IL268703A

IL268703A - Two sided panel with foam concrete filling for walls

Info

Publication number: IL268703A
Application number: IL26870319A
Authority: IL
Inventors: Algazi Shmuel
Original assignee: Algazi Shmuel
Priority date: 2019-08-14
Filing date: 2019-08-14
Publication date: 2021-03-01
Also published as: WO2021028901A1

Description

111t FIG. 1 103a 107 100 109 111h C 106a 111c 102 104 108 103d 103c 102 111w 110 103b 106b 1 11FIG. 2 103a 108 C 102 107 109 106a 108 103c 102 206 2 11FIG. 3 302 Decorative board(s 304 Low density cement 306 frame 3 11FIG. 4 412 Place track 413 Supply a plurality of panels 414 Cut panel to fit and/or install guide 418 Position panel 420 Attach panel 4 11FIG. 5 406 Attach frame and/or guides to back of first decorative board 403 Supply low density cement (LDC) 404 Fill frame with LDC 402 Position second decorative board st opposite 1 sheet 406 ’ nd st Attach 2 sheet opposite 1 sheet / 11FIG. 6 607 600 B ’ 610 A ’ 602 609 606a 608 608 602 ’ 606c A 606b B 6 / 11607 FIG. 7 600 609 606a 602 ’ 602 704 606b 7 / 11FIG. 8 600 606d 610 602 ’ 602 704 606c 8 / 11111t FIG. 9 107 900 103a 109 111h 106a 111c 102 907 108 103d 102 ’ 103c 103b 111w 106b 9 / 11FIG. 10 1000b 1000a 1072 1012a 1012c 1012b 1074 1080 / 11FIG. 11 1104 11 / 11 TWO SIDED PANEL WITH FOAM CONCRETE FILLING FOR WALLS FIELD AND BACKGROUND OF THE INVENTION The present invention, in some embodiments thereof, relates to a wall panel and, more particularly, but not exclusively, to a wall panel with a metal frame and gypsum facing. U.S. Patent No. 3,736,715 appears to disclose, “A prefabricated load-supporting building panel ... The panel consists of a metal stud frame to which a sheet of moisture proof gypsum board is affixed. A thickness of molded polystyrene, supported by a peripheral casing attached to the frame, is bonded to the gypsum board. Exterior finish for the panel consists of synthetic plastic which is trowled onto a glass fiber fabric bonded to the polystyrene.” U.S. Patent No. 4,161,087 appears to disclose, “A building wall panel [that] includes vertical studs welded to top and bottom channels to provide a rigid framework the maximum width of which is such that the panels may be transported over highways and the length of which is determined by the wanted wall height. Finish sheet material is secured to the inner or rear surfaces of the framework to provide an inner wall.

Sections of insulating material are lodged in the rectangular spaces of the framework against a vapor barrier backed by the inner wall and dimensioned to be spaced from the outer surfaces of the framework. A vertically spaced, series of horizontal sub-girts has one secured to each channel and others secured to the studs and the sub-girts secured and the channels may be used to secure flashing. Metal panelling is secured to the sub- girts to provide an outer wall thus providing the panel with a dead airspace. The framework is modified to meet door and window requirements. In installation, the end edges of adjacent panels are interconnected, the lower edges of the panels are secured to lengthwise retainers anchored to the floor and upper portions are connected to roof structure.” U.S. Patent No. 7,849,650 B2 appears to disclose, “A fire resistive assembly including metal framing members, for example, C-joists, U-joists, open web joists, HAMBRO or other metal frame systems that support a reinforced, light-weight, 1 dimensionally stable SCP panel. The assembly is non-combustible, water durable, mold and rot resistant, termite resistant and is capable of resisting shear loads equal to or exceeding shear loads provided by plywood or oriented Strandboard panels. The panels employ one or more layers of a continuous phase resulting from the curing of an aqueous mixture of inorganic binder, for example, calcium Sulfate alpha hemihydrate, hydraulic cement, an active pozzolan and lime. The continuous phase is reinforced with glass fibers and contains lightweight filler particles, for example, ceramic microspheres.” U.S. Patent No. 2008/0295450 A1 appears to disclose, “A multi-layer prefabricated wall panel for modular building and a method for manufacturing the same. The panel comprises a load-bearing and vapor barrier core layer, an interior insulating and utility installation layer bonded to the inner face of the core layer; an exterior sheet of a first rigid building material bonded to the interior insulating layer; and an interior sheet of a second building material bonded to the outer face of said core layer. The method for manufacturing the wall panel comprises the steps of forming a stack of the panel layers with adhesive coating between successive layers and bonding the layers to each other by uniform compressing forces.” U.S. Patent No. 2010/0146874 A1 appears to disclose, “A non load-bearing interior demising wall construction comprising a plurality of CAF panels each sized to span the full wall height and placed in aligned edge to edge abutted position and a plurality of stiffening means also sized to span the full wall height. CAF panels and stiffening means slidably disposed within a top and bottom track and sized to provide a friction fit therein. A plurality of wall facing sheets sized to span the full wall height placed in edge to edge abutted position to as to provide a seamless wall face with said wall facing sheets residing outside said top and bottom tracks and attached to said stiffening means. Preferably, top and bottom track and stiffening means are comprised of readily available standard drywall materials.” U.S. Patent No. 2011/0162293 A1 appears to disclose, “A volumetric module that can have all of its exterior claddings, windows, doors, interior finishes, cabinetry, plumbing, electrical, mechanical, and roofing installed and completed in the factory minimizing work to be completed in the field, and a method to protect the fully finished building module during transport with a series of demountable transport panels. The finished and protected building module is transported to a site utilizing the intermodal 2 shipping network or by different modes of shipping and transportation. At the building site, the finished building module is placed on a foundation or other form of support, the transport panels are removed from the module revealing a fully finished building module suitable for use as a habitable building both in it singular use as well as the creation of a larger habitable building by joining finished building modules at the building site.” U.S. Patent No. 2016/0160515 A1 appears to disclose, “Construction systems for erecting budding structures comprise a plurality of prefabricated interconnectable modular budding units, each unit comprising framing members and a plurality of nodes, each node situated for selective interconnection with other units, the nodes and the exterior dimensions of the frame conforming to ISO shipping standards such that each unit is transportable using the ISO intermodal transportation system, and such that when the units are interconnected, a building structure is formed. The modular units are assembled at a remote location, and are there constructed to a semi-finished state, following which the semi-finished modular units are transported from the remote location to the job site, where they are secured to form the structure being erected, and the semi-finished modular units are thereafter constructed to a finished state.” SUMMARY OF THE INVENTION According to an aspect of some embodiments of the invention, there is provided a method of manufacturing a wall panel including: attaching a first edge of a frame to the back of a first decorative board; filling the frame with foam concrete; attaching the back of a second decorative board to a second edge of the frame opposite the first edge thereby sandwiching the frame between the first decorative board and the second decorative board and enclosing the foam concrete in a space delineated on opposite sides by the first decorative board the second decorative board and the frame.

