006 shown in FIGS. 10A-10C. As described above, the connector 1006 may define a receiving portion 1008 that is positioned between a first flange 1020 and a second flange 1022 of the connector 1006. The first flange 1020 and the second flange 1022 may define the apertures 1016, which may receive a respective fastener, such as a respective one of the fasteners 1018, therein to secure the connector 1006 to a structure (e.g., the structure 1014). One or more of the apertures 1016, such as the aperture 1016A, may be positioned along the connector 1006 adjacent to the receiving portion 1008 so that, when a longitudinal member (e.g., the longitudinal member 1002) is positioned within the receiving portion 1008, a fastener may extend through the aperture 1016A and into the longitudinal member to secure the longitudinal member to the connector 1006.

[0125] While the first flange 1020 and the second flange 1022 are shown in FIG. 11 as coextensive along a length of the connector 1006, any orientation of the first flange 1020 with respect to the second flange 1022 may be possible. For example, the first flange 1020 and the second flange 1022, with respect to one another, may be substantially parallel, perpendicular, or skewed (e.g., any other desired angle) to facilitate additional mounting schemes. Moreover, a length (Li) of the first flange 1020 and a length (L2) of the second flange 1022 may be any desired length. Similarly, the length (Li) of the first flange 1020 may be greater than, equal to, or less than the length (L2) of the second flange 1022.

[0126] FIG. 12 illustrates a close-up perspective view of the connector 1006 shown in FIGS. 10A-11. As shown, the connector 1006 may also include one or more projections, such as the projection 1028 disposed along a surface of the first flange 1020. Similar flanges may also be present anywhere along the first flange 1020 and / or the second flange 1022. For example, the234857-5085-0654, v. 1Attorney Docket No. CFS-100-B-WO first flange 1020 and the second flange 1022 may each include one or more projections, which may be the same or similar to the projection 1028, along an interior surface such that the projection(s) may contact the structure (e.g., the structure 1014) to further improve engagement between the connector 1006 and the structure 1014 when the connector 1006 is mounted to the structure. For example, the projection(s) may improve friction between the connector 1006 and the structure to decrease or eliminate unwanted rotation and / or slippage of the connector 1006 along the structure before, during, or after coupling the connector 1006 to the structure.

[0127] The projection(s) may be any size and / or shape. For example, as shown in FIG. 12, the projection 1028 may extend along a width of the first flange 1020 between opposing side edges of the first flange 1020. The projection 1028 may project away from the first flange 1020 and may have or include a rounded terminal end (e.g., an end of the projection 1028 that does not contact the first flange 1020) or may include a taper such that the terminal end is a point (e.g., the projection 1028 is a tooth). The projection 1028 may also be integrally (e.g., monolithically) formed with the connector 1006 or may be coupled to the connector 1006, such as via an adhesive. The above description of the projection 1028 may be applicable to any projections of the connector 1006 and the connector 1006 may have any number of projections.

[0128] FIG. 13 illustrates a side view of an eighth example of a structural support assembly 1300. The structural support assembly 1300 may be similar to the structural support assembly 100, the structural support assembly 200, the structural support assembly 300, the structural support assembly 500, the structural support assembly 700, the structural support assembly 800, and the structural support assembly 1000 described above.

[0129] The structural support assembly 1300 may include a longitudinal member 1302 and a connector 1306. The longitudinal member 1302 may be mounted to a structure 1314 (e.g., a wall, stud ceiling, other structure, etc.) by the connector 1306. That is, the longitudinal member 1302 may be coupled to the connector 1306, and the connector 1306 may be coupled to the structure 1314 to secure the longitudinal member 1302 to the structure 1314. By way of example, the connector 1306 may define a receiving portion 1308 (e.g., a channel, groove, recess, etc.) therein that may receive the longitudinal member 1302 to secure the longitudinal member 1302 to the connector 1306. The longitudinal member 1302 may then be directly and / or indirectly coupled to the structure 1314 via the connector 1306.244857-5085-0654, v. 1Attorney Docket No. CFS-100-B-WO

[0130] For example, as shown in FIG. 13, the connector 1306 may include a first flange 1320 and a second flange 1322. The first flange 1320 and the second flange 1322 may be connected to each other such that the first flange 1320 may abut a first surface 1324 of the structure 1314 and the second flange 1322 may abut a second surface 1326 of the structure 1314. By way of example, the structure 1314 may be a structural support, such as a stud, which may form a substantially right angle between the first surface 1324 and the second surface 1326 (e.g., the first surface 1324 and the second surface 1326 form a corner of the structure 1314). As such, the connector 1306 may abut both the first surface 1324 and the second surface 1326 (e.g., abut the comer of the structure 1314).

