Description:Background of the Invention

[0001] The present invention relates to a method of constructing a dry wall system. More specifically, the present invention refers to a method of constructing a dry wall system using non-reinforced, post-compressed, autoclaved aerated concrete panels.

[0002] Methods of constructing dry wall systems are known in the art. For example, Chinese patent application CN111173147A, assigned to Hangzhou Jianling New Material Technology, describes an installation joint for autoclaved aerated concrete panels. The joint uses an assembly of tie screws, expansion bolts, and lengthened nuts along with a special adhesive or polyurethane foam. Japanese patent application JP2019078115A, assigned to Kajima Corp., describes a concrete precast floor slab and joint method. Here precast floor slabs are joined using an adhesive, and tension applied to the joint using a tendon, to improve and reinforce the joint. However, these techniques typically require longer installation times, and requirement of skilled manpower to assemble these panels. Further, joining wall panels using concrete or mortar requires long periods of manpower-intensive curing. Also, the joining of concrete wall panels using adhesives, may result in poor joint strength, leading to the possibility of joint failure, water leakage, etc.

[0003] Thus, there is a need in the art for methods of constructing dry wall systems that are quick, and simple, while reducing the amount of time required for installation, curing and finishing of the dry wall system.

Summary

[0004] One embodiment of the present invention is method of constructing a dry wall system. The method includes the steps of assembling two or more pre-fabricated wall panels adjacent to each other, applying an adhesive at a junction of the at least two pre-fabricated wall panels, encasing the junction of the at least two pre-fabricated wall panels with a mesh to form an encased junction. The method includes the step of applying a bonding agent to the encased junction of the at least two pre-fabricated wall panels to obtain a bonded wall panel assembly, positioning at least one lift jack assembly at a predetermined position along a location where the dry wall system is to be installed. Further the method includes placing the bonded wall panel assembly in a substantially vertical orientation at the location where the dry wall system is to be installed, and operating the at least one lift assembly to apply a compressive force to the bonded wall panel assembly.

[0005] Another embodiment of the present invention is a dry wall system. The dry wall system includes a bonded wall panel assembly made up of post-compressed non-reinforced autoclaved aerated concrete, and at least one lift assembly positioned at a predetermined position along a location where the dry wall system is to be installed.

Description of Drawings

[0006] Figure 1 is a flowchart depicting a method of constructing a dry wall system according to an embodiment of the present invention.

[0007] Figure 2 is a drawing of a dry wall system made by a method of constructing a dry wall system according to an embodiment of the present invention.

Detailed Description

[0008] While various embodiments of the invention have been shown and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions may occur to those skilled in the art without departing from the invention. It should be understood that various alternatives to the embodiments of the invention described herein may be employed.

[0009] In the specification and the claims which follow, reference will be made to a number of terms which shall be defined to have the following meanings:

[00010] The singular forms “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise. “Optional” or “optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where the event occurs and instances where it does not. “Substantially” means a range of values that is known in the art to refer to a range of values that are close to, but not necessarily equal to a certain value.

[00011] Other than in the examples or where otherwise indicated, all numbers or expressions referring to quantities of ingredients, reaction conditions, and the like, used in the specification and claims are to be understood as modified in all instances by the term “about.” In some aspects of the current disclosure, the terms “about” or “approximately” are defined as being close to as understood by one of ordinary skill in the art.

[00012] As used herein, the term “substantially” and its variations are defined as being largely but not necessarily wholly what is specified as understood by one of ordinary skill in the art.

[00013] Various numerical ranges are disclosed herein. Because these ranges are continuous, they include every value between the minimum and maximum values. Unless expressly indicated otherwise, the various numerical ranges specified in this application are approximations, and not to be considered as limiting the scope of the invention.

[00014] As used herein, the term “dry wall” refers to an interior wall or partition finished in a dry material. The dry material is usually in the form of prefabricated sheets or panels.

