EP4627162A1

EP4627162A1 - A web member for connecting lightweight construction element

Info

Publication number: EP4627162A1
Application number: EP23897069.3A
Authority: EP
Inventors: Antonin Poupart; Kanakavel S
Original assignee: Saint Gobain Placo SAS
Current assignee: Saint Gobain Placo SAS
Priority date: 2022-11-30
Filing date: 2023-11-28
Publication date: 2025-10-08
Also published as: WO2024116200A1

Abstract

A web member (10) for connecting a lightweight construction element (100) is disclosed. The lightweight construction element (100) comprises a first and second flange member (30, 40) and a plurality of web members (10) placed an interval from each other. This replacement of conventional full length web member to a spaced web member (10) results in reduction of metal usage and thus resulting in a lightweight construction element (100). Further, the web member (10) is configured so as to form I-shape with a first portion (50), a pair of second portions (60) with two distal ends (70) and third portions (75) arising from the distal ends (70). The major axis of the first portion (50) is different from the major axis of the pair of second portions (60).

Description

A WEB MEMBER FOR CONNECTING LIGHTWEIGHT CONSTRUCTION ELEMENT

Technical Field

The present disclosure relates to a web member for connecting a lightweight construction element. More specifically, the present disclosure relates to web members spaced at a predetermined distance from each other and connecting a first and second flange member of the lightweight construction element. Further, the web member in the present disclosure results in I-shaped configuration.

Background

Though drywall or the construction panels are the most common component of a drywall system, it wouldn’t be anything without the conventional construction element and framing members it’s attached to. Conventional construction element framed wall is a type of wall partition system, which is used to build a new room within an existing space - such as in an office or commercial building. Hence it has a wide range of application in the industry. Though conventional construction elements may be built with timber, glass, brick, plaster slab or even concrete, metal conventional construction elements has the widest applicability. The use of metal conventional construction elements provides advantages like dimensional stability, ease of manufacturing and conservation of natural resources among others.

Now, 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. Steel production is an energy-intensive process as it requires high temperatures to transform iron ore into steel. The energy and heat from the processes come from fossil fuels, which is primarily coal. The use of fossil fuels means that the average CO2 emissions from steel production is about 1.85 tonnes CO2 per tonne of steel produced (as mentioned in the article -Cleaning up the Steel Industry: Reducing CO2 emissions with CCUS). With the world moving towards sustainability, everywhere there is a requirement of reduced CO2 emissions with the aim to move towards global net-zero targets. Thus, is the evolution and development of the lightweight metal components which contributes largely in reduction of CO2 emissions.

In the drywall framing industry, there had been various developments in the lighweight domain. 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.

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 KR101637145B1 describes a structural modification of the construction element, which is a stud, resulting in a lightweight 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 and in turn lower CO2 emission, 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 web member for a lightweight construction element which is placed at a predetermined interval, 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 30-40% lower weight as compared to any conventional construction element.

Summary of the Disclosure

In one aspect of the present disclosure, web member for connecting a first and second flange member of a lightweight construction element is disclosed. The web member comprises a first portion with two distal ends and a pair of second portions having length L and width D with two distal ends. The pair of second portions arise from the distal ends of the first portion and comprise a major axis different from a major axis of the first portion, the distal ends are extended to comprise third portions having orientation different from the major axis of the pair of second portions.

In another aspect of the present disclosure, a lightweight construction element is disclosed. The lightweight construction element comprises a first and second flange member and a plurality of web members. The first and second flange member each has a front surface facing each other and a back surface non-facing each other, wherein, the first flange member and the second flange member are spaced at a distance Y between the back surface of the first and second flange member. Further, the plurality of web members are placed between the front surface of the first and second flange members at an interval from each other to physically couple and hold the first and second flange members together. The web members are coupled to embossed portions of the first and second flange member.

In yet another aspect of the present disclosure, a method of making lightweight construction element is disclosed. The method involves the steps of: providing a first and second flange member spatially separated from each other at the distance Y between the back surface and thereafter coupling the first and second flange members together by a plurality of web members. In the method of coupling, the web members are first fixed to the embossed portion.

