Modular fiberglass wall components and connection systems and methods

Abstract

A modular fiberglass wall components and connections system and method that utilizes fiberglass as the primary material in the components. A novel molding process is used for manufacturing the components. The systems and methods utilize new primary sheathing material and adjoining and locking mechanisms. These features reduce the need for several other materials used in typical construction, including lumber, sheetrock, siding, and paint. Buildings to be constructed with the present systems and methods are broken into various modules or components constructed separately, including roof components, wall components, and floor components. Included are various component connections depending on the type: roof to wall, wall to wall, floor to floor, and roof to roof. The various components are then assembled onsite with the connections.

What is claimed is: 
     
         1 . A modular fiberglass wall connection system, the system comprising:
 a first wall component;   a first floor component; and   a first roof component connected to the first wall component with a roof-to-wall connector,   wherein the first wall component, first floor component, and first roof component primarily comprise fiber reinforced plastic.   
     
     
         2 . The system of  claim 1 , wherein the roof-to-wall connector includes a mortise and tenon joint, a self-locking implanted cotter pin, and an epoxy. 
     
     
         3 . The system of  claim 1 , further including a second wall component connected to the first wall component with a wall-to-wall connector. 
     
     
         4 . The system of  claim 3 , wherein the wall-to-wall connector includes a lap joint and epoxy adhesive. 
     
     
         5 . The system of  claim 1 , further including a second roof component connected to the first roof component with a roof-to-roof connector. 
     
     
         6 . The system of  claim 5 , wherein the roof-to-roof connector includes a lap joint and epoxy adhesive. 
     
     
         7 . The system of  claim 1 , further including a second floor component connected to the first floor component with a floor-to-floor connector. 
     
     
         6 . The system of claim  7 , wherein the floor-to-floor connector includes a lap joint and epoxy adhesive. 
     
     
         7 . The system of  claim 1 , wherein the first wall component, first floor component, and first roof component further comprise internal structural fiberglass members. 
     
     
         8 . The system of  claim 1 , wherein the first wall component, first floor component, and first roof component further comprise an open cell foam insulation between and inner layer of fiberglass and an exterior layer of fiberglass. 
     
     
         9 . The system of  claim 1 , wherein the first roof component and first wall component are configured to fold and unfold. 
     
     
         10 . The system of  claim 1 , wherein the first wall component includes a conduit for receiving an electrical system. 
     
     
         11 . A modular fiberglass wall connection system, the system comprising:
 a first wall component connected to a second wall component with a wall-to-wall connector;   a first floor component connected to a second floor component with a floor-to-floor connector; and   a first roof component connected to a second roof component with a roof-to-roof connector and connected to the first wall component with a roof-to-wall connector,   wherein the first wall component, first floor component, and first roof component primarily comprise fiber reinforced plastic.   
     
     
         12 . The system of  claim 11 , wherein the roof-to-wall connector includes a mortise and tenon joint, a self-locking implanted cotter pin, and an epoxy. 
     
     
         13 . The system of  claim 11 , wherein the wall-to-wall connector includes a lap joint and epoxy adhesive. 
     
     
         14 . The system of  claim 11 , wherein the roof-to-roof connector includes a lap joint and epoxy adhesive. 
     
     
         15 . The system of  claim 11 , wherein the floor-to-floor connector includes a lap joint and epoxy adhesive. 
     
     
         16 . The system of  claim 11 , wherein the first wall component, first floor component, and first roof component further comprise internal structural fiberglass members. 
     
     
         17 . The system of  claim 11 , wherein the first wall component, first floor component, and first roof component further comprise an open cell foam insulation between and inner layer of fiberglass and an exterior layer of fiberglass. 
     
     
         18 . A modular fiberglass wall connection method, the method comprising the steps of:
 using a molding process, creating a first and second wall component, a first and second floor component, and a first and second roof component, wherein each component primarily comprises fiber reinforced plastic;   connecting the first wall component to the second wall component with a wall-to-wall connector;   connecting the first floor component to the second floor component with a floor-to-floor connector;   connecting the first roof component to the second roof component with a roof-to-roof connector; and   connecting the first roof component to the first wall component with a roof-to-wall connector.   
     
     
         19 . The method of  claim 18 , wherein the roof-to-wall connector includes a mortise and tenon joint, a self-locking implanted cotter pin, and an epoxy. 
     
     
         20 . The method of  claim 18 , wherein the wall-to-wall, roof-to-roof, and floor-to-floor connectors include a lap joint and epoxy adhesive.