Support structure

Abstract

The present disclosure provides a hemp-based wall stud comprising a composite material formed from hemp fibers and hemp shives, and a binder material impregnating the composite material. The wall stud has a C-shaped profile and a density sufficient for structural use in wall construction. The hemp-based wall stud offers an environmentally sustainable alternative to conventional steel studs while maintaining structural integrity. A method of manufacturing the hemp-based wall stud involves combining hemp fibers and shives, impregnating with a binder, pressing into a board, and shaping into a C-profile. The resulting wall stud can be integrated into wall assembly systems, providing a bio-based solution for construction that reduces carbon footprint and utilizes renewable materials.

Description

SUPPORT STRUCTUREFIELD OF INVENTION

[0001] The present disclosure relates to a support structure, and more particularly, to the development and manufacture of bio-based structural components for use in building wall systems.BACKGROUND

[0002] The construction industry has long relied on traditional materials such as wood, steel, and concrete for building structural components. Wall studs, which form the vertical framing elements in walls, have typically been made from timber or light gauge steel. These materials have proven effective but come with certain drawbacks. Timber studs, while renewable, can be susceptible to moisture damage, insect infestation, and fire. Steel studs offer durability and strength but have high embodied energy from production and limited thermal insulation properties.

[0003] In recent years, there has been growing interest in developing more sustainable building materials that can reduce the environmental impact of construction. Bio-based composites made from plant fibers and agricultural byproducts have emerged as potential alternatives. These materials aim to utilize renewable resources, sequester carbon, and provide comparable structural performance to conventional options. However, challenges remain in achieving consistent material properties, fire resistance, and cost-effectiveness at commercial scale.

[0004] The use of hemp as a construction material has gained attention due to its rapid growth cycle, high biomass yield, and favorable mechanical properties. Hemp fibers and shives (the woody core of the plant) can be processed into various building products. Efforts have been made to incorporate hemp into insulation, concrete-like composites, and fiberboard panels. However, applications as load-bearing structural elements like wall studs have been limited by difficulties in achieving sufficient strength, dimensional stability, and ease of installation comparable to timber or steel alternatives.

[0005] It has been appreciated that a structural component is needed that overcomes one or more of these problems.SUMMARY

[0006] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0007] In a first aspect, a hemp-based wall stud is provided. The hemp-based wall stud includes a composite material formed from hemp fibers and hemp shives, a binder material impregnating said composite material, wherein said hemp-based wall stud has a C-shaped profile, and wherein said hemp-based wall stud has a density sufficient for structural use in wall construction.

[0008] This hemp-based wall stud provides an environmentally friendly alternative to traditional steel studs, utilizing renewable hemp materials while maintaining the structural integrity required for wall construction. The C-shaped profile allows for compatibility with existing wall assembly systems, facilitating easy integration into current construction practices.

[0009] The composite material may comprise 50% to 95% by weight of the wall stud. The binder material may comprise 5% to 50% by weight of the wall stud. These composition ranges allow for optimization of the stud's properties, balancing strength, weight, and costeffectiveness.

[0010] The binder material may comprise a thermosetting resin. The use of a thermosetting resin can enhance the structural stability and durability of the wall stud, providing resistance to environmental factors and long-term performance.

[0011] The hemp-based wall stud may further comprise a fire retardant. The inclusion of a fire retardant improves the safety profile of the wall stud, enhancing its suitability for use in various building types and meeting fire safety regulations.

[0012] The density of the wall stud may be between 600 kg / m3 and 1200 kg / m3. This density range ensures that the hemp-based wall stud has sufficient strength and stability for structural applications while remaining lightweight enough for easy handling and installation.

[0013] In a second aspect, a method of manufacturing a hemp-based wall stud is provided. The method comprises combining hemp fibers and hemp shives to form a composite material, impregnating the composite material with a binder, pressing the impregnated composite material into a board, and shaping the board into a C-shaped profile.

[0014] This manufacturing method allows for efficient production of hemp-based wall studs, utilizing readily available hemp materials and established manufacturing techniques to create a sustainable alternative to traditional steel studs.

[0015] The method may further comprise applying heat during the pressing step. The application of heat during pressing can enhance the bonding between the hemp fibers, shives, and binder material, resulting in improved structural properties of the final product.

[0016] Shaping the board may comprise feeding the board through a haul-off machine. The use of a haul-off machine provides a consistent and efficient means of creating the C- shaped profile, ensuring uniformity across manufactured studs.

[0017] The method may further comprise adding a fire retardant to the composite material. Incorporating a fire retardant during the manufacturing process ensures even distribution throughout the material, enhancing the overall fire resistance of the wall stud.

[0018] The binder may comprise a thermosetting resin. Using a thermosetting resin in the manufacturing process can provide improved structural integrity and durability to the final product.

[0019] In a third aspect, a wall assembly system is provided. The wall assembly system comprises one or more hemp-based wall studs according to the first aspect, and at least one wall panel attached to said one or more hemp-based wall studs.

