EP4039903A1

EP4039903A1 - Partition wall or wall lining requiring little or no screws

Info

Publication number: EP4039903A1
Application number: EP21305166.7A
Authority: EP
Inventors: Gaël MAILLE; Frédéric PLE; Jimmy CHAOUCHE; Mélina JEAN; Pierre PEYRON; Emmanuel Vial; Stéphan ZERBIB; Bastien ROUANET; Emiie SAVANIER
Original assignee: Etex Building Performance International SAS
Current assignee: Etex Building Performance International SAS
Priority date: 2021-02-08
Filing date: 2021-02-08
Publication date: 2022-08-10
Anticipated expiration: 2041-02-08
Also published as: PL4039903T3; EP4039903B1; ES2964141T3; EP4039903C0

Abstract

The present invention concerns a permanent drywall comprising, a support structure formed by
• top and bottom U-profile tracks (2u, 2d) comprising first and second U-flanges, which are fixed to a ceiling and a floor, respectively, extending along a longitudinal axis (X),
• i-profile beams (3) comprising a beam web (3w) sandwiched between first and second beam flanges (3f1, 3f2) coupled to the first U-flange of the top U-profile track (2u) by insertion of a beam slit (3s) provided at a free end of he beam web (3w), such as to extend normal to the top U-profile tracks along a vertical axis (Z), the first beam flange (3f1) is located outside of the top U-profile tracks.

Rectangular boards (1) are fixed to the support structure. The boards comprise first and second vertical edges parallel to the vertical axis (Z) and provided with a groove (1g) running along the whole height (H1) of the boards. The boards are held in place between two between two i-profile beams (3) by spline joints formed by the first beam flange (3f1) being inserted in the grooves of two adjacent boards.

A drywall according to the present invention is very simple to install.

Description

TECHNICAL FIELD

The present invention concerns a partition wall or wall lining, collectively referred to as drywalls, of the type comprising boards to be coupled to a frame. The coupling of the boards to the frame of the partition wall or wall lining requires no or a limited number only of screws compared to state-of-the-art drywalls. The elements of the support frame and the boards are designed for interlocking with one another without screws. The present invention facilitates installation of partition walls or wall linings by amateur home carpenters or do-it-yourselfers (DIYer) rather than relying on professional installers.

BACKGROUND OF THE INVENTION

Refurbishing an interior of a building can comprise knocking down existing walls and building new partition walls and wall linings. A partition wall is a non-load bearing wall which divides a space into two sub-spaces separated from one another. Partition walls generally have two visible surfaces and may comprise insulation material, piping, or cables hidden from view. Wall linings are used for cladding an existing wall, e.g., to enhance the appearance of the existing wall, for insulating the existing wall, or for hiding piping or cables running along the existing wall. Wall linings can also include ceilings and, in some cases, floors. Wall linings only have one visible surface. Partition walls and wall linings are commonly referred to as drywalls without distinction. Permanent drywalls are to be distinguished from modulable partition walls which can be removed easily, as commonly used in modulable offices for rent. The present invention concerns permanent partition walls and wall linings.
Beside using heavy materials, such as concrete, bricks, blockworks, or the like, partition walls and wall linings are generally formed by a support frame supporting boards made of e.g., plaster (= calcium sulphate dehydrate), cement, wood, plywood, metal, or the like. The boards are fixed to a frame generally made of metallic or wooden studs. For this reason, partition walls are sometimes referred to as stud walls. Because of wood shortage and higher fire resistance, however, metallic studs are often preferred.
The metallic studs generally comprise top U-profile tracks fixed to a top position, such as a ceiling, and a bottom U-profile track fixed to a bottom position, generally a floor. C-studs cut to a length corresponding to a height of the partition wall are screwed in place to the top and bottom U-profile tracks to form a frame on which boards can be fixed. The frame can be designed to incorporate openings for windows and doors, requiring more cutting to size and screwing in place of the metallic studs. The boards can then be fixed side-by-side to the frame with screws, thus securing the boards to the top and bottom U-profile tracks and to the vertical C-stud. In partition walls, boards are screwed on both sides of the frame, whilst in wall linings and ceilings, boards are screwed to one side only of the frame. The vertical C-Stud may comprise openings in the webs thereof to allow the passage of piping and cables along a length of the partition wall or wall lining.
Once the boards are screwed in place on one or both sides of the frame, the joints between adjacent boards are sealed with a paste and optionally covered by an adhesive paper tape to smoothen the surface of the thus built drywall.
Although building a drywall is considered by professional builders as a relatively simple operation, only well-trained amateur home carpenters dare building a partition wall on their own. Indeed, as described supra, the metallic studs must be cut to size, which is time consuming. The studs must be screwed to the top and bottom U-profile tracks to form the frame. The boards must be screwed to the frame. Care must be taken with plasterboards or cement boards which may be brittle and get damaged when pierced by screws in case the wrong type of screws is used.
The present invention proposes a solution for substantially simplifying the building of a permanent drywall, reducing the number of metal studs to be cut to dimensions and considerably reducing the number of screws or even making without them for coupling the vertical I-profile beams to the top and bottom U-profile tracks, and for fixing the boards to the frame. Even moderately trained do-it-yourselfers can now build a partition wall or wall lining requiring only limited technical skills with excellent results. These and other advantages of the present invention are presented in continuation.

SUMMARY OF THE INVENTION

The present invention is defined in the appended independent claims. Preferred embodiments are defined in the dependent claims. In particular, the present invention concerns a kit-of-parts for installing a permanent partition wall or a permanent lining wall comprising,

(A) a support frame comprising,
- a top U-profile track and a bottom U-profile track being configured for forming top and bottom horizontal studs of the support frame, respectively, extending along a longitudinal axis (X), each of the top and bottom U-profile comprising first and second U-flanges parallel to each other separated by a U-web extending normal to the U-flanges and defining a U-opening,
- two or more I-profile beams, each I-profile beam comprising a beam web normal to and sandwiched between first and second beam flanges and configured for being coupled to the top U-profile track to form vertical beams extending along a vertical axis (Z) normal to the longitudinal axis (X) over a beam height (H3), with the first and second beam flanges extending parallel to a wall plane (X, Z) defined by the longitudinal axis (X) and vertical axis (Z), and with the beam web extending normal to the wall plane (X, Z),
(B) two or more boards, each board having a rectangular geometry, comprising a first main surface parallel to and separated from a second main surface by a thickness measured along a transverse axis (Y) normal to the wall plane (X, Z), and forming a peripheral edge comprising first and second longitudinal edges of length (L) extending along the longitudinal axis (X), normal to and separated from one another by first and second vertical edges of board height (H1) extending along the vertical axis (Z), and wherein a groove (1g) extends along each of the first and second vertical edges, each groove having an opening width (w) measured normal to the wall plane (X, Z), and a depth (d) measured parallel to the longitudinal axis (X),

A free end of the beam web of each I-profile beam comprises a beam slit configured for engaging over the first U-flange of the top U-profile track such that,

a corresponding free end of the second beam flange is located between the first and second U-flanges of the top U-profile track preferably contacting an inner surface of the second U-flange, and such that
a corresponding free end of the first beam flange is located outside of the top U-profile track, at a distance from the first U-flange of the top U-profile track such that the first beam flange can be introduced into the grooves of first and second adjacent boards forming a spline joint between the first and second adjacent boards, with the second main surfaces of each of the first and second adjacent boards extending parallel to the wall plane (X, Z) and contacting an outer surface of the first U-flange of the top U-profile track.

In a preferred embodiment, the beam height (H3) is smaller than the board height (H1) (i.e., H3 < H1). In this embodiment, the kit-of parts further comprises a stabilizing element formed by a T- or L-profile comprising an element web and an element flange normal to the element web. A free end of the element web comprises an element slit configured for engaging one of the two U-flanges of the bottom U-profile track such that,

The element web (4w) extends normal to the wall plane (X, Z), such that
a height (H4) of the stabilizing element measured along the vertical axis (Z) is shorter than the difference between the board height (H1) and the beam height (H3) (i.e., H4 < H1 - H3), and such that
a corresponding free end of the element flange (4f) is located outside of the bottom U-profile track, at a distance from the first U-flange of the bottom U-profile track such that the element flange can be introduced into the groove of a first board with the second main surface of the first board extending parallel to the wall plane (X, Z) and contacting an outer surface of the first U-flange of the bottom U-profile track (2d).

