Wall assembly, components, and methods for manufacture and installation thereof

Abstract

Aspects of the present invention relate to a wall assembly for mounting a wall in a residential or commercial building space. The wall assembly has a wall body having an upper region configured to be laterally supported at one or more upper surfaces thereof to maintain the wall body in a substantially upright position, and a lower region configured to be laterally supported at one or more lower surfaces thereof to maintain the wall body in a substantially upright position. The wall assembly further has at least one lateral support comprising an engagement portion configured to engage the one or more upper surfaces of the upper region or one or more lower surfaces of the lower region of the wall body. The wall body has a unitary body having a molded material.

What is claimed is: 
     
         1 . A wall for mounting in a residential or commercial building space, the wall comprising:
 a wall body having:
 an upper region configured to be laterally supported at one or more upper surfaces thereof to maintain the wall body in a substantially upright position; and 
 a lower region configured to be laterally supported at one or more lower surfaces thereof to maintain the wall body in a substantially upright position, 
   wherein the wall body comprises a unitary body having a molded material.   
     
     
         2 . The wall according to  claim 1 , wherein the wall body comprises a fire rating according to International Building Code (IBC) Chapter 7 of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours. 
     
     
         3 . The wall according to any preceding claim, wherein the wall body comprises a fire rating according to Underwriters Laboratory (UL) standard number 263 (Standard for Fire Tests of Building Construction and Materials) of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours. 
     
     
         4 . The wall according to any preceding claim, wherein the wall body comprises at least one of moisture resistance, UV resistance, termite resistance, acoustic dampening, a relatively low coefficient of expansion and/or contraction, and a relatively high compressive strength, tensile strength, and/or resistance to bending and impact. 
     
     
         5 . The wall according to any preceding claim, wherein the wall body comprises a thermal conductivity of no more than 0.040 W/m·K, no more than 0.036 W/m·K and/or no more than 0.04 W/m·K. 
     
     
         6 . The wall according to any preceding claim, wherein the wall body comprises a plurality of voids therein, such that the density of the wall body is sufficiently low to allow the wall body to be buoyant when immersed in water. 
     
     
         7 . The wall according to any preceding claim, wherein the wall body comprises a height as defined between opposing top and bottom sides of the wall body of at least 6 feet, at least 8 feet, and/or at least 10 feet, and a width as defined between opposing lateral sides of the wall body of at least 1 foot, at least 2 feet, at least 4 feet and/or at least 6 feet. 
     
     
         8 . The wall according to any preceding claim, wherein the wall body optionally further comprises one or more compartments, channels and/or recesses formed therein. 
     
     
         9 . The wall according to any preceding claim, wherein the wall body comprises substantially 90° corners at one or more and even both of the upper and lower regions. 
     
     
         10 . The wall according to any preceding claim, wherein the wall body comprises at least one of opposing back surface and front surfaces that is substantially planar, and/or does not comprise any of grooves, channels, recesses and/or compartments formed therein. 
     
     
         11 . The wall according to any preceding claim, wherein the wall body comprises one or more compartments and/or recesses formed therein and optionally having one or more panels to cover said one or more compartments and/or recesses. 
     
     
         12 . The wall according to any preceding claim, wherein the one or more compartments and/or recesses has a horizontal length that extends substantially across a horizontal length of the wall body between first and second opposing lateral sides of the wall body. 
     
     
         13 . The wall according to any preceding claim, wherein the panel comprises a wall board having a layer of magnesium-containing material. 
     
     
         14 . The wall according to any preceding claim, wherein the wall body optionally comprises one or more conduits embedded therein, and extending from a first side of the wall body to a second side of the wall body. 
     
     
         15 . The wall according to any preceding claim, wherein the conduits are vertical conduits extending from a top to a bottom of the wall body. 
     
     
         16 . The wall according to any preceding claim, wherein the wall body is configured to cooperate with a second wall body to form a finished wall upon completion of mounting of the wall, and optionally wherein the finished wall comprises a space between the wall body and second wall body, or the wall body and second wall body are flush with one another. 
     
     
         17 . The wall according to any preceding claim, wherein the wall body comprises one or more of a notch, groove, indentation and/or channel formed in the upper surface of the upper region that is configured to engage a lateral support. 
     
     
         18 . The wall according to any preceding claim, wherein the wall body comprises a mechanical mechanism configured to connect an upper surface of the upper region to a lateral support. 
     
     
         19 . The wall according to any preceding claim, wherein a thickness of the wall body as measured between inner and outer surfaces is configured to be accommodated by one or more lateral supports that laterally support the wall body by bracing the opposing inner and outer surfaces at the upper region of the wall body. 
     
