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.

Description

REFERENCE TO RELATED APPLICATIONS

[0001] This application is a continuation-in-part of two pending patents U.S. Ser. No. 12/231,875 filed Sep. 8, 2008 and U.S. Ser. No. 12/456,707 filed Jun. 6, 2009. In addition this application contains information on two provisional patent applications U.S. Ser. No. 61/628,044 filed on Oct. 24, 2011 and U.S. Ser. No. 61/629,442 filed Nov. 22, 2011.

BACKGROUND OF THE INVENTION

[0002] (1) Field of the Invention

[0003] The present invention relates to an improved wall system where the structural insulating core uses various wall forming structures and spacer blocks interconnecting between each other. Another aspect is a new horizontal bracing channel and electrical chases incorporated into the wall forming structure.

[0004] (2) Background of the Invention

[0005] Exterior metal framing has always been difficult to insulate because of the configuration of the support channels like a C channel. The lip and flange of the C channel protrudes from the web making it difficult to insulate. When horizontal bracing channels are installed between support channels for additional strength, insulation became even more difficult to install as well as form a good insulated wall.

[0006] The metal framing was installed first, then a rigid insulation was installed on the exterior, mechanicals were then added and a fibre glass insulation was installed between the support channels. Later insulation was blown into the wall cavity that is between the support channels after the sheathing was installed on the exterior.

[0007] Closed cell rigid insulation has been increasing in popularity, however the solutions has been to mold the closed cell insulation into the support channels. In addition, closed cell rigid insulation has been cut into panels where several support channels slide into the rigid insulation panel from the top of the rigid insulation in order to install the support channels. The closed cell rigid insulation solutions are usually installed in a manufacturing plant rather that at the job site.

[0008] The creation of a smaller spacer blocks that has flexibility to be assembled into panels at a manufacturing plant or at the construction site as well as incorporating various types of horizontal bracing channels and electrical chases or troughs gives the spacer block additional flexibility. In addition, the size of the spacer block can vary depending on the type of closed cell rigid insulation is used like polystyrene, cellular light weight concrete or aerated autoclaved concrete.

[0009] The horizontal bracing channels within the wall forming structure is generally provided by installing bridging members which tie the support channels together. These bridging members may be attached on the outside of the flanges of the support channels or maybe internal bridging members installed through openings provided in the web of the support channels. None of the bridging members used today have a limited function and do not provide a solution for interacting with rigid insulation between support channels and the holes the internal bridging members pass through.

DESCRIPTION OF PRIOR ART

[0010] There are many different aspects to the invention which involves many different subjects which are noted below.

[0011] Foam Block With Holes

[0012] In U.S. Pat. No. 5,842,276 by Ashner cuts a hole in a larger block so a conduit can be installed. The block remains as one piece and a tongue and groove connection is not incorporated in the assembly of the synthetic panel.

[0013] In U.S. Pat. No. 7,028,440 (filed Nov. 29, 2003) by Brisson uses foam blocks with vertical holes to form concrete columns and uses a horizontal recess at the top of the panels to form a beam pocket. The foam panels are made using a tongue and groove type connections between panels and the panels are glued together. Since the holes for the concrete are only support by foam, the size is limited as the concrete will deform as well as break the foam panels. Again the beam pocket is also fragile as there is not support to stop the wet concrete from deforming the beam.

[0014] Foam Panel

[0015] In U.S. Pat. No. 5,943,775 (filed Jan. 7, 1998) and U.S. Pat. No. 6,167,624 (filed Nov. 3, 1999) by Lanahan uses a polymeric foam panel with metal channels installed within the foam. The panels are interlocked together by a tongue and groove connection using the foam as the connector. An electrical conduit is horizontally installed within the panel for electrical distribution. The metal channels are embedded within the foam. Walpole in U.S. Pat. No. 7,395,999 embeds a metal channel in foam for support and uses a tongue & groove joint sealer between panels. In U.S. Pat. No. 5,722,198 (filed Oct. 7, 1994) and U.S. Pat. No. 6,044,603 (filed Fe. 27, 1998) by Bader discloses a panel & method to form a metal channel and foam panel where the flanges are embedded into the sides of the foam panels. In U.S. Pat. No. 5,279,088 (filed Jan. 17, 1992), U.S. Pat. No. 5,353,560 (filed Jun. 12, 1992) and U.S. Pat. No. 5,505,031 (filed May 4, 1994) by Heydon show a wall and panel structures using overlapping foam and metal channels in various configurations. Carlin in U.S. Pat. No. 5,822,940 uses support channels that slide vertically into the wall panel.

[0016] Horizontal Bracing Channels

[0017] Rice in U.S. Pat. No. 8,011,160 uses a bracket to connect the horizontal bracing channels to the vertical C channels. Poliquin in U.S. Pat. No. 6,199,336 uses a tab to hold the horizontal bracing channel to the vertical support channel. diGirolamo in U.S. Pat. No. 7,596,921, U.S. Pat. No. 7,836,657 & U.S. Pat. No. 6,701,689 shows various horizontal bracing channels, however the U channel facing downward with groove is shown in the pending patent used in conjunction with the spacer blocks. Dietrich Industries uses Brunt in U.S. Pat. No. 7,017,310, Elderson in U.S. Pat. No. 6,920,734 & U.S. Pat. No. 6,708,460, U.S. Pat. No. 7,168,219, U.S. Pat. No. 7,159,369 and Collins in U.S. Pat. No. 6,694,695 to disclose to show a V shaped horizontal bracing channel between the vertical support channels of a metal framing system. The V shaped horizontal bracing channel is always pointing upward and is not used in conjunction with a spacer block. The V shaped is used in the pending patent along with the spacer block and incorporating various hole configurations. Hughes in U.S. Pat. No. 6,164,928 forms a horizontal bracing channel that does not reflect the pending patent.