The element flange can have first and second surfaces separated by a thickness of the element flange, wherein the first and second surfaces are textured or comprise protrusions configured for applying a friction against walls of the groove of the first board it is inserted in.
In an alternative embodiment, the beam height (H3) is equal to the board height (H1) (i.e., H3 = H1) and preferably comprises openings provided in the beam web for allowing passage of wires and tubing.
The thickness (T) of the boards can be comprised between 6 and 40 mm measured at a centre of the board, preferably between 18 and 25 mm, more preferably between 19 and 22 mm, or preferably between 20 and 35 mm, more preferably between 25 and 30 mm. The boards can have a density comprised between 0.35 and 2.00 preferably between 0.4 and 0.65, more preferably between 0.50 and 0.60, or preferably between 0.70 and 1.6. It is preferred that the boards comprise a core comprising at least 80 wt.% relative to the core weight of calcium sulphate dihydrate, or calcium silicate, or fibre-cement, or wood, or plywood.
The vertical edges of the boards can be tapered, preferably chamfered, relative to a centre of the boards, such that each board has an edge thickness (Te) measured at the vertical edges which is smaller than a thickness measured at the centre of the board. The thickness measured at the vertical edges is preferably comprised between 4 and 36 mm, more preferably between 14 and 22 mm, most preferably between 15 and 18 mm, or more preferably between 25 and 30 mm. The grooves of the boards can have an opening width (w) of 2 mm ± 0.3 mm, and a depth (d) comprised between 25 and 60 mm, preferably between 30 and 50 mm.
The kit-of-parts can further comprise an end beam for fixing the first vertical beam to a first board having no adjacent second board. The end beam can be formed by a U-profile comprising first and second end-flanges parallel to each other separated by an end-web extending normal to the end-flanges and defining an end-opening. In a preferred embodiment, a free end of the end web comprises an end slit configured for engaging the first U-flange of the top U-profile track. The end-opening is then wider than the U-opening of the top U-profile track, such that, a corresponding free end of the first end flange is located outside of the top U-profile track, at a distance from the first U-flange of the top U-profile track such that the first end flange can be introduced into the groove of the first vertical edge of the first board with the second main surface of the first board extending parallel to the wall plane (X, Z) and contacting an outer surface of the first U-flange of the top U-profile track and said end web being wider than the U- opening of the top U-profile track,.
The present invention also concerns a permanent partition wall or permanent wall lining (collectively referred to as drywall) composed of the elements of the kit-of-parts described supra. The drywall comprises:

one or more top U-profile tracks are fixed to a top position, extending along the longitudinal axis (X) with the U- opening facing towards a bottom position,
one or more bottom U-profile tracks fixed to the bottom position, extending along the longitudinal axis (X) with the U- opening facing towards the top position,
the beam slit of a first I-profile beam is engaged in the first U-flange of the top U-profile track such that,
∘ a corresponding free end of the second beam flange is located between the first and second U-flanges of the top U-profile track, preferably contacting an inner surface of the second U-flange, and such that

a corresponding free end of the first beam flange is located outside of the top U-profile track, and is engaged in the groove of the first vertical edge of a first board with the second main surface contacting an outer surface of the first U-flange of the top U-profile track the beam slit of a second I-profile beam is engaged in the first U-flange of the top U-profile track in the same way as the first I-profile beam, with the second flange of the second I-profile beam being engaged in the groove of the second vertical edge of the first board,
The second main surface of a second board contacts the outer surface of the first U-flange of the top U-profile track with the groove of the first vertical edge being engaged in the second beam flange of the second I-profile beam.

In the embodiment wherein the height (H3) of the I-profile beams is smaller than the height (H1) of the boards, first and second stabilizing elements are preferably coupled to the bottom U-profile tracks, with the respective slits of the first and second stabilizing elements being engaged in the first U-flange of the bottom U-profile track with the respective element webs extending normal to the wall plane (X, Z). The element flange of the first stabilizing element is engaged in the groove of the first vertical edge of the first board. The element flange of the second stabilizing element can be engaged in the groove of the first vertical edge of the second board.
The present invention also concerns a method for installing a permanent partition wall or permanent wall lining as described supra of desired length measured along the longitudinal axis (X), comprising the following steps,

providing a kit-of-parts as discussed supra,
fixing side by side one or more top U-profile tracks to a top position, extending along the longitudinal axis (X) with the U- opening facing towards a bottom position,
fixing side by side one or more bottom U-profile tracks to the bottom position, preferably to a floor, extending along the longitudinal axis (X) with the U-opening facing towards the top position, and aligned relative to the vertical axis (Z) with the one or more top U-profile tracks,
engaging the beam slit of a first I-profile beam into the first U-flange of the top U-profile track) such that,
- ∘ a corresponding free end of the second beam flange is located between the first and second U-flanges of the top U-profile track, preferably contacting an inner surface of the second U-flange, and such that
- ∘ a corresponding free end of the first beam flange is located outside of the top U-profile track, at a distance from the first U-flange (2f) of the top U-profile track (2u),
positioning a first board parallel to the wall plane (X, Z), and engaging the groove of the first vertical edge over the first beam flange with the second main surface contacting an outer surface of the first U-flange of the top U-profile track,
engaging the beam slit of a second I-profile beam into the first U-flange of the top U-profile track in the same way as the first I-profile beam, and engaging the first flange of the second I-profile beam into the groove of the second vertical edge of the first board,
repeating the last two steps to obtain a first row of boards of the desired length of the permanent partition wall or wall lining.

In the embodiment wherein the height (H3) of the I-profile beams is smaller than the height (H1) of the boards, the method can further comprise the steps of,

engaging the slit of the first stabilizing element into the first U-flange of the bottom U-profile track with the element web extending normal to the wall plane (X, Z), and
engaging the element flange of the first stabilizing element into the groove of the first vertical edge of the first board.
repeating the last two steps for at least some of, preferably all the boards of the first row of boards.

The method applied for the installation of a permanent partition wall can further comprise forming a second row of boards with the second main surface of each board contacting an outer surface of the second U-flange of the top U-profile tracks, the method comprising the following steps,

optionally applying acoustic and / or thermal insulation in contact with the first main surface of the boards of the first row of boards, and further optionally positioning electric cables and / or tubing in a volume defined between the top and bottom U-profile tracks,
applying an adhesive or a double-sided tape to the second beam flange of an I-profile beam to form a first adhesive I-profile beam,
engaging the beam slit of the first adhesive I-profile beam into the second U-flange of the top U-profile track between the first and second I-profile beams, preferably at half the distance separating the first and second I-profile beams, such that,
- ∘ a corresponding free end of the second beam flange is located between the first and second U-flanges of the top U-profile track (2u), preferably contacting an inner surface of the first U-flange, and such that
- ∘ the adhesive or double-sided tape on the second beam flange of the first adhesive I-profile beam contacts the second main surface of the first board of the first row of boards and such that
- ∘ a corresponding free end of the first beam flange is located outside of the top U-profile track, at a distance from the second U-flange of the top U-profile track,
positioning a new first board parallel to the wall plane (X, Z), and engaging the groove of the first vertical edge over the first beam flange with the second main surface contacting an outer surface of the second U-flange of the top U-profile track,
applying an adhesive or a double-sided tape to the second beam flange of a different I-profile beam to form a second adhesive I-profile beam,
engaging the beam slit of the second adhesive I-profile beam into the second U-flange of the top U-profile track in the same way as the first adhesive I-profile beam, and engaging the first flange of the second adhesive I-profile beam into the groove of the second vertical edge of the new first board,
repeating the last three steps with third and following I-profile beams and with corresponding new second and following boards to obtain a second row of boards to form a permanent partition wall of the desired length.

In the embodiment wherein the height (H3) of the I-profile beams is smaller than the height (H1) of the boards, the method for installing a permanent partition wall can further comprise the steps of,

engaging the slit of a stabilizing element into the second U-flange of the bottom U-profile track with the element web (4w) extending normal to the wall plane (X, Z), and
engaging the element flange of the stabilizing element into the groove of the first vertical edge of the new first board,
repeating the last two steps for at least some of, preferably all the boards of the second row of boards.