[0131] The first flange 1320 may be configured to secure the connector 1306 - and thus the longitudinal member 1302 - to the structure 1314. For example, the first flange 1320 may define one or more apertures, such as the apertures 1316. The apertures 1316 may be configured to receive a fastener (e.g., the fasteners 1018 shown in FIG. 10A) therein such that the fasteners may extend through the connector 1306 (e.g., through the apertures 1316) and into the structure 1314. As such, in circumstances where the second surface 1326 of the structure 1314 is inaccessible (e.g., covered by dry wall or paneling), the connector 1306 may still be connected to the structure 1314 via the first flange 1320. Based on such a configuration, the receiving portion 1308 may be coupled to the second flange 1322 of the connector 1306 such that the longitudinal member 1302 may be secured to the second surface 1326 of the structure 1314 without requiring direct mounting of the connector 1306 to the second surface 1326 of the structure 1314.

[0132] FIG. 14 illustrates a perspective view of the connector 1306 shown in FIG. 13. As described above, the connector 1306 may define the receiving portion 1308. The receiving portion 1308 may be defined by a channel or sleeve, such as the sleeve 1430, which may be coupled to the second flange 1322 of the connector 1306. Thus, the sleeve 1430 may be positioned to extend along the second flange 1322 such that the sleeve 1430 may extend along a surface, such as the second surface 1326 of the structure 1314. As such, the connector 1306 may be secure to the structure 1314 via fasteners extending through the apertures 1316 defined by the first flange 1320 of the connector 1306.

[0133] FIG. 15 illustrates another example of a structure of the connector 1306. As shown in FIG. 15, the sleeve 1430, which may define the receiving portion 1308 therein, may be substantially closed and have a substantially square cross-sectional shape. Conversely, as shown254857-5085-0654, v. 1Attorney Docket No. CFS-100-B-WO in FIG. 15, the sleeve 1430 may be opened along a side of the sleeve 1430 that may abut the second flange 1322 of the connector 1306. That is, the cross-scctional shape of the sleeve 1430 may be C-shaped or U-shaped as opposed to being entirely closed along a perimeter of the sleeve 1430.

[0134] FIG. 16 illustrates a side view of a ninth example of a structural support assembly 1600. The structural support assembly 1600 may be similar to the structural support assembly 100, the structural support assembly 200, the structural support assembly 300, the structural support assembly 500, the structural support assembly 700, the structural support assembly 800, the structural support assembly 1000, and the structural support assembly 1300 described above.

[0135] The structural support assembly 1600 may include a first longitudinal member 1602, a second longitudinal member 1604, and a connector 1606. The connector 1606 may connect the first longitudinal member 1602 and the second longitudinal member 1604 to one another to form a substantially right- angle between the first longitudinal member 1602 and the second longitudinal member 1604. That is, the connector 1606 may facilitate connection of the first longitudinal member 1602 to the second longitudinal member 1604 to such that the first longitudinal member 1602 and the second longitudinal member 1604 are substantially orthogonal to one another.

[0136] By way of example, the connector 1606 may include a first surface 1620 and a second surface 1622, whereby the first surface 1620 is substantially orthogonal to the second surface 1622. The first surface 1620 may include a first receiving portion 1624 that is configured to receive the first longitudinal member 1602 therein and the second surface 1622 may include a second receiving portion 1626 that is configured to receive the second longitudinal member 1604 therein. The receiving portions may be projections, fingers, slots, channels, or another mechanical engaging means that configured to at least partially align and / or secure the longitudinal members to the connector 1606.

