Structural Insulating Core Wall With A Reverse Lip Channel

Abstract

The present invention relates to a structural insulating core wall consists of spacer blocks with a tongue space and a groove space interlocking the spacer blocks between vertical metal support channels and the horizontal bracing channels forming a horizontal tongue and trough within the spacer blocks connecting the spacer blocks, vertical support channels and horizontal bracing channels together. Various types of horizontal bracing channels, support channels, couplings, hole shapes within the support channels and orientation of the various elements and the shape of the spacer blocks changes affect how the structural insulating core wall is used including the type of material the spacer blocks made of.

1 . A structural insulating core wall of a building comprising of:
 spaced apart vertically oriented metal support channels with holes, horizontal bracing channels that pass through the holes, spacer blocks positioned between and at least spanning the distance between the channels, consisting of:   spaced apart vertically oriented metal support channels that have two flanges and a web with a hole in the web;   a hole in the webs so the horizontal bracing channel can be lodged in the holes of the vertically oriented metal support channels securing itself to the sides of the holes;   a block depth dimension greater than the depth of the support channels, a groove and a transverse mating tongue fully extending along a transverse length of facing, opposed side block surfaces, the groove and tongue surfaces contacting the web and channel flanges without overlapping the flanges, a base plate groove running perpendicular to the tongue and groove, the base plate groove in a bottom block face and positioned from a front or back surface a dimension equal to a foam thickness from the front or the back of the block to the channel flange and,   a base plate having a flange inserted in a base angle groove of the blocks, the base plate flanges secured to the channel flanges, and, another base plate flange, perpendicular to the first, secured to a building floor adjacent the structural insulating core wall.   
     
     
         2 . The structural insulating core wall of  claim 1  wherein bracing is fastened over the spacer block to the support channel flanges. 
     
     
         3 . The structural insulating core wall of  claim 1  wherein the support channels and spacer blocks are glued together to form the wall. 
     
     
         4 . The structural insulating core wall of  claim 1  including a trough with a horizontal bracing channel aligned with the holes in the support channel, and in the middle of the block, the trough parallel to the base plate groove, and aligned with holes in the channels, and a horizontal tongue fitting into the trough of another spacer block. 
     
     
         5 . The structural insulating core wall of  claim 4  wherein the horizontal tongue of the spacer block fits between the flanges of the horizontal bracing channel. 
     
     
         6 . The structural insulating core wall of  claim 1  including inner and outer rigid boards adhered to both sides of the structural insulating core. 
     
     
         7 . The structural insulating core wall of  claim 6  wherein the support channel at the flanges forms a gap separating the spacer blocks and between the inner or outer rigid boards. 
     
     
         8 . The structural insulating core wall of  claim 1  wherein the spaced apart vertically oriented elongated metal support channels have a web with flanges perpendicular to the web with lips parallel and oriented away from the web. 
     
     
         9 . The structural insulating core wall of  claim 1  where the spaced apart vertically oriented metal support channels have an indentation in the web so the vertical projection of the spacer blocks can fit into and around. 
     
     
         10 . The structural insulating core wall of  claim 1  wherein the hole of the vertically oriented support channel is sloped corresponding to the slope of the horizontal bracing channel. 
     
     
         11 . The structural insulating core wall of  claim 10  wherein the sloped hole in the support channel has a blunt end at the vortex allowing the flanges of the horizontal bracing channel to engage with the sloped sides of the hole. 
     
     
         12 . The structural insulating core wall of  claim 7  wherein rigid board fillers separate the inner and outer rigid boards from the support channels. 
     
     
         13 . The structural insulating core wall of  claim 1  wherein a coupling is a horizontal bracing channel that is short in length that passes through the hole in the support channels connecting the trough or horizontal tongue of the spacer block. 
     
     
         14 . The structural insulating core wall of  claim 1  wherein U shaped horizontal bracing channels are connected end to end by a coupling consisting of a web and two flanges and where the flanges and the web fits between the web and flanges of the U shaped horizontal bracing channels align with each other forming a continuous horizontal bracing channel. 
     
     
         15 . The structural insulating core wall of  claim 14  wherein the horizontal reverse lip bracing channel is a coupling consisting of a web and two flanges where the flanges and the web fits between the web and flanges of the horizontal reverse lip bracing channels and the notch in the lip of the coupling fit into the hole of support channel. 
     