[0020] This wall assembly system demonstrates the practical application of hemp-based wall studs in construction, providing a complete solution for creating sustainable, structurally sound walls.

[0021] The at least one wall panel may comprise a gypsum board. The compatibility with standard gypsum boards allows for easy integration of hemp-based wall studs into conventional construction practices.

[0022] The wall assembly system may further comprise a horizontal track for securing the one or more hemp-based wall studs. The inclusion of a horizontal track provides additional stability and ease of installation, mirroring traditional wall framing techniques.

[0023] The one or more hemp-based wall studs may be spaced at intervals of 400 mm to 600 mm. This spacing range allows for flexibility in design while ensuring structural integrity, accommodating various building codes and architectural requirements.

[0024] The foregoing general description of the illustrative embodiments and the following detailed description thereof are merely exemplary aspects of the teachings of this disclosure and are not restrictive.BRIEF DESCRIPTION OF FIGURES

[0025] Non-limiting and non-exhaustive examples are described with reference to the following figures. The above and other objects and advantages of the disclosure will be apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, which:FIG. 1 illustrates a section view of a hemp-based wall stud, according to aspects of the present disclosure.FIG. 2 depicts a flowchart of a manufacturing process for producing C-shaped steel studs, in accordance with some examples of the present disclosure.FIG. 3 shows a process flow diagram for the initial material preparation steps in producing a hemp-based wall stud, according to an embodiment.FIG. 4 presents a sequence of steps for forming a pre-preg flat board into a C-profile wall stud, in accordance with aspects of the present disclosure.FIG. 5 depicts a flowchart of a method for manufacturing a hemp-based wall stud, in accordance with some examples of the present disclosure.FIG. 6 shows a flowchart of a method for manufacturing a C-profile board, according to aspects of the present disclosure.DETAILED DESCRIPTION

[0026] The following description sets forth exemplary aspects of the present disclosure. It should be recognised, however, that such a description is not intended as a limitation on the scope of the present disclosure. Rather, the description also encompasses combinations and modifications to those exemplary aspects described herein.

[0027] The description of illustrative embodiments according to principles of the present invention is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description of embodiments of the invention disclosed herein, any reference to direction or orientation is merely intended forconvenience of description and is not intended in any way to limit the scope of the present disclosure. Relative terms such as “lower,” “upper,” “horizontal,” “vertical,” “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivatives thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description only and do not require that the apparatus be constructed or operated in a particular orientation unless explicitly indicated as such. Terms such as “attached,” “affixed,” “connected,” “coupled,” “interconnected,” and similar refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. Moreover, the features and benefits of the disclosure are illustrated by reference to the exemplified embodiments / examples. Accordingly, the invention expressly should not be limited to such exemplary embodiments illustrating some possible non-limiting combination of features that may exist alone or in other combinations of features; the scope of the invention being defined by the claims appended hereto.

[0028] FIG. 1 shows an image of the view along the inside surface of a substantially C- shaped stud of an embodiment of the present invention. In this embodiment, the composite material is comprised of two layers which have been bonded together by heat and compression, in which the layer on the inside of the C-shape comprises hemp shives and the layer on the ouside of the C-shape comprises hemp fibres. The resin used is acForm® Power 2888 (produced by BASF in 2024).

[0029] In some examples, the present disclosure relates to a hemp-based wall stud for use in construction. The hemp-based wall stud may provide an alternative to traditional steel or wood studs in building applications. Hemp-based wall studs may offer potential benefits such as reduced environmental impact and improved sustainability compared to conventional materials.

[0030] In some examples, the hemp-based wall stud comprises a composite material formed from hemp fibers and hemp shives. The composite material may be impregnated with a binder to create a structural element suitable for use in wall assemblies. The hemp-based wall stud may be manufactured into a C-shaped profile to facilitate integration into standard wall framing systems.

[0031] In some examples, the hemp plant used as a raw material for the wall stud may uptake significant quantities of carbon dioxide during its growth cycle. This carbonsequestration potential of hemp plants may contribute to reducing the overall carbon footprint associated with the production and use of the wall studs in construction applications.

[0032] In some examples, the hemp-based wall stud comprises a composite material formed from hemp fibers and hemp shives. The composite material may be impregnated with a binder to create a structural element suitable for use in wall construction. FIG. 1 illustrates a section view of an example hemp-based wall stud. As shown in FIG. 1 , the hemp-based wall stud has a C-shaped profile, forming a generally rectangular channel or cavity. The interior surface of the channel exhibits a textured appearance characteristic of the hemp fiber and shive composite structure.

[0033] In some examples, the composite material comprises 50% to 95% by weight of the wall stud. The binder material may comprise 5% to 50% by weight of the wall stud. In some examples, the binder material comprises a thermosetting resin, which may provide structural integrity and durability to the wall stud.