According to some embodiments of the invention, the attaching forms an open- faced enclosure on a back face of the first decorative board.

According to some embodiments of the invention, the attaching is performed while the foam concrete is still wet.

According to some embodiments of the invention, further includes: mixing the foam concrete includes forming a mixture of between 50% to 90% binder with between 3 % to 30% aggregate and a foaming agent foaming the mixture.

According to some embodiments of the invention, the frame is formed of at least one of iron, steel and aluminum.

According to some embodiments of the invention, the first decorative facing is an interior wall panel.

According to some embodiments of the invention, the second decorative facing is an interior wall panel.

According to some embodiments of the invention, the method where the first decorative facing is at least one of gypsum board and cement board.

According to some embodiments of the invention, the attaching of at least one wall of the frame is inset at least 3 cm from an edge of the first decorative facing.

According to some embodiments of the invention, the attaching of at least two walls of the frame are inset at least 3 cm from an edge of the first decorative facing.

According to some embodiments of the invention, the attaching of a top wall of the frame is inset at least 10 cm from a top of the first decorative facing.

According to an aspect of some embodiments of the invention, there is provided a method of installing an interior wall panel including: supplying a plurality of wall panels each wall panel including two decorative boards joined by a frame, the frame surrounding a filler of foam concrete; installing a track; cutting each plurality of wall panel to a length that matches the height of the wall from a floor to a ceiling; positioning the plurality of wall panels along the track to form a continuous wall.

According to some embodiments of the invention, the method further includes: installing a plurality of vertical studs and wherein the positioning is with a frame of a at least one wall panel of the plurality of wall panels on each of two opposing sides of each stud of the plurality of vertical braces and the decorative boards overlapping a front face and a back face of the each stud.

According to an aspect of some embodiments of the invention, there is provided a wall panel having a top edge, a bottom edge and two side edges including: a first board having a decorative front and a back; a second board having a decorative front and a back; a frame joining the back of the first decorative board parallel to a the back of the second decorative board; foam concreted filling the frame and sandwiched between the back of the first decorative board and the back of the second decorative board. 4 According to some embodiments of the invention, the frame is inset at least 3 cm from at least one of the side edges.

According to some embodiments of the invention, the frame is inset at least 3 cm from at least two of the side edges.

According to some embodiments of the invention, the frame is inset at least 10 cm from the top edge.

According to some embodiments of the invention, the wall panel of system further includes an upper guide joining a back of the first board to a back of the second board at least 3 cm above the frame.

According to some embodiments of the invention, the first board is an indoor wall board.

According to some embodiments of the invention, the second board is an indoor wall board.

According to some embodiments of the invention, the first board and second board include at least one of gypsum board and cement board.

According to some embodiments of the invention, the foam concrete includes a mixture of between 50% to 90% binder with between 10% to 30% aggregate.

According to some embodiments of the invention, the foam concrete has a density of between 300 to 1000 kg/m3. Unless otherwise defined, all technical and/or scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention pertains. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of embodiments of the invention, exemplary methods and/or materials are described below. In case of conflict, the patent specification, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and are not intended to be necessarily limiting. BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS Some embodiments of the invention are herein described, by way of example only, with reference to the accompanying drawings. With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and 5 for purposes of illustrative discussion of embodiments of the invention. In this regard, the description taken with the drawings makes apparent to those skilled in the art how embodiments of the invention may be practiced.

