WO2023248238A1

WO2023248238A1 - A lightweight construction element

Info

Publication number: WO2023248238A1
Application number: PCT/IN2023/050563
Authority: WO
Inventors: Kanakavel S; Vikram S
Original assignee: Saint-Gobain Placo
Priority date: 2022-06-21
Filing date: 2023-06-14
Publication date: 2023-12-28

Abstract

A lightweight construction element is disclosed comprising a first and a second flange member 10, 20 each having front face 13, 23 facing each other and back face 14, 24 non-facing each other. The first flange member and the second flange member 10, 20 are aligned alongside each other at a distance X. Further, the lightweight construction element comprises a plurality of web members 50, whereby, the length of the plate portion 51 of web members 50 defines the spacing between the first flange member 10 and the second flange member 20. The plurality of web members 50 are physically coupled to the first and second flange members 10, 20 by attaching to either the front surface 13, 23, or the back surface 14, 24 of each flange member 10, 20, and are bent at an angle ranging between 90-110 degrees to the plate portion 51 along the attachment line 60. The plurality of web members 50 eliminate the need of a full length web and which results in reduction of metal usage and thus in turn reduced CO2 emission.

Description

A LIGHTWEIGHT CONSTRUCTION ELEMENT

Technical Field

The present disclosure relates to a lightweight construction element, in particular, to a lightweight construction element having a plurality of a web members spaced at a predetermined distance from each other. More specifically, the present disclosure relates to a lightweight construction element having two flange members spaced apart and coupled together with the plurality of web members.

Background

Conventional construction element and framing members have been widely used as a part of a drywall system wherein the construction panels are connected to the conventional construction element. A plurality of the conventional construction elements are placed at a predetermined spacing such that the construction panels can be installed and affixed to the conventional construction element from one or both sides. Typically, a conventional construction element is comprised of a central region which is the web with a minimum of two flanges rising from either side of the web. Typically, the conventional construction elements are formed from one piece of metal and weigh about 1.4kg to 1.6kg per meter for a height of around 3.2 meter to 3.6 meter. It is significant to note that the manufacture of every single conventional construction element involves a huge quantity of metal consumption.

Over the years, there have been various developments in the configuration and structure of the conventional construction element leading to its design improvements. These design improvements include various attempts at structural modifications of the conventional construction element structure, targeted towards varied functionalities not limiting to sound insulation and thermal insulation among others. There has also been attempts at design improvements for reduction of metal consumption in the past. However, past changes in designing and technology in this space have not resulted in substantially less metal usage over that of a conventional construction element.

For example, in the prior art KR20130036982A, there is a structural modification made to the web of the stud such that the web is bent in a W-shaped format which thereby delays the noise and vibration transmission path. Further, some of the embodiments of this prior art, disclose a plurality of slots in the web for blocking a sound and vibration transmission path. However, the structural modification doesn’t result in a substantial reduction in metal consumption or metal usage.

In yet another prior art WO2020125916A1, there has been a structural modification done in the web of the conventional construction element, which is a stud, aiming at the thermal decoupling of two limbs (or flanges). The webs in the prior art are in the form of plates which are fastened to a portion of the limbs. The structural modification so formed also results in reduced sound propagation. Still, there is no substantial reduction in metal usage of the stud and also the mode of connection of the web with the limbs could potentially result in disconnection of the joint during twisting and bending and thus resulting in the failure of the stud. In addition, it would be complex to manufacture and assemble the construction elements described in WO2020125916A1.

In the recent times, design improvements have also been targeted towards reduction in the weight of the stud, whereby skilled artisans explore means to reduce raw material consumption as a means of reducing the carbon footprint. It is well known that for construction and framing elements, each step of the manufacturing process (metal casting, metal forming, metal machining, metal joining, finishing and the related) involves a huge amount of CO2 emission.

Hence, there have been attempts in the prior art to reduce the weight of the conventional construction element. However, the prior art design modifications have certain drawbacks which include complexity in manufacturing and handling, additional manufacturing operation requirement, weakening of the construction element such that it is incapable of resisting forces such as bending moments or even punching of metal parts which thereafter leads to metal wastage.

For example, as in the prior art WO2017015766A1, a conventional web in a stud is replaced by a wire matrix which in turn also provides passages for utility lines. Though the prior art results in reduction of the overall weight of the construction element, the arrangement of the web adds complexity and demands a technical expertise for installation, thus increasing the cost.

Further, the prior art KR101637145B 1 describes a structural modification of the construction element, which is a stud, resulting in a lightweight partitioning stud. However, the complex arrangement makes the whole stud cumbersome to manufacture.