[0034] In some examples, the hemp-based wall stud further comprises a fire retardant. The fire retardant may be incorporated into the composite material or applied as a separate treatment to enhance the fire resistance properties of the wall stud.

[0035] In some examples, the density of the hemp-based wall stud is between 600 kg / m3and 1200 kg / m3. This density range may provide sufficient structural strength for use in wall construction while maintaining a relatively lightweight profile compared to traditional steel studs.

[0036] In some examples, the hemp-based wall stud includes wool fibers in addition to hemp fibers. The composite material may comprise 85% hemp and 15% wool. The addition of wool fibers may enhance certain properties of the wall stud, such as insulation or moisture management.

[0037] As shown in FIG. 1 , the hemp-based wall stud has a generally uniform thickness throughout its cross-section. The edges of the wall stud appear to have a fibrous texture, indicating where the hemp material has been cut or formed. The interior channel surface shows a pattern of compressed hemp fibers and shives that have been bonded together during the manufacturing process.

[0038] In some examples, the C-shaped profile of the hemp-based wall stud allows for compatibility with standard wall framing systems. The profile may facilitate the attachment of wall panels or other building materials to create a complete wall assembly.

[0039] In some examples, the manufacturing process for the hemp-based wall stud involves several steps, including material preparation, impregnation, pressing, and shaping. FIG. 2 illustrates an overview of the initial stages of the manufacturing process.

[0040] In some examples, the process begins with combining hemp fibers and hemp shives to form a composite material. As shown in FIG. 2, non-woven needle punched hemp matting may be used as a source of hemp fibers. The hemp matting may also include a small percentage of wool fibers, which may enhance certain properties of the final product.

[0041] In some examples, the composite material is impregnated with a binder. FIG. 2 depicts the impregnation of the non-woven hemp matting with a resin. The binder may be a thermosetting resin, which provides structural integrity to the wall stud. In some examples, a fire retardant may be added to the composite material during this stage to enhance the fire resistance properties of the final product.

[0042] In some examples, the impregnated composite material is pressed into a board. As illustrated in FIG. 2, the impregnated hemp matting and hemp shives are combined and pressed into a pre-preg flat board. The pressing process may involve applying heat, typically at a temperature of around 180 degrees Celsius, to facilitate the curing of the resin and consolidation of the materials.

[0043] In some examples, the next stage of the manufacturing process involves shaping the board into a C-shaped profile. FIG. 3 depicts one method for achieving this shape. The pre-preg flat board is first heated to a temperature between 150-190 degrees Celsius. The heated board is then fed through a haul-off machine, which forms the material into the desired C-profile shape. As the material passes through the machine, the sides of the board are folded upward to create the characteristic channel configuration of the wall stud.

[0044] In some examples, an alternative shaping method may be employed. This method involves sliding the pre-preg flat board into a former and mechanically folding the sides upward to create the C-shaped profile.

[0045] In some examples, the manufacturing process may involve different steps being performed at various locations. For example, the initial impregnation of materials may occur at one facility, while the pressing and shaping steps may be carried out at separate locations. This distributed manufacturing approach may allow for optimization of resources and expertise at each stage of production.

[0046] In some examples, the hemp-based wall stud comprises a composite material formed from hemp fibers, hemp shives, a binder material, and a fire retardant. The specificcomposition of the wall stud may vary depending on the desired properties and performance characteristics.

[0047] In some examples, the composite material comprises approximately 21.9% by mass hemp fiber and 53% by mass hemp shives. The hemp fibers and shives provide the primary structural component of the wall stud, contributing to its strength, rigidity, and lightweight nature. Hemp fibers may offer high tensile strength and durability, while hemp shives may provide insulation properties and help reduce the overall density of the composite.

[0048] In some examples, the binder material comprises approximately 25% by mass of the wall stud. The binder material may be a thermosetting resin, such as an acrodur resin, which impregnates the hemp fibers and shives to create a cohesive structural element. The thermosetting resin may provide enhanced mechanical properties, moisture resistance, and dimensional stability to the wall stud.

[0049] In some examples, a fire retardant is incorporated into the composite material at approximately 0.1% by mass. The fire retardant may be an ammonium polyphosphate compound, which can enhance the fire resistance properties of the wall stud without significantly altering its other physical characteristics.

[0050] In some examples, the hemp-based wall stud may include a small percentage of wool fibers in addition to hemp fibers. For instance, the non-woven matting used in manufacturing may comprise 85% hemp and 15% wool. The inclusion of wool fibers may contribute to improved thermal insulation properties and moisture management within the wall stud.

[0051] In some examples, the density of the hemp-based wall stud ranges from 600 kg / m3to 1200 kg / m3. This density range may provide sufficient structural strength for use in wall construction while maintaining a relatively lightweight profile. The specific density may be adjusted by varying the ratios of hemp fibers, hemp shives, and binder material during the manufacturing process.

