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 &amp; 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 &amp; 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 &amp; 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 &amp; 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&#39;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  42   a  of the C channel  42 . The horizontal reverse lip channel  156  has a notch  156   n  in the lip  156   c  as shown in the enlarged view of  FIG. 18  that locks the horizontal reverse lip channel  156  to the web  42   a  of the support channel. The lip  157   c  rests on top of the trough  132  formed in the middle of the spacer block  56  and the flanges  156   b  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  56   t  fits between the flanges  156   b  and against the web  156   a  of the horizontal reverse lip channel  156 . All the spacer blocks  56  within  FIG. 1  are shown deeper than the length of the web  42   a  of the support channel shown as a C channel  42  and extend beyond the flanges  42   b.  The spacer blocks  56  all have a tongue shape  56   a  that fits between the lips  42   c  and abut the webs  42   a  of the C channels  42 . The opposite side of the spacer block is referred to the groove side where a vertical projection  56   vp  is shown. The C channel  42  on the right has an indentation  42   i  in the web  42   a  so the vertical projection  56   vp  can fit into the indentation  42   i  of the C channel  42 . The base plate  120  passes through the smaller spacer block  56   s  and the base plate  120  has a notch  120   n  in the flange  120   b  where the web  42   b  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  241   c  of the anchor bracket  241  extends over the flange  120   b  and is extended downward to form a hook  241   h.  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  42   b  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  42   i  in the web  42   a  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 &amp; 10 .  FIGS. 2 &amp; 3  show the horizontal bracing channel  150  as a horizontal reverse lip channel  156  where the flanges  156   b  and the web  156   a  form a U shape that is facing up which is contrary to  FIGS. 4 &amp; 5  where the web  156   a  is above and the flanges  156   b  and lip  156   c  are below or installed in reverse of  FIGS. 2 &amp; 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  56   t  is inserted into the U shape from the spacer block  56  above, while if the U shape is facing downward the horizontal tongue  56   t  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  156   a  is on top and the lips  156   c  are below with the hole  36  above the web  156   a.  The spacer block  56  is shown separated from the short spacer block  56   s  below. When the spacer block  56  is placed onto the short spacer block  56   s,  the horizontal tongue  56   t  is on the top of the spacer block  56  so the horizontal tongue  56   t  can fit into the flanges  156   b  of the horizontal reverse lip channel  156  and the lips  156   c  rest onto the short spacer block  156   s  below. The spacer block  56  above the horizontal reverse lip channel  156  has a trough  132  that is equal to the web  156   a  of the horizontal reverse lip channel  156   a  and the flanges  156   b  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  42   a  of the C channel  42 , the notches  42   n  in the lip  42   c  fit into the web  42   a  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  42   b  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  42   b  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  42   n  is shown fitting between the web  42   a  of the C channel at the hole  36  therefore the notch  42   n  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  56   t  on top of the spacer block  56  so the horizontal tongue  56   t  can fit between the flanges  42   b  and against the web  42   a.  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  79   c  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  79   c  so the rigid board  50  and rigid insulation  51  do not touch the reverse lip channel  79 . The web  79   a  is perpendicular to the flanges  79   b  so the rigid board  50  and rigid insulation  51  so fasteners can be attached to the flanges  79   b.    
         [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  42   a.  The spacer block  56  has a tongue shape  56   a  that abuts the web  42   a  and the lip  42   c  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  42   b.  The opposite end of the spacer block  56  shows the groove shape  56   b  abutting the web  42   a  of the adjacent support channel and also extend over the hole  36  and past the flange  42   b.  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  115   b  are shown below the web  155   a  which allows the horizontal tongue  56   t  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  &amp;  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 &amp; 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  36   c  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  36   r.    FIG. 13-15  show a rectilinear hole  36   r  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  36   o  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  56   p  that overlaps the flanges  42   b  of the support channel shown as a C channel  42 . Various other projections  56   p  are shown in  FIGS. 44 ,  47 ,  49 . The horizontal bracing channel  156  shows the lip  156   c  resting on the top of the starter spacer block  56   s  and the web  156   a  and flange  156   b  fit into the trough  132 . The horizontal tongue  56   t  in the spacer block  56  above gets inserted between the flanges  156   b  to the web  156   a.  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  36   r  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  42   a  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  156   a  and between the flanges  156   b  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  155   a  and flanges  155   b  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  155   b  and web  155   a  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  36   v  configuration where the V hole  36   v  has a pointed configuration at one side and shown at the bottom of the V hole  36   v.  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 &amp; 23  both show the pointed configuration in the V hole  36   v  at the bottom of the V hole. The horizontal V channel  157  rests in the pointed configuration of the V hole  36   v  and the notches  126  are engages into the V hole  36   v.    FIG. 24  shows the horizontal reverse channel  156  passing through the V hole  36   v,  however two notches  126  are shown at the intersection of the web  156   a  and flanges  156   b  of the horizontal reverse lip channel  156 .  FIGS. 20 &amp; 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  36   v  and the spacer blocks  56 .  FIGS. 25 &amp; 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  56   t  has an extension  56   ex  to the horizontal tongue  56   t  to form a better interlocking fit between two spacer blocks  56 . The trough  132  is shown rectilinear with a trough depression  56   dp  to accommodate the horizontal tongue  56   t  extension  56   ex,  however a pointed configuration could also be used in the hole  36   v  and within the spacer block  56 . The upper horizontal tongue  56   t  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  36   v.    FIG. 28  shows the V hole  37   v  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 &amp; 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  56   t  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  56   t  fits into the V configuration of the horizontal V channel, however an extension  56   ex  is not used making the connection between spacer blocks less secure. 