Thus, the known prior art references may result in reduction of metal usage and weight reduction of the construction element, but the solutions add complexity and difficulties to the manufacture of the products leading to increased manufacture and sale cost. Further, increased manufacturing complexity is likely to involve increased CO2 emission, which will offset any CO2 savings due to reduction in overall metal amount. Furthermore, there is no evidence in the prior art that the proposed lightweight construction elements do indeed result in decrement of CO2 emission.

Thus, there is still need in the art to develop a construction element, addressing the shortcomings of the prior art mentioned above. In particular, there is a need in the art to develop a lightweight construction element that results in reduced CO2 emission in the process of its manufacture and is simple and economical to manufacture.

Thus the present disclosure provides a lightweight construction element which eliminates the requirement of any additional manufacturing complexity, reduces the metal consumption and metal wastage and thereby results in a significant reduction in CO2 emission. Most importantly, the present disclosure results in a lightweight construction element which has 25-40% lower weight as compared to any conventional construction element.

Summary of the Disclosure

In one aspect of the present disclosure, a lightweight construction element is disclosed comprising a first and a second flange member and a plurality of web members. Each flange members have a front surface facing each other and a back surface non-facing each other. The first flange member and the second flange member are aligned alongside each other such that they are spaced at a distance X measured between the closest points on each flange member. Further, the flanges are such that they comprise a plurality of deformed regions and those deformed regions are aligned opposite and facing the deformed region in the flange. Each of the plurality of the web members have a plate portion with a length, width, a first edge region, a second edge region, a third edge region and a fourth edge region. The arrangement is such that the first edge region and the second edge region lies across the width of the plate portion, the third edge region and the fourth edge region lies along the length of the plate portion and the width of the plate portion defines the spacing between the first flange member and the second flange member. The plurality of web members are physically coupled to the first and second flange member via deformed regions on each of the first and second flange member.

In another aspect of the present disclosure, a method of making of a lightweight construction element is disclosed. The method involves the steps of placing the first and second flange members spatially separated from each other spaced at a distance X measured between the closest points on each flange member. Thereafter the first flange member and the second flange member is coupled together by providing multiple web members. Further, the web members are spaced at a distance of 50-300mm.

Yet another aspect of the present disclosure discloses a dry wall partition comprising a framing assembly. The framing assembly comprises a horizontal framing member fixed to the floor and another horizontal framing member fixed to the ceiling such that it is substantially parallel to and spaced from the horizontal framing member fixed to the floor, a plurality of lightweight construction elements and at least one construction panel. The plurality of lightweight construction elements are spaced vertically and mounted to the horizontal framing members at the top end and the bottom end. Further, the lightweight construction elements are mounted such that the flange members of the lightweight construction element abut and support the surface of the construction panel at positions outside the deformed regions of the flange members when at least one construction panel is fixed to one or either sides of the framing assembly.

Other features and aspects of this disclosure will be apparent from the following description and the accompanying drawings.

Brief Description of the Drawings

The present disclosure can be better understood, and its numerous features and advantages made apparent to those skilled in the art by referencing the accompanying drawings. Embodiments are illustrated by way of example and are not limited in the accompanying figures.

FIG. 1A illustrate a perspective view of a lightweight construction element in unassembled stage in accordance with one embodiment of the present disclosure;

FIG. IB illustrate a perspective view of a lightweight construction element in assembled stage in accordance with one embodiment of the present disclosure;

FIGS. 2A, 2B and 2C illustrate a perspective view of a web member in accordance with various embodiments of the present disclosure;

FIG. 3A illustrate a perspective view of a lightweight construction element in unassembled stage in accordance with another embodiment of the present disclosure;

FIG. 3B illustrate a perspective view of a lightweight construction element in assembled stage in accordance with another embodiment of the present disclosure;

FIG. 4A illustrate a perspective view of a lightweight construction element in unassembled stage in accordance with yet another embodiment of the present disclosure; FIG. 4B illustrate a perspective view of a lightweight construction element in assembled stage in accordance with yet another embodiment of the present disclosure;

FIG. 5A and 5B illustrate perspective views of a lightweight construction element in assembled stage in accordance with two other embodiments of the present disclosure; and

FIG. 6 illustrates a perspective view of a dry wall partition comprising a framing assembly along with drywall partition framing components in accordance with one embodiment of the present disclosure.

The use of the same reference symbols in different drawings indicates similar or identical items.

Skilled artisans appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments of the disclosure.