In another aspect of the present disclosure, a drywall partition framing assembly is disclosed. The drywall partition comprises: a horizontal framing member fixed to the floor and a horizontal framing member substantially parallel to and spaced from the horizontal framing member and fixed to the ceiling, a plurality of lightweight construction elements and at least one construction panel. The plurality of lightweight construction elements are mounted such that the back surface of the first and second flange members abut and support the surface of the construction panel at positions outside the regions wherein the web member is coupled to the first and second flange members when the 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 illustrates a perspective view of a lightweight construction element in accordance with one embodiment of the present disclosure;

FIG. IB illustrates a perspective view of a lightweight construction element in accordance with one more embodiment of the present disclosure;

FIG. 2A illustrates a perspective view of a web member in accordance with one embodiment of the present disclosure;

FIG. 2B illustrate a top view of the web member as shown in FIG. 2A connected to a lightweight construction element;

FIG. 3 illustrates a perspective view of a lightweight construction element in accordance with another embodiment of the present disclosure;

FIG. 4A illustrates a perspective view of a web member in accordance with another embodiment of the present disclosure;

FIG. 4B illustrate a top view of the web member as shown in FIG. 4A connected to a lightweight construction element;

FIG. 5 illustrates a perspective view of a lightweight construction element in accordance with yet another embodiment of the present disclosure;

FIG. 6 illustrates a perspective view of a web member in accordance with yet another embodiment of the present disclosure;

FIG. 7 illustrates a perspective view of a drywall partition framing assembly 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” construction element is defined as a construction element comprising a pair of flanges substantially parallel to each other and connected substantially perpendicularly at their base by a web.

As used throughout, a “C-shaped” construction element is defined as a 5 construction element comprising a pair of flanges substantially parallel to each other and connected substantially perpendicularly at their base by a web, with the pair of flanges having return edges pointing inwards substantially parallel to the web.

As used throughout, an “I-shaped” construction element is defined as a construction element comprising a pair of flanges substantially parallel to each other and connected substantially perpendicularly by a web, preferably positioned central to the pair of flanges.

FIG. 1A is a perspective view of a lightweight construction element 100 in accordance with one embodiment of the present disclosure. The lightweight construction element 100 as disclosed comprises of a first and second flange member 30, 40 and a plurality of web members 10. Both the first and second flange member 30, 40, has a front surface 30a, 40a facing each other and a back surface 30b, 40b non-facing each other. Further, the first flange member 30 and second flange member 40 are oriented parallel to each other and spaced at a distance Y between the back surface 30b, 40b of the first and second flange members 30, 40. The plurality of web members 10 are such that they comprise a first portion 50 with two distal ends and a pair of second portions 60 having length L and width D arising from the distal ends of the first portion 50. The pair of second portions 60 further has a length L and a width D with two distal ends 70. The major axis of the pair of second portions 60 is different from the major axis of the first portion 50. Third portions 75 arises from the distal ends 70 and has an orientation different from the major axis of the pair of second portions 60. These web members 10 are placed between the front surface 30a, 40a of the first and second flange members 30, 40 at an interval from each other to physically couple and hold the first and second flange members 30, 40 together. In the present embodiment, the first and second flange member 30, 40 comprises a pair of lips 35 placed opposite to each other, rising at an angle ranging from 90° to 110° from the first and second flange member 30, 40 and placed at an interval from each other. Optionally in some of the embodiments as depicted in FIG. IB, the flange members 30, 40 can be without lips. The lips 35 further comprise an embossed portion 25 with a slit 45. Additionally, the first and second flange member 30, 40 comprise embossed portions 25a with a slit 45a. FIGs. 2A and 2B depicts the perspective view of the web member 10 and the top view of the web member 10 connected to a lightweight construction element as used in the lightweight construction element 100 as depicted in FIG. 1A respectively. As in FIGs. 2A and 2B, for the web member 10 of the current embodiment, the distal ends 70 of the web member 10 comprise third portions 75 perpendicular to the pair of second portions 60 and parallel to the first portion 50. In the specified embodiment, the pair of second portions 60 are in same plane as the first portion 50. Further, the pair of second portions 60 comprise a fourth portion 75’ extending perpendicular to the major axis of the pair of second portions 60.. Optionally in embodiments as depicted in FIG. IB, the third portions 75 are absent. The configuration of the present embodiment is such that web member 10 has an I- shape. Additionally, the third portions 75 comprise end portions 80. The end portions 80 are such that they form a return lip on the third portion 75, as shown in FIGS. 1A, IB and 2A. End portions 80 helps grip and hold the slit 45 in the embossed portions 25 of the first and second flange members 30, 40 respectively. Similarly, fourth portions 75’ comprise end portions 80a. These end portions 80a helps grip and hold the slit 45’ in the embossed portions 25a of the first and second flange members 30, 40 respectively. In other words, the slit 45, 45a of the first and the second flange member 30, 40 houses the third and fourth portions 75, 75’ inside. More specifically, the end portions 80, 80a of the web member 10 houses the embossed portion 25, 25a in the lips 35 and the first and second flange member 30, 40. For the secured coupling, the thickness of the gap of the slit 45, 45a and the end portion 80, 80a is proportional to the thickness of the material of the web 10 and the embossed portion 25, 25a respectively. For the present embodiment, a part of the lightweight construction element 100 if taken along with the web member 10 gives a I-shaped perspective view. Optionally, in some other embodiments, a part of the lightweight construction element 100 if taken along with the web member 10 can give rise to a U/C-shaped perspective view.

