WO2024116194A1

WO2024116194A1 - A connector for connecting drywall framing elements

Info

Publication number: WO2024116194A1
Application number: PCT/IN2023/051084
Authority: WO
Inventors: Kanakavel S; Antonin Poupart
Original assignee: Saint-Gobain Placo
Priority date: 2022-11-29
Filing date: 2023-11-23
Publication date: 2024-06-06

Abstract

A connector (10) to be used for a lightweight construction element (100) is disclosed. The connector (10) is such that it has a first and second pair of angular arms (1a) and (1b) forming angles (Z) and (Z') respectively and meeting at a first and a second point of intersections (P) and (P'). The first and second pair of angular arms (1a) and (1b) are either oriented parallel to each other or are perpendicularly oriented to each other and helps couple a first and a second flange member (130), (140), which again can be oriented parallel or perpendicular to each other. The connector (10) is placed at distance from each other and acts as a replacement for the conventional web in framing structures. The plurality of connectors (10) thus eliminate the need of a full-length web, which results in reduction of metal usage and thus in turn reduced CO2 emission.

Description

A CONNECTOR FOR CONNECTING DRYWALL FRAMING ELEMENTS

Technical Field

The present disclosure relates to a connector for connecting drywall framing elements. More specifically, the present disclosure relates to a connector spaced at a predetermined distance from each other connecting flange members placed either in parallel or perpendicular orientation. Further, the connector in the present disclosure comprises two pairs of angular arms which are orientented either in parallel or perpendicular orientation.

Though dry wall or the construction panels are the most common component of a drywall system, it would not suffice without the conventional construction element and framing members they are attached to.

Conventional construction elements 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 wide range of applications in the industry. Though conventional construction elements may be built with timber, glass, brick, plaster slab or even concrete, metal conventional construction elements have the widest applicability. The use of conventional metal 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 1.4 kg to 1.6 kg 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 implies an average CO2 emissions from steel production to be about 1.85 tonnes CO2 per tonne of steel produced (as explained in a non-patent literature entitled ‘Cleaning up the Steel Industry: Reducing CO2 emissions with CCUS’). With the world moving towards sustainability, a requirement of reduced C0₂ emissions is inevitable with the aim to move towards global net-zero targets. So is the evolution and need for development of lightweight metal components that contribute largely in reduction of CO₂ emissions.

In the drywall framing industry, there had been various developments in the lighweight constructions. 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 does not result in a substantial reduction in metal consumption or metal usage.

In yet another prior art WO2020125916A1 , there has been structural modifications done in the web of a 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, resulting in the failure of the stud. In addition, it would be complex to manufacture and assemble the construction elements described in said reference, WO2020J259J6AJ .

Modification of the web has been one of the key areas to work over the reduction of weight of the conventional construction elements. Hence, there have been attempts in the prior art to reduce the weight of the conventional construction element by modifying the web design. However, the prior art design modifications have certain drawbacks which include complexity in manufacturing and handling thereof, 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 a conventional 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 that in turn lower CO2 emission, but these 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.

Additionally, in the prior art, it has been always observed that the components for a drywall stud as used in drywall partition framing assembly and a drywall grid system are individually different. Though the end result stands the same, that is the pratition framing assembly, due to the fact the components need to be individually manufactured, that again involves high amount of CO2 emission.

Thus, there is still a 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. Additionally, there is also a need to formulate interchangeable components which can be used for both drywall stud drywall grid system components and thus resulting in sustainable manufacture.

Thus, the present disclosure provides a lightweight construction element which eliminates the requirement of any additional manufacturing complexity, reduces the metal consumption and metal wastage and thereby results in a significant reduction in CO2 emission. Most importantly, the present disclosure results in a lightweight construction element which has 30-40% lower weight as compared to any conventional construction element. Further, the present invention also discloses a connector component, which is a replacement of conventional web and can be interchangeably used for both drywall studs as well as drywall partition framing components.

Summary of the Disclosure

In one aspect of the present disclosure, a connector for connecting drywall framing elements is disclosed. The connector comprises a first pair of angular arms and a second pair of angular arms. The first pair of angular arms comprising first arm section meet at a first point of intersection P and the second pair of angular arms comprising first arm section meet at a second point of intersection P’ wherein a major axis of the first section of arm is oriented at an angle Z relative to a major axis of the first arm section and wherein a major axis of the first section of arm is oriented at an angle Z’ relative to a major axis the first section of arm. Further, the first and second pair of angular arms comprises a second arm section with a height H and a major axis different from the major axis of the first section and each pair of angular arms comprise a third arm section with a major axis substantially orthogonal to the major axis of the second arm section.