[00015] As used herein, the term “Autoclaved aerated concrete” refers to lightweight precast foam concrete building material. The autoclaved aerated concrete is composed of fly-ash, lime, sand, calcium sulfate, gypsum, cement, water, and aluminum. Parts made of this composition are cured under heat and pressure in an autoclave.

[00016] As used herein, the term “non-reinforced wall panel” refers to a wall panel that does not have any metal-based reinforcing members embedded inside the wall panel.

[00017] As used herein, the term “post-compression” refers to the application of a compressive force to a wall panel assembly, after placing the wall panel assembly at a location where a dry wall system is to be installed.

[00018] As used herein, the term “mesh” refers to a material that is loosely woven out of fibres of fabric thread, metal, or plastic.

[00019] One embodiment of the present invention is method of constructing a dry wall system. The method includes the steps of assembling two or more pre-fabricated wall panels adjacent to each other, applying an adhesive at a junction of the at least two pre-fabricated wall panels, encasing the junction of the at least two pre-fabricated wall panels with a mesh to form an encased junction. The method also includes applying a bonding agent to the encased junction of the at least two pre-fabricated wall panels to obtain a bonded wall panel assembly, and positioning at least one lift jack assembly at a predetermined position along a location where the dry wall system is to be installed. The method further includes placing the bonded wall panel assembly in a substantially vertical orientation at the location where the dry wall system is to be installed, and operating the at least one lift assembly to apply a compressive force to the bonded wall panel assembly.

[00020] A method of constructing a dry wall system is depicted in Figure 1 according to an embodiment of the present invention. The method 100 includes the step of assembling 102 two or more pre-fabricated wall panels adjacent to each other, applying 104 an adhesive at a junction of the at least two pre-fabricated wall panels, encasing 106 the junction of the at least two pre-fabricated wall panels with a mesh to form an encased junction. The method 100 includes applying 108 a bonding agent to the encased junction of the at least two pre-fabricated wall panels to obtain a bonded wall panel assembly, and positioning 110 at least one lift jack assembly at a predetermined position along a location where the dry wall system is to be installed. The method 100 includes placing 112 the bonded wall panel assembly in a substantially vertical orientation at the location where the dry wall system is to be installed, and, operating 114 the at least one lift assembly to apply a compressive force to the bonded wall panel assembly.

[00021] In an embodiment of the present invention, the two or more pre-fabricated wall panels may be non-reinforced wall panels, or reinforced wall panels.

[00022] In an embodiment of the present invention, the two or more pre-fabricated wall panels may be autoclaved aerated concrete wall panels. In an embodiment of the present invention, the two or more pre-fabricated wall panels may be non-reinforced autoclaved aerated concrete wall panels.

[00023] In an embodiment of the present invention, the junction of the at least two pre-fabricated wall panels may refer to a horizontal junction, or a vertical junction.

[00024] In an embodiment of the present invention, the two or more pre-fabricated wall panels may have a length ranging from about 500 millimeters to about 3500 millimeters. In an embodiment of the present invention, the two or more pre-fabricated wall panels may have a length ranging from about 1000 millimeters to about 2000 millimeters.

[00025] In an embodiment of the present invention, the two or more pre-fabricated wall panels may have a breadth ranging from about 400 millimeters to about 800 millimeters. In an embodiment of the present invention, the two or more pre-fabricated wall panels may have a breadth ranging from about 550 millimeters to about 650 millimeters.

[00026] In an embodiment of the present invention, the two or more pre-fabricated wall panels may have a thickness ranging from about 50 millimeters to about 250 millimeters. In an embodiment of the present invention, the two or more pre-fabricated wall panels may have a thickness ranging from about 100 millimeters to about 200 millimeters. In an embodiment of the present invention, the two or more pre-fabricated wall panels may have a thickness of about 100 millimeters, 150 millimeters, or 200 millimeters.

