Universal construction profiles system

Abstract

A universal profile system for use in structural and decorative construction work. The system comprising: a metal profile, for supporting boards, including folded flanges and double webs formed between the flanges, wherein the double webs include a bracing passage to fit in a bracing profile; the bracing profile, H-shaped, designed with folded flanges and minimum one web significantly contributing to the load distribution, resisting lateral forces like wind, seismic, and other loads that can sway or collapse the construction; a primary anchor that inserts in cavities of the metal profile; an external anchor that slides over the metal profile; an external connector that slides over the bracing profile; and more accessories with the metal profiles and anchors ensure stable, strong and fitting ease connecting the system elements to a main structure.

Description

[0001] UNIVERSAL CONSTRUCTION PROFILES SYSTEM

[0002] FIELD OF THE INVENTION

[0003]

[0001] Embodiments of the present invention are about a universal metal profiles system used in construction as building materials.

[0004] The present invention generally relates to a universal profiles system, more particularly designed and intended for the structures of light gauge steel framing construction systems, drywalls partitions, board ceilings, struts, trusses & joists, and as a decorative false ceiling.

[0005] BACKGROUND OF THE INVENTION

[0006]

[0002] The construction industry continuously seeks advancements to improve the structural integrity, efficiency, and aesthetic appeal of building elements. Metal profiles are fundamental components in this regard, playing a crucial role in constructing drywall partitions, ceilings, struts, trusses, joists, and light gauge steel framing systems. Traditionally, various systems comprising stud and track configurations, furring channels, and main channels with accompanying hanging accessories have been utilized. While these conventional systems serve their purpose, they present limitations in terms of structural strength, economic efficiency, and ease of installation.

[0007]

[0003] In modern construction, the use of metal profiles for creating structural and decorative elements such as drywall partitions, ceilings, struts, trusses, joists, and light gauge steel framing systems is widespread. This system, including all its elements, is crucial for ensuring the structural integrity and aesthetic appeal of buildings. Universal Profiles System is an essential innovation in the field of construction and building materials. It comprises precisely shaped and fabricated metal components that provide support and stability for a range of applications.

[0008]

[0004] Traditional metal framing systems used in construction rely on individual components such as metal studs, runner s / tracks, furring and main channels which are manufactured in standard sizes and shapes. These components require manual cutting and fitting at construction sites to meet specific layout requirements, a process that is labor-intensive and results in significant material waste from leftover pieces discarded after customization. Additionally, the manual nature of these operations can lead to inconsistencies in dimensions and quality across the construction project.

[0009]

[0005] Design flexibility is another challenge posed by traditional metal framing systems. Standardized shapes and limited component options can constrain architects and builders in creating innovative designs or accommodating unique architectural features. For instance, achieving curved walls or irregular ceiling shapes with these systems typically requires costly and time-consuming custom solutions, which adds complexity to construction projects.

[0010]

[0006] Long-standing traditional metal framing and existing metal profile systems, encounter challenges such as labor-intensive processes, material waste, structural limitations, and restricted design flexibility. These shortcomings highlight the necessity for innovations like the Universal Profiles System. It leverages advanced manufacturing methods, improved component designs, and integrated system solutions to overcome these challenges effectively.

[0011]

[0007] Hence, there exists a need for an innovative metal profile system that offers enhanced performance and versatility. The present invention introduces a universal metal profiles system designed to meet these requirements, providing significant improvements over existing systems and methods. The system includes a series of components engineered for better structural support, ease of installation, and overall cost efficiency.

[0012]

[0008] The Universal Profile System is a complete system that works across many platforms i.e. light gauge steel structures and framing, partitions and partitioning styles, board ceilings, trusses, struts, joists and even decorative false ceilings.

[0013] OBJECT OF THE INVENTION

[0014]

[0009] To provide a more versatile universal profiles system and method of formation of the component elements.

[0015]

[0010] To provide one adequate universal metal profile system for drywalls partitions, board ceilings, struts, trusses, joists, light gauge steel framing construction systems, and as a decorative false ceiling.

[0016] [Oil] To develop a simple and cost-effective multi-purpose system for the construction industry.

[0017]

[0012] To obtain a versatile robust profile system for building homes, businesses, and construction, supporting a variety of construction needs.

[0018] SUMMARY OF THE INVENTION

[0019]

[0013] The present invention is a universal profiles system designed for use in structural and decorative construction work. The system (100) comprises:

[0020]

[0001] A metal profile the ‘Ultimate Profile’ (110) for supporting boards for both walls and ceilings and strut for different construction uses.