Features and advantages of the present disclosure will become more apparent in light of the following detailed description of embodiment, as illustrated in the accompanying figures. As will be realized, the disclosure is capable of modifications in various respects, all without departing from the present disclosure. Accordingly, the drawings and the description are to be regarded as illustrative in nature, and not restrictive.

Detailed Description

Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or similar parts. Hereinafter, exemplary embodiments of the present disclosure will be described in detail with reference to the accompanying drawings.

As used throughout, a “U-shaped” lightweight construction element is defined as a lightweight construction element comprising a pair of flanges substantially parallel to each other and connected substantially perpendicularly at their base by one or more web members.

As used throughout, a “C-shaped” lightweight construction element is defined as a lightweight construction element comprising a pair of flanges substantially parallel to each other and connected substantially perpendicularly at their base by one or more web members, with the pair of flanges having return edges pointing inwards substantially parallel to the web member.

As used throughout, a “I-shaped” lightweight construction element is defined as a lightweight construction element comprising a pair of flanges substantially parallel to each other and connected substantially perpendicularly by one or more web members, preferably positioned central to the pair of flanges. As used throughout, substantially parallel indicates parallel with +/- 10 degrees and substantially perpendicular indicates perpendicular with +/- 10 degrees.

FIG. 1A is a perspective view of a lightweight construction element 100a in unassembled stage in accordance with one embodiment of the present disclosure. The lightweight construction element comprises a first and second flange member 10, 20 and a plurality of web members 50. The web members 50 each comprise a plate portion 51 with a length and a width, a first edge region 52a, a second edge region 52b, a third edge region 53a and a fourth edge region 53b. In the present embodiment, the web member 50 and plate portion 51 is one and the same. The first edge region 51a and the second edge region 52a lies across the width of the plate portion 51 and the third edge region 53a and the fourth edge 53b lies across the length of the plate portion 51. Further, the width of the plate portion 51 defines the spacing between the first flange member 10 and the second flange member 20. The first and second flange member 10, 20 each has front surface 13, 23 facing each other and aback surface 14, 24 non-facing each other. The first flange member 10 and the second flange member 20 are aligned alongside each other spaced at a distance X between the closest points on each flange member 10, 20. Further, the closest points for measuring distance X there between the flange members 10, 20 lies at their respective edges or at their respective centers or at respective points lying between their edges at their centers. Each of the flanges 10, 20 comprise a plurality of deformed regions such that each of the deformed region in the first flange 10 is aligned opposite and facing the deformed region in the second flange 20. The deformed region in the present embodiment shown in FIG. 1A comprises apertures 30a and 30b. The apertures 30a, 30b are cut out from the first and second flange members 10, 20 and the cut portions of each flange is bent at right angles to the respective front surfaces 13, 23 of the flanges to form flap portions 31a, 31b. Additionally, in the present embodiment, the first and second flange member 10, 20 are extended along their respective first edge 11, 21 and second edge 12, 22 at a non-zero angle to their respective front surfaces 13, 23 to form stiffener members 15, 25 respectively. The stiffener members 15, 25 adds to the rigidity of the lightweight construction element and hence is capable to bear deflection. Optionally, in some other embodiment, the lightweight construction element 100a is without stiffener.

The FIG. IB depicts the perspective view of lightweight construction element 100a in assembled stage in accordance with another embodiment of the present disclosure. The web members 50, which are flat plates, are physically coupled to the flap portions 31a, 31b arising from the apertures of the first and second flange 10, 20. The aperture 30a and 30b are spaced at a distance 50 to 300 mm from each other. The coupling is done via by snap fitting, screwing riveting, bolting, nailing, welding, clinching or crimping or a combination thereof. In optional embodiments, the web member 50 can comprise pre-punctured holes for ease of screwing, nailing, riveting, or bolting, for example pre-punctured holes may be located near to all four comers of the web member. In the present embodiment, the web member 50 is devoid of pre-punctured holes.

The usage of web members 50 at pre-determined intervals reduces raw material consumption. It is to be noted here, the lightweight construction element in the present embodiment is an I-shaped drywall stud. In alternative embodiments, the drywall stud is C- shaped or U-shaped. For the embodiments to be U-shaped, the apertures are placed in alignment with the topmost or bottommost part of the first and second flanges 10, 20 such that the web member 51 when coupled with the flap portions arising from the apertures, lies at the top or bottom. C-shaped embodiments are similar to the U-shaped embodiments, but additionally with return edges along one edge of each flange, where the return edges are substantially parallel to the web members.