     
         16 . The structural insulating core wall of  claim 15  wherein the coupling connects two perpendicular structural insulating walls at the corner with notches and flexible tabs at both ends fitting between the holes of the support channels of each structural insulating walls. 
     
     
         17 . The structural insulating core wall of  claim 1  wherein the spacer block depth dimension being greater than the depth of the support channels comprising of two smaller depth spacer blocks of different physical properties being supported by the tongue and groove shapes at the support channels. 
     
     
         18 . The structural insulating core wall of  claim 16  wherein the spacer block overlaps the flange of the support channel on one side of the support channel and extends past the flange on the opposite side. 
     
     
         19 . The structural insulating core wall of  claim 1  wherein the shape of the hole in the support channels, profile and orientation of the horizontal bracing channel determines wherein the horizontal tongue fits into the trough or the horizontal bracing channel profile interlocking each together within the spacer block. 
     
     
         20 . The structural insulating core wall of  claim 18  wherein the profile of the electric chase as described in claim  70  has a horizontal trough in the spacer blocks that the top and bottom of the spacer blocks for the electric chase to fit into. 
     
     
         21 . The structural insulating core wall of  claim 1  wherein the spaced apart oriented metal support channels are oriented horizontally and positioned between the spacer blocks as described in  claim 33 . 
     
     
         22 . A spacer block between vertically oriented metal support channels positioned between and at least spanning the distance between the channels and between horizontally spaced apart members connected to the vertically oriented metal support channels and positioned between and at least spanning the distance between the horizontally spaced members comprising of:
 a horizontal block dimension positioned between and at least spanning the distance between the vertically oriented metal support channels; wider than the width of the web of the support channels; the width does not overlap the flanges of the vertical channels support; and interlocking between causing a tongue shape and a groove shape between the vertical support channels   a vertical block dimension positioned between and at least spanning the distance between the horizontally spaced apart members; a width equal to the width of the horizontal block dimension;   a horizontal trough wherein a horizontally spaced apart member fits into and aligns with the holes of the vertical support channels;   a horizontal tongue that fits into the horizontal trough of an adjacent spacer block.   
     
     
         23 . The spacer block according to  claim 22  wherein the horizontal tongue is rectilinear and fits between the flanges and against the web of a horizontally spaced member. 
     
     
         24 . The spacer block according to  claim 22  wherein two spacer blocks are connected by the horizontal tongue of one spacer block fitting into the horizontal channel and the other spacer block and the adjacent spacer block with is horizontal trough fits over the horizontally spaced apart member and aligns with the holes of the support channels. 
     
     
         25 . The spacer block according to  claim 22  wherein the horizontal tongue is rectilinear and has grooves on both sides of the horizontal tongue where the flanges of the horizontal bracing channel flanges fit into and against the web of a horizontally spaced member. 
     
     
         26 . The spacer block according to  claim 22  wherein the horizontal tongue is V shaped and fits into the flanges of the horizontally spaced member. 
     
     
         27 . The spacer block according to  claim 26  wherein the V shaped horizontal tongue or horizontal trough have a rectilinear extension added for the V shaped horizontal bracing member. 
     
     
         28 . The spacer block according to  claim 22  wherein the horizontal trough is rectilinear in shape. 
     
     
         29 . The spacer block according to  claim 22  wherein the horizontal trough is V shaped. 
     
     
         30 . The spacer block according to  claim 29  wherein the horizontal trough has a combination of rectilinear sides and angular sides for a horizontal V shaped horizontal bracing member to fit into. 
     
     
         31 . The spacer block according to  claim 28  wherein the width of the horizontal trough is the width of a U shaped horizontal bracing channel. 
     
     
         32 . The spacer block according to  claim 22  wherein the horizontal trough has a combination of rectilinear sides and a round trough for a round horizontal bracing member to fit into. 
     
     
         33 . The spacer block according to  claim 22  wherein the two reverse lip horizontal bracing channels are inverted to each other requiring a horizontal trough on the top and bottom of the spacer block corresponds to the width of the webs of the elongated channels for the elongated channels to fit into. 
     
     
         34 . The spacer block according to  claim 22  wherein the tongue shape between the vertical support channels has a vertical indentation in the support channels and the groove shape within the spacer blocks have a vertical projection that fits into the indentation of the support channel. 
     
     
         35 . The spacer block according to  claim 22  wherein the horizontal block dimension positioned between and at least spanning the distance between the vertically oriented metal support channels; wider than the width of the web of the support channels has one projection that extends over the flanges of the vertical support channels interlocking between causing a tongue shape and groove shape between the vertical support channels and the opposite projection that extends past the flanges and does not overlap the flanges of the vertical support channels. 
     