[0137] For example, the first receiving portion 1624 may be a pair of fingers that aligns the first longitudinal member 1602 with the first surface 1620 of the connector 1606 so that the first longitudinal member 1602 may abut the first surface 1620 of the connector 1606. As such, a fastener may extend through the connector 1606 and into the first longitudinal member 1602 to secure the first longitudinal member 1602 to the connector 1606. For example, the connector 1606 may define a cavity 1628 therein and the first surface 1620 may define a first aperture264857-5085-0654, v. 1Attorney Docket No. CFS-100-B-WO1630, which may extend through the first surface 1620 and permit access to the cavity 1628. As such, the fastener may extend through the cavity 1628 and into the first longitudinal member 1602 to secure the first longitudinal member 1602 to the connector 1606 or the fastener may extend through the first longitudinal member 1602 and into the cavity 1628 (e.g., through the first aperture 1630) to secure the first longitudinal member 1602 to the connector 1606. Similarly, the second surface 1622 may define a second aperture 1632, which may extend through the second surface 1622 and permit access to the cavity 1628. As such, a fastener may extend through the cavity 1628 and into the second longitudinal member 1604 to secure the second longitudinal member 1604 to the connector 1606 or the fastener may extend through the second longitudinal member 1604 and into the cavity 1628 (e.g., through the second aperture 1632) to secure the second longitudinal member 1604 to the connector 1606.

[0138] FIG. 17 illustrates a perspective view of the connector 1606 shown in FIG. 16. FIG. 18 illustrates a front view of the connector 1606. As described above, the connector 1606 may define a first receiving portion 1624 and a second receiving portion 1626 located on the first surface 1620 and the second surface 1622, respectively. As shown in FIGS. 17 and 18, the receiving portions (e.g., the first receiving portion 1624 and the second receiving portion 1626) may each be a pair of fingers or arms, which may extend from opposing sides of the first surface 1620 and the second surface 1622 such that the receiving portions may receive one of the longitudinal members (e.g., the first longitudinal member 1602 or the second longitudinal member 1604). The receiving portions may thus retain the longitudinal members along the connector 1606 to thereafter secure the longitudinal members to the connector 1606.

[0139] Illustrative Embodiments

[0140] The implementations of this disclosure include an assembly. The assembly includes two or more longitudinal members comprising a continuous fiber composite material and interconnected by a connector comprised of a receptacle in which a portion of the two or more longitudinal members are inserted.

[0141] In some implementations, the continuous fiber composite material is comprised of synthetic fibers.

[0142] In some implementations, the continuous fiber composite material is comprised of carbon fibers.274857-5085-0654, v. 1Attorney Docket No. CFS-100-B-WO

[0143] In some implementations, the continuous fiber composite material traverses all or a portion of a length of the two or more longitudinal members, the length being measured along or parallel to a longitudinal axis of the two or more longitudinal members.

[0144] In some implementations, the two or more longitudinal members are a laminate that include the continuous fiber composite material.

[0145] In some implementations, the continuous fiber composite material has a density of about 2 g / cc or less.

[0146] In some implementations, the two or more longitudinal members have an axial tensile strength of about 250 Ksi or more.

[0147] In some implementations, the two or more longitudinal members have a flex modulus of about 19,000 Ksi or more.

[0148] In some implementations, the connector receives a terminal end of each of the two or more longitudinal members.

[0149] In some implementations, the connector receives a central portion of each of the two or more longitudinal members, the central portion being a portion of the two or more longitudinal members that is located between terminal ends of the two or more longitudinal members.

[0150] In some implementations, the two or more longitudinal members are a bar.

[0151] In some implementations, the two or more longitudinal members are a tube.

[0152] In some implementations, the two or more longitudinal members are uniform in cross- sectional shape.

[0153] In some implementations, the assembly supports additional structures.

[0154] In some implementations, the two or more longitudinal members are inserted into the connector, and an insertion force to insert the two or more longitudinal members is less than a force required to remove the two or more longitudinal members from the connector.

[0155] In some implementations, the force required to remove the two or more longitudinal members from the connector is about 50% greater than the insertion force.

[0156] In some implementations, the force required to remove the two or more longitudinal members from the connector is about 100% greater than the insertion force.

[0157] In some implementations, the force required to remove the two or more longitudinal members from the connector is about 200% greater than the insertion force.284857-5085-0654, v. 1Attorney Docket No. CFS-100-B-WO

[0158] In some implementations, the two or more longitudinal members are inserted into the connector and coupled to the connector free of any additional fasteners.

[0159] In some implementations, the two or more longitudinal members are inserted into the connector and coupled to the connector via a friction fit between the two or more longitudinal members and the connector.