BRIEF DESCRIPTION OF THE FIGURES

For a fuller understanding of the nature of the present invention, reference is made to the following detailed description taken in conjunction with the accompanying drawings in which:

Figure 1(a) shows an embodiment of vertical I-profile beam according to the present invention.
Figure 1(b) &1(c): show two embodiments of vertical end beams according to the present invention.
Figure 2 : shows an example of top or bottom U-profile track.
Figure 3 : shows a detail of an edge of a board provided with a groove.
Figure 4(a) & 4(b) : show two embodiments of stabilizing elements.
Figure 5(a) : sows a first step in a first embodiment of coupling a first vertical I-profile beam and stabilizing element to the top and bottom U-profiles and coupling of a board to the first vertical I-profile beam and stabilizing element.
Figure 5(b) : shows a second step in the first embodiment of coupling a second vertical I-profile beam and stabilizing element to the top and bottom U-profiles and to the board which is fixed to the frame by the first and second I-profile beams and by the first stabilizing element.
Figure 6(a) : shows a first step in a second embodiment of coupling a first vertical I-profile beam to the top and bottom U-profiles and coupling of a board to the first vertical I-profile beam.
Figure 6(b) : shows a second step in the second embodiment of coupling a second vertical I-profile beam to the top and bottom U-profiles and to the board which is fixed to the frame by the first and second I-profile beams.
Figure 7(a) : shows a top view of a wall lining hiding an existing wall and comprising boards coupled to one sides of the frame.
Figure 7(b) : shows a top view of a partition wall comprising boards coupled to both sides of the frame with the boards coupled to a first side of the frame being offset relative to the boards coupled to the second side of the frame.
Figure 7(c) : shows a detail of Figure 7(b), showing two adjacent boards coupled to an I-profile beam, forming a spline joint with two wings of the flange thereof being inserted in the grooves of the two boards.
Figure 7(d) : shows a cross-section of a drywall according to Figure 7(b), showing an I-profile beam coupled to a top U-profile track and boards coupled to both side of the frame by spline joints.
Figure 8(a) : shows a top-view of a spline joint formed by the wings of the flange of an I-profile beam inserted in the grooves of two adjacent boards having different thicknesses.
Figure 8(b) : shows a top-view of a preferred embodiment of spline joint formed by the wings of the flange of an I-profile beam inserted in the grooves of two adjacent boards of different thicknesses and having tapered edges.
Figures 9(a) to 9(f) : show various embodiments of boards having tapered or thinned edges.
Figures 10(a) to 10(e) : show various stages of the building of a drywall according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention concerns a partition wall or wall liner, collectively called drywalls, which are easier to build than state-of-the-art drywalls. The drywalls of the present invention are permanent drywalls, which are not meant to be moved from one position to another as exist in modulable open spaces for forming individual offices à la carte. The drywalls of the present invention comprise boards coupled by means of spline joints to a support frame formed of metallic studs, including top and bottom U-profile tracks (2u, 2d) and vertical I-profile beams (3). The elements required for building the drywall are supplied as a kit-of-parts comprising two or more boards and the elements for forming a support frame for supporting the two or more frames.
Each of the one or more boards (1) have a rectangular geometry, comprising a first main surface parallel to and separated from a second main surface by a thickness (T) measured along a transverse axis (Y), and forming a peripheral edge comprising first and second longitudinal edges of length (L) extending along a longitudinal axis (X) normal to the transverse axis (Y) and separated from one another by first and second vertical edges of board height (H1) measured along a vertical axis (Z) normal to both longitudinal and transverse axes (X) and (Y). A groove (1g) extends along each of the first and second vertical edges, each groove having an opening width (w) measured normal to a wall plane (X, Z) normal to the transverse axis (Y), and a depth (d) measured parallel to the longitudinal axis (X).
The elements for forming the support frame comprise a top U-profile track (2u) and a bottom U-profile track (2d) configured for forming top and bottom horizontal studs of the support frame, respectively. As illustrated in Figure 2, each of the top and bottom U-profile tracks extend along the longitudinal axis (X) and comprise first and second U-flanges (2f) substantially parallel to each other and separated by a U-web (2w) extending substantially normal to the U-flanges and defining a U-opening.
The elements for forming the support frame also comprise two or more I-profile beams (3). As illustrated in Figure 1(a), each I-profile beam comprises a web (3w) normal to and sandwiched between first and second beam flanges (3f1, 3f2) normal to the web (3w). The I-profile beams are configured for being coupled to the top U-profile track (2u) to form vertical beams extending along a vertical axis (Z) normal to both longitudinal and transverse axes (X) and (Y) over a beam height (H3), with the first and second beam flanges extending parallel to the wall plane (X, Z) and with the web extending normal to the wall plane (X, Z).
The gist of the present invention is that the I-profile beams (3) can be coupled to the top U-profile tracks without using any screws. Similarly, the boards can be coupled to the support frame without using any screws either. This is made possible by providing a free end of the beam web (3w) of each I-profile beam (3) with a beam slit (3s) configured for engaging over the first U-flange (2f) of the top U-profile track (2u) such that,

a corresponding free end of the second beam flange (3f2) of each I-profile beam (3) is located between the first and second U-flanges (2f) of the top U-profile track (2u), preferably contacting an inner surface of the second U-flange (2f), and such that
a corresponding free end of the first beam flange (3f1) is located outside of the top U-profile track (2u), at a distance from the first U-flange of the top U-profile track (2u) such that the first beam flange (3f1) can be introduced into the grooves (1g) of first and second adjacent boards (1) forming a spline joint between the first and second adjacent boards (1), with the second main surfaces of each of the first and second adjacent boards (1) extending parallel to the wall plane (X, Z) and contacting an outer surface of the first U-flange of the top U-profile track (2u).

SUPPORT FRAME - U-PROFILE TRACKS (2u, 2d)

The support frame is composed at least of a top U-profile track (2u) and a bottom U-profile track (2d) forming top and bottom horizontal studs of the support frame of a vertical drywall, and vertical I-profile beams (3), forming the vertical studs of the support frame of the vertical drywall. In case of a ceiling, the I-profile beams (3) are horizontal.
The top and bottom U-profile tracks (2u, 2d) are separated from one another by a distance substantially equal to a height (H1) of the boards (1) measured along the vertical axis (Z). The top U-profile tracks (2u) are fixed side by side to a top position extending along the longitudinal axis (X) with the U- opening facing towards a bottom position. The bottom U-profile tracks (2d) are fixed side by side to the bottom position extending along the longitudinal axis (X) with the U-opening facing towards the top position. In many instances, wherein a partition wall must divide a large room into two smaller rooms, extending from floor to ceiling, the top position is a ceiling of the large room and the top U-profile tracks (2u) are fixed to the ceiling. The bottom position is a floor of the large room and the bottom U-profile tracks (2d) are fixed to the floor. The top and bottom U-profile tracks (2u, 2d) are preferably aligned side by side along the longitudinal axis (X) defining the position of the partition wall or wall lining. In special cases the top and bottom U-profile tracks may define a broken line. But this depends on the wishes of the builder and does not restrict the present invention.
The top and bottom U-profile tracks (2u, 2d) can be fixed to the ceiling and floor with screws, an adhesive, double-sided tapes, and the like. This operation requires cutting one top and one bottom U-profile track only, in case the length of the drywall measured along the longitudinal axis (X) is not a multiple of a length of the U-profile tracks. The number of different elements of the kit-of-parts can be reduced by designing identical top and bottom U-profile tracks (2u, 2d). This reduces the risks of making a mistake by fixing a bottom U-profile track to a ceiling instead of to a floor. For example, for building a wall of 4.3 m length measured along the longitudinal axis (X) using 2 m long top and bottom U-profile tracks, two top and two bottom U-profile tracks can be fixed side-by-side to the ceiling and floor, respectively, and a fifth U-profile track can be cut into two sections of 0.3 m length and fixed to the ceiling and floor for completing the length of the wall to be built. If the drywall must comprise an opening between the drywall and the ceiling, then the top U-profile (2u) is not fixed to the ceiling, but at the desired height between existing walls.
Once the top and bottom U-profile tracks are fixed to their respective top and bottom positions, vertical I-profile beams (3) and, optionally, stabilizing elements (4) can be coupled to the top and bottom U-profile tracks to complete the support frame for the drywall.