     
         20 . The wall according to any preceding claim, wherein the wall body is configured to be attached to one or more lateral supports via an adhesive, and/or the one or more lateral supports are configured to be attached to a structure such as a ceiling or floor of the residential or commercial building space via an adhesive. 
     
     
         21 . The wall according to any preceding claim, wherein the wall body is configured to be attached to one or more lateral supports without an adhesive. 
     
     
         22 . The wall according to any preceding claim, wherein the wall body is formed from a building material comprising a magnesium-containing material. 
     
     
         23 . The wall according to any preceding claim, wherein the wall body comprises a material having one or more of magnesium oxide, magnesium chloride, and magnesium oxychloride, formed from the reaction of MgO, MgCl 2  and water. 
     
     
         24 . The wall according to any preceding claim, wherein the material is formed by combining MgO with MgCl 2  in a weight ratio that is sufficient to provide for a chemical reaction of MgO and MgCl 2  in a curing process that forms a final bonded solid product. 
     
     
         25 . The wall according to any preceding claim, wherein the material further comprises a tensile strength material comprising any one or more of horse hair, carbon fiber, type 1 collagen fibrils, bamboo mesh, natural fiber mesh, burlap mesh, wood fiber mesh, wood chips, natural fibers, plant fibers, wood fibers, cellulose, PVA fibers, acrylic fibers, AR glass fiber, alpha gypsum additive, polymer modified gypsum, pozzolans, fumed silica, metakaolin, liquid polymers including but not limited to acrylic emulsion polymer, powdered polymers, calcium aluminum sulfate crystals, portland cement, plasticizers, epoxies including epoxy putties, casting epoxies, composite epoxies, PVA fibers, fiberglass mesh, alkali resistant glass fibers, and alkali resistant scrim. 
     
     
         26 . The wall according to any preceding claim, wherein the mesh material comprises a woven bamboo mesh having interleaving bamboo fibers, the bamboo fibers having a diameter of less than 1 about 1 cm, 0.5 cm, 0.05 cm, and even less than 1 mm. 
     
     
         27 . The wall according to any preceding claim, wherein the interleaving bamboo fibers have first fibers extending in a first primary direction, and second fibers extending primarily in a second direction, the first and second fibers being interwoven with one another to form a matrix of the first and second fibers, and wherein the bamboo mesh extends across at least 50%, at least 75%, at least 80% and event at least 95% of the area of the wall body. 
     
     
         28 . The wall according to any preceding claim, wherein the material comprises voids and/or spaces formed by the addition of a foaming agent to in preparing the material. 
     
     
         29 . The wall according to any preceding claim, wherein the foaming agent comprises less than 10%, less than 8%, less than 6%, less than 5%, and/or less than 3% benzene, formaldehyde or other carcinogen. 
     
     
         39 . The wall according to any preceding claim, wherein the foaming agent comprises substantially no benzene, formaldehyde or other carcinogen. 
     
     
         40 . The wall according to any preceding claim, wherein the material comprises a higher content by weight of the magnesium-containing material than gypsum. 
     
     
         41 . The wall according to any preceding claim, wherein the material comprises a higher content by weight of the magnesium-containing material than concrete. 
     
     
         42 . The wall according to any preceding claim, wherein the material comprises a higher content by weight of the magnesium-containing material than cement. 
     
     
         43 . The wall according to any preceding claim, wherein at least one of the outer and inner surfaces of the wall body is textured, patterned, molded, painted, sculpted and/or wall-papered. 
     
     
         44 . A finished and installed building wall comprising the wall according to any preceding claim. 
     
     
         45 . A wall assembly comprising the wall of any preceding claim, and further comprising at least one upper lateral support configured to laterally support the upper region of the wall body, wherein the wall assembly comprises a fire rating according to International Building Code (IBC) Chapter 7 of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours. 
     
     
         46 . The wall assembly according to  claim 45 , wherein the wall assembly comprises a fire rating according to Underwriters Laboratory (UL) standard number 263 (Standard for Fire Tests of Building Construction and Materials) of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours. 
     
     
         47 . The wall assembly according to any of  claims 45 - 46 , wherein the upper lateral support comprises an engagement portion with a mechanical connector to mechanically connect the upper lateral support to the upper region of the wall body. 
     
     
         48 . The wall assembly according to according to any of  claims 45 - 47 , wherein the upper lateral support comprises a clip to connect to a connector extending from an upper region of the wall body. 
     
     
         49 . The wall assembly according to according to any of  claims 45 - 48 , wherein the upper lateral support comprises a projection that extends outwardly at a periphery of the lateral support to engage the wall body. 
     
