GB2586129A

GB2586129A - Dry wall formations

Info

Publication number: GB2586129A
Application number: GB1911154.1A
Authority: GB
Inventors: Hart William
Original assignee: Taylor Hart Ltd
Current assignee: Taylor Hart Ltd
Priority date: 2019-08-05
Filing date: 2019-08-05
Publication date: 2021-02-10
Also published as: GB202002148D0; GB2615389A; GB2615390A; GB201911154D0; GB202217630D0; GB202217627D0; GB202217628D0; GB2615391B; GB2615390B; GB2615389B; GB2586179A; GB2615391A; GB2586179B

Abstract

A prefabricated plasterboard element (300) formed of a plasterboard panel (302) having an external sheet (308) and a body (312) formed by plaster, wherein the plasterboard element (300) comprises a first face (316) and a second face (318), angled with respect to the first face (316), the first and second face (316, 318) joined along an edge; wherein the first and second faces (316, 318) are formed by the external sheet (308) of a plasterboard section; wherein the external sheet (308) is continuous, and the body (312) includes a break along the edge, to form separate body portions. The panel can be folded along the line of the break to allow relative movement of the separate body portions and corners can be formed between the portions

Description

DRY WALL FORMATIONS

The present invention relates to prefabricated elements for dry walls. In particular, but not exclusively, the present invention relates to, for example, access hatches, builders work openings corner braces for door frames, and deflection heads.

Dry walling can be used to partition a large internal space into smaller areas. Typically, a dry wall dividing wall includes an arrangement of studs, with plasterboard secured to the studs.

In typical dry walls, various features may need to be formed. These include window and door frames, openings through which services may pass, and various other features. Furthermore, deflection heads may be formed at the top of the dry wall to accommodate shifts in the building structure and/or dry wall.

Regulatory and/or manufacturer standards, such as the British Gypsurni:g) White Book and British Standard BS 1230-1:1985, may specify certain requirements of the dry wall including structural strength, fire protection and acoustic isolation. The various features formed in the dry wall must remain in compliance with the required standards, whilst also being easy to install.

Typically, the frames and plasterboard for dry walls are provided in fixed sizes, which can be cut down for the desired use. When forming the various features, this can result in high waste. Furthermore, whilst the assembly of dry walls can be relatively straight forward, forming the additional features required can add significant time and complexity to the work. Also, cutting plasterboard can cause high levels of dust.

In addition, where corners are formed in dry walls, a trim or plaster bead is required to provide a sharp edge at the corner. This necessitates further work and further cost due to the additional components.

According to a first aspect of the invention, there is provided a prefabricated frame element for forming a portion of a dry wall including: a track member having: a base with a top surface and an opposing bottom surface; and walls extending from opposing sides of the base, defining a channel on the bottom surface of the base; a plasterboard section secured to the top surface of the base, extending between the sides of the base and along at least a portion of the length of the track member.

The prefabricated frame clement can be manufactured off-site, thus reducing the amount of time and dust when installing the wall. The elements can be assembled in a controlled environment that allows for better management of the dust (e.g. by proper extractions/ventilation). Furthermore, the amount of waste can be reduced by assembling multiple elements at the same time, and the prefabricated frame element can be made with a high level of repeatability, avoiding any problems that may occur with on site-ad hoc labour.

The plasterboard section may have a width equal to or substantially equal to the width between the sides of the base.

The plasterboard section may be secured to the track member by screws or other mechanical fixing means. Alternatively the plasterboard section may be secured to the track member by an adhesive.

The prefabricated frame element may have screw holes extending through the plasterboard and track member. for securing the prefabricated frame element to one or more dry wall studs.

The screw holes may be at predetermined distances along the length of the frame section.

The use of screw holes at predetermined positions ensures that the prefabricated frame element complies with the required standards and further reduces the on-site work required.

The prefabricated frame element may include one or more corners along the length of the track member.

The corners may be right angles or substantially right angled.

The prefabricated frame element may include one or more straight sections, joined by the corners. Separate plasterboard sections may be provided for each straight section.

At least some of the corners may be formed by cuts in the walls of the track member, allowing the track member to be bent. The base may be continuous around the corner, such that the base forms a pivot for forming the corners. One of the corners may be formed by overlapping opposing ends of the track sections, and securing the overlapping ends together. In order to form the overlap, the base of the track section may be removed at one of the ends, such that the opposing end is received within the channel of the track member.

The prefabricated frame element may include two or more layers of plasterboard sections stacked on the frame.