[00027] In an embodiment of the present invention, the wall panel assembly may have dimensions of about 3000 millimeters X 600 millimeters X 100 millimeters, or dimensions of about 3000 millimeters X 600 millimeters X 150 millimeters, or dimensions of about 3000 millimeters X 600 millimeters X 200 millimeters. In an embodiment of the present invention, the two or more pre-fabricated wall panels may have dimensions of about 1000 millimeters X 600 millimeters X 100 millimeters.

[00028] In an embodiment of the present invention, the wall panel assembly includes two or more pre-fabricated wall panels. In one embodiment the pre-fabricated wall panel may have a weight in a range from about 100 kilograms to about 300 kilograms. In an embodiment of the present invention, pre-fabricated wall panels may have a weight ranging from about 100 kilograms to about 250 kilograms.

[00029] In an embodiment of the present invention, the adhesive may be an epoxy-based adhesive, an elastomer based adhesive, a silicone based adhesive, a resin based adhesive, a cement composite based adhesive, or a mortar based adhesive. In an embodiment of the present invention, the adhesive may be a self-curing adhesive.

[00030] In an embodiment of the present invention, the mesh may be a metallic mesh, a polymer-based mesh, a fiber-based mesh, or a glass fiber-based mesh. In an example embodiment of the present invention, the mesh may be a glass fiber-based mesh.

[00031] In an embodiment of the present invention, the bonding agent may be a self-curing bonding agent. In an embodiment of the present invention, the bonding agent may be a cementitious polymer modified material.

[00032] In an embodiment of the present invention, the at least one lift assembly may be a screw-driven lift jack assembly, a hydraulic-driven lift jack assembly or a scissor lift jack assembly. In an example embodiment of the present invention, the at least one lift assembly may be a screw-driven lift jack assembly.

[00033] In an embodiment of the present invention, the at least one lift assembly may be operated to apply a compressive force to the bonded wall panel assembly. In an embodiment of the present invention, the at least one lift assembly may be operated to apply a compressive force, and thus induce a post-compression to the bonded wall panel assembly.

[00034] In an embodiment of the present invention, the predetermined position along a location where the dry wall system is to be installed may be the center of the wall panel, at the bottom edge of the wall panel.

[00035] In an embodiment of the present invention, a metallic frame may be installed at a location where the dry wall system is to be installed, prior to installation of the dry wall system.

[00036] In an embodiment of the present invention, a torque of at least 4 Newton-metre to at most about 5 Newton-metre may be applied to the at least one lift jack assembly. In another embodiment of the present invention, a torque of at least 4 Newton-metre to at most about 4.5 Newton-metre may be applied to the at least one lift jack assembly.

[00037] In an embodiment of the present invention, the method may further include the step of surface finishing the surface of the dry wall system.

[00038] In an embodiment of the present invention, the surface of the dry wall system may be finished using a finishing agent. In an embodiment of the present invention, the finishing agent may be a cement based agent, or a gypsum based agent. In another embodiment of the present invention, the finishing agent may preferably be a gypsum based agent.

[00039] In an embodiment of the present invention, grooves may be cut into the wall panel assembly to provide space for example service conduits for housing electrical wiring, water piping, or central heating piping and the like.

[00040] In an embodiment of the present invention, the dry wall system may be painted using a whitewash, a water based paint, or an oil based paint.

[00041] Another embodiment of the present invention is a dry wall system. The dry wall system includes a bonded wall panel assembly made up of post-compressed non-reinforced autoclaved aerated concrete, and at least one lift assembly positioned at a predetermined position along a location where the dry wall system is to be installed.

[00042] Referring now to Figure 2, a schematic 200 of a dry wall made by a method according to an embodiment of the present invention, is shown. The wall panels 202 are joined to each other, using an adhesive, encased with a mesh, and coated with a bonding agent, to form junctions 204. The wall panel assemblies are installed between a roof 206 and a floor 208. Lift jack assemblies are installed at the predetermined positions 210, and a torques applied to the lift jack assemblies to apply a compressive force to the wall panel assembly. The wall panel assembly thus covers the entire height 212 between the floor 208 and the roof 206.