SUPPORT FRAME - I-PROFILE BEAMS (3)

The I-profile beams (3) can be coupled to the top U-profile tracks (2u) without any screws or glue, such as to extend along the vertical axis (Z) between the top and bottom U-profile tracks (2u, 2d). As shown in Figure 1(a) the I-profile beams (3) comprise a comprise a web (3w) normal to and sandwiched between first and second beam flanges (3f1, 3f2) defining an I-profile. A free end of the beam web (3w) of each I--profile beam (3) comprises a beam slit (3s) configured for engaging over the first or second U-flange (2f) of the top U-profile track (2u).
In a preferred embodiment illustrated in Figures 5(a) and 5(b), the I--profile beams (3) have a beam height (H3) smaller than the board height (H1) (i.e., H3 < H1) and are coupled to the top U-profile tracks only (not to the bottom U-profile tracks) through the beam slit (3a). The I--profile beams (3) are further stabilized upon inserting the flanges of the beam web (3w) into the grooves (1g) of the boards.
In this embodiment, the support frame is further composed of stabilizing elements (4), illustrated in Figures 4(a) and 4(b), which are formed by a T-profile comprising an element web (4w) and an element flange (4f) normal to the element web (4w). The stabilizing elements (4) can also be formed by an L-profile. A free end of the element web (4w) comprises an element slit (4s) configured for engaging one of the two U-flanges (2f) of the bottom U-profile track (2d) such that,

The element web (4w) extends normal to the wall plane (X, Z), such that
a height (H4) of the stabilizing element (4) measured along the vertical axis (Z) is shorter than the difference between the board height (H1) and the beam height (H3) (i.e., H4 < H1 - H3), and such that
a corresponding free end of the element flange (4f) is located outside of the bottom U-profile track (2d), at a distance from the first U-flange of the bottom U-profile track (2u) such that the element flange (4f) can be introduced into the groove (1g) of a first board (1) with the second main surface of the first board (1) extending parallel to the wall plane (X, Z) and contacting an outer surface of the first U-flange of the bottom U-profile track (2d).

As shown in Figure 5(b), the stabilizing element (4) is independent of the corresponding I--profile beam (3), and fixes a bottom of a board to the bottom U-profile track (2d). This two-element embodiment, comprising an I--profile beam (3) of height H3 < H1, and a stabilizing element (4) is very versatile in that it permits to easily compensate for slight misalignments, either in the structure (walls, celling, floor) of the room to be divided, or of the various top and bottom U-profile tracks (2u, 2d). Furthermore, with this embodiment, there is no need to cut any of the I-profile beams (3) to the specific board height (H1) of the drywall, and they can be used directly off-the-shelves. Finally, cables and piping can easily run between the first and second rows of boards of a drywall, without need of openings in the web of the I-profile beams (3).
To better stabilize the coupling of the stabilizing element and the board (1), the element flange (4f) has first and second surfaces separated by a thickness of the element flange, wherein the first and second surfaces are preferably textured (4t) as shown in Figure 4(a) or comprise protrusions (4p) as shown in Figure 4(b), configured for applying a friction against walls of the groove (1g) of the first board (1) it is inserted in.
In an alternative embodiment, illustrated in Figures 6(a) and 6(b), the beam height (H3) is substantially equal to the board height (H1) (i.e., H3 ≃ H1). The beam web (3w) preferably comprises openings (3h) for allowing passage of wires and tubing. This embodiment comprises less elements than the former embodiment, as no stabilizing element (4) is required here. All I-profile beams (3) of a drywall must, however, be cut to the required beam height (H3 ≃ H1), which is more work for the builder. This embodiment is very stable, but in case of even small misalignments either of the walls, ceiling or floor of the room to be divided, or of the top and bottom U-profile tracks (2u, 2d), it could be more difficult to fit the beam slits of the I-profile beams into both top and bottom U-profile tracks (2u, 2d) and, at the same time to engage the flanges (3f1, 3f2) into the grooves (1g) of two adjacent boards, to form a spline joint over the whole height (H3 ≃ H1) thereof.
A drywall extends along the longitudinal axis (X) between two ends, which can be free ends or contact ends, contacting another wall forming an angle with the drywall or prolonging an existing wall. I-profile beams (3) would be ill fitted to define the ends of the drywall for aesthetical reasons. It is preferred to define an end of the drywall with an end beam (9) for fixing the first vertical beam of a first board (1) having no adjacent second board. As illustrated in Figures 1(b) and 1(c) the end beam (9) is formed by a U-profile comprising first and second end-flanges (9f) parallel to each other separated by an end-web (9w) extending normal to the end-flanges and defining an end-opening, which is wider than the U- opening of the top U-profile tracks (2u, 2d). In one embodiment illustrated in Figure 1(c), a free end of the end web (9w) comprises an end slit (9s) configured for engaging the first U-flange (2f) of the top U-profile track (2u) in a similar way to the I-profile beams (3) such that, a corresponding free end of the first end flange (9f) is located outside of the top U-profile track (2u), at a distance from the first U-flange of the top U-profile track (2u) such that the first end flange (9f) can be introduced into the groove (1g) of the first vertical edge of the first board (1) with the second main surface of the first board (1) extending parallel to the wall plane (X, Z) and contacting an outer surface of the first U-flange of the top U-profile track (2u). The end beam (9) may not have an end slit (9s) as shown in Figure 1(b). In this embodiment, the end beam (9) is held in place by the end flange (9f) inserted in the groove (1g) of the first board (1). In case of a free end of the drywall, it is preferred that the end beam (9) extends over the whole height (H1) of the board (1) from top to bottom U-profile tracks (2u, 2d), so that the end web (9w) forms a continuous hard surface protecting the free edge of the drywall from impacts (cf. left hand-side of Figure 7(b)).

BOARDS (1)

Each one of the one or more boards (1) has a rectangular geometry, comprising a first and second main surfaces parallel to the wall plane (X, Z) and separated from one another by a thickness (T) measured along a transverse axis (Y) normal to the wall plane (X, Z) forming a peripheral edge. The peripheral edge comprises first and second longitudinal edges of length (L) extending along the longitudinal axis (X), normal to and separated from one another by first and second vertical edges of board height (H1) extending along the vertical axis (Z). A groove (1g) extends along each of the first and second vertical edges. Each groove has an opening width (w) measured normal to the wall plane (X, Z), and a depth (d) measured parallel to the longitudinal axis (X) which is configured for snugly engaging a beam flange (3f1, 3f2) of an I-profile beam (3).
The boards (1) can comprise a core comprising at least 80 wt.% relative to the core weight of calcium sulphate dihydrate, or calcium silicate, or fibre-cement, or wood, or plywood, or can even be made of metal. The boards can have a density comprised between 0.35 and 2.00 preferably between 0.4 and 0.65, more preferably between 0.50 and 0.60, or preferably between 0.70 and 1.6, depending on the core composition.
For example, a board core made of calcium sulphate dihydrate can comprise at least 94 wt.% calcium dihydrate relative to the core weight, starch in an amount comprised between 3.15 and 6.30 kg /m³ of the core, polyvinyl acetate (PVA), optionally a foaming agent, and preferably reinforcing fibres (e.g., glass fibres). Such boards can have a density of 0.4 to 0.65.
The boards (1) can have a height (H1) of up to 2400 mm and even up to 3050 mm measured along the vertical axis (Z). The boards can conveniently be cut to the desired height (H1) at the shop, as most DIY-shops offer such service. The boards (1) can have a width of the order of 1300 mm ± 300 mm, measured along the longitudinal axis (X). The thickness (T) of the boards (1) can be comprised between 6 and 40 mm measured at a centre of the board, preferably between 18 and 25 mm, more preferably between 19 and 22 mm, or preferably between 20 and 35 mm, more preferably between 25 and 30 mm. A centre of the board is located at the intersection of the diagonals of the first main surface.
As illustrated in Figures 3, 7(c), 8(b), and 9(a) to 9(f), it is preferred that the vertical edges of the boards are tapered, preferably chamfered, relative to a centre of the boards, such that each board has an edge thickness (Te) measured at the vertical edges which is smaller than a thickness measured at the centre of the board. For example, the thickness measured at the vertical edges can be comprised between 4 and 36 mm, more preferably between 14 and 22 mm, most preferably between 15 and 18 mm, or more preferably between 25 and 30 mm. As visible when comparing Figures 8(a) and 8(b), a tapered edge has the advantage to substantially reduce the visual impact caused by two adjacent boards (1) of thicknesses (T) differing from one another by a thickness difference (δ). Even small thickness differences (δ) of the order of 1 or 2 mm which are comprised within tolerance boundaries for plasterboards (made of gypsum) or fibre-cement boards, can create a step which is disturbingly visible on the final drywall. As shown in Figure 8(a), even after filling the gap between the two adjacent boards with a filler, the slope of the filler bridging the edges of the two adjacent boards (1) forms such an angle that the light reflects differently onto the surface of the drywall at the level of the joint. By contrast, as shown in Figure 8(b), if the edges are tapered, the filler can bridge the edges of the two adjacent boards with an angle much closer to zero than in the case of Figure 8(a). This way, with tapered edges, the thickness difference between the two adjacent boards (1) yields a substantially less disturbing optical effect on the appearance of the final drywall, with a more homogeneous light reflection on the drywall surface.
As shown in Figures 9(a) to 9(f), a tapered edge can have a variety of geometries. When the geometry illustrated in Figure 9(a) is what is generally considered as a taper, Figure 9(b) shows a specific tapered geometry generally referred to as chamfered, as the taper forms an angle of approximately 45°. The expression "tapered edge" is construed herein as any geometry having a board thickness at the level of the edges which is smaller than the thickness of the board measured at the centre thereof. This expression therefore encompasses also any one of the following geometries: comprising a step (cf. Figure 9(c)), comprising a concave step (cf. Figure 9(d)) or a convex edge (cf. Figure 9(e)) or both concave step and convex edge (cf. Figure 9(f)), and the like. The tapered portion of the edges of a board (1) can extend over a distance (Le) measured along the longitudinal axis of at least 30 mm, preferably at least 50 mm, more preferably at least 100 mm, and of not more than 300 mm, preferably not more than 200 mm. The thickness difference (T - Te) between the board thickness measured at the centre and at the edge of a board can be comprised between 0.5 to 5 mm, preferably between 1 and 3 mm.
The groove (1g) preferably extends along the first and second vertical edges of the boards over the whole board height (H1). The grooves (1g) of the boards (1) must be dimensioned such as to snugly engage the beam flanges (3f1, 3f2) of the I-profile beams (3), preferably opposing a moderate friction against the introduction of a beam flange into the groove. The grooves (1g) preferably have an opening width (w) of 2 mm ± 0.3 mm, measured along the transverse axis (Y), and a depth (d) comprised between 25 and 60 mm, preferably between 30 and 50 mm, measured along the longitudinal axis (X).

