U.S. patent application number 10/587886 was filed with the patent office on 2007-11-29 for framing system and method for assembling the same.
Invention is credited to Donald A. Stevens.
Application Number | 20070271866 10/587886 |
Document ID | / |
Family ID | 34826067 |
Filed Date | 2007-11-29 |
United States Patent
Application |
20070271866 |
Kind Code |
A1 |
Stevens; Donald A. |
November 29, 2007 |
Framing System and Method for Assembling the Same
Abstract
A framing system has a plank member with ribs protruding
therefrom and a frame member with a receptor pocket therein such
that the rib of the plank member is resiliently engaged within the
receptor pocket of the frame member to secure the plank member to
the frame member. The plank member may also be laterally moved
relative to the frame member such that the ribs slide within and
engage the receptor pockets. The invention is also directed to a
method for engaging the plank member with the frame member along
with a method for fabricating the frame member.
Inventors: |
Stevens; Donald A.;
(Winchester, VA) |
Correspondence
Address: |
THE WEBB LAW FIRM, P.C.
700 KOPPERS BUILDING
436 SEVENTH AVENUE
PITTSBURGH
PA
15219
US
|
Family ID: |
34826067 |
Appl. No.: |
10/587886 |
Filed: |
January 27, 2005 |
PCT Filed: |
January 27, 2005 |
PCT NO: |
PCT/US05/03084 |
371 Date: |
June 1, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60539361 |
Jan 27, 2004 |
|
|
|
Current U.S.
Class: |
52/483.1 ;
29/897 |
Current CPC
Class: |
E04B 5/00 20130101; E04F
2203/04 20130101; E04F 2201/0529 20130101; E04F 2201/05 20130101;
E04F 15/02 20130101; Y10T 29/49616 20150115 |
Class at
Publication: |
052/483.1 ;
029/897 |
International
Class: |
E04B 5/02 20060101
E04B005/02 |
Claims
1. A framing system comprising: a) a plank member having a front,
generally flat, surface and an opposing back surface with at least
one rib protruding therefrom or at least one receptor pocket
extending therein; b) a frame member of an underlying structure
having at least one receptor pocket extending therein or at least
one rib protruding therefrom, wherein the frame member rib or
pocket is matable with the plank member pocket or rib; c) wherein
the at least one rib has a profile with a first side and a second
side which diverge from one another as they extend away from the
member to which they are attached and then converge; d) wherein the
maximum height of a rib occurs at the place of maximum divergence;
and e) wherein the receptor pocket has a minimum width less than
that of the maximum height of the rib such that the rib may be
captured within the receptor pocket.
2. The framing system according to claim 1, wherein plank member
and the frame member are secured to one another through the
engagement of the at least one rib with the at least one receptor
pocket.
3. The framing system according to claim 3 wherein the at least one
rib is resilient.
4. The framing system according to claim 4, wherein the at least
one rib has a hollow interior and the rib bends for resiliency.
5. The framing system according to claim 4, wherein the material of
the at least one rib is capable of resilient bending.
6. The framing system according to claim 3, wherein the at least
one rib is made of a resilient material that compresses for
resiliency.
7. The framing system according to claim 6, wherein the rib is
solid and the material is compressible.
8. The framing system according to claim 2, wherein at least one
receptor pocket has walls which are resilient.
9. The framing system according to claim 8, wherein the walls of
the at least one receptor pocket are pushed apart to accommodate
the rib.
10. The framing system according to claim 2, wherein one or both of
the at least one rib and the at least one pocket receptor are
barbed.
11. The framing system according to claim 2, wherein the at least
one rib and the walls of the at least one receptor pocket are
rigid.
12. The framing system according to claim 1, wherein the at least
one receptor pocket is within the frame member and wherein the at
least one rib is within the plank member.
13. The framing system according to claim 12, wherein the at least
one rib is a separate piece secured to the back surface of the
plank member.
14. The framing system according to claim 1, wherein the at least
one receptor pocket is in the plank member and the at least one rib
is in the frame member.
15. The framing system according to claim 1, wherein each plank
member interlocks with an adjacent plank member.
16. The framing system according to claim 1, wherein each of the
plank members are overlapping with adjacent plank members.