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 connectors there between. The first and second flange members each have flat members and a pair of side faces rising at an angle ranging from 90° to 110° from the flat members. Further, the first and second flange members each have 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. The connectors are spaced at an interval from each other and placed between the front surface of the first and second flange member and coupled to the side faces of the first and the second flange members.

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 coupling the first and second flange members together by a plurality of connectors. The coupling is done by deflection of the first or second pair of angular arms, the joining portion of the connector housing the first or second flange member and the arm of the connector securing the first or second flange member. In one another aspect of the present disclosure, a drywall partition having a framing assembly is disclosed. The drywall partition comprises of: a horizontal framing member fixed to the floor and another horizontal framing member substantially parallel to and spaced from the horizontal framing member fixed to the floor, fixed to the ceiling, a plurality of lightweight construction elements and at least one construction panel. The plurality of lightweight construction elements are spaced vertically and mounted to the horizontal framing member at its bottom end and to the horizontal framing member at its top end. Further, the lightweight construction elements are mounted such that the flat members of the first and second flange member abut and support the surface of the construction panel and at least one construction panel is fixed to one or either side 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 connector in accordance with one embodiment of the present disclosure;

FIG. 1A’ illustrates a perspective view of a connector in accordance with one more embodiment of the present disclosure;

FIG. IB illustrates a perspective view of the parts of a connector as shown in FIG. 1A;

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

FIG. 2A illustrates a perspective view of a connector in accordance with another embodiment of the present disclosure;

FIG. 2B illustrate a perspective view of a lightweight construction element in accordance with another embodiment of the present disclosure; FIG. 2C illustrate a cross-sectional view of a lightweight construction element as shown in FIG. 2B;

FIG. 2D illustrate a cross-sectional view of a lightweight construction element in accordance with yet another embodiment of the present disclosure;

FIG. 3A illustrates a perspective view of a connector in accordance with one another embodiment of the present disclosure;

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

FIG. 4A illustrates a cross-sectional view of a connector fixed to a lightweight construction element in accordance with yet one another embodiment of the present disclosure;

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

FIG. 5 illustrate a perspective view of a drywall partition framing assembly in accordance with one embodiment of the present disclosure;

FIG. 6A illustrates a perspective view of a connector in accordance with one more embodiment of the present disclosure;

FIG. 6B illustrate a perspective view of a drywall partition framing assembly in accordance with one more 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.

The present disclosure proposes a connector configured to replace the web of a drywall construction element and therefore form a new lightweight drywall construction element. The connector component may also be used for connecting metal components in a drywall grid framing assembly. For the lightweight construction element as in the present disclosure, the present connector (with different embodiments), serves as a web (as depicted in FIGS. 1C, 2B, 3B and 4B) and also as a connector for flange members for a drywall grid system (as depicted in FIG. 6B). FIG. 1A is a perspective view of a connector 10 for connecting dry wall framing elements in accordance with one embodiment of the present disclosure and FIG. IB depicts the parts of the connector 10. The connector 10 as depicted replaces a web of a conventional construction element (not shown in the figures), in order to reduce the weight of the conventional construction element which enables reduced raw material usage and lower CO2 emission. The connector 10 as depicted, comprises of a first pair of angular arms la and a second pair of angular arms lb. The orientation of the first pair of angular arms la is parallel to the orientation of the second pair of angular arms lb. The first pair of angular arms la comprising first arm section 10a, 10a’ meet at a first point of intersection P and the second pair of angular arms lb comprising first arm section 10a, 10a’ meet at a second point of intersection P’. The embodiment is configured such that a major axis of a first section of arm 10a is oriented at an angle Z relative to a major axis of a first arm section 10a’ and wherein a major axis of a first section of arm 10b is oriented at an angle Z’ relative to a major axis a first section of arm 10b’ The angle Z is equal to or different from the angle Z’ and ranges from 30° to 90°.