PERMANENT WALL LINING

The elements of the kit-of-parts described supra can be used to build a permanent wall lining. A wall lining is a drywall which hides from view a portion of a room from the rest of the room. A wall lining can stand against or close to an existing wall (11), hiding a poor looking wall, or pipes, wires, insulation, and the like, showing in front of the existing wall, or can hide a portion of the room to be hidden from view, such as the last 50 to 100 cm separating a floor from a sloping roof in a room under the roof, Basically, a wall lining needs be aesthetically appealing on one side of the drywall only and therefore comprises boards (1) fixed to one side only of the top and bottom U-profile tracks (2u, 2d), as shown in Figure 7(a). The term "permanent" indicates that the wall lining is not designed for being mounted and dismounted repeatedly but is meant to remain in place.
A wall lining according to the present invention comprises one or more top U-profile tracks (2u) fixed to a top position, extending along the longitudinal axis (X) with the U-opening facing towards a bottom position, and one or more bottom U-profile tracks (2d) fixed to the bottom position, extending along the longitudinal axis (X) with the U- opening facing towards the top position. The top and bottom U-profile tracks (2u, 2d) define the position of the wall lining and are preferably aligned vertically.
As shown in Figures 5(a) and 6(a), a first I-profile beam (3) is fixed to the top U-profile track (2u) and extends along the vertical axis (Z). The beam slit (3s) of the first I-profile beam (3) is engaged in the first U-flange (2f) of the top U-profile track (2u). When the beam slit (3s) is engaged in the first U-flange (2f), a corresponding free end of the second beam flange (3f2) is located in the U-opening, between the first and second U-flanges of the top U-profile track (2u), preferably contacting an inner surface of the second U-flange, and a corresponding free end of the first beam flange (3f1) is located outside the U-opening of the top U-profile track (2u). The free end of the first beam flange (3f1) is engaged in the groove (1g) of the first vertical edge of a first board with the second main surface contacting an outer surface of the first U-flange (2f) of the top U-profile track (2u). The I-profile beam (3) and the board edges and corresponding grooves (1g) must be dimensioned such that the distance separating the first beam flange (3f1) from the first U-flange (2f) of the top U-profile track (2u) corresponds to the thickness of the lip formed by the groove (1g) and the second main surface of a board. This way, upon engaging the first U-flange (3f1) into the groove (1g) of a board, the second main surface contacts the first U-flange (2f) of the top U-profile track (2u).
In Figures 10(a) and 10(b) the first I-profile beam (3) is replaced by an end-beam (9) defining a free end of the drywall. End beams (9) comprising an end slit (9s) are positioned in a similar fashion as described supra for the first I-profile beam (3). End beams (9) devoid of an end slit (9s) can be simply engaged into the groove (1g) of the first board (1). It is preferred, however, to secure the end beam (9) to the top and preferably to the bottom U-profile tracks with screws (8). End beams can be used at the ends of a drywall, be it a free end or an end forming an angle with an existing wall.
As shown in Figures 5(b) and 6(b), the beam slit (3s) of a second I-profile beam (3) is engaged in the first U-flange (2f) of the top U-profile track (2u) in the same way as the first I-profile beam (3), with the second flange (3f2) of the second I-profile beam (3) being engaged in the groove (1g) of the second vertical edge of the first board. The second main surface of a second board (1) contacts the outer surface of the first U-flange (3f1) of the top U-profile track (2u) with the groove (1g) of the first vertical edge being engaged in the second beam flange (3f2) of the second I-profile beam (3). The wall lining can extend indefinitely along the longitudinal axis (X) by adding successive boards (1) and I-profile beams (3) as described supra and illustrated in Figures 7(a) and 10(b).
In the embodiment illustrated in Figures 5(a) and 5(b), wherein the I-profile beams (3) have a beam height (H3) smaller than the board height (H1) of the boards, the wall lining also comprises first and second stabilizing elements (4) as described supra with the respective slits (4s) of the first and second stabilizing elements (4) engaged in the first U-flange of the bottom U-profile track (2d) with the respective element webs (4w) extending normal to the wall plane (X, Z), and wherein the element flange (4f) of the first stabilizing element (4) is engaged in the groove of the first vertical edge of the first board (1), and wherein the element flange (4f) of the second stabilizing element (4) is engaged in the groove of the first vertical edge of the second board (1). The building of a wall lining according to this embodiment is particularly simplified as there is no need to cut the I-profile beams (3) to the required length corresponding to the height (H1) of the boards (1) and of the final wall lining. Furthermore, this embodiment simplifies engaging the flanges (3f1, 3f2, 4f) of the I-profile beams (3) and of the stabilizing elements (4) into the respective grooves (1g) of the boards, even in old buildings with not perfectly straight walls, floors, and ceilings.