[0002] Two types of anchors for securing and stabilizing the Ultimate Profiles:

[0021] - An internal slipping anchor the ‘Ultimate Primary Anchor’ (130).

[0022] - An externally sliding anchor the ‘Ultimate External Anchor’ (140).

[0023]

[0003] Two types of connectors to securely connect two metal Profiles (110) when extensions are needed:

[0024] - An internal connector, the ‘Ultimate Primary Connector’ (150), designed to slip in the cavities of the Ultimate Profiles (110) extremities to securely and strongly connect two Ultimate Profiles when extensions are required. The Ultimate Primary Connector is suitable for connecting the Ultimate Profiles (110) in any configuration and types of installations.

[0025] - An external connector, the ‘Ultimate External Connector’ (160), is particularly designed for the board ceiling fitting. It slides over the metal profile (110), tightly bounding it, to securely and strongly hook it through the pre-cut slot (1601) at its upper side to the ceiling hook, the ‘Ultimate Hook’ (170), via the dropdown, the ‘Ultimate Dropdown’ (170A), (both elements described below).

[0026] The external connector (160) can also be used similarly as the internal connector (150) to safely and adequately attach two metal profiles (110) when such extension is required.

[0027]

[0004] A ceiling hook, the ‘Ultimate Hook’ (170), for securing / attaching the system (100) to the top structure.

[0028]

[0005] A dropdown element, the ‘Ultimate Dropdown’ (170A), for setting and levelling the ceiling at any required height.

[0029]

[0006] A bracing profile, the ‘Ultimate Bracing’ (120), to strengthen the system and counter lateral forces.

[0030]

[0007] A bracing anchor, the ‘Ultimate Bracing Anchor’, for securing the Ultimate Bracing Profile when required. This anchor is like the Ultimate External Anchor (140), it is designed to tightly engulf the single web it incorporates in contrast to the double webs of the Ultimate Profile (110).

[0031] Further, skilled artisans will appreciate that elements in the figures are illustrated for simplicity and may not have necessarily been drawn to scale. Furthermore, in terms of the construction of the system, one or more components of it may have been represented in the figures by conventional symbols, and the figures may show only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the figures with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

[0032] In accordance with an embodiment of the present invention: a. The ultimate profile (110) is designed to hold the boards for finishing the walls and ceilings (the board is selected from a range of boards including gypsum board, cement board, fiberboard, particleboard, or plasterboard. . The ultimate profile (110) is formed with a minimum of two flanges (1103) of equal sizes on its exterior delimiting its sides (flanges is where the intended boards are attached). As per ASTM standards flanges come in two sizes, 36mm and 48mm. These dimensions can be altered as per the project’s consultant / engineer / architect recommendations. The extremities of the flanges are each folded 180° degrees over one third of the flanges’ length increasing the rigidity and stiffness of this profile.

[0033] A double web (1104) is shaped between the flanges. The webs are formed at one third of each of the flange’s lengths providing the ultimate profile (110) a doubled lateral support. The size of the webs (1104) is set to the required wall depth / thickness.

[0034] The webs (1104) include the bracing passages to fit the ultimate bracing profile (120) and the service pre-cuts. The perforated ‘H’ shaped bracing passage (1102) is aligned with the utilities service pre-cuts (1101). The pre-cuts are centered between the perforations of the bracing passage and measure 50mm in height at 10mm from the edges of the Hs’ perforations (1102). b. The ultimate anchors’ (130 and 140) main advantage is that they are not long profiles and attach to the metal profile (110) extremities allowing the system to be fixed at any interval and location on the side (wall), bottom (floor) and top (ceiling) structures.

[0035] The length of the ultimate primary anchor’s flanges (1301) (the portion that slips in the extremities of the ultimate Profile (110)) are set to 50mm and 70mm. The base (1303) of the ultimate primary anchor includes two chamfered pre-cut holes (1304) at the centers of its side sections (1306) to effortlessly secure and tie it to the sides or the bottom and top structures.

[0036] The ultimate external anchor (140) is used for embedding and securing the ultimate profile (110) to the side structures and can be fully utilized for fixing the ceilings’ structures at the consul tant / architect / engineer’s recommendation. c. The ultimate hook (170) is a cold formed ninety degrees (90°) angle “L” shaped element measuring 45x45x45x45mm and of a minimum thickness of 0.80mm. The thickness can be recommended by the projects’ consultant / architect / engineer.