According to one embodiment of the present invention shown in FIG. 1A, the first point of intersection P and the second point of intersection P’ are spaced apart by a central portion 70, however, optionally, in other embodiments of the present invention, the first point of intersection P and the second point of intersection P’ are at same position such that the pair of first angular arms la and the pair of second angular arms lb meet at the same point of intersection P, P’ forming a X-shape (as depicted in FIG. 1A’.). In the present embodiment, the first and second pair of angular arms la, lb comprise a second arm section 40 with a height H and a major axis different from the major axis of the first section 10a, 10a’, 10b, 10 b’; and each pair of angular arms la, lb comprises a third arm section 50 with a major axis substantially orthogonal to the major axis of the second arm section 40. In an exemplary embodiment as shown in FIG. 1A or 1A’ or IB or 1C, the second arm section 40 is an orthogonally raised portion and the third arm section 50 is a securing member.

The connector 10 of the present disclosure is formed from a single piece of sheet or strip material, such as sheet and/or strip steel. The sheet or strip of material is slit transversely and progressively along its length. Additionally, the present embodiment is such that a part LH of the connector 10 comprises a depression D and clipping members 80 and a part RH of the connector 10 comprises a projection D’ (as depicted in FIG.1B).

The part RH slides and sits within the depression D of the part LH that clips the RH with clipping members 80, thus forming the complete connector 10. While this embodiment teaches a clipping action for making the connector, according to alternate embodiments, the connector can also be made by welding or screwing or other similar actions. Optionally, in some other embodiments, the connector 10 may be a single piece component, for example as depicted in FIG. 3A, made for example, by casting. The connector 10 may be manufactured in whole or in parts and may also be assembled onsite. The connector 10 may be at least one of plastic, polymer, cardboard, wood, steel or other suitable metals or non-metals.

FIG. 1C illustrate a perspective view of a lightweight construction element 100 made using the connector 10 (as illustrated above and depicted in FIG. 1A & IB). The lightweight construction element 100 comprises a first and second flange members 130, 140 and a plurality of connectors 10 spaced at an interval from each other. Each of the first and second flange members 130, 140 comprise flat members 105, 105’ and a pair of side faces 105a, 105b, 105a’, 105b’, rising at an angle ranging from 90° to 110° from the flat members 105, 105’. The first and second flange members 130, 140 further comprise a front surface 130a, 140a facing each other and a back surface 130b, 140b non-facing each other. The first flange member 130 and the second flange member 140 are spaced at a distance Y between the back surface 130b, 140b of the first and second flange member 130, 140. The distance Y ranges from a minimum of 40 mm to a maximum of 200 mm. Additionally, the connectors 10 are configured to secure the first and second flange member 130, 140 so that the relative angle between the planes of the first and second flange member 130, 140 ranges from 0° to 10°. This accounts for the connectors being used to form studs where the first and second flange member 130, 140 are parallel (standard) or slightly non-parallel (for acoustic benefit).

Each of the pair of side faces 105a, 105b, 105a’, 105b’ have plurality of deformations 180 in pairs spaced at an interval from each other whereby the plurality of connectors 10 are coupled while being placed between the front surface 130a, 140a of the first and second flange member 130, 140. In the present embodiment, the pair of first and second flange members 130, 140 are oriented parallel to each other, characterized in that the axis along the length of the flange member 130 is parallel to the axis along the length of the flange member 140, wherein the length is the longest dimension of the flange member. Alternatively, in other embodiments (as depicted in FIG. 6B), the pair of first and second flange members 130, 140 are oriented perpendicularly to each other, characterized in that the axis along the length of the flange member 130 is perpendicular to the axis along the length of the flange member 140, wherein the length is the longest dimension of the flange member. The pair of first and second flange members 130, 140, according to the present embodiment comprise lips 150, 160 respectively protruding outward from the first and second flange members 130, 140. In the present embodiment, the distance between the farthest point in the pair of angular arms la and lb of the connector 10 facing the front surface 130a, 140a of the first and second flange members 130, 140 respectively is equal to or more than the horizontal length of the flat members 105, 105’ respectively.