The two or more layers of plasterboard sections may be secured together by screws or other mechanical fixing means. The same screws may secure the two or more plasterboard layers to each other and the frame.

Alternatively, the two or more layers of plasterboard may be secured to each other and/or the track member by an adhesive.

The prefabricated frame element may comprise one or a combination of the following: - An access hatch for building services to pass through; A builders work opening; A right angle frame for securing a door frame to a dry wall at the base of the door frame; -A "U" shaped member; or - A deflection head.

According to a second aspect of the invention there is provided a dry wall dividing wall having: a plurality of studs extending vertically; a plurality of plasterboard panels secured to the studs to form a wall; and a plurality of prefabricated elements according to the first aspect, the prefabricated frame elements forming one or more features in the dividing wall.

The prefabricated frame element can be manufactured off-site, thus reducing the amount of time and dust when installing the wall. The elements can be assembled in a controlled environment that allows for better management of the dust (e.g. by proper extractions/ventilation). Furthermore, the amount of waste can be reduced by assembling multiple elements at the same time, and the prefabricated frame element can be made with a high level of repeatability, avoiding any problems that may occur with on site-ad hoc labour.

The plasterboard panels may define a wall formed in a first plane. The plasterboard sections of the prefabricated frame elements may define surfaces extending perpendicular to the first plane.

According to a third aspect of the invention, there is provided a kit of parts for forming a dry wall, the kit of parts comprising: a plurality of prefabricated frame elements according to the first aspect of the invention: a plurality of studs for forming a frame; and a plurality of plasterboard panels for securing to the frame.

According to a fourth third aspect of the invention, there is provided a method of forming dry walls, the method comprising: pre-fabricating frame elements according to the first aspect of the invention; assembling a dry wall frame including studs and the prefabricated frame elements; and securing plasterboard to the frame.

The steps of assembling the frame and securing the plasterboard panels to the frame may be carried out on-site. The step of pre-fabricating the frame elements may be carried out off-site.

Pre-fabricating frame elements according to the first aspect of the invention may comprise: cutting one or more track members from a stock length of track; cutting one or more plasterboard sections from a stock plasterboard panel; and securing at least one of the plasterboard sections to a track member.

Pre-fabricating frame elements according to the first aspect of the invention may further comprise: cutting a stock length of track to form a plurality of track members; cutting a stock plasterboard panel to form a plurality of plasterboard sections; and assembling a plurality of frame elements according to the first aspect of the invention.

The method may include forming a corner in the prefabricated frame clement.

Forming a corner in the prefabricated frame element may comprise: cutting the walls of the track member in a direction perpendicular to the length of the track member, whilst keeping the base section of the track member continuous to form a pivot point; and bending the track member at a pivot point formed where the cuts are made.

Forming a corner may comprise: removing a portion of the base adjacent a first end of the track section; and overlapping the first end of the track section and the opposing second end, such that the opposing second end is received within the channel formed at the first end.

The track member may include two straight sections, joined by a corner.

The method may comprise securing the plasterboard sections to the track member after forming the corner.

Alternatively, the method may comprise: securing two plasterboard sections two the track member, spaced apart along the track member such that a gap is formed there between; and forming the corner in the gap between the plasterboard sections, wherein the spacing is such that the plasterboard sections abut each other when the corner is formed.

The prefabricated frame element may have screw holes extending through the plasterboard and track member, for securing the prefabricated frame element to one or more dry wall studs.

The screw holes may be at predetermined distances along the length of the frame 20 section.

The prefabricated frame element may comprises one of the following: An access hatch for building services to pass through; A builders work opening; A right angle frame for securing a door frame to a dry wall frame at the base of the door frame; A " U" shaped member; or A deflection head.

According to a fifth aspect of the invention, there is provided: a prefabricated plasterboard element formed of a plasterboard panel having an external sheet and a body formed by plaster, wherein the plasterboard element comprises a first face and a second face, angled with respect to the first face, the first and second face joined along an edge; wherein the first and second faces are formed by the external sheet of a plasterboard section; wherein the external sheet is continuous, and the body includes a break along the edge, to form separate body portions.

The prefabricated plasterboard element allows a sharp right angle corner to be formed, without having to use an edge bead or similar component. Thus the corner is easy to form and requires fewer components. Furthermore, the plasterboard element can be fabricated off site, reducing waste from cutting parts, reducing dust on site, and reducing the time spend on site. This also allows the plasterboard element to be made with greater repeatability.