In the drawings: FIG. 1 is a cross-sectional view of a wall panel in accordance with an embodiment of the current invention; FIG. 2 is a perspective close-up view of a wall panel in accordance with an embodiment of the current invention; FIG. 3 is an exemplary block diagram illustrating the relationship between the components of a wall panel in accordance with an embodiment of the current invention; FIG. 4 is a flow chart illustration of a method of installing wall panel in accordance with an embodiment of the current invention; FIG. 5 is a flow chart illustration of a method of manufacturing a wall pane in accordance with an embodiment of the current invention; FIG. 6 is a perspective view of a wall panel in accordance with an embodiment of the current invention; FIG. 7 is a longitudinal cross-sectional, perspective view of a wall panel; FIG. 8 is a lateral cross-sectional, perspective view of a wall panel; FIG. 9 is a cross-sectional view of a wall panel with a male coupling in accordance with an embodiment of the current invention; and FIG. 10, is a schematic illustration of a wall in accordance with an embodiment of the current invention; and FIG. 11 is an image of a block of LCD concrete in accordance with an embodiment of the current invention. DESCRIPTION OF SPECIFIC EMBODIMENTS OF THE INVENTION The present invention, in some embodiments thereof, relates to a wall panel and, more particularly, but not exclusively, to a wall panel with a metal frame and gypsum facing.

Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not necessarily limited in its application to the details of construction and the arrangement of the components and/or methods set forth in the 6 following description and/or illustrated in the drawings. The invention is capable of other embodiments or of being practiced or carried out in various ways. OVERVIEW An aspect of some embodiments of the current invention relates to a prefabricated wall panel. Optionally, the wall panel has decorative facing on opposite sides and a frame inset around the edges. For example, panel may be used to build an interior non-load bearing partition wall. Low density concrete optionally fills the frame in between the boards.

An aspect of some embodiments of the current invention relates to a wall built of prefabricated panels. Optionally, the panels are supported by rails and/or studs. For example, each panel is slid onto and/or attached to the rails and/or studs. The boards optionally overlap the rails and/or studs. In some embodiments, each panel is the entire height of a standard room with an unfilled top section that can be cut to size to fit lower ceilings. DETAILED EMBODIMENTS Referring now to the drawings, FIG. 1 is a cross-sectional perspective view of a wall panel in accordance with an embodiment of the current invention. In some embodiments the wall panel 100 comprises a first decorative board 102 on a front face and a second decorative board 102’ a back face. Optionally, the wall panel comprises a frame with top and bottom members 106a, 106b. In some embodiments, the frame also includes side members (for example as illustrated in FIG. 2 side member 206 and/or in FIG. 6 and FIG. 8 frame side elements 606c and 606d). In some embodiments, the frame is inset from one, two, three or four edges (103a, 103b, 103c, 103d) of the decorative boards. For example, the inset may create an open channel at the edge of the panel 100. Optionally, the channel fits a wall stud and/or a rail. Optionally one or more frame members (e.g. top member 106a) may be inset further than the other members (e.g. bottom member 106b and/or side member 206). For example, there may be between 10 to 30 cm between the decorative boards that is empty between top frame member 106a and the top edge 103a of the panel. For example, when constructing a 7 wall, part of the empty section may be cut off for fitting the panel to a space. Optionally a guide 107 may be positioned between the edge of the frame 106a and the top edge 103a of the panel. In some embodiments, wall panel 100 is intended and/or installed as an internal partition wall. In some embodiments, wall panel 100 is intended and/or installed as a non-load bearing wall. For example, the decorative boards 102, 102’ may include gypsum boards and/or cement boards. Optionally a decorative face is facing outward and a back of the board 102 faces the frame, the filling and/or the other board 102’. Optionally the boards 102, 102’ are parallel to each other. Optionally, the boards 102, 102’ are the same size and/or mounted opposite each other such that 1, 2, 3, and/or 4 of the edges (103a, 103b, 103c, 103d) of the boards 102, 102’ line up to form a edge of the panel that is perpendicular to the boards.

In some embodiments, a frame member (e.g. 106a, 106b, 206c) and/or a guide (e.g. 107) comprise metal (for example galvanized steel and/or aluminum). For example, the metal could have a thickness of between 0.4 to 1.0 mm and/or between 0.1 to 0.4 mm and/or between 1 to 3 mm. Optionally, a frame member (e.g. 106a, 106b, 206c) and/or a guide (e.g. 107) may have a U-profile. Alternatively or additionally, a frame member (e.g. 106a, 106b, 206c) and/or guide (e.g. 107) may have a I-profile, a box-profile and/or another profile.

In some embodiments, a webbing of each side frame member (e.g. 206) and/or bottom frame member 106b and/or guide 107 may be inset between 0.1 to 5 cm from the corresponding edge (e.g. 103c, 103b and/or 103a respectively) of each decorative board 102, 102’. For example, the inset may fit a wall stud and/or a rail. For example, the stud and/or rail may hold the wall panel in place.