EXAMPLES

[00043] Example 1: A dry wall system was made according to an embodiment of the present invention. Panels of non-reinforced, autoclaved aerated concrete of dimension 3000 millimeters X 600 millimeters X 100 millimeters were selected. The panels were joined to each other by applying an adhesive, for example the proprietary adhesive C-Fix supplied by Chetana Exponential Technologies Pvt. Ltd., at the junction of two panels. The junction was then encased in a mesh, for example the proprietary mesh C-mesh supplied by Chetana Exponential Technologies Pvt. Ltd., to form an encased junction. The encased junction was then coated by a bonding agent, for example, the proprietary bonding agent C-Bond supplied by Chetana Technologies Exponential Pvt. Ltd, to form a bonded wall assembly. A groove was cut into the center of the wall panel assembly at the base of the wall panel assembly. This wall panel assembly was then placed in a vertical orientation at a location where the wall is to be installed, and a lift jack assembly was placed in the groove. A torque of about 4.32 Newton-meter was then applied to the lift jack assembly so that a compressive force was applied to the wall assembly. The surface of the wall panel assembly was then finished using a surface finishing agent for example the proprietary surface finishing agent C-Gyp, supplied by supplied by Chetana Exponential Technologies Pvt. Ltd.

Advantages:

1. The method allows for quick and easy installation of non-load bearing walls, with reduced labour, time and requirement of skilled manpower.
2. The method does not require water for curing, thus water consumption and cost at the building site is reduced.
3. The method uses adhesives and bonding agents that are self-curing, thus long curing times are not required.
4. The method allows for construction of dry walls with high strength, stability, and a good surface finish.
5. The method allows for early serviceability of the post-compressed dry wall system as wall element, as the method does not require a curing step, which is time-consuming.

[00044] It is to be understood that the above described embodiments are merely illustrative of numerous and varied other embodiments which may constitute applications of the principles of the invention. Such other embodiments may be readily understood by those skilled in the art without departing from the spirit or scope of this invention.
 
, C , Claims:1. A method of constructing a dry wall system, comprising the steps of:
assembling two or more pre-fabricated wall panels adjacent to each other;
applying an adhesive at a junction of the at least two pre-fabricated wall panels,
encasing the junction of the at least two pre-fabricated wall panels with a mesh to form an encased junction;
applying a bonding agent to the encased junction of the at least two pre-fabricated wall panels to obtain a bonded wall panel assembly;
positioning at least one lift jack assembly at a predetermined position along a location where the dry wall system is to be installed;
placing the bonded wall panel assembly in a substantially vertical orientation at the location where the dry wall system is to be installed; and
operating the at least one lift assembly to apply a compressive force to the bonded wall panel assembly.
2. The method of claim 1, wherein the two or more pre-fabricated wall panels are a non-reinforced autoclaved aerated concrete wall panel.
3. The method of claim 1, wherein the adhesive is an epoxy-based adhesive, an elastomer based adhesive, a silicone based adhesive, a resin based adhesive, a cement composite based adhesive, or a mortar based adhesive.
4. The method of claim 1, wherein the mesh is a metallic mesh, a polymer-based mesh, a fiber-based mesh, or a glass fiber-based mesh.
5. The method of claim 1, wherein the bonding agent is a cementitious polymer modified material.
6. The method of claim 1, wherein the at least one lift assembly is a screw-driven lift jack assembly, a hydraulic-driven lift jack assembly or a scissor lift jack assembly.
7. The method of claim 1, wherein the adhesive is a self-curing adhesive.
8. The method of claim 1, wherein the bonding agent is a self-curing bonding agent.
9. The method of claim 1, further comprising the step of surface finishing the surface of the dry wall system.
10. A dry wall system, comprising,
a bonded wall panel assembly made up of post-compressed non-reinforced autoclaved aerated concrete, and
at least one lift assembly positioned at a predetermined position along a location where the dry wall system is to be installed.