[0037] One face of the ultimate hook (170) has at its center a pre-punched beveled hole (1701) to facilitate fastening to the main structure. The second face includes two parallel rows (1702), at 10mm (1703) gap, of three pre-punched notches (1704) of 10x5mm at 10mm gaps (1705) for connecting it to the ultimate dropdown (170A) element. d. The ultimate dropdown (170A) element purpose is for leveling the ceiling height. At 15mm from its top (1801) the dropdown element features two parallel rows (170A2) of pre-cuts. The gap between the rows is 10mm (1803). The pre-cuts (1804) are to securely attach the dropdown element to the ultimate hook’s (170) notches (1704) in a sliding motion. The lower length of the ultimate dropdown element is bent by 35° (170A5). The bent length is 25mm (170A6), it facilitates hooking the ultimate dropdown element to the ultimate external connector’s (160) top side hooking slot (1601). The ultimate dropdown can be of any required and recommended length and thickness. e. The ultimate bracing profile (120) is a cold formed profile similar to the metal profile (110) but features a minimum of one web. The ultimate bracing profile connects to the ultimate profiles (110) across the pre-cut ‘H’ (1102) shaped bracing way on its webs (1104). The ultimate bracing profile provides more rigidity, stability and counters lateral force.

[0038] BRIEF DESCRIPTION OF THE DRAWINGS

[0039]

[0022] Above mentioned features, aspects, and advantages of the example embodiments will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

[0040]

[0023] Fig. 1 illustrates the ultimate profile showing flanges and double webs, in accordance with an embodiment of the present invention.

[0041]

[0024] Fig. 2 illustrates the ultimate bracing profile depicting flanges and a single web, in accordance with an embodiment of the present invention.

[0042]

[0025] Fig. 3 illustrates the ultimate primary anchor, in accordance with an embodiment of the present invention.

[0043]

[0026] Fig. 4 illustrates the ultimate external anchor, in accordance with an embodiment of the present invention.

[0027] Fig. 5 illustrates the ultimate primary connector, in accordance with an embodiment of the present invention.

[0044]

[0028] Fig. 6 illustrates the ultimate external connector, in accordance with an embodiment of the present invention.

[0029] Fig. 7 illustrates the ultimate hook, in accordance with an embodiment of the present invention.

[0045]

[0030] Fig. 8 illustrates the ultimate dropdown, in accordance with an embodiment of the present invention.

[0046] DETAILED DESCRIPTION OF THE DRAWINGS

[0047]

[0031] While the present invention is described herein by way of example using embodiments, those skilled in the art will recognize that the invention is not limited to the embodiments described herein. The description herein is not intended to limit the invention to the particular form disclosed, but on the contrary, the invention is to cover all modification / s, equivalent / s and alternative / s falling within the scope of the present invention. The headings used herein are for organizational purposes only and are not meant to be used to limit the scope of the description or the claim. As used throughout this description, the word "may" be used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Further, the words "a" or "an" means "at least one” unless otherwise mentioned. Furthermore, the terminology and phraseology used herein is solely used for descriptive purposes and should not be construed as limiting in scope. Language such as "including", "comprising", "having", "containing", or "involving" and variations thereof, is intended to be broad and encompass the subject matter listed thereafter, equivalents, and additional subject matter not recited, and is not intended to exclude other additives, components, integers or steps. Likewise, the term "comprising" is considered synonymous with the terms "including" or "containing" for applicable legal purposes. Any discussion of documents, acts, materials, devices, articles and the likes are included in the specification solely for the purpose of providing a context for the present invention. It is not suggested or represented that any or all these matters form part of the prior art base or were common general knowledge in the field relevant to the present invention.

[0048]

[0032] In this disclosure, whenever an element or a group of elements is preceded with the transitional phrase “comprising”, it is understood that we also contemplate the same composition, element or group of elements with transitional phrases “consisting of’, “consisting”, “selected from the group of consisting of’, “including”, or “is” preceding the recitation of the composition, element or group of elements and vice versa.

[0049]

[0033] This invention described herein may be embodied in many different forms and should not be construed as limited to the embodiment set forth herein. Rather, the embodiments are provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those skilled in the art. In the following description, numeric values and ranges are provided for various aspects of the implementations described. These values and ranges are to be treated as examples only and are not intended to limit the scope of the claims. In addition, several materials are identified as suitable for various facets of the implementations. These materials are to be treated as exemplary and are not intended to limit the scope of the invention.