Optionally, the wall panel further comprises concrete filling 103 in the space between the decorative boards 102 and 102’. For example, the concrete filling may be sandwiched between the decorative boards 102, 102’ and/or surrounded on two, three or four sides by frame members (e.g. 106a, 106b, 206). Optionally, the concrete filling104 includes a low-density concrete (LDC), for example foam concrete. For 3 example, the density of the filing 104 may range between 100 to 350 kg/m and/or 3 3 between 350 to 500 kg/m and/or between 500 to 1200 kg/m and/or between 1200 to 3 2400 kg/m . In testing it was found that the best sound insulation was achieved for a 3 density between 400 to 450 kg/m . In some embodiments lower density may be used, for example to achieve a lighter panel. In some embodiments higher density may be 8 used, for example to achieve a stronger panel. For example, using filling of 400-500 3 kg/m a panel weight of approximately 70 kg. In some embodiments, the mass of a panel may range between 50 to 85 kg and/or between 85 to 100 kg and/or between 100 to 200 kg and/or between 25 to 50 kg.

In some embodiments the LDC filling 104 comprises air pockets. Optionally, air is added to concrete before, during and/or after it’s placement between the decorative boards 102, 102’. Additionally, or alternatively, the foamed concrete includes a foaming agent (e.g. a protein foaming agent (e.g. hydrolysed animal carcass residues) and/or a surfactant for example detergent and/or soap). Optionally, the foamed concrete includes approximately 50 grams to 200 grams of foaming agent per liter of water added to the mixture. Additionally, or alternatively, the foamed concrete mixture may include for example between 0.1% to 1% and/or 1% - 10% and/or between 10 to 30% foaming agent. Additionally, or alternatively, the foamed concrete comprises ground rock.

Optionally, the foamed concrete comprises approximately between 5% to 10% and/or between 10% to 25% and/or between 25% to 35% and/or between 35% to 50% aggregate. For example, aggregate may include ground rock and/or sand. For example, the diameter of aggregate particles may range between 0.01 to 0.4 mm and/or between 0.4 to 1.2 mm and/or between 1.2 to 3 mm. For example, the mean aggregate diameter may range between 0.4 to 1.2 mm.

In some embodiments the LDC concrete comprises one or more substances other than concrete. For example, the foamed concrete may comprise concrete and one of air, soap, ground rocks, sand and a surfactant. Additionally, or alternatively, the foamed concrete comprises a plurality of substances other than concrete.

In some embodiments the foamed concrete is manufactured by mixing cement, water and a small amount of a foaming agent. Optionally, the cement used is Portland cement and/or a similar cement. Optionally, the foaming agent includes a protein and/or a surfactant for example detergent. Optionally, this mixture creates a foam, for example the mixture may be mixed with water and/or air. For example, the mixture may whipped to form a foam.

In some embodiments, the use of foamed concrete as the concrete filling 104 provides a lower density to the wall panel as compared to a wall panel comprising standard concrete. Optionally, the LDC has a density between approximately 300 9 kg/m3 and 1000 kg/m3. For example, foamed concrete may have a density of approximately 400 kg/m3.

In some embodiments the wall panel 100 has a width 111w of approximately 40 cm to 80 cm. For example, the wall panel 100 may have a width 111w of approximately 60 cm. Optionally, the wall panel 100 has a thickness 111t of approximately 5 cm to 20 cm. For example, the wall panel 100 may have a thickness 111t of approximately 10 cm. Optionally, the wall panel 100 has a height 111h of approximately 250 cm to 310 cm. For example, each decorative board 102, 102’may have a thickness ranging between 6 to 16 mm and/or between 3 to 6 mm and/or between 16 to 32 mm. For example, the filling 104 of foam concrete may have a thickness ranging between 60 to 80 mm and/or between 80 to 120 mm and/or between 30 to 60 mm and/or between 10 to 30 mm. For example, the wall panel 100 may have a height 111h of approximately 280 cm.

In some embodiments the height 111h of the wall panel 100 is approximately cm to 30 cm greater than the standard and/or desired height of a wall panel. For example, the height 111h of the wall panel 100 may be approximately 20 cm greater than the standard height of a room (e.g. from ceiling to floor).

In some embodiments the left side and/or right side of a wall panel 100 frame comprise side frame elements (e.g. 206). Optionally, side elements 207 extend from a bottom member 106b of the frame to the top element 106a of the frame. Additionally, or alternatively, side elements 207 extend from a bottom edge 103b of the wall panel 100 to the top edge 103a of the wall panel 100. In some embodiments, there is extra space between one or more of the frame members (e.g. 106a, 106b, 206) and one or more corresponding edges (e.g. 103a, 103b, 103c respectively) of the panel 100.

Optionally, top frame member 106a is positioned 111c approximately 10 cm to 30 cm below the top edge 103a of the wall panel 100. For example, side members (e.g. 207) of the frame may extend from the bottom member 106b to the top member 106a approximately 20 cm below the top edge 103a of the wall panel 100. Optionally a channel 109 between a guide 107 and a corresponding frame member 106a may be empty and/or may be used as a channel 109 for wiring and/or plumbing in a wall.