Web members 50 in other embodiment of the present invention have similar characteristics to the web member 50 as described above with reference to FIG. 1A. In furtherance to that, the web members 50 at the first edge region 52a and second edge region 52b are extended into glider portions 54 that are angled at right angle to the edges of the plate portion 51 and the third edge region 53a and the fourth edge region 53b are provided with at least one cut-out slot 55 as depicted in FIG. 2A and FIG. 2B. In some other embodiments, the web member 50 is without the cut-out slots 55 as depicted in FIG. 2C. This web member 50 arrangement is such that the glider portions 54 help to retain the web members 50 in place when coupled with the deformed regions in the first and second flange members 10, 20 of the lightweight construction element 100b or 100c. Further, the cut-out slots 55 minimizes the metal resistance to coupling and hence providing ease of installation. In yet another optional embodiment as depicted in FIG. 2B, the web member 50 has extended metal part 57 which further adds to the stiffness of the web member 50 and also further maintains it in place after the assembly. Additionally, in some other embodiments as depicted in FIG. 2C, the web member 50 are such that third and fourth edge region 53a, 53b of the web member 50 are placed perpendicular to the front surface 13, 23 of the flange member 10, 20. FIG. 3A illustrate a perspective view of a lightweight construction element 100b in unassembled stage in accordance with another embodiment of the present disclosure. The flange members 10, 20 in the present embodiment has deformations in the form of embossed portions 40a, 40b which are spaced at a distance of 50-300mm. The embossed portions 40a, 40b comprise slit opening 41a, 41b and 41a’, 41b’ at the top and bottom along their respective longitudinal axis. In some other embodiment, the embossed portions 40a, 40b comprise only one slit opening 41a, 41b. The embossed portions 40a, 40b are such that they have rectangular profile whose length matches in the length of the web members 50 and height H matches the height of the cut-out slots H’ in the web members 50. As depicted by a call-out, there can be two pattern of web members 50a, 50b. The web members 50a in the present embodiment are bent at right angle to the plate portion 51 at edge regions 53a, 53b (as depicted in FIG. 2A) to form a U-shaped profile. In some other optional embodiment, the web members 50b are bent at right angles to the plate portion 51 at edge regions 53a, 53b (as depicted in FIG. 2B) such that the edge regions53a, 53b are no longer opposed to each other.

The FIG. 3B depicts the perspective view of lightweight construction element 100b in assembled stage in accordance with another embodiment the present disclosure. The web members 50 are secured to the first and second flange 10, 20 by snap fitting wherein the bent parts of the web members 50 at the edge regions 53a, 53b are fitted into the slit opening 41a, 41b and 41a’, 41b’ of the embossed portions 40a and 40b of flanges 10, 20 respectively. The bent parts are slightly pressed inwards while going inside the slit openings 41a, 41b and 41a’, 41b’ whereby the glider portions 54 gets snap fitted with the bottom end of the embossed portions 40a, 40b and locks to provide strong fitment. The cut out slots 55 eases the pressing phenomenon by reducing the plate stiffness. It is to be noted, for the ease of fitment of the web members 50 into the embossed portions 40a and 40b of flanges 10, 20 respectively, the thickness of the web members 50 matches with that of the slit openings 41a, 41b and 41a’, 41b’ (as depicted in FIG 2A). In other optional embodiments wherein there is only one slit opening 41a, 41b at the top, the web members are devoid of glider portions 54 and the bent part of the web members 51 gets snap fitted inside the embossed portions 40a, 40b. Further, in the optional embodiments wherein the web member has extended metal part 57, the extended metal parts 57 help provide add-on stiffness to the web members 50 as well as aid in retaining the web members 51 within the embossed portions 40a, 40b. The web members are secured to the first and second flange members 10, 20 by snap fitting, screwing riveting, bolting, nailing, welding, clinching or crimping or a combination thereof. Further, there are also other embodiments wherein the web member 50 are mere flat metal plates as depicted in FIG. 1A or IB. The FIG. 4A depicts the perspective view of lightweight construction element 100c in un-assembled stage in accordance with yet another embodiment of the present disclosure. The flanges 10, 20 comprise a plurality of deformed regions such that each of the deformed region in the first flange 10 is aligned opposite and facing the deformed region in the second flange 20. The deformed region in the present embodiment comprises apertures 30a and 30b. The apertures 30a, 30b in the first and second flange member 10, 20 are cut out and bent at right angles to their respective front surfaces 13, 23 (as depicted in FIG. 1A) to form flap portions 3 la, 3 lb. The flap portions 3 la, 3 lb in the present embodiment further comprises embossed portions 40a, 40b respectively. The embossed portions 40a, 40b in the present embodiment have two slit openings 41a, 41b and 41a’, 41b’ provided on top and bottom of the embossed portions 40a, 40b along their respective longitudinal axis. This facilitates the web members 50 to snap-fit into the embossed portions 40a, 40b resulting in a I-shaped lightweight construction element 100c. In some other optional embodiment, the embossed portions 40a, 40b comprise only one slit opening 41a, 41b wherein the web members 51 are devoid of glider portions 54.

