UNITIZED PANEL SYSTEMS INCLUDING FIBER-REINFORCED POLYMER COMPOSITE PANELS WITH WEATHERPROOF JOINT TO PERIMETER ALUMINUM UNITIZED FRAMES

Abstract

A unitized panel system may include a perimeter aluminum unitized frame. The unitized panel system may also include a fiber-reinforced polymer (FRP) composite panel. The unitized panel system may also include an aluminum structure attached to the perimeter aluminum unitized frame. An end portion of the FRP composite may be enclosed in the aluminum structure or sandwiched between the aluminum structure and the perimeter aluminum unitized frame.

Description

FIELD

The disclosure is directed to unitized panel systems, unitized curtain wall systems, and structural joints. In particular, the disclosure relates to unitized panel systems including fiber-reinforced polymer (FRP) composite panels with weatherproof joint to perimeter aluminum unitized frames.

BACKGROUND

In a unitized panel system, a curtain wall frame includes large units that are assembled and glazed in a factory, shipped to a construction site, and erected on a building. The unitized panel system may be used in a unitized curtain wall system, which includes large units that are pre-assembled and glazed in factory before shipping to building site for installation. The wind and gravity load of the unitized curtain wall system can be transferred to the building structure. The unitized curtain wall system is an external building façade, including unitized panel systems, unitized curtain walls, aluminum-framed walls, aluminum spandrel panels, thin composite panels, or concrete spandrel panels, among others.

In the unitized curtain wall system, the transfer of horizontal loads, mainly wind loads, from an upper unit into a lower unit is achieved through the head/notch interlocking connection.

The unitized panel systems are the non-structural outer covering or cladding of a building, and are utilized to keep the weather out and occupants in. It is anchored to a building to form the building facade, cladding, or envelope. The unitized panel systems typically include panels constructed from glass, metal, or cement and a connection system for joining the panels together. The panels are typically fixed to the building via anchors or brackets. The unitized panel systems may be unitized systems that are assembled at a factory.

BRIEF SUMMARY

In one aspect, a unitized panel system may include a perimeter aluminum unitized frame having a first section connected to a second section angled from the first section. The unitized panel system may also include a fiber-reinforced polymer (FRP) composite panel including a first side surface, a second side surface opposite to the first side surface, and an end surface connected between the first side surface and the second side surface within the perimeter aluminum unitized frame. The unitized panel system may also include an aluminum structure having a first U-shaped portion enclosing an end portion of the FRP composite panel, the first U-shaped portion including a bottom section coupled between a first arm and a second arm, the first arm of the first U-shaped portion of the aluminum structure attached to the first section of the perimeter aluminum unitized frame by using a first structural adhesive.

In some aspects, the aluminum structure may have an angled outer surface configured to match with a shape of the perimeter aluminum unitized frame.

In some aspects, the aluminum structure may include a second portion extending along the bottom section away from the second arm of the first U-shaped portion to add stiffness to the aluminum structure.

In some aspects, the second portion of the aluminum structure may be attached to the second section of the perimeter aluminum unitized frame by using the first structural adhesive.

In some aspects, the end portion of the FRP composite panel may be enclosed between the first arm and the second arm substantially parallel to the first arm and attached to the first and second arms by a fastener. The end portion of the FRP composite panel may include a portion of the first side surface, a portion of the second side surface, and the end surface.

In some aspects, the FRP composite panel may include a fire-resistant FRP composite.

In some aspects, the first structural adhesive may include silicone.

In some aspects, the unitized panel system may also include a second structural adhesive bonding the FRP composite panel to the first portion of the aluminum structure.

In some aspects, the aluminum structure may include an Alodine coating.

In some aspects, the first structural adhesive may be weatherproof.

In another aspect, a unitized panel system may include a perimeter aluminum unitized frame having a first section coupled to a second section that is angled from the first section. The unitized panel system may also include a fiber-reinforced polymer (FRP) composite panel including a first side surface, a second side surface opposite to the first side surface, and an end surface coupled between the first side surface and the second side surface. The unitized panel system may also include an angled aluminum structure having a first portion coupled to a second portion angled from the first portion, the first portion attached to the first section of the perimeter aluminum unitized frame by using a first structural adhesive, wherein the angled aluminum structure has an angled outer surface shaped to match to the perimeter aluminum unitized frame.

