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The present invention describes an interlocking metal framing system where two concentric support members slide between each other to enable the support member to form a longer length without using extensions to add the additional length to the support members. The concentric support members have apertures with perimeter notches for the connector spacing-bracing member to interlock the perimeter notches together to form a longer support member. The connector can be a clip connecting the two concentric support members together whether installed vertically or horizontally; or by having a longitudinal spacing-bracing member pass through the apertures connecting the hole notches of adjacent support members. The hole notches interlock the spacing-bracing member to the two concentric support members together eliminating vertical and horizontal movement between the concentric support members as well as the adjacent support members. The apertures are setback from both ends or both concentric support members allowing the additional length to be projected above or below the concentric support members. The top end and the bottom end to the concentric support members have two L-shape gaps. The floor base channel or ceiling base channel are mounted to the floor and ceiling with each having lips extending from web and flanges with the lips extending into the short leg of the L-shaped notch. The lips have lip notches to keep the bottom or top ends of the concentric support members from moving vertically and or horizontally, the lip notches are cut into the distal edge of the lip that connect to the hole notches at the aperture.
Light gauge metal framing consists of vertical and horizontal framing members that are screwed or welded together to form a structural frame for walls, floors, and ceiling framing for buildings. The vertical support members are typically a C-shape configuration that connect to a floor base channel or ceiling base channel by placing the support member into the floor base the flanges until aligned within the base channel, fasteners are then installed at the flanges of the floor base plate into the flanges of the support member. In addition, holes are installed into the web of the support members and horizontal bracing members connect the support members together. Early assembly connections had horizontal bracing members supported loosely within the holes, later adding angles to the support member to then connect fasteners to the angles and the horizontal bracing members. Over the years the properties of the metal for structural framing members have changed where the exterior surface of the metal is more abrasive allowing the connection between the horizontal bracing members and the vertical structural framing members to fit temporarily together.
Metal framing has progressed from interior metal framing supports to metal framing components having structural properties for load bearing wall systems and panelized wall systems with the exterior façade being finished and craned into position at and exterior wall. On the other hand, there has been no means to interlock the panelized wall sections to the building structure in a fast and efficient means.
When constructing buildings, it is easy to be off and inch here to a meter there, that then requires cutting or adding to existing support members in a very costly and effective method to construct metal framing. In addition, concrete structures are difficult because of the uneven surfaces. In high rise buildings high partition walls are difficult to install as well as deliver a long framing member up 30 stories. It is much easier to deliver materials up an elevator rather than requiring a crane to lift the materials up thirty stories which is expensive and time-consuming waiting for crane availability.
Typically metal framing members are connected by screws or by welding the individual components together. The screws fasteners are used for light gauge framing but are also used for the heavier gauge metal. The bearing walls using metal framing are a heavier gauge metal and the components are connected by fasteners but are also crimped or welded together or threaded bolts with washer are used for heavy gauge metal. Some horizontal bracing members have used rivets or crimping two members together. Prior art has made some improvements to restrict horizontal movement between metal framing members, however, there has been no attempt to eliminate vertical movement without fasteners.
In addition, vertical and horizontal wall framing members have not been fastened together without screws or welding that is have not been compatible to just click to twist together without the mechanical means of screws or welding. The present invention allows the horizontal and vertical framing members to just mechanically connect two components together. Many variations of a floor base channel have been developed using various notches however, none of the variations have eliminated the flanges for the floor channel base as the flanges of the base channel is used as the connecting means to secure the support member to the base channel. In addition, early attempts of securing the vertical and horizontal members together do not use an aperture in the web at the top and bottom of the support member nor in the service aperture in the middle of the web. In fact, this application shows notches within the service holes and the connection holes at the top and bottom of the support member that include notches. The lips with its notches in the base plate fit into the L-shaped notches at the vertical support member.