PERMANENT PARTITION WALL

A partition wall divides a room into two subspaces. Unlike the wall linings, a partition wall must be aesthetically appealing from both sides of the partition wall. Boards must be coupled to the support frame on both sides thereof. Piping, cables, insulation, and the like can run along a partition wall in the space comprised between the boards coupled to either side of the support frame. As explained for wall linings, the term "permanent" indicates that the partition wall is not designed for being mounted and dismounted repeatedly but is meant to remain in place.
A partition wall according to the present invention is characterized by the same features of a wall lining discussed in the section entitled "Permanent Wall Lining" supra and illustrated in Figures 7(a), 10(a) and 10(b), which content is included in the present section by reference, including a first series of I-profile beams (3) coupling a first row of boards (1) as illustrated in Figures 7(a) and 10(b). A partition wall further comprises a second row of boards (1) supported by a second series of I-profile beams (3) and applied against the second U-flanges (2f) of the top and bottom U-profile tracks, thus sandwiching the support frame between two series of boards.
In a preferred embodiment enhancing the structural resistance of the partition wall, each I-profile beam (3) of the second series of I-profile beams (3) is located between two I-profile beam (3) of the first series of I-profile beams (3). As illustrated in Figures 7(b) and 10(c) to 10(e), the I-profile beams (3) of the second series preferably alternate with the I-profile beams (3) of the first series such that all the I-profite beams (3) are separated from one another by a distance of about L / 2, wherein L is the width of a (uncut) board (1) measured along the longitudinal axis (X). The I-profile beams (3) of the second series are coupled to the support structure as follows.
The beam slit (3s) of the I-profile beams of the second series are inserted in the second U-flange (2f) of the top U-profile track (2u), and alternate along the longitudinal axis (X) with the I-profile beams (3) of the first series. The I-profile beams (3) of the first and second series are preferably distanced from each other by about half the width (= L/2) of the (uncut) boards (1). A corresponding free end of the second beam flange (3f2) is located between the first and second U-flanges of the top U-profile track (2u), preferably contacting an inner surface of the first U-flange, and a corresponding free end of the first beam flange (3f1) is located outside of the top U-profile track (2u), at a distance from the second U-flange (2f) of the top U-profile track (2u). The second beam flanges (3f2) of the I-profile beam of the second series contact the second main surface of the boards (1) of the first row of boards. The second beam flanges (3f2) of the I-profile beams of the second series are preferably coated with an adhesive (5) or a double-sided tape, such that the I-profile beams of the second series are adhesively coupled to the first row of boards (1) (cf. Figure 10(c)).
The boards (1) of the second series extend parallel to the wall plane (X, Z), with the grooves (1g) of the vertical edges being engaged in the first beam flanges (3f1) of the I-profile beams (3). The second main surface of the boards contact an outer surface of the second U-flange (2f) of the top U-profile track (2u). As illustrated in Figures 7(b), and 10(c) to 10(e), the second flange (3f2) of the I-profile beams (3) of the first series are coated with an adhesive (5) or a double-sided tape, such that the I-profile beams of the first series are adhesively coupled to the second row of boards (1). This sequence of I-profile beams (3) located every L/2 along the length of the longitudinal axis (X) and coupled to the first and second rows of boards (1) either by spline joints or by an adhesive (5) or double-sided tape imparts high stiffness and strength to the partition wall. It is clear that, if desired, the boards (1) of the first and second rows can be coupled to the I-profile beams (3) of the second and first series, respectively, with screws instead of an adhesive (5) or a double-sided tape.
Figures 7(c) and 7(d) show a top view and a side view of a partition wall according to the embodiment of the present invention illustrated in Figure 7(b). Figure 7(c) clearly shows, on the one hand,

how a first board of the first (or second) row of boards is secured to the support structure by spline joints as discussed supra and, on the other hand,
how a central portion of the second main surface of a second board of the second (or first) row of boards is secured to the support structure with an adhesive (5) or a double-sided tape as explained supra.

Figure 7(d) shows a side view of the partition wall with an I-profile beam (3) coupled to the top U-profile track (2u) via the beam slit (3s). The groove (1g) of the board on the right-hand side is inserted over a wing of the flange (3f) of the I-profile beam (3). The top U-profile track (2u) has a width (d2w) measured normal to the wall plane (X, Z). The U-flanges (2f) of the U-profile tracks have a thickness (t2f) which matches a width (d3w) of the beam slit (3s) such that the latter can be inserted over the U-flanges (2f) with some friction. The adhesive or double-sided tape preferably has a thickness similar to the thickness (t2f), to avoid having to flex the board to adhere the second main surface thereof to the corresponding beam flange (3f2). A distance (t1) of the groove to the edge of the second main surface is approximately equal to the distance the first beam flange (3f1) protrudes out of the top U-profile track (2u) such that the second main surface is placated against the flange of the top U-profile track (2u) when the groove (1g) is inserted over the first flange (3f1).

METHOD FOR INSTALLING A PERMANENT DRYWALL

The present invention greatly simplifies the installation of a permanent partition wall or wall lining to a point that even unexperienced amateur do-it-yourselfers can achieve an excellent result. The permanent partition wall or wall lining can be installed using a kit-of-parts as described supra, as follows.
One or more top U-profile tracks (2u) are fixed side by side to a top position, extending along the desired position of the drywall, with the U-opening facing towards a bottom position. If the drywall is straight, the desired position extends linearly along the longitudinal axis (X). Alternatively, the drywall may follow a broken line.
Similarly, one or more bottom U-profile tracks (2d) are fixed side by side to the bottom position, preferably to a floor, extending along the same desired position of the drywall with the U-opening facing towards the top position, and aligned relative to the vertical axis (Z) with the one or more top U-profile tracks (2u). The sequence of fixing the top and bottom U-profile tracks (2u, 2d) to their corresponding positions is unimportant for the present invention. The top and bottom U-profile tracks (2u, 2d) can be fixed to the top and bottom positions with screws, double-sided tape, and the like.
A shown in Figures 5(a) and 6(a), the beam slit (3s) of a first I-profile beam (3) is engaged into the first U-flange (2f) of the top U-profile track (2u) such that,

a corresponding free end of the second beam flange (3f2) is located between the first and second U-flanges of the top U-profile track (2u), preferably contacting an inner surface of the second U-flange, and such that
a corresponding free end of the first beam flange (3f1) is located outside of the top U-profile track (2u), at a distance from the first U-flange (2f) of the top U-profile track (2u).

As shown in Figures 5(a) and 5(b), and 6(a) and 6(b), a first board (1) is positioned parallel to the wall plane (X, Z), and the groove (1g) of the first vertical edge is engaged over the first beam flange (3f1) with the second main surface contacting an outer surface of the first U-flange (2f) of the top U-profile track (2u).
As shown in Figures 5(b) and 6(b), the beam slit (3s) of a second I-profile beam (3) is engaged into the first U-flange (2f) of the top U-profile track (2u) in the same way as the first I-profile beam (3). The first flange (3f1) of the second I-profile beam (3) is engaged into the groove (1g) of the second vertical edge of the first board. The first board of a first row of boards is thus firmly and simply fixed to the support structure as this is being built.
As shown in Figures 10(b) these last two steps are repeated to obtain a first row of boards of the desired length of the permanent partition wall or wall lining. In case the drywall comprises a free end, the first I-profile beam (3) is replaced by an end beam (9) in a similar fashion as the first I-profile beam (3) (cf. Figure 10(a)).
For installing a drywall with the embodiment wherein the I-profile beams (3) have a height (H3) smaller than the height (H1) of the boards (1), the slit (4s) of a first stabilizing element (4) is engaged into the first U-flange of the bottom U-profile track (2d) with the element web (4w) extending normal to the wall plane (X, Z), and the element flange (4f) of the first stabilizing element (4) is engaged into the groove of the first vertical edge of the first board (1). The foregoing steps are repeated for at least some of, preferably all the boards of the first row of boards. For wall linings, any cable, piping, or insulation material can be installed behind the wall lining under construction before or during coupling the first row of boards (1) to the support frame, such that they are hidden after completion of the coupling of the first row of boards.
For installing a partition wall, a second row of boards needs be coupled to the other side of the support frame, with the second main surface of each board contacting an outer surface of the second U-flange (2f) of the top U-profile tracks (2u). If desired, before coupling the second row of boards, acoustic and / or thermal insulation can be installed in contact with the second main surface of the boards of the first row of boards. Also, electric cables and / or tubing can be drawn in a volume defined between the top and bottom U-profile tracks (2u, 2b).
An adhesive (5) or a double-sided tape is applied to the second beam flange (3f2) of an I-profile beam (3) of a second series of I-profile beam (3) to form a first adhesive I-profile beam. The beam slit (3s) of the first adhesive I-profile beam is inserted into the second U-flange (2f) of the top U-profile track (2u) between the first and second I-profile beams (3) of the first series, preferably at half the distance separating the first and second I-profile beams (3), such that (cf. Figures 10(c) to 10(e)),

a corresponding free end of the second beam flange (3f2) is located between the first and second U-flanges of the top U-profile track (2u), preferably contacting an inner surface of the first U-flange, and such that
the adhesive (5) or double-sided tape on the second beam flange (3f2) of the first adhesive I-profile beam contacts and adheres to the second main surface of the first board (1) of the first row of boards and such that
a corresponding free end of the first beam flange (3f1) is located outside of the top U-profile track (2u), at a distance from the second U-flange (2f) of the top U-profile track (2u).