     
         50 . The wall assembly according to according to any of  claims 45 - 49 , wherein the upper lateral support comprises a projection with a ledge at a periphery of the lateral support having an upturned lip, and wherein the wall body comprises at least one channel formed in an inner surface of the upper region that is configured to engage with the projection. 
     
     
         51 . The wall assembly according to according to any of  claims 45 - 50 , wherein the upturned lip extends upwardly from the ledge at an angle. 
     
     
         52 . The wall assembly according to according to any of  claims 45 - 51 , wherein the upper lateral support comprises a groove, notch, indentation and/or channel to engage an upper region of the wall body. 
     
     
         53 . The wall assembly according to any of  claims 45 - 52 , wherein the upper lateral support is configured to engage a groove, notch, indentation and/or channel formed in an upper region of the wall body. 
     
     
         54 . The wall assembly according to any of  claims 45 - 53 , comprising first and second upper lateral supports that are configured to cooperatively laterally support an upper region of the wall body. 
     
     
         55 . The wall assembly according to any of  claims 45 - 54 , wherein the first and second upper lateral supports are configured to contact opposing upper surfaces of the wall body. 
     
     
         56 . The wall assembly according to any of  claims 45 - 55 , wherein the lateral support comprises a track having a beam portion and an engagement portion. 
     
     
         57 . The wall assembly according to any of  claims 45 - 56 , further comprising a lower lateral support configured to laterally support the lower region of the wall body. 
     
     
         58 . A lateral support for a wall assembly for mounting a wall in a commercial or residential building space, the lateral support comprising;
 an engagement portion configured to engage a surface of an upper or lower region of a wall body,   the lateral support comprising a unitary body having a molded material, and the lateral support comprising fire rating according to International Building Code (IBC) Chapter 7 of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours.   
     
     
         59 . A lateral support assembly for supporting a wall mounted in a commercial or residential building space, the lateral support assembly comprising at least one lateral support according to  claim 58 . 
     
     
         60 . A wall assembly for mounting a wall in a residential or commercial building space, the wall assembly comprising:
 a wall body having:
 an upper region configured to be laterally supported at one or more upper surfaces thereof to maintain the wall body in a substantially upright position; and 
 a lower region configured to be laterally supported at one or more lower surfaces thereof to maintain the wall body in a substantially upright position; and 
   at least one lateral support comprising an engagement portion configured to engage the one or more upper surfaces of the upper region or one or more lower surfaces of the lower region of the wall body,   wherein the wall body comprises a unitary body having a molded material, and wherein the wall assembly comprising the wall as mounted with the at least one lateral support in a residential or commercial building comprises a fire rating according to International Building Code (IBC) Chapter 7 of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours.   
     
     
         61 . A finished and installed building wall comprising the wall assembly according to  claim 60 . 
     
     
         62 . A method of manufacturing a piece of a wall assembly for mounting a wall in a residential or commercial space, the method comprising:
 providing a mold in the shape of the piece;   providing a mixture of MgO, MgCl 2  and water in the mold;   curing the mixture to form a material by the reaction of MgO, MgCl 2  and water; and   optionally, machining one or more channels, grooves, notches, and/or indentations into the piece.   
     
     
         63 . A method of installing a wall using a wall assembly for mounting the wall in a residential or commercial space, the method comprising:
 mounting at least one lateral support within the residential or commercial space;   providing a wall body having upper and lower regions; and   engaging one or more of an upper or lower surface of the upper or lower region of the wall body with the at least one lateral support,   wherein the at least one lateral support engages the wall body at one or more of the upper and lower regions to support the wall body in a substantially upright position in the residential or commercial space.   
     
     
         64 . A finished wall installed according to the method of  claim 63 , wherein the finished wall comprises a fire rating according to International Building Code (IBC) Chapter 7 of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours. 
     
     
         65 . A wall board for a residential or commercial building space, the wall board comprising:
 a tensile strength layer comprising a mesh material; and   a magnesium-containing layer,   wherein a surface of the magnesium-containing layer is optionally textured to provide a textured surface of the wall board.   
     
     
         66 . An exterior wall for the exterior of a residential or commercial building, the wall comprising;
 a wall body having a first side adapted to be exposed to an exterior of the residential or commercial building, and a second opposing side facing an interior space of the commercial building, the wall body comprising:
 an upper region configured to be connected to one or more roof joists of the residential or commercial building; and 
 a lower region configured to be connected to a foundation of the residential or commercial building, 
   wherein the wall body comprises a unitary body having a molded material, the unitary body extending between and including the upper and lower regions.