[0160] In some implementations, the two or more longitudinal members are coupled to the connector via compression fittings.

[0161] In some implementations, the compression fittings are configured to compressibly contact an outer surface of the two or more longitudinal members to maintain engagement between the connector and the two or more longitudinal members.

[0162] In some implementations, the compression fittings are configured to releasably contact the outer surface of the two or more longitudinal members to release engagement between the connector and the two or more longitudinal members.

[0163] In some implementations, the two or more longitudinal members are mechanically interlocked with the connector to couple the two or more longitudinal members to the connector.

[0164] In some implementations, the two or more longitudinal members are inserted into the connector and coupled to the connector by an adhesive.

[0165] In some implementations, at least about 5 centimeters or more of a length of each of the two or more longitudinal members is inserted into the connector, the length being measured along or parallel to a longitudinal axis of the two or more longitudinal members.

[0166] In some implementations, at least about 10 centimeters or more of the length of each of the two or more longitudinal members is inserted into the connector.

[0167] In some implementations, the adhesive is comprised of one or more of an epoxy resin, an acrylate adhesive, and a polyurethane adhesive.

[0168] In some implementations, the adhesive abuts a longitudinal surface of each of the two or more longitudinal members to form an adhesive layer between the two or more longitudinal members and the connector.

[0169] In some implementations, the adhesive abuts a terminal end of each of the two or more longitudinal members to form a secondary adhesive layer between the two or more longitudinal members and the connector.294857-5085-0654, v. 1Attorney Docket No. CFS-100-B-WO

[0170] In some implementations, the adhesive layer has an average thickness of about 0.01 mm to about 3 mm.

[0171] In some implementations, the two or more longitudinal members have a rectangular cross-sectional shape.

[0172] In some implementations, the two or more longitudinal members have a length that is parallel to a direction of fibers of the continuous fiber composite material, a width that is perpendicular to the direction of the fibers of the continuous fiber composite material, and a thickness that is perpendicular to the direction of the fibers of the continuous fiber composite material.

[0173] In some implementations, the two or more longitudinal members are uniform in length.

[0174] In some implementations, the width of the two or more longitudinal members is greater than the thickness of the two or more longitudinal members.

[0175] In some implementations, the continuous fiber composite material is comprised of at least one of natural fibers and synthetic fibers.

[0176] In some implementations, the continuous fiber composite material is a continuous fiber polymer composite material.

[0177] In some implementations, the continuous fiber polymer composite material is a pultruded or extruded continuous polymer composite material.

[0178] In some implementations, a polymer of the continuous fiber polymer composite material is comprised of one or more of an epoxy, polyurethane, or polyurea.

[0179] In some implementations, the connector defines a cavity that extends through a thickness of the connector between a first surface of the connector and an opposing second surface of the connector.

[0180] In some implementations, the connector defines an opening and the two or more longitudinal members are inserted into the opening such that the two or more longitudinal members are arranged in a stacked manner.

[0181] In some implementations, the two or more longitudinal members are inserted into the cavity to interconnect the two or more longitudinal members to facilitate transference of a load between the two or more longitudinal members.

[0182] In some implementations, a cross-section of the two or more longitudinal members is complementary in shape to a cross-section of the cavity.304857-5085-0654, v. 1Attorney Docket No. CFS-100-B-WO

[0183] In some implementations, the cavity is at least partially filled with a foam and the foam at least partially fills a gap between the two or more longitudinal members and the connector.

[0184] In some implementations, the foam at least partially fills a gap between the two or more longitudinal members.

[0185] In some implementations, the two or more longitudinal members define one or more apertures that extend through a thickness of the two or more longitudinal members.

[0186] In some implementations, the one or more apertures are pre-drilled holes that are configured to receive a fastener to secure the two or more longitudinal members to a structure.

[0187] In some implementations, the one or more apertures are located near a first terminal end of each of the two or more longitudinal members, and an opposing end of each of the two or more longitudinal members is connected to the connector.

[0188] In some implementations, each of the two or more longitudinal members defines a cavity therein that is configured to receive a portion of the connector.

[0189] In some implementations, the cavity of each of the two or more longitudinal members is complementary in shape to a respective portion of the connector.

[0190] In some implementations, the portion of the connector includes one or more engaging features located along an exterior surface of the portion.

