Manufacturing and assembly of fiber reinforced polymer building systems

Abstract

A frame assembly is constructed from a plurality of Fiber Reinforced Polymer (FRP) structural components and is configured to provide a dry seal at a joint between frame assemblies. The frame assembly comprises FRP C-channel structural components joined together with FRP corner connectors. The FRP C-channel structural components and the FRP corner connectors are designed to employ a flexible waterproofing material that provides a dry seal at the joint where the frame assembly joins to another frame assembly.

Description

Manufacturing and Assembly of Fiber Reinforced Polymer Building SystemsCROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the priority benefit of U.S. Provisional Appl. Ser. No. 63 / 526.168, filed on July 11. 2023; which is hereby incorporated by reference herein in its entirety.

[0002] U.S. Pat. Appl. Ser. No. 18 / 126,987, filed on 3 / 27 / 2023; U.S. Pat. Appl. Ser. No. 17 / 093,262, filed on 11 / 09 / 2020; U.S. Pat. Appl. Ser. No. 18 / 207,438, filed on 6 / 08 / 2023; U.S. Pat. Appl. Ser. No. 17 / 41 1,041, filed on 8 / 24 / 2021; and PCT Appl. Ser. No. PCT / US21 / 47414, filed on 8 / 24 / 2021 are each expressly incorporated by reference herein in its entirety.INTRODUCTIONI. Field

[0003] Aspects of the disclosure relate to building systems, and more specifically, building systems and structural components comprising Fiber Reinforced Polymer (FRP).II. Background

[0004] The background description includes information that may be useful in understanding the present inventive subject matter. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed subject matter, or that any publication, specifically or implicitly referenced, is prior art. All publications disclosed herein are incorporated by reference in their entireties. Without limiting the scope of this disclosure as expressed by the claims which follow, some features will now be discussed briefly.

[0005] An exterior panelized wall assemblies can provide the basic function of the envelope or enclosure of a building or structure. Panelized wall assemblies can be prefabricated offsite, allowing for efficient and faster construction. The panels are manufactured in controlled environments which increase quality control and reduce the impact of weather delays on the construction timeline. Once on-site, the panels can be installed onto a frame assembly, saving time and labor costs. Panelized wall assemblies offer numerous advantages including improved quality, design flexibility, energy efficiency, reduced on-site disruption, and sustainable construction practices. These benefits make them an attractive option for many construction projects.

[0006] Panelized exterior wall assemblies can be made from a variety of materials depending on the desired characteristics, aesthetics, and construction requirements. Some panelized exterior wall assemblies comprise metal panels, fiber cement panels, wood panels, composite panels, concrete panels, glass panels, and structural insulated panels. Multiple wall panel assemblies can be joined together, and may be secured to a frame assembly, such as to create an envelope or enclosure of a building or structure. The point at which two panels (e.g., wall panels) meet is a panel joint, and is often a source for water and air intrusion if not properly sealed. Rainwater penetration and moisture ingress impede the structural integrity7and performance of the building enclosure, or envelope. A wet seal is commonly used for preventing rainwater intrusion into panel joints of exterior panelized wall assemblies. Wet seals typically employ caulk, backer rod, sealants, and other waterproofing membranes. Waterproofing panel joints is labor-intensive and prone to errors.

[0007] Furthermore, materials used in panelized wall assemblies are often subject to degradation. Concrete cracks, steel and aluminum oxidizes and deforms under force; and wood can rot, crack, and deform. Such degradations compromise traditional waterproofing systems at panel joints.SUMMARY

[0008] These and other needs in the construction industry' can be remedied by employing building materials that better resist degradation. Advanced composite technology, in combination with disclosed dry-seal waterproofing methods, can provide for a single-source application to provide advantageous features and benefits over current building systems, suchas panelized wall assemblies. Disclosed aspects can improve energy efficiency, safety, productivity, quality of life, customer experience, and / or sustainability; and can reduce environmental impacts.

[0009] Some aspects of the disclosure can provide for frame assemblies (such as panelized wall assemblies) that incorporate a dry seal waterproofing system, thus, reducing or eliminating the need for wet seal waterproofing at panel joints. Disclosed aspects include building systems comprising disclosed frame assemblies. Disclosed aspects can provide for frame assemblies configured to advantageously exploit properties of flexible epoxy, Fiber Reinforced Polymer (FRP), Pultruded Fiber Reinforced Polymer (PFRP), and high- performance fire-resistant flexible rubber (such as Ethylene Propylene Diene Monomer (EPDM) or fire-resistant silicone). Some disclosed aspects can provide a monolithic composite frame assembly with an integrated waterproofing system.

[0010] Some aspects of the disclosure can be directed to modular construction. Modular building components are manufactured in a controlled environment before delivery to a construction site, where they are assembled. Offsite construction enables the use of lean manufacturing techniques to create prefabricated modules. Thus, modular building systems are more easily fabricated to standards that exceed traditional site-built projects, improving quality control. The modular assembly can be performed onsite using inter-module connections (or inter-connections) to join the units together. Some aspects include manufacturing the disclosed components. Some aspects include assembling disclosed components to produce building systems that might comprise multiple frame assemblies.

[0011] In disclosed aspects, the process of applying a wet seal to a wall-panel joint can be bypassed by incorporating a dry seal into a composite frame assembly during its manufacturing. This can provide a more efficient and effective method for waterproofing panel joints, and simplify construction and reduce maintenance requirements of the building.

[0012] In some aspects, a composite frame assembly can comprise FRP, PFRP, flexible epoxy, and / or EPDM. FRP can include fiberglass, which is a composite comprising a polymer resin matrix reinforced with embedded glass fibers. The strength of a fiberglass element is based on the type, orientation, quantity, and location of the glass fibers within the composite. This allows components to be engineered to specific performance requirements.such as ballistic protection or predetermined flexibility and stiffness. The composition of resins can be configured for a predetermined coefficient of thermal expansion. In some aspects, the selection and / or design of FRP, PFRP, flexible epoxy, and / or high-performance fire-resistant flexible rubber components can be configured to provide a uniform coefficient of thermal expansion throughout a wall-panel joint, thus mitigating deformation and degradation of the joint, and thus, preventing failure of the seal. The selection and / or design of FRP, PFRP. flexible epoxy, and / or and high-performance fire-resistant flexible rubber components can be configured to provide a uniform coefficient of thermal expansion throughout a composite frame assembly and larger building systems.