[0034] The present invention offers a highly efficient system for constructing drywall partitions, board ceilings, and light gauge steel framing constructions by utilizing specially designed metal profiles and accessories. By incorporating these components, the universal profile system creates a strong, economical, and easily workable structure that surpasses traditional systems in terms of efficiency and versatility. This innovative approach significantly enhances the construction process, making it more effective and adaptable to different building needs. The universal profile system components can be manufactured from various materials, each selected for its specific properties and suitability for different construction needs. Galvanized steel is one of the most common materials used due to its excellent corrosion resistance, strength, and durability, making it ideal for both indoor and outdoor applications. Aluminum, known for its lightweight and corrosion-resistant properties, is often used in projects where reducing the overall weight of the structure is crucial. Stainless steel offers superior strength and corrosion resistance, making it suitable for environments exposed to harsh weather conditions or chemicals, and is frequently used in high-end construction projects. Cold-rolled steel is prized for its high tensile strength and smooth finish, making it ideal for precision engineering applications. In some advanced construction projects, composite materials such as fiber-reinforced polymers (FRPs) are used for their combination of high strength and lightweight properties, as well as resistance to corrosion and impact. Additionally, zinc-aluminum alloy (galvalume) is used for its enhanced corrosion resistance and thermal reflectivity, making it suitable for environments where durability and energy efficiency are important. The choice of material depends on the specific requirements of the construction project, including environmental conditions, load-bearing needs, and budget considerations. For instance, galvanized steel might be preferred for its robustness in structural applications, while aluminum could be chosen for its ease of installation in interior partitioning and lighter weight. The intended boards such as, but not limited to, gypsum board, cement board, fiberboard, particleboard, and plasterboard. The primary function of the intended board in the system is to provide a durable and stable surface for constructing walls, ceilings, and other structural elements. These boards, such as gypsum board, cement board, fiberboard, particleboard, or plasterboard, are crucial for creating smooth, even surfaces that can be finished with paint, wallpaper, or other decorative treatments. Gypsum boards are often used for their fire-resistant properties and ease of installation, thus commonly used in residential and commercial construction. Cement boards, on the other hand, offer excellent moisture resistance and are ideal for use in areas exposed to high humidity, such as bathrooms and kitchens construction. Fiberboard and particleboard provide good insulation and soundproofing properties, while plasterboard is valued for its ease of handling and flexibility in creating various architectural designs.

[0035] The first main component of the universal profiles system (100) is the ultimate profile (110). Figure 1 illustrates the ultimate profile (110) for use in structural and decorative construction work in accordance with an embodiment of the present invention. The ultimate profile (110) supports any intended board. These boards are supported by the ultimate profiles (110) that are secured by the ultimate anchors (130 and 140) to ensure the structural integrity and aesthetic quality of the construction project.

[0050]

[0036] The ultimate profde’s (110) design consists of the following components:

[0051] Two or more flanges (1103), that form the external sides of the profile where the board is fixed.

[0052] One or more double webs (1104) having not less than three ribs (1105) formed along the lengths of the webs to increase the profile’s sturdiness. The double webs (1104) are designed to form a rectangular shape between the flanges (1103) substantially increasing the profde’s lateral strength and support. The shape is such that it increases the strength of the flanges (1103) in the system (100). The length of the flanges (1103) is equally divided into three equal sections. The four lower and top edges of the flanges (1103) enclose the webs (1104) under any required size. The length of the webs (1104) can be produced based on the recommendations and needs of consultants, engineers, and architects as per the construction project requirements; the same applies to the metal profile (110) thickness.

[0053] For example, in a high-rise commercial building, the ultimate profile (110) might be adjusted to accommodate thicker or multiple boards for enhanced sound insulation. In residential construction, the ultimate profile (110) could be tailored to fit thinner boards for interior walls, optimizing space and material usage. The height of the flanges (1103) provides ample space for proper attachment of boards. The size of the flanges (1103) size is manufactured in two optional lengths, the thirty- six millimeters (36mm) and the forty-eight millimeters (48mm), in accordance with American Society for Testing and Materials (ASTM) standards. The extremities of the flanges (1103) are each folded at 180 degrees over one-third of the total flanges’ lengths. By folding the edges, the initial metal thickness is effectively doubled at these critical points, which in turn boosts the rigidity, stiffness, and load-bearing capacity of the profile (110). This method of edge folding works in tandem with the double-web (1104) design of the profile (110) to provide superior mechanical properties. The combination of edge folding, seconded by the enclosed rectangularshaped webs (1104) grants the metal profile (110) superior mechanical properties compared to conventional metal profiles, allowing for the use of thinner materials and increased spacing between ultimate profiles. To minimize heat transfer, twenty-millimeter- wide pin perforations can be included along over the full length of the webs’ (1104) centers. For added rigidity and sturdiness, three ribs (1105) are formed in parallel along the lengths of each web. These ribs (1105) are alternately shaped: one web (1104) has side ribs formed upward and the middle rib facing downward, while the opposite web has the ribs (1105) in the inverse order.