[0191] In some implementations, the one or more engaging features are bumps or projections that extend away from the exterior surface of the portion to contact an inner surface of the cavity of each of the two or more longitudinal members.

[0192] In some implementations, the one or more engaging features are an abrasive surface disposed along the exterior surface of the portion.

[0193] In some implementations, the connector comprises a thermoplastic material.

[0194] In some implementations, the connector comprises a thermosetting material.

[0195] In some implementations, the connector is comprised of a metal, a polymer, a ceramic, or any combination thereof.

[0196] In some implementations, the connector is comprised of the metal, and the metal is configured to thermally expand and contact the two or more longitudinal members to create a compression fitting between the two or more longitudinal members and the connector.

[0197] In some implementations, the connector is comprised of a composite comprised of a fiber reinforcement.314857-5085-0654, v. 1Attorney Docket No. CFS-100-B-WO

[0198] In some implementations, the composite is a carbon fiber polymer composite.

[0199] In some implementations, the connector is comprised of a deformable polymer material.

[0200] In some implementations, the connector is comprised of a rigid polymer material.

[0201] In some implementations, the connector defines two or more channels that are spaced apart from one another by a body of the connector, and the two or more longitudinal members are at least partially inserted into a respective one of the two or more channels.

[0202] In some implementations, the two or more channels are complementary in shape to a cross-section of the two or more longitudinal members.

[0203] In some implementations, the body of the connector includes two or more faces, and the two or more channels each include an opening that is located on a different one of the two or more faces.

[0204] In some implementations, the body of the connector includes a face, and the two or more channels each include an opening that is located on the face.

[0205] In some implementations, the connector defines a channel, and the two or more longitudinal members are at least partially inserted into the channel.

[0206] In some implementations, when the two or more longitudinal members are at least partially inserted into the connector, the two or more longitudinal members extend in a same direction away from the connector.

[0207] In some implementations, when the two or more longitudinal members are at least partially inserted into the connector, each of the two or more longitudinal members abut at least another one of the two or more longitudinal members.

[0208] In some implementations, when the two or more longitudinal members are at least partially inserted into the connector, the two or more longitudinal members extend in different directions away from the connector.

[0209] In some implementations, when the two or more longitudinal members are at least partially inserted into the connector, the two or more longitudinal members are nonparallel to one another.

[0210] In some implementations, when the two or more longitudinal members are at least partially inserted into the connector, the two or more longitudinal members are perpendicular to one another.324857-5085-0654, v. 1Attorney Docket No. CFS-100-B-WO

[0211] The implementations of this disclosure include a method of assembling a reinforcement structure. The method includes connecting a first longitudinal member to a connector and connecting a second longitudinal member to the connector to interconnect the first longitudinal member to the second longitudinal member. The connector is an intermediary component that mechanically connects the first longitudinal member to the second longitudinal member. The first longitudinal member and the second longitudinal member are a continuous fiber composite material comprised of carbon fibers.

[0212] In some implementations, the connector includes a first connecting portion and a second connecting portion, the first longitudinal member is connected to the first connecting portion, and the second longitudinal member is connected to the second connecting portion.

[0213] In some implementations, the connector includes a connecting portion, and the first longitudinal member and the second longitudinal member are both inserted into the connecting portion.

[0214] In some implementations, the first longitudinal member abuts the second longitudinal member after insertion into the connecting portion.

[0215] In some implementations, the first connecting portion and the second connecting portion are a channel or a cavity defined by the connector.

[0216] In some implementations, the connecting portion is a channel or a cavity defined by the connector, and a cross-section of the cavity is complementary in shape to a cross-section of the first longitudinal member and the second longitudinal member when the first longitudinal member and the second longitudinal member abut one another.

[0217] In some implementations, the first longitudinal member and the second longitudinal member are inserted into the connector, and an insertion force required to insert the first longitudinal member and the second longitudinal member into the connector is less than a force required to remove the first longitudinal member and the second longitudinal member from the connector.

[0218] In some implementations, an adhesive is disposed between the first longitudinal member and the connector and between the second longitudinal member and the connector.

[0219] In some implementations, the method further comprises activating the adhesive after inserting the first longitudinal member and the second longitudinal member into the connector.