17. A plank member comprising: a) a front, generally flat, surface
and an opposing back surface with the at least one rib protruding
therefrom; b) wherein the at least one rib has a profile with a
first side and a second side which diverge from one another as they
extend away from the member to which they are attached and then
converge; d) wherein the maximum height of a rib occurs at the
place of maximum divergence such that the rib is adapted to be
received within a receptor pocket having a minimum width less than
that of the maximum height of the rib.
18. The plank member according to claim 17, wherein the at least
one rib is resilient.
19. A frame member of an underlying structure, wherein the frame
member comprises: a) at least one receptor pocket extending
therein, wherein the pocket is adapted to receive a rib; b) wherein
the receptor pocket has a minimum width less than that of the
maximum height of the rib such that the rib may be captured within
the receptor pocket.
20. The frame member according to claim 19, wherein the frame
member is a C-shape structural member.
21. A method of assembling a framing system having a plank member
with a front, generally flat, surface and an opposing back surface
with at least one rib protruding therefrom or at least one receptor
pocket extending therein and having a frame member of an underlying
structure with the other of at least one receptor pocket extending
therein or at least one rib protruding therefrom, wherein the frame
member rib or pocket is matable with the plank member pocket or rib
comprising the steps of: a) aligning the at least one rib with the
at least one receptor pocket; b) urging the at least one rib within
the at least one receptor pocket until the rib snaps into the
pocket; and c) wherein the at least one rib or the at least one
receptor pocket is resilient.
22. A method of making a frame member adapted to receive protruding
ribs from a plank member comprising the steps of: a) punching slots
within a flat sheet; and b) bending the sheet into a structural
member having a top surface and a bottom surface, wherein the slots
extend within the top surface to provide a receptor pocket adapted
to receive the protruding ribs from the plank member.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 60/539,361, filed Jan. 27, 2004.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to frame construction, such as decks
and docks, and, more particularly, to a fastener-free framing
system by which plank members are secured to frame members through
ribs which are engaged within receptor pockets.
[0004] 2. Description of Related Art
[0005] Exterior decks are considered to be the most popular
addition to homes throughout the United States today. Decks are
places where people can extend their living space beyond the walls
of their home. Decks are built out of a variety of materials and
are fabricated in a variety of designs.
[0006] Typically, decks and similar structures are constructed with
horizontal planking materials and are fastened to an underlying
structural frame. The most popular planking and structural framing
material is pressure treated wood. Pressure treated wood contains
harmful toxins; one of them is called Copper-Chromium Arsenic
(CCA). It is designed to extend the life of the product in exterior
elements and protect it from weather and insect infestation, such
as termites. However, pressure treated wood planking tends to warp,
rot, splinter and require periodic maintenance. These problems are
inherent only in wood and are accelerated in exterior climates.
[0007] The structural frame for the majority of the decks built in
the United States is constructed out of pressure treated wood due
to the familiarity and availability of the product. However, other
alternative planking materials are plastic/wood composite,
synthetic, extruded plastics, extruded metals, cold-rolled metals,
and extruded aluminum, etc.
[0008] Attaching the planking to the structural frame with
fasteners, through the surface into the underlying structure, is
the most commonly accepted method in the industry. There are other
methods that conceal the fastening system from the underside using
special clips, brackets and the like. However, this typically
requires the same amount or additional fasteners to adequately
connect planking to the supporting substructure.
[0009] Attaching the planking to the structural frame through the
top planking surface yields unsightly blemishes to the decking
surface. Typically, planking members require two fasteners to be
installed through its surface into the underlying substructure
(joists) to be adequately installed. More specifically, where a
planking member crosses over the underlying substructure, two
fasteners must be installed.
[0010] Attaching the planking to the structural frame through the
bottom planking surface using specialty clips is a slow and tedious
process requiring more skilled labor and fasteners to adequately
install. There are often space requirements below the structure and
above the ground to adequately install subsurface fastening
systems.
[0011] If nailed, these fasteners can work themselves out of the
substructure, just above the surface, and cause injury. Special
screws can reduce the chances of nail popping but are typically
more expensive since they must be non-corrosive to avoid weathering
and often require specialty tools to fasten them. Fastening the
planks to the substructure using screws is the most advantageous
method, however, it requires some skill to properly place so that
the fastening holes align somewhat consistently with the
others.