[0052] In some examples, the combination of hemp fibers and shives in the composite material may result in a wall stud with good acoustic insulation properties. The porous nature of the hemp materials may help absorb sound waves, potentially reducing noise transmission through walls constructed with these studs.

[0053] In some examples, the hemp-based wall stud may exhibit favorable thermal insulation characteristics due to the natural properties of hemp fibers and shives. Thecomposite structure may create small air pockets within the material, which can help reduce heat transfer through the wall assembly.

[0054] In some examples, the use of a thermosetting resin as the binder material may provide the hemp-based wall stud with enhanced moisture resistance. This property may help prevent warping or degradation of the stud when exposed to varying humidity levels in different building environments.

[0055] In some examples, the incorporation of ammonium polyphosphate as a fire retardant may allow the hemp-based wall stud to meet specific fire resistance standards required for building materials. The fire retardant may work by forming a protective char layer when exposed to high temperatures, potentially slowing the spread of flames through a wall assembly.

[0056] In some examples, the hemp-based wall stud offers significant environmental benefits compared to traditional steel studs. A comprehensive Life Cycle Assessment (LCA) study has been conducted to evaluate the environmental impacts of the hemp-based wall stud across various categories.

[0057] In some examples, the hemp-based wall stud demonstrates lower environmental impacts than both blast furnace-basic oxygen furnace (BF-BOF) and electric arc furnace (EAF) steel studs in multiple impact categories. These categories may include global warming potential, freshwater ecotoxicity, marine ecotoxicity, and terrestrial ecotoxicity.

[0058] In some examples, the carbon footprint of the hemp-based wall stud can be further reduced through improvements in the manufacturing process. By utilizing organic fertilizers in hemp cultivation, sourcing renewable energy for production, and optimizing transportation distances, the environmental impact of the hemp-based wall stud may be significantly decreased.

[0059] In some examples, with these optimizations implemented, the hemp-based wall stud may approach carbon neutrality. The potential for carbon neutrality stems from the ability of hemp plants to sequester carbon dioxide during their growth cycle, offsetting emissions associated with production and transportation.

[0060] In some examples, the use of hemp-based wall studs in building construction can lead to substantial reductions in carbon emissions. When applied to the internal non-load bearing walls of a typical 11 -story office building, hemp-based wall studs may reduce carbon emissions by approximately 100,000 kg CO2-equivalent compared to traditional steel studs.

[0061] In some examples, the recyclability of hemp-based wall studs contributes to their overall environmental performance. At the end of their useful life, hemp-based wall studs may be more readily recyclable or biodegradable compared to steel studs, potentially reducing waste and environmental impact associated with building demolition or renovation.

[0062] In some examples, the production of hemp-based wall studs may consume less energy compared to steel stud manufacturing. The cultivation and processing of hemp fibers and shives typically requires less energy-intensive processes than the mining, smelting, and forming operations involved in steel production.

[0063] In some examples, the use of hemp-based wall studs may contribute to improved indoor air quality in buildings. Unlike some synthetic building materials, hemp-based products may emit fewer volatile organic compounds (VOCs), potentially creating healthier indoor environments.

[0064] In some examples, the environmental benefits of hemp-based wall studs extend beyond their production and use phases. The cultivation of industrial hemp for wall stud production may have positive impacts on soil health, biodiversity, and agricultural sustainability compared to intensive monoculture crops or mining operations associated with steel production.

[0065] In some examples, hemp-based wall studs can be integrated into various construction projects, offering a sustainable alternative to traditional steel or wood studs. The hemp-based wall studs may be particularly well-suited for use in gypsum partition wall systems, which are commonly found in commercial and residential buildings.

[0066] In some examples, a wall assembly system comprises one or more hemp-based wall studs and at least one wall panel attached to the studs. This configuration allows for the creation of interior walls and partitions that benefit from the environmental and performance characteristics of the hemp-based studs.

[0067] In some examples, the wall panel attached to the hemp-based wall studs comprises a gypsum board. Gypsum board, also known as drywall, is a common material used in interior wall construction due to its fire resistance and ease of installation. The combination of hemp-based wall studs and gypsum board may create a wall assembly that balances structural integrity, environmental sustainability, and standard construction practices.

[0068] In some examples, the wall assembly system includes a horizontal track for securing the hemp-based wall studs. This horizontal track may be similar to those used intraditional steel stud framing systems, allowing for compatibility with existing construction methods and tools. The horizontal track may be positioned at the top and bottom of the wall assembly, providing a secure attachment point for the hemp-based wall studs.

[0069] In some examples, the hemp-based wall studs in a wall assembly system are spaced at intervals of 400 mm to 600 mm. This spacing range is consistent with common practices in wall framing and allows for the efficient use of standard-sized wall panels and insulation materials. The specific spacing may be adjusted within this range based on local building codes, load requirements, or other design considerations.

[0070] In some examples, the integration of hemp-based wall studs into gypsum partition wall systems may offer benefits in terms of thermal insulation and acoustic performance. The natural properties of the hemp composite material may contribute to improved energy efficiency and sound attenuation compared to traditional steel stud systems.