The second flange (3f2) of the first series of I-profile beams (3) supporting the first row of boards can be coated with an adhesive (5) or a double-sided tape.
A new first board (1) is positioned parallel to the wall plane (X, Z), and the groove (1g) of the first vertical edge is engaged over the first beam flange (3f1) of the first adhesive I-profile beam with the second main surface contacting an outer surface of the second U-flange (2f) of the top U-profile track (2u) and contacting and adhering to the adhesive (5) or a double-sided tape coated on the second flange (3f2) of the I-profile beam (3) of the first series which is next to the first adhesive I-profile beam.
An adhesive (5) or a double-sided tape is applied to the second beam flange (3f2) of a different I-profile beam (3) to form a second adhesive I-profile beam. The beam slit (3s) of the second adhesive I-profile beam is engaged into the second U-flange (2f) of the top U-profile track (2u) in the same way as the first adhesive I-profile beam, and the first flange (3f1) of the second adhesive I-profile beam is engaged into the groove (1g) of the second vertical edge of the new first board.
The foregoing steps can be repeated with third and following I-profile beams and with corresponding new second and following boards to obtain a second row of boards to form a permanent partition wall of the desired length. The boards at one end of the drywall may need to be cut to the desired width measured along the longitudinal axis. The newly formed vertical edge of a cut board does not comprise a groove anymore. The thus cut board can be fixed to the support frame with screws, as in state-of-the-art drywalls.
Again, for installing a partition wall with the embodiment wherein the adhesive I-profile beams (3) have a height (H3) smaller than the height (H1) of the boards (1), the slit (4s) of a first stabilizing element (4) is engaged into the second U-flange of the bottom U-profile track (2d) with the element web (4w) extending normal to the wall plane (X, Z), and the element flange (4f) of the first stabilizing element (4) is engaged into the groove of the first vertical edge of the first board (1) of the second row of boards. The foregoing steps are repeated for at least some of, preferably all the boards of the second row of boards.

CONCLUDING REMARKS

Drywalls according to the present invention are substantially simpler to install then state-of-the-art kits. An unexperienced amateur do-it-yourselfer can easily install a drywall with little to no technical difficulties associated with such operations as encountered with state-of-the-art kits. The number of profiles to be cut is reduced to a minimum and so is the number of screws, limited to the fixing of the top and bottom U-profile tracks to a top position (such as a ceiling) and a bottom position (such as a floor), respectively, and one or two board which are cut to the required width to complete the full length of the wall lining or partition wall.

REF	DESCRIPTION
1	Board
1g	Groove
2d	Bottom U-profile track
2f	U-flange of the U-profile track
2u	Top U-profile track
2w	U-web of the U-profile track
3	I-profile beam
3f1, 3f2	First and second beam flanges of the I-profile beam
3s	Slit of the I-profile beam
3w	Beam Web of the I-profile beam
4	Stabilizing element
4f	Element flange of the stabilizing element
4s	Element slit of the stabilizing element
4w	Element web of the stabilizing element
5	Adhesive or double-sided tape
9	End beam
9f	End flange of end beam
9w	Web of end beam
11	Permanent wall

d	Depth of groove
d2w	Width of the U-profile tracks measured normal to the wall plane (X, Y)
d3w	Width of the beam slit measured normal to the wall plane (X, Y)
H1	Height of the boards measured alonq the vertical axis (Z)
H3	Height of the I-profile beams measured along the vertical axis (Z)
H4	Height of the stabilizing element measured along the vertical axis (Z)
L	Width of the board measured along the lonqitudinal axis (X)
T	Thickness of the board measured at a centre of the board
Te	Thickness of the board measured at a vertical edge
t1	Distance from the groove to the edge of the second main surface
t2f	Thickness of the U-flange of the U-profile tracks
w	Width of the groove
(X, Z)	Wall plane
X, Y, Z	Longitudinal, transverse, and vertical axes

Claims

A kit-of-parts for installing a permanent partition wall or a permanent lining wall comprising,
(C) a support frame comprising,
• a top U-profile track (2u) and a bottom U-profile track (2d) being configured for forming top and bottom horizontal studs of the support frame, respectively, extending along a longitudinal axis (X), each of the top and bottom U-profile comprising first and second U-flanges (2f) parallel to each other separated by a U-web (2w) extending normal to the U-flanges and defining a U-opening,

• two or more I-profile beams (3), each I-profile beam comprising a beam web (3w) normal to and sandwiched between first and second beam flanges (3f1, 3f2) and configured for being coupled to the top U-profile track (2u) to form vertical beams extending along a vertical axis (Z) normal to the longitudinal axis (X) over a beam height (H3), with the first and second beam flanges extending parallel to a wall plane (X, Z) defined by the longitudinal axis (X) and vertical axis (Z), and with the beam web extending normal to the wall plane (X, Z),

(D) two or more boards (1), each board having a rectangular geometry, comprising a first main surface parallel to and separated from a second main surface by a thickness (T) measured along a transverse axis (Y) normal to the wall plane (X, Z), and forming a peripheral edge comprising first and second longitudinal edges of length (L) extending along the longitudinal axis (X), normal to and separated from one another by first and second vertical edges of board height (H1) extending along the vertical axis (Z), and wherein a groove (1g) extends along each of the first and second vertical edges, each groove having an opening width (w) measured normal to the wall plane (X, Z), and a depth (d) measured parallel to the longitudinal axis (X),
characterized in that, a free end of the beam web (3w) of each I-profile beam (3) comprises a beam slit (3s) configured for engaging over the first U-flange (2f) of the top U-profile track (2u) such that,
• a corresponding free end of the second beam flange (3f2) is located between the first and second U-flanges of the top U-profile track (2u), preferably contacting an inner surface of the second U-flange, and such that

• a corresponding free end of the first beam flange (3f1) is located outside of the top U-profile track (2u), at a distance from the first U-flange of the top U-profile track (2u) such that the first beam flange (3f1) can be introduced into the grooves (1g) of first and second adjacent boards (1) forming a spline joint between the first and second adjacent boards (1), with the second main surfaces of each of the first and second adjacent boards (1) extending parallel to the wall plane (X, Z) and contacting an outer surface of the first U-flange of the top U-profile track (2u).
Kit-of-parts according to claim 1, wherein the beam height (H3) is smaller than the board height (H1) (i.e., H3 < H1), and wherein the kit-of parts further comprises a stabilizing element (4) formed by a T- or L-profile comprising an element web (4w) and an element flange (4f) normal to the element web (4w), a free end of the element web (4w) comprises an element slit (4s) configured for engaging one of the two U-flanges (2f) of the bottom U-profile track (2d) such that,
• The element web (4w) extends normal to the wall plane (X, Z), such that

• a height (H4) of the stabilizing element (4) measured along the vertical axis (Z) is shorter than the difference between the board height (H1) and the beam height (H3) (i.e., H4 < H1 - H3), and such that

• a corresponding free end of the element flange (4f) is located outside of the bottom U-profile track (2d), at a distance from the first U-flange of the bottom U-profile track (2u) such that the element flange (4f) can be introduced into the groove (1g) of a first board (1) with the second main surface of the first board (1) extending parallel to the wall plane (X, Z) and contacting an outer surface of the first U-flange of the bottom U-profile track (2d).
Kit-of-parts according to claim 2, wherein the element flange (4f) has first and second surfaces separated by a thickness of the element flange, and wherein the first and second surfaces are textured (4t) or comprise protrusions (4p) configured for applying a friction against walls of the groove (1g) of the first board (1) it is inserted in.
Kit-of-parts according to claim 1, wherein the beam height (H3) is equal to the board height (H1) (i.e., H3 = H1) and preferably comprises openings (3h) provided in the beam web (3w) for allowing passage of wires and tubing.
Kit-of-parts according to any one of the preceding claims, wherein the thickness (T) of the boards (1) is comprised between 6 and 40 mm measured at a centre of the board, preferably between 18 and 25 mm, more preferably between 19 and 22 mm, or preferably between 20 and 35 mm, more preferably between 25 and 30 mm.
Kit-of-parts according to any one of the preceding claims, wherein the boards have a density comprised between 0.35 and 2.00 preferably between 0.4 and 0.65, more preferably between 0.50 and 0.60, or preferably between 0.70 and 1.6.
Kit-of-parts according to the preceding claim, wherein the boards comprise a core comprising at least 80 wt.% relative to the core weight of calcium sulphate dihydrate, or calcium silicate, or fibre-cement, or wood, or plywood.
Kit-of-parts according to any one of the preceding claims, wherein the vertical edges of the boards are tapered, preferably chamfered, relative to a centre of the boards, such that each board has an edge thickness (Te) measured at the vertical edges which is smaller than a thickness measured at the centre of the board, and wherein the thickness measured at the vertical edges is preferably comprised between 4 and 36 mm, more preferably between 14 and 22 mm, most preferably between 15 and 18 mm, or more preferably between 25 and 30 mm.
Kit-of-parts according to any one of the preceding claims, wherein the grooves (1g) of the boards (1) have an opening width (w) of 2 mm ± 0.3 mm, and a depth (d) comprised between 25 and 60 mm, preferably between 30 and 50 mm.
Kit-of-parts according to any one of the preceding claims, further comprising an end beam (9) for fixing the first vertical beam to a first board (1) having no adjacent second board, wherein the end beam is formed by a U-profile comprising first and second end-flanges (9f) parallel to each other separated by an end-web (9w) extending normal to the end-flanges and defining an end-opening, wherein preferably a free end of the end web (9w) comprises an end slit (9s) configured for engaging the first U-flange (2f) of the top U-profile track (2u) and the end-opening is wider than the U-opening of the top U-profile track, such that, a corresponding free end of the first end flange (9f) is located outside of the top U-profile track (2u), at a distance from the first U-flange of the top U-profile track (2u) such that the first end flange (9f) can be introduced into the groove (1g) of the first vertical edge of the first board (1) with the second main surface of the first board (1) extending parallel to the wall plane (X, Z) and contacting an outer surface of the first U-flange of the top U-profile track (2u) and said end web (9w) being wider than the U- opening of the top U-profile track,.
Permanent partition wall or permanent wall lining composed of the elements of the kit-of-parts according to any one of the preceding claims, wherein,
• one or more top U-profile tracks (2u) are fixed to a top position, extending along the longitudinal axis (X) with the U- opening facing towards a bottom position,