The FIG. 4B depicts the perspective view of lightweight construction element 100c in assembled stage in accordance with yet another embodiment the present disclosure. The web members 50 are secured to the first and second flange 10, 20 by snap fitting wherein the web members 50 are fitted into the sit opening 41a, 41b and 41a’, 41b’ of the embossed portions 40a and 40b of flap portions 31a, 31b respectively. The edge regions 53a, 53b (as in FIG. 2A) are slightly pressed inwards while going inside the slit openings 41a, 41b and 41a’, 41b’ whereby the glider portions 54 gets snap fitted with the embossed portions 40a, 40b and locks to provide strong fitment. The cut out slots 55 eases the pressing phenomenon by reducing the plate stiffness. For the ease of fitment of the web members 50 into the embossed portions 40a and 40b of flanges 10, 20 respectively, the thickness of the web members 50 matches that of the slit openings 41a, 41b and 41a’, 41b’. Further, in the optional embodiments wherein the web member has extended metal part 57, the extended metal parts 57 helps provide add-on stiffness to the web members 50 as well as helps maintain the fixture. It is to be noted, in some embodiments, the web members are secured to the first and second flange members 10, 20 by snap fitting, screwing riveting, bolting, nailing, welding, clinching or crimping or a combination thereof.

The FIG. 5A and 5B depict perspective views of lightweight construction element lOOd and lOOe respectively in accordance with one another embodiment the present disclosure. The lightweight construction element lOOd and lOOe is such that the first and second flange members 10, 20 are extended along their respective first edge 11, 21 and second edge 12, 22 at 90° to their respective front surfaces 13, 23 to form stiffener members 15, 25, respectively. In both the lightweight construction element lOOd and lOOe, stiffeners 15, 25 of the flange members 10, 20 further comprise slots 15’, 25’. The slots 15’, 25’ can be such that they are placed at a frequent interval with each other as depicted in FIG. 5A. In the present embodiment, the slots 15’, 25’ are spaced at an interval of 10-50mm from each other. In some other embodiments, the slots 15’, 25’ are placed only at the areas wherein the web member 50 are to be coupled to the flange members 10, 20, as depicted in FIG. 5A. In the present embodiment, the slots 15’, 25’ are spaced at an interval of 100-500mm from each other. The slots 15’, 25’ receive the glider portions 54 of the web member 50 by a snap fit action while coupling the web member 20 with the flange members 10, 20.

Further, it is to be noted, all the other features of embodiments as depicted in FIGS. 3A, 3A, 4A and 4B has similar characteristics as that of the embodiment as detailed out in FIGS. 1A and IB

The preferred dimensions of the lightweight construction element 100a, 100b, 100c, lOOd or lOOe are as follows: The length of the web member ranges from 20mm to 200mm and the width ranges from 10mm to 150mm. The height of the first and second flanges ranges from 2.5m to 8m. Further, the spacing between the web members 50 ranges from 50mm to 300mm.

It is to be noted that the length of the web members 50 are not equal to the length of the flange members 10, 20. They are spaced at a predetermined interval such that together the plurality of web members 50 cover a small fraction of length with respect to the flange member 10, or 20. This results in reduction of the weight of the lightweight framing component 100a, 100b, 100c, lOOd or lOOe and enables ease of installation due to the reduced weight. Additionally, the lightweight construction element of the present disclosure is equally efficient with respect to structural performance and deflection and is comparable to any conventional lightweight construction element. Moreover, as already mentioned, reduction in metal usage in turn results in reduction of CO2 emission by the reduced consumption of fuel required to melt and mold the metal sheet. Hence, the present invention promotes sustainability and sustainable living without compromising on the quality.

In the embodiments of the present disclosure, the lightweight construction element 100a, 100b, 100c, lOOd or lOOe is made of metal however in alternative embodiments, it can be of plastic, polymer, cardboard, wood, steel or any varied type of metal composition. The components of the lightweight framing element 100 can be manufactured as a whole or in parts taking into consideration the requirements and usages. Further, the lightweight framing element 100a, 100b, 100c, lOOd or lOOe as described in the present disclosure is a dry wall stud which helps hold the construction panel 350, but then, in alternative embodiments, this can be used as a ceiling or a floor channel.