FIG. 3 depicts a perspective view of a lightweight construction element in accordance with another embodiment of the present disclosure. In the present embodiment, the first and second flange members 30, 40 comprise a pair of continuous lips 35 placed opposite to each other, rising at an angle ranging from 90° to 110° from the first and second flange member 30, 40. The lips further comprises an embossed portion 25 spaced at an interval from each other and comprising a slit 15. FIG. 4A and 4B depicts the perspective view of the web member 10 and the top view of the web member 10 connected to a lightweight construction element as used in the lightweight construction element 100 as depicted in FIG. 3 respectively. In the present embodiment, the pair of second portions 60 of the web member 10 are in different plane than the first portion 50. Further, the distal ends 70 comprises third portions 75 perpendicular to the pair of second portions 60 and parallel to the first portion 50 and facing inward. This thereby depicts, orientation of the third portions 75 is different form the major axis of the first portion 50 and the pair of second portions 60. The third portions 75 has rounded edges to avoid handling difficulties on-site. This web member 10 gets coupled to the slit 15 in the flange wherein the dimensions of the hole formed by the slit 15 in the embossed portion 25 is equal or preferably slightly greater than the dimensions of the third portions 75 of the web member lOfor the ease of coupling and thereafter a stable connection. In other words, the embossed portion 25 houses the third portion 75. More specifically, the slit 15 of the embossed portion houses the third portions 75 of the web member 10. In the present embodiment, the slit 15 is one side open slit which helps clip and hold the third portion 75 of the web member 10. All the other features of embodiments as depicted in FIGS. 4A and 4B has similar characteristics as that of the embodiment as detailed out in FIGS. 2A and 2B. Additionally, even all other features of embodiments as depicted in FIG. 3 has similar characteristics as that of the embodiment as detailed out in FIG. 1.

FIG. 5 depicts a perspective view of a lightweight construction element in accordance with yet another embodiment of the present disclosure. In the present embodiment, the first and second flange member 30, 40 comprises embossed portions 25 with a slit 55. FIG. 6 depicts the perspective view of the web member 10 as used in the lightweight construction element as in FIG. 5. In the current configuration, for the web member 10 the pair of second portions 60 of the web member 10 are in different plane than the first portion 50. Additionally, for the current embodiment, the third portions 75 comprise a stepped region with an upper portion 75a having a width W, and a lower portion 75b having a width W’. The width W of the upper portion 75a is more than a width W’ of the lower portion 75b and the width W’ of the lower portion 75b is proportional to the width of the slit 55. This configuration helps in housing the lower portion 75b of the web member 10 to the slit 55 of the embossed portion 25 and get fitted into. This shape of third portions 75 could equally be used in other embodiments of the invention, including the embodiments shown in Figs. 1A, IB and 3. All the other features of embodiments as depicted in FIGS. 5 and 6 has similar characteristics as that of the embodiment as detailed out in FIGS. 1 and 2A or 2B.

