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.

1 . An article of manufacture, comprising:
 a plurality of Fiber Reinforced Polymer (FRP) C-channel structural components; and   a plurality of FRP corner 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 corner connectors configured to employ a flexible waterproofing material that provides a dry seal for at least one panel joint where the panelized wall assembly meets another panelized wall assembly.   
     
     
         2 . The article of manufacture of  claim 1 , wherein each of the plurality of FRP corner connectors comprises one or more connector insert sections, and each of the plurality of FRP C-channel structural components comprises one or more corner connector insert raceways, the one or more connector insert sections being configured to fit into the one or more corner 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 corner 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 raceway 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 corner 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 corner connectors comprise a gasket raceway for a glass seal. 
     
     
         12 . An article of manufacture, comprising:
 a Fiber Reinforced Polymer (FRP) C-channel structural component, comprising:
 a plurality of corner connector insert sections or a plurality of corner 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 corner connector. 
     
     
         14 . The article of manufacture in  claim 12 , further comprising a gasket raceway for a glass seal. 
     
     
         15 . 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 corner 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 corner 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.   
     
     
         16 . The building system of  claim 15 , further comprising a flexible epoxy that bonds the plurality of FRP corner 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. 
     
     
         17 . The building system of  claim 15 , wherein the plurality of FRP C-channel structural components and the plurality of FRP corner 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 corner connectors have at least one secondary gasket connection raceway; the main gasket and alignment spline and the at least one secondary gasket connection raceway being configured to employ a flexible waterproofing material that provides the dry seal.