The prefabricated plasterboard element may include an adhesive to secure the separate body portions together.

The prefabricated plasterboard element may include two or more edges joining angled faces, and may include a second external sheet on an opposing side of the body to the external sheet. At each edge, one of the external sheet and second external sheet may be continuous across the edge. At each edge, the body may include a break extending from the external sheet opposing the continuous external sheet, towards the continuous external sheet.

According to a sixth aspect of the invention, there is provided a method of forming a prefabricated plasterboard element, the method comprising: forming a cut in the body of a plasterboard panel to form separate body portions, whilst keeping an external sheet of the plasterboard panel intact; and bending the plasterboard panel around the cut to form an edge.

The prefabricated plasterboard element allows a sharp right angle corner to be formed, without having to use an edge bead or similar component. Thus the corner is easy to form and requires less parts. Furthermore, the plasterboard element can be fabricated off site, reducing waste from cutting parts, reducing dust on site, and reducing the time spend on site. This also allows the plasterboard element to be made with greater repeatability.

The method may further comprise: fixing the body portions together after bending the plasterboard panel to form the edge, using an adhesive.

The cut may be arranged such that the body portions abut each other once the edge is formed.

The element may be formed off-site, and the method may further nclude assembling a dry wall incorporating the element on-site.

The cut may widen away from the external sheet.

it will be appreciated that any feature described in relation to a particular aspect of the invention may be applied to any other aspect of the invention, except where mutually exclusive Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which: Figure 1 schematically illustrates an example of a dividing wall formed by a dry wall, with a cutaway section to show the components of the wall; Figure 2A schematically illustrates a frame element for providing a services opening in a dry wall dividing wall; Figure 2B shows the track member used to form the frame element of Figure 2A: and Figure 2C schematically shows the steps for joining the ends of the track member of Figure 2B; Figure 3 illustrates a cross-section view taken through the frame dement of Figure 2A; Figure 4A schematically illustrates a first step of forming an inl.ne corner n the frame dement of Figure 2A; Figure 4B schematically illustrates a second step of forming an inline corner in the frame element of Figure 2A; Figure 5 illustrates a method of assembling a dry wall; Figure 6 schematically illustrates an exterior corner for use in a frame element; Figure 7A schematically illustrates a plasterboard panel in cross section; Figure 7B schematically illustrates the formation of routing lines in the rear surface of the plasterboard panel; Figure 7C illustrates a first example of a plasterboard element formed by the panel of Figure 7B; Figure 7D schematically illustrates an alternative example of the formation of routing lines in the rear surface of the plasterboard panel Figure 7E illustrates a second example of a plasterboard element formed by the panel of Figure 7D; and Figure 8 illustrates the method for forming the plasterboard element of Figures 7C or 7E.

Figure I schematically illustrates an example of a dry wall I used to form partitions in an interior space. A cutaway section A shows the internal components of the wall 1.

In this example, the dry wall 1 is formcd of a frame 3 fixed between a floor 5 and a ceiling 7. The frame 3 is made up of vertically extending studs 9a and horizontally extending studs 9b. In one example, the studs 9a,9b are metal, such as steel, with a C-shaped cross section. In other eases, any suitable shape and material stud can be used. Plasterboard panels 11 are fixed to the studs 9a,b.

The dividing wall 1 shown in Figure 1 is a simple planar wall with a continuous surface. However, in practice, a dividing wall 1 may include a number of additional features. For example, there may be openings for doors or windows. Also, dry walls 1 are often formed with deflection heads at the top of the frame 3.

in order to incorporate these features, and maintain the structural integrity, fire safety and acoustic damping of the wall 1, the frame 3 requires additional frame elements. Figure 2A illustrates an example of one such element 100. Figure 2A illustrates a frame 100 for forming a hatch through which services (such as pipes and cables) can pass. in some instances, this may be referred to as a builder's work opening.

The frame element 100 is rectangular in shape, having two opposing sides 102, 104, a bottom 106, and a top 108. The sides 102, 104 are spaced such that the frame 100 can be secured between two vertical studs 9a. An opening 110 is formed between the sides 102, 104, bottom 106 and top 108 through which services are provided.

The hatch frame element 100 is formed by a single length of track member 112. Figure 2B shows the track member 112 in a partially assembled state.