In some embodiments the height of a wall panel may be reduced by cutting the gypsum facing. Optionally, a portion of the space between decorative boards 102, 102’ does not contain concrete. Optionally, the space between front side gypsum board 102 and back side gypsum board 102’ is hollow. For example, the hollow section of the wall panel 100 may be cut to adjust the height 111h of the panel.

In some embodiments part of the space between board 102 and board 102’ is partially filled with concrete. Optionally, the space between the board 102 and board 102’ is filled with concrete from the bottom member 106b of internal frame of the wall panel 100 to a top member 106a of the frame. Optionally the space is below the top edge 103a of the wall panel 100 and above the top frame member 106a. Optionally, the space between top edge 103a of the wall and the top frame member 106a is hollow and/or contains a guide 107.

In some embodiments, a hollow space between the board 102 and the board 102’ facilitate the cutting of the wall panel 100 to size. For example, the hollow space between the top member 106a of the frame and the top edge 103a of the panel 100 may be cut to trim the panel 100 to a desired height. Optionally, the top guide 107 is disconnected from the panel 100 before the system is cut to size and/or is reconnected to the wall panel 100 after the wall panel 100 is cut to a desired height. Additionally, or alternatively, the top guide 107 is supplied separate from the panel and is connected to the wall panel 100 after the panel 100 is cut to a desired height.

In some embodiments, a frame member 106a, 106b and/or 206 and/or a guide 107 is attached to one or more of the decorative boards 102, 102’ with screws 108.

Optionally, when trimming the top of panel 100, guide 107 is removed and reconnected to the decorative boards 102, 102, by removing and/or reinstalling screw 108.

In some embodiments the wall panel 100 functions as a panel of an internal wall.

Additionally, or alternatively, the wall panel 100 functions as a panel of an external wall. Optionally, the front board 102 of a wall panel 100 is used as an external wall panel and/or includes an external facing and/or faces outside the building. Optionally, a front board 102 that faces outside a building comprises facing other than gypsum.

Optionally, the front board 102 facing outside a building comprises a weatherproof facing.

In some embodiments, a wall panel will include complimentary coupling elements for attachment of wall panels. For example, one edge 103c of a wall panel 100 may include a female coupling (e.g. the frame side element 207 may be inset from the side edge 103c). For example, an opposite edge 103d of a wall panel 100 may include a male couple (e.g. the frame side element and or a guide may protrude from the side 11 edge 103d) (for example as illustrated in FIG. 9). Optionally, wall panels may be assembled one next to the other with complimentary coupling elements attaching one panel 100 to another panel 100.

In some embodiments, a decorative board 102, 102’ may include tapered edges.

Optionally, the wall panel 100 edges taper until they are thin enough to allow the placement of plaster on a joint without causing the joint to protrude.

In some embodiments, filler material 104 (e.g. the foamed concrete) will hold a screw without the need for a dibble and/or will be workable for example with a router (for example to create a channel in which to run wiring and/or an opening in which to install and electrical socket and/or switch). In some embodiments the foamed concrete is sufficiently soft to allow for its use with a router. For example, the foamed concrete may be used as wood is used.

FIG. 2 is a perspective close-up view of an area C of a wall panel in accordance with an embodiment of the current invention.

FIG. 3 is an exemplary block diagram illustrating the relationship between the components of a wall panel in accordance with an embodiment of the current invention.

Optionally, two decorative boards 302 are joined by a frame 306. For example, the frame 306 may be inset from the edges of the board 302 leaving an open channel along one or more sides and/or a top and/or a bottom of the panel. Optionally a guide may close one or more of the channels. In some embodiments, the frame 306 is attached to the decorative boards 302, for example with screws. In some embodiments, on one or more sides, a frame 306 and/or one or more guides may protrude beyond the edge of the decorative boards 302. For example, the protruding frame 306 may be included in a male coupling that connects to a female coupling (e.g. an open channel) on an edge of another panel. Optionally, a relatively large area is left on at least one edge of the panel (for example a top edge thereof) without filling 304. A portion area without may be cut off, for example to trip the panel to size.

FIG. 4 is a flow chart illustration of a method of installing wall panel in accordance with an embodiment of the current invention. In some embodiments, a track is placed 412 in a room for example delineating a place for a partition wall. The track may include an upper rail, for example attached to a ceiling. Additionally or alternatively, the track may include a lower rail for example attached to a floor.