In some aspects, the second portion of the angled aluminum structure may be attached to the first side surface of the FRP composite panel by a fastener.

In some aspects, the second side surface of the FRP composite panel may be attached to the second section of the perimeter aluminum unitized frame by using the first structural adhesive.

In some aspects, the end surface of the FRP composite panel may be attached to an end portion of the first section of the perimeter aluminum unitized frame by using the first structural adhesive.

In some aspects, the end portion may be near an intersection of the first section and the second section.

In some aspects, the FRP composite panel may include a fire-resistant FRP composite.

In some aspects, the first structural adhesive may include silicone.

In some aspects, the unitized panel system may also include a second structural adhesive bonding the FRP composite panel to the first portion of the angled aluminum structure.

In some aspects, the angled aluminum structure may include an Alodine coating.

Additional embodiments and features are set forth in part in the description that follows, and will become apparent to those skilled in the art upon examination of the specification or may be learned by the practice of the disclosed subject matter. A further understanding of the nature and advantages of the disclosure may be realized by reference to the remaining portions of the specification and the drawings, which form a part of this disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The description will be more fully understood with reference to the following figures and data graphs, which are presented as various embodiments of the disclosure and should not be construed as a complete recitation of the scope of the disclosure, wherein:

FIG. 1A illustrates an elevation view of a unitized panel system including a fiber-reinforced polymer (FRP) composite panel within an aluminum structure bonded to a perimeter aluminum unitized frame according to one embodiment of the disclosure;

FIG. 1B illustrates a sectional view of the unitized panel system including an FRP composite panel within an aluminum structure bonded to a perimeter aluminum unitized frame of FIG. 1A;

FIG. 1C is a perspective front view of unitized panel system of FIG. 1A;

FIG. 1D is a perspective rear view of unitized panel system of FIG. 1A;

FIG. 2A illustrates an elevation view of a unitized panel system including an FRP composite panel between a perimeter aluminum unitized frame and an angled aluminum structure bonded to the perimeter aluminum unitized frame according to another embodiment of the disclosure;

FIG. 2B illustrates a sectional view of a unitized panel system including an FRP composite panel between a perimeter aluminum unitized frame and an angled aluminum structure bonded to the perimeter aluminum unitized frame of FIG. 2A;

FIG. 2C is a perspective front view of unitized panel system of FIG. 2A-2B;

FIG. 2D is a perspective rear view of unitized panel system of FIG. 2A-20;

FIG. 2E is a perspective front view of unitized panel system of FIG. 2C without the FRP composite panel; and

FIG. 3 illustrates a bonding layer between a first panel and a second panel and the joint stress distribution according to an embodiment.

DETAILED DESCRIPTION

The disclosure may be understood by reference to the following detailed description, taken in conjunction with the drawings as described below. It is noted that, for purposes of illustrative clarity, certain elements in various drawings may not be drawn to scale.

Structural adhesive can be used to bond metal to metal or metal to fiber-reinforced polymer composite. It has more uncertainty when bonding two dissimilar materials, such as fiber-reinforced polymer composite and aluminum. Although the fiber-reinforced polymer composite has a similar coefficient of thermal expansion (CTE) to aluminum, its stiffness is about 5 to 10 times higher than aluminum. As such, load sharing on a bond joint between the fiber-reinforced polymer composite and aluminum may not be compatible.

The disclosure provides a design that adds an aluminum structure to an end portion of a fiber-reinforced polymer (FRP) composite panel and mechanically fastens the aluminum structure to the FRP composite panel. Then, a structural adhesive can be used to form bonding from the aluminum structure to a perimeter aluminum unitized frame. This design allows bonding the FRP composite panel indirectly to the perimeter aluminum unitized frame via the aluminum structure. The aluminum-to-aluminum bonding may provide better long-term durability in application than the bonding between dissimilar materials, such as bonding between the FRP composite panel and the perimeter aluminum unitized frame.