The patent by Andrews, Wm U.S. Pat. No. 7,223,043 issued May 29, 2007, U.S. Pat. No. 8,074,416 issue Dec. 13, 2011 changes the shape of the U-shaped floor framing member having V-shaped bulges at the floor track and support member extending inward toward the flanges of the support member that has a recess in the flanges to accommodate the V-shaped protrusion. The patent attempts to connect the two members together without using fasteners, the patent prevents vertical movement of the support member with no means of preventing horizontal movement. Another patent by Andrews, Wm U.S. Pat. No. 8,061,099 issued Nov. 22, 2011 where a telescoping support member is extended above a stationary support member and the telescoping support member moves when the ceiling above has movement for excessive floor loads and the telescoping support member has concave flanges so drywall fasteners will not connect to the telescoping support member.
The concentric support members have an inner concentric support member and an outer concentric support member where the inner support member slides within the C-shape configuration of the concentric outer support member. The inner concentric support member overlaps the outer concentric support member so the apertures in the web of the concentric support members can overlap each other, and where each aperture has perimeter notches. The support member can be adjusted so the perimeter notches in the aperture of the inner and the outer concentric support members can be aligned. The apertures have at least three perimeter notches to increase or decrease the inner and outer support member length of the two support members when joined together by changing the alignment of the perimeter notches in the inner and outer concentric support member alignments. The perimeter notches act like fasteners to secure the desired length settings between the concentric support members. A spacing-bracing member is inserted into the apertures and engaging the desired perimeter notches settings in order to become logged into the side edges of the perimeter notches, thereby securing the support member to the desired length. The aperture connection can be a U-clip that overlaps the perimeter notches in both support members, against the webs of both support members; or the aperture connection can be a short clip shaped as a spacing-bracing member; or a spacing-bracing member that connects two adjacent concentric support member apertures by using the spacing-bracing member to connect the two adjacent concentric support members. The U-clip connection can be installed as described above, or a short sb-clip (spacing-bracing clip) can be installed having the same configuration as the spacing-bracing member. The short sb-clip or U-clip can be installed first at both concentric support members, then the spacing-bracing member can be installed connecting both concentric support members. Depending on the difficulty of the installation the spacing-bracing members the continuous aperture between the inner and outer support member could be installed without using either clip for connection and the continuous spacing-bracing member could be installed that can connect adjacent support members. The drawings also show the U-clip having a receiver end, that is a flange extension of the U-shape clip that forms a W-shape clip. The W-shape clip has the receiver end on both sides allowing for a spacing-bracing member having a tongue end at both ends to fit into the receiver ends of a W-shape clip.
Depending on the end configuration of the support members, the top end of the inner concentric support member and the bottom end of the outer concentric support member can have two L-shaped gaps in the apertures at the inner and outer concentric support ends. The two L-shaped gaps connect to a hat-channel shaped ceiling and floor mounted spacer brace. The base of the hat-channel shape is a web that is mounted to the floor or ceiling; and the brim or lips of the hat-channel shape are installed into the L-shaped gaps. The L-shaped gaps can be located at both ends of the inner and outer concentric support members where the extension may occur above or below the outer concentric support.
The perimeter notches at the apertures should have the side edges of the notches angled allowing the lips extending from the spacing-bracing member to be pressured to abut the angle notch edges of the perimeter notches at the aperture, thereby increasing friction and creating a tighter connection. The lips of the spacing-bracing members should have lip notches that are angled for the perimeter side walls to abut the angular side edges of the lip notch and the lip notches should be offset to each other allowing the angled side edges of the lip notches to engage the sloped side edges of the perimeter notches. The lip ends with its notches allows the notches of both the metal support member and the spacing-bracing members to engage and interlock between each other thereby securing the two framing members together from vertical and horizontal movement between each other. The notches interlock between each other in such a way that the notches function as screws as the fastening method for connecting metal framing therefore eliminating a screwdriver and the man hours to install screws rather than just snapping notches together.