Additionally or alternatively, the frame may include vertical studs, for example running 12 from the upper rail to the lower rail and/or from the ceiling to the floor. In some embodiments, a plurality of prefabricated panels is supplied 413. For example, a panel may include two decorated boards joined by a frame and/or LDC (e.g. as described in any of the embodiments herein). Optionally, a panel may be cut 414 to fit. For example, a portion of an unfilled top section of the panel may be cut 414 off such that the length of the panel so just fits between a floor and ceiling of a room. Optionally a guide is installed between the cut edge of the panel. For example, the guide may stabilize the edge and/or attach 420 to the track. In some embodiments, the panels are positioned 418 along the track. For example, an open channel at an edge of a panel may fit over a portion of the track. Optionally, an edge of a decorative board may overlap the face of the track. For example, a front face of a top track may be completely covered by a front board extending below a frame of the panel. For example, a rear face of a top track may be completely covered by a rear board extending below a frame of the panel. For example, a left side of a front face of a vertical stud may be covered by a front board extending to the right of a frame of a panel on the left side of the stud. For example, a right side of a front face of a vertical stud may be covered by a front board extending to the left of a frame of a panel on the right side of the stud. For example, a left side of a rear face of a vertical stud may be covered by a rear board extending to the right of a frame of a panel on the left side of the stud. For example, a right side of a rear face of a vertical stud may be covered by a rear board extending to the left of a frame of a panel on the right side of the stud. Optionally, edges of adjacent boards meet. For example, sides of two adjacent boards may overlap a stud and/or may meet at the stud. Optionally, the edges may be tapered where they meet and/or the joint may be smoothed for example with joint compound and/or joint tape. In some embodiments the wall panels are attached 420 to the track, the floor, the ceiling and/or each other. For example, a panel may be screwed to a lower rail and/or an upper rail and/or a stud. Alternatively or additionally, adjoining panels may be attached 420 without a stud. For example, the adjoining panels may have complimentary coupling elements at adjacent edges.

FIG. 5 is a flow chart illustration of a method of manufacturing a wall panel in accordance with an embodiment of the current invention. For example, a frame may be attached 406 to a back of a first decorative board. Optionally, the frame and/or the board form an open-faced hollow. Optionally, LDC is supplied 403 and/or used to fill 404 the hollow of the frame. 13 In some embodiments, supplying LDC includes forming foam concrete. For example, forming the concrete may include adding aggregate into a foamed cement.

For example, the cement may include various Portland and/or other forms of binder and/or a foaming agent. Optionally, the aggregate includes ground rock and/or sand.

Optionally, the stone and/or sand is added while continuing to mix the foam concrete mixture. Optionally, the mixing continues as the third stage of the preparation of the foamed concrete, after the addition of stone and/or sand. For example, mixing continues until the foam contains a desired air content and/or until the foam stabilizes. Optionally, this three-stage process adds strength and/or lightness to the foamed concrete.

Optionally, the foamed concrete is lighter than standard concrete and/or stronger than generally available foamed concrete.

Optionally, the frame of the panel is filled 404 with wet concrete foam.

Additionally, or alternatively, the foamed concrete includes a foaming agent (e.g. a protein foaming agent (e.g. hydrolyzed animal carcass residues) and/or a surfactant for example detergent and/or soap). Optionally, the foamed concrete includes approximately 50 grams to 200 grams of foaming agent per liter of water added to the mixture. Additionally, or alternatively, the foamed concrete mixture may include for example between 0.1% to 1% and/or 1% - 10% and/or between 10 to 30% foaming agent. Additionally, or alternatively, the foamed concrete comprises ground rock.

Optionally, the foamed concrete comprises approximately between 5% to 15% and/or to 35% and/or between 35% to 50% aggregate. For example, aggregate may include ground rock and/or sand. For example, the diameter of aggregate particles may range between 0.01 to 0.4 mm and/or between 0.4 to 1.2 mm and/or between 1.2 to 3 mm.

For example, the mean aggregate diameter may range between 0.4 to 1.2 mm.

In some embodiments the LDC concrete comprises one or more substances other than concrete. For example, the foamed concrete may comprise concrete and one of air, a foaming agent and/or an aggregate. Additionally, or alternatively, the foamed concrete comprises a plurality of substances other than concrete.

In some embodiments the foamed concrete is manufactured by mixing cement, water and a small amount of a foaming agent. Optionally, the cement used is Portland cement and/or a similar cement. Optionally, the foaming agent may include a protein and/or a surfactant for example hydrolyzed animal carcass residue, a detergent and/or 14 soap. Optionally, this mixture creates a foam, for example the mixture may be mixed with water and/or air. For example, the mixture may whipped to form a foam.

In some embodiments, the use of foamed concrete as the concrete filling provides a lower density to the wall panel as compared to a wall panel comprising standard concrete. Optionally, the LDC has a density between approximately 300 kg/m3 and 1000 kg/m3. For example, foamed concrete may have a density of approximately 400 kg/m3.

In some embodiments, a second decorative board is positioned 402 and/or attached 406’ to the frame and/or the filler parallel to and/or facing the back of the first decorative board. In some embodiments the first and/or second decorative board may include gypsum board, cement board, an indoor wall board and/or an outside wall board. Optionally some or all of the edges of the board may be tapered.

In some embodiments, one or more guides are positioned between the boards and/or attached to the boards. Optionally, guides may be attached between an edge of the frame and an edge of the decorative boards. For example, the frame may be attached between the top of the frame and a top edge of the board. For example, a space between a guide and the frame may be used for trimming the panel. Optionally, after the panel is assembled, the filler is allowed to dry and/or form a solid matrix FIG. 6 is a perspective view of a wall panel 600 in accordance with an embodiment of the current invention. Optionally the structure and/or materials of panel 600 may be the same as described with regards to panel 100. Additionally or alternatively, panel 600 may be made as described with regards to FIG. 5. Additionally or alternatively, panel 600 may be installed into a room as described with regards to FIG. 4 and/or FIG. 10.