[0018] Channel Indentations

[0019] Rice in U.S. Pat. No. 7,849,640 uses an indentation in the support channel and has a base channel and a support channel connection, but does not reflect how the channel indentation is applied in the pending patent. In U.S. Pat. No. 7,836,657 by diGirolamo uses channel indentations to explain a horizontal bridging member, but does not relate the indentations to spacer blocks. Meyer in U.S. Pat. No. 5,157,883 uses an indentation in the metal channels to describe a clip.

[0020] Holes in Vertical Channels

[0021] Edmondson in U.S. Pat. No. 7,866,112 uses a punched hole with flanges to form the holes in the vertical channels of a metal framed wall. Bodnar in U.S. Pat. No. 4,793,113 show large holes with bent flaps does not reflect the pending patent.

[0022] SIP

[0023] Structural insulated panels known as SIP's are typically made using rigid insulation in the middle with plywood on both sides and wood blocking or metal connectors are installed in the middle connecting the two panels together.

[0024] Porter has developed many SIP patents using metal components including U.S. Pat. No. 5,497,589, U.S. Pat. No. 5,628,158, U.S. Pat. No. 5,842,314, U.S. Pat. No. 6,269,608, U.S. Pat. No. 6,308,491, and U.S. Pat. No. 6,408,594 as well as Babcock U.S. Pat. No. 6,256,960, Brown U.S. Pat. No. 6,564,521 and Kligler U.S. Pat. No. 6,584,742 of which Babcock shows a metal channel between two panels to interlock adjacent panels. In U.S. Pat. No. 5,638,651 uses metal channels at interior but does not have a thermal break on the metal channels. Porter shows 5 more patents using wood and one more U.S. Pat. No. 5,950,389 using splines to interlock panels.

[0025] Panel Construction

[0026] In U.S. Pat. No. 5,638,651 filed Jun. 21, 1996 by Ford uses an interlocking panel system where two U channels interlocks with an OSB board and the metal channel to form a building panel. In U.S. Pat. No. 6,701,684 filed Jun. 26,2002 by Stadler uses vertical back to back U metal channels in a foam panel and a cementous coating over the foam to form a wall. In U.S. Pat. No. 6,880,304 filed Sep. 9, 2003 by Budge, uses vertical slotted framed to support a foamed wall assembly.

SUMMARY OF THE INVENTION

[0027] The present invention relates to an improved wall system where a structural insulating core wall uses various wall forming structures and spacer blocks interconnecting between each other. The various support channels, horizontal bracing channels, holes in the web of the support channels and base plates all alter the shape of the spacer blocks. The orientation of the holes, support channels, horizontal bracing channels also change the shape of the spacer blocks and the type of material used to form the spacer blocks. The spacer blocks have vertical and horizontal interlocking tongue and groove connections that connect between the wall forming structure and the spacer blocks. The spacer blocks can cover the flanges of the support channels or just protrude beyond the support channels to form a thermal break.

[0028] Another variation of the invention is when the spacer blocks are wider than the support channels, but do not overlap the flanges of the support channels. The inner and outer boards that are installed over the spacer blocks are not in contact with the support channels and a gap occurs creating a thermal break in the improved wall system.

[0029] Various types of electrical chases can be installed within the structural insulating core depending on the shape of the horizontal bracing channels. The horizontal bracing channel can be oriented so the U or V shape of the horizontal bracing channel is oriented upward or downward causing the trough within the spacer channel or the electric chase to be above or below the horizontal bracing channels and whether the horizontal bracing channel fits within the trough or is larger than the trough within the spacer blocks. When the horizontal bracing channel is larger than the hole in the web of the support channels, a notch is added to the lip of the horizontal bracing channels to secure the channels together. When two horizontal bracing channels are installed into the same hole of the support channel and one horizontal bracing channel is reversed, the reversed horizontal bracing channel becomes a cover over the other horizontal bracing channel.

[0030] Various types of holes in the web of the support channels will have an effect on the horizontal bracing channels by allowing additional notches to be installed within the horizontal bracing channels.

[0031] Brackets which are shorter than full height support channels can be used when constructing a wall forming structure. The brackets also have a hole into which the horizontal bracing channel can connect to allowing the spacer blocks to be secured together when load bearing materials can be used rather than closed cell insulation materials.

[0032] Another aspect of the invention is that exterior wall sheathing and interior rigid insulation in a wall are formed as one and together form an integrated material referred to a spacer block. The integrated wall sheathing speeds construction since usually two different construction trades installs the wall sheathing and the interior insulation and the spacer blocks provides a measurement say 16'' or 24'' on center for a faster wall installation.

[0033] Another aspect of the pending patents it the formation of a structural insulating panel (SIP) when the structural insulating core and the rigid board and rigid insulating are all glued together.