[0071] In some examples, hemp-based wall studs may be suitable for use in a variety of building types, including residential homes, office buildings, schools, and healthcare facilities. The versatility of the hemp-based studs allows for their application in both load-bearing and non-load-bearing wall assemblies, depending on the specific design requirements and structural calculations.

[0072] In some examples, the use of hemp-based wall studs in construction projects may contribute to achieving green building certifications or meeting sustainability goals. The reduced environmental impact of hemp-based studs compared to traditional materials may be a factor in earning points for certifications such as LEED (Leadership in Energy and Environmental Design) or BREEAM (Building Research Establishment Environmental Assessment Method).

[0073] In some examples, the integration of hemp-based wall studs into construction projects may require minimal changes to existing building practices. The compatibility of these studs with standard gypsum board and framing techniques may allow for a relatively seamless transition from traditional materials to more sustainable alternatives.

[0074] In some examples, the use of hemp-based wall studs in gypsum partition wall systems may offer advantages in terms of moisture management. The natural properties of hemp fibers may help regulate humidity levels within the wall assembly, potentially reducing the risk of mold growth or moisture-related issues.

[0075] In some examples, the lightweight nature of hemp-based wall studs may provide benefits during the construction process. The reduced weight compared to steel studs mayfacilitate easier handling and installation, potentially improving on-site efficiency and reducing labor costs.

[0076] In some examples, the fire-resistant properties of hemp-based wall studs, enhanced by the incorporation of fire retardants, may contribute to the overall fire safety of buildings. When used in conjunction with fire-rated gypsum board, these wall assemblies may meet or exceed fire resistance requirements specified in building codes.

[0077] In some examples, the various components of the hemp-based wall stud work in concert to provide structural support, fire resistance, and environmental benefits in construction applications. The combination of hemp fibers and hemp shives forms the primary structural matrix of the wall stud, with each component contributing unique properties to the overall performance.

[0078] In some examples, the hemp fibers provide tensile strength and flexibility to the wall stud. These fibers may interlock and distribute loads throughout the composite material, enhancing the overall structural integrity of the stud. The hemp shives, in contrast, may contribute to the compressive strength and lightweight nature of the stud. The porous structure of the shives can also provide thermal and acoustic insulation properties.

[0079] In some examples, the binder material, typically a thermosetting resin, permeates the hemp fiber and shive matrix, creating strong bonds between the components. This impregnation process may result in a cohesive composite material with enhanced mechanical properties. The cured resin can provide additional rigidity and moisture resistance to the wall stud, contributing to its durability in various construction environments.

[0080] In some examples, the incorporation of a fire retardant, such as ammonium polyphosphate, works synergistically with the natural fire-resistant properties of hemp. When exposed to high temperatures, the fire retardant may form a protective char layer, potentially slowing the spread of flames through the wall assembly. This char formation, combined with the dense structure of the composite material, may contribute to the overall fire resistance of the wall stud.

[0081] In some examples, the C-shaped profile of the hemp-based wall stud allows for efficient load distribution and provides space for utilities or insulation within the wall cavity. This profile may also facilitate the attachment of wall panels or other building materials, enabling seamless integration into standard wall framing systems.

[0082] In some examples, the combination of hemp fibers, hemp shives, and binder material results in a wall stud with a density that balances structural strength and lightweightproperties. This optimized density may contribute to ease of handling during construction while maintaining sufficient load-bearing capacity for various building applications.

[0083] In some examples, the natural properties of hemp fibers and shives work together to provide moisture management within the wall stud. The hygroscopic nature of hemp may help regulate humidity levels, potentially reducing the risk of mold growth or moisture-related issues in wall assemblies.

[0084] In some examples, the environmental benefits of the hemp-based wall stud stem from the interaction of its components throughout its lifecycle. The carbon sequestration potential of hemp during cultivation, combined with the relatively low energy requirements for processing and manufacturing, may result in a reduced carbon footprint compared to traditional building materials.

[0085] In some examples, the recyclability or biodegradability of the hemp-based components at the end of the wall stud's useful life may contribute to reduced waste and environmental impact associated with building demolition or renovation. This aspect of the wall stud's lifecycle may align with circular economy principles in construction.

[0086] In some examples, the combination of structural performance, fire resistance, and environmental benefits provided by the hemp-based wall stud may contribute to achieving green building certifications or meeting sustainability goals in construction projects. The interaction of these properties may offer a comprehensive solution for builders and architects seeking to balance performance and environmental considerations.

[0087] The present disclosure provides a support structure comprising sustainable bio mass mixed with a resin. For example, the support structure may be an elongate structure with a substantially C-shaped cross section for use in the construction industry. Other cross sectional shapes are also possible and intended to be within the scope of the present disclosure.