[0054] For example, in a traditional drywall partition system using standard c-channel profiles, the profiles might need to be placed at close intervals to ensure stability. However, with the enhanced strength of the new metal profile (110) design, the intervals between profiles can be increased without sacrificing structural integrity. This not only reduces the amount of material required but also speeds up the installation process, leading to overall cost savings and increased efficiency on the construction site.

[0055]

[0037] The ultimate profde’s webs (1104) include, on parallel levels, pre-perforated “bracing ways” (1102) in the shape of an “H” to accommodate the ultimate bracing profile (120) (as clearly shown in FIG. 2), with additional service pre-cuts (1101). These service pre-cuts (1101), are located at 10mm from the edges of the “H” perforations (1102) and measure 50mm in length, allow the passage of cables, tubes, pipes and other service items. By integrating these pre-cuts (1101), the ultimate profile system (100) not only supports the physical structure but also accommodates the necessary utilities, streamlining the installation process. This specific location of the pre-cuts (1101) takes full advantage of the ultimate bracing profile when it is used as a support element, such as a cable tray, further enhancing the system's versatility.

[0056]

[0038] Further, the pre-cuts (1101) are designed to be easily folded inward or outward, by the push of a finger or a screwdriver, creating a smooth tunnel that minimizes sharp edges compared to commonly used open, perforated detachable, or not foldable pre-cuts available on common c- channels. Pre-cuts (1101) are positioned at 600mm from the profile edges, with intermediate precuts equidistant between them. The bracing perforations, combined with the service pre-cuts (1101), form an “H” shape to fit the “H” shaped ultimate bracing profile and consequently transforming into a tunneled passage for cables and similar utilities. This configuration allows even the service pre-cuts (1101) to double as a localized cable tray.

[0057]

[0039] Additionally, the flanges (1103) of the ultimate profile are slightly knurled (1106) to provide a better screwing grip, which enhances the ease and security of board attachment. This feature ensures that screws hold more firmly, contributing to the overall stability and durability of the profile system (100).

[0058]

[0040] In another embodiment of the present invention, the second essential element of this system (100) are the ultimate anchors. The design of the anchors integrating the ultimate profile renders the structure of the universal profile system sturdier and unified. Two types and concepts of ultimate anchors are designed in the present universal profile system (100): • The ultimate primary anchor (130) (as shown in FIG.3) and the ultimate external anchor (140) (as shown in FIG. 4), these ultimate anchors replace the traditional runner (track / runner or rail) typically used as part of walls structures and the main channels as part of the board ceilings structures, thus streamlining the construction process.

[0059] • The ultimate primary anchor (130) in FIG. 3 is designed so that its flanges (1301) slide in the cavities at the extremities of the ultimate profile (110). The ultimate primary anchor’s web (1302) size is 2 millimeters narrower than the receiving ultimate profde’s web (1104) size. Once inserted, the ultimate primary anchor is fastened to the sides or bottom and top main structures at designated gaps, ensuring the stability and proper placement of the ultimate profile (110) and the complete wall. The ultimate primary anchor’s design reflects the universal profile system’s (100) essential strength to effectively hold the structure, the necessary load factors and the stability of the structure. The base (1303) of the ultimate primary anchor has a double layer at its wings (1306) providing a stronger integrated and secure connection and include chamfered holes (1304) for ease of fixing; the double layer is hemmed (1305) upwards to 180° at the end of the opposite wing increasing the strength and the rigidity of the ultimate primary anchor. For example, in constructing a high-rise building, the metal primary anchor (130) can be used to firmly secure the metal profiles (110) to the sides or bottom and top main structures, ensuring that the walls / ceilings remain stable even under significant loads and during seismic activities. By sliding into the ultimate profile (110) extremities’ cavities, the ultimate primary anchor (130) helps distribute the load evenly and enhances the structural integrity of the wall and the ceiling.

[0060] • The design of these anchors provides this structural universal profile system (100) much higher grip while also enhancing the ultimate profile’s (110) mechanical properties.