BRIEF DESCRIPTION OF THE DRAWINGS

[0034] FIG. 1 shows an isometric view of the structural insulating wall where the spacer blocks are wider than the support channels and horizontal bracing channels fit into a trough of the spacer blocks connecting to the support channels together along with the base plate connections to the spacer blocks and support channels. The inner and outer boards form a thermal break gap between the elements.

[0035] FIG. 2 shows a wall section of the horizontal reverse lip channel connecting into a support channel hole where the hole is below the horizontal reverse lip channel.

[0036] FIG. 3 shows the wall section of FIG. 2 with the trough below the horizontal reverse lip channel forming an electric/mechanical chase in a half wall.

[0037] FIG. 4 shows a wall section of the horizontal reverse lip channel upside down and the hole in the support channel is above the horizontal reverse lip channel.

[0038] FIG. 5 shows a wall section of FIG. 4 with the horizontal reverse lip channel upside down and the trough is above the horizontal reverse lip channel.

[0039] FIG. 6 shows an isometric view of the wall system using a face down horizontal reverse lip channel and the trough is above the horizontal reverse lip channel.

[0040] FIG. 7 is a plan view of FIG. 6.

[0041] FIG. 8 is a plan view of the reverse lip channel used as a support channel.

[0042] FIG. 9 is an isometric view of a half wall using the spacer blocks with an exposed trough.

[0043] FIG. 10 is a plan view of FIG. 9.

[0044] FIG. 11 is an isometric view of an enlargement of structural insulating wall with the inner and outer boards shown in FIG. 1

[0045] FIG. 12 show an isometric view of a horizontal bracing channels as a round rod or a tube passing through the round hole in the support channel.

[0046] FIG. 13 shows an isometric view of a U channel as the support channel with the horizontal U channel as the horizontal bracing channel.

[0047] FIG. 14 shows an isometric view of a hat channel as the support channel with a rectilinear hole and a horizontal U channel.

[0048] FIG. 15 shows an isometric view of a reverse lip channel as the support channel, a rectilinear hole and a horizontal U channel as the horizontal bracing channel.

[0049] FIG. 16 shows an isometric view of a C channel with an oval hole and the horizontal U channel.

[0050] FIG. 17 shows and isometric view of the horizontal reverse lip channel with notches in the structural insulating wall.

[0051] FIG. 18 shows an isometric view of a support channel with a rectilinear hole and the horizontal reverse lip channel with notches. The reverse lip support channel is also being used as a connector between two horizontal U channels.

[0052] FIG. 19 is an isometric view of a C channel as the support channel with a V hole with the V pointing downward and a blunt end at the vortex of the V hole.

[0053] FIG. 20 shows the isometric view of FIG. 19 with a horizontal V channel having a groove in the bottom to accept the blunt end.

[0054] FIG. 21 is an isometric view of a C channel as the support channel with a V hole and the V pointing downward.

[0055] FIG. 22 shows the support channel and the V hole have a horizontal V channel with notches.

[0056] FIG. 23 is an isometric view of a C channel as the support channel with a V hole and the V pointing downward.

[0057] FIG. 24 show a horizontal reverse lip channel with notches in the web and flanges passing through the V hole as well as the notches in the lip of the horizontal reverse lip channel.

[0058] FIG. 25 shows a wall section of the horizontal V channel pointing upwards and the trough is above the horizontal V channel.

[0059] FIG. 26 shows a wall section where the horizontal V channel is pointing downward and the trough is below and the horizontal tongue of spacer blocks requiring an extension.

[0060] FIG. 27 shows a wall section where the horizontal V channel is pointing downward.

[0061] FIG. 28 shows the wall section with on V hole and the V is pointing downward.

[0062] FIG. 29 is a wall section showing the horizontal V channel is wider and has a notch requiring an extension of the horizontal tongue, while another section shows the horizontal V channel within the size of the V hole and lastly where the horizontal V channel is bent with notches.

[0063] FIG. 30 show the same horizontal V channels however the V is pointing downward.

[0064] FIG. 31 shows a wall section with the horizontal U channel facing downward.

[0065] FIG. 32 shows a plan view of the wall section in FIG. 31.

[0066] FIG. 33 shows a corner connection of two wall panels and the coupling between them connects the two wall panels together.

[0067] FIG. 34 shows a plan view the spacer channel is formed from different material and the support channel has an indentation in the web.

[0068] FIG. 35 shows the plan view separated by the C channel and the two spacer blocks.

[0069] FIG. 36 shows an isometric view of a channel with an indentation and a V hole with the vortex facing downward.

[0070] FIG. 37 show the same configuration as FIG. 36 however the horizontal reverse lip channel passes through the V hole having notches in the flange, web and lips that are secured to the V hole.

[0071] FIG. 38 shows a plan view of FIG. 37.

[0072] FIG. 39 shows an enlargement of the support channel with an indentation and the vertical projection of the spacer block fitting into the indentation and the gap between the inner and outer walls.

[0073] FIG. 40 shows a perspective view of the spacer block intersecting the C channel and horizontal bracing channel forming a gap.

[0074] FIG. 41 shows a wall section of FIG. 40 where the horizontal tongue fits into the trough.

[0075] FIG. 42 shows a perspective view of the spacer block intersecting the C channel and the horizontal reverse lip channel.

