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Title:
METHOD FOR INSTALLING A PARTITION WALL OR WALL LINING REQUIRING FEW SCREWS
Document Type and Number:
WIPO Patent Application WO/2024/028320
Kind Code:
A1
Abstract:
The permanent invention concerns a method for installing a permanent wall drywall made of comprising rectangular boards (1) comprising first and second vertical edges parallel to the vertical axis (Z) and provided with a groove (1g) running along the whole height (H1) of the boards. The boards are held in place between two between two I-profile beams (3) by spline joints formed by the first beam flange (3f1) being inserted in the grooves of two adjacent boards.

Inventors:
MAILLE GAEL (FR)
PLE FRÉDÉRIC (FR)
CHAOUCHE JIMMY (FR)
JEAN MÉLINA (FR)
PEYRON PIERRE (FR)
VIAL EMMANUEL (FR)
ZERBIB STEPHAN (FR)
ROUANET BASTIEN (FR)
SAVANIER EMILIE (FR)
Application Number:
PCT/EP2023/071285
Publication Date:
February 08, 2024
Filing Date:
August 01, 2023
Export Citation:
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Assignee:
ETEX BUILDING PERFORMANCE INT SAS (FR)
ETEX FRANCE BUILDING PERFORMANCE SA (FR)
International Classes:
E04B2/74; E04B2/76; E04B2/82
Foreign References:
US4231205A1980-11-04
US4329820A1982-05-18
US3882652A1975-05-13
Attorney, Agent or Firm:
ETEX SERVICES NV - ETEX IPSC (BE)
Download PDF:
Claims:
CLAIMS

1 . Method for installing a permanent wall lining of desired length measured along the longitudinal axis (X), comprising the following steps,

• Providing o two or more boards (1), each board having a rectangular geometry, comprising a first main surface parallel to and separated from a second main surface by a thickness (T) measured along a transverse axis (Y) normal to the wall plane (X,Z), and forming a peripheral edge comprising first and second longitudinal edges of length (L) extending along the longitudinal axis (X), normal to and separated from one another by first and second vertical edges of board height (H1) extending along the vertical axis (Z), and wherein a groove (1g) extends along each of the first and second vertical edges, each groove having an opening width (w) measured normal to the wall plane (X, Z), and a depth (d) measured parallel to the longitudinal axis (X), o a support frame comprising,

■ a top U-profile track (2u) and a bottom U-profile track (2d) being configured for forming top and bottom horizontal studs of the support frame, respectively, extending along a longitudinal axis (X), each of the top and bottom U-profile comprising first (2f1) and second U-flanges (2f2) parallel to each other separated by a U-web (2w) extending normal to the U-flanges and defining a U-opening,

■ two or more i-profile beams (3), each i-profile beam comprising a beam web (3w) normal to and sandwiched between first and second beam flanges (3f1 , 3f2), said i-profile beam does not comprise any slit, said i-profile beam (3) having a height (H3) smaller than the board height (H1) by at least 10%,

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

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

• positioning a first board (1) parallel to the wall plane (X, Z), and fixing the board to the first flange (2f1) of the top U-profile track, preferably by using two fixing means,

• engaging a first, i-profile to the first board such that, a free end of the first flange (3f1) of the i-profile is engaged in the groove of the first vertical edge of the board and such as the second flange (3f2) sits under the top U profile,

• positioning a second board (1) parallel to the wall plane (X, Z) and engaging the free end of the remaining first flange (3f1) of the first i-profile in the groove of the first vertical edge of the second board,

• fixing the second board to the first flange (2f1) of the top U-profile track preferably by using two fixing means,

• engaging a second i-profile to the second board such that, a free end of the first flange (3f1) of the i-profile is engaged in the groove of the second vertical edge of the second board and such as the second flange (3f2) sits under the top U profile,

• repeating the last three steps to obtain a first row of boards of the desired length of the wall lining,

• applying a joint between two adjacent boards. Method according to claim 1 for installing a permanent wall lining, further comprising the steps of,

• providing a stabilizing element (4) formed by a T- or L-profile comprising an element web (4w) and an element flange (4f) normal to the element web (4w), a free end of the element web (4w) comprises an element slit (4s) configured for engaging one of the two U-flanges (2f) of the bottom U-profile track (2d) such that, o the element web (4w) extends normal to the wall plane (X, Z), such that o a height (H4) of the stabilizing element (4) measured along the vertical axis (Z) is shorter than the difference between the board height (H1) and the beam height (H3) (i.e., H4 < H1 - H3), and such that o a corresponding free end of the element flange (4f) is located outside of the bottom U- profile track (2d), at a distance from the first U-flange of the bottom U-profile track (2u) such that the element flange (4f) can be introduced into the groove (1g) of a first board (1) with the second main surface of the first board (1) extending parallel to the wall plane (X, Z) and contacting an outer surface of the first U-flange of the bottom U-profile track (2d)

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

• engaging the element flange (4f) of the first stabilizing element (4) into the groove of the first vertical edge of the first board (1), repeating the last two steps for at least some of, preferably all the boards. 3. Method for installing permanent wall lining according to claim 2, wherein the element flange (4f) has first and second surfaces separated by a thickness of the element flange, and wherein the first and second surfaces are textured (4t) or comprise protrusions (4p) configured for applying a friction against walls of the groove (1g) of the first board (1) it is inserted in.