[0061] • The ultimate anchors (130 and 140) help minimize the wastage generated from unutilized material, a common factor in the conventional structure; an example is the track / runner profile which is laid across the length of the sides or the bottom and the top of the main structure to retain at repeated paces the stud profdes rendering most of the track’s length useless and generating unnecessary added weight and financial cost to the construction.

[0062] • The ultimate external anchor (140) in FIG.4 is designed for ease of use and faster installation particularly for board ceilings structures. The ultimate anchor slides over the ultimate profile (110), encompassing its flanges (1103) and webs (1104). The ultimate external anchor is designed to not only attach the ultimate profile (110) to the structure but to increase its strength.

[0063]

[0041] In yet another embodiment of the present invention, as shown in FIG. 3, the ultimate primary anchor (130) is inserted into the cavities at the extremities of the ultimate profile (110). Once inserted, it is fixed to the sides or bottom and top structures at designated intervals, ensuring the proper placement, the stability and the rigidity of the ultimate profile (110) and the whole wall. This type of anchor provides a more integrated and secure connection.

[0064]

[0042] The ultimate anchors not being long profiles and attach to the extremities of the ultimate profile (110) allows the system (100) to be fixed at any interval and position, thus reducing material waste compared to using tracks and runners. Using traditional tracks and runners in construction, several issues can lead to material waste and inefficiencies.

[0065]

[0043] Additionally, connecting multiple tracks / runners to cover large spans requires extra materials like joiners, connectors, and screws. These connection points can also be weak spots, potentially compromising the structural integrity and necessitating additional reinforcement. Use of ultimate anchors provides strong and stable attachment points without the need for continuous lengths of material, accommodating a wider range of design variations and reducing overall material usage. This approach not only minimizes waste but also simplifies the installation process, making it more efficient and cost-effective.

[0066]

[0044] The ultimate anchors’ (130 & 140) designs easily enable the erection and construction of various wall and ceiling configurations, including curved and other designer styles. This system provides a sturdy structure without the need for additional accessories or slicing of floor and ceiling profiles. However, for board ceilings, the anchors are secured to the side walls, and the ultimate profile (110) is supported with the metal hanging system (160, 180 & 170) and when required with the metal bracing profile (120).

[0067]

[0045] The length of the ultimate primary anchor flanges’ (the part inserted into the metal profile) is at least sixty millimeters, which is more than double the length of standard runner flanges and twenty percent longer than those of the deflection tracks. The ultimate anchor flanges’ (the part of the ultimate primary anchor inserted in the ultimate profile) (1301) slide into each cavity at the extremities of the ultimate profile (110). The ultimate anchor enhances the system’s load-bearing capacity, rigidity, and strength. It is fully enclosed / boxed, with no open gaps, due to the double layers at the base (1303) extremities (1306), further increasing its strength as well as that of the ultimate profile (110). The ultimate anchors facilitate easy installation for straight, curved, or designer walls and ceilings without additional cost and effort, significantly reducing labor time compared to conventional systems.

[0068]

[0046] In yet another embodiment of the present invention, the third element of the present invention includes accessories for connecting, reinforcing, and stabilizing the walls and ceilings’ ultimate profiles (110), along with suitable hanging metal accessories for the ultimate profiles’ (110) ceiling fitting. The accessories consist of ultimate connectors (150 and 160), ultimate ceiling hook (170), ultimate dropdown element (170A), and an ultimate bracing profile (120).

[0069]

[0047] The cold-formed ultimate connectors (150 and 160), as shown in FIG. 5 and FIG. 6 are for connecting two ultimate profiles (110) as and when such extension is needed. These ultimate connectors are to enhance interlocking, robustness and facilitate the installation. The lengths of the ultimate connectors (150 & 160) will be in the range of 120mm to 250mm, with thicknesses equivalent to match the ultimate profiles (110) being connected. The ultimate prime connector (150) can be used to connect the ultimate profiles (110) when used in both the walls or the ceilings structures, while the ultimate external connector (160) is mainly to use for the ceiling structures; the ultimate external connector (160) has a double utility, the main of these utilities is to attach the ultimate profile (110) to the ceiling / top structure to increase the load bearing capacity and the strength of the metal profile (110), and secure the ceiling stability and rigidity; its secondary utility is optionally replacing the ultimate prime connector (150) for connecting two ceiling ultimate profiles (110) when needed to interlock and secure the extension.