     
         36 . The spacer block according to  claim 22  wherein the horizontal and vertical block dimension positioned between and at least spanning the distance between the vertically oriented metal support channels; the width covering the holes in the vertical support channels on one side and extending past the flange on the other side and engaging a horizontal trough wherein a horizontally spaced apart member fits into and aligns with the holes of the vertical support channels. 
     
     
         37 . The spacer block according to  claim 22  wherein the vertical block dimension positioned between and at least spanning the distance between the horizontally spaced apart members is smaller having a vertical hole installed through the horizontal trough to another horizontally spaced apart member. 
     
     
         38 . A support channel/horizontal bracing channel member comprising:
 an elongate member having a U shaped lateral cross-section having a web and two flanges and two lips jointed at the flanges and aligned with the web that defines a longitudinal axis; and   at least two pair of spaced apart notches in at least one of said longitudinally extending lips for receiving and engaging a hole in a web of a support channel, each notch extending inwardly to the U shaped cross-section that is perpendicular to the longitudinal axis of the elongate member.   
     
     
         39 . The horizontal bracing channel member of  claim 38 , wherein the notches extend inwardly in the same direction. 
     
     
         40 . The horizontal bracing channel member of  claim 38 , wherein the notches extend inwardly at an angle. 
     
     
         41 . The horizontal bracing channel member of  claim 38  wherein the horizontal bracing channel is a coupling consisting of a web and two flanges and long enough to where the flanges and the web fits between the web and flanges of the horizontal U bracing channels located on either side of the coupling and the notch in the lip of the coupling fit into the hole in the web of the support channel. 
     
     
         42 . The horizontal bracing channel member of  claim 38 , wherein the horizontal bracing channel is a clip consisting of a web and two flanges with notches at the lips and where a continuous horizontal U channel fit into the flanges of the clip and the clip secures the continuous horizontal U channel to the hole in the web of the support channel. 
     
     
         43 . A support channel/horizontal bracing channel member and a hole comprising;
 an elongated member having a V shaped lateral cross-section having each side define a longitudinal axis; and   a hole where the edges in a hole in the web of a support channel align with the V shaped horizontal bracing channel when the V shape is pointing downward.   
     
     
         44 . A support channel/horizontal bracing channel member and hole according to  claim 43  wherein comprising:
 an elongated member having a V shaped lateral cross-section having each side define a longitudinal axis; and 
 at least one notch for receiving and engaging a hole in a web of a support channel; 
 a hole where the edges are angular conforming to the V shaped horizontal bracing channel with a horizontal edge at the vortex of the hole engaging the vortex of the horizontal bracing channel. 
 
     
     
         45 . The support channel/horizontal bracing channel member and hole according to  claim 43  wherein the sides of the horizontal bracing channel has grooves at both sides of the V shaped later cross-section engaging both sides of the hole in the support channel. 
     
     
         46 . A support channel/horizontal bracing channel member comprising:
 an elongate member having a round hollow lateral cross-section that defines a longitudinal axis; and   at least a continuous raised groove that spirals around the round hollow lateral cross-section a hole in a web of a support channel, each groove extending outwardly so the edges of the raised groove will engage the cross-section of the opening of the support channel; and   an opening that conforms to the diameter of the horizontal bracing channel.   
     
     
         47 . A metal framed wall comprising:
 of support channels each having at least two flanges interconnected by a web, the web of the support channel having an hole, and the support channels being arranged in a row with the holes in the webs thereof aligned with one another; and   at least one horizontal bracing channel as set forth in  claim 38  extending through the openings of the support channels, the support channels longitudinally spaced apart with notches engaging the web of the studs.   
     
     
         48 . The metal framed wall of  claim 38  wherein at least one horizontal bracing channel includes a second horizontal bracing channel set in reverse so the lips of the second horizontal bracing channel are adjacent to the first horizontal bracing channel to each other as set forth in  claim 37  so the flanges and web of the second horizontal bracing channel extend above the first horizontal bracing channel forming an enlarged enclosure extending through the openings of the support channels forming a passageway for electric wiring. 
     
     
         49 . The metal framed wall of  claim 46  wherein at least one punched hole is installed in a horizontal bracing channel for means of attaching electric conduit to the horizontal bracing channel with the punched hole.