[0013] Some aspects are directed to a composite frame assembly for exterior panelized wall systems comprising a monolithic design using FRP structural components and high- performance fire-resistant flexible rubber dry-seal waterproofing. Flexible epoxy might be selected to join the components and provide for a uniform coefficient of thermal expansion throughout the frame assembly. The frame assembly can be in-filled with FRP and / or other building materials to form an exterior panelized wall system. The frame assembly can be configurable to attach to other frame assemblies. For example, FRP connectors and FRP interlocking splines might be used. Disclosed aspects employ dry -seal techniques to waterproof joints between composite frame assemblies. Aspects of the disclosure include the manufacture and / or assembly of such building systems.

[0014] In one aspect, a frame assembly comprises a plurality7of FRP structural components. At least one of the outer edges of the frame assembly has at least one receiver slot and / or at least one protrusion configured to join an FRP spline to the frame assembly. In one example the spline comprises a flexible w aterproofing material configured to make a waterproof dry seal between the spline and the frame assembly. For example, the spline might comprises a pair of longitudinal faces, at least one of w hich is configured for attaching a gasket comprising the flexible waterproofing material. In some aspects, at least one of the outer edges of the frame assembly is configured for attaching at least one gasket comprising the flexible waterproofing material. For example, the outer edges of the frame’s FRP structural elements (e.g., comer connectors and C-channel members) might comprise one or more secondary' gasket connection raceways. The flexible waterproofing material can comprise a high performance fire resistant flexible rubber, such as EPDM, fire-resistant silicone, or any other suitable fire-resistant flexible material. One or more of the FRP structural elementsmight comprise PFRP structural elements. Where appropriate, FRP elements disclosed herein might be PFRP elements.

[0015] The frame assembly can comprise an FRP comer connector on each of its comers, each FRP comer connector comprising at least one of a receiver slot or an alignment post configured to join together two or more FRP C channels. Comer connectors disclosed herein might be C-channel comer connectors. For example, the FRP structural components might comprise four FRP C channels and four FRP comer connectors. Each FRP comer connector might comprise at least one receiver slot configured to receive an FRP interconnecting spline. Each FRP comer connector might comprise at least one secondary gasket connection raceway. Each FRP C channel might comprise at least one secondary gasket connection raceway and at least one main gasket and alignment spline raceway. The primary and secondary gaskets comprise a flexible waterproofing material to make a waterproof dry seal between the components of the frame assembly, and possibly, between multiple frame assemblies.

[0016] An FRP comer connector might have multiple receiver slots (i.e., raceways) and / or protrusions (e.g., connector insert sections) configured to join multiple FRP C channels together. Each FRP comer connector and / or FRP C channel might have at least one receiver slot (i.e., main gasket and alignment spline raceway) configured to join an FRP alignment spline to the frame assembly. The spline can be configured to join multiple frame assemblies together.

[0017] The frame assembly can be configured as a wall, a floor, a ceiling, or a roof frame assembly. In some aspects, the frame assembly is a panelized wall assembly. The frame assembly might be an exterior panelized wall assembly or an interior panelized wall assembly. The frame assembly might be an all-FRP frame assembly. The frame assembly can further comprise an FRP infill material or a non-FRP infill material.

[0018] In one aspect of the disclosure, an article of manufacture, comprises an FRP main seal alignment spline having a top longitudinal side and a bottom longitudinal side. At least one of the top longitudinal side and the bottom longitudinal side is configured to fit into at least one of a receiver slot of an FRP C-channel structural frame assembly. The spline might be configured to connect a first FRP frame assembly to a second FRP frame assembly.

[0019] In one example, the FRP main seal alignment spline might be configured to fit in the receiver slot (i.e., main gasket and alignment spline raceway) of an FRP C-channel structural frame assembly, and may be configured to provide a main seal between the spline and the C- channel structural frame assembly. For example, the spline might comprise at least one gasket main seal receiver slot that is configured to receive at least one rubber gasket or some other flexible waterproofing material. The at least one rubber gasket mam seal can be configured to provide a dry seal between the spline and at least one C-channel structural frame assembly.

[0020] In another aspect, a building system comprises at least one FRP main seal alignment spline having a left longitudinal face and a right longitudinal face; the spline being configured to have a flexible waterproofing material along at least one of the left longitudinal face and the right longitudinal face. The flexible waterproofing material provides a (dry) main seal between the spline and at least one FRP C-channel structural frame assembly. For example, the spline might comprise at least one gasket main seal receiver slot along at least one of the left longitudinal face and the right longitudinal face that is configured to receive at least one rubber gasket or some other flexible waterproofing material. The at least one rubber gasket main seal can be configured to provide a dry seal between the spline and at least one C- channel structural frame assembly.

[0021] The building system might further comprise a flexible epoxy that bonds its FRP components together. In one example, the flexible epoxy bonds the spline to the at least one C-channel structural frame assembly, and the flexible epoxy can be configured to provide a uniform coefficient of thermal expansion throughout the building system. The spline can comprise atop longitudinal side and a bottom longitudinal side. At least one of the top longitudinal side and the bottom longitudinal side is configured to fit into a receiver slot (i.e., main gasket and alignment spline raceway) of an FRP C-channel structural frame assembly. The flexible epoxy can bond the spline to the receiver slot in the FRP C-channel structural frame assembly.