4. Method for installing permanent wall lining according to any one of the previous claims wherein the vertical edges of the boards are tapered, preferably chamfered, relative to a centre of the boards, such that each board has an edge thickness (Te) measured at the vertical edges which is smaller than a thickness measured at the centre of the board, and wherein the thickness measured at the vertical edges is preferably comprised between 4 and 36 mm, more preferably between 14 and 22 mm, most preferably between 15 and 18 mm, or more preferably between 25 and 30 mm.

5. Method for installing permanent wall lining according to any one of the previous claims, wherein the boards (1) have a width of the order of 900 mm, preferably 600 mm measured along the longitudinal axis (X) and a thickness (T) comprised between 18 and 25 mm, preferably between 19 and 22 mm.

6. Method for installing permanent wall lining according to any one of the previous claims, wherein the boards (1) have a density comprised between 0.35 and 2, preferably 0.5 and 0.8 for gypsum boards comprising more than 80 wt% of calcium sulphate dihydrate preferably between0.7 and 1 .6 for fiber cement boards.

7. Method for installing permanent wall lining according to any one of the previous claims, wherein the boards comprise a core comprising at least 80 wt.% relative to the core weight of calcium sulphate dihydrate, or calcium silicate, or fibre cement preferably.

8. Method for installing permanent partition wall of desired length measured along the longitudinal axis (X), comprising the following steps,

• Providing o four or more boards (1), each board having a rectangular geometry, comprising a first main surface parallel to and separated from a second main surface by a thickness (T) measured along a transverse axis (Y) normal to the wall plane (X, Z), and forming a peripheral edge comprising first and second longitudinal edges of length (L) extending along the longitudinal axis (X), normal to and separated from one another by first and second vertical edges of board height (H1) extending along the vertical axis (Z), and wherein a groove (1g) extends along each of the first and second vertical edges, each groove having an opening width (w) measured normal to the wall plane (X, Z), and a depth (d) measured parallel to the longitudinal axis (X), o a support frame comprising, a top U-profile track (2u) and a bottom U-profile track (2d) being configured for forming top and bottom horizontal studs of the support frame, respectively, extending along a longitudinal axis (X), each of the top and bottom U-profile comprising first (2f1) and second U-flanges (2f2) parallel to each other separated by a U-web (2w) extending normal to the U-flanges and defining a U-opening,

■ two or more i-profile beams (3), each i-profile beam comprising a beam web (3w) normal to and sandwiched between first and second beam flanges (3f1 , 3f2), said i-profile beam does not comprise any slit, said i-profile beams (3) having a height (H3) smaller than the board height (H1) by at least 10%,

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

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

• positioning a first board (1) parallel to the wall plane (X, Z), and fixing the board to the first flange (2f1) of the top U-profile track, preferably by using two fixing means,

• positioning a second board (1) in front and parallel to the first board, and fixing the board to the second flange of the top U-profile track, preferably by using two fixing means,

• engaging a first i-profile to the first and second board such that, o a free end of the first flange (3f1) of the i-profile is engaged in the groove of a first vertical edge of the first board while the corresponding free end of the second flange (3f2) is engaged in the groove of a first vertical edge of the second board,

• positioning a third board parallel to the wall plane (X, Z) by engaging the groove of a first vertical edge of the third board over the remaining free end of the first flange (3f1) of the i-beam and fixing the board to the first flange (2f1) of the top U-profile track, preferably by using two means,

• positioning a fourth board in front and parallel to the third board by engaging the groove of a first vertical edge (3f1) of the fourth board over the remaining free end of the second flange of the i-profile beam and fixing the board to the second flange (2f2) of the top U-profile, preferably by using two fixing means,

• engaging a second i-profile to the third and fourth board such that, o a free end of the first flange (3f1) of the i-profile is engaged in the groove of the second vertical edge of the third board while the corresponding free end of the second flange (3f2) is engaged in the groove of the second vertical edge of the fourth board,

• repeating the last three steps to obtain a permanent partition board of the desired length.

• filing a joint between two adjacent boards.

9. Method for installing a permanent partition wall according to previous claim, further comprising the steps of,

• providing a stabilizing element (4) formed by a T- or L-profile comprising an element web (4w) and an element flange (4f) normal to the element web (4w), a free end of the element web (4w) comprises an element slit (4s) configured for engaging one of the two U-flanges (2f) of the bottom U-profile track (2d) such that, o the element web (4w) extends normal to the wall plane (X, Z), such that o a height (H4) of the stabilizing element (4) measured along the vertical axis (Z) is shorter than the difference between the board height (H1) and the beam height (H3) (i.e., H4 < H1 - H3), and such that o a corresponding free end of the element flange (4f) is located outside of the bottom U- profile track (2d), at a distance from the first U-flange of the bottom U-profile track (2u) such that the element flange (4f) can be introduced into the groove (1g) of a first board (1) with the second main surface of the first board (1) extending parallel to the wall plane (X, Z) and contacting an outer surface of the first U-flange of the bottom U-profile track (2d)

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

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

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

10. Method for installing a permanent partition wall according to claim 9, wherein the element flange (4f) has first and second surfaces separated by a thickness of the element flange, and wherein the first and second surfaces are textured (4t) or comprise protrusions (4p) configured for applying a friction against walls of the groove (1g) of the first board (1) it is inserted in.

