Structural assembly having injection-bonded joint and method of forming

A structural assembly, comprising:

• a first part having opposing inner and outer surfaces and a second part having opposing inner and outer surfaces, a second part upper edge and a second part lower edge, a respective one of the inner and outer surfaces of the second part being disposed parallel or concentric to a corresponding respective one of the inner and outer surfaces of the first part, and opposing mating surfaces of the first part and the second part being adhesively bonded together along a bondline region having a bondline length;
• a series of chamber walls formed along the bondline length and dividing the bondline length into a plurality of adhesive chambers;
• a bondline dam formed along each of the second part upper edge and the second part lower edge in a manner such that the chamber walls, the bondline dams, and the mating surfaces collectively enclose the adhesive chambers;
• a structural adhesive injected into each of the adhesive chambers through an injection port formed in the second part and bonding the first part to the second part, and excess structural adhesive being discharged from each adhesive chamber through a bleed hole located between the first and second parts and formed within the bondline dam of the adhesive chamber along the second part upper edge;
• and
• a plurality of adhesive reservoirs, each fluidly coupled to a respective one of the bleed holes for collecting the excess structural adhesive, each adhesive reservoir being formed as one of a vertical column comprising a longitudinally-extending channel attached to the respective inner or outer surface of the first part, and a shelf attached to the corresponding respective inner or outer surface of the second part and projecting therefrom, adjacent the second part upper edge.