Further, the angle Z between the pair of first angular arms la and the angle Z’ between the second pair of angular arms lb in the connector 10 is configured to snap fit within the plurality of deformations 180 in the flange members 130, 140. Also, in the present embodiment, the farthest distance between the first or the second pair of angular arms la and lb is equal to or greater than the width of the flange member 130 or 140. According to the present embodiment, the width W of the plurality of deformations 180 is slightly more than the thickness of the material of the connector 10 to help in snap fit connection. According to the present embodiment, in order to make the lightweight construction element 100, the third arm section 50 of the connector 10 gets inserted into the deformations 180 in the flange members 130, 140 and the face 5 grips and holds the connector 10 in place. Optionally, in some other embodiments, the third arm section 50 may be secured by snap fitting into the plurality of deformations 180 in the flange members 130, 140. The end portion of the third arm section 50 is configured such that it enables this connection between the third arm section 50 and the flange members 130, 140. Optionally, in other embodiments, the third arm section 50 may be secured by clipping or press fitting or welding or screwing or riveting or bolting or nailing or clinching or crimping or a combination thereof to the plurality of deformations 180 in the flange members 130, 140. Once coupled, each of the connectors 10 are placed at a distance ranging from 250 mm to 400 mm from each other along the length of the first and second flange members 130, 140 which herein results in reduction of the overall weight by 30%.

Further, the first and second flange members 130, 140 comprise at least one of plastic, polymer, cardboard, wood, steel or other suitable metals or non-metals. Alternatively, in some other embodiments, the first and second flange members 130, 140 comprises metal. The lightweight construction element 100 is manufactured in whole or in parts and in the present embodiment, the first and second flange member 130, 140 and the connectors 10 are detachable. Further, the lightweight construction element 100 may be used as a drywall stud in the present embodiment, optionally, in some other embodiments, it may be used as a ceiling channel. All the features of the lightweight construction element 100 as depicted in FIG. 3B has similar characteristics as the lightweight construction element 100 as in FIG. 1C, except for the fact that it uses the one-piece connector 10 as depicted in FIG. 3A.

FIG. 2A illustrates a perspective view of a connector 10 in accordance with another embodiment of the present disclosure while FIG. 2B illustrate a perspective view of a lightweight construction comprising the connector 10 as shown in FIG. 2A. In the present embodiment, the connector 10 is a single piece component but alternatively in other embodiments, the connector 10 could be formed from multiple parts. The connector 10 comprises a first and second pair of angular arms la, lb comprising first arm section 10a, 10a’ and 10b, 10b’ meeting at a first and second point of intersection P and P’, respectively. Further, the first and second point of intersection P and P’ are separated by a central portion 70, but, alternatively in some other embodiments, the first and second point of intersection may be a single point with no central portion. In the present embodiment, in the connector 10, the first pair of angular arms la comprising first arm section 10a, 10a’ meet at a first point of intersection P and the second pair of angular arms lb comprising first arm section 10b, 10b’ meet at a second point of intersection P’ wherein a major axis of a first section of arm 10a is oriented at an angle Z relative to a major axis of a first arm section 10a’ and wherein a major axis of a first section of arm 10b is oriented at an angle Z’ relative to a major axis a first section of arm 10b’. Further, the first and second pair of angular arms la, lb comprises a second arm section 40 with a height H and a major axis different from the major axis of the first arm section 10a, 10a’, 10b, 10 b’ and each pair of angular arms la, lb comprises a third arm section 50 with a major axis substantially orthogonal to the major axis of the second arm section 40. In an exemplary embodiment as shown in FIG. 2A or 2B or 2C or 2D, the second arm section 40 is an orthogonally raised portion and the third arm section 50 is a securing member. The third arm section 50 is configured to enable snap fitting into the plurality of deformations 180 of side faces 105a, 105b, 105a’, 105b’ of the lightweight construction element 100 (as depicted in FIG. 2B). In the present embodiment, the farthest distance between the first or the second pair of angular arms la and lb is equal to or greater than the width of the flange member 130 or 140. Thus, here, the third arm section 50 rest on the lips 150, 160 and secures the first and second flange members 130, 140. This helps in coupling of the first and the second flange members 130, 140 with outward lips 150 and 160 respectively by the connectors 10. In the present embodiment, the deformations 180 provided in pairs on the side faces 105a, 105b, 105a’, 105b’ of the lightweight construction element 100 comprises of protrusion 180a (which is depicted in the cross-sectional view as in FIG. 2C). This of protrusion 180a helps arrest the movement of the third arm section 50 inward and locks the connector in its place even under stressed condition. Optionally, in other embodiments, the deformation 180 can be without the protrusion 180a (as is depicted in the cross-sectional view as in FIG. 2D).