[0022] In accordance with some aspects of the disclosure, a method comprises manufacturing an FRP alignment spline having a left longitudinal face and a right longitudinal face; and designing the spline to support a flexible waterproofing material along at least one of the leftlongitudinal face and the right longitudinal face, the flexible waterproofing material being configured to provide a (dry) main seal between the spline and at least one FRP C-channel structural frame assembly. The spline might comprise at least one gasket main seal receiver slot along at least one of the left longitudinal face and the right longitudinal face, the at least one gasket main seal receiver slot being configured to receive at least one rubber gasket or some other flexible waterproofing material. The at least one main seal can be configured to provide a dry seal between the spline and at least one C-channel structural frame assembly.

[0023] In some instances, the at least one spline and the at least one connector can be configured to connect the frame assembly to at least one other frame assembly.

[0024] There are various methods of assembling a building system. One method comprises inserting at least one FRP alignment spline into a main gasket and alignment spline raceway in an FRP C-channel structural frame assembly; and inserting at least one FRP connector into the FRP C-channel structural frame assembly. The at least one spline can have a top longitudinal side and a bottom longitudinal side; wherein either or both the top longitudinal side and bottom longitudinal side can be configured to fit into a receiver slot (main gasket and alignment spline raceway) in the FRP C-channel structural frame assembly. A flexible epoxy might be selected to join the spline to the receiver slot in the FRP C-channel structural frame assembly. The flexible epoxy might be used to bond the comer connectors to their respective C-channel structural frame assembly members. The at least one spline can have a left longitudinal face and a right longitudinal face; and can be configured to have a flexible waterproofing material joined, attached, or adhered to at least one of the left longitudinal face and the right longitudinal face. The flexible waterproofing material can provide a dry seal to a panel joint where C-channel structural frame assemblies meet.

[0025] Providing for, and / or configuring an element for, attaching a flexible waterproofing material thereto can comprise inserting a gasket comprising the flexible waterproofing material into a gasket receiver slot (e.g.. raceway) in the element. In any of the disclosed methods, a flexible epoxy might be used to bond elements together that are described herein as being joined, connected, bonded, attached, or adhered, the flexible epoxy being configured to provide a uniform coefficient of thermal expansion throughout the building system. In one example, a flexible epoxy can be used to bond each of the at least one FRP spline and the at least one FRP comer connector to the FRP frame assembly.

[0026] The method might further comprise inserting the at least one FRP spline or the at least one FRP connector into a second FRP frame assembly, thereby joining the FRP frame assembly to the second FRP frame assembly. Inserting the at least one FRP interlocking spline into the FRP frame assembly might employ at least one of a first slot or a first protrusion in the at least one FRP connector configured to join with at least one of a second protrusion or a second slot in the FRP frame assembly. The method might further comprise infilling the FRP frame assembly with at least one of an FRP infill material or a non-FRP infill material. Gaskets employed in the frame assemblies can be configured to provide a dry seal to a panel joint where the frame assemblies meet.

[0027] In another aspect of the disclosure, a method comprises assembling a plurality of FRP structural components to produce a frame assembly, wherein the frame assembly comprises a plurality7of outer edges; and providing at least some of the plurality of the outer edges with a receiver slot (e g., main gasket and alignment spline raceway) configured to lock at least one of an FRP mam gasket and alignment spline. By way of example, the structural components might comprise C channels and / or comer connectors. Assembling the structural components might comprise joining the C channels with the comer connectors.

[0028] The method might further comprise providing for attaching a flexible waterproofing material to at least some of the plurality of outer edges of the frame assembly. The frame assembly might be an all-FRP frame assembly. The method might further comprise infilling the frame assembly with at least one of an FRP infill material or a non-FRP infill material. The frame assembly might be configured to be a frame assembly of a wall, a floor, a ceiling, or a roof. The method might further comprise configuring the frame assembly to function as an exterior panelized wall system or an interior panelized wall system. For example, configuring the frame assembly can comprise at least one of selecting an infill material, selecting the FRP structural components, or assembling the FRP structural components.

[0029] The frame assembly can be an all-FRP frame assembly. In one example, the FRP structural components comprise C channels and comer connectors. Manufacturing or assembling the frame assembly comprises joining the C channels with the comer connectors. Aspects can employ dry-seal waterproofing and flexible epoxy disclosed herein.

[0030] In accordance with some aspects of the disclosure, a method comprises manufacturing a main gasket and alignment spline having a top longitudinal side and a bottom longitudinal side; and a left longitudinal face and a right longitudinal face. The method comprises configuring each of the top longitudinal side and the bottom longitudinal side to fit into a receiver slot (e.g., main gasket and alignment spline raceway) in a frame assembly, thereby providing for connecting a first frame assembly to a second frame assembly. Connecting might comprise employing a flexible epoxy. The method further comprises configuring at least one of the left longitudinal face and the right longitudinal face to support a flexible waterproofing material to provide for a dry seal between the first frame assembly and the second frame assembly.

[0031] In another aspect, a method, comprises manufacturing an FRP connector (e.g., a comer connector) having a plurality of surrounding edges that comprise multiple secondary gasket connection raceways. Optionally, at least one of the surrounding edges or faces comprises a gasket raceway for sealing a glass pane. The connector can be configured with multiple comer connector insert sections configured to attach to corresponding comer connector insert raceways in C-channel frame assembly members.

[0032] Groupings of alternative elements or aspect of the disclosed subject matter disclosed herein are not to be constmed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and / or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified, thus fulfilling the written description of all Markush groups used in the appended claims.

[0033] All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., ‘"such as”) provided with respect to certain aspect herein is intended merely to better illuminate the inventive subject matter and does not pose a limitation on the scope of the inventive subject matter otherwise claimed. No language in the specification should be constmed as indicating any non-claimed element as essential to the practice of the inventive subject matter.BRIEF DESCRIPTION OF THE DRAWINGS

[0034] So that the manner in which the above-recited features of the present disclosure can be understood in detail, a more particular description, briefly summarized above, may be had by reference to aspects, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only certain typical aspects of this disclosure and are therefore not to be considered limiting of its scope, for the description may admit to other equally effective aspects.

[0035] FIGs. 1A and IB show cross-sectional and isometric views (respectively) of an exemplary FRP composite integrated C-channel structural frame assembly.