11. Method for installing a permanent partition wall according to any one of claims 8 to 10, wherein the vertical edges of the boards are tapered, preferably chamfered, relative to a centre of the boards, such that each board has an edge thickness (Te) measured at the vertical edges which is smaller than a thickness measured at the centre of the board, and wherein the thickness measured at the vertical edges is preferably comprised between 4 and 36 mm, more preferably between 14 and 22 mm, most preferably between 15 and 18 mm, or more preferably between 25 and 30 mm.

12. Method for installing permanent partition wall according to any one of claims 8 to 11 , wherein the boards (1) have a width of the order of 900 mm, preferably 600 mm measured along the longitudinal axis (X) and a thickness (T) comprised between 18 and 25 mm, preferably between 19 and 22 mm.

13. Method for installing permanent partition wall according to any one of claims 8 to 12, wherein the boards (1) the boards have a density comprised 0.35 and 2, preferably 0.5 and 0.8 for gypsum boards comprising more than 80 wt% of calcium sulphate dihydrate and preferably between 0.7 and 1 .6 for fiber cement boards. 14. Method for installing permanent partition wall according to any one of claims 8 to 13, wherein the boards are gypsum boards or fiber cement boards.

Description:
METHOD FOR INSTALLING A PARTITION WALL OR WALL LINING REQUIRING FEW SCREWS

TECHNICAL FIELD

[0001] The present invention concerns a method for installing a partition wall or wall lining, collectively referred to as drywalls, of the type comprising boards to be coupled to a frame. The coupling of the boards to the frame of the partition wall or wall lining requires a limited number only of screws compared to state-of-the-art drywalls. The present invention facilitates installation of partition walls or wall linings by amateur home carpenters or do-it-yourselfers (DIYers) rather than relying on professional installers.

BACKGROUND OF THE INVENTION

[0002] Refurbishing an interior of a building can comprise knocking down existing walls and building new partition walls and wall linings. A partition wall is a non-load bearing wall which divides a space into two sub-spaces separated from one another. Partition walls generally have two visible surfaces and may comprise insulation material, piping, or cables hidden from view. Wall linings are used for cladding an existing wall, e.g. to enhance the appearance of the existing wall, for insulating the existing wall, or for hiding piping or cables running along the existing wall. Wall linings can also include ceilings and, in some cases, floors. Wall linings only have one visible surface. Partition walls and wall linings are commonly referred to as drywalls without distinction. Permanent drywalls are to be distinguished from modulable partition walls which can be removed easily, as commonly used in modulable offices for rent. The present invention concerns permanent partition walls and wall linings. Permanent partition walls cannot be dismantled without damaging the plasterboards which are the elements of the partition wall. Another difference with a removable partition wall is the presence of joint between adjacent boards of the wall.

[0003] Beside using heavy materials, such as concrete, bricks, blockworks, or the like, partition walls and wall linings are generally formed by a support frame supporting boards made of e.g., plaster (= calcium sulphate dehydrate), cement, wood, plywood, metal, or the like. The boards are fixed to a frame generally made of metallic or wooden studs. For this reason, partition walls are sometimes referred to as stud walls. Because of wood shortage and higher fire resistance, however, metallic studs are often preferred.

[0004] The metallic studs generally comprise top U-profile tracks fixed to a top position, such as a ceiling, and a bottom U-profile track fixed to a bottom position, generally a floor. C-studs cut to a length corresponding to a height of the partition wall are screwed in place to the top and bottom U-profile tracks to form a frame on which boards can be fixed. The frame can be designed to incorporate openings for windows and doors, requiring more cutting to size and screwing in place of the metallic studs. The boards can then be fixed side-by-side to the frame with screws, thus securing the boards to the top and bottom U-profile tracks and to the vertical C-stud. In partition walls, boards are screwed on both sides of the frame, whilst in wall linings and ceilings, boards are screwed to one side only of the frame. The vertical C-stud may comprise openings in the webs thereof to allow the passage of piping and cables along a length of the partition wall or wall lining.

[0005] Once the boards are screwed in place on one or both sides of the frame, the joints between adjacent boards are sealed with a paste and optionally covered by an adhesive paper tape to smoothen the surface of the thus built drywall.

[0006] Although building a drywall is considered by professional builders as a relatively simple operation, only well-trained amateur home carpenters dare building a partition wall on their own. Indeed, as described supra, the metallic studs must be cut to size, which is time consuming. The studs must be screwed to the top and bottom U-profile tracks to form the frame. The boards must be screwed to the frame. Knowing that a screw is used every 30 cm, for a board having a length of 120 cm and a height of 240 cm, eight screws must be used to fix the board to the top and the bottom rack while 18 screws to fix the board to the vertical studs! Care must be taken with plasterboards which may be brittle and get damaged when pierced by screws in case the wrong type of screws is used.