FIG. 4A illustrate a cross-sectional view of a lightweight construction element 100 in accordance with one another embodiment of the present disclosure, and FIG. 4B illustrates the perspective view of the same. In the present embodiment of the lightweight construction element 100, the side faces 105a, 105b, 105a’, 105b’ of the first and the second flange members 130, 140 further comprises an upper portion 105ai, 105bi and 105a’i, 105b’ i and a lower portion 105a2, 105b2 and 105a’2, 105b’2 which are connected to each other by a connecting portion 115. The connection portion 115 is placed such that it is perpendicular to the upper portion 105ai, 105bi and 105aT, 105b’ i as well as the lower portion 105a2, 105b2 and 105a’2, 105b’2,thus giving rise to a stepped portion. The distance between the lower portion 105a2, 105b2 and 105a’2, 105b’2 is more than the distance between the upper portion 105ai, 105bi and 105aT, 105b’i. Further, the height of the upper portion 105ai, 105bi and 105aT, 105b’ i is equal to or less than the height of the lower portion 105a2, 105b2 and 105a’2, 105b’2. In the present embodiment, the first and second flange member 130, 140 having the lower portion 105a2, 105b2 and 105a’2, 105b’2 comprise lips 150, 160 respectively that extend inwardly. Alternatively, in some other embodiments of the present invention, the first and second flange members 130, 140 are without lips (not shown in figures).

In the present embodiment, the height H of the second arm section 40 in the connector 10 is equal to the height of the lower portion 105a2, 105b2 and 105a’2, 105b’2. For the present embodiment, the connector 10 has a flat portion 20 which gets connected with the second arm section 40. In this embodiment, the length of the flat region 20 is equal to the length of the lips 150, 160 which thereby facilitates the resting of the lips 150 and 160 on the flat region 20. In alternate embodiments without lips, the lower portion 105a2, 105b2 and 105a’2, 105b’2 rests on the flat region 20. Further, the third arm section 50 of the connector 10 in the present embodiment rests on the connecting portion 115 and secures the lower portion 105a2, 105b2 and 105a’2, 105b’2 of the first and second flange members 130, 140 and hence coupling the flange members 130, 140. 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. 1A and 1C.

The preferred dimensions of the lightweight construction element 100 is as follows: The length of the first and second flanges ranges from 3.2 meters to 3.6 meters. Further, the spacing between the connectors ranges from 250 mm to 400 mm. The spacing between the farthest points of the angular arms is proportional to the angle Z, Z’ and ranges from 50 mm to 100 mm. In all the embodiments, the connectors 10 are spaced at a predetermined interval such that put together the plurality of connectors 10 cover a small fraction of length of the flange members 130 or 140. 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 connectors 100 along the flange members 130, 140 and coupling the same. The lightweight construction element 100 of the present invention is equally efficient with respect to structural performance of deflection as compared to any conventional construction element. 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 130, 140 spatially separated from each other at the distance Y between the back surface 130b, 140b and thereafter coupling the first and second flange members 130, 140 together by a plurality of connectors 10. Coupling is done by deflection of first or second pair of angular arms la and lb, the joining portion 25 housing the first or second flange member 130 or 140 and the third arm section 50 securing the lips 150, 160 (as depicted in FIG. 2B) or the connecting portion 115 (as depicted in FIG. 4B) or the plurality of deformations 180 (as depicted in FIG. 1C, 3B).

The disclosure also depicts a method of making a connector 10 which in accordance with some embodiments of the present invention can be made as a single piece and according to other embodiments can be made in multiple parts such as a RH part and a LH part wherein the RH part is connected to the LH part of the connector by clipping, snap fitting, press fitting, welding, screwing, riveting, bolting, nailing, clinching, crimping, or a combination thereof. FIG. IB illustrates an exemplary connector 10 that is made in parts. The central portion 70 of the connector 10 in FIG. IB comprises a clipping member 80, a projection D’ of a part RH of the connector 10 sits into the depression D of a part LH which clips the RH with a clipping member 80 and the connectors 10 are first fixed to the first or second flange member 130 or 140 and thereafter fixed to first or second flange member 130 or 140. Alternatively, the connector 10 can be a single component. Such pre-formed connectors 100 may be formed by 3D printing, molding or other suitable methods for forming non-planar elements.

