Patent Application
20250198151
The present invention pertains to the field of building construction, specifically to an adjustable support system designed to support a roof or a floor in a building with access holes and even more particular building construction applications requiring an adjustable support to accommodate varying size roof openings or floor openings.
Large building roofs, for example, often span significant distances and require structural support systems to distribute the weight of the roof and any additional loads, such as HVAC systems and other equipment. Given the substantial weight of this equipment, the weight of the equipment can impose significant loads on, for example, the roof structure. To efficiently distribute these loads along the length of the roof, I-beams or H-beams are commonly used. However, the installation of large access holes in the roof for these systems can weaken the roof between supports. Additionally, traditional I-beam support systems may lack the flexibility needed to adapt to varying building designs, truss configurations, and open sizes. This lack of adaptability often results in increased costs and time required to customize each support system to fit specific building requirements.
Buildings, especially commercial ones, frequently incorporate access openings in their roofs or floors to accommodate utilities and structures like HVAC systems, electrical wiring, and plumbing. Ensuring the structural integrity of the building around these openings is essential. Without adequate support, these openings can compromise the stability of the roof or floor, risking damage or failure when subject to loads. Therefore, providing additional structural support around these openings is crucial to prevent such risks.
To tackle this challenge, roof support systems have been engineered to offer essential support around access holes, redistributing loads to adjacent structural elements like trusses. However, conventional support systems have proven costly to produce and install, mainly due to the bespoke nature of each building's requirements and the diverse dimensions of access holes. Consequently, these systems are often custom-made for eachinstallation, resulting in elevated expenses and extended lead times. There's been a demand for a versatile roof or floor support system capable of adapting to various scenarios and accommodating a range of access hole sizes.
Moreover, traditional roof support systems are typically prefabricated off-site and then transported to the building location for installation. However, this method poses several challenges. The assembled frames are often bulky, requiring significant space for transportation, thereby escalating shipping and handling expenses. Additionally, each custom frame must be tailored to accommodate the specific item being installed on the roof or floor, leading to increased design costs for each bespoke system. Many of these types of structures are not designed with adjustability in mind. This lack of adjustability can lead to difficulties during installation, particularly in buildings with unique or non-standard truss configurations. Additionally, current solutions lack the strength and durability required for long-term structural support, which can lead to premature wear and potential failure of the support system over time.
There has long been a demand in the market for a more efficient solution capable of supporting both roof and floor access holes. Such a system should be shipped in a disassembled state and easily assembled on-site, reducing shipping and handling costs while enhancing overall project efficiency.
Therefore, there is a need for an adjustable roof support system that can adapt to various building designs and truss configurations, provide a secure and stable connection to the building truss, offer adjustability for ease of installation, and be made from materials that ensure long-term strength and durability.
The present invention addresses the shortcomings of previous designs by introducing an adjustable roof support system for supporting a roof or a floor in a building. The support system can be particularly beneficial for buildings with at least one truss, offering a versatile solution that can be adapted to various building structures and requirements. The support system can be composed of a plurality of interlocking elements, each having at least one fastener slot and a rectangular cross-section. These interlocking elements can include at least one female segment and at least one male segment, designed to fit together securely and adjustably.
The assembled length of the interlocking segments can be slidably adjustable, providing flexibility and adaptability to different building structures. The system can also include at least one fastener configured to pass through the fastener slots of the male segment and the female segment of the interlocking elements, securing the male segment from sliding relative to the female segment once secured. This ensures stability and robustness of the support system.
The support system can include an attachment point coupled to at least one of the ends of the assembled segments. This attachment point can be designed to secure the end to the truss, providing additional support and stability. The attachment point can comprise a horizontal member coupled to a vertical member, which can then be coupled to the end of the assembled segments.