In one embodiment, an aluminum structure may be positioned between an FRP composite panel and a perimeter aluminum unitized frame. The aluminum structure may enclose a portion of the FRP composite panel, which may attach to the aluminum structure by using fasteners. The aluminum structure can attach to the perimeter aluminum unitized frame by using structural adhesive. If the FRP composite panel is attached to the perimeter aluminum unitized frame without the aluminum structure, the bonding of the FRP composite panel to the perimeter aluminum unitized frame may be weaker than the bonding of the aluminum structure to the perimeter aluminum unitized frame.

FIG. 1A illustrates an elevation view of a unitized panel system including an FRP composite panel within an aluminum structure bonded to a perimeter aluminum unitized frame according to one embodiment of the disclosure. As shown in FIG. 1A, a unitized panel system 100 may include a perimeter aluminum unitized frame 11 and an FRP composite panel 12 within the perimeter aluminum unitized frame 11. The unitized panel system 100 may also include an aluminum structure 13 between the perimeter aluminum unitized frame 11 and the FRP composite panel 12. The aluminum structure 13 may be attached or bonded to the perimeter aluminum unitized frame 11 by using a first structural adhesive 14. The first structural adhesive 14 may be weatherproof such that the joint to the perimeter aluminum unitized frame 11 is weatherproof.

In this example, the perimeter aluminum unitized frame 11 has a rectangular shape including four corners 15. It will be appreciated by those skilled in the art that the shape and size of the perimeter aluminum unitized frame may vary.

FIG. 1B illustrates a sectional view of the unitized panel system including an FRP composite panel within an aluminum structure bonded to a perimeter aluminum unitized frame of FIG. 1A. As shown in FIG. 1B, the perimeter aluminum unitized frame may include a first section 11A coupled to a second section 11B angled from the first section 11A. In this example, the first section 11A is a horizontal section while the second section 11B is a vertical section.

As shown in FIG. 1B, the unitized panel system 100 may also include stiffening ribs 17 attached to the FRP panel 12, such as bonding with an adhesive.

As shown in FIG. 1B, the FRP composite panel 12 may have a first side surface 12A, a second side surface 12B opposite to the first side surface 12A, and an end surface 12C coupled between the first side surface 12A and the second side surface 12B.

The aluminum structure 13 may be positioned between the FRP composite panel 12 and the perimeter aluminum unitized frame 11. The aluminum structure 13 may include a first U-shaped portion 13A customized to enclose an end portion 12D of the FRP composite panel. The first U-shaped portion 13A may include a bottom section 19C coupled between a first arm 19A and a second arm 19B. The first arm 19A of the first U-shaped portion of the aluminum structure may be attached or bonded to the first section 11A of the perimeter aluminum unitized frame 11 by using a first structural adhesive 14. The end portion 12D of FRP composite panel may include a portion of the first side surface 12A, a portion of the second side surface 12B, and the end surface 12C.

The aluminum structure 13 may also include a second portion 13B extending from the bottom section 19C away from second arm 19B. The second portion 13B may add stiffness to the aluminum structure 13 and increases the bonding area to the perimeter aluminum unitized frame 11. The second portion 13B and the bottom section 19C of the aluminum structure 13 may be bonded to the second section 11B of the perimeter aluminum unitized frame 11 by using the first structural adhesive 14. Both the first U-shaped portion 13A and the second portion 13B of the aluminum structure 13 may be attached to the first section 11A and the second section 11B of the perimeter aluminum unitized frame 11 by using the first structural adhesive 14, which may be silicone, among others.

The aluminum structure may also have an angled outer surface 33 configured to match with the shape of the perimeter aluminum unitized frame 11.

The unitized panel system 100 may also include one or more mechanical fastener(s) 16 that can be used to attach the FRP composite panel 12 to the first arm 19A and the second arm 19B of the aluminum structure 13.

Optionally, the unitized panel system 100 may also include a second structural adhesive 17 that can be used for bonding between the aluminum structure 13 and the FRP composite panel 12. The second structural adhesive 17 may help distribute the load. The second structural adhesive 17 may be methyl methacrylate (MMA) structural adhesive, among others.

FIG. 1C is a perspective front view of unitized panel system of FIG. 1A. FIG. 1D is a perspective rear view of unitized panel system of FIG. 1A. As shown in FIG. 10, the aluminum structure or aluminum frame 13 surrounding the FRP composite panel 12 is visible from the front view. In unitized panel system 100, the aluminum structure 13 would be visible when the unitized panel system 100 is mounted on a building.