[0088] In some examples, the hemp-based wall stud may be manufactured in various cross-sectional shapes to suit different construction requirements and applications. These alternative profiles may include:1. l-shaped profile, which may provide enhanced load-bearing capacity for certain structural applications2. Box-shaped or rectangular profile, which may offer increased stability and resistance to torsional forces3. Z-shaped profile, which may be useful for creating interlocking wall systems or specialized framing applications4. Hat-shaped profile, which may provide additional surface area for attaching wall panels or other building materials5. T-shaped profile, which may be beneficial for corner installations or creating partition intersections6. U-shaped profile, similar to the C-shape but with a closed section, potentially offering increased rigidity7. L-shaped profile, which may be useful for creating corner supports or trim elements8. Omega-shaped profile, which may provide enhanced load distribution and stability in certain wall assemblies9. Triangular or truss-like profile, which may offer a balance of strength and material efficiency10. Hollow circular or oval profile, which may be suitable for specialized architectural designs or column applications11. H-shaped profile, which may provide additional structural support for heavy-duty applications12. Corrugated or wave-shaped profile, which may enhance the stud's resistance to bending forces13. Honeycomb or cellular profile, which may offer a combination of strength and lightweight properties14. Asymmetrical profiles, which may be designed to meet specific architectural or engineering requirements15. Composite profiles combining multiple shapes, which may be tailored to optimize performance for particular building designs or load conditions

[0089] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. The detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended to be given by way of example only.

[0090] FIG. 5 illustrates a flowchart of a method (500) for manufacturing a hemp-based wall stud. The method (500) may begin with a step (502) of combining hemp fibers and hemp shives to form a composite material. This step may involve mixing the fibers and shives in predetermined ratios to achieve desired material properties.

[0091] In some embodiments, the method (500) proceeds to a step (504) where binder material is prepared. The binder material may be a thermosetting resin, such as an acrodur resin, which can be formulated to specific viscosity and reactivity requirements.

[0092] Following the binder preparation, the method (500) may move to a step (506) where the composite is impregnated with the binder. This impregnation process may involve thoroughly coating the hemp fibers and shives with the binder material to ensure uniform distribution throughout the composite.

[0093] In some examples, the method (500) then continues to a step (508) where heat and pressure are applied to the impregnated composite. This step may involve using a press to compress the material while simultaneously applying heat to initiate curing of the binder.

[0094] The method (500) may then proceed to a decision step (510) where a determination is made whether a desired thickness is achieved. If the desired thickness is not achieved, the method (500) may return to step (508) to apply additional heat and pressure. This iterative process may continue until the desired thickness is reached.

[0095] In some embodiments, once the desired thickness is achieved, the method (500) moves to a step (512) where the pre-preg board is cooled and cut to specified dimensions. The cooling process may help stabilize the material structure, while cutting ensures the board meets size requirements for further processing.

[0096] The method (500) may conclude with a step (514) where the pre-preg board is stored or transported. This step may involve packaging the boards to protect them from environmental factors during storage or shipping.

[0097] FIG. 6 illustrates a flowchart of a method (600) for forming a C-profile from a prepreg board. The method (600) may begin with a step (602) of retrieving a pre-preg board, which may involve selecting a board with appropriate dimensions and properties for the intended application.

[0098] The method (600) may then proceed to a step (604) where the pre-preg board is heated to a temperature range of 150-190°C. This heating process may soften the material and prepare it for shaping.

[0099] Following the heating step, the method (600) may move to a decision step (606) where a determination is made whether to use a haul-off machine or former for shaping the C-profile. This decision may be based on factors such as production volume, equipment availability, or specific profile requirements.

[0100] In some embodiments, if the haul-off machine option is selected, the method (600) proceeds to a step (608) where the board is fed through a haul-off machine. The method (600) then continues to a step (612) where a C-profile is formed using the haul-off machine. This process may involve gradually bending the heated board into the desired shape as it passes through the machine.

[0101] Alternatively, if the former option is selected at step (606), the method (600) may proceed to a step (610) where the board is fed into a former. The method (600) then continues to a step (614) where the sides are mechanically folded to form a C-profile. This process may involve using mechanical presses or rollers to bend the heated board into the desired shape.

[0102] After either forming path is completed, the method (600) may converge at a step (616) where the formed C-profile board is cooled. This cooling process may help set the shape and stabilize the material properties.

[0103] In some examples, the method (600) concludes with a step (618) where the C- profile board is inspected and packaged. This final step may involve quality control checks to ensure the profile meets specifications, followed by appropriate packaging for storage or shipment.

[0104] In another aspect of the invention, there is provided a support structure comprising a composite material, wherein the composite material comprises: at least 50 weight % of hemp derived material; and at least 15 weight % of resin.