FIG. 5 illustrates a perspective view of drywall partition framing assembly 500 comprising dry wall framing components in accordance with one of the embodiments of the present disclosure. The drywall partition framing assembly 500 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. 1C, 2B, 3B or 4B) 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 flat members 105, 105’ of the first and second flange members 130, 140 abut and support the surface of the construction panel 350 and at least one construction panel 350 is fixed to one or either sides of the framing assembly 500. Moreover, the connectors 10 coupling the first and the second flange member 130, 140 rests away from the horizontal framing member 200 fixed to the floor and at least one of the connector 10 coupling the first and the second flange member 130, 140 rests away from the horizontal framing member 300 fixed to the ceiling. Similar to the conventional arrangement, the construction panel 350 are 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.

FIG. 6A illustrates a perspective view of a connector 10 in accordance with one more embodiments of the present disclosure and FIG. 6B depicts a perspective view of a drywall partition framing assembly 500’. According to this embodiment, the orientation of the first pair of angular arms la is opposite to the orientation of the second pair of angular arms lb in the connector 10 and correspondingly, for the dry wall partition framing assembly 500’, the pair of first and second flange member 130, 140 are oriented perpendicular to each other, characterized in that the axis along the length of the flange member 130 is perpendicular to the axis along the length of the flange member 140, wherein the length is the longest dimension of the flange member. This present orientation of the first and second flange member 130, 140 helps in the formation of a drywall grid system (referred to as drywall partition framing assembly 500’ in the disclosure). All the other features of embodiments as depicted in FIGS. 6A and 6B have similar characteristics as that of the embodiment as detailed out in FIGS. 1A and 1C.

Thus, the connector 10 of the present invention can be used to replace conventional web in a conventional construction element such as studs. Advantageously the connector 10 can also be used as a connecting member for assembling a grid framing assembly.

Industrial Applications

The connector 10 when used according to the present disclosure forms a construction element 100 which is lightweight due to the elimination of a continuous web. The lightweight construction element 100 of the present disclosure requires less CO2 emission during its manufacture, compared to a traditional construction element. In addition, the lightweight construction element 100 herein possesses the following advantages:

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

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

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

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

Additionally, the connectors can serve dual purpose of being used as a replacement of conventional web in drywall studs or a replacement of conventional connectors in drywall grids.

The lightweight construction element 100 with the connector 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 drywall construction element or channel component or even drywall grid system. It provides ease of manufacture, is sustainable, easy to transport and assemble and is also cost effective. Further, no additional assembly tools or accessories are required for the assembly of the web members in the lightweight construction element as described in the present disclosure.

Having thus described the disclosure with particular reference to the preferred forms thereof, it will be obvious that various changes and modifications can be made therein without departing from the spirit and scope of the present disclosure as defined by the appended claims. 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 nonexclusive 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 CONNECTOR FOR CONNECTING DRYWALL FRAMING ELEMENTS la: First Pair of Angular Arms lb: Second Pair of Angular Arms

5: Faces

10: Connector

10a, 10a’, 10b, 10b’ : First Arm Section

20: Flat Region

25: Joining Portion

40: Second arm section

50: Third arm section

70: Central Portion

80: Clipping Member

100: Lightweight Construction element

105, 105’: Flat Members

105a, 105b, 105a’, 105b’ : Pair of Side Faces

105ai, 105bi, 105a’i, 105b’r_: Upper Portion

105a2, 105b2 and 105a’2, 105b’2: Lower Portion

115: Connecting Portion

130: First Flange Member

140: Second Flange Member

130a, 140a: Front Surface

130b, 140b: Back Surface

150, 160: Lips

180: Deformations

180a: Protrusion

200, 300: Horizontal Framing Member

350: Construction Panel

500, 500’: Framing Assembly

D: Depression

D’ : Projection

LH, RH: Part P: First Point of Intersection

P’ : Second Point of Intersection

Y: Distance

Z, Z’: Angle

Claims

Claims: We claim:

1. A connector 10 for connecting drywall framing elements comprising: a first pair of angular arms la a second pair of angular arms lb, the first pair of angular arms la comprising first arm section 10a, 10a’ meet at a first point of intersection P and the second pair of angular arms lb comprising first arm section 10b, 10b’ meet at a second point of intersection P’ wherein a major axis of a first section of arm 10a is oriented at an angle Z relative to a major axis of a first arm section 10a’ and wherein a major axis of a first section of arm 10b is oriented at an angle Z’ relative to a major axis a first section of arm 10b’ wherein, the first and second pair of angular arms la, lb comprises a second arm section 40 with a height H and a major axis different from the major axis of the first arm section 10a, 10a’, 10b, 10 b’ and each pair of angular arms la, lb comprises a third arm section 50 with a major axis substantially orthogonal to the major axis of the second arm section 40.