The track member 112 has a length extending from a first end 116 to a second end 118. In the assembled state (Figure 2A), the length of the track member 112 extends around the perimeter of the opening 110. The track member 112 is the same C-section track as used to form the studs 9a,b of the frame 3 of the dividing wall 1. Figure 3 shows a cross section through the frame 100, perpendicular to the length of the track member 112, as shown by the dashed line in Figure 2A.

The track member 112 includes a planar base 13 defining a bottom surface 15 and a top surface 17. Sidewalls 19, 21 extend from the bottom surface 15, on opposing sides of the base 13, thus defining a channel 23. The base 13 and sidewalls 19, 21 thus form the "C" shaped section of the track 112.

The rectangular frame element 100 shown in Figure 2A is formed by bending the track member 112 at three "in-line-corners 114 to form the desired shape. The in-line corners 114 are the corners formed part way along the length of the track section 112. The opposite ends 116, 118 of the track member 112 join other to form the fourth corner 115 of the rectangle (the overlapping corner 115). Figure 2C shows the fourth corner 115 in more detail.

To form the fourth corner 115, the second end 118 of the track section 112 overlaps the first end 116. At an end portion 117 of the track section 112 formed at the second end 118, the base 13 of the track section 112 is cut away, leaving only the walls 19, 21. This allows the first end 116 of the track section 112 to be received within the channel 23 at the second end 118 of the track section. Therefore the sidewalls 19, 21 at the first end 116 overlap the sidewalls 19, 21 at the second end 118.

The first end 116 and second end 118 are secured to each other by screws 119 extending through the corresponding side walls 19, 21. Screws 119 are provided in both sidewalls 19, 21, although only one sidewall 19 is shown in Figure 2C. In one example, the screw 119 may be a wafer head screw.

The sides 102, 104, bottom 106 and top 108 of the frame element 100 are straight sections. On each straight section 102, 104, 106, 108, a plasterboard section 120 is fixed on the top surface 17 of the track member 112. Each plasterboard section 120 is a simple rectangle in shape, and overlies the top surface, with a top face 122 facing inwards towards the opening 110 (i.e. perpendicular to an axis through the opening 110).

The plasterboard sections 120 are sized to be the same width as the base 13 of the track member 112, and are secured by screws (not shown) which pass through the plasterboard section 116 and base 13, into the channel 23 of the track member 112.

The plasterboard sections 116 are sized so that plasterboard sections 116 from neighbouring straight sections 102, 104, 106, 108 abut at the corners (as best shown in Figure 4B discussed below).

In the assembled wall 1, the frame element 100 is secured to the vertical studs 9a,b by screws 121 (such as nr screws) passing through the sidewalls 102, 104 of the track member 112, into the sidewalls of the studs 9a, 9b, in a direction parallel to the axis through the opening 110.

It should be noted that the screws used to secure the plasterboard section 120 to the track sections 114 in the prefabricated frame element 100 are sufficiently short that they do not interfere with the studs 9a in the frame 3. For example, the screws may only be 10mm. To further accomplish this, there may be an offset between the studs 9a and the frame dement 100. Furthermore, the screws 121 used to secure the frame element 100 to the studs 9a are sufficiently short that the frame element 100 can be secure from both sides, and the screws 121 do not interfere within the channel of the stud 9a.

The plasterboard panels 11 are fixed to the frame 3 and optionally the frame member 100 in the usual manner. The plasterboard panels II are cut to size to ensure the opening 110 remains clear.

The plasterboard panels 11 of the wall 1 have an outward facing surface perpendicular to the plasterboard sections 116 in the frame element 100 (i.e. perpendicular to the axis passing through the opening 110). The plasterboard panels 11 of the wall are cut to size such that the tops of the panels are level with the top surface 122 of the plasterboard sections to form a sharp edge.

In one example, the screw 119 used to secure the two ends 116, 118 of the track member 112 together may be used to also secure the element 100 to the stud members 9a, 9b. For example, the first side 102, including the first end 116, may be secured to a first vertical stud 9a by a screw 121 towards the base of the first side 102. Then the opposite side 104 may be secured to a second vertical stud 9b by a pair of screws 121, before the top 108 is bent down and the overlapping corner 115 secured together and to the stud 9a.

The plasterboard panels 11 may be fitted at any suitable time during this process.

Figures 4A and 4B illustrate how the in-line corners 114 in the frame element 100 are formed in more detail. The plasterboard sections 120 are secured to the base 13 of the track member 112 prior to bending. A gap 124 is left between adjacent plasterboard section 120. A cut 126 is formed in the sidewalls 19. 21 of the track 112. The cut 126 extends the full height of the sidewall 19, 21 up to the base 13, but the base 13 itself is kept intact.