[0076] FIG. 43 shows a wall section of FIG. 42 where the horizontal tongue fits between the flanges of the horizontal reverse lip channel and the trough is below the horizontal bracing channel.

[0077] FIG. 44 is an isometric view where one side of the structural insulating core has projections overlapping the flange on one side and the opposite flange having no projections.

[0078] FIG. 45 is a plan view of FIG. 44.

[0079] FIG. 46 is a plan view of FIG. 47.

[0080] FIG. 47 is an isometric view of the of the reverse lip channel as a support channel where the projection of the spacer block overlaps one flange and not the other flange.

[0081] FIG. 48 is an isometric view of a hat channel as the support channel or bracket with both sides of the spacer block overlaps the sloped flange and a short horizontal U channel connecting the spacer blocks.

[0082] FIG. 49 is an isometric view of a U channel as a support channel and a horizontal U channel as a bracing channel and where the groove side of the spacer block overlaps the flange and extends beyond the flange onto the adjacent spacer block and the other side does not overlap the flange.

[0083] FIG. 50 is a plan view of FIG. 49.

[0084] FIG. 51 is a plan view of FIG. 48

[0085] FIG. 52 is an isometric view similar to FIG. 49, except here the tongue side of the spacer block also has the projection of the spacer block with the extension that rests on the adjacent spacer block and the opposite of the spacer block has no overlap.

[0086] FIG. 53 is an isometric view similar to FIG. 52 except both sides of the spacer blocks have projections and extensions over the U channel and the round hole is used for a round rod to connect two spacer blocks together.

[0087] FIG. 54 shows an isometric of two spacer blocks stacked above each other shows the vertical project, troughs and the vertical hole in the short spacer block.

[0088] FIG. 55 is similar to FIG. 54 except one side of the spacer block has a projection and the other side does not.

[0089] FIG. 56 shows an isometric of the structural insulated core where an electric chase with a cover on top of the lower horizontal reverse lip channel.

[0090] FIG. 57 shows an enlargement of the electric chase passing through the rectangular hole.

[0091] FIG. 58 shows an isometric view of the horizontal U channel turned downward having notches with the spacer block having the tongue fitting into the horizontal bracing channel

[0092] FIG. 59 shows a wall section with the horizontal U channel facing downward into the horizontal tongue with the inner and outer boards.

[0093] FIG. 60 shows a similar wall section as FIG. 59 except the overlapping projections of the spacer block at the flanges.

[0094] FIG. 61 shows a floor section of the spacer block similar to FIG. 10.

[0095] FIG. 62 shows a similar floor section to FIG. 61 with an extension added to the projection of the spacer block.

[0096] FIG. 63 shows the floor section sliding together with the support channels.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0097] FIG. 1 shows an isometric drawing of the structural insulating core 111 where the left side shows the wall assembled and the right side shows the various wall components separated. The right side shows the support channel as a C channel 42 with the horizontal bracing channel 150 shown as a horizontal reverse lip channel 156 passes through the hole 36 in the web 42a of the C channel 42. The horizontal reverse lip channel 156 has a notch 156n in the lip 156c as shown in the enlarged view of FIG. 18 that locks the horizontal reverse lip channel 156 to the web 42a of the support channel. The lip 157c rests on top of the trough 132 formed in the middle of the spacer block 56 and the flanges 156b fit into the trough 132 which is below the horizontal reverse lip channel 156 forming an electrical/mechanical chase within the trough 132. Another spacer block 56 is shown above the horizontal reverse lip channel 156 where a horizontal tongue 56t fits between the flanges 156b and against the web 156a of the horizontal reverse lip channel 156. All the spacer blocks 56 within FIG. 1 are shown deeper than the length of the web 42a of the support channel shown as a C channel 42 and extend beyond the flanges 42b. The spacer blocks 56 all have a tongue shape 56a that fits between the lips 42c and abut the webs 42a of the C channels 42. The opposite side of the spacer block is referred to the groove side where a vertical projection 56vp is shown. The C channel 42 on the right has an indentation 42i in the web 42a so the vertical projection 56vp can fit into the indentation 42i of the C channel 42. The base plate 120 passes through the smaller spacer block 56s and the base plate 120 has a notch 120n in the flange 120b where the web 42b of the C channel 42 slides into the notch. Also shown is an anchor bracket 241 that attaches to the base plate 120; however a lip 241c of the anchor bracket 241 extends over the flange 120b and is extended downward to form a hook 241h. The left side of FIG. 1 shows the wall panel 65 consisting of the structural insulating core 111 assembled together with the rigid board 50 and rigid insulation 51 are the inner and outer rigid boards that define the outer surfaces of the wall panel 65. Since the spacer blocks 56 extends beyond the flanges 42b of the C channel 42 a gap 45 is shown on both sides of the C channel 42 when the rigid board 50 and rigid insulation 51 is installed over the structural insulating core 111. Neither the rigid board 50 and rigid insulation 51 touches the C channel 42 leaving gap 45 function as a thermal break and therefore heat or cold are not transmitted directly through the C channel 42 also shown in the enlargement FIG. 18. The C channel 42 shown on the left does not have an indentation 42i in the web 42a of the C channel 42.

