BOX BEAM ADJUSTABLE SUPPORT SYSTEMS

Abstract

An adjustable roof support system is disclosed for supporting a roof or a floor in a building having at least one truss. The system includes a plurality of interlocking segments, each having at least one fastener slot and a cross-section comprising a main rail with a top extension and a bottom extension that define an interior channel and an external periphery. The interlocking segments include at least one female length and one male length, wherein the exterior periphery of the male length fits within the interior channel of the female length. The assembled length is slidably adjustable, and the system can be assembled on a structure having a first truss and a second truss. The system may also include a cross connector configured to secure one interlocking length to another at an angle.

Claims

1.-13. (canceled)

14. A support system for supporting a roof or a floor in a building comprising: a plurality of interlocking elements each interlocking element comprising a first interlocking element end and a second interlocking element end; a female segment having a female segment exterior surface, a female segment interior surface, and at least one female segment fastener slot, and a male segment having a male segment exterior surface and at least one male segment fastener slot, wherein the female segment fastener slot aligns with the at least one male segment fastener slot when a portion of the male exterior surface of the male segment engages the female segment interior surface of the female segment; at least one fastener operable to pass through the female segment fastener slot and the male segment fastener slot to secure the male segment in a position relative to the female segment; and at least one of an attachment point couplable to at least one of the first interlocking element end and the second interlocking element end wherein the attachment point is operable to secure the first interlocking element end or the second interlocking element end to a truss, and at least one cross-connector couplable to the interlocking element wherein the cross-connector is operable to secure a first interlocking element to a second interlocking element at an angle.

15. The support system of claim 14, wherein a length of at least one of the plurality of interlocking elements is slidably adjustable.

16. The support system of claim 14, wherein the male segment has a first cross-section length and width and the female segment has a second cross-section length and width greater than the first cross-section length and width.

17. The support system of claim 16, wherein the first cross-section is square, rectangular, or I-beam.

18. The support system of claim 2, wherein the first cross-section length and width is smaller than the second cross-section length and width allowing the male segment t slide within the female segment.

19. The support system of claim 14, wherein the attachment point comprises a horizontal member coupled to a vertical member wherein the attachment point is coupled to at least one of the first interlocking element end and the second interlocking element end.

20. The support system of claim 19, wherein the vertical member of the attachment point is coupled to an angle member having at least one truss fastener wherein the truss fastener is tightenable against the at least one truss.

21. The support system of claim 14, wherein the angle is a perpendicular angle.

22. The support system of claim 14, wherein the at least one fastener is at least one of a bolt and a nut.

23. The support system of claim 14, wherein the plurality of interlocking elements have a size selected from 6 gauge, 10 gauge, 12 gauge, 3/16ths inch steel, and 3/16th inch aluminum.

24. The support system of claim 14, wherein the cross-connector can be angled steel.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] 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.

[0018] FIG. 1 depicts an isometric view of the adjustable support system in accordance with one, or more embodiments engaging a truss;

[0019] FIG. 2 depicts a top view of the adjustable support system in accordance with one, or more embodiments;

[0020] FIG. 3a depicts a side view of the adjustable support system in accordance with one, or more embodiments;

[0021] FIG. 3b depicts a cross sectional view of FIG. 3a of the adjustable support system in accordance with one, or more embodiments;

[0022] FIG. 3c depicts an exploded view of FIG. 3b of the adjustable support system in accordance with one, or more embodiments;

[0023] FIG. 4 depicts a top view of another embodiment of the adjustable support system in accordance with one, or more embodiments;

[0024] FIG. 5a depicts a side view of the adjustable support system in accordance with one, or more embodiments;

[0025] 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;

[0026] FIG. 5c depicts a close-up view of FIG. 5b of another embodiment of the adjustable support system in accordance with one, or more embodiments;

[0027] FIG. 6 depicts an isometric view of an interlocking element of the adjustable support system in accordance with one, or more embodiments;

[0028] 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;

[0029] FIG. 8 depicts an isometric view of the attachment point of the adjustable support system in accordance with one, or more embodiments;

[0030] 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;

[0031] FIG. 10 depicts isometric view of another embodiment of the adjustable support system installed on I-beams in accordance with one, or more embodiments;

[0032] FIG. 11 depicts isometric view of another embodiment of the adjustable support system in accordance with one, or more embodiments;

[0033] FIG. 12a depicts front view of another embodiment of the adjustable support system in accordance with one, or more embodiments;

[0034] FIG. 12b depicts cross sectional view of FIG. 12a of another embodiment of the adjustable support system in accordance with one, or more embodiments;

[0035] FIG. 12c depicts close-up view of FIG. 12c another embodiment of the adjustable support system in accordance with one, or more embodiments;

[0036] FIG. 13 depicts side view of the adjustable rectangular box beam of the adjustable support system in accordance with one, or more embodiments;

[0037] FIG. 14 depicts isometric view of the adjustable rectangular box beam of the adjustable support system in accordance with one, or more embodiments;

[0038] FIG. 15 depicts front view of the adjustable square box beam of another embodiment of the adjustable support system in accordance with one, or more embodiments; and

[0039] FIG. 16 depicts isometric view of the adjustable square box beam of another embodiment of the adjustable support system in accordance with one, or more embodiments.

