ADJUSTABLE SUPPORT SYSTEMS AND METHODS

Description

FIELD OF THE INVENTION

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.

BACKGROUND OF THE INVENTION

Buildings, particularly commercial ones, often feature access openings in their roofs or floors to accommodate various utilities and structures such as HVAC systems, electrical wiring, and plumbing,. Ensuring the structural support around these openings is important to maintain the structural integrity of the building. If no additional support is provided, the roof or floor may be damaged or weakened and may become compromised or weakened when subjected to load, potentially leading to structural damage or failure.

To address this issue, roof support systems have been developed to provide the necessary support around these access holes, effectively redistributing the load to adjacent structural elements such as trusses. However, these support systems have traditionally been costly to manufacture and install due to the unique requirements of each building and the varying dimensions of the access holes. As a result, these support systems have often been custom-designed and manufactured for each specific application, leading to increased costs and longer lead times. What has been needed is a roof or floor support system that can be adapted to different situations and fit a variety of access hole sizes.

Furthermore, conventional roof support systems are typically assembled off-site and then transported to the building location for installation. This approach presents several challenges, including the bulky nature of the assembled frames which require significant space for transportation, thereby increasing shipping and handling costs. In addition, each custom frame has to be rates for the specific item that is being installed on the roof or floor thus increasing the design costs for each custom-built system. The market has long needed a system that is a more efficient solution that could support both a roof access hole and a floor access hole that can be shipped in a disassembled state and then easily assembled on-site, reducing shipping and handling costs and improving overall efficiency of the project.

Therefore, there is a need for a support system that is not only robust, strong and reliable, but also adjustable and easy to install. Such a support system would provide greater flexibility in the construction process, allowing for the accommodation of a wide range of architectural designs and load-bearing requirements. It would also reduce installation time and labor costs and allow for easy adjustments or modifications after installation.

BRIEF SUMMARY OF THE INVENTION

The present invention relates to an adjustable support system designed to support a roof or a floor in a building with at least one truss. The support system comprises a plurality of interlocking elements, each interlocking element having at least one fastener slot and a cross-section that includes a main rail with a top extension and a bottom extension. These extensions define an interior channel and an external periphery, with the top extension being longer than the bottom extension.

The interlocking elements can include at least one female segment and one male segment, with the exterior periphery of the male segment fitting within the interior channel of the female segment. When the male segment is situated within the female segment, the fastener slots align, and the assembled segments have a first end and a second end, The support system also includes at least one fastener designed to pass through the fastener slots of the male and female segments of the interlocking elements when the male segment is situated within the female segment, securing the male segment from sliding relative to the female segment. An attachment point is coupled to either the first end or the second end and is configured to secure the end to the truss. The assembled length of the support system is slidably adjustable, and the fastener slot is located on the main rail. The lengths of the male and female segments may vary, and can include lengths of, for example, 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 attachment point can include a horizontal member coupled to a vertical member that can be attached to the first end and/or the second end. The vertical member can be coupled to an angle member with at least one truss fastener attached to it, which is tightened against the truss. The support system can also include a cross connector designed to secure one interlocking elements to another at an angle, which can be a perpendicular angle. The top and bottom extensions have a vertical extension that substantially extends away from them. The fasteners can be a bolt and/or nut.

The invention can also include a method of assembling the adjustable support system on a structure with a first truss and a second truss. This involves providing the adjustable support system, assembling a first and second rail, arranging the first rail a desired distance from the second rail, and coupling the ends of the rails with the trusses. A cross rail can be provided, which spans the desired distance and can be secured to the first and second rails. The number of cross rails and gauge of the interlocking elements may be selected on required loading.

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 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.

BRIEF DESCRIPTION OF THE DRAWINGS

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.