[0098] FIGS. 2-5 show the horizontal bracing channel 150 as a horizontal reverse lip channel 156 and used where the spacer blocks 56 is not the full thickness of the C channel 42 as shown in FIGS. 9 & 10. FIGS. 2 & 3 show the horizontal bracing channel 150 as a horizontal reverse lip channel 156 where the flanges 156b and the web 156a form a U shape that is facing up which is contrary to FIGS. 4 & 5 where the web 156a is above and the flanges 156b and lip 156c are below or installed in reverse of FIGS. 2 & 3. When installing the horizontal reverse lip channel 156 with the U shape facing up, the hole 36 is below the horizontal reverse lip channel 156 and therefore the trough 132 is also below the horizontal reverse lip channel 156. Since the spacer block 56 is not the full thickness of the C channel 42, the trough 132 is open on one side leaving the electric chase be exposed on one side. The spacer block 56 extends pass the C channel 42 as shown in FIG. 1 and the rigid board 50 is also installed on the structural insulating core 111. As explained above, the horizontal reverse lip channel 156 is facing downward leaving the hole 36 above the horizontal reverse lip channel 156. When the horizontal reverse lip channel 156 is facing upward the horizontal tongue 56t is inserted into the U shape from the spacer block 56 above, while if the U shape is facing downward the horizontal tongue 56t is inserted into the U shape from the spacer block 56 below.

[0099] FIG. 6 is similar to FIG. 1 except the horizontal bracing channel 150 shown as a horizontal reverse lip channel 156 is turned upside down, that is the web 156a is on top and the lips 156c are below with the hole 36 above the web 156a. The spacer block 56 is shown separated from the short spacer block 56s below. When the spacer block 56 is placed onto the short spacer block 56s, the horizontal tongue 56t is on the top of the spacer block 56 so the horizontal tongue 56t can fit into the flanges 156b of the horizontal reverse lip channel 156 and the lips 156c rest onto the short spacer block 156s below. The spacer block 56 above the horizontal reverse lip channel 156 has a trough 132 that is equal to the web 156a of the horizontal reverse lip channel 156a and the flanges 156b fits into the trough 132 making a tight connection between the two and the remainder of the trough 132 above the horizontal reverse lip channel 156 is used as an electrical/utility chase. When passing through the web 42a of the C channel 42, the notches 42n in the lip 42c fit into the web 42a of the support channels to form the structural insulating core 111. The spacer block 56 is also wider than the support channel and extends beyond the flanges 42b of the C channel 42 as shown in FIG. 11. The assembled structural insulating core 111 is shown on the left side of the isometric drawing and the rigid board 50 and rigid insulation 51 is shown attached to the structural insulating core 111. Fasteners 37 can be installed through the rigid board 50 and rigid insulation 51 directly into the flanges 42b of the C channel 42 leaving a gap 45 between them. If the rigid board 50 and rigid insulation 51 was glued to the structural insulating core, the assembly would be consider a SIP known as a Structural Insulated Panel and could be manufactured into various lengths and heights.

[0100] FIG. 7 is a plan view of FIG. 6 which shows the relationship of the horizontal bracing channel 150 shown as the horizontal reverse lip channel 156. The notch 42n is shown fitting between the web 42a of the C channel at the hole 36 therefore the notch 42n locks in the adjacent support channels shown as C channels 42. Since the horizontal reverse lip channel 156 is used, the spacer block 56 has the horizontal tongue 56t on top of the spacer block 56 so the horizontal tongue 56t can fit between the flanges 42b and against the web 42a. The plan view also show the spacer block 56 interlocking into the C channel 42 and how the spacer blocks 56 create the gap 45 when the spacer blocks 56 fit into the C channel 42.

[0101] FIG. 8 shows the same plan configuration as FIG. 7 except a reverse lip channel 79 is used as the support channel between the spacer blocks 56. Since the lip 79c extends away from the reverse lip channel 79 or in an opposite direction of a C channel 42 shown in FIG. 7. The spacer block 56 is wider than the depth of the reverse lip channel 79 and slightly longer than the lip 79c so the rigid board 50 and rigid insulation 51 do not touch the reverse lip channel 79. The web 79a is perpendicular to the flanges 79b so the rigid board 50 and rigid insulation 51 so fasteners can be attached to the flanges 79b.

[0102] FIG. 9 shows an isometric drawing and FIG. 10 a plan view of a half wall where the spacer blocks 56 do not extend the full width of the support channels shown as a C channel 42. The horizontal bracing channel 150 is shown as a horizontal U channel 155 that passes through the holes 36 in the web 42a. The spacer block 56 has a tongue shape 56a that abuts the web 42a and the lip 42c of the C channel 42. The width of the spacer block extends over the hole 36 in the support channel and the other side extends past the flange 42b. The opposite end of the spacer block 56 shows the groove shape 56b abutting the web 42a of the adjacent support channel and also extend over the hole 36 and past the flange 42b. The spacer block 56 on both sides of the C channel 42 form a gap 45 when the rigid board 50 extends over the spacer blocks 56. The interior side of the wall panel 65 shows the horizontal trough 132 above the horizontal bracing channel and is open to the interior for easy access to the horizontal trough 132. The different configuration of the horizontal U channel is shown in FIG. 31 which can be used in FIG. 9 to connect two spacer blocks together. By reversing the horizontal U channel 155 as shown in FIG. 31 the flanges 115b are shown below the web 155a which allows the horizontal tongue 56t from the spacer block 56 below to interlock into the horizontal U channel 155.