In unitized panel system design 100, the FRP composite panels 12 may look like glass panels held in a frame. The unitized panel system 100 may be preferable when there is a need for an exposed aluminum structure 13, or when the FRP composite panel has a relatively flat surface.

In another embodiment, an angled aluminum structure may be designed to have a first portion bonded to the perimeter aluminum unitized frame and a second portion attached to an FRP composite panel by using fasteners. The FRP composite panel may be sandwiched between the perimeter aluminum unitized frame and the second portion of the aluminum structure and bonded to the perimeter aluminum unitized frame.

FIG. 2A illustrates an elevation view of a unitized panel system including an FRP composite panel between a perimeter aluminum unitized frame and an aluminum structure bonded to the perimeter aluminum unitized frame according to another embodiment of the disclosure. As shown in FIG. 2A, a unitized panel system 200 may include a perimeter aluminum unitized frame 21 and an FRP composite panel 22 within the perimeter aluminum unitized frame 21. The unitized panel system 200 may also include an aluminum structure 23 between the perimeter aluminum unitized frame 21 and the FRP composite panel 22. The aluminum structure 23 may be bonded to the perimeter aluminum unitized frame 21 by using a structural adhesive 24.

In this example, the perimeter aluminum unitized frame 21 has a rectangular shape including four corners 25. It will be appreciated by those skilled in the art that the shape and size of the perimeter aluminum unitized frame may vary.

FIG. 2B illustrates a sectional view of a unitized panel system including an FRP composite panel between a perimeter aluminum unitized frame and an angled aluminum structure bonded to the perimeter aluminum unitized frame of FIG. 2A. The perimeter aluminum unitized frame 21 may include a first section 21A connected to a second section 21B angled from the first section. The angle 28 may be about 90° as illustrated. It will be appreciated by those skilled in the art that the angle 28 may vary depending upon particular applications.

The FRP composite panel 22 may have an end portion 29 having a first side surface 22A, a second side surface 22B opposite to the first side surface, and an end surface 22C connected between the first side surface and the second side surface.

The angled aluminum structure 23 may have an angle outer surface 27 shaped to match the shape of the perimeter aluminum unitized frame 21 to carry the load. The angled aluminum structure 23 may include a first portion 23A coupled to a second portion 23B, which may be angled from the first portion 23A. The first portion 23A extends away from the first or second side surface 22A or 22B of the FRP composite panel 22. The first portion 23A of the angled aluminum structure 23 may be attached to or bonded to the first section 21A of the perimeter aluminum unitized frame 21, for example, by using a first structural adhesive 24. The first structural adhesive 24 may be weatherproof such that the joint to the perimeter aluminum unitized frame 21 is weatherproof.

The end portion 29 of the FRP composite panel 22 is sandwiched between the perimeter aluminum unitized frame 21 and the angled aluminum structure 23. The first side surface 22A of the end portion 29 of the FRP composite panel 22 may be attached to the second portion 23B of the angled aluminum structure 23 by one or more fastener(s). The second side surface 22B of the end portion 29 of the FRP composite panel 22 may be attached to the second section 21B of the perimeter aluminum unitized frame 21 by using the first structural adhesive 24. The end surface 22C of the FRP composite panel 22 may be attached to an end portion 21C of the first section 21A of the perimeter aluminum unitized frame 21 by using the first structural adhesive 24. The end portion 21C may extend from the first section 21A toward the corner 25 and may be coupled to the second section 21B.

FIG. 2C is a perspective front view of unitized panel system of FIG. 2A. FIG. 2D is a perspective rear view of unitized panel system of FIG. 2A. FIG. 2E is a perspective front view of unitized panel system of FIG. 2C without the FRP composite panel. As shown in FIGS. 2C-2E, the aluminum structure 23 is invisible or hidden behind the FRP composite panel.

The unitized panel system 200 may allow the FRP composite panels to stick out from its surrounding building if desired. The unitized panel system 200 may be is preferable when a hidden aluminum structure 23 is desirable or when the FRP composite panel has a surface that is not flat.

Although a flat and rectangular panel is illustrated in FIGS. 1A-1D and 2A-2D, it will be appreciated by those skilled in the art that the shape of the FRP composite panel may vary.