[0007] The present invention proposes a solution for substantially simplifying the building of a permanent drywall, reducing the number of metal studs to be cut to dimensions and considerably reducing the number of screws. Even moderately trained do-it-yourselfers can now build a partition wall or wall lining requiring only limited technical skills with excellent results. These and other advantages of the present invention are presented hereunder.

SUMMARY OF THE INVENTION

[0008] The present invention is defined in the appended independent claims. Preferred embodiments are defined in the dependent claims.

[0009] The present invention concerns a method for installing a permanent wall lining and a method for installing permanent partition wall of desired length measured along the longitudinal axis (X), comprising the following steps.

BRIEF DESCRIPTION OF THE FIGURES

[0010] For a fuller understanding of the nature of the present invention, reference is made to the following detailed description taken in conjunction with the accompanying drawings in which:

Figure 1(a) shows an embodiment of vertical i-profile beam used in the present invention.

Figure 1 (b): show an embodiment of vertical end beam used in the present invention.

Figure 2: shows an example of top or bottom U-profile track.

Figure 3: shows a detail of an edge of a board provided with a groove. Figure 4(a) & 4(b): show two embodiments of stabilizing elements.

Figure 5: shows a first step in a first embodiment of fixing a first vertical i-profile beam to the top U- profile and using a stabilizing element.

Figure 6(a): shows an optimised screwing of a board.

Figure 6(b): shows a poor screwing.

Figure 7(a): shows a top view of a wall lining hiding an existing wall and comprising boards coupled to one side of the frame.

Figure 7(b): shows a top view of a partition wall comprising boards coupled to both sides of the frame with the boards coupled to a first side of the frame being not aligned with to the boards coupled to the second side of the frame.

Figure 8(a): shows a top-view of a spline joint formed by the wings of the flange of an i-profile beam inserted in the grooves of two adjacent boards having different thicknesses.

Figure 8(b): shows a top-view of a preferred embodiment of spline joint formed by the wings of the flange of an i-profile beam inserted in the grooves of two adjacent boards of different thicknesses and having tapered edges.

Figures 9(a) to 9(f): shows various embodiments of boards having tapered or thinned edges.

Figures 10(a) to 10(d): shows various stages of the building of a drywall according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0011] The present invention concerns a method for installing a permanent partition wall or wall liner, collectively called drywalls, which are easier to build than state-of-the-art drywalls. The drywalls are not meant to be moved from one position to another as exist in modulable open spaces for forming individual offices a la carte.

[0012] Each of the one or more boards (1) have a rectangular geometry, comprising a first main surface parallel to and separated from a second main surface by a thickness (T) measured along a transverse axis (Y), and forming a peripheral edge comprising first and second longitudinal edges of length (L) extending along a longitudinal axis (X) normal to the transverse axis (Y) and separated from one another by first and second vertical edges of board height (H1) measured along a vertical axis (Z) normal to both longitudinal and transverse axes (X) and (Y). A groove (1g) extends along each of the first and second vertical edges, each groove having an opening width (w) measured normal to a wall plane (X, Z) normal to the transverse axis (Y), and a depth (d) measured parallel to the longitudinal axis (X). [0013] The elements for forming the support frame comprise a top U-profile track (2u) and a bottom U-profile track (2d) configured for forming top and bottom horizontal studs of the support frame, respectively. As illustrated in figure 2, each of the top and bottom U-profile tracks extend along the longitudinal axis (X) and comprise first and second U-flanges (2f) substantially parallel to each other and separated by a U-web (2w) extending substantially normal to the U-flanges and defining a U-opening.

[0014] The elements for forming the support frame also comprise two or more i-profile beams (3). As illustrated in figure 1 (a), each i-profile beam comprises a web (3w) normal to and sandwiched between first and second beam flanges (3f1 , 3f2) normal to the web (3w). The i-profile beams are configured for being engaged in the groove of two adjacent boards suppressing then the need of vertical studs between two adjacent boards and the need of screws on the height of the board. The number of screws has been consequently reduced significantly.

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

[0015] The support frame is composed at least of a top U-profile track (2u) and a bottom U-profile track (2d) forming top and bottom horizontal studs of the support frame of a vertical drywall, and vertical i-profile beams (3), forming the vertical studs of the support frame of the vertical drywall.

[0016] The top and bottom U-profile tracks (2u, 2d) are separated from one another by a distance substantially equal to a height (H1) of the boards (1) measured along the vertical axis (Z). The top U-profile tracks (2u) are fixed side by side to a top position extending along the longitudinal axis (X) with the U-opening facing towards a bottom position. The bottom U-profile tracks (2d) are fixed side by side to the bottom position extending along the longitudinal axis (X) with the U-opening facing towards the top position. In many instances, wherein a partition wall must divide a large room into two smaller rooms, extending from floor to ceiling, the top position is a ceiling of the large room and the top U-profile tracks (2u) are fixed to the ceiling. The bottom position is a floor of the large room and the bottom U-profile tracks (2d) are fixed to the floor. The top and bottom U-profile tracks (2u, 2d) are preferably aligned side by side along the longitudinal axis (X) defining the position of the partition wall or wall lining. In special cases the top and bottom U-profile tracks may define a broken line. But this depends on the wishes of the builder and does not restrict the present invention.