[0105] Plant based natural materials are low cost renewable materials which can be found in abundant supply in many countries. Hemp is a plant in the botanical class of Cannabis sativa cultivars which may be grown specifically for industrial and consumable use. Hemp is a fast-growing resource, which removes carbon from the atmosphere by fixing carbon dioxide in the plant itself. Hemp grows in abundant supply in many countries, which advantageously limits transport costs and supply chain carbon emissions. The use of hemp advantageously contributes to the low embodied carbon and sustainability of the support structure of the present dsiclosure.

[0106] In some examples, the hemp derived material may comprise hemp fibres and / or hemp shives. The hemp derived material may consist of hemp fibres and / or hemp shives.Hemp fibre (or tow) is the fibre which has been collected from the phloem (or bast) surrounding the stem of the hemp plant. Hemp shives (also known as shoves or hurd) are often a byproduct of the hemp fibre production, and are the woody inner portion of the hemp plant stem, which may be chopped into pieces. The hemp fibre and hemp shives may be dried before use, for example by using heat and / or a vacuum. In an embodiment, the moisture content of the hemp fibre and hemp shives after drying may be between 1 and 15 weight % water, between 2 and 10 weight % water, or between 4 and 8 weight % water, and following the addition of the resin may be between 2 and 25 weight % water, 5 and 20 weight % water, or 9 and 12 weight %.

[0107] In some examples, the composite material may comprise at least 50 weight %, optionally at least 70 weight %, optionally at least 80 wt %, optionally at least 85 wt %, and further optionally at least 90 wt%, of the hemp derived material.

[0108] The hemp fibres have inherent mechanical strength and advantageously provide reinforcement support to the composite material. The hemp shives may be interspersed between the hemp fibres providing additional support and reinforcement to the composite material. Use of hemp shives in the composite material is also advantageous as the hemp shives are not discarded so there is less overall waste.

[0109] In some examples, the composite material may comprise hemp fibres and hemp shives in substantially equal weight %. For example, the composite material may comprise 42.5 wt % hemp fibres and 42.5 wt % hemp shives, so that the total content of hemp derived material in the composite material is 85 weight %. The hemp derived material, including the hemp fibres and hemp shives, may be dried so that the hemp derived material has between 4 and 8 weight % water. There may be 15 weight % of thermoplastic resin.

[0110] The use of equal weight % quantities of hemp fibres and shives in the composite material is advantageous because the density of shives interspersed between the hemp fibres provides excellent reinforcement to the composite material.

[0111] In some examples, the hemp fibres may be arranged in random directions and distributed substantially homogeneously throughout the composite material. In this way, the elongate fibres provide excellent structural integrity, reinforcing support and strength in all directions to the composite material.

[0112] Alternatively, in some examples, the hemp fibres may be arranged substantially in one direction and distributed substantially evenly throughout the composite material. In thisway, the elongate fibres may provide more reinforcing support and strength in a particular direction.

[0113] In some examples, the average length of a hemp fibre may be between 30 and 100mm, optionally between 50 and 80mm, and further optionally between 60 and 70mm. It is advantageous to use hemp fibres with an average length of between 30 and 100mm in the composite material, as fibres shorter than this minimum length provide lower levels of reinforcement in the composite material.

[0114] The hemp shives may have an average length of up to 25mm, wherein the length is the longest measurement that can be measured in any direction. In an embodiment, the hemp shives are milled into pieces with an average longest length of up to 5mm, optionally up to 4 mm, and further optionally up to 3mm. In an embodiment, the hemp shives may have an average length of between 2 and 3mm.

[0115] It is advantageous to use shives with an average longest length of up to 5mm, because shives larger than 5mm mix less readily with the resin. The shives may be distributed substantially homogeneously throughout the composite material. In this way, the shives are embedded in the polymer resin between the fibres providing bulk reinforcement and strength to the composite material.

[0116] In some examples, the composite material may be constructed of two or more layers of composite material, in which a first layer may comprise a different plant based material and / or a different resin when compared to a second or further layer. The two or more layers may be stacked and bonded together using heat and pressure. The plant based material may include a particular part of a plant, such as the fibrous stem, which provides a particular type of support for the composite material.

[0117] The particular plant based material and resin may be chosen depending upon the desired use of the composite material. In an embodiment, the support structure may comprise two or more layers of composite material, in which each layer substantially comprises either hemp fibres or hemp shives. In an embodiment, a first layer substantially comprises hemp fibres as the plant based material, and a second layer substantially comprises hemp shives as the plant based material. The resin used in each layer may be the same, for example AcForm® Power 2889 X (produced by BASF in 2024). The resulting composite material may be used to form an elongate support structure with a substantially C-shaped cross-section, in which the inside of the C-shape comprises the hemp fibre layer, and the outside of the C- shape comprises the hemp shives layer. In this way, the hemp fibres may provide excellentstructural integrity to the innermost layer of the support structure, and the hemp shives provide strength.