[0103] FIG. 11 shows an enlargement of the structural insulating core 111 at the gap 45 shown in FIGS. 1, 6 & 9. The wall sections in FIGS. 2-5 shows the horizontal bracing channel 150 as a horizontal reverse lip channel 156, but both the horizontal bracing channels have a similar configurations.

[0104] FIGS. 12-16 different support channels and different horizontal bracing channels 150. FIGS. 12 & 13 show U channels 41 as the support channel and FIG. 14 a hat channel 46, FIG. 15 a reverse lip channel 79 and FIG. 16 a C channel 42. All the various support channels all serve the same function of supporting a wall panel 65. The holes 36 in the various support channels have different shapes to accommodate the shapes and function of the horizontal bracing channels. FIG. 12 shows a round hole 36c at the bottom of the hole 36 to accommodate the round rod 166 or a hollow tube 167. Both the round rod 166 or hollow tube 167 are shown having small ridges 168 that would engage the sides of the hole 36r. FIG. 13-15 show a rectilinear hole 36r where the horizontal bracing channels are a horizontal U channel 155 or a horizontal reverse lip channel 156 as shown in FIG. 18. FIG. 16 shows an oblong hole 36o where the horizontal U channel 155 just rests into the hole.

[0105] FIG. 17 is similar to FIG. 1 except the spacer blocks 56 has a projection 56p that overlaps the flanges 42b of the support channel shown as a C channel 42. Various other projections 56p are shown in FIGS. 44, 47, 49. The horizontal bracing channel 156 shows the lip 156c resting on the top of the starter spacer block 56s and the web 156a and flange 156b fit into the trough 132. The horizontal tongue 56t in the spacer block 56 above gets inserted between the flanges 156b to the web 156a. An enlargement of the horizontal bracing channel 156 is shown in FIG. 18 with notches 126 that fit into the web 42 through the square hole 36r locking the spacer block 56 with the C channel 42 to the horizontal reverse lip channel 156. The horizontal reverse lip channel 156 can also be used as a bracket 138. In FIG. 18 the horizontal reverse lip channel is shown as a coupling 63 that is secured to the web 42a of the support channel by notches 126 and connects to two other horizontal bracing channels 155 (shown dotted) on either side of the horizontal reverse lip channel 156. The horizontal U channel 155 on the left side rests on the web 156a and between the flanges 156b and is connected to the coupling 63. The opposed end of the coupling 63 shows another horizontal U channel 155 installed under the coupling 63 so the web 155a and flanges 155b are on the inside of the coupling 63 shown as a horizontal reverse lip channel 156. A coupling 63 connects two horizontal bracing channels 150, however this same horizontal reverse lip channel 156 can be a bracing clip 128. A bracing clip 128 functions differently than a coupling 63. A horizontal bracing channel 150 shown as a horizontal U channel 155 passes through the hole 36 of the support channel on to another support channel and the bracing clip 128 fits over the horizontal U channel 155 and the notches 126 of the bracing clip 128 fit into the holes 36 of the support channel. The bracing clip 128 is shown shaded to differentiate between the coupling 63 and the bracing clip 128 which is shorter in length. The bracing clip 128 fits into and between the flanges 155b and web 155a of the horizontal U channel 155. The coupling 63 and bracing clip can be used with the flanges 156 facing upward or downward.

[0106] FIGS. 19-24 shows the hole 36 of a support channel as a C channel 42 as a V hole 36v configuration where the V hole 36v has a pointed configuration at one side and shown at the bottom of the V hole 36v. The pointed configuration in FIG. 19 has a blunt end 159 at the vortex of the pointed configuration and the horizontal V channel 157 in FIG. 20 has the blunt end 159 of horizontal V channel 157 protrude through the notch 126 in the horizontal V channel 157. FIGS. 21 & 23 both show the pointed configuration in the V hole 36v at the bottom of the V hole. The horizontal V channel 157 rests in the pointed configuration of the V hole 36v and the notches 126 are engages into the V hole 36v. FIG. 24 shows the horizontal reverse channel 156 passing through the V hole 36v, however two notches 126 are shown at the intersection of the web 156a and flanges 156b of the horizontal reverse lip channel 156. FIGS. 20 & 22 shows the horizontal V channel 157 passing through a support channel, however the horizontal V channel 157 can be used as a coupling 63 or as a bracing clip 128 as shown in FIG. 18 in both a V shape pointing upward or downwards.

[0107] FIGS. 25-30 show different variations locations of the V hole 36v and the spacer blocks 56. FIGS. 25 & 29 shows the horizontal V channel 157 shown with the pointed configuration pointing upwards. When the pointed configuration is pointed upward, the trough 132 is above the horizontal V channel 157 and the horizontal tongue is also pointed and fits into the V shaped horizontal channel 157. The horizontal tongue 56t has an extension 56ex to the horizontal tongue 56t to form a better interlocking fit between two spacer blocks 56. The trough 132 is shown rectilinear with a trough depression 56dp to accommodate the horizontal tongue 56t extension 56ex, however a pointed configuration could also be used in the hole 36v and within the spacer block 56. The upper horizontal tongue 56t is wider to accommodate the notch 126 in the horizontal V channel 157, however the trough 132 is narrower to fit the size of the hole 36v. FIG. 28 shows the V hole 37v with the pointed configuration pointing downward and FIG. 27 shows the horizontal V channel 157 in two sizes, that is the larger horizontal V channel 157 having notches 126 and a bent flange in FIGS. 29 & 30. FIG. 26 shows both sizes of the horizontal V channels 157 being installed in the spacer blocks 56. When the horizontal V channels 157 have the pointed configuration pointing downward, the trough 132 is better when installed below the horizontal bracing channel 157 so the horizontal tongue 56t can fit into the horizontal V channel 157. The horizontal V channel 157 in the lower wall section shows a bent flange with a notch on the V channel 157. When using that configuration the horizontal tongue 56t fits into the V configuration of the horizontal V channel, however an extension 56ex is not used making the connection between spacer blocks less secure.