FIG. 1 depicts an isometric view of the adjustable with support system in accordance with one, or more embodiments;

FIG. 2 depicts a top view of the adjustable support system in accordance with one, or more embodiments;

FIG. 3a depicts a side view of the adjustable support system in accordance with one, or more embodiments;

FIG. 3b depicts a cross-sectional view of FIG. 3a of the adjustable support system in accordance with one, or more embodiments;

FIG. 3c depicts an exploded view of FIG. 3b of the adjustable support system in accordance with one, or more embodiments;

FIG. 4 depicts a top view of another embodiment of the adjustable support system in accordance with one, or more embodiments;

FIG. 5a depicts a side view of the adjustable support system in accordance with one, or more embodiments;

FIG. 5b depicts a cross-sectional view of another embodiment of FIG. 5a of the adjustable support system in accordance with one, or more embodiments;

FIG. 5c depicts a close-up view from FIG. 5b of another embodiment of the adjustable support system in accordance with one, or more embodiments;

FIG. 6 depicts an isometric view of an interlocking element of the adjustable support system in accordance with one, or more embodiments;

FIG. 7 depicts an isometric view of another embodiment of an interlocking element of the adjustable support system in accordance with one, or more embodiments;

FIG. 8 depicts an isometric view of the attachment point of the adjustable support system in accordance with one, or more embodiments; and

FIG. 9 depicts an isometric view of another embodiment of the attachment point of the adjustable support system in accordance with one, or more embodiments.

Elements and acts in the figures are illustrated for simplicity and have not necessarily been rendered according to any particular sequence or embodiment.

DETAILED DESCRIPTION

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.

I. Support Systems

Referring initially to FIGS. 1-7, the present invention relates to an adjustable support system for supporting a roof or a floor in a building having at least one truss 12, 13 shown generally in FIG. 1. The support system 10 comprises a plurality of interlocking elements 14, each element having at least one fastener slot 16. As shown in FIGS. 1, 2 and 4 four interlocking elements 14 are used with two of the interlocking sections 14 engaging a truss 12, 13 (truss engaging interlocking elements) at either end and the remaining two interlocking elements 14 (cross-rail interlocking elements) are secured to a truss engaging interlocking element at either end. The truss engaging interlocking elements and the cross-rail interlocking elements are interchangeable.

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 FIG. 3C). The top extension 22 and the bottom extension 24 can be spaced at a position parallel each other at opposite ends of the main rail 20. The main rail 20 has an interior surface and an exterior surface. Additionally, the top extension 22 and the bottom extension 24 can be perpendicular, or substantially perpendicular, to the main rail 20. The support system 10 can be configurable to be adjustable during installation. The fastener slot 16 can be located on the main rail 20. The main rail 20, top extension 22 and bottom extension 24 extends from a first side of the main rail 20 and a second side of the main rail 20 to define an interior channel 26. The main rail 20 has an external periphery 28, with the top extension 22 extending from the main rail 20 and having a longer length than the bottom extension 24. The interlocking elements 14 can be any suitable size or length to fit the needs of the application of the support system 10, for example a heavier roof will require a bigger interlocking element 14 to be able to withstand the heavier loads of the heavier roof, or if the access port is long or short the interlocking element 14 can also adjust in length to fit various opening sizes. The interlocking elements 14 can also be made from such as, for example, steel, stainless steel, carbon steel, galvanized steel, aluminum or the like. The main rail 20 (shown in FIG. 3C), top extension 22 and the bottom extension 24 can be, for example, cold rolled, extruded, forged, welded, or the like from one piece or multiple pieces.