[0036] FIGs. 2A and 2B show top and isometric views (respectively) of an exemplar}790- degree comer connector.

[0037] FIGs. 3A and 3B illustrate relative orientations for fitting an exemplary 90-degree comer connector to a C-channel structural frame assembly.

[0038] FIG. 4 illustrates a 90-degree comer connector configured to join a pair of C-channel structural frame assemblies at a right angle.

[0039] FIGs. 5A and 5B illustrate a pair of C-channel structural frame assemblies joined together at a right angle by a 90-degree comer connector.

[0040] FIGs. 6A and 6B show cross-sectional and isometric views, respectively, of a main seal alignment spline.

[0041] FIG. 7 is a cross-section view of a main seal alignment spline joined to a C-channel structural frame assembly.

[0042] FIG. 8 is an isometric view of the spline inserted into a frame assembly comprising the pair of C-channel structural frame assemblies joined together at a right angle by the 90- degree comer connector.

[0043] FIG. 9A and 9B illustrate exemplary- methods of assembling a building system in accordance with some aspects of the disclosure.

[0044] FIGs. 10A and 10B illustrate methods according to some aspects of the disclosure wherein a plurality of FRP structural components are assembled to produce an frame assembly.

[0045] FIG. Il a method for making an FRP C -channel structural component.

[0046] To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is contemplated that elements disclosed in one aspect may be beneficially utilized on other aspects without specific recitation.DETAILED DESCRIPTION

[0047] The description that follows includes exemplary systems, methods, and techniques that embody techniques of this disclosure. How ever, it is understood that the described aspects may be practiced without these specific details. Apparatuses and methods are described in the following description and illustrated in the accompanying drawings byvarious blocks, modules, components, steps, parts, processes, etc. (collectively referred to as "elements").

[0048] As used herein and in the claims, each of the terms defined in this glossary is understood to have the meaning set forth in this glossary. As such, claims should first be construed based on intrinsic evidence. If a claim term remains ambiguous after considering the intrinsic evidence, then extrinsic evidence is to be considered.

[0049] Coefficient of Thermal Expansion (CTE) - CTE is a measure of how a material expands or contracts in response to changes in temperature. It quantifies the fractional change in length, area, or volume of a material per degree of temperature change. Different materials have different CTE values, which can vary- significantly depending on the material's composition and structure.

[0050] Composite Material - is a composition made from two or more constituent materials, which can have significantly different physical or chemical properties. The composition can have physical characteristics that differ from each of the constituent materials.

[0051] Dry Seal - Dry seal waterproofing provides a physical barrier to prevent water from entering the structure. Unlike wet seal methods, dry seal methods do not rely on liquid application. Dry seal waterproofing materials may include membrane sheets (such as PVC, silicone, EPDM rubber, or other suitable materials), waterproofing tapes, and waterstops. Dry seal waterproofing disclosed herein can comprise high-performance fire-resistant flexible rubber gaskets, such as EPDM, fire-resistant silicone, or other high-performance fire-resistant flexible rubber gaskets.

[0052] Fiberglass - is a fiber-reinforced plastic using glass fibers. The fibers may be randomly arranged, flattened into a sheet, or woven into a fabric, for example. The plastic matrix may be a thermoset polymer matrix, such as epoxy, polyester resin, vinyl ester, or a thermoplastic.

[0053] Fiber Reinforced Polymer (FRP) - is a composite consisting of a polymer resin matrix reinforced with embedded fibers.

[0054] Flexible Epoxy - A type of epoxy resin that exhibits flexibility and elasticity after curing. Epoxy resins are typically known for their high strength and rigidity, but flexible epoxy formulations have been developed to provide a balance between strength and flexibility. Flexible epoxy resins are commonly used in various applications where the material needs to withstand bending, stretching, or impact without cracking or breaking.

[0055] Frame Assembly - An assembly of structural components that is configured to create a framework, such as to provide stability, strength, and support needed for in-fill of materials and / or paneling. A frame assembly might be part of a wall, a floor, a ceiling, a roof, or some other structural element of a building. A frame assembly for a wall might comprise an frame assembly (for an outer wall) or an inner frame assembly (for an inner wall).

[0056] Intumescent - is a substance that swells when exposed to heat, thus leading to an increase in volume and decrease in density. Intumescents are typically used in passive fireprotection and require listing, approval, and compliance in their installed configurations to comply with building codes and laws.

[0057] Monolithic - In product design, a monolithic design approach can involve creating products that have a unified and seamless appearance, with all components integrated into a single, solid form. Monolithic product design often prioritizes simplicity and functionality.

[0058] Panel joints - Panel joints are used to accommodate movement and prevent cracks in panel systems. These joints might be filled with a flexible sealant or gasket material that allows for expansion and contraction while maintaining a waterproof seal.

[0059] Polymer - is a substance or material consisting of very large molecules, or macromolecules, composed of many repeating sub-units. Polymer can be synthetic or natural.

[0060] Protrusion - is a projection, protrusion, protuberance, obtrusion, pin, ridge, or post. These terms may be used interchangeably. A protrusion can describe a structural feature of a first structural element that is configured to fit into a corresponding slot of a second structural element, such as to join or connect the first structural element to the second structural element. The protrusion can be configured to fit snugly in the slot.

[0061] Pultruded Fiber Reinforced Polymer (PFRP) - a continuous molding process using material consisting of strong fibers embedded in a resin matrix. The fibers in FRP can include glass, carbon, and / or synthetic fibers. PFRP materials are formed using a pultrusion method, which can eliminate out-gassing.

[0062] Pultrusion - is a continuous process for manufacturing composite materials, such as into shapes that have a constant cross-section. The term is a portmanteau word, combining "pull" and "extrusion". As opposed to extrusion, which pushes the material, pultrusion works by pulling the material.

[0063] Resin - is a generic term used to designate the polymer, polymer precursor material, and / or mixture or formulation thereof with various additives or chemically reactive components.