2. The connector 10 as claimed in claim 1, wherein the second portion 40 and the third portion 50 of each of the first and second pair of angular arms la, lb are connected by a joining portion 25.

3. The connector 10 as claimed in claim 1, wherein the first point of intersection P and the second point of intersection P’ are at same position so that the first and second pair of angular arms la, lb meet at the same point of intersection P, P’ in the form of a X-shape.

4. The connector 10 as claimed in claim 1, wherein the first point of intersection P and the second point of intersection P’ are spaced apart by a central portion 70.

5. The connector 10 as claimed in claim 1, wherein the third arm section 50 of each pair of angular arms la, lb comprise a lip 5 comprising a major axis substantially orthogonal to the major axis of the third arm section 50. The connector 10 as claimed in claim 1, wherein the first pair of angular arms la is in a parallel orientation to the second pair of angular arms lb. The connector 10 as claimed in claim 1, wherein the first pair of angular arms la, is in a perpendicular orientation to the second pair of angular arms lb. The connector 10 as claimed in claim 1, wherein, the angle Z is equal to or different than the angle Z’. The connector 10 as claimed in claim 1, wherein, the second portion 40 of each pair of angular arms la, lb is connected to the distal ends by a flat region 20. The connector 10 as claimed in claim 4, wherein, the central portion 70 comprises a part LH comprising a depression D and clipping members 80 and a part RH comprising a projection D’. The connector 10 as claimed in claim 1, is manufactured in whole or in parts. The connector 10 as claimed in claim 1, comprises at least one of plastic, polymer, cardboard, wood, steel or other suitable metals or non-metals. The connector 10 as claimed in claim 1, is made of metal. A lightweight construction element 100 comprising: a first and second flange member 130, 140 each having flat members 105, 105’ and a pair of side faces 105a, 105b, 105a’, 105b’ rising at an angle ranging from 90° to 110° from the flat members 105, 105’, and each flat member 105, 105’ having a front surface 130a, 140a facing each other and a back surface 130b, 140b non-facing each other, wherein the first flange member 130 and second flange member 140 are spaced at a distance Y between the back surface 130b, 140b of the first and second flange members 130, 140; and a plurality of connectors 10 as claimed in claim 1 spaced at an interval from each other and placed between the front surface 130a, 140a of the first and second flange member 130, 140; characterized in that: the plurality of connectors 10 are coupled to the side faces 105a, 105b, 105a’, 105b’ of the first and the second flange members 130, 140. The lightweight construction element 100 as claimed in claim 14, wherein the connectors are configured to secure the first and second flange member 130, 140 so that the relative angle between the planes of the first and second flange member 130, 140 ranges from 0° to 10°. The lightweight construction element 100 as claimed in claim 14, wherein, each of the side faces 105a, 105b, 105a’, 105b’ have a pair of deformations 180 with a width W spaced at an interval from each other. The lightweight construction element 100 as claimed in claim 14, wherein, the pair of first and second flange member 130, 140 are oriented parallel to each other, characterized in that the axis along the length of the flange member 130 is parallel to the axis along the length of the flange member 140, wherein the length is the longest dimension of the flange member 130 orl40. The lightweight construction element 100 as claimed in claim 14, wherein, the pair of first and second flange member 130, 140 are oriented perpendicular to each other, characterized in that the axis along the length of the flange member 130 is perpendicular to the axis along the length of the flange member 140, wherein the length is the longest dimension of the flange member 130 or 140. The lightweight construction element 100 as claimed in claim 14, wherein, the pair of first and second flange member 130, 140 comprise lips 150, 160 respectively. The lightweight construction element 100 as claimed in claim 14, wherein, the pair of side faces 105a, 105b, 105a’, 105b’ further comprises an upper portion 105ai, 105bi and 105aT, 105b’ i and a lower portion 105a2, 105b2 and 105a’2, 105b’2 connected to each other by a connecting portion 115, wherein the distance between the lower portion 105a2, 105b2 and 105a’2, 105b’2 is more than the distance between the upper portion 105ai, 105bi and 105aT, 105bT. The lightweight construction element 100 as claimed in claim 14, wherein, the connecting portion 115 is perpendicular to the upper portion 105ai, 105bi and 105aT, 105b’i and the lower portion 105a2, 105b2 and 105a’2, 105b’2. The lightweight construction element 100 as claimed in claim 14, wherein, the height of