In some embodiments, the panel includes two parallel decorative boards 602 and 602’ with backs facing each other and/or decorative facings facing outward.

Optionally the lengths of boards 602, 602’ are sized to fit from ceiling to floor in a standard room and/or slightly longer (allowing to cut the length of the boards to fit the height of a wall exactly). Optionally the widths of boards 602, 602’ are sized to fit between studs (and/or overlapping studs for example, between the centers of adjacent studs) in a standard room and/or slightly longer (allowing to cut the length of the boards to fit between studs exactly). Optionally, a frame includes frame elements 606a, 606b, 606c and/or 606d (e.g. see FIG. 8). Frame elements 606a, 606b, 606c and/or 606d are 15 optionally attached to boards 602, 602’, for example with screws 608. Optionally each frame element serves as a wall to a LDC concrete filling 704 (e.g. see Fig. 7) of the panel 600. Optionally each frame element is inset from a corresponding edge of the boards 602, 602’. Optionally one or more guides 607 are installed between a wall of the frame and/or an edge of a board 602, 602’. For example, guide 607 is attached between a top element 606a of the frame and a top edge of the boards 602, 602’. For example, a closed channel 609 may be formed between the guide 607 and/or the frame (e.g. frame element 606a). Optionally attachment of guide 607 to boards 602, 602’ may be by means of screws 608. Optionally a frame element and/or a guide may protrude to form a male coupling.

FIG. 7 illustrates a longitudinal cut along line B-B’ cross-sectional view of a wall panel 600.

FIG. 8 illustrates a lateral cut along line A-A’ cross-sectional view of a wall panel 600.

FIG. 9 is a cross-sectional view of a wall panel 100 with a male mating profile in accordance with an embodiment of the current invention. In some embodiments, multiple wall panels may have interlocking features. For example, a wall panel 900 may have a female coupling on one edge 103d (e.g. the female edge may be similar to edge 103b and/or edge 103c of panel 100 of FIG. 1) and a complimentary male coupling 907 protruding from an opposite edge 103c. When two wall panels 900 are positioned side by side, male coupling 907 may fit into female channel at edge 103d of an adjacent panel 900. The connection between the male and female couplings may stabilize the wall without vertical studs and/or with fewer vertical studs (for example there may be 2 to 5 and/or 5 to 10 interconnected panels without vertical studs (optionally connected to an upper and/or lower rail). Then there may be a stud coupled to two adjacent panels and/or then there may be more interlocking panels.

FIG. 10, is a schematic illustration of a wall in accordance with an embodiment of the current invention. For example, an interior partition wall 1080 may include a track. Optionally partition wall 1080 may be constructed as described in the flow chart of FIG. 4 and/or the accompanying description. For example, the track may include a lower rail 1012b. For example, rail 1012b may be attached to a floor 1074. For example, the track may include an upper rail 1012a. For example, rail 1012a may be attached to a ceiling. Optionally, there may be one or more vertical studs 1012c. For example, studs 16 1012c may run from a lower rail 1012b to an upper rail 1012a and/or from a floor 1074 to a ceiling. Optionally one or more panels 1000a, 1000b may be attached to a rail 1012a, 1012b and/or to a stud 1012c. For example, panels 1000a, 1000b may include panels as described in panels 100, 600. Optionally, a lower rail 1012b may fit into an open channel between the lower edges of decorative boards of the panel 1000a, 1000b.

Optionally, an upper rail 1012a may fit into an open channel between the upper edges of decorative boards of the panel 1000a, 1000b. Optionally, a vertical stud 1012c may be fit into side channels of adjacent panels 1000a, 1000b. Optionally, one or both faces of the wall is completely covered by adjacent decorative boards of the panels 1000a, 1000b. In some embodiments, panels 1000a, 1000b are attached to upper and/or lower rails 1012a, 1012b and/or studs 1012c, for example with screws.

In some embodiments, a wall may not include vertical studs 1012c and/or may include fewer vertical studs 1012c. For example, wall panels 900 may be interlocked at some points without vertical studs. Optionally vertical studs will be supplied at one or more ends of a partition wall 1080, for example on wall 1072. Alternatively or additionally, there may be some vertical studs 1012c. For example, there may 1 to 5 and 5 to 10 or more interlocked panels 900 and then a stud interconnected to female panels 100 etc. Panels 900 are optionally attached to an upper rail 1012a and/or a lower rail 1012b.

FIG. 11 is an image of a block 1104 of LCD concrete in accordance with an embodiment of the current invention. In some embodiments, the matrix of LCD concrete is strong and/or dense enough to hold a screw. In some embodiment, the matrix is soft enough to be worked with woodworking type tools (for example a drill and/or a router). The LCD concrete may have other properties, for example as described in embodiments herein above. It is expected that during the life of a patent maturing from this application many relevant technologies will be developed and the scope of the terms studs, decorative boards used herein is intended to include all such new technologies a priori.

As used herein the term “about” and “approximately” refer to ± 10%.