[0220] In some implementations, the adhesive is activated by heat.334857-5085-0654, v. 1Attorney Docket No. CFS-100-B-WO

[0221] In some implementations, the adhesive is a metal filler that is inserted into the connector at or above a melting temperature of the metal filler such that, when cooled, the adhesive joins the first longitudinal member and the second longitudinal member to the connector.

[0222] In some implementations, the adhesive is a two-part adhesive, a first part of the adhesive is disposed between the first longitudinal member and the connector and between the second longitudinal member and the connector, and a second part of the adhesive is inserted between the first longitudinal member and the connector and between the second longitudinal member and the connector to activate the adhesive.

[0223] In some implementations, a foaming material is disposed between the first longitudinal member and the connector and between the second longitudinal member and the connector.

[0224] In some implementations, the method further comprises activating the foaming material after inserting the first longitudinal member and the second longitudinal member into the connector to expand the foaming material and fill a gap between the first longitudinal member and the connector, a gap between the second longitudinal member and the connector, and a gap between the first longitudinal member and the second longitudinal member.

[0225] In some implementations, the first longitudinal member and the second longitudinal member are equal in length and have a same cross-sectional shape.

[0226] In some implementations, the first longitudinal member and the second longitudinal member vary in length or shape.

[0227] In some implementations, the first longitudinal member and the second longitudinal member are a bar, and a cross-sectional shape of the bar is rectangular, oval, circular, T-shaped, H-shaped, V-shaped, or J-shaped.

[0228] In some implementations, the first longitudinal member is a first cut segment of the bar and the second longitudinal member is a second cut segment of the bar.

[0229] In some implementations, prior to connecting the first longitudinal member and the second longitudinal member to the connector, the method further comprises cutting a first segment from a pultruded continuous length of the continuous fiber composite material to form the first longitudinal member and cutting a second segment from the pultruded continuous length of the continuous fiber composite material to form the second longitudinal member.

[0230] In some implementations, prior to connecting the first longitudinal member and the second longitudinal member to the connector, the method further comprises cutting a third344857-5085-0654, v. 1Attorney Docket No. CFS-100-B-WO segment from a second pultruded continuous length of the continuous fiber composite material to form the connector.

[0231] In some implementations, the continuous fiber composite material is a continuous polymer composite material comprised of at least one of natural fibers and synthetic fibers.

[0232] The implementations of this disclosure include a connector configured to receive two or more longitudinal members therein. An insertion force to insert the two or more longitudinal members is less than a force required to remove the two or more longitudinal members from the connector. The two or more longitudinal members are configured to be inserted into the connector and coupled to the connector free of any additional fasteners.

[0233] In some implementations, the two or more longitudinal members comprise a continuous fiber composite material, and the connector comprises a receptacle that is configured to receive a portion of the two or more longitudinal members.

[0234] In some implementations, the force required to remove the two or more longitudinal members from the connector is about 200% greater than the insertion force.

[0235] While the disclosure has been described in connection with certain embodiments, it is to be understood that the disclosure is not to be limited to the disclosed embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law.

[0236] Persons skilled in the art will understand that the various embodiments of the present disclosure and shown in the accompanying figures constitute non-limiting examples, and that additional components and features may be added to any of the embodiments discussed hereinabove without departing from the scope of the present disclosure. Additionally, persons skilled in the art will understand that the elements and features shown or described in connection with one embodiment may be combined with those of another embodiment without departing from the scope of the present disclosure to achieve any desired result and will appreciate further features and advantages of the presently disclosed subject matter based on the description provided. Variations, combinations, and / or modifications to any of the embodiments and / or features of the embodiments described herein that are within the abilities of a person having ordinary skill in the art are also within the scope of the present disclosure, as are alternative354857-5085-0654, v. 1Attorney Docket No. CFS-100-B-WO embodiments that may result from combining, integrating, and / or omitting features from any of the disclosed embodiments.

[0237] Use of the term “optionally” with respect to any element of a claim means that the element may be included or omitted, with both alternatives being within the scope of the claim. Additionally, use of broader terms such as “comprises,” “includes,” and “having” should be understood to provide support for narrower terms such as “consisting of,” “consisting essentially of,” and “comprised substantially of.” Accordingly, the scope of protection is not limited by the description set out above, but is defined by the claims that follow, and includes all equivalents of the subject matter of the claims.