[0012] As mentioned, wood structures have many disadvantages. They
rot, warp, split, splinter, burn, require annual maintenance, burn,
get eaten by termites, are only produced in limited pre-cut
lengths, and are not recyclable just to name a few. In order to
extend the life of wood structures, special preservatives, like
Copper-Chromium Arsenic (CCA) are applied to them. However these
chemicals have been found to be toxic and the growing environmental
impact concerns have led the Environmental Protection Agency (EPA)
to begin nationwide bans on these chemicals starting Jan. 1, 2004.
There will be serious impacts on the industry like lack of product
supply, increased costs and product capabilities.
[0013] It is obvious that an alternative framing system that
eliminates fastening of the planking must be developed. If it is
possible to produce an alternative underlying framing structure
that does not require chemicals treatment to make them effective,
then that must be developed as well. Currently, there are no
solutions that integrate popular planking systems like composite
and extruded decking materials with the underlying substructure
without the use of special fasteners like screws, nails or clips,
etc.
[0014] Therefore, an object of the present invention is to provide
a plank member that has a special shape integrated on the underside
of the plank, which is used to attach itself to the underlying
structure without fasteners.
SUMMARY OF THE INVENTION
[0015] One embodiment of the subject invention is directed to a
framing system comprising a plank member having a front, generally
fiat, surface and an opposing back surface with at least one rib
protruding therefrom or at least one receptor pocket extending
therein. The framing system has a frame member of an underlying
structure having at least one receptor pocket extending therein or
at least one rib protruding therefrom, wherein the frame member rib
or pocket is matable with the plank member pocket or rib. The at
least one rib has a profile with a first side and a second side
which diverge from one another as they extend away from the member
to which they are attached and then converge. The maximum height of
a rib occurs at the place of maximum divergence and the receptor
pocket has a minimum width less than that of the maximum height of
the rib such that the rib may be captured within the receptor
pocket.
[0016] Another embodiment of the subject invention is directed to a
plank member comprising a front, generally flat, surface and an
opposing back surface with at least one rib protruding therefrom.
The at least one rib has a profile with a first side and a second
side which diverge from one another as they extend away from the
member to which they are attached and then converge. The maximum
height of a rib occurs at the place of maximum divergence such that
the rib is adapted to be received within a receptor pocket having a
minimum width less than that of the maximum height of the rib.
[0017] Yet another embodiment of the subject invention is directed
to a frame member of an underlying structure, wherein the frame
member comprises at least one receptor pocket extending therein,
wherein the pocket is adapted to receive a rib. The receptor pocket
has a minimum width less than that of the maximum height of the rib
such that the rib may be captured within the receptor pocket.
[0018] Yet another embodiment of the subject invention is directed
to a method of assembling a framing system having a plank member
with a front, generally flat, surface and an opposing back surface
with at least one rib protruding therefrom or at least one receptor
pocket extending therein and having a frame member of an underlying
structure with the other of at least one receptor pocket extending
therein or at least one rib protruding therefrom, wherein the frame
member rib or pocket is matable with the plank member pocket or
rib. The method comprises the steps of: [0019] a) aligning the at
least one rib with the at least one receptor pocket; [0020] b)
urging the at least one rib within the at least one receptor pocket
until the rib snaps into the pocket; and [0021] c) wherein the at
least one rib or the at least one receptor pocket is resilient.