Alodine® Coating

The angled aluminum structure 13 or 23 can be applied with an Alodine® coating, which is a chromate conversion coating that protects aluminum and other metals from corrosion. The process of applying a chromate conversion coating is referred to as chromating. The chromate conversion coating is a chemical conversion coating in which the metal undergoes a chemical reaction at the surface. The chemical conversion coating transforms the metal surface into a protective layer via a chemical reaction. The Alodine coating not only provides corrosion protection but also provides better adhesion for the structural adhesive 14.

MIL-DTL-5541 specification for Chemical Conversion Coatings on Aluminum and Aluminum Alloys is commonly used for chromating aluminum. The MIL-DTL-5541 specification distinguishes between different types and classes of conversion coating for aluminum. The type of chemical coating depends on the chemical composition of the coating material.

For the present application, MIL-DTL-5541 Type 2, also known as hex-free chromate, may be selected. The hexavalent chromium has been replaced with trivalent chromium, titanium, or zirconium.

Bonding Thickness and Bond Tests

FIG. 3 illustrates a bonding layer 33 between a first panel 31 and a second panel 32 according to an embodiment. The bonding layer 33 may be formed of the structural adhesive 14 or 24. If the bonding layer 33 is thin, unknown conditions may lead to peaks 34A and 34B in joint stress as shown in FIG. 3.

In some variations, the structural adhesive layer 14 or 24 may have a thickness above a minimum value to allow load distribution.

In some variations, the structural adhesive layer 14 or 24 may also have a thickness of less than a maximum value to provide substantially uniform stress along the edge regardless of the center of the edge or end of the edge.

The structural adhesives can be selected based upon bonding tests for substrates of interest. Bonding tests can be performed using various structural adhesives per ASTM C794. ASTM C794 is provided for Adhesion-in-Peel Elastomeric Joint Sealants Test Equipment. ASTM C794 determines the strength and characteristics of the peel properties of a cured-in-place elastomeric joint sealant, single component or multicomponent, for use in building construction. The bonding tests can demonstrate the ability of the cured elastomeric joint sealant to maintain a bond to the substrate under severe conditions and can be utilized to determine the adhesive characteristics with substrates of interest. The peel test is configured with a 180° peel angle.

FRP Composite Panels and Fabrication Methods

The FRP composite panel may be formed of an FRP composite that is fire-resistant. U.S. Pat. No. 9,365,017, entitled “Moldable Fire-Resistant Composites,” by William Krysler, issued on Jun. 14, 2016, discloses the processes for making the fire-resistant composites, which is incorporated by reference in its entirety.

Examples

The following examples are for illustration purposes only. It will be apparent to those skilled in the art that many modifications, both to materials and methods, may be practiced without departing from the scope of the disclosure.

Proper structural adhesive can be selected based on the ASTM C794 testing results. Various structural adhesives may be evaluated.

For example, the structural adhesive 14 or 24 may include DOW silicone 795, which is a one-part, neutral-cure, architectural-grade sealant that easily extrudes in any weather and cures quickly at room temperature. This cold-applied, non-sagging silicone material cures to form a silicone rubber upon exposure to atmospheric moisture.

When DOWSIL™ 795 Silicone, supplied by Dow Chemical, is used as the structural adhesive 14 or 24, the thickness of the adhesive may be at least 0.25 inches as recommended by the manufacturer. This thickness value may vary with the supplier of the adhesive. Once cured, the structural sealant forms a durable, flexible, waterproof bond that can be warranted for a long time, such as 20 years, and the structural sealant can be used in +25% movement weather seal applications, such as windy conditions.

The structural adhesives 14 or 24 may also include DOWSIL™ 983 Silicone, supplied by Dow Chemical, which is suitable for dual structural and weather seal applications, such as factory glazing and curtainwall production. Once cured, the structural sealant forms a durable, flexible, watertight bond that can be warranted for 20 years and used in +25% movement weather seal applications. DOW 983 also has excellent unprimed adhesion to glass, Alodine, and anodized aluminum.

The structural adhesives 14 or 24 may also include GE silicone, such as SSG4600 UltraGlaze silicone structural glazing sealant, or Plexus® structural adhesives, among others.