By forming the cut 126 in this way, a pivot point (or live hinge) is formed in the track member 126, around which it can be bent to form the corner 114. By correctly sizing the gap 124, and aligning the cut 126 at or near one end of the gap 124, the track member 112 is free to rotate whilst the plasterboard sections 120 properly align and abut each other when the corner 114 is formed.

The frame element 100 can be constructed off-site, away from the location where the dry wall 1 is installed. As such, the lengths required for the track member 112 can be cut from larger stock portions of tracks. Similarly, the plasterboard sections 120 can also be cut from larger stock plasterboard panels. In this way, wastage of track length and plasterboard panels can be reduced, as a large number of frame elements can be constructed at the same time, and the required lengths and areas can be efficiently cut form the larger stock pieces. Furthermore, this reduces the work required on site. it also allows the cutting of the track members and plasterboard sections to be automated, reducing labour required.

Figure 5 schematically illustrates a method 200 of forming a dry wall 1.

The first portion 200a of the method 200 is the offsite formation of the prefabricated frame element 100. This is then shipped to the building site, where the wall 1 is installed in a second portion 200b of the method 200.

The first (off-site) portion 200a includes the steps of cutting the track members 112 to length 202, cutting the plasterboard sections to size 204, securing 206 the plasterboard section 120 to the track member 112, and forming 208 the corners 114 as discussed above, including the inline corners 114.

The second (on-site) portion 200b includes the steps of assembling 210 the frame 3 of the wall, including installing the frame elements 100 and securing 212 the panels 11 to the frame 3.

The step of forming the overlapping corner 115, and thus assembling the pre-formed element into its final shape, can be carried out as part of either the off-site portion 200a or the on-site portion 200b. Where the overlapping corner 115 is formed offsite, the pre-formed element is packaged and shipped in it completed shape. However, when the overlapping corner 115 is formed onsite, the pre-formed element is packaged and shipped in the format shown in Figure 2B. It will be appreciated that in this example, as discussed above, the step of forming the overlapping corner may also form part of securing the preformed element to the frame.

In at least some examples, the method 200 may also include the step of drilling or punching screw holes for securing the plasterboard sections 120 to the track member 112.

In at least some examples, the method 200 may further include the step of drilling or punching the screw holes for securing the frame element 100 to the studs 9a,b of the dry wall 1 and at the overlapping corner 115. This may allow the frame element 100 to be secured to the studs 9a,b at fixed points.

It will be appreciated that the dry wall 1 discussed above is given by way of example only. The dry wall 1 may have a number of different structures, as will be understood by the person skilled in the art.

Furthermore, it will also be understood that various aspects of the dry wall 1 may be specified by the manufacturer or regulatory bodies. In particular, the spacing of the vertical studs 9a and/or the location of fixing points from weak points (such as the ends of studs 9a,b) may be specified, allowing the frame element 100 to have certain specified dimensions.

in the example discussed above, the sharp edge where the frame element 100 meets the plaster panels 11 is formed by having the plasterboard sections 120 the same width as the base 13, and the plasterboard panels 11 overlapping the plasterboard sections 120 in the vertical direction. It will be appreciated that this is by way of example only.

In other examples, the plasterboard sections 120 may overhang the base by the same length as the width of the plasterboard panels II. The plaster board panels 1 I are then fitted to abut the underside of the plasterboard section 120 at the overhand.

in the above examples. the plasterboard sections 120 are fixed to the track member 112 before the track member 112 is bent. This is by way of example only. Instead, the track member 112 may be bent first, and then the plasterboard sections 120 attached.

The corner discussed in Figures 4A and 4B is considered an internal corner because the plasterboard member 120, which forms an external facing surface of the element 100, is on the inside of the corner 114. it will be appreciated that by forming the cut 126 in the sidewalls 19, 21 such that widens away from the base 13, an external corner 114 with a mitre joint can be formed, as shown in Figure 6. Alternatively, a section of the sidewall 19, 21 could be removed to also allow an external corner to be formed.

In the above example, the pivot for forming the corners 114 is formed by cutting through the sidewall 19,21 and leaving the base intact. it will be appreciated that the pivot may be formed in other ways. For example, the cut 126 may extend into the base 13 or alternatively, the cut 126 may only extend along a portion of the sidewall 19, 21. in further examples, a material weakness may be formed in the sidewall 19, 21 and/or base 13 to form the pivot.