[0238] In the preceding description, reference may be made to the spatial relationship between the various structures illustrated in the accompanying drawings, and to the spatial orientation of the structures. However, as will be recognized by those skilled in the art after a complete reading of this disclosure, the structures described herein may be positioned and oriented in any manner suitable for their intended purpose. Thus, the use of terms such as “above,” “below,” “upper,” “lower,” “inner,” “outer,” “left,” “right,” “upward,” “downward,” “inward,” “outward,” “horizontal,” “vertical,” etc., should be understood to describe a relative relationship between the structures and / or a spatial orientation of the structures. Those skilled in the art will also recognize that the use of such terms may be provided in the context of the illustrations provided by the corresponding figure(s).

[0239] Additionally, terms such as “approximately,” “generally,” “substantially,” and the like should be understood to allow for variations in any numerical range or concept with which they are associated and encompass variations on the order of 25% (e.g., to allow for manufacturing tolerances and / or deviations in design). For example, the term “generally parallel” should be understood as referring to configurations in with the pertinent components are oriented so as to define an angle therebetween that is equal to 180° ± 25% (e.g., an angle that lies within the range of (approximately) 135° to (approximately) 225°). The term “generally parallel” should thus be understood as referring to encompass configurations in which the pertinent components are arranged in parallel relation.

[0240] Although terms such as “first,” “second,” “third,” etc., may be used herein to describe various operations, elements, components, regions, and / or sections, these operations, elements, components, regions, and / or sections should not be limited by the use of these terms in that these364857-5085-0654, v. 1Attorney Docket No. CFS-IOO-B-WO terms are used to distinguish one operation, element, component, region, or section from another. Thus, unless expressly stated otherwise, a first operation, clement, component, region, or section could be termed a second operation, element, component, region, or section without departing from the scope of the present disclosure.4857-5085-0654, v. 1

Claims

Attorney Docket No. CFS-IOO-B-WOCLAIMSWhat is claimed is:

1. An assembly, comprising: two or more longitudinal members comprising a continuous fiber composite material and interconnected by a connector comprised of a receptacle in which a portion of the two or more longitudinal members are inserted.

2. The assembly of claim 1, wherein the continuous fiber composite material is comprised of synthetic fibers.

3. The assembly of claim 2, wherein the continuous fiber composite material is comprised of carbon fibers.

4. The assembly of claim 1, wherein the continuous fiber composite material traverses all or a portion of a length of the two or more longitudinal members, the length being measured along or parallel to a longitudinal axis of the two or more longitudinal members.

5. The assembly of claim 1 , wherein the two or more longitudinal members are a laminate that include the continuous fiber composite material.

6. The assembly of claim 1, wherein the continuous fiber composite material has a density of about 2 g / cc or less.

7. The assembly of claim 1, wherein the two or more longitudinal members have an axial tensile strength of about 250 Ksi or more.

8. The assembly of claim 1, wherein the two or more longitudinal members have a flex modulus of about 19,000 Ksi or more.384857-5085-0654, v. 1Attorney Docket No. CFS-IOO-B-WO9. The assembly of claim 1 , wherein the connector receives a terminal end of each of the two or more longitudinal members.

10. The assembly of claim 1, wherein the connector receives a central portion of each of the two or more longitudinal members, the central portion being a portion of the two or more longitudinal members that is located between terminal ends of the two or more longitudinal members.

11. The assembly of claim 1, wherein the two or more longitudinal members are inserted into the connector, and an insertion force to insert the two or more longitudinal members is less than a force required to remove the two or more longitudinal members from the connector.

12. The assembly of claim 11, wherein the force required to remove the two or more longitudinal members from the connector is about 200% greater than the insertion force.

13. The assembly of claim 1, wherein the two or more longitudinal members are inserted into the connector and coupled to the connector free of any additional fasteners.

14. The assembly of claim 1, wherein the two or more longitudinal members are inserted into the connector and coupled to the connector by an adhesive.

15. The assembly of claim 14, wherein at least about 5 centimeters or more of a length of each of the two or more longitudinal members is inserted into the connector, the length being measured along or parallel to a longitudinal axis of the two or more longitudinal members.

16. The assembly of claim 14, wherein the adhesive is comprised of one or more of an epoxy resin, an acrylate adhesive, and a polyurethane adhesive.