[0022] Still another embodiment of the subject invention is
directed to a method of making a frame member adapted to receive
protruding ribs from a plank member comprising the steps of: [0023]
a) punching slots within a flat sheet; and [0024] b) bending the
sheet into a structural member having a top surface and a bottom
surface, wherein the slots extend within the top surface to provide
a receptor pocket adapted to receive the protruding ribs from the
plank member.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a perspective view of a framing system in
accordance with the subject invention;
[0026] FIG. 2 is an enlargement of the encircled portion found in
FIG. 1;
[0027] FIG. 3 is a section view indicating the manner in which the
plank member and frame member are engaged;
[0028] FIGS. 4A and 5A are section views similar to that of FIG. 3,
but illustrating different embodiments of the plank member;
[0029] FIGS. 4B and 5B are section views identical to FIGS. 4A and
4B, except the rib in each is in a compressed state;
[0030] FIGS. 6A and 6B are side views similar to that of FIG. 3,
but illustrating how the frame member may deflect to accommodate
the rib;
[0031] FIG. 7 is a section view of a framing system with the
receptor pockets on the plank member and the ribs on the frame
member;
[0032] FIG. 8 is a section view of the plank member with a separate
piece rib attached thereto;
[0033] FIG. 9 is a section view of the framing system with
overlapping plank members;
[0034] FIG. 10 is a side section view of a plank member and end
view of a frame member;
[0035] FIGS. 11-16 are alternate embodiments of the plank
member;
[0036] FIGS. 17A-17G illustrate sketches of different rib
profiles;
[0037] FIG. 18 is a section view illustrating a dovetail
arrangement for the rib and receptor pocket;
[0038] FIG. 19 is a top view of a flat plate prior to being formed
into a plank member;
[0039] FIG. 20 is an end view of a finished plank member;
[0040] FIG. 21 is a side view of the framing system being utilized
for a wall; and
[0041] FIG. 22 is an end view of a framing member with a rib
embedded therein.
DETAILED DESCRIPTION OF THE INVENTION
[0042] FIG. 1 illustrates the framing system 10 in accordance with
the subject invention, while FIG. 2 illustrates an enlargement of
the encircled portion of the framing system 10 in FIG. 1. The
framing system 10 is comprised of a plank member 15 having a front
generally flat surface 17 and an opposing back surface 19 with at
least one rib 20 protruding therefrom. A frame member 25 of an
underlying structure 27 has at least one receptor pocket 30
extending therein. The rib 20 extending from the plank member 15 is
matable with the receptor pocket 30 of the frame member 25.
[0043] FIG. 3 is a side view of a portion of the framing system
illustrating the manner by which the rib 20 of the plank member 15
engages the receptor pocket 30 of the frame member 25. In
particular, the rib 20 has a profile with a first side 35 and a
second side 37 which diverge from one another as they extend away
from the plank member 15 to which they are attached. Thereafter,
they converge and connect with one another. The maximum height H of
the rib 20 occurs at the place of maximum divergence. The receptor
pocket 30 has a minimum width W less than that of the maximum
height H of the rib 20 such that the rib 20 may be captured within
the receptor 30. It should be noted that while the rib 20 has a
general shape of a teardrop, it will hereinafter be made clear that
this shape is not to be intended as a limitation to the subject
invention.
[0044] As illustrated in FIG. 1, the plank member 15 and the frame
member 25 are secured to one another through the engagement of the
ribs 20 with the pocket receptors 30.
[0045] In one embodiment of the subject invention, the rib 20 is
resilient such that the rib 20 deforms in order to enter the
receptor pocket 30. Directing attention to FIG. 3, the height H of
the rib 20 would diminish so that the rib 20 would be able to enter
the receptor pocket 30. This may be achieved in one of at least two
ways.
[0046] In particular, with attention directed to FIG. 4A, the rib
20 may have a hollow interior 40 such that a compressive force
indicated by arrows 42 will deform the walls 44 of the rib 20, as
illustrated in FIG. 4B, such that the resultant height J is less
than the width W of the opening within the receptor pocket 30.
Because the rib 20 is resilient upon entry within the receptor
pocket 30, the rib 20 will expand, thereby locking the plank member
15 within the frame member 25. The walls 44 of the rib 20 actually
bend to provide the resiliency of the rib 20.
[0047] As illustrated in FIG. 5A, the rib 20 may also be made of a
resilient material which itself compresses. In particular, FIG. 5A
illustrates the rib 20 having a height H and subsequent to
compressive forces 42, the rib 20, which may be solid, resiliently
compresses to a height J as shown in FIG. 5B, sufficient to fit
within the receptor pocket 30.
[0048] It should be noted that the compressive forces 42 required
to reduce the width of the rib 20 are those compressive forces
generated by urging the plank member 15 against the receptor pocket
30 of the frame member 25.