Statement 1. A unitized panel system comprising; a perimeter aluminum unitized frame having a first section connected to a second section angled from the first section; a fiber-reinforced polymer (FRP) composite panel comprising a first side surface, a second side surface opposite to the first side surface, and an end surface connected between the first side surface and the second side surface within the perimeter aluminum unitized frame; and an aluminum structure having a first U-shaped portion enclosing an end portion of the FRP composite panel, the first U-shaped portion comprising a bottom section coupled between a first arm and a second arm, the first arm of the first U-shaped portion of the aluminum structure attached to the first section of the perimeter aluminum unitized frame by using a first structural adhesive.

Statement 2. The unitized panel system of statement 1, wherein the aluminum structure has an angled outer surface configured to match with a shape of the perimeter aluminum unitized frame.

Statement 3. The unitized panel system of statement 1, wherein the aluminum structure comprises a second portion extending along the bottom section away from the second arm of the first U-shaped portion to add stiffness to the aluminum structure.

Statement 4. The unitized panel system of statement 3, wherein the second portion of the aluminum structure is attached to the second section of the perimeter aluminum unitized frame by using the first structural adhesive.

Statement 5. The unitized panel system of statement 1, wherein the end portion of the FRP composite panel is enclosed between the first arm and the second arm substantially parallel to the first arm and attached to the first and second arms by a fastener, wherein the end portion of the FRP composite panel comprises a portion of the first side surface, a portion of the second side surface, and the end surface.

Statement 6. The unitized panel system of statement 1, wherein the FRP composite panel comprises a fire-resistant FRP composite.

Statement 7. The unitized panel system of statement 1, wherein the first structural adhesive comprises silicone.

Statement 8. The unitized panel system of statement 1, further comprising a second structural adhesive bonding the FRP composite panel to the first portion of the aluminum structure.

Statement 9. The unitized panel system of statement 1, wherein the aluminum structure comprises an Alodine coating.

Statement 10. The unitized panel system of statement 1, wherein the first structural adhesive is weatherproof.

Statement 11. A unitized panel system comprising; a perimeter aluminum unitized frame having a first section coupled to a second section that is angled from the first section; a fiber-reinforced polymer (FRP) composite panel comprising a first side surface, a second side surface opposite to the first side surface, and an end surface coupled between the first side surface and the second side surface; and an angled aluminum structure having a first portion coupled to a second portion angled from the first portion, the first portion attached to the first section of the perimeter aluminum unitized frame by using a first structural adhesive, wherein the angled aluminum structure has an angled outer surface shaped to match to the perimeter aluminum unitized frame.

Statement 12. The unitized panel system of statement 9, wherein the second portion of the angled aluminum structure is attached to the first side surface of the FRP composite panel by a fastener.

Statement 13. The unitized panel system of statement 9, wherein the second side surface of the FRP composite panel is attached to the second section of the perimeter aluminum unitized frame by using the first structural adhesive.

Statement 14. The unitized panel system of statement 9, wherein the end surface of the FRP composite panel is attached to an end portion of the first section of the perimeter aluminum unitized frame by using the first structural adhesive.

Statement 15. The unitized panel system of statement 14, wherein the end portion is near an intersection of the first section and the second section.

Statement 16. The unitized panel system of statement 9, wherein the FRP composite panel comprises a fire-resistant FRP composite.

Statement 17. The unitized panel system of statement 9, wherein the first structural adhesive comprises silicone.

Statement 18. The unitized panel system of statement 9, further comprising a second structural adhesive bonding the FRP composite panel to the first portion of the angled aluminum structure.

Statement 19. The unitized panel system of statement 9, wherein the angled aluminum structure comprises an Alodine coating.

Statement 20. The unitized panel system of statement 9, wherein the first structural adhesive is weatherproof.

Any ranges cited herein are inclusive. The terms “substantially” and “about” used throughout this Specification are used to describe and account for small fluctuations. For example, they can refer to less than or equal to +5%, such as less than or equal to +2%, such as less than or equal to +1%, such as less than or equal to +0.5%, such as less than or equal to +0.2%, such as less than or equal to +0.1%, such as less than or equal to +0.05%.