The disclosure also depicts a method of making a lightweight construction element 100a, 100b, 100c, lOOd or lOOe which involves: providing a first flange member 10 and a second flange member 20 spatially separated from each other at the closest points by a distance X, followed by coupling the first flange member 10 and a second flange member 20 together by providing multiple web members 50 there between spaced at a distance 50 to 300 mm. The web members 50 are snap fitted or clinched, riveted, bolted, crimped or welded to the deformed regions on the first flange member 10 and a second flange member 20 comprising at least one of apertures 30a, r 30b, embossed portion 40a, 40b or slots 15’, 25’. Further in some other alternative embodiments, the web members 50 are snap fitted into the embossed 40a, 40b by sliding action wherein the glider portions 54 (as depicted in FIGS. 2A or 2B) are deflected and inserted into slit opening 41a, 41b of the embossed portions 40a, 40b or in slots 15’, 25’ (as depicted in FIG. 2C).

The FIG. 6 which is the perspective view drywall partition having a framing assembly 500 along with the construction panel 350 in accordance with one of the embodiments of the present disclosure. The framing assembly 500 comprises a horizontal framing member 200 fixed to the floor 201, a horizontal framing member 300 substantially parallel to and spaced from the horizontal framing member 200 and fixed to the ceiling 310, a plurality of lightweight construction elements 100b spaced vertically and mounted to the horizontal framing member 200 at its bottom end and to the horizontal framing member 300 at its top and at least one construction panel 350. The lightweight construction elements 100b are mounted such that the flange members 10, 20 of the lightweight construction elements 100b abut and support the surface of the construction panel 350 at positions outside the deformed regions of the flange member 10, 20 respectively when the at least one construction panel 350 is fixed to one or either sides of the framing assembly 500. Further, the flange members 10, 20 near or at the bottom end of the lightweight construction elements 100b are fixed to the horizontal framing member 200 and flange member 10, 20 near to at the top end of the lightweight construction elements 100b are fixed to the horizontal framing member 300 at positions outside the deformed regions of the flange members 10, 20 respectively. Industrial Applications

Thus the lightweight construction element 100a, 100b, 100c, lOOd or lOOe of the present disclosure is lightweight (in terms of eliminating the need of a continuous web) and results in reduction of CO2 emission during its manufacture. In addition, the lightweight construction element 100a, 100b, 100c, lOOd or lOOe herein possesses the following advantages:

The lightweight construction element 100a, 100b, 100c, lOOd or lOOe of the present disclosure can be used in conjunction with currently existing industry standardized drywall components (viz. board for the drywall etc.) without necessitating a modification of other system components;

The plurality of web members 50 being spaced apart and having a gap in between consecutive web members results in light weight components and thereby results in ease of installation;

Further, the lightweight construction element readily accommodates the use of mechanical fastening devices thereby eliminating deflection, bending or breakage of these devices due to any obstructions owing to its design;

The web members 50 are cut from flat metal sheets which thereby results in near to zero metal scrap and metal wastage.

The lightweight construction element 100a, 100b, 100c, lOOd or lOOe of the present disclosure finds application in building constructions not limiting to commercial and residential spaces. The structural modification as in the present disclosure eliminates the usage of a continuous web to connect the flanges of a dry wall stud or channel component. It provides ease of manufacture, is sustainable, easy to transport and assemble and is also cost effective. Further, no additional assembly tools or accessories are required for the assembly of the web members in the lightweight construction element as described in the present disclosure.

Having thus described the disclosure with particular reference to the preferred forms thereof, it will be obvious that various changes and modifications can be made therein without departing from the spirit and scope of the present disclosure as defined by the appended claims. Therefore, the embodiments described in the specification and the drawings shown in the drawings are only the most preferred embodiment of the present disclosure and do not represent all of the technical ideas of the present disclosure, various modifications that can be replaced at the time of the present application It should be understood that there may be equivalents and variations. Note that not all of the activities described above in the general description or the examples are required, that a portion of a specific activity may not be required, and that one or more further activities may be performed in addition to those described. Still further, the order in which activities are listed is not necessarily the order in which they are performed.

Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature of any or all the claims.