         [0108]      FIGS. 31-39  shows the support channel with an indentation  42   i  in the C channel  42  allowing for a better connection at the tongue space  56   a  and groove space  56   b  in the spacers blocks  56 .  FIG. 31  shows a wall section using the a horizontal U channel  155  facing downward where the horizontal tongue  56   t  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  42   b  of the C channel  42  leaving a gap  45  between the inner and outer boards.  FIGS. 32 &amp; 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  50   f  attached to the flanges  42   b  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  42   b  causing a gap  45  as shown in  FIG. 11  and the opposite side of the spacer block  56  shown with an a projection  56   p  and the extension  56   e  at the groove side  56   b  as well as a vertical projection  56   vp.  The vertical projection  56   vp  projects from the spacer block  56  into the indentation  42   i  of the C channel  42 .  FIG. 36  shows the indentation  42   i  in the C channel  42  with a V hole  36   v  and  FIG. 37  shows the horizontal reverse lip channel  156  with notches  126  in the lip  42   c  and at the web  42   a  and flanges  42   b.    FIGS. 38 &amp; 39  show the wall panel  65  and an enlargement of the gap  45  with the indentation  42   i  in the C channel  42  along with the rigid board  50  and rigid insulation  51 . The indentation  42   i  in the web  42   a  of the C channel  42  has two sides  42   is  and a back  42   ib.  The indentation  42   i  in the C channel  42  creates an indented projection  56   ip  at the spacer block  56 . When the indentation  41   i  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  56   a  of the spacer block  56 . 
         [0109]      FIGS. 40 &amp; 41  show and enlarged view of the horizontal U channel  155  fitting into the bottom of the trough  132  and the rectilinear hole  36   r  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  56   t  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  156   b  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 &amp; 35 . In  FIGS. 44 &amp; 45  the projection  56   p  extends over the flange  42   b  of the C channel  42 , but stops at the end of the flange  42   b  by the lip  42   c.  The base plate  120  has a groove  121  in the spacer block  56  for the flange  120   b  of the base plate  120  fits over the flange  42   b  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 &amp; 47  show a plan view and isometric view of the support channel as a reverse lip channel  79  where the projection  56   p  stops at the lip  79   c  and the opposite side has no projection.  FIGS. 48 &amp; 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  70   c  &amp;  79   c  where the projections  56   p  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  56   t  of the spacer blocks  56  have physical strength characteristics that the coupling  63  the trough  132  and the horizontal tongue  56   t  become one structural element about equal to the horizontal bracing channel  155 .  FIGS. 49 &amp; 50  shows the projection  56   p  extending over the flange  41   b  and to the recess  131  of the adjacent spacer block  56 . The projection  56   p  is shown on the groove side of the spacer block  56  like as shown in  FIGS. 34 &amp; 35 .  FIG. 52  shows the groove side  56   a  and the projection  56   p  on the same side of the spacer block  56  and  FIG. 53  shows the projection  56   p  on the opposite side of the spacer block  56 .  FIG. 53  shows round hole  36   r  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 &amp; 55  shows enlarged views of the spacer blocks  56  and the small spacer block  56   s.    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  56   vp  (shown as dashed) of the spacer block  56  extends into the indentation  42   i  of the support channel  42 .  FIG. 55  shows the projection  56   p  on one side of the spacer block  56  and a recess  131  on the opposite side allowing the projection  56   p  to fit into an adjacent spacer block  56 . Both FIG&#39;s the width W is the distance between adjacent spacer blocks  56  and the height h 1  and h 2  show the height of each spacer block  56  &amp;  56   s.  Both  FIGS. 54 &amp; 55  show a vertical hole  36   v  in the small spacer blocks  56   s.    
         [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  36   r.  The horizontal bracing channel  150  is using a horizontal reverse lip channel  156  where the flanges  156   b  fit into the trough  132  of the spacer block  56  and the horizontal reverse lip channel  156  is facing upwards so the flanges  156   b  and the web  156   a  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  156   c  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  155   b  having notches  126  fit into the rectilinear hole  36   r.  A groove  121  is installed adjacent to the horizontal tongue  56   t  so the flanges  155   b  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  56   p.    
         [0114]      FIG. 62  is a roof section or a wall section of the structural insulating core  111  shown in  FIGS. 9 ,  10  &amp;  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  42   a  and against the lip  42   c  and rests on the rigid board  50 . The opposite side of the spacer block  56  rests against the web  42   a  of the adjacent C channel  42  and above the flanges  42   b.    FIG. 61  also shows that the projection  56   p  is longer similar to  FIG. 58  where the extension  56   e  is shown and is shown extending longer than the width of the flange  42   b  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  56   p  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.