[0064] Slot - is a receiver slot, raceway, groove, channel, slit, notch, kerf, indentation, or keyway. These terms may be used interchangeably. A slot can describe a structural feature in a first structural element that is configured to receive a second structural element, such as to join or connect the first structural element to the second structural element. In one example, the second structural element is a spline. In some examples, the second structural element comprises a protrusion, and the slot can be configured to receive the protrusion. The protrusion might fit snugly in the slot.

[0065] Spline - is a thin strip of material used in building construction. A spline can be a key that is fixed to one of two connected mechanical parts and fits into a key way in the other. By way of example, a spline might be configured to fit into a slot in a structural element.

[0066] Thermal Conductivity - is defined as the rate at which heat is conducted through a unit area of a material when there is a temperature gradient across it. Materials with high thermal conductivity are efficient conductors of heat, meaning they can transfer heat quickly. The thermal conductivity of a material depends on various factors, including its composition, density, and structure.

[0067] By way of example, but without limitation, FRP C channels 1 and FRP comer connectors 2 can comprise a slot and / or other structure for receiving (and optionally locking) at least one FRP spline 5. The FRP C channels 1 and FRP comer connectors 2 can be configured to attach to various structures, such as via alignment grooves, alignment ridges, alignment posts, and / or alignment pins.

[0068] At least some of the FRP “C” channels 1 and FRP comer connectors 2 might be configured to enable attachment of a flexible waterproofing material 4 (such as EPDM rubber gaskets, fire-resistant silicone gaskets, or any other suitable high-performance fire-resistant flexible rubber gasket) in a manner that is designed to provide a waterproof seal at a joint, such as where one frame assembly joins another structure, such as another frame assembly.

[0069] In one aspect, the frame assembly can be a non-load bearing or load-bearing wall panel configured to provide an integrated dry-seal waterproof panel joint. In some aspects, the composite waterproof frame assembly 100 can be in-filled with FRP, steel, concrete, w ood, glass, or any other type of material to create various types of wall panel.

[0070] In some aspects, the disclosed FRP structural components can comprise an applied exterior intumescent fire-resistant coating (instead of an internal fire-retardant product). Such coatings can meet fire testing certification and building code requirements. This enables disclosed aspects to pass building fire code regulations and fire safety requirements for low- rise, mid-rise, and high-rise buildings.

[0071] FIGs. 1A and IB show cross-sectional and isometric views (respectively) of an exemplary FRP composite integrated C-channel structural frame assembly 1. The assembly 1 is configured to provide for a dry seal, and comprises a main gasket and alignment spline raceway 7, at least one comer connector insert raceway 6. one or more secondary gasket connection raceways 8, and an optional raceway 17 for a gasket employed for sealing a glass pane, such as might be used in a glass curtain wall. By way of example, the one or more secondary gasket connection raceways 8 are configured to receive gaskets. The C-channel structural frame assembly 1 is designed such that the main and secondary gaskets provide a dry seal at a joint that is formed when the C-channel structural frame assembly 1 is joined wi th another structural element, such as another C-channel structural frame assembly 1. It should be appreciated that the C-channel structural frame assembly 1 might be a straight section, or rail, or might be formed into other shapes.

[0072] FIGs. 2A and 2B show top and isometric views (respectively) of an exemplary 90- degree comer connector 2. The comer connector 2 might be an FRP composite integrated C- channel structural frame assembly. The comer connector 2 can be configured to connect to at least one C-channel structural frame assembly 1, such as by means of one or more connector insert sections 10 configured to fit into one or more comer connector insert raceways (e.g., slots) 6. The comer connector 2 comprises a main gasket and alignment spline raceway 7, one or more secondary gasket connection raceways 8, and an optional raceway 17 for a gasket employed for sealing a glass pane, such as might be used in a glass curtain wall.

[0073] In one example, an article of manufacture, comprises an FRP C-channel structural component (1 or 2), comprising: a plurality of connector insert sections 10 configured to join with one or more insert raceways 6 of a second FRP C-channel structural component (1 or 2); or a plurality of insert raceways 6 configured to join with one or more connector insert sections 10 of the second FRP C-channel structural component (1 or 2); a main gasket andalignment spline raceway 7 configured to receive an FRP main gasket and alignment spline 5; and at least one secondary gasket connection raceway 8; wherein the main gasket and alignment spline raceway 7 and the at least one secondary gasket connection raceway 8 configure a flexible waterproofing material (4 and 19, respectively) to provide a dry seal at a joint between the FRP C-channel structural component (1 or 2) and at least one other FRP C- channel structural component (1 or 2).

[0074] The FRP C-channel structural component might be a straight element 1 or a comer connector 2. The FRP C-channel structural component (1 or 2) and the second FRP C- channel structural component (1 or 2) can be configured to be parts of a frame assembly, such as a panelized wall assembly. The joint might be a panel joint. Disclosed aspects include methods for manufacturing and / or assembly of the disclosed items of manufacture. The FRP C-channel structural component (1 or 2) might optionally comprise a gasket raceway 17 for a gasket 20 to provide a glass seal.

[0075] FIGs. 3A and 3B illustrate relative orientations for fitting an exemplary 90-degree comer connector 2 to a C-channel structural frame assembly 1. This is illustrative of how disclosed structural components can be configured to produce a dry-seal frame assembly. For example, the comer connector 2 can join to at least one C-channel structural frame assembly 1, and each gasket raceway (e.g., 8 and / or 17) can be aligned to provide for a continuous raceway across the joined components. A gasket 4 can be inserted into the continuous raceway 8 to provide a dry' seal. Similarly, FIG. 4 illustrates fitting an exemplary' 90-degree comer connector 2 to join a pair of C-channel structural frame assemblies 1 at a right angle. FIGs. 5A and 5B illustrate a pair of C-channel structural frame assemblies 1 joined together at a right angle by a 90-degree comer connector 2, and gaskets 4 and 20 inserted into the secondary gasket connection raceways 8 and the raceways 17 employed for sealing the glass pane. By way of example, the gaskets 4 and 20 might be high-performance fire-resistant rubber gaskets. The above examples of joining structural components are illustrative of assembly methods that can be performed in accordance with the disclosure.