[0108] FIGS. 31-39 shows the support channel with an indentation 42i in the C channel 42 allowing for a better connection at the tongue space 56a and groove space 56b in the spacers blocks 56. FIG. 31 shows a wall section using the a horizontal U channel 155 facing downward where the horizontal tongue 56t is in the lower spacer block 56 and the trough 132 is in the upper spacer block 56. The rigid board 50 and rigid insulation 51 are shown on both sides of the spacer block 56 as shown in FIG. 1. The base plate 120 is shown attached to the flanges 42b of the C channel 42 leaving a gap 45 between the inner and outer boards. FIGS. 32 & 33 show a plan view of the wall panel 65 and the gap 45 that is formed when the spacer block 56 extends past the C channel 45 and the rigid board 50 and rigid insulation 51 are attached to the spacer block 56. FIG. 33 shows a rigid board filler 50f attached to the flanges 42b of the C channel 42 in the area occupied by the gap 45 at the corner of where two wall panels 65 intersect in order to make a more solid connection. A coupling 63 is a smaller sized horizontal U channel 155 that fits between the flanges of the horizontal U channel 155. The coupling can be square shaped, angular (as shown) or curved in order to make a direct connection between the two wall panels 65 as well as a horizontal reverse lip channel shown in FIG. 18. FIG. 35 shows two different half sections of the spacer block 56 with each half section shown as two different materials. In addition, one side of the spacer block 56 has the spacer block 56 extending past the flange 42b causing a gap 45 as shown in FIG. 11 and the opposite side of the spacer block 56 shown with an a projection 56p and the extension 56e at the groove side 56b as well as a vertical projection 56vp. The vertical projection 56vp projects from the spacer block 56 into the indentation 42i of the C channel 42. FIG. 36 shows the indentation 42i in the C channel 42 with a V hole 36v and FIG. 37 shows the horizontal reverse lip channel 156 with notches 126 in the lip 42c and at the web 42a and flanges 42b. FIGS. 38 & 39 show the wall panel 65 and an enlargement of the gap 45 with the indentation 42i in the C channel 42 along with the rigid board 50 and rigid insulation 51. The indentation 42i in the web 42a of the C channel 42 has two sides 42is and a back 42ib. The indentation 42i in the C channel 42 creates an indented projection 56ip at the spacer block 56. When the indentation 41i is used in a U channel 41 or a reverse lip channel 79 (neither not shown) the area that is shaded (the opposite shaded side not shown) would be applied to the tongue side 56a of the spacer block 56.

[0109] FIGS. 40 & 41 show and enlarged view of the horizontal U channel 155 fitting into the bottom of the trough 132 and the rectilinear hole 36r in the support channel shown as a C channel 42. The spacer blocks 56 are shown with the gap 45 between the C channel 42 and the rigid board 50 and the rigid insulation 51. The horizontal tongue 56t fits into the trough 132 in FIG. 41 but into the horizontal reverse lip channel 156 in FIG. 43. When using the horizontal reverse lip channel 156 the trough 132 is best located below the horizontal reverse lip channel 155 in order to have the horizontal tongue fit between the flanges 156b for a snug fit.

[0110] FIGS. 44-53 s shows various projections extending over one flange of the support channels similar to the projections shown in FIGS. 34 & 35. In FIGS. 44 & 45 the projection 56p extends over the flange 42b of the C channel 42, but stops at the end of the flange 42b by the lip 42c. The base plate 120 has a groove 121 in the spacer block 56 for the flange 120b of the base plate 120 fits over the flange 42b of the C channel 42. FIG. 45 shows a plan view of FIG. 44, showing the trough 132 at the top of the spacer block 56. FIGS. 46 & 47 show a plan view and isometric view of the support channel as a reverse lip channel 79 where the projection 56p stops at the lip 79c and the opposite side has no projection. FIGS. 48 & 51 show an isometric view and a plan view of the hat channel 70 as support channels. The hat channel 70 and the reverse lip channel 79 have a lip 70c & 79c where the projections 56p overlap the support channels. The hat channel 70 works well if the spacer block is load bearing like a concrete block since the sloped slides do not allow drywall or other rigid boards 50 and rigid insulations 51 (not shown) to be fastened to the hat channel 70. Since the support channel and horizontal bracing channel 150 interlock with each other, the spacer blocks 56 can be installed with or without mortar 242 between the spacer blocks 56. FIG. 51 shows a horizontal bracing channel 150 overlapping both spacer blocks 56 and secures the support channel shown as a hat channel 70 interlocking all three together. When the horizontal bracing channel 150 is short it can be also call a coupling 63. The coupling 63 is used to connect the spacer blocks 56 on both sides of a support channel and the trough 132 and/or horizontal tongue 56t of the spacer blocks 56 have physical strength characteristics that the coupling 63 the trough 132 and the horizontal tongue 56t become one structural element about equal to the horizontal bracing channel 155. FIGS. 49 & 50 shows the projection 56p extending over the flange 41b and to the recess 131 of the adjacent spacer block 56. The projection 56p is shown on the groove side of the spacer block 56 like as shown in FIGS. 34 & 35. FIG. 52 shows the groove side 56a and the projection 56p on the same side of the spacer block 56 and FIG. 53 shows the projection 56p on the opposite side of the spacer block 56. FIG. 53 shows round hole 36r with the round rod 166 along with the trough 132 conforming to the round rod 166 where the rides shown in FIG. 12 interlock the support channel, round rod 166 or hole tube 167 and spacer block 56 interlock together.