[0070]

[0048] The ultimate prime connector (150), as shown in FIG. 5, is a cold-formed rectangular metal tube designed to slip in the cavities at the ultimate profiles’ (110) extremities to bond two ultimate profiles (110) when needed. To ensure proper installation and equal reinforcement distribution, notched stoppers (1501) are pre-cut at the center of the ultimate prime connector webs, locking the two ultimate profiles (110) at equidistance. These stoppers ensure that the ultimate prime connector is evenly inserted into each of the ultimate profiles (110).

[0071]

[0049] The second connector, the ultimate external connector (160) (as shown in FIG. 6), is designed to slide over the ultimate profile (110) encompassing one of its flanges (1103) and its double webs (1104). The ultimate external connector serves two functions:

[0072] 1. The main use of the ultimate external connector is to retain and connect the ultimate profile (110) and attach it to the ultimate dropdown (170A) that is securely attached to the ultimate hook (170) which is tied to the main ceiling / top structure.

[0073] 2. The second application of the ultimate external connector is to optionally use it instead of the ultimate prime connector (150), consequently taking advantage of the ultimate external connectors’ (160) pre-cut slot (1601) connecting not only the two ultimate profiles (110) and also further enhancing their stability, adding to their load bearing and strength by attaching it through the ultimate dropdown element (170A) to the ultimate hook (170) directly tied to the main structure.

[0074]

[0050] The ultimate ceiling hook (170) in FIG. 7 secures the system to the ceiling / top structure. It is a cold formed metal strip of 45mm width and 90mm length bent at its middle length (i.e. 45mm) at ninety-degree (90°) angle resulting in an "L" shape of 45x45mm sides. One side of the ultimate ceiling hook (170) is pre-punched with three chamfered hole (1701) to facilitate fastening to the top structure. The second side hooks with the ultimate dropdown element (170A) through the 5mm vertically (1703) spaced two rows (1702) of three notches (1704) starting at 10mm from the top of the side; the notches (1704) measure 10x5mm and are horizontally spaced by 5mm gaps (1705), this placement is depicted in FIG. 7.

[0075]

[0051] The ultimate dropdown element (170A) as shown in FIG.8, is a cold-formed steel strip intended to attach the ultimate ceiling hook (170) to the external connector (160) at the required height, ensuring the levelling, strength, and rigidity of the ceiling.

[0076] The ultimate dropdown (170A) lengths are in the range of 300mm to 2000mm and its thickness range is from 0.70mm to 2.50mm.

[0077] The ultimate dropdown bottom’s 30mm (170A6) is bent at a 30° angle (170A5) designed to slide onto the hooking slot (1601) of the ultimate external connector (160). Six cut-outs, measuring 6x10mm, are pre-cut at the top of the ultimate dropdown element and arranged in sets of three distributed over two rows, the first row located at 10mm from the top edge of the ultimate dropdown; the rows are vertically separated by a 5mm gap while the cut-outs are horizontally spaced by 5mm gaps. The cut-outs are configured to smoothly hook onto the notches (1704) of the ultimate ceiling hook (170), providing a stable, strong and secure hold. The ultimate dropdown (170 A) connects the ultimate ceiling hook (170) to the ultimate external connector (160) by slipping the ultimate dropdown 30mm bend in slot (1601) at the top side of the ultimate external connector. The ultimate dropdown element is necessary to level the ceiling at the required height, increasing the strength and rigidity of the ceiling structure and the ceiling in general.

[0078]

[0052] In another embodiment of the present invention, the ultimate bracing profile (120). The ultimate bracing profile looks similar to the ultimate profile (110), it is H-shaped but is designed with a single web (1202) that is enclosed at the middle length of the flanges (1201). The return flanges in the ultimate bracing profile are folded similarly to the ultimate profile (110), the four extremities of the flanges are each bent towards the interior by 180° but half length of the flanges in comparison of the third of the flanges’ length for the ultimate profile (110). The flanges length can vary from 15mm to any length recommended by the consultant, architect or site engineer. The web size of the ultimate bracing profile is the required width to slip in the width of the receiving ultimate profde (110) webs’ bracing way (1102). The ultimate bracing profde’s web incorporates a bracing way (1203) enabling the ‘X’ bracing configuration when required. The ultimate bracing profile can be used for both wall and ceiling configurations. The bracing stabilizes the structure, significantly contributing to the load distribution, resisting lateral forces like wind, seismic, and other loads that can sway or collapse the construction. It provides restraint to compression of the flanges that might otherwise buckle laterally. The design of the ultimate bracing profile (120) and its connection within the ultimate profile (110) also offers an additional benefit as a cable and pipe tray when placed horizontally.