[0076] An article of manufacturing might comprise a plurality7of FRP C-channel structural components 1; and include a plurality of FRP comer connectors 2 that join together the plurality of FRP C-channel structural components 1 to provide a panelized wall assembly. The plurality of FRP C-channel structural components 1 and the plurality7of FRP comerconnectors 2 can be configured to employ a flexible waterproofing material (e.g., gaskets 4) that provides a dry seal for at least one panel joint.

[0077] Each of the plurality of FRP comer connectors 2 might comprise one or more connector insert sections 10, and each of the plurality of FRP C-channel structural components 1 might comprise one or more comer connector insert raceways 6. the one or more connector insert sections 10 being configured to fit into the one or more comer connector insert raceways 6.

[0078] Each of the plurality of FRP C-channel structural components 1 and each of the plurality of FRP comer connectors 2 might comprises a main gasket and alignment spline raceway 7 and at least one secondary gasket connection raceway 8. The main gasket and alignment spline raceway 7 and the at least one secondary’ gasket connection raceway 8 can configure the flexible waterproofing material 4 and 19 to provide the dry seal. The article of manufacture might further comprise at least one main seal alignment spline 5 inserted in the main gasket and alignment spline raceway 7. At least one main seal alignment spline 7 can configure the spline 5 to provide a dry seal between the panelized wall assembly and at least one other panelized wall assembly. The panelized wall assembly might further comprise an FRP infill material or a non-FRP infill material. The panelized wall assembly can be an exterior panelized wall system or an interior panelized wall system.

[0079] In some instances, the article of manufacture may employ a flexible epoxy to join together the FRP comer connectors 2 with the FRP C-channel structural components 2. The flexible epoxy can be configured to provide a uniform coefficient of thermal expansion throughout the panelized wall assembly. At least one of the FRP C-channel structural components 1 and the plurality of FRP comer connectors 2 might further comprise a gasket raceway 18 for a glass seal.

[0080] FIGs. 6A and 6B illustrate cross-section and isometric views, respectively, of a main seal alignment spline 5. One or more main seal connection raceways 18 are provided for receiving one or more gaskets, such as might comprise a high-performance fire-resistant rubber.

[0081] An article of manufacture might comprise an FRP main gasket and alignment spline 5 having a top longitudinal side and a bottom longitudinal side; and a pair of longitudinal faces, at least one of the pair of longitudinal faces being configured (e.g., 18) for attaching a main gasket 19. The top longitudinal side is configured to fit into a first main gasket and alignment spline raceway 7 in a first FRP C -channel structural component 1 or 2, and the bottom longitudinal side is configured to fit into a second main gasket and alignment spline raceway 7 in a second FRP C-channel structural component 1 or 2. The main gasket 19 provides a dry seal at a joint where the first FRP C-channel structural component 1 or 2 and the second FRP C-channel structural component 1 or 2 meet.

[0082] FIG. 7 illustrates a cross section of a main seal alignment spline 5 joined to a C- channel structural frame assembly 1. The spline 5 can be inserted into the spline receiver slot 7. Gaskets 4 are inserted into the secondary gasket connection raceways 8, main seal gaskets19 are inserted into gasket raceways 20 to provide for the main seal connection, and gasket20 is inserted into the gasket raceway 17 for the glass pane. FIG. 8 illustrates an isometric view of the spline 5 inserted into a frame assembly comprising the pair of C-channel structural frame assemblies 1 joined together at a right angle by the 90-degree comer connector 2. The examples shown in FIGs. 7 and 8 are illustrative of assembly methods that can be performed in accordance with the disclosure.

[0083] In one aspect, a building system comprises a plurality of frame assemblies, each comprising: a plurality of FRP C-channel structural components 1; and a plurality of FRP comer connectors 2 that join together the plurality of FRP C-channel structural components 1; the plurality of FRP C-channel structural components 1 and the plurality of FRP comer connectors 2 configured to employ a flexible waterproofing material 4, 19 that provides a dry seal for at least one joint where the plurality of frame assemblies meet.

[0084] The building system might employ a flexible epoxy that bonds the FRP comer connectors 2 to the FRP C-channel structural components 1, the flexible epoxy configured to provide a uniform coefficient of thermal expansion throughout the building system.

[0085] In some instances, the FRP C-channel structural components 1 and the FRP comer connectors 2 have a main gasket and alignment spline raceway 7 configured for receiving a main gasket and alignment spline 5; and the plurality of FRP C-channel structuralcomponents 1 and the plurality of FRP comer connectors 2 have at least one secondary gasket connection raceway 8; the main gasket and alignment spline 5 and the at least one secondary gasket connection raceway 8 being configured to employ a flexible waterproofing material (19 and 4) that provides the dry' seal.

[0086] FIG. 27A illustrates an exemplary method of assembling a building system. The method comprises configunng 101 an FRP mam gasket and alignment spline to provide a dry seal for ajoint between a first FRP C-channel structural component and a second FRP C- channel structural component. This can involve employing a flexible waterproofing material. The method further comprises inserting (102) the FRP main gasket and alignment spline into a first main gasket and alignment spline raceway in the first FRP C-channel structural component; and inserting (103) the FRP main gasket and alignment spline into a second main gasket and alignment spline raceway in the second FRP C-channel structural component, thereby providing a dry' seal to ajoint formed by where the first FRP C-channel structural component and the second FRP C-channel structural component meet.

[0087] In FIG. 27B, a flexible epoxy might be used to bond 104 the FRP interlocking spline to the first FRP C-channel structural component and the second FRP C-channel structural component. The flexible epoxy can be configured to provide a uniform coefficient of thermal expansion throughout a building system constructed from such FRP components.