[0049] In yet another embodiment of the subject invention
illustrated in FIGS. 6A and 6B, the receptor pocket 30 has receptor
pocket walls 46, 48 which initially have a width K and are expanded
by the rib 20 having a height H such that the width K of the walls
46, 48 expands to accommodate the height H of the rib 20, as
illustrated in FIG. 6B. Under these circumstances, the rib 20 is
relatively rigid and the materials of the frame member 25 must be
resilient.
[0050] Typical materials that may be used for the rib 20 may be
structural metal of any kind, wood, wood composites, cementitious
composites, plastic composites, structural steel composites,
fiberglass, and carbon composites. It should be appreciated that
this list is not exhaustive and that any material suitable for the
application described herein may be suitable.
[0051] In each of these scenarios described in FIGS. 4A through 6B,
at least one rib 20 or the receptor pocket walls 46, 48 are
rigid.
[0052] What has been discussed so far is a receptor pocket 30
within the frame member 25 and the rib 20 within the plank member
15. Directing attention to FIG. 7, it is entirely possible for the
plank member 15 to have receptor pockets 50 while the frame member
25 has ribs 55 which engage the receptor pockets 50 in the manner
previously described.
[0053] Directing attention to FIG. 8, it is also possible for the
rib 20 to be a separate piece 60 secured within the plank member 15
or, in the alternative, secured within the frame member 25, which
is not shown but is an obvious variation of the arrangement
illustrated in FIG. 8. The rib 20 may be secured to the plank
member using any number of different fastener techniques. As an
example, the rib 20 may have a threaded shank 62 which engages the
plank member 15.
[0054] FIG. 9 illustrates a cross-section view of one embodiment of
the framing system 10, whereby each plank member 15 has a recess 65
which is covered by an overhang 70 in an adjacent plank member 15'.
Such an arrangement promotes retention of the plank member 15
within the frame member 25.
[0055] FIG. 10 illustrates a side view of the framing system 10,
whereby the rib 20 of the plank member 15 is aligned to be engaged
with a plurality of frame members 25. A complete framing system 10
may be comprised of a plurality of plank members 15 arranged
side-by-side over a plurality of spaced apart frame members 25.
[0056] In one embodiment illustrated in FIG. 11, the plank member
115 may have a tongue 117 on one side and a groove 119 on the other
side which engage a mating groove 119' in plank member 115', and a
mating tongue 117' associated with plank member 115''.
[0057] It should be appreciated that one focal point of the subject
invention is the interlocking ribs and receptor pockets. The plank
member may embrace a variety of different designs to satisfy the
different needs to which the framing system may be subjected.
[0058] FIG. 12 illustrates a plank member 215 having a generally
oval cross-section with ribs 220 similar to those previously
discussed extending therefrom.
[0059] The material of the plank member discussed herein may be
wood, composite wood, metal, plastic or a carbon fiber composite.
As an example, if the rib 220 of plank 220 is solid therethrough,
then it is necessary for the material of the rib 220 to itself be
resilient such that the rib 220 resiliently fits within the
receptor pocket 230 of the frame member 225. In the alternative, if
the rib 220 has a hollow portion therein, then it is only necessary
for the walls of the rib 220 to flex to fit within the receptor
pocket 230. Furthermore, as previously discussed, it is also
possible for the receptor pocket walls to have resiliency
themselves to accept a rib 220.
[0060] FIG. 13 illustrates another variation of a plank member 315
having a front surface 317 and a back surface 319 with ribs 320
protruding therefrom. The variety of designs available for the
plank member 315 are unlimited inasmuch as the back surface 319 has
extending therefrom ribs 320 that may interlock with receptor
pockets (not shown) of a frame member.
[0061] FIGS. 14, 15 and 16 illustrate further variations of plank
members 415, 515, 615, respectively, having back surfaces for 419,
519, 619 with ribs 420, 520, 620 extending therefrom. The designs
illustrated in FIGS. 14-16 are of particular interest because these
designs may be fabricated through extrusion processes using a
variety of different materials including structural steel,
structural metal, and structural plastic or other structural
materials capable of being extruded.