Having described several embodiments, it will be recognized by those skilled in the art that various modifications, alternative constructions, and equivalents may be used without departing from the spirit of the invention. Additionally, a number of well-known processes and elements have not been described to avoid unnecessarily obscuring the invention. Accordingly, the above description should not be taken as limiting the scope of the invention.

Those skilled in the art will appreciate that the presently disclosed embodiments teach by way of example and not by limitation. Therefore, the matter contained in the above description or shown in the accompanying drawings should be interpreted as illustrative and not in a limiting sense. The following claims are intended to cover all generic and specific features described herein, as well as all statements of the scope of the method and system, which, as a matter of language, might be said to fall therebetween.

Claims

1. A unitized panel system comprising; a perimeter aluminum unitized frame having a first section connected to a second section angled from the first section;a fiber-reinforced polymer (FRP) composite panel comprising a first side surface, a second side surface opposite to the first side surface, and an end surface connected between the first side surface and the second side surface within the perimeter aluminum unitized frame; andan aluminum structure having a first U-shaped portion enclosing an end portion of the FRP composite panel, the first U-shaped portion comprising a bottom section coupled between a first arm and a second arm, the first arm of the first U-shaped portion of the aluminum structure attached to the first section of the perimeter aluminum unitized frame by using a first structural adhesive.

2. The unitized panel system of claim 1, wherein the aluminum structure has an angled outer surface configured to match with a shape of the perimeter aluminum unitized frame.

3. The unitized panel system of claim 1, wherein the aluminum structure comprises a second portion extending along the bottom section away from the second arm of the first U-shaped portion to add stiffness to the aluminum structure.

4. The unitized panel system of claim 3, wherein the second portion of the aluminum structure is attached to the second section of the perimeter aluminum unitized frame by using the first structural adhesive.

5. The unitized panel system of claim 1, wherein the end portion of the FRP composite panel is enclosed between the first arm and the second arm substantially parallel to the first arm and attached to the first and second arms by a fastener, wherein the end portion of the FRP composite panel comprises a portion of the first side surface, a portion of the second side surface, and the end surface.

6. The unitized panel system of claim 1, wherein the FRP composite panel comprises a fire-resistant FRP composite.

7. The unitized panel system of claim 1, wherein the first structural adhesive comprises silicone.

8. The unitized panel system of claim 1, further comprising a second structural adhesive bonding the FRP composite panel to the first portion of the aluminum structure.

9. The unitized panel system of claim 1, wherein the aluminum structure comprises an Alodine coating.

10. The unitized panel system of claim 1, wherein the first structural adhesive is weatherproof.

11. A unitized panel system comprising; a perimeter aluminum unitized frame having a first section coupled to a second section that is angled from the first section;a fiber-reinforced polymer (FRP) composite panel comprising a first side surface, a second side surface opposite to the first side surface, and an end surface coupled between the first side surface and the second side surface; andan angled aluminum structure having a first portion coupled to a second portion angled from the first portion, the first portion attached to the first section of the perimeter aluminum unitized frame by using a first structural adhesive, wherein the angled aluminum structure has an angled outer surface shaped to match to the perimeter aluminum unitized frame.

12. The unitized panel system of claim 9, wherein the second portion of the angled aluminum structure is attached to the first side surface of the FRP composite panel by a fastener.

13. The unitized panel system of claim 9, wherein the second side surface of the FRP composite panel is attached to the second section of the perimeter aluminum unitized frame by using the first structural adhesive.

14. The unitized panel system of claim 9, wherein the end surface of the FRP composite panel is attached to an end portion of the first section of the perimeter aluminum unitized frame by using the first structural adhesive.

15. The unitized panel system of claim 14, wherein the end portion is near an intersection of the first section and the second section.

16. The unitized panel system of claim 9, wherein the FRP composite panel comprises a fire-resistant FRP composite.

17. The unitized panel system of claim 9, wherein the first structural adhesive comprises silicone.

18. The unitized panel system of claim 9, further comprising a second structural adhesive bonding the FRP composite panel to the first portion of the angled aluminum structure.

19. The unitized panel system of claim 9, wherein the angled aluminum structure comprises an Alodine coating.

20. The unitized panel system of claim 9, wherein the first structural adhesive is weatherproof.