The support system can also include a cross connector, designed to secure one interlocking element to another interlocking element at an angle, providing additional structural support. The fasteners used in the support system can be a bolt and/or nut, and the interlocking elements can be composed of various gauges of steel or aluminum, offering durability and strength. The support system can provide an adjustable, robust, and versatile support system that can be adapted to various building structures and requirements, overcoming the limitations of previous designs.
Aspects and applications of the support system presented here are described below in the detailed description and shown in the accompanying figures. Unless specifically noted, it is intended that the words and phrases in the specification and the claims be given their plain, ordinary, and accustomed meaning to those of ordinary skill in the applicable arts. The inventors are fully aware that they can be their own lexicographers if desired. The inventors expressly elect, as their own lexicographers, to use only the plain and ordinary meaning of terms in the specification and claims unless they clearly state otherwise and then further, expressly set forth the “special” definition of that term and explain how it differs from the plain and ordinary meaning. Absent such clear statements of intent to apply a “special” definition, it is the inventors' intent and desire that the simple, plain and ordinary meaning to the terms be applied to the interpretation of the specification and claims. Aspects and applications of the invention presented here are described below in the drawings and detailed description of the invention. Unless specifically noted, it is intended that the words and phrases in the specification and the claims be given their plain, ordinary, and accustomed meaning to those of ordinary skill in the applicable arts.
The inventors are also aware of the normal precepts of English grammar. Thus, if a noun, term, or phrase is intended to be further characterized, specified, or narrowed in some way, then such noun, term, or phrase will expressly include additional adjectives, descriptive terms, or other modifiers in accordance with the normal precepts of English grammar. Absent the use of such adjectives, descriptive terms, or modifiers, it is the intent that such nouns, terms, or phrases be given their plain, and ordinary English meaning to those skilled in the applicable arts as set forth above.
Further, the inventors are fully informed of the standards and application of the special provisions of 35 U.S.C. § 112 (f). Thus, the use of the words “function,” “means” or “step” in the Detailed Description or Description of the Drawings or claims is not intended to somehow indicate a desire to invoke the special provisions of 35 U.S.C. § 112 (f), to define the invention. To the contrary, if the provisions of 35 U.S.C. § 112 (f) are sought to be invoked to define the inventions, the claims will specifically and expressly state the exact phrases “means for” or “step for, and will also recite the word “function” (i.e., will state “means for performing the function of . . . ”), without also reciting in such phrases any structure, material or act in support of the function. Thus, even when the claims recite a “means for performing the function of . . . ” or “step for performing the function of . . . ,” if the claims also recite any structure, material or acts in support of that means or step, or that perform the recited function, then it is the clear intention of the inventors not to invoke the provisions of 35 U.S.C. § 112 (f).
Moreover, even if the provisions of 35 U.S.C. § 112 (f) are invoked to define the claimed inventions, it is intended that the inventions not be limited only to the specific structure, material or acts that are described in the preferred embodiments, but in addition, include any and all structures, materials or acts that perform the claimed function as described in alternative embodiments or forms of the invention, or that are well known present or later-developed, equivalent structures, material or acts for performing the claimed function.
A more complete understanding of the present invention may be derived by referring to the detailed description when considered in connection with the following illustrative figures. In the figures, like reference numbers refer to like elements or acts throughout the figures.
Elements and acts in the figures are illustrated for simplicity and have not necessarily been rendered according to any particular sequence or embodiment.