The specification and illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The specification and illustrations are not intended to serve as an exhaustive and comprehensive description of all of the elements and features of apparatus and systems that use the structures or methods described herein. Certain features, that are for clarity, described herein in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in a sub combination. Further, reference to values stated in ranges includes each and every value within that range. Many other embodiments may be apparent to skilled artisans only after reading this specification. Other embodiments may be used and derived from the disclosure, such that a structural substitution, logical substitution, or another change may be made without departing from the scope of the disclosure. Accordingly, the disclosure is to be regarded as illustrative rather than restrictive.

The description in combination with the figures is provided to assist in understanding the teachings disclosed herein, is provided to assist in describing the teachings, and should not be interpreted as a limitation on the scope or applicability of the teachings. However, other teachings can certainly be used in this application.

As used herein, the terms "comprises," "comprising," "includes," "including," "has," "having" or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such method, article, or apparatus. Further, unless expressly stated to the contrary, "or" refers to an inclusive-or and not to an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present). Also, the use of "a" or "an" is employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the disclosure. This description should be read to include one or at least one and the singular also includes the plural, or vice versa, unless it is clear that it is meant otherwise. For example, when a single item is described herein, more than one item may be used in place of a single item. Similarly, where more than one item is described herein, a single item may be substituted for that more than one item.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The materials, methods, and examples are illustrative only and not intended to be limiting. To the extent that certain details regarding specific materials and processing acts are not described, such details may include conventional approaches, which may be found in reference books and other sources within the manufacturing arts.

While aspects of the present disclosure have been particularly shown and described with reference to the embodiments above, it will be understood by those skilled in the art that various additional embodiments may be contemplated by the modification of the disclosed machines, systems and methods without departing from the spirit and scope of what is disclosed. Such embodiments should be understood to fall within the scope of the present disclosure as determined based upon the claims and any equivalents thereof.

List of Elements

A LIGHTWEIGHT CONSTRUCTION ELEMENT

10: First Flange Member

13, 23: Front Surface

14, 24: Back Surface

15, 25: Stiffener

15’, 25’ : Slots

20: Second Flange Member

30a, 3b: Aperture

31a, 31b: Flap Portions

40a, 40b: Embossed Portions

41a, 41a’, 41b, 41b’ : Slit Opening

50: Web Member

51 : Plate portion

52a: First Edge Region

52b: S econd Edge Regi on

53a: Third Edge Region

53b: F ourth Edge Regi on

54: Glider Portion

55: Cut-out Slot

100a, 100b, 100c, lOOd, lOOe: Lightweight construction element

200, 300: Horizontal Framing Member

210: Floor

310: Ceiling

350: Construction Panel

1000: Dry wall Stud

500: Framing Assembly

H, H’: Height

X: Distance

Claims

Claims We claim:

1. A lightweight construction element comprising: a first and second flange members 10, 20, each having a front surface 13, 23 facing each other and a back surface 14, 24 non-facing each other, wherein the first flange member 10 and second flange member 20 are aligned alongside each other spaced at a distance X between the closest points on each flange member 10 and 20; and a plurality of web members 50, each having plate portion 51 with a length, a width, a first edge region 52a, a second edge region 52b, a third edge region 53a and a fourth edge region 53b, the first edge region 52a and the second edge region 52b lying across the width of the plate portion, the third edge region 53a and the fourth edge region 53b lying across the length of the plate portion 51, the width of the plate portion 51 defines the spacing between the first flange member 10 and the second flange member 20, characterized in that each of the flanges 10, 20 comprise a plurality of deformed regions, wherein each of the deformed region in flange 10 is aligned opposite and facing the deformed region in flange 20, and the plurality of web members 50 are physically coupled to the first and second flange members 10, 20 via the deformed regions on each of the first and second flange member 10, 20.

2. The lightweight construction element as claimed in claim 1, wherein the deformed regions on each of the first and second flange member 10, 20 comprises at least one of apertures 30a, 30b, embossed portions 40a, 40b or slots 15’, 25’.

3. The lightweight construction element as claimed in claim 1, wherein the first and second flange members 10, 20 are extended along their respective first edge 11, 21 and second edge 12, 22 at 90 degree to their respective front surfaces 13, 23 to form stiffener members 15, 25, respectively.