the upper portion 105ai, 105bi and 105aT, 105b’ i is equal to or less than the height of the lower portion 105a2, 105b2 and 105a’2, 105b’2. The lightweight construction element 100 as claimed in claim 14, wherein the lower portion 105a2, 105b2 and 105a’2, 105b’2 comprise lips 150, 160 respectively. The lightweight construction element 100 as claimed in claim 23, wherein, the lips 150, 160 extend inwardly from the lower portion 105a2, 105b2 and 105a’2, 105b’2. The lightweight construction element 100 as claimed in claim 14, wherein, the width W of the deformation 180 is more than the thickness of the material of the connector 10. The lightweight construction element 100 as claimed in claim 14, wherein, the height H of the second portion 40 of the connector is equal to the height of the lower portion 105a2, 105b2 and 105a’2, 105b’2. The lightweight construction element 100 as claimed in claim 14, wherein, the distance between the farthest point in the pair of angular arms la or lb facing the front surface 130a, 140a respectively is equal to or more than the horizontal length of the flat members 105, 105’ respectively. The lightweight construction element 100 as claimed in claim 14, wherein, the angle Z between the pair of first angular arms la and the angle Z’ between the second pair of angular arms lb is configured to snap fit with the first and second flange members 130, 140. The lightweight construction element 100 as claimed in claim 14, wherein, a length of flat region 20 of the connector 10 is equal to the length of the lips 150, 160 of the first and second flange members 130, 140. The lightweight construction element 100 as claimed in claim 29, wherein, the lips 150, 160 rests on the flat region 20. The lightweight construction element 100 as claimed in claim 29, wherein, the lower portion 105a2, 105b2 and 105a’2, 105b’2 rests on the flat region 20. The lightweight construction element 100 as claimed in claim 14, wherein, the third portion 50 of the connector 10 rest on the lips 150, 160 of the first and second flange members 130, 140 and secures the first and second flange members 130, 140. The lightweight construction element 100 as claimed in claim 14, wherein, the third portion 50 rests on the connecting portion 115 and secures the lower portion 105a2, 105b2 and 105a’2, 105b’2 of the first and second flange members 130, 140. The lightweight construction element 100 as claimed in claim 14, wherein the third portion 50 is secured 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 into the deformations 180. The lightweight construction element 100 as claimed in claim 14, wherein the connectors 10 are placed at a distance of 250mm to 400mm from each other. The lightweight construction element 100 as claimed in claim 14, wherein the first and second flange members 130, 140 comprises at least one of plastic, polymer, cardboard, wood, steel or other suitable metals or non-metals. The lightweight construction element 100 as claimed in claim 14, wherein the first and second flange members 130, 140 comprise metal. The lightweight construction element 100 as claimed in claim 14, is manufactured in whole or in parts. The lightweight construction element 100 as claimed in claim 14, where first and second flange member 130, 140 and the connectors 10 are detachable. The lightweight construction element 100 as claimed in claim 14 is a drywall stud or a ceiling channel. A method of making the lightweight construction element 100 of claim 1, comprising the steps of: providing a first and second flange members 130, 140 spatially separated from each other at the distance Y between the back surface 130b, 140b, coupling the first and second flange members 130, 140 together by a plurality of connectors 10, wherein the coupling is done by deflection of first or second pair of angular arms la or lb and the joining portion 25 of the connector 10 and housing the first or second flange member 130 or 140 and the third portion 50 of the connector 10 securing the first or second flange member 130 or 140. A drywall partition having a 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 and fixed to the ceiling; a plurality of lightweight construction elements 100 as claimed in claim 13 spaced vertically and mounted between the horizontal framing member 200 at its bottom end and 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 flat members 105, 105’ of the first and second flange members 130, 140 abut and support the surface of the construction panel 350 and at least one construction panel 350 is fixed to one or either sides of the framing assembly 500. The dry wall partition as claimed in claim 42, wherein at least one of the connectors 10 coupling the first and the second flange member 130, 140 rests away from the horizontal framing member 200 fixed to the floor and at least one of the connector 10 coupling the first and the second flange member 130, 140 rests away from the horizontal framing member 300 fixed to the ceiling.