The terms "comprises", "comprising", "includes", "including", “having” and their conjugates mean "including but not limited to".

The term “consisting of” means “including and limited to”. 17 The term "consisting essentially of" means that the composition, method or structure may include additional ingredients, steps and/or parts, but only if the additional ingredients, steps and/or parts do not materially alter the basic and novel characteristics of the claimed composition, method or structure.

As used herein, the singular form "a", "an" and "the" include plural references unless the context clearly dictates otherwise. For example, the term "a compound" or "at least one compound" may include a plurality of compounds, including mixtures thereof. Throughout this application, various embodiments of this invention may be presented in a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the invention. Accordingly, the description of a range should be considered to have specifically disclosed all the possible subranges as well as individual numerical values within that range. For example, description of a range such as from 1 to 6 should be considered to have specifically disclosed subranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6 etc., as well as individual numbers within that range, for example, 1, 2, 3, 4, 5, and 6. This applies regardless of the breadth of the range.

Whenever a numerical range is indicated herein, it is meant to include any cited numeral (fractional or integral) within the indicated range. The phrases “ranging/ranges between” a first indicate number and a second indicate number and “ranging/ranges from” a first indicate number “to” a second indicate number are used herein interchangeably and are meant to include the first and second indicated numbers and all the fractional and integral numerals therebetween.

It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable subcombination or as suitable in any other described embodiment of the invention. Certain features described in the context of various embodiments are not to be considered essential features of those embodiments, unless the embodiment is inoperative without those elements. 18 Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims.

All publications, patents and patent applications mentioned in this specification are herein incorporated in their entirety by reference into the specification, to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated herein by reference. In addition, citation or identification of any reference in this application shall not be construed as an admission that such reference is available as prior art to the present invention. To the extent that section headings are used, they should not be construed as necessarily limiting. 19

Claims

CLAIMED IS:

1. A method of manufacturing a wall panel comprising: attaching a frame to a back of a first decorative board; filling said frame with a foam concrete; attaching a back of a second decorative board to a second edge of said frame opposite said first edge thereby sandwiching said frame between said first decorative board and said second decorative board and enclosing said foam concrete in a space delineated on opposite sides by said first decorative board said second decorative board and said frame.

2. The method of claim 1, wherein said attaching forms an open-faced enclosure on a back face of the first decorative board.

3. The method of claim 1, wherein said attaching is performed while said foam concrete is still wet.

4. The method of claim 1, further comprises: mixing said foam concrete including forming a mixture of between 50% to 90% binder with between 10% to 30% aggregate and a foaming agent foaming said mixture.

5. The method of claim 1, wherein said frame is formed of at least one of iron, steel and aluminum.

6. The method of claim 1, wherein said first decorative board is an interior wall board.

7. The method of claim 6, wherein said second decorative board is an interior wall board.

8. The method of claim 6, where said first decorative board is at least one of gypsum board and cement board.

9. The method of claim 1, wherein said attaching of said frame includes attaching at least one wall of the frame inset at least 3 cm from an edge of said first decorative board.

10. The method of claim 1, wherein said attaching of said frame includes attaching least two walls of said frame inset at least 3 cm from an edge of said first decorative board. 20

11. The method of claim 1, wherein said attaching of a top wall of said frame is inset at least 10 cm from a top of said first decorative board.

12. A method of installing an interior wall panel comprising: supplying a plurality of wall panels each wall panel comprising two decorative boards joined by a frame, said frame surrounding a filler of foam concrete; installing a track; cutting each said plurality of wall panels to a length that matches a height of a wall from a floor to a ceiling; positioning said plurality of wall panels along said track to form a continuous wall.

13. The method of claim 12, further comprising: installing a plurality of vertical studs and wherein said positioning is with a frame of a at least one wall panel of said plurality of wall panels on each of two opposing sides of each stud of said plurality of vertical studs and said decorative boards overlapping a front face and a back face of said each stud.

14. A wall panel having a top edge, a bottom edge and two side edges comprising: a first board having a decorative front and a back; a second board having a decorative front and a back; a frame joining said back of said first decorative board parallel to a said back of said second decorative board; foam concreted filling said frame and sandwiched between said back of said first decorative board and said back of said second decorative board.

15. The wall panel of claim 14, wherein said frame is inset at least 3 cm from at least one of said side edges.

16. The wall panel of claim 14, wherein said frame is inset at least 3 cm from at least two of said side edges.

17. The wall panel of claim 14, wherein said frame is inset at least 10 cm from said top edge.

18. The wall panel of of claim 17, further comprising an upper guide joining a back of said first board to a back of said second decorative board at least 3 cm above said frame.

19. The wall panel of claim 14, wherein said first board is an indoor wall board.

20. The wall panel of claim 19, wherein said second board is an indoor wall board.

21. The wall panel of claim 20, wherein said first board and second board include 21 at least one of gypsum board and cement board.

22. The wall panel of claim 14, wherein said foam concrete includes a mixture of between 50% to 90% binder with between 10% to 30% aggregate.

23. The wall panel of claim 14, wherein said foam concrete has a density of 3 between 300 to 1000 kg/m . 22