[0111] FIGS. 54 & 55 shows enlarged views of the spacer blocks 56 and the small spacer block 56s. FIG. 54 shows the spacer block 56 with no projections so the spacer block 56 extends past the support channels so a gap 45 (not shown) is between the support channels. The vertical projection 56vp (shown as dashed) of the spacer block 56 extends into the indentation 42i of the support channel 42. FIG. 55 shows the projection 56p on one side of the spacer block 56 and a recess 131 on the opposite side allowing the projection 56p to fit into an adjacent spacer block 56. Both FIG's the width W is the distance between adjacent spacer blocks 56 and the height h1 and h2 show the height of each spacer block 56 & 56s. Both FIGS. 54 & 55 show a vertical hole 36v in the small spacer blocks 56s.

[0112] FIG. 56 shows spacer blocks 56 connected by a horizontal bracing channel 150 and the support channel as a C channel 42 with a rectangular hole 36r. The horizontal bracing channel 150 is using a horizontal reverse lip channel 156 where the flanges 156b fit into the trough 132 of the spacer block 56 and the horizontal reverse lip channel 156 is facing upwards so the flanges 156b and the web 156a form are exposed forming a U shape. Another horizontal reverse lip channel 156 is installed upside down over the first horizontal reverse lip channel so the lips 156c and their respective notches 126 are touching each other forming a cover over the first horizontal reverse lip channel 156. The top horizontal reverse lip channel 156 shows a punched hole 169 so electric conduit (not shown) can be attached.

[0113] FIGS. 58-60 shows the horizontal U channel 155 facing downward where the flanges 155b having notches 126 fit into the rectilinear hole 36r. A groove 121 is installed adjacent to the horizontal tongue 56t so the flanges 155b can fit into. The trough is above the horizontal bracing channel 150 and is large enough for the horizontal U channel 155 can fit into. FIG. 59 show the wall section with the inner and outer walls shown as rigid board 50 and rigid insulation 51 and FIG. 60 is shown with the projections 56p.

[0114] FIG. 62 is a roof section or a wall section of the structural insulating core 111 shown in FIGS. 9, 10 & 34 and is similar to the plan view shown in FIG. 61 except the C channels 42 are shown deeper, since the structural capacity of the C channels 42 would typically have a greater strength. In FIG. 62 the wall panel 65 shows the spacer block 56 to be the full depth of the C channels 42 and the spacer blocks 56 fits against the webs 42a and against the lip 42c and rests on the rigid board 50. The opposite side of the spacer block 56 rests against the web 42a of the adjacent C channel 42 and above the flanges 42b. FIG. 61 also shows that the projection 56p is longer similar to FIG. 58 where the extension 56e is shown and is shown extending longer than the width of the flange 42b forming a greater thermal break in the spacer block 56 and the C channel 42. The support member in the structural insulating core can be formed with wood blocking 72 or the C channel 42.

[0115] FIG. 63 is the same section as FIG. 62; however the bottoms of the spacer blocks 56 are shown deeper than the C channels 42. The additional depth of the spacer blocks 56 forms a gap 45 between the C channels 42 and a finished ceiling (not shown). In addition, the spacer blocks 56 are shown sliding into position in the wall panel 65. Since the spacer blocks 56 do not have a projection 56p on the underside of the spacer blocks 56, the spacer blocks 56 can slide into position after the C channels 42 have been installed instead of installing the C channels 42 at the same time as the spacer blocks 56.

CONCLUSION AND SCOPE OF INVENTION

[0116] Different types of wall forming supports, horizontal bracing channels and the holes within the support channel are shown as a wall structure. Spacer blocks are used between the wall structure interlocking the spacer blocks together. The tongue space and groove space within the spacer blocks interlock the spacer blocks and support channels together.

[0117] The various holes shapes are shown in the support channels and the horizontal bracing channels, holes and trough locations within the spacer block can reversed to achieve different configurations. The spacer blocks interlock with overlapping flanges at the support channels.

[0118] Another structural insulating core wall is when the spacer block does not cover the support channels forming a gap between the spacer blocks for a better thermal break from the support channels.

[0119] A horizontal reverse lip channel with notches forms a new horizontal bracing channel and greater strength and versatility.

[0120] It is understood that the invention is not to be limited to the exact details of operation or structures shown and describing in the specification and drawings, since obvious modifications and equivalents will be readily apparent to those skilled in the art. The flexibility of the described invention is very versatile and can be used in many different types of building applications.

Claims

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.