[0062] The ribs 20 so far discussed have been in the general shape
of a teardrop. A number of other rib shapes may be used inasmuch as
these ribs may be snapped into the receptor pocket 30 of the frame
member 25. FIGS. 17A-17G illustrate a few such ribs 720 shapes. In
each of these shapes, the first side 722 divergence from the second
side 724 and then converges. As a result, these ribs 720 may snap
into an approximately sized receptor pocket (not shown) located in
the frame member. As illustrated in FIGS. 17F and 17G, each rib 720
may also resemble a barb 726.
[0063] Briefly returning to FIGS. 1 and 2, one method of attaching
the plank member 15 to the frame member 25 is to press the plank
member 15 against the frame member 25 such that the ribs 20
resiliently deform to engage the receptor pocket 30 or, in the
alternative, a rib 20 engages the resilient walls 46, 48 of the
receptor pocket 30 until the rib 20 snaps into place within the
receptor pocket 30. It should be appreciated that, to the extent
the rib 20 conforms with the shape of the receptor pocket 30, it is
possible to slide the plank member 15 into the frame member 25 such
that the rib 20 engages the receptor pocket 30 without the need for
resilient deformation. Under such circumstances, the plank member
15 slides into the frame member 25 from the side. Since the rib 20
is no longer required to resiliently fit with the receptor pocket
30, the shape of these two elements may change.
[0064] Directing attention to FIG. 18, a plank member 815 may have
a rib 820 in the shape of a dove-tail which engages the frame
member 825 through a receptor pocket 830 in the shape of a matching
dove-tail. It should be appreciated that, while the shape of the
dove-tail has been presented, any number of different positive
locking shapes may be utilized for this arrangement.
[0065] The subject invention is also directed to a method of
assembling a framing system 10 having a plank member 15 with the
front generally flat surface 17 and an opposing back surface 19
with at least one rib 20 protruding therefrom or at least one
receptor pocket 30 extending therein and having a frame member 25
of an underlying structure with the other of at least one receptor
pocket 30 extending therein or at least one protruding rib 20
extending therefrom. The frame member rib 20 or pocket 30 is
matable with the plank member pocket 30 or rib 20. The method
comprises the steps of aligning the ribs 20 with the receptor
pockets 30. The ribs 20 are then urged within the receptor pockets
30 until the ribs 20 snap into the pockets 30. For this to occur,
the rib 20 or the receptor pocket 30 must be resilient.
[0066] In an alternative embodiment, the method of assembling a
framing system 10 would comprise the steps of aligning the rib 20
with the receptor pocket 30 and sliding the rib 20 within the
receptor pocket 30 until properly positioned. Under these
circumstances, it is not necessary for either the rib 20 or the
receptor pocket 30 to be resilient.
[0067] So far illustrated is a frame member 25 having a generally C
shape. Although other shapes may be utilized, this is a convenient
shape that will typically be implemented for these structures.
FIGS. 19 and 20 illustrate the method by which the frame member 25
is manufactured from a flat sheet 900. In particular, openings 905
are punched within the flat sheet 900, wherein at each end of the
opening 905 is a slightly enlarged portion 910 which, in this
instance, is designed to have the general shape of a rib 15
illustrated in FIG. 1. Once the openings 905 are punched, the flat
sheet 900 is then bent into a structural member having a top
surface 915 and a bottom surface 920, wherein the openings 905
extend within the top surface 915 to provide a receptor pocket 930
adapted to receive the protruding ribs 20 from the plank member 15
illustrated in FIG. 1.
[0068] While FIGS. 1 and 2 illustrate the use of the framing system
10 for decking, the framing system 10 should not be limited to such
applications and may be used in any application for which this
design is appropriate. FIG. 21 illustrates the use of the framing
system 10 as a fence or a wall. The framing system in accordance
with the subject invention may have a multitude of other
applications including use as a dock or an interior or exterior
wall of a structure such as a building.
[0069] FIG. 22 illustrates a sketch whereby the rib 1020 is
embedded within the frame member 1025. This may be achieved by
embedding the rib 1020 during an extrusion process used to form the
frame member 1025.
[0070] While specific embodiments of the invention have been
described in detail, it will be appreciated by those skilled in the
art that various modifications and alternatives to those details
could be developed in light of the overall teachings of the
disclosure. The presently preferred embodiments described herein
are meant to be illustrative only and not limiting as to the scope
of the invention which is to be given the full breadth of the
appended claims and any and all equivalents thereof.
* * * * *