[0017] The top and bottom U-profile tracks (2u, 2d) can be fixed to the ceiling and floor with screws, an adhesive, double-sided tapes, and the like. This operation requires cutting one top and one bottom U-profile track only, in case the length of the drywall measured along the longitudinal axis (X) is not a multiple of a length of the U-profile tracks. The number of different elements can be reduced by designing identical top and bottom U-profile tracks (2u, 2d). This reduces the risk of making a mistake by fixing a bottom U-profile track to a ceiling instead of to a floor. For example, for building a wall of 4.3 m length measured along the longitudinal axis (X) using 2 m long top and bottom U-profile tracks, two top and two bottom U-profile tracks can be fixed side-by-side to the ceiling and floor, respectively, and a fifth U-profile track can be cut into two sections of 0.3 m length and fixed to the ceiling and floor for completing the length of the wall to be built. If the drywall must comprise an opening between the drywall and the ceiling, then the top U-profile (2u) is not fixed to the ceiling, but at the desired height between existing walls.

SUPPORT FRAME - l-PROFILE BEAMS (3)

[0018] The i-profile beams (3) connect two adjacent boards without any screws or glue, such as to extend along the vertical axis (Z) between the top and bottom U-profile tracks (2u, 2d). As shown in figure 1 (a) the i-profile beams (3) comprise a web (3w) normal to and sandwiched between first and second beam flanges (3f1 , 3f2) defining an i-profile.

[0019] Figures 5 shows that the i-profile beams (3) have a beam height (H3) of at least 10 % smaller than the board height (H1). The i-profile beams (3) are stabilized upon inserting the flanges of the beam web (3w) into the grooves (1g) of the boards. The beam height is preferably 10-30 % shorter than the board height. This allows the passage of electrical cables for example. However, a minimum height is required to confer to the partition or the lining sufficient rigidity as no vertical studs are used.

[0020] In figure 5, the support frame is further composed of stabilizing elements (4), illustrated in figures 4(a) and 4(b), which are formed by a T-profile comprising an element web (4w) and an element flange (4f) normal to the element web (4w). The stabilizing elements (4) can also be formed by an L- profile. A free end of the element web (4w) comprises an element slit (4s) configured for engaging one of the two U-flanges (2f) of the bottom U-profile track (2d) such that,

• the element web (4w) extends normal to the wall plane (X, Z), such that

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

• a corresponding free end of the element flange (4f) is located outside of the bottom U-profile track (2d), at a distance from the first U-flange of the bottom U-profile track (2u) such that the element flange (4f) can be introduced into the groove (1g) of a first board (1) with the second main surface of the first board (1) extending parallel to the wall plane (X, Z) and contacting an outer surface of the first U-flange of the bottom U-profile track (2d).

[0021] The stabilizing element (4) is independent of the corresponding i-profile beam (3) and fixes a bottom of a board to the bottom U-profile track (2d). Using an i-profile beam (3) of height H3 < H1 , and a stabilizing element (4) is very versatile in that it permits to easily compensate for slight misalignments, either in the structure (walls, celling, floor) of the room to be divided, or of the various top and bottom U-profile tracks (2u, 2d). Furthermore, there is no need to cut any of the T-profile beams (3) to the specific board height (H1) of the drywall, and they can be used directly off-the-shelves. Cables and piping can easily run between the first and second rows of boards of a drywall. Finally, there is no need of screwing the board to the bottom U-profile track.

[0022] To better stabilize the coupling of the stabilizing element and the board (1), the element flange (4f) has first and second surfaces separated by a thickness of the element flange, wherein the first and second surfaces are preferably textured (4t) as shown in figure 4(a) or comprise protrusions (4p) as shown in figure 4(b), configured for applying a friction against walls of the groove (1g) of the first board (1) it is inserted in.

[0023] A drywall extends along the longitudinal axis (X) between two ends, which can be free ends or contact ends, contacting another wall forming an angle with the drywall or prolonging an existing wall, i-profile beams (3) would be ill fitted to define the ends of the drywall for aesthetical reasons. It is preferred to define an end of the drywall with an end beam (9) for fixing the first vertical beam of a first board (1) having no adjacent second board. As illustrated in figures 1 (b) the end beam (9) is formed by a U-profile comprising first and second end-flanges (9f) parallel to each other separated by an end-web (9w) extending normal to the end-flanges and defining an end-opening which can be wider than the U- opening of the top U-profile tracks (2u, 2d). The end beam (9) is fixed to the wall. In the embodiment wherein the end-opening is wider than the U-opening of the top U-profile tracks (2u, 2d), the end flange (9f) is inserted in the groove (1g) of the first board. In the embodiment wherein the end-opening is equal to the opening of the top U-profile tracks (2u, 2d), the first board is fixed on the vertical flange (9f) of the end beam (9). In case of a free end of the drywall, it is preferred that the end beam (9) extends over the whole height (H1) of the board (1) from top to bottom U-profile tracks (2u, 2d), so that the end web (9w) forms a continuous hard surface protecting the free edge of the drywall from impacts.