At the overlapping corner 115, the base 13 of the top section is removed so that the side 102 can be received in the top section. The section of base removed can be any suitable size to allow the overlap. In other examples, the base 13 of the side 102 may be removed so that the top section 108 is received in the base 13. The corner 115 where the two ends 116, 118 meet may also be formed in any other suitable way.

The corners 114, 115 need not necessarily be right angles, and other shapes of corner 114 may also be formed.

in the above, screws are used to fix the plasterboard sections 120 to the track member 112, and the frame element 100 to the frame 3 of the wall 1. This is by way of example only. Any suitable mechanical fixing means may be used. Alternatively, adhesive or other fixing means may also be used.

In the example discussed above, a rectangular frame 100 is formed. It will, however, be appreciated that the same techniques can be used to form different frame elements off-site.

In one example, a "U" shaped member may be formed. The "U" shaped member is similar to the element 100 shown in Figure 2A, but includes only the sides 102, 104 and base 106. In some examples, the two sides are of similar length, but this is not essential.

When securing the "U" shaped member to the frame, a first side 102 is secured to a first vertical stud 9a, and a second side 104 is secured to a second vertical stud 9b, with the base 106 level. Each of the sides may be secured to the studs 9a by a pair of screws (not shown).

The "U" shaped member may be used to form an access hatch where the top of the access hatch is formed by a building soffit (not shown), rather than the horizontal track 9b of the frame 3. The plasterboard sections 120 may extend longer than the sides 102, 104 of the track member 112, to form an overlap with adjacent features. For example where the "U" shaped member forms a three sided hatch, and a break is provided in the horizontal stud 9b, the plaster panels 11 may overlap cut ends of the stud 9b (and optionally the deflection head, if provided).

Furthermore, the "U" shaped member may be inverted to form a head of an opening, rather than a base.

Where an opening with a large vertical extent is required, such as a window, a "U" shaped member, and an opposing inverted "U" shaped member may be used instead of a single complete frame as shown in Figure 2. Additional track members may be used to form the sides of the opening, extending between the "U" member and the inverted "U" member. In some cases, the side tracks may overlap the sides 102, 104 of the "U" shaped elements (and may be referred to as sleeves). In this way, the height of the opening can be easily varied, as required.

As discussed above, the plasterboard sections 120 (which face parallel to a direction through the opening) may extend longer than the sides 102, 104 of the track member 112. The sides may be formed with plasters board sections 120 that do not extend the full length of the track 112. Thus when the side tracks, and the "U" shaped members and sides are combined, a continuous plaster panel surface is formed. This may also help to accommodate overlap between the track sections 112. Alternatively, the plasterboard sections 120 may overlap the end of the side tracks 112, whilst the plasterboard sections 120 on the "U" shaped members do not reach the end of the track 112.

in a further example, the side tracks and/or "U" shaped member may have plaster panels 112 that extend to the ends of the track sections 112, such that the joins between the track sections and the joins between the plasterboard panels align.

in another example, an L shaped frame member for joining a door frame to the horizontal stud 9b at the base of the frame 3 may be provided. The top of the door frame may be formed by an inverted "U" shaped member, as discussed above, and the sides of the door may be formed by side tracks. Therefore, the doorframe is similar to the window, except it has two -I," shaped members at the base instead of a "U" shaped member. The "L" shaped member may overlap the horizontal stud 9b at the base of the frame, or may abut it.

In further examples, the frame element may be a deflection head. A deflection head is fitted to the top of the frame 3 of a dry wall 1. The deflection head includes two layers of plasterboard sections 120 stacked on top of the track member 112. The layers may be secured to each other by mechanical fixing means or adhesive discussed above.

In general, any desired frame shape can be formed. This may comprise a single simple straight sections, or may comprise a more complex shape having, for example, multiple straight sections joined at corners 114.

Furthermore, different pre-formed elements 100 can be combined to form more complex features, such as the door or window frame, as discussed above.

In all the above examples, the pre-formed clement 100 can be packaged and shipped in either a completed form, or in a state with the plaster board sections 120 fitted to the track and the cuts necessary to form the corners 114, 115 made. In this second example, final assembly is done on site, and, in some eases, assembly into the final shape may only be achieved as the pre-formed element is secured to the frame 3 of the wall. In other examples, some, but not all of the corners may be bent to ease transport.

Furthermore, where multiple pre-formed elements 100 are combined to form a feature in the frame (for example at a doorway), the pre-formed elements may be shipped attached to each other, or unconnected. Again, it may be that final assembly only occurs during fitting of the pre-formed elements to the frame 3.