In all the embodiments, the web members 10 is plastic, polymer, cardboard, wood, steel or other suitable metals or non-metals. Optionally, in some of the embodiments, the web member 10 can be metal - preferably any lightweight metal like steel. The web member 10 is manufactured in whole or in parts. Further, the first and second flange members 30, 40 comprise plastic, polymer, cardboard, wood, steel or other suitable metals or non-metals. Optionally, in some of the embodiments, the first and second flange members 30, 40 can be metal. The present disclosure is such that the lightweight construction element 100 is manufactured in parts,. Further, the present configuration being versatile in nature, it can be suitably used as both dry wall stud as well as ceiling channel.

The preferred dimensions of the lightweight construction element 100 is as follows: The length of the first and second flanges ranges from 3.2meter to 3.6meter. Further, the spacing between the web members ranges from 250mm to 400mm - this results in 30% decrement of weight of the lightweight construction element 100 of the present disclosure as compared to all conventional construction element. The length of the central portion 50 is proportional to the distance between the front surface 30a, 40a of the first and second flange members 30, 40, and the length of the portions 60 is proportional to a width of the first and second flange members 30, 40.

Again, for all the embodiments, the web members 10 are spaced at a predetermined interval such that together the plurality of web members 10 cover a small fraction of length with respect to the flange member 30 or 40. This design modification and configuration results in reduction of the weight of the lightweight framing component 100 and enables ease of installation due to the reduced weight. Further, it is to be noted the coupling process involves mere placing of the web members 10 along the flange members 30, 40 and coupling the same. The lightweight construction element of the present invention is equally efficient with respect to structural performance of deflection as compared to any conventional construction element. Additionally, they are easy to transport as the flange members 30, 40 can be stacked one over the other and coupling with the web members 10 can be done on-site on need basis. Moreover, 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, this is a step towards sustainability and sustainable living without compromising on the quality.

The disclosure also depicts a method of making a lightweight construction element 100 which involves: providing a first and second flange member 30, 40 spatially separated from each other at the distance Y between the back surface 30b, 40b and thereafter coupling the first and second flange members 30, 40 together by a plurality of web members 10. Coupling is done by whereby the web members 10 are first fixed to the first or second flange member 30 or 40 and thereafter fixed to first or second flange member 30 or 40, and the embossed portion 25 houses the extended portions 75. Additionally, the web members 10 are coupled to the first and second flange members 30, 40 by clipping or snap fitting or press fitting or welding or screwing or riveting or bolting or nailing or clinching or crimping or a combination thereof of the extended portions 75 to the embossed portions 25 in the first and second flange members 30, 40.

FIG. 7 illustrates a perspective view of drywall partition framing assembly 500 comprising drywall framing components in accordance with one of the embodiments of the present disclosure. It comprises: a horizontal framing member 200 fixed to the floor, a horizontal framing member 300 substantially parallel to and spaced from the horizontal framing member and fixed to the ceiling, a plurality of lightweight construction elements 100 (as depicted in FIG. 1, 3 or 5) 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. The lightweight construction elements 100 are mounted such that the back surface 30b, 40b of the first and second flange members 30, 40 abut and support the surface of the construction panel 350 at positions outside the regions wherein the web member 10 is coupled to the first and second flange members 30, 40 when the at least one construction panel 350 is fixed to one or either sides of the framing assembly. In the present embodiment, there is an insulating panel 250 sandwiched in between the construction panels 350. Optionally, in some other embodiment, there is no requirement of the insulating panel. The construction panel 350 in the present embodiment is most commonly gypsum plaster boards, gypsum fiber boards, cellulose fiber reinforced cement boards, magnesium boards, or plywood boards but alternatively may be any other suitable construction boards. Additionally, in the present configuration, at least one of the web member 10 coupling the first and the second flange member 30, 40 rests on the horizontal framing member 200 fixed to the floor and at least one of the web member 10 coupling the first and the second flange member 30, 40 rests on the horizontal framing member 300 fixed to the ceiling.