BOARDS (1)

[0024] Each one of the one or more boards (1) has a rectangular geometry, comprising a first and second main surface parallel to the wall plane (X, Z) and separated from one another by a thickness (T) measured along a transverse axis (Y) normal to the wall plane (X, Z) forming a peripheral edge. The peripheral edge comprises first and second longitudinal edges of length (L) extending along the longitudinal axis (X), normal to and separated from one another by first and second vertical edges of board height (H1) extending along the vertical axis (Z). A groove (1g) extends along each of the first and second vertical edges. Each groove has an opening width (w) measured normal to the wall plane (X, Z), and a depth (d) measured parallel to the longitudinal axis (X) which is configured for snugly engaging a beam flange (3f1 , 3f2) of an i-profile beam (3).

[0025] The boards (1) can comprise a core comprising at least 80 wt.% relative to the core weight of calcium sulphate dihydrate, or calcium silicate, or fibre-cement, or wood, or plywood, or can even be made of metal. The boards can have a density comprised between 0.35 and 2.00 preferably between 0.50 and 0.80 for boards comprising more than 80 wt % of calcium sulphate dihydrate, or preferably between 0.70 and 2.0 for fiber cement boards and more preferably between 0.7 and 1.6, depending on the thickness of the boards.

[0026] For example, a board core made of calcium sulphate dihydrate can comprise at least 94 wt.% calcium dihydrate relative to the core weight, starch in an amount comprised between 3.15 and 6.30 kg/m 3 of the core, polyvinyl acetate (PVA), optionally a foaming agent, and preferably reinforcing fibres (e.g., glass fibres). Such boards can have a density of 0.4 to 0.80.

[0027] The boards are cement boards and more preferably gypsum boards comprising more than 85% of calcium sulphate dihydrate. For non-professionals, screwing a cement board or a gypsum board is not straightforward. Indeed, when screwing a board, the right strength must be applied in order to stop the screwing before the top of the screw exceeds the surface of the board as illustrated in figure 6a. Applying a higher strength, the screw head sinks down in the gypsum board decreasing then the strength of the fixation. In addition, extra work is required to fill the created gap by further filler as illustrated in figure 6b. This problem is not met by professionals as most of them are using screwdrivers with stop clutch.

[0028] The boards (1) can have a height (H1) of up to 2400 mm and even up to 3050 mm measured along the vertical axis (Z). The boards can conveniently be cut to the desired height (H1) at the shop, as most DIY-shops offer such service. The boards (1) may have a width of the order of 900 mm, preferably 600 mm measured along the longitudinal axis (X). The thickness (T) of the boards (1) can be comprised between 6 and 40 mm measured at a centre of the board, preferably between 18 and 25 mm, more preferably between 19 and 22 mm, or preferably between 20 and 35 mm, more preferably between 25 and 30 mm. A centre of the board is located at the intersection of the diagonals of the first main surface.

[0029] In particular the invention deals with boards comprising more than 80 % of calcium sulphate dihydrate having a thickness measured at a centre of the board between 18 and 25mm and a density higher than 0.65.

[0030] As illustrated in figures 3, 8(b), and 9(a) to 9(f), it is preferred that the vertical edges of the boards are tapered, preferably chamfered, relative to a centre of the boards, such that each board has an edge thickness (Te) measured at the vertical edges which is smaller than a thickness measured at the centre of the board. For example, the thickness measured at the vertical edges can be comprised between 4 and 36 mm, more preferably between 14 and 22 mm, most preferably between 15 and 18 mm, or more preferably between 25 and 30 mm. As visible when comparing figures 8(a) and 8(b), a tapered edge has the advantage to substantially reduce the visual impact caused by two adjacent boards (1) of thicknesses (T) differing from one another by a thickness difference (8). Even small thickness differences (8) of the order of 1 or 2 mm which are comprised within tolerance boundaries for plasterboards (made of gypsum) or fibre-cement boards, can create a step which is disturbingly visible on the final drywall. As shown in figure 8(a), even after filling the gap between the two adjacent boards with a filler, the slope of the filler bridging the edges of the two adjacent boards (1) forms such an angle that the light reflects differently onto the surface of the drywall at the level of the joint. By contrast, as shown in figure 8(b), if the edges are tapered, the filler can bridge the edges of the two adjacent boards with an angle much closer to zero than in the case of figure 8(a). This way, with tapered edges, the thickness difference between the two adjacent boards (1) yields a substantially less disturbing optical effect on the appearance of the final drywall, with a more homogeneous light reflection on the drywall surface.