In the following description, and for the purposes of explanation, numerous specific details are set forth to provide a thorough understanding of the various aspects of the invention. It will be understood, however, by those skilled in the relevant arts, that the present invention may be practiced without these specific details. In other instances, known structures and devices are shown or discussed more generally to avoid obscuring the invention. In many cases, a description of the operation is sufficient to enable one to implement the various forms of the invention, particularly when the operation is to be implemented in software. It should be noted that there are many different and alternative configurations, devices, and technologies to which the disclosed inventions may be applied. The full scope of the inventions is not limited to the examples that are described below. Referring initially to
The interlocking elements 14 have a main rail 20 with a top extension 22 (e.g., flange) and a bottom extension 24 (e.g., flange). The main rail 20 has, for example, a C-channel shape (e.g., a c-beam or channel beam with a depth, width, and thickness formed from a wide web with two flanges that extended from either side), as shown in cross-section 18 (shown in
Turning to
When the male segment 32 is situated within the female segment 30, the fastener slot 16 of the female segment can be aligned with the fastener slot 16 of the male segment 32 as shown, for example, in
The support system 10 can include at least one fastener 34 configured to pass through the fastener slots 16 of the male segment 32 and female segments 30 when the male segment 32 is positioned within the female segment 30. The length of assembled segments forming the interlocking segments 14 can be slidably adjustable, adjusting to the user's specified lengths. The at least one fastener 34 secures the male segment 32 from sliding relative to the female segment 30 when the fastener is secured within the fastener slot 16. The at least one fastener 34 can be, for example, bolts, nuts, screws, washers, anchors, clips, clamps, rivets, welds, hanger, brackets, or the like. The support system 10 can comprise one or more assembled segments coupled together to form an opening in the shape of such as, for example, a square, rectangle or the like as shown in
As shown in
In certain embodiments, the top extension 22 and the bottom extension 24 may have a vertical extension 60, 60′ substantially extending away from the top extension 22 and the bottom extension 24 as shown in
An attachment point 42 can be coupled to at least one of the first end 36 and the second end 38 of the interlocking element 14. The attachment point 42 can be configured to secure the first end 36 of the interlocking element 14 or the second end 38 of the interlocking element 14 to the at least one truss 12, 13. As shown in
The attachment point 42 can further comprise an angled member 48 having at least one truss fastener 50 (shown in
The invention also includes a method of assembling an adjustable roof support system on a structure having a first truss and a second truss. The method involves providing the adjustable roof support system, assembling a first rail by assembling a male segment with a female segment and slidably adjusting the assembled length of the first rail to extend between the first truss and the second truss. A second rail is assembled in a similar manner. The first rail can be arranged a desired distance from the second rail. The first end of the first and second rails is coupled with the first truss and the second end of the first and second rails with the second truss. At least one cross rail is provided, comprising at least one of the plurality of interlocking segments, a first cross connector and a second cross connector that when assembled span the desired distance. The first cross connector is secured to the first rail and the second cross connector to the second rail.
The first rail and the second rail can be comprised of a single male segment and a single female segment. A segment length for the male segment and the female segment can be selected from a plurality of segment lengths to allow the first rail and the second rail to stretch between the first truss and the second truss with a single male segment and a single female segment. The plurality of rail lengths can comprise segments having a length of 15 inches, 20 inches, 25 inches, 30 inches, 35 inches, 40 inches, 45 inches, 50 inches, 55 inches, 60 inches, 65 inches, 70 inches, 75 inches, 80 inches, 85 inches, 90 inches, 95 inches, 100 inches, 105 inches, 110 inches, 115 inches, or 120 inches.
The combined length of one of the at least one of the plurality of interlocking segments, the first cross connector and the second cross connector is the desired distance. The desired distance can be between 21 and 27 inches. The method can further comprise securing at least one fastener in at least one of the fastener slots. The at least one cross rail can be one cross rail for every 25 inches of the distance between the first truss and the second truss. The interlocking segments can be composed of 6 gauge, 10 gauge, 12 gauge, or 3/16ths inch steel or aluminum selected based on required loading. In general, the thickness of the material may be varied according to the desired distance to ensure sufficient system strength about the full length of the desired distance.
The gauge of the interlocking segments can be chosen by the size of the access hole in the building and the load the adjustable roof support system will see such as, for example, the greater the distance between the first and second truss the higher the structural load will be, and the heavier the item on the roof or floor is the higher the structural load will be on the adjustable roof support system requiring the thicker material to withstand the loads seen. The thicker the material the better it can resist the forces and stresses imposed on the adjustable roof support system by the distance and load on roof or floor. Additionally, the thicker the material provides a built-in safety margin that may be required by some builders to ensure the material can withstand the loads beyond the anticipated maximum capacity reducing the risk of unexpected failures or structural collapses. The thicker the material the stiffer the material tends to be increasing the rigidity of the adjustable roof support system 10.