The spacing-bracing clip member has a U-shape configuration where the web of the configuration fits into the perimeter notches and, the flanges of the U-shape configuration abuts the web of both the inner and outer concentric support members. The U-shape configuration of the spacing-bracing clip can have a short segment of the spacing-bracing member where the lip fits into the perimeter notches and where the lip has lip notches that engage the perimeter notches. When the perimeter notches are deeper, the flange with notches or the hat-shape configuration with notches can engage the larger perimeter side notches as well as the lips with lip notches.
Another embodiment is the present invention describes a metal framing system having metal support members connect to horizontal spacing-bracing members through the intermediate access holes in the web of metal support members, through the apertures of concentric support members and at the top end and bottom end of the metal support members. The horizontal spacing-bracing members intersect and connect the metal support members by having perimeter side notches that are vertical notches that indent the perimeter side edges of the aperture in the support member and the spacing-bracing member to overhang the aperture letting the notches make the connection. The perimeter notches in the aperture should be angled for the lips to engage the side edges of the perimeter notches and to prevent and eliminate vertical movement. The spacing-bracing member has notches in the lips or flange extensions having notched ends that engage the aperture side edges with the spacing-bracing member overhangs the aperture in the support member. The metal support member has two L-shaped gaps in the web that correspond to the two L-shaped flange lip extensions at the ceiling and floor horizontal spacing-bracing members for the L-shaped flange-lip extensions with the lip notches engage the gap notches.
The center reverse lip spacing-bracing member at the base plate has the same configuration as a horizontal spacing-bracing member installed in the apertures of the metal support members connecting adjacent support members. The horizontal spacing member can vary in shape and consist of a web with extending flanges from the web and additional flanges or lips extending from the flanges with flange or lip notches that engage the aperture side edges. The lip notches or flange notches are angled and or offset to the lip of flange notches on the opposing flange from the web. When bulge notches are used the bulge notches can be cut at a slight angle allowing the side edge of the slide gap 45s to engage the side edges of the bulge notch and the bulge notch on the first flange can be offset to the bulge notch on the second flange if the bulge notch is required to have friction to reduce movement. On the other hand the bulge notches would be in alignment with the slide gap side edge at the ends of the support member.
Another aspect of the invention allows the structural wall system to be used as a load-bearing wall system where the inner support member has a rigid connection between the inner and outer support member; or as a non-load-bearing wall system where the floor and ceiling mounted horizontal spacing-bracing member can be installed as a two-step process, that is the center inner U-shaped bracing member is installed first and fastened to the floor and ceiling. The outside irregular shaped members are installed over an array of the support members with or without the exterior rigid boards like drywall are installed at the flanges of the support members forming a rigid framing panel. The rigid framing panel is then installed over the center inner U-shaped bracing member, so the lips of the center inner U-shaped bracing member engages the L-shaped notches in the web of the support member interlocking the two members together.
Another aspect of the invention where the two concentric support members can be installed with a horizontal orientation rather than a vertical orientation. When installing a drywall ceiling, the horizontal support members are not referred to as studs, but a floor or ceiling joists. A drywall solution can be installed for appearance or for a fire resistance barrier and therefore the weight requires a strong support member to carry the load of drywall. So, when installing the support members, ceiling hangers are installed at the connector member apertures of the support member and the perimeter notches in the apertures allow for adjustments to occur when intersecting the wall support members that at the construction site. The horizontal support members are the lateral bracing requirements for a drywall framed ceiling.
Another aspect of the invention is the connection of the horizontal connector member can be installed back-to-back where the web of a first horizontal connector is attached to a second horizontal connector at the web, therefore the lip notches at the top end of a lower support member is connected to the first horizontal connector and the upper support member connects to the second horizontal connector. When this occurs the upper and lower support members do not overlap between the outer support member and the inner support member. With no overlapping additional bracing between the upper and lower support member will be required to reduce buckling.