[0079]

[0053] The present invention offers several unique features:

[0080] - The folded flanges and the webs as designed in the ultimate and the bracing profiles provide increased lateral support and structural integrity to the construction.

[0081] - The system includes various elements such as the ultimate primary anchor (130), ultimate external anchor (140), ultimate bracing profile (120) and ultimate bracing anchor, ultimate ceiling hook (170), ultimate dropdown (170A), and ultimate profiles connectors. These elements facilitate quick and secure installation, reducing labor time and costs.

[0082] - The system is highly adaptable, suitable for a range of construction applications from structural framing to decorative false ceilings.

[0083] - The tunneled pre-cut service holes in the ultimate profiles (110) allows for easy passage of cables and other service items, streamlining the installation of utilities and reducing the need for additional modifications.

[0084] - The folding of the edges of the flanges in the system allows to double the initial metal thickness enhances the rigidity and load -bearing capacity of the ultimate profiles, ensuring long-lasting performance under various load conditions.

[0085]

[0054] Various modifications to these embodiments are apparent to those skilled in the art from the description and the accompanying drawings. The principles associated with the various embodiments described herein may be applied to other embodiments. Therefore, the description is not intended to be limited to the embodiments shown along with the accompanying drawings but is to be providing the broadest scope, consistent with the principles and the novel and inventive features disclosed or suggested herein. Accordingly, the invention is anticipated to hold on to all other such alternatives, modifications, and variations that fall within the scope of the present invention and the appended claims.

Claims

CLAIMS1. A universal profile system for use in structural and decorative construction work, the system comprising:A metal profile for supporting a board, wherein the metal profile includes, two or more, 180° internally folded, flanges that form the sides of the metal profile where the board(s) is attached, one or more double webs formed between the flanges to provide lateral support to the flanges and the metal profile, wherein the double webs include a bracing way to fit in the metal bracing profile and one or more ribs formed along the lengths of each web to provide increased sturdiness to the metal profile;Two anchors for securing the metal profile including:An internal anchor that inserts in the cavities of the metal profile to be fixed at the sides or the top and the bottom structures where the wall or the ceiling is to be erected. It is fixed at designated gaps ensuring the placement and stability of the metal profile and the wall.An external anchor that slides on the exterior surface of the metal profile and allows rapid installation of the metal ceiling structure system on the main structure.More accessories with the metal profiles and anchors ensure stable, strong and fitting ease connecting the system elements to the main structure, the accessories comprising:♦♦♦ Two connectors:• A prime connector that slides in the cavities of the metal profile to join two metal profiles.• An external connector configured to slide over the metal profiles to safely, greatly and tightly attach the metal profile to the supporting structure and also joints two metal profiles when such extensions are needed.♦♦♦ A ceiling hook for providing a strong grip with the main structure, it has three pre-punched chamfered holes to facilitate fixing to the main structure on one side and two rows and three notches on the other side for hooking with the dropdown.♦♦♦ A dropdown element is configured to level the ceiling height and connect the ceiling hook with the external connector.♦♦♦ A bracing profile enables the wall and ceiling system to resist horizontal forces i.e. racking forces, applied to the building by wind and / or earthquakes.

2. The system as claimed in claim 1, wherein the length of the flanges is in the range of 36- 48mm in length, but this length of the flanges can be altered. The extremities of the flanges are each folded by 180° degrees over one third of the flange’s length to increase rigidity, stiffness and load capability of the metal profile.

3. The system as claimed in claim 1, wherein the web contains a perforated H- shaped bracing way to fit the bracing profile doubled by service pre-cuts on both webs at 10mm from the edges of the bracing profde’s ‘H’ perforations and of 50mm length.

4. The system as claimed in claim 1, wherein the anchors flanges’ length is in range of 50- 70mm.

5. The system as claimed in claim 1, wherein the ceiling hook is cold formed in an ‘L’ shape from galvanized steel in thicknesses in the range of 0.70 to 2.50mm.

6. The system as claimed in claim 1, wherein the ceiling hook is connected to the dropdown element through two rows at 5mm gap each of three notches of 10x5mm.

7. The system as claimed in claim 1, wherein the bend height of dropdown element is of 30mm and bent at an angle of 30°.

8. The system as claimed in claim 1, wherein the length of the dropdown is in the range of 300-2000mm, and thickness is in the range of 0.70 to 2.50mm.

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