[0040] 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

[0041] 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 FIGS. 1-7, the present invention relates to a support system 10 for supporting a roof or a floor in a building having at least one truss 12, 13 is shown generally in FIG. 1. The support system 10 comprises a plurality of interlocking elements 14, each segment having at least one fastener slot 16. As shown in FIG. 1, FIG. 2 and FIG. 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.

[0042] 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 can be integrally formed to extend 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 and 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 adjust in length to fit various opening sizes. The interlocking element 14 can 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.

[0043] 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 32 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 different lengths. The female segment 30 and the male segment 32 can have a length of, for example, at least 1 inch to 240 inches and can have a standard unit of measure of, for example, 6 gauge, 10 gauge, 12 gauge, 14 gauge, 16 gauge, 18 gauge, 30 gauge, 3/16.sup.th 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 of either the female segment 30 or the male segment 32 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 segments 30 and male segments 32) may vary, and can include segment 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.

[0044] 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 (e.g., interlocking element 14) having an assembled segment length Ls (shown in FIG. 2). The male segment 32 can slide in the female segment 30 to allow 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.

[0045] 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 FIG. 2.

[0046] 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.

[0047] 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.

[0048] 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 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. Any of the slots can be circular, square, oval, rectangular, elongated, etc. without departing from the scope of the disclosure.

[0049] 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 at more than one location as shown in FIG. 1 and FIG. 2.

[0050] 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.

[0051] 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.

[0052] 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.

[0053] 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.

[0054] Referring to FIGS. 10-12c, in other embodiments, the present invention pertains to an adjustable support system 100 for supporting a roof or a floor in a building (shown generally in FIGS. 10-11) having at least one truss. The support system 100 comprises a plurality of interlocking elements 102, each interlocking element 102 can have at least one fastener slot 104 and a cross-section that is, for example, rectangular having a height (h) and a width (w) as shown in FIG. 13. The interlocking elements 102 can include at least one female segment 106 and at least one male segment 108. The exterior periphery 110 of the male segment 108 can be designed to fit within the interior channel 112 of the female segment 106. When the male segment 108 is situated within the female segment 106, at least one fastener slot 104 of the female segment 106 aligns with a fastener slot 104 of the male segment 108. The assembled female segment 106 and male segment 108 have a first end 114 and a second end 116, and an assembled length Ls.

[0055] 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.

[0056] 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.

[0057] 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 FIG. 14 and FIG. 16. The at least one male segment 108 has a first rectangular cross-section 105, and the at least one female segment 106 has a second cross-section 107 wherein the rectangular cross-section can be, for example, square or other generally rectangular shape, or the like in shape as shown in FIG. 13 and FIG. 15. The first cross-section 105 (length and width) can smaller than the second cross-section 107 (length and width), allowing the female segment 106 (with the first cross-section 105) to slide over the male segment 108 (with the second cross-section 107) as shown in FIG. 14 and FIG. 16.

[0058] As shown in FIG. 11, the support system 100 can also include a cross connector 120, which is configured to secure one interlocking element such as the at least one female segment 106 and the at least one male segment 108 to another interlocking element at an angle. This angle can be a perpendicular angle, providing additional stability to the support system. The cross connector 120 can be, for example, angle bracket with at least one slot, angle iron, L-shape brackets, adjustable angle brackets, offset angle brackets, slotted angle brackets, or the like. The cross connector 120 can be coupled to the at least one female segment 106 and the at least one male segment 108 by at least one connector fastener 138 through the at least one fastener slot 104. The fasteners 118 and connector fastener 138 used in the support system 100 can be a bolt and nut, screw, rivet, or the like. The cross connector 120 can be on the inside of the support system 100 or on the outside of the support system 100. The connector 120 can be made from, for example, steel, stainless steel, aluminum carbon steel or the like and can be thickness of 6 gauge, 10 gauge, 12 gauge, or 3/16ths inch, or the like.

[0059] 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.

[0060] 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.

[0061] 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.

[0062] 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.