Referring to
The at least one fastener slot 104 can be, for example, a thru hole, aperture, fastener slot, keyway slot, square slot, a slot with a length, or the like and can be sized to fit at least one fastener 118. The at least one fastener 118 can be, for example, bolt, screws, rivets, dowel pins, clevis pins, anchors, or the like and can be configured to pass through the at least one fastener slots 104 of the male segment 108 and female segment 106 when the male segment 108 is situated within the female segment 106, which can secure the male segment 108 from sliding relative to the female segment 106 after assembly. The at least one fastener slot 104 is present on both the at least one female segment 106 and the at least one male segment 108, facilitating secure assembly.
An attachment point 130 can be coupled to at least one of the first end 114 and the second end 116 of the interlocking element 102. The attachment point 130 can be secured the first end 114 or the second end to the truss 12. The attachment point 130 of the support system 100 comprises a horizontal member 132 coupled to a vertical member 134 that is coupled to the first end 114 and/or the second end 116 of an interlocking element 102. The vertical member 134 is coupled to an angle member having at least one truss fastener 136 coupled to it. The at least one truss fastener 136 can be tightened against the truss 12 to secure the support system 100 to the truss 12. Additionally a fastener 151 can be provided that secures the male segment to the female segment. The fastener 151 can be, for example, a bolt with a nut, or a bolt with a nut and a washer.
The assembled length of the interlocking element 102 comprising the at least one female segment 106 and the at least one male segment 108 of the support system 100 is slidably adjustable, allowing for flexibility in installation and use in the roof or ceiling of the building as shown in
As shown in
The interlocking elements such as the at least one female segment 106 and the at least one male segment 108 can be made of material thickness such as, for example, 6 gauge, 10 gauge, 12 gauge, or 3/16ths inch steel or aluminum, providing robust and durable support. The at least one female segment 106 and the at least one male segment 108 can be such as, for example, cold rolled, extruded, casted, or the like and can be steel, stainless steel, aluminum carbon steel or the like.
The adjustable roof support system 10 of the present invention offers a versatile and robust solution for supporting roofs or floors in buildings. Its adjustable nature allows for customization to fit a variety of building structures and sizes. The interlocking segments and fasteners provide a secure and stable support system, while the attachment points ensure secure connection to the building's trusses. The use of durable materials like steel or aluminum ensures the longevity and reliability of the support system.
In closing, it is to be understood that although aspects of the present specification are highlighted by referring to specific embodiments, one skilled in the art will readily appreciate that these disclosed embodiments are only illustrative of the principles of the subject matter disclosed herein. Therefore, it should be understood that the disclosed subject matter is in no way limited to a particular methodology, protocol, and/or reagent, etc., described herein. As such, various modifications or changes to or alternative configurations of the disclosed subject matter can be made in accordance with the teachings herein without departing from the spirit of the present specification. Lastly, the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of the present disclosure, which is defined solely by the claims. Accordingly, embodiments of the present disclosure are not limited to those precisely as shown and described.
Certain embodiments are described herein, including the best mode known to the inventors for carrying out the methods and devices described herein. Of course, variations on these described embodiments will become apparent to those of ordinary skill in the art upon reading the foregoing description. Accordingly, this disclosure includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described embodiments in all possible variations thereof is encompassed by the disclosure unless otherwise indicated herein or otherwise clearly contradicted by context.
This application is a continuation-in-part of U.S. patent application Ser. No. 18/542,131 filed Dec. 15, 2023, the contents of each of which is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 18542131 | Dec 2023 | US |
| Child | 18629299 | US |
