Patent Application
20250019966
Aspects of the disclosure relate to building systems, and more specifically, building systems and structural components comprising Fiber Reinforced Polymer (FRP).
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.
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 off-site, 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.
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 integrity and 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.
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.
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, such as panelized wall assemblies. Disclosed aspects can improve energy efficiency, safety, productivity, quality of life, customer experience, and/or sustainability; and can reduce environmental impacts.
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.
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.
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.
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.
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.
In one aspect, a frame assembly comprises a plurality of 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 waterproofing 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 which 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., corner 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 elements might comprise PFRP structural elements. Where appropriate, FRP elements disclosed herein might be PFRP elements.
The frame assembly can comprise an FRP corner connector on each of its corners, each FRP corner connector comprising at least one of a receiver slot or an alignment post configured to join together two or more FRP C channels. Corner connectors disclosed herein might be C-channel corner connectors. For example, the FRP structural components might comprise four FRP C channels and four FRP corner connectors. Each FRP corner connector might comprise at least one receiver slot configured to receive an FRP interconnecting spline. Each FRP corner 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.
An FRP corner 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 corner 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.
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.
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.
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 main seal can be configured to provide a dry seal between the spline and at least one C-channel structural frame assembly.
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.
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 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 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.
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 left longitudinal 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.
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.
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 corner 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.
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 corner connector to the FRP frame assembly.
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.
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 plurality of 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 main gasket and alignment spline. By way of example, the structural components might comprise C channels and/or corner connectors. Assembling the structural components might comprise joining the C channels with the corner connectors.
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.
The frame assembly can be an all-FRP frame assembly. In one example, the FRP structural components comprise C channels and corner connectors. Manufacturing or assembling the frame assembly comprises joining the C channels with the corner connectors. Aspects can employ dry-seal waterproofing and flexible epoxy disclosed herein.
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.
In another aspect, a method, comprises manufacturing an FRP connector (e.g., a corner 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 corner connector insert sections configured to attach to corresponding corner connector insert raceways in C-channel frame assembly members.
Groupings of alternative elements or aspect of the disclosed subject matter disclosed herein are not to be construed 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.
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 construed as indicating any non-claimed element as essential to the practice of the inventive subject matter.
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.
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.
The description that follows includes exemplary systems, methods, and techniques that embody techniques of this disclosure. However, 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 by various blocks, modules, components, steps, parts, processes, etc. (collectively referred to as “elements”).
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.
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.
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.
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.
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.
Fiber Reinforced Polymer (FRP)—is a composite consisting of a polymer resin matrix reinforced with embedded fibers.
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.
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).
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 fire protection and require listing, approval, and compliance in their installed configurations to comply with building codes and laws.
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.
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.
Polymer—is a substance or material consisting of very large molecules, or macro-molecules, composed of many repeating sub-units. Polymer can be synthetic or natural.
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.
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.
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.
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.
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.
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 keyway in the other. By way of example, a spline might be configured to fit into a slot in a structural element.
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.
By way of example, but without limitation, FRP C channels 1 and FRP corner 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 corner connectors 2 can be configured to attach to various structures, such as via alignment grooves, alignment ridges, alignment posts, and/or alignment pins.
At least some of the FRP “C” channels 1 and FRP corner 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.
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, wood, glass, or any other type of material to create various types of wall panel.
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.
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 and alignment 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).
The FRP C-channel structural component might be a straight clement 1 or a corner 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.
An article of manufacturing might comprise a plurality of FRP C-channel structural components 1; and include a plurality of FRP corner 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 plurality of FRP corner connectors 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.
Each of the plurality of FRP corner 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 corner connector insert raceways 6, the one or more connector insert sections 10 being configured to fit into the one or more corner connector insert raceways 6.
Each of the plurality of FRP C-channel structural components 1 and each of the plurality of FRP corner 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.
In some instances, the article of manufacture may employ a flexible epoxy to join together the FRP corner 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 corner connectors 2 might further comprise a gasket raceway 18 for a glass seal.
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.
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 corner 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 corner 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.
The building system might employ a flexible epoxy that bonds the FRP corner 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.
In some instances, the FRP C-channel structural components 1 and the FRP corner 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 structural components 1 and the plurality of FRP corner 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.
In
In one example, the FRP C-channel structural components and the FRP corner 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.
In some instances, the first frame assembly is infilled with at least one of an FRP infill material or a non-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.
The FRP C-channel structural component might be a straight element or a corner 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.
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 corner connectors 2 for each frame assembly. The corner 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 corner 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.
A high-performance fire-resistant flexible rubber gasket 4 might be inserted into each of the gasket receiver slots 8 in each of the corner 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 corner connectors 2, and splines 5 joined with FRP C channels 1 and/or corner 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 dry seals to joints between the frame assemblies. The frame assemblies might include panelized wall assemblies.
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 disclosure is 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.
This application claims the priority benefit of U.S. Provisional Appl. Ser. No. 63/526,168, filed on Jul. 11, 2023; which is hereby incorporated by reference herein in its entirety. U.S. patent application Ser. No. 18/126,987, filed on Mar. 27, 2023; U.S. patent application Ser. No. 17/093,262, filed on Nov. 9, 2020; U.S. patent application Ser. No. 18/207,438, filed on Jun. 8, 2023; U.S. patent application Ser. No. 17/411,041, filed on Aug. 24, 2021; and PCT Appl. Ser. No. PCT/US21/47414, filed on Aug. 24, 2021 are each expressly incorporated by reference herein in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63526168 | Jul 2023 | US |