Where a pre-formed element 100 is shipped in its unassembled state, it may be wrapped in a protective tape, to hold it flat and prevent unwanted bending of the corners. This wrapping also protects the plasterboard sections 120, and the track 112 during transportation. Where a preformed element 100 is shipped in its assembled state, this may also be wrapped for transport.

in one example, any dement which has a full track length of less than size a standard palette (i.e. 1200mm square) may be shipped unassembled, and larger elements may be assembler (fully or partially). This is by way of example only.

The preformed element 100 may have one, two, or more layers of plasterboard sections 120, no matter what the shape of the preformed element 100. Where multiple layers of plasterboard sections 120 are used in an element 100 with corners, each of the sections 120 may cut to allow the proper formation of the corners, where the plasterboard sections 120 abut each other.

Furthermore, as discussed above, in some examples, the plasterboard panels 112 may extend longer or shorter than the length of the track, or the same length, and narrower or wider than the track 112, or the same width.

it will be appreciated that where frame elements 100 are secured to the frame 3, the various standards may require fixing screws to be a minimum distance from an end of the track members and from any corners, and from each other, and may require a minimum length of overlap. Thus the length of any side sections 104, 106 and the length of any overlap between a pre-formed element 100 and the frame should be sufficient to match these requirements.

In some examples, the horizontal width of the element may be wider than the defined spacing between the vertical studs 9a. In this case, the vertical studs 9a may be cut where the pre-formed elements define an opening, and the cut ends of the studs 9a may be received in the track sections 112 forming the top and/or bottom 106, 108 of the frame in the examples discussed above, the frame element 100 includes a track member 112 and plasterboard sections 120. Figures 7A to 7E illustrate the steps in forming a plasterboard element 300 that only includes a shaped plasterboard panel 302. The method 400 of shaping the plasterboard element 300 is also illustrated in Figure 8.

Figure 7A shows a cross section through a plasterboard panel 302 used to make the element 300. The plasterboard panel 302 includes a front surface 304 for forming an exterior surface of a dry wall 1, and an opposing rear surface 306. Both the front and rear surfaces 304, 306 a formed by a sheet 308, 310. in one example, the sheet may be paper, but any suitable material can be used. Between the front and rear sheets 308, 310 a plaster body 312 is provided.

In various situations, corners 314 arc formed in dry walls 1. These may be aesthetic features or joins between different walls 1. The corners 314 are formed by edges extending vertically between two faces 316, 318 on the exterior of the wall. Typically, the faces 316, 318 may be perpendicular to each other, but this need not necessarily be the case.

In order to form edges such as shown in Figure 7C, the plaster board panel 302 is routed along its back 306 to form routing line 320, in step 404 of the method 400. Figure 7B shows an example of a plasterboard panel 302 with two such routing lines 320 formed in the rear surface 306.

As shown in Figure 7B the routing lines 320 extend through the rear sheet 310 and body 312 of the plasterboard panel 320, to the front sheet 308. However, the front sheet 308 is not cut and is continuous along the full extent of the panel 302.

Furthermore, the routing line is tapering in shape such that it narrows towards the front sheet 308. The angle formed at the apex of the routing line adjacent the front panel is 90 degrees. The angle is bisected by an axis extending perpendicular to the front surface 304 of the panel 302.

Once the routing lines have been formed, the panel 302 can be bent at step 406, to form the desired edges. The front sheet 308 acts as a pivot (or live hinge) around which the edge is formed. In the case shown in Figures 7B and 7C, two exterior corners 314e are formed, such that the structure forms a "U" shape. In these exterior corners 314e, the front face 306 of the panel 302 is on the exterior of the corner.

On the other hand, in Figure 7D, one of the rout lines 320 is formed on the rear surface 306 to form an exterior corner 314e, whilst the second rout line 320 is formed on the front surface 304, to form an interior corner 3I4i. In the interior corner 314i, the front face 306 of the panel is on the interior of the corner.

Figure 7E shows the element 300 formed when the panel of Figure 7D is bent. In this example the lower corner is an exterior corner 314e as in Figure 7C, whilst the upper corner is an interior corner 314i, therefore forming a "Z" shape.

it will be appreciated that on the interior and exterior corners 314, the cut edges 322 of the body 312 join in a mitre type joint. Adhesive 324 may be applied to the joint at step 408 to hold the element 300 together.