• one or more bottom U-profile tracks (2d) are fixed to the bottom position, extending along the longitudinal axis (X) with the U- opening facing towards the top position,

• the beam slit (3s) of a first I-profile beam (3) is engaged in the first U-flange (2f) of the top U-profile track (2u) such that,
∘ a corresponding free end of the second beam flange (3f2) is located between the first and second U-flanges of the top U-profile track (2u), preferably contacting an inner surface of the second U-flange, and such that

∘ a corresponding free end of the first beam flange (3f1) is located outside of the top U-profile track (2u), and is engaged in the groove (1g) of the first vertical edge of a first board with the second main surface contacting an outer surface of the first U-flange (2f) of the top U-profile track (2u),

• the beam slit (3s) of a second I-profile beam (3) is engaged in the first U-flange (2f) of the top U-profile track (2u) in the same way as the first I-profile beam (3), with the second flange (3f2) of the second I-profile beam (3) being engaged in the groove (1g) of the second vertical edge of the first board,

• The second main surface of a second board (1) contacts the outer surface of the first U-flange (3f1) of the top U-profile track (2u) with the groove (1g) of the first vertical edge being engaged in the second beam flange (3f2) of the second I-profile beam (3).
Permanent partition wall or permanent wall lining according to claim 11, wherein the kit-of-parts according to claim 2, comprising first and second stabilizing elements (4) as defined in claim 2 with the respective slits (4s) of the first and second stabilizing elements (4) engaged in the first U-flange of the bottom U-profile track (2d) with the respective element webs (4w) extending normal to the wall plane (X, Z), and wherein the element flange (4f) of the first stabilizing element (4) is engaged in the groove of the first vertical edge of the first board (1), and wherein the element flange (4f) of the second stabilizing element (4) is engaged in the groove of the first vertical edge of the second board (1).
Method for installing a permanent partition wall or permanent wall lining according to claim 11 or 12 of desired length measured along the longitudinal axis (X), comprising the following steps,
• providing a kit-of-parts according to any one of claims 1 to 10,

• fixing side by side one or more top U-profile tracks (2u) to a top position, extending along the longitudinal axis (X) with the U- opening facing towards a bottom position,

• fixing side by side one or more bottom U-profile tracks (2d) to the bottom position, preferably to a floor, extending along the longitudinal axis (X) with the U-opening facing towards the top position, and aligned relative to the vertical axis (Z) with the one or more top U-profile tracks (2u),

• engaging the beam slit (3s) of a first I-profile beam (3) into the first U-flange (2f) of the top U-profile track (2u) such that,
∘ a corresponding free end of the second beam flange (3f2) is located between the first and second U-flanges of the top U-profile track (2u), preferably contacting an inner surface of the second U-flange, and such that

∘ a corresponding free end of the first beam flange (3f1) is located outside of the top U-profile track (2u), at a distance from the first U-flange (2f) of the top U-profile track (2u),

• positioning a first board (1) parallel to the wall plane (X, Z), and engaging the groove (1g) of the first vertical edge over the first beam flange (3f1) with the second main surface contacting an outer surface of the first U-flange (2f) of the top U-profile track (2u),

• engaging the beam slit (3s) of a second I-profile beam (3) into the first U-flange (2f) of the top U-profile track (2u) in the same way as the first I-profile beam (3), and engaging the first flange (3f1) of the second I-profile beam (3) into the groove (1g) of the second vertical edge of the first board,

• repeating the last two steps to obtain a first row of boards of the desired length of the permanent partition wall or wall lining.
Method according to claim 13 for installing a permanent partition wall or permanent wall lining according to claim 12, further comprising the steps of,
• providing a kit-of-parts according to any one of claims 2 or 3,

• engaging the slit (4s) of the first stabilizing element (4) into the first U-flange of the bottom U-profile track (2d) with the element web (4w) extending normal to the wall plane (X, Z), and

• engaging the element flange (4f) of the first stabilizing element (4) into the groove of the first vertical edge of the first board (1),

• repeating the last two steps for at least some of, preferably all the boards of the first row of boards.
Method according to ciam13 or 14 for installing a permanent partition wall, further comprising forming a second row of boards with the second main surface of each board contacting an outer surface of the second U-flange (2f) of the top U-profile tracks (2u), the method comprising the following steps,
• optionally applying acoustic and / or thermal insulation in contact with the first main surface of the boards of the first row of boards, and further optionally positioning electric cables and / or tubing in a volume defined between the top and bottom U-profile tracks (2u, 2d),

• applying an adhesive (5) or a double-sided tape to the second beam flange (3f2) of an I-profile beam (3) to form a first adhesive I-profile beam,

• engaging the beam slit (3s) of the first adhesive I-profile beam into the second U-flange (2f) of the top U-profile track (2u) between the first and second I-profile beams (3), preferably at half the distance separating the first and second I-profile beams (3), such that,
∘ a corresponding free end of the second beam flange (3f2) is located between the first and second U-flanges of the top U-profile track (2u), preferably contacting an inner surface of the first U-flange, and such that

∘ the adhesive (5) or double-sided tape on the second beam flange (3f2) of the first adhesive I-profile beam contacts the second main surface of the first board (1) of the first row of boards and such that

∘ a corresponding free end of the first beam flange (3f1) is located outside of the top U-profile track (2u), at a distance from the second U-flange (2f) of the top U-profile track (2u),

• positioning a new first board (1) parallel to the wall plane (X, Z), and engaging the groove (1g) of the first vertical edge over the first beam flange (3f1) with the second main surface contacting an outer surface of the second U-flange (2f) of the top U-profile track (2u),

• applying an adhesive (5) or a double-sided tape to the second beam flange (3f2) of a different I-profile beam (3) to form a second adhesive I-profile beam,

• engaging the beam slit (3s) of the second adhesive I-profile beam into the second U-flange (2f) of the top U-profile track (2u) in the same way as the first adhesive I-profile beam (3), and engaging the first flange (3f1) of the second adhesive I-profile beam into the groove (1g) of the second vertical edge of the new first board,

• repeating the last three steps with third and following I-profile beams and with corresponding new second and following boards to obtain a second row of boards to form a permanent partition wall of the desired length.
Method according to claim 15 for installing a permanent partition wall according to claim 12, further comprising the step of,
• providing a kit-of-parts according to any one of claims 2 or 3,

• engaging the slit (4s) of a stabilizing element (4) into the second U-flange of the bottom U-profile track (2d) with the element web (4w) extending normal to the wall plane (X, Z), and

• engaging the element flange (4f) of the stabilizing element (4) into the groove of the first vertical edge of the new first board (1),

• repeating the last two steps for at least some of, preferably all the boards of the second row of boards.