[0088] FIG. 10A illustrates a method according to some aspects of the disclosure wherein a plurality of FRP structural components are assembled 201 to produce a frame assembly, such as for a panelized wall system. The method comprises joining together (201) a plurality of FRP C-channel structural components with a plurality of FRP comer connectors to produce a first frame assembly; and configuring 202 the plurality of FRP C-channel structural components and the plurality' of FRP comer connectors to employ a flexible waterproofing material that provides a dry seal for at least one joint between the first frame assembly and at least a second frame assembly. Joining 203 can comprise using a flexible epoxy to bond the FRP comer connectors to the FRP C-channel structural components, the flexible epoxy being configured to provide a uniform coefficient of thermal expansion throughout the first frame assembly.

[0089] In one example, the FRP C-channel structural components and the FRP comer connectors form a main gasket and alignment spline raceway: and configuring 202 includes inserting an FRP main gasket and alignment spline into the main gasket and alignment spline raceway.

[0090] FIG. 10B illustrates a method according to some aspects of the disclosure wherein the frame assembly is joined 203 with the at least a second frame assembly. Joining 203 can comprise using a flexible epoxy to bond the spline to the main gasket and alignment spline raceway, the flexible epoxy being configured to provide a uniform coefficient of thermal expansion throughout the joint between the first frame assembly and the second frame assembly.

[0091] In some instances, the first frame assembly is infilled with at least one of an FRP infill material or anon-FRP infill material. The first frame assembly might be configured to function as an exterior panelized wall system or an interior panelized wall system, such as by selecting an infill material, selecting the FRP structural components, or selecting the design and / or assembling the FRP structural components.

[0092] FIG. 11 illustrates a method for making an FRP C-channel structural component. The method comprises: forming 301 a plurality of connector insert sections that are configured to join with one or more insert raceways of a second FRP C-channel structural component; or forming 301 a plurality of insert raceways configured to join with one or more connector insert sections of the second FRP C-channel structural component. A main gasket and alignment spline raceway is formed and configured 302 to receive an FRP main gasket and alignment spline; and at least one secondary gasket connection raceway is formed 303. The main gasket and alignment spline raceway and the at least one secondary gasket connection raceway configure a flexible waterproofing material to provide 304 a dry seal at a joint between the FRP C-channel structural component and at least one other FRP C-channel structural component.

[0093] The FRP C-channel structural component might be a straight element or a comer connector. The FRP C-channel structural component and the second FRP C-channel structural component can be parts of a frame assembly, such as a wall panel assembly. The joint might be a panel joint.

[0094] It should be appreciated that an FRP building structure can be formed by joining multiple frame (e.g., wall panel) assemblies together. In one aspect, a method for constructing a composite waterproof outer framing system comprises provisioning a plurality of FRP C channels 1 and comer connectors 2 for each frame assembly. The comer connectors 2 join the C channels 1, thereby providing joints in the frame assembly. Each frame assembly might be constructed by adhering flexible epoxy onto the comer connector 2 alignment posts 10 and / or corresponding C channel 1 receiver slots 6 prior to inserting the alignment posts 10 into the receiver slots 6. The flexible epoxy can be selected to provide for a uniform thermal coefficient of expansion relative to the FRP material, thus providing for uniform thermal expansion to occur within the joints of the frame assembly.

[0095] A high-performance fire-resistant flexible rubber gasket 4 might be inserted into each of the gasket receiver slots 8 in each of the comer connectors 2 and C channels 1. A high- performance fire-resistant flexible rubber gasket 19 might be inserted into each of the gasket receiver slots 18 in each spline 5. The FRP components are joined (e.g., FRP C channels 1 joined with comer connectors 2, and splines 5 joined with FRP C channels 1 and / or comer connectors 2), wherein the gaskets 4 and 19 provide a dry' seal at each joint formed by where FRP components are joined. This can provide for dry -sealed frame assemblies. The frame assembly may be in-filled with FRP and / or other types of building materials, such as steel, aluminum, concrete, wood, or glass to produce a panelized wall assembly, for example, which can be employed in modular construction techniques. Splines 5 might join together multiple frame assemblies (and / or other structural elements), the gaskets 19 providing dryseals to joints between the frame assemblies. The frame assemblies might include panelized wall assemblies.

[0096] The previous description is provided to enable a person skilled in the art to make or use the disclosure. Various modifications to the disclosure will be readily apparent to those skilled in the art. and the common principles defined herein may be applied to other variations without departing from the spirit or scope of the disclosure. Furthermore, although elements of the described aspects and / or embodiments may be described or claimed in the singular, the plural is contemplated unless limitation to the singular is explicitly stated. Additionally, all or a portion of any aspect and / or embodiment may be utilized with all or a portion of any other aspect and / or embodiment, unless stated otherwise. Thus, the disclosureis not to be limited to the examples and designs described herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

Claims1. An article of manufacture, comprising: a plurality of Fiber Reinforced Polymer (FRP) C-channel structural components; and a plurality' of FRP comer connectors that join together the plurality of FRP C-channel structural components to provide a panelized wall assembly; the plurality of FRP C-channel structural components and the plurality of FRP comer connectors configured to employ a flexible waterproofing material that provides a dry seal for at least one panel joint.

2. The article of manufacture of claim 1, wherein each of the plurality of FRP comer connectors comprises one or more connector insert sections, and each of the plurality’ of FRP C-channel structural components comprises one or more comer connector insert raceways, the one or more connector insert sections being configured to fit into the one or more comer connector insert raceways.

3. The article of manufacture of claim 1, wherein each of the plurality of FRP C-channel structural components and each of the plurality of FRP comer connectors comprises a main gasket and alignment spline raceway and at least one secondary gasket connection raceway.

4. The article of manufacture of claim 3, wherein the main gasket and alignment spline raceway and the at least one secondary' gasket connection racew ay configure the flexible waterproofing material to provide the dry seal.

5. The article of manufacture of claim 3, further comprising at least one main seal alignment spline inserted in the main gasket and alignment spline raceway.

6. The article of manufacture of claim 5. wherein the at least one main seal alignment spline is configured to provide a dry seal between the panelized wall assembly and at least one other panelized wall assembly.

7. The article of manufacture of claim 1, wherein the panelized wall assembly further comprises an FRP infill material or a non-FRP infill material.