[0031] As shown in figures 9(a) to 9(f), a tapered edge can have a variety of geometries. When the geometry illustrated in figure 9(a) is what is generally considered as a taper, figure 9(b) shows a specific tapered geometry generally referred to as chamfered, as the taper forms an angle of approximately 45°. The expression “tapered edge” is construed herein as any geometry having a board thickness at the level of the edges which is smaller than the thickness of the board measured at the centre thereof. This expression therefore encompasses also any one of the following geometries: comprising a step forming approximately a 90 degree angle (cfr. figure 9(c)), comprising a concave step (cfr. figure 9(d)) or a convex edge (cfr. figure 9(e)) or both concave step and convex edge (cfr. figure 9(f)), and the like. The tapered portion of the edges of a board (1) can extend over a distance (Le) measured along the longitudinal axis of at least 30 mm, preferably at least 50 mm, more preferably at least 100 mm, and of not more than 300 mm, preferably not more than 200 mm. The thickness difference (T - Te) between the board thickness measured at the centre and at the edge of a board can be comprised between 0.5 to 5 mm, preferably between 1 and 3 mm. The preferred embodiment is a tapered edge comprising a step forming an approximately 90° angle as shown in figure 9(c). This kind of tapered edge is indeed easier to be filled by an unexperienced amateur.

[0032] The groove (1g) preferably extends along the first and second vertical edges of the boards over the whole board height (H1). The grooves (1g) of the boards (1) must be dimensioned such as to snugly engage the beam flanges (3f1 , 3f2) of the i-profile beams (3), preferably opposing a moderate friction against the introduction of a beam flange into the groove. The grooves (1 g) preferably have an opening width (w) of 2 mm + 0.3 mm, measured along the transverse axis (Y), and a depth (d) comprised between 25 and 60 mm, preferably between 30 and 50 mm, measured along the longitudinal axis (X).

[0033] For the unexperienced amateur taking into account the weight and the handling of the board and the easiness of the installation, the boards are preferably plasterboards having a width of 60 mm, a thickness of 18-25 mm and a density of 0.4 to 0.65 with a tapered edge which has preferably a step.

PERMANENT WALL LINING

[0034] A wall lining is a drywall which hides from view a portion of a room from the rest of the room. A wall lining can stand against or close to an existing wall (11), hiding a poor looking wall, or pipes, wires, insulation, and the like, showing in front of the existing wall, or can hide a portion of the room to be hidden from view, such as the last 50 to 100 cm separating a floor from a sloping roof in a room under the roof. Basically, a wall lining needs be aesthetically appealing on one side of the drywall only and therefore comprises boards (1) fixed to one side only of the top and bottom U-profile tracks (2u, 2d), as shown in figure 7(a). The term “permanent’ indicates that the wall lining is not designed for being mounted and dismounted repeatedly but is meant to remain in place.

[0035] According to the national legislation such NF_DTU25.41 P1-1 (2012) chapter 5.2 in France, permanent also means that the wall lining comply with minimum mechanical strength.

PERMANENT PARTITION WALL

[0036] A partition wall divides a room into two subspaces. Unlike the wall linings, a partition wall must be aesthetically appealing from both sides of the partition wall. Boards must be coupled to the support frame on both sides thereof. Piping, cables, insulation, and the like can run along a partition wall in the space comprised between the boards coupled to either side of the support frame. As explained for wall linings, the term “permanent’ indicates that the partition wall is not designed for being mounted and dismounted repeatedly but is meant to remain in place. The dismantlement would indeed require the damaging of the boards.

[0037] According to the national legislation such NF_DTU25.41 P1-1 (2012) chapter 5.2 in France, permanent also means that the wall lining comply with minimum mechanical strength.

[0038]

METHOD FOR INSTALLING A PERMANENT DRYWALL

[0039] The present invention greatly simplifies the installation of a permanent partition wall or wall lining to a point that even unexperienced amateur do-it-yourselfers can achieve an excellent result. The permanent partition wall or wall lining can be installed as follows.

[0040] One or more top U-profile tracks (2u) are fixed side by side to a top position, extending along the desired position of the drywall, with the U-opening facing towards a bottom position. If the drywall is straight, the desired position extends linearly along the longitudinal axis (X). Alternatively, the drywall may follow a broken line.

[0041] Similarly, one or more bottom U-profile tracks (2d) are fixed side by side to the bottom position, preferably to a floor, extending along the same desired position of the drywall with the U-opening facing towards the top position, and aligned relative to the vertical axis (Z) with the one or more top U-profile tracks (2u). The sequence of fixing the top and bottom U-profile tracks (2u, 2d) to their corresponding positions is unimportant for the present invention. The top and bottom U-profile tracks (2u, 2d) can be fixed to the top and bottom positions with screws, double-sided tape, and the like.

[0042] In order to install a permanent wall lining, a first board (1) is positioned parallel to the wall plane (X, Z). The board is then fixed to the first flange (2f1) of the top U-profile track, preferably by using two fixing means,

[0043] A first, i-profile to the first board is used such that, a free end of the first flange (3f1) of the i-profile is engaged in the groove of the first vertical edge of the board and such as the second flange (3f2) sits under the top U profile.

[0044] A second board (1) is positioned parallel to the wall plane (X, Z) and the free end of the remaining first flange (3f1) of the first i-profile is engaged in the groove of the first vertical edge of the second board.