Turning to FIG. 2, the plurality of interlocking elements 14 includes at least one female segment 30 and at least one male segment 32 wherein the exterior periphery of the male segment fits within the interior channel 26 of the female segment 30. The female segment 30 and the male segment 32 can be made of the same material or can be different material and can be the same length or can be varying lengths. The female segment 30 and the male segment 32 can have a standard unit of measure of, for example, at least 1 inch to 240 inches and can be, for example, 6 gauge, 10 gauge, 12 gauge, 14 gauge, 16 gauge, 18 gauge, 30 gauge, 3/16th inch, or the like in thickness. The size, length and thickness of the female segment 30 and the male segment 32 can be changed by the user to fit the application type such as, for example, load, size of access hole, or the like. The segment length may be selected to ensure that a single male segment 32 and a single female segment 30, when assembled into an assembled length (Ls), will span the distance between trusses to provide a single splice point in each section of assembled segments. The lengths of the segments (e.g., female segment 30 and male segment 32) may vary, and can include lengths of, for example, 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 at least one male segment 32 is configurable to have a cross-section with a first height and a first width and the at least one female segment 30 is configurable to have a second cross-section with a second height and a second width different than the first height and the first width. Either of the first or second cross-sections can be square, open or partially open on one side, or have an I-beam shape.

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 FIGS. 3A-3B. The assembled female segment 30 and male segments 32 can have a first end 36 and a second end 38 resulting in an assembled segment length Ls (shown in FIG. 2). The male segment 32 can slide in the female segment 30 and adjust to the overall assembled segment length to be adjusted based on a user's specification allowing the user to choose the length of the interlocking elements 14 and fit to the user's application.

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 the assembled segments forming the interlocking elements 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 FIG. 2.

As shown in FIG. 1, the support system 10 can further include a cross-connector 66 configured to secure one interlocking element 14 to another interlocking element 14 at an angle or the assembled segments can be coupled together by at least one fastener 34 and a cross connector 66. The cross-connector 66 can be secured by, for example, bolts, nuts, screws, washers, anchors, clips, clamps, rivets, welds, hanger, brackets, or the like. The angle can be a perpendicular angle but in other embodiments the angle can be, for example, zero degree to one hundred and eighty degrees. The cross-connector 66 can also be coupled to either the male segment 32 or the female segment 30 through the fastener slots 16 by at least one fastener 34 in at least one location. In other embodiments the cross-connector 66 can be, for example, welded or riveted together.

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 FIG. 3C and FIG. 7. The vertical extension 60, 60′ can be at a perpendicular angle to the top extension 22 and/or bottom extension 24 or in other embodiments the vertical extension can be, for example, between at least 1 degree and at least 180 degrees or at most 1 degree to at most 180 degrees. In other embodiments, the vertical extension 60, 60′ can be omitted as shown in FIG. 6.

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 FIG. 8 and FIG. 9, the attachment point 42 can comprise a horizontal member 44 coupled to a vertical member 46. Moreover, the horizontal member 44 and the vertical member 46 can be coupled together by, for example, welds, fasteners, rivets, adhesive, or the like. The vertical member 46 can also have at least one attachment point fastener slot 52 for a truss fastener 50 to couple the attachment point 42 to the male segment 32 and/or female segment 30 of the interlocking element 14 through the plurality of fastener slots 16. The vertical member 46 can be centered on the horizontal member 44 as shown in FIG. 8 or it can be offset one direction as shown in FIG. 9.

The attachment point 42 can further comprise an angled member 48 having at least one truss fastener 50 (shown in FIG. 3C) coupled to the attachment point 42. The angled member 48 can be used for tightening to the truss 12. In certain embodiments the angled member 48 can be omitted as shown in FIG. 9. Additionally, a fastener 51 can be provided that secures the male segment to the female segment. The fastener 51 can be, for example, a bolt with a nut, or a bolt with a nut and a washer. In embodiments, the attachment point 42 can be made from, for example, steel, stainless steel, carbon steel, galvanized steel, or the like. The attachment point 42 can couple the adjustable roof system 10 to the truss 12, 13 at more than one location as shown in FIG. 1 and FIG. 2.

II. Method of Using Support Systems

The invention also includes a method of assembling an adjustable support system on a structure having a first truss and a second truss. The method involves providing the adjustable 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 elements, 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 elements, 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 elements can be composed of 6 gauge, 10 gauge, 12 gauge, or 3/16ths inch steel or aluminum selected based on required loading.

The gauge of the interlocking elements can be chosen by the size of the access hole in the building and the load the adjustable 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 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 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 support system 10.

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.