Industrial Applications

Thus the web member 10 when used in the lightweight construction element 100 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 100 herein possesses the following advantages:

The web member can be used in conjunction with currently existing industry standardized drywall components (viz. conventional flange members, drywall components etc.) without necessitating a modification of other system components;

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

The web configuration is such that it delays in the heat transfer and hence providing the thermal comfort;

Sound transmission is discontinuous due to the non-continuous web and hence resulting in acoustic comfort as well; 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;

In some embodiments the web members are cut from flat metal sheets which thereby results in near to zero metal scrap and metal wastage;

Additionally, them being lightweight, they are capable of reducing construction time and cutting costs, whilst still demonstrating desirable characteristics and compatibility with the surrounding construction.

The lightweight construction element 100 with the web member 10 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 flange members of a lightweight construction element or channel component or even drywall grid system. It provides ease of manufacture, is sustainable, easy to transport and assemble, is durable, can be fabricated on-site 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. Such changes and modifications include combinations of compatible features from different embodiments of the present disclosure. 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

TITLE: A LIGHTWEIGHT CONSTRUCTION ELEMENT

10: Web Members

15, 45, 45a, 55: Slit 25, 25a: Embossed portion

30: First Flange Member

35: Lips

40: Second Flange Member

30a, 40a: Front surface

30a, 40a: Back surface

50: First Portion

60: Pair of Second Portions

70: Distal End

75: Third Portions

75 ’ : F ourth Portions

75a: Upper Portion

75b: Lower Portion

80, 80a: End Portions

100: Lightweight Construction Element

200, 300: Horizontal Framing Member

250: Insulating Panel

350: Construction Panel

500: Partition Framing Assembly

W, W’: Width

Y: Distance

Claims

Claims:

1. A web member 10 for connecting a first and second flange member 30, 40 of a lightweight construction element 100, the web member 10 comprising: a first portion 50 with two distal ends; a pair of second portions 60 having a length L and a width D with two distal ends 70; wherein, the pair of second portions 60 arise from the distal ends of the first portion 50 and comprise a major axis different from a major axis of the first portion 50, the distal ends 70 are extended to comprise third portions 75 having orientation different from the major axis of the pair of second portions 60.

2. The web member 10 as claimed in claim 1, wherein, the pair of second portions 60 are in same plane as the first portion 50.

3. The web member 10 as claimed in claim 1, wherein, the third portions 75 comprise an end portions 80.

4. The web member 10 as claimed in claim 2, wherein, the pair of second portions 60 further comprise fourth portions 75’ extending perpendicular to the major axis of the pair of second portions 60.

5. The web member 10 as claimed in claim 4, wherein, the fourth portions 75’ comprise end portions 80a.

6. The web member 10 as claimed in claim 1, wherein, the pair of second portions 60 are in different plane than the first portion 50.

7. The web member 10 as claimed in claim 1, wherein, the third portions 75 comprise a stepped region with an upper portion 75a having a width W, and a lower portion 75b having a width W’.

8. The web member 10 as claimed in claim 7, wherein, the width W of the upper portion 75a is more than the width W’ of the lower portion 75b.

9. The web member 10 as claimed in claim 1, is made of plastic, polymer, cardboard, wood, steel, or other suitable metals or non-metals.

10. The web member 10 as claimed in claim 1, is made of metals.

. The web member 10 as claimed in claim 1, is manufactured in whole or in parts. . A lightweight construction element 100 comprising: a first and second flange member 30, 40, each having a front surface 30a, 40a facing each other and a back surface 30b, 40b non-facing each other wherein the first flange member 30 and the second flange member 40 are oriented parallel to each other and spaced at a distance Y between the back surface 30a, 40a of the first and second flange member 30, 40 and have embossed portions 25 and/or 25a; and a plurality of web members 10 as claimed in claim 1, placed between the front surfaces 30a, 40a of the first and second flange member 30, 40 at an interval from each other to physically couple and hold the first and second flange member 30, 40; characterized in that: the web members are coupled to the embossed portions 25 and/or 25a of the first and second flange member 30, 40. . The lightweight construction element 100 as claimed in claim 12, wherein, the first and second flange member 30, 40 comprise a pair of lips 35 placed opposite to each other, rising at an angle ranging from 90° to 110° from the first and second flange member 30, 40 and placed at an interval from each other. . The lightweight construction element 100 as claimed in claim 12, wherein, the first and second flange member 30, 40 comprise a pair of lips 35 placed opposite to each other, rising at an angle ranging from 90° to 110° from the first and second flange member 30, 40 and are continuous. . The lightweight construction element 100 as claimed in claim 12, wherein, the embossed portion 25 are located in the pair of lips 35 and comprise a slit 45.