[0045] The second board is then fixed to the first flange (2f1) of the top U-profile track preferably by using two fixing means,

[0046] A second i-profile to the second board is used such that, a free end of the first flange (3f1) of the i-profile is engaged in the groove of the second vertical edge of the second board and such as the second flange (3f2) sits under the top U profile.

[0047] A joint is applied between two adjacent boards

[0048] Preferably the joint does not require a tape. It is a tapeless jointing system. The joint comprises organic polymers with glass beads in order to provide elasticity and prevent form the formation of cracks. A polyacrylic polymer is preferred.

[0049] By repeating the last three steps a first row of boards of the desired length of the wall lining is obtained. Figure 7(a) shows a lining obtained according to the method.

[0050] Figures 10(a) to fig.10(d) illustrate the method to install a partition wall. A first board (1) is positioned parallel to the wall plane (X, Z). The board is then fixed to the first flange (2f1) of the top U- profile. Glue can be used to fix the board to the track. Preferably two fixing means such as screws are used.

[0051] A second board (1) is positioned parallel to the wall plane (X, Z) and in front of the first board. The board is then fixed to the first flange (2f1) of the top U-profile. Preferably two fixing means such as screws are used.

[0052] As shown in fig. 10(b), a first i-profile is engaged in the groove of the first and second board, such as a free end of the first flange (3f1) of the i-profile engaged in the groove of a first vertical edge of the first board while the corresponding free end of the second flange (3f2) is engaged in the groove of a first vertical edge of the second board.

[0053] Figure 10(c) shows the positioning of a third board by engaging the groove of a first vertical edge of the third board over the remaining free end of the first flange (3f1) of the i-beam and fixing the third board to the first flange (2f1) of the top U-profile track. The third board is then positioned next to the one of the already fixed board. The fixed board is the first or the second board.

[0054] Fig.10 (d) shows the positioning of a fourth board by engaging the groove of a first vertical edge of the fourth board over the remaining free end of the second flange (3f2) of the i-beam and fixing the board to the second flange (2f2) of the top U-profile, preferably by using two fixing means. The fourth board is then next to the second board and in front and parallel to the third board. In case the third board was positioned next to the second board, the fourth board would be of course positioned next to the first board.

[0055] A second i-profile is then engaged in the groove of the third and fourth board such that, a free end of the first flange (3f1) of the i-profile is engaged in the groove of the second vertical edge of the third board while the corresponding free end of the second flange (3f2) is engaged in the groove of the second vertical edge of the fourth board.

[0056] The three last steps are then repeated to obtain a permanent partition board of the desired length.

[0057] In order to finish the installation a joint is filled between two adjacent boards.

[0058] Preferably the joint does not require a tape. It is a tapeless jointing system. The joint comprises organic polymers with glass beads in order to provide elasticity and prevent form the formation of cracks. A polyacrylic polymer is preferred.

[0059]

[0060] Before coupling the two opposite boards, acoustic and/or thermal insulation can be installed between the main surfaces of the boards of the opposite boards. Also, electric cables and/or tubing can be drawn in a volume defined between the top and bottom U-profile tracks (2u, 2b).

STABILIZING ELEMENT (4)

[0061] In order to stabilise the installation of the boards, the boards are further fixed to the bottom U- profile track (2d) by preferably using two screws.

[0062] The stabilisation of the boards could also be done by using a stabilizing element (4). The slit (4s) of a first stabilizing element (4) is engaged into the first U-flange of the bottom U-profile track (2d) with the element web (4w) extending normal to the wall plane (X, Z), and the element flange (4f) of the first stabilizing element (4) is engaged into the groove of the first vertical edge of the first board (1). The foregoing steps are then repeated for at least some of, preferably all the boards. For wall linings, any cable, piping, or insulation material can be installed behind the wall lining under construction before or during coupling the first row of boards (1) to the support frame, such that they are hidden after completion of the coupling of the first row of boards. [0063] Another advantage of the stabilizing element is to compensate uneven floor.

EXPERIMENTAL

Partition and lining boards made of gypsum boards comprising more than 80 wt% of gypsum and having a thickness of 18 mm and a density of 0.7 have been tested according to NF DTU 25.41 P1-1 (2012) 5.2 & Annex D and comply with the norm. To fulfil its role, the lining wall or the partition wall must withstand impacts characterized by their energy:

• performance conservation: 60 Nm, impact of bag of 50 kg , no cracking must be observed.

• safety shock: 240 Nm. the wall must not be pierced by the impact body and must not cause falling part of the wall.

CONCLUDING REMARKS

[0064] Drywalls according to the present invention are substantially simpler to install then state-of-the-art kits. An unexperienced amateur do-it-yourselfer can easily install a drywall with little to no technical difficulties associated with such operations as encountered with state-of-the-art kits. The number of profiles to be cut is reduced to a minimum and so is the number of screws, limited to the fixing of the top and bottom U-profile tracks to a top position (such as a ceiling) and a bottom position (such as a floor), respectively, and one or two board which are cut to the required width to complete the full length of the wall lining or partition wall.