4. The lightweight construction element as claimed in claim 3, wherein the stiffeners 15, 25 are provided with slots 15’, 25’. The lightweight construction element as claimed in claim 2, wherein the slots 15’, 25’, apertures 30a, 30b and embossed portions 40a, 40b are spaced at a distance of 10 - 500 mm. The lightweight construction element as claimed in claim 2, wherein at the apertures 30a, 30b, the first and second flange member 10, 20 are cut out and bent at right angles to their respective front surfaces 13, 23 to form flap portions 31a, 31b. The lightweight construction element as claimed in claim 2, wherein the embossed portions 40a, 40b comprise at least one slit opening 41a, 41b. The lightweight construction element as claimed in claim 1, wherein the web members 50 at the first edge region 52a and second edge region 52b are extended into glider portions 54 that are angled at right angle to the edge regions of the plate portion 51 and wherein the third edge region 53a and the fourth edge region 53b are provided with at least one cut-out slot 55. The lightweight construction element as claimed in claim 1, wherein the first and second flange members 10, 20 are extended along their respective first edge 11, 21 and second edge 12, 22 at a non-zero angle to their respective front surfaces 13, 23 to form stiffener members 15, 25, respectively. The lightweight construction element as claimed in claim 2, wherein the embossed portions 40a, 40b are provided on the flap portions 3 la, 3 lb. The lightweight construction element as claimed in claim 2, wherein the embossed portions 40a, 40b are rectangular profile whose length matches the length of the web members 50 and height H matches that of the cut-out slot 55 in web members 50. The lightweight construction element as claimed in claim 1, wherein the web members 50 are bent at right angles to the plate portion 51 at edge regions 53a, 53b to form a U- shaped profile such that the edge regions 53a, 53b lie opposed. The lightweight construction element as claimed in claim 1, wherein the web members 50 are bent at right angles to the plate portion 51 at edge regions 53a, 53b such that the edge regions 53a, 53b are not opposed to each other. The lightweight construction element as claimed in claim 1, wherein the web members 50 are secured to the first and second flange member 10, 20 by snap fitting, screwing riveting, bolting, nailing, welding, clinching or crimping or a combination thereof. The lightweight construction element as claimed in claim 6, wherein the thickness of the web members 50 matches that of the slit openings 41a, 41b. The lightweight construction element as claimed in claim 2, wherein the embossed portions 40a, 40b have two slit openings 41a, 41b and 41a’, 41b’ provided on top and bottom of the embossed portions 40a, 40b along their respective longitudinal axis. The lightweight construction element as claimed in claim 1, wherein the length of the web members 50 is not equal to the length of the flange members 10, 20. The lightweight construction element as claimed in claim 1, wherein the closest points for measuring distance X there between the flange members 10, 20 lies at their respective edges or at their respective centers or at respective points lying between their edges and their centers. The lightweight construction element as claimed in claim 1, is an I-shaped stud. The lightweight construction element as claimed in claim 1 comprises plastic, polymer, cardboard, wood, steel or other metals. The lightweight construction element as claimed in claim 1 comprises metal. The lightweight construction element as claimed in claim 1, is manufactured in whole or in parts. The lightweight construction element as claimed in claim 1 is a drywall stud. A method of making the lightweight construction element of claim 1, comprising the steps of providing a first flange member 10 and a second flange member 20 spatially separated from each other at the closest points by a distance X; and coupling the first flange member 10 and a second flange member 20 together by providing multiple web members 50 there between spaced at a distance of 50 - 300 mm. The method as claimed in claim 24, wherein the web members 50 are clinched, riveted, bolted, crimped or welded to the deformed regions on the first flange member 10 and a second flange member 20 comprising at least one of apertures 30a, 30b, embossed portions 40a, 40b or slot 15’a, 25 ’a.

The method as claimed in claim 24, wherein the web members 50 are snap fitted into the embossed portions 40a, 40b by a sliding action wherein the glider portions 54 are deflected and inserted into slit opening 41a, 41b of the embossed portions 40a, 40b.

A drywall partition having a framing assembly 500 comprising: a horizontal framing member 200 fixed to the floor 210; a horizontal framing member 300 substantially parallel to and spaced from the horizontal framing member 200 and fixed to the ceiling 310; a plurality of lightweight construction elements 100b as claimed in claim 1 spaced vertically and mounted to the horizontal framing member 200 at its bottom end and to the horizontal framing member 300 at its top end; and at least one construction panel 350, characterized in that: the lightweight construction elements 100b are mounted such that the flange members 10, 20 of the lightweight construction elements 100b abut and support the surface of the construction panel 350 at positions outside the deformed regions of the flange member 10, 20, respectively when the at least one construction panel 350 is fixed to one or either side of the framing assembly 500.

The dry wall partition as claimed in claim 27, wherein the flange member 10, 20 near or at the bottom end of the lightweight construction elements 100b are fixed to the horizontal framing member 200 and flange member 10, 20 near or at the top end of the lightweight construction elements 100b are fixed to the horizontal framing member 300 at positions outside the deformed regions of the flange member 10, 20, respectively.