No additional FIG's are shown, however when the profile of
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It is understood that the invention is not to be limited to the exact details of operation or structures shown and describing in the specification and drawings, since obvious modifications and equivalents will be readily apparent to those skilled in the art. The flexibility of the described invention is very versatile and can be used in many different types of building applications.
This application is a continuous-in-part pending application U.S. Ser. No. 12/456,707, filed on Jun. 22, 2009, now U.S. Pat. No. 8,161,699 and this application claims priority to the following: continuous-in-part pending application US this application filed Mar. 20, 2024 which claims benefit to;provisional application U.S. 63/549,580 filed Feb. 5, 2024 and,provisional application U.S. 63/469,793 filed May 30, 2023 and,continuous-in-part pending application U.S. Ser. No. 18/495,080 filed Oct. 11, 2024 which claims benefit to;provisional application U.S. 63/313,624 filed Nov. 24, 2023 and,provisional application US 63/453,124 filed Mar. 19, 2023 and,provisional application U.S. 63/469,793 filed May 30, 2023 and,continuous-in-part pending application U.S. Ser. No. 17/960,127 filed Oct. 4, 2022 which claims benefit to:provisional application U.S. 63/313,624 filed Feb. 24, 2022 and,provisional application US 63/282,152 filed Nov. 22, 2021 and,provisional application U.S. 63/252,615 filed Oct. 5, 2021 and,continuous-in-part pending application U.S. Ser. No. 17/871,964 filed Jul. 24, 2022 which claims benefit to;provisional application U.S. 63/313,624 filed Feb. 24, 2022 and,provisional application US 63/282,152 filed Nov. 22, 2021 and,provisional application U.S. 63/252,615 filed Oct. 5, 2021 and,continuous-in-part pending application U.S. Ser. No. 16/657,989 filed Nov. 18, 2019 and;provisional application U.S. 63/900,501 filed Sep. 14, 2019 and,provisional application U.S. 63/898,181 filed Sep. 10, 2019 and,continuous-in-part pending application U.S. Ser. No. 16/525,578 filed Jul. 29, 2019, and;continuous-in-part pending application U.S. Ser. No. 16/503,324 filed Jul. 3, 2019 and;continuous-in-part pending application U.S. Ser. No. 16/449,386 filed Jun. 22, 2019 and;continuous-in-part pending application U.S. Ser. No. 16/439,640 filed Jun. 12, 2019 and;continuous-in-part pending application U.S. Ser. No. 16/406,289 filed May 8, 2019 and;continuous-in-part pending application U.S. Ser. No. 16/396,624 filed Apr. 26, 2019 and;continuous-in-part pending application U.S. Ser. No. 16/354,081 filed Mar. 14, 2019 and;continuous-in-part pending application U.S. Ser. No. 16/198,831 filed Nov. 22, 2018 and;continuous-in-part pending application U.S. Ser. No. 16/195,847 filed Nov. 19, 2018 and;continuation-in-part pending application U.S. Ser. No. 15/724,137 filed Nov. 3, 2017 now U.S. Pat. No. 10,442,136 issued Sep. 24, 2019 which claims benefit to;provisional application U.S. 62/533,092 filed Jul. 16, 2017 (now expired) and,provisional application U.S. 62/490,917 filed Apr. 27, 2017 (now expired) and,provisional application US 62/485,114 filed Apr. 13, 2017 (now expired) and,continuous-in-part pending application U.S. Ser. No. 15/449,250 filed Mar. 3, 2017 now U.S. Pat. No. 10,683,665 issued Jun. 6, 2016 which claims benefit to;provisional application U.S. 62/399,434 filed Sep. 25, 2016 (now expired) and,provisional application U.S. 62/385,932 filed Sep. 9, 2016 (now expired) and,provisional application U.S. 62/378,615 filed Aug. 23, 2016 (now expired) and,provisional application U.S. 62/360,041 filed Jul. 30, 2016 (now expired) and,provisional application