17. The assembly of claim 16, wherein the adhesive abuts a longitudinal surface of each of the two or more longitudinal members to form an adhesive layer between the two or more longitudinal members and the connector.394857-5085-0654, v. 1Attorney Docket No. CFS-IOO-B-WO18. The assembly of claim 1, wherein the two or more longitudinal members have a length that is parallel to a direction of fibers of the continuous fiber composite material, a width that is perpendicular to the direction of the fibers of the continuous fiber composite material, and a thickness that is perpendicular to the direction of the fibers of the continuous fiber composite material.

19. The assembly of claim 1, wherein the continuous fiber composite material is comprised of at least one of natural fibers and synthetic fibers.

20. The assembly of claim 1, wherein the continuous fiber composite material is a continuous fiber polymer composite material.

21. The assembly of claim 20, wherein the continuous fiber polymer composite material is a pultruded or extruded continuous polymer composite material.

22. The assembly of claim 20, wherein a polymer of the continuous fiber polymer composite material is comprised of one or more of an epoxy, polyurethane, or polyurea.

23. The assembly of claim 1, wherein the two or more longitudinal members define one or more apertures that extend through a thickness of the two or more longitudinal members.

24. The assembly of claim 23, wherein the one or more apertures are pre-drilled holes that are configured to receive a fastener to secure the two or more longitudinal members to a structure.

25. A method of assembling a reinforcement structure, comprising: connecting a first longitudinal member to a connector; and connecting a second longitudinal member to the connector to interconnect the first longitudinal member to the second longitudinal member, wherein the connector is an404857-5085-0654, v. 1Attorney Docket No. CFS-IOO-B-WO intermediary component that mechanically connects the first longitudinal member to the second longitudinal member, wherein the first longitudinal member and the second longitudinal member are a continuous fiber composite material comprised of carbon fibers.

26. The method of claim 25, wherein the connector includes a first connecting portion and a second connecting portion, the first longitudinal member is connected to the first connecting portion, and the second longitudinal member is connected to the second connecting portion.

27. The method of claim 25, wherein the connector includes a connecting portion, and the first longitudinal member and the second longitudinal member are both inserted into the connecting portion.

28. The method of claim 27, wherein the first longitudinal member abuts the second longitudinal member after insertion into the connecting portion.

29. The method of claim 26, wherein the first connecting portion and the second connecting portion are a channel or a cavity defined by the connector.

30. The method of claim 27, wherein the connecting portion is a channel or a cavity defined by the connector, and a cross-section of the cavity is complementary in shape to a crosssection of the first longitudinal member and the second longitudinal member when the first longitudinal member and the second longitudinal member abut one another.

31. The method of claim 25, wherein the first longitudinal member and the second longitudinal member are inserted into the connector, and an insertion force required to insert the first longitudinal member and the second longitudinal member into the connector is less than a force required to remove the first longitudinal member and the second longitudinal member from the connector.414857-5085-0654, v. 1Attorney Docket No. CFS-IOO-B-WO32. The method of claim 31 , wherein an adhesive is disposed between the first longitudinal member and the connector and between the second longitudinal member and the connector.

33. The method of claim 32, further comprising activating the adhesive after inserting the first longitudinal member and the second longitudinal member into the connector.

34. The method of claim 25, wherein a foaming material is disposed between the first longitudinal member and the connector and between the second longitudinal member and the connector.

35. The method of claim 34, further comprising activating the foaming material after inserting the first longitudinal member and the second longitudinal member into the connector to expand the foaming material and fill a gap between the first longitudinal member and the connector, a gap between the second longitudinal member and the connector, and a gap between the first longitudinal member and the second longitudinal member.

36. A connector configured to receive two or more longitudinal members therein, wherein an insertion force to insert the two or more longitudinal members is less than a force required to remove the two or more longitudinal members from the connector, and wherein the two or more longitudinal members are configured to be inserted into the connector and coupled to the connector free of any additional fasteners.

37. The connector of claim 36, wherein the two or more longitudinal members comprise a continuous fiber composite material, and wherein the connector comprises a receptacle that is configured to receive a portion of the two or more longitudinal members.

38. The connector of claim 36, wherein the force required to remove the two or more longitudinal members from the connector is about 200% greater than the insertion force.424857-5085-0654, v. 1

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