. The lightweight construction element 100 as claimed in claim 12, wherein the embossed portion 25a are located in the first and second flange member 30, 40 and comprise a slit 45a. . The lightweight construction element 100 as claimed in claim 15 or 16, wherein, the dimension of the hole formed by the slit 45 in the embossed portion 25 or by the slit 45a in the embossed portion 25a are equal to or greater than the dimensions of the third portions 75 and fourth portion respectively of the web member 10. . The lightweight construction element 100 as claimed in claim 12, wherein, the thickness of the end portions 80 in the third portions 75 and the thickness of the end portions 80a in the fourth portions 75’ in the web member 10 is proportional to the thickness of the embossed portion 25, 25a in the first and second flange member 30, 40 and lips 35 respectively. . The lightweight construction element 100 as claimed in claim 12, wherein the web members 10 are placed at a distance of 250mm to 400mm from each other. . The lightweight construction element 100 as claimed in claim 12, wherein the first and second flange member 30, 40 comprises plastic, polymer, cardboard, wood, steel or other non-metals or metals. . The lightweight construction element 100 as claimed in claim 12, wherein the first and second flange member 30, 40 comprises metal. . The lightweight construction element 100 as claimed in claim 12, is manufactured in parts. . The lightweight construction element 100 as claimed in claim 12 is a dry wall stud or a ceiling channel. . A method of making the lightweight construction element 100 of claim 12, comprising the steps of providing a first and second flange member 30, 40 spatially separated from each other at the distance Y between the front surface 30a, 40a, coupling the first and second flange member 30, 40 by a plurality of web members 10, wherein the web members 10 are coupled to the embossed portions 25 and/ or 25a and are thereby coupled to the first or second flange member 30 or 40.. The method of making the lightweight construction element 100 as claimed in claim 24, wherein third portions 75 and fourth portions 75’ of the web members 10 are housed inside a slit 45, 45a in the first and second flange member 30, 40. . The method of making the lightweight construction element 100 as claimed in claim 24, wherein, end portions 80, 80a of the web members 10 houses the embossed portion 25, 25a of the first and second flange member 30, 40 respectively. . The method of making the lightweight construction element 100 as claimed in claim 24, wherein, the third portions 75 of the web members 10 are housed inside the embossed portion 25. . The method of making the lightweight construction element 100 as claimed in claim 24, wherein, a lower portion 75b of the web member 10 is housed inside the embossed portion 25. . The method of making the lightweight construction element 100 as claimed in claim 24, wherein web members 10 are secured to the first and second flange member 30, 40 by clipping or snap fitting or press fitting or welding or screwing or riveting or bolting or nailing or clinching or crimping or a combination thereof. A drywall partition framing assembly 500 comprising: a horizontal framing member 200 fixed to the floor; a horizontal framing member 300 substantially parallel to and spaced from the horizontal framing member 200 and fixed to the ceiling; a plurality of lightweight construction elements 100 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 100 are mounted such that the back surface 30b, 40b of the first and second flange member 30, 40 abut and support the surface of the construction panel at positions outside the regions wherein the web member 10 is coupled to the first and second flange member 30, 40 when the at least one construction panel is fixed to one or either sides of the framing assembly. The dry wall partition framing assembly 500 as claimed in claim 30, wherein at least one of the web member 10 coupling the first and the second flange member 30, 40 rests on the horizontal framing member 200 fixed to the floor and at least one of the web member 10 coupling the first and the second flange member 30, 40 rests on the horizontal framing member 300 fixed to the ceiling.