8. The article of manufacture of claim 1, wherein the panelized wall assembly is configured to be an exterior panelized wall system or an interior panelized wall system.

9. The article of manufacture of claim 1, wherein the flexible waterproofing material comprises Ethylene Propylene Diene Monomer (EPDM), fire-resistant silicone, or another high-performance fire-resistant flexible rubber.

10. The article of manufacture of claim 1, wherein a flexible epoxy is employed to join together the plurality of FRP comer connectors with the plurality of FRP C-channel structural components, the flexible epoxy being configured to provide a uniform coefficient of thermal expansion throughout the panelized wall assembly.

11. The article of manufacture in claim 1, wherein at least one of the plurality of FRP C- channel structural components and the plurality of FRP comer connectors comprise a gasket raceway for a glass seal.

12. An article of manufacture, comprising: a Fiber Reinforced Poly mer (FRP) C-channel structural component, comprising: a plurality of comer connector insert sections or a plurality of comer connector insert raceways configured to connect the FRP C-channel structural component to at least one other FRP C-channel structural component to assemble a frame assembly; a main gasket and alignment spline raceway configured for receiving a main gasket and alignment spline; at least one secondary gasket connection raceway; wherein the main gasket and alignment spline and the at least one secondary gasket connection raceway are configured to employ a flexible waterproofing material that provides a dry seal for at least one joint between the frame assembly and at least one other frame assembly.

13. The article of manufacture in claim 12, wherein the C-channel structural component is a straight C-channel structural component or a comer connector.

14. The article of manufacture in claim 12, further comprising a gasket raceway for a glass seal.

15. An article of manufacture, comprising: a Fiber Reinforced Polymer (FRP) main gasket and alignment spline having a top longitudinal side and a bottom longitudinal side; and a pair of longitudinal faces, at least one of the pair of longitudinal faces being configured for attaching a mam gasket; wherein the top longitudinal side is configured to fit into a first main gasket and alignment spline raceway in a first FRP C -channel structural component, and the bottom longitudinal side is configured to fit into a second main gasket and alignment spline raceway in a second FRP C-channel structural component; and wherein the main gasket provides a dry seal at a joint where the first FRP C-channel structural component and the second FRP C-channel structural component meet.

16. A building system, comprising: a plurality of frame assemblies, each comprising: a plurality of Fiber Reinforced Polymer (FRP) C-channel structural components; and a plurality of FRP comer connectors that join together the plurality of FRP C- channel structural components; the plurality of FRP C-channel structural components and the plurality of FRP comer connectors configured to employ a flexible waterproofing material that provides a dry seal for at least one joint where the plurality of frame assemblies meet.

17. The building system of claim 16, further comprising a flexible epoxy that bonds the plurality of FRP comer connectors to the plurality of FRP C-channel structural components, and is configured to provide a uniform coefficient of thermal expansion throughout the building system.

18. The building system of claim 16, wherein the plurality of FRP C-channel stmctural components and the plurality of FRP comer connectors have a main gasket and alignment spline raceway configured for receiving a main gasket and alignment spline; and wherein the plurality of FRP C-channel structural components and the plurality of FRP comer connectors have at least one secondary gasket connection raceway; the main gasket andalignment spline and the at least one secondary' gasket connection raceway being configured to employ a flexible waterproofing material that provides the dry seal.

19. A method, comprising: joining together (201) a plurality of Fiber Reinforced Polymer (FRP) C-channel structural components with a plurality of FRP comer connectors to produce a first frame assembly; and configuring (202) the plurality of FRP C-channel structural components and the plurality of FRP comer connectors to employ a flexible waterproofing material that provides a dry seal for at least one joint between the first frame assembly and at least a second frame assembly.

20. The method of claim 19, wherein the plurality of FRP C-channel structural components and the plurality' of FRP comer connectors have a main gasket and alignment spline raceway; and configuring includes inserting an FRP main gasket and alignment spline into the main gasket and alignment spline raceway.

21. The method of claim 19, wherein joining comprises using a flexible epoxy to bond the plurality of FRP comer connectors to the plurality of FRP C-channel structural components, flexible epoxy being configured to provide a uniform coefficient of thermal expansion throughout the first frame assembly.

22. A method, comprising:Inserting (102) a Fiber Reinforced Polymer (FRP) main gasket and alignment spline into a first main gasket and alignment spline raceway in a first FRP C-channel structural component; andInserting (103) the FRP main gasket and alignment spline into a second main gasket and alignment spline raceway in a second FRP C-channel structural component; the FRP main gasket and alignment spline employing (101) a flexible waterproofing material configured to provide a dry seal for a joint between the first FRP C-channel structural component and the second FRP C-channel structural component.

23. The method of claim 22. wherein inserting the FRP main gasket and alignment spline into the first main gasket and alignment spline raceway and inserting the FRP main gasket andalignment spline into the second main gasket and alignment spline raceway comprises using a flexible epoxy to bond the FRP main gasket and alignment spline to the first FRP C-channel structural component and the second FRP C-channel structural component, the flexible epoxy being configured to provide a uniform coefficient of thermal expansion throughout the j oint.

24. A method of making a Fiber Reinforced Polymer (FRP) C-channel structural component, comprising: forming 301 a plurality of connector insert sections that are configured to join with one or more insert raceways of a second FRP C-channel structural component; or forming 301 a plurality of insert raceways configured to join with one or more connector insert sections of the second FRP C-channel structural component; forming 302 a main gasket and alignment spline raceway configured to receive an FRP main gasket and alignment spline; and forming 303 at least one secondary gasket connection raceway; wherein the main gasket and alignment spline raceway and the at least one secondary gasket connection raceway configure a flexible waterproofing material to provide 304 a dry seal at a joint between the FRP C-channel structural component and at least one other FRP C-channel structural component.

25. The method of claim 24, wherein the FRP C-channel structural component is a straight element or a comer connector.

26. The method of claim 24, wherein the FRP C-channel structural component and the second FRP C-channel structural component are parts of a frame assembly.

27. The method of claim 24, wherein the joint is a panel joint.

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