US 62/345,153 filed Jun. 3, 2016 (now expired) and,provisional application U.S. 62/308,520 filed Mar. 13, 2016 (now expired) and,continuous-in-part pending application U.S. Ser. No. 15/430,781 filed Feb. 13, 2017 which claims benefit to;provisional application U.S. 62/339,434 filed Sep. 25, 2016 (now expired) and,provisional application U.S. 62/385,932 filed Sep. 9, 2016 (now expired) and,provisional application U.S. 62/378,615 filed Aug. 23, 2016 (now expired) and,provisional application U.S. 62/369,041 filed Jul. 30, 2016 (now expired) and,provisional application U.S. 62/345,153 filed Jun. 3, 2016 (now expired) and,provisional application U.S. 62/308,520 filed Mar. 15, 2016 (now expired) and,provisional application U.S. 62/298,762 filed Feb. 23, 2016 (now expired) and,continuation-in-part pending application U.S. Ser. No. 15/295,172 dated Oct. 17, 2016 now U.S. Pat. No. 10,364,566 issued Jul. 30, 2019 which claims benefit to; which claims benefit to;provisional application U.S. 62/242,705 filed Oct. 16, 2015 (now expired) and,provisional application US 62/244,135 filed Oct. 20, 2015 (now expired) and,provisional application U.S. 62/264,033 filed Dec. 7, 2015 (now expired) and,provisional application US 62/274,134 filed Dec. 31, 2015 (now expired) and,provisional application U.S. 62/345,153 filed Jun. 3, 2016 (now expired) and,continuous-in-part of pending application U.S. Ser. No. 15/090,460 filed Nov. 19, 2015 now U.S. Pat. No. 10,060,281 issued Jul. 13, 2021 which claims benefit to; which claims benefit to;provisional application U.S. 62/242,705 filed Nov. 16, 2015 (now expired) and,provisional application U.S. 62/208,766 filed Aug. 23, 2015 (now expired) and,provisional application U.S. 62/143,097 filed Apr. 4, 2015 (now expired) and,continuous-in-part of pending application U.S. Ser. No. 14/946,378 filed Mar. 3, 2015 now U.S. Pat. No. 11,391,038 issued Jul. 19, 2022 which claims benefit to; which claims benefit to;provisional application U.S. 62/175,191 filed on Jun. 12, 2015 (now expired), and,provisional application U.S. 62/170,269 filed Jun. 3, 2015 (now expired) and,provisional application U.S. 62/139,916 filed Mar. 30, 2015 (now expired and,provisional application U.S. 62/083,276 filed Nov. 23, 2014 (now expired) and,continuous-in-part of application U.S. Ser. No. 13/398,243 filed on Feb. 16, 2012, now abandoned, said application Ser. No. 13/398,243 is a continuation-in-part of application U.S. Ser. No. 12/456,707 filed on Jun. 22, 2009 now patent U.S. Pat. No. 8,161,699 issued Apr. 24, 2012 and,provisional application U.S. 61/629,552 filed on Nov. 22, 2011 (now expired) and,provisional application U.S. 61/628,044 filed on Oct. 24, 2011 (now expired) the disclosures of the above cited US patent applications and US Provisional applications of the Applicant, including all drawings and all the specifications, are hereby incorporated by reference in their entireties into this US patent application. The four applications prior to Mar. 16, 2013: include (U.S. Ser. No. 13/398,243; U.S. 61/629,552; U.S. 61/628,044; and U.S. Ser. No. 12/456,707).
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63469793 | May 2023 | US | |
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63313624 | Feb 2022 | US | |
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63252615 | Oct 2021 | US | |
63313624 | Feb 2022 | US | |
63282152 | Nov 2021 | US | |
63252615 | Oct 2021 | US | |
62900501 | Sep 2019 | US | |
62878181 | Jul 2019 | US | |
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62490917 | Apr 2017 | US | |
62485114 | Apr 2017 | US | |
62399434 | Sep 2016 | US | |
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