By using the above dement 300, the front sheet 308 is continuous through the whole element 300, with sharp edges formed. It will be appreciated that the body of the panel 302 is split into a number of body portions, joined by the front sheet 308 or rear sheet at the corners 314, depending on the type of corner.

The plasterboard element 300 formed, as shown in Figures 7C or 7E, can be secured to the frame 3 of a dry wall 1 in the usual manner.

it will be appreciated that the method may also include the step 802 of cutting the panel to the desired size to fit into the rest of the dry wall 1. This may occur before the routing lines 320 are formed, as shown in Figure 8. Alternatively, this may occur after the routing line is formed, or even after the panel 302 is bent or after the adhesive is applied.

The routing lines 320 can be formed in any suitable manner. In one example, the routing lines are formed by an appropriate mitre cut tool. The formation of the routing lines may be automated, based on a pre-programmed design. It will further be appreciated that in some example, the routing lines 320 may not extend through the full width of the body. The steps of routing and cutting may be performed by automated machinery. whilst the final assembly is by hand.

The plasterboard element 300 can be formed off-site and shipped to site for simple installation.

in the example discussed above, a tapering routing line 320 is used to make both interior and exterior corners 314. it will be appreciated that any suitable cut may be used to make both corners 314.

For example, to make interior corners 314i, a simple straight rout line could be used. Alternatively, to make interior or exterior corners 314, a rectangular section of the body could be removed.

In the examples discussed above, the corners arc right angled. However, this is by way of example only, and the corners can be given any angle by an appropriately shaped routing line 320. Any combination of corners and angles may be made, thus providing different shape elements 300. The element may extend the full height of a plasterboard panel 302, or may be shorter.

Using the above methodology, complex shapes for features in dry walls can be made off-site and in advance, reducing the time and effort required on-site.

It will be appreciated that the structure of the plasterboard shown in Figure 7A is by way of example only. Any suitable structure may be provided. For example, the back sheet 310 may be omitted, and other reinforcing structures and the like may be provided.

Claims

Claims A prefabricated plasterboard clement formed of a plasterboard panel having an external sheet and a body formed by plaster, wherein the plasterboard element comprises a first face and a second face, angled with respect to the first face, the first and second face joined along an edge; wherein Lhe first and second faces are formed by Lhe external sheet of a plasterboard section; wherein the external sheet is continuous, and the body includes a break along the edge, to form separate body portions.
The prefabricated plasterboard clement of claim 1, wherein a portion of the body connected to the first face abuts a portion of the body connected to the second face.
3. The prefabricated plasterboard element of claim 1 or claim 2, including an adhesive O to secure the separate body portions together. C\I
CO The prefabricated plasterboard element of any preceding claim, including two or more edges joining angled faces.
O The prefabricated plasterboard element of any preceding claim, including a second external sheet on an opposing side of the body to the external sheet.
The prefabricated plasterboard element of claim 5, wherein, at the or each edge, one of the external sheet and second external sheet is continuous across the edge, and the body includes a break extending from the external sheet opposing the continuous external sheet, towards the continuous external sheet.
A method of forming a prefabricated plasterboard element, the method comprising: forming a cut in the body of a plasterboard panel to form separate body portions, whilst keeping an extern& sheet of the plasterboard panel intact; and bending the plasterboard panel around the cut to form an edge.
The method of claim 7, wherein the cut may be arranged such that the body portions abut each other once the edge is formed.
The method of claim 7 or claim 8, further comprising: fixing the body portions together after bending the plasterboard panel to form the edge, using an adhesive.
10. The method of any of claims 7 to 9, wherein the cut widens away from the external sheet.
The method of any of claims 7 to 10, wherein the body defines a pair of opposing faces, the external sheet overlying a first of the pair of opposing face, and wherein the plasterboard panel further comprising a second external sheet overlying a second of the pair of opposing faces.
12. The method of claim 11, further comprising: forming a second cut in the body of a plasterboard panel to form separate body portions, whilst keeping the external sheet or the second external sheet intact; and C\I bending the plasterboard panel around the cut to form an edge.CO
13. The method of claim 11 or claim 12, wherein, at the or each edge, one of the in external sheet and second external sheet is continuous across the edge, and the body includes a break extending from the external sheet opposing the continuous external sheet, towards the continuous external sheet.
14. The method of any of claims 7 to 13, further ncluding assembling a dry wall incorporating the clement.
15. The method of any of claims 7 to 14, wherein the prefabricated plasterboard element is formed off-site.