[0118] As herein disclosed, alternative sustainable materials may be used in combination with the hemp derived material or in place of the hemp derived material. For example, other plant fibres that could be used include coir, plantain, banana, bamboo, water hyacinth, flax, ramie, sisal and jute, and / or the bast fibres from wild plants, such as stinging nettles, and from trees such as lime, linden, willow, oak, wisteria, and / or mulberry. Optionally, other natural fibres may be used such as basalt fibres. For example, the composite material may comprise up to 40 weight % of hemp derived material and up to 45 weight % of a different plant derived material. Optionally, the different plant material may be coir. As herein disclosed, the composite material may comprise coir in place of the hemp derived material.

[0119] In some examples, the ratio of hemp derived material to resin in the support structure of the present disclsoure is from 98:2 to 60:40, optionally from 95:5 to 70:30, and further optionally from 90:10 to 80:20. Further optionally, the ratio of hemp derived material to resin in the support structure is about 85:15.

[0120] The resin may be a thermoplastic resin. A property of thermoplastic resins is that they can be melted down again after curing. In contrast, thermoset resins retain their form and remain solid after curing.

[0121] The glass-liquid transition, or glass transition, is the gradual and reversible transition in amorphous materials from a hard and relatively brittle "glassy" state into a viscous or rubbery state as the temperature is increased. The glass transition temperature (Tg) of the thermoplastic resin may be between 50°C and 250°C, between 55°C and 210°C, between 60°C and 170°C, between 65°C and 140°C, between 70°C and 110°C, or between 80°C and 100°C. Further optionally, the glass transition temperature of the thermoplastic resin may be between 85°C and 97°C.

[0122] In some examples, the resin may comprise one or more selected from the acForm® resins (produced by BASF in 2024, including acForm® Power 2888 and acForm® Power 2889 X), ACRODUR® (BASF), MDI (melamine-urea-formaldehyde) resin, and transfurans PFA (perfluoroalkoxy copolymer) resin. In an embodiment, the resin may be any suitable thermoplastic resin, or the resin may be any suitable thermoset resin.

[0123] In some examples, the resin may comprise a bio-resin, wherein the bio-resin is derived from renewable biological sources. For example, the bio-resin may be derived from renewable and sustainable agricultural crops and residual agricultural waste. In this way, theemissions are minimised during processing as well as in the final product, helping to promote sustainability, reduce embodied carbon emissions and to achieve a structure support product which is carbon neutral. In an embodiment, the bio-resin is not obtained from fossil fuels.

[0124] In some examples, the resin or bio-resin may be substantially free from formaldehyde, which advantageously enables a safer working environment. The bio-resin may be a low-emission, water-based alternative to traditional formaldehyde-based urea, melamine or phenolic resins. In particular, the bio-resin may be formed from an aqueous solution of a modified polyacrylate, such as for example, acForm® Power 2888 or acForm® Power 2889 X (produced by BASF in 2024). In some examples, all registered materials disclosed herein conform to the product as manufactured on 1 January 2024.

[0125] In some examples, the thermoplastic resin may be recyclable, and the composite material may be advantageously melted down and reformed into a new product, such as a new support structure. Ensuring that the support structure has a long life and can be efficiently recycled or repurposed at the end of its useful life helps to align with circular economy principles.

[0126] In some examples, the composite material may additionally comprise one or more additives selected from biocides, pigments, surfactants, water repellents, antifoaming agents, intumescents, hardeners, and / or flame retardants to provide long-term structural integrity.

[0127] The one or more additives may be simply mixed into the liquid resin before curing. Alternatively, the additive may be absorbed into the hemp derived material, or coated onto the hemp derived material in advance and before mixing with the resin. Advantageously, the additives may be mixed throughout the whole of the support structure. There is no need to separately coat the finished support structure with the additive (although this can also be done). In contrast, steel studs must have any additives sprayed on to the outside of a formed steel stud because steel is formed at very high temperatures and additives can harm the properties of steel.

[0128] Advantageously, biocides may be used as an additive to help prevent rot, mildew or fungus, and resistance to pests or decay.

[0129] Advantageously, water repellents may be used as an additive to increase weather resistance.

[0130] Advantageously, the use of surfactants and antifoaming agents as additives may be used to improve the mixing of the resin with the hemp derived material.

[0131] Advantageously, the use of pigments as additives may be used to provide a colour indicator of the weight % of hemp derived material in the composite material, or to indicate which other additives have been added to the resin. Further, pigments may be added for aesthetic reasons.

[0132] The structure support may match or surpass the mechanical properties of traditional steel studs, such as strength and durability, and the acoustic and thermal properties of traditional steel studs. In some examples, the composite material has a physical property which is equal to or better than the same physical property in light-gauge steel, and wherein the physical property is selected from Young’s modulus, tensile strength, compressive strength, acoustic measurement (Rw), and / or thermal transmittance (U-value). For example, the composite material may have the following physical properties:Young’s modulus from 1.9 x 1011 N / m2 to 2.0 x 1011 N / m2 Tensile strength of 8.0 x 108 N / m2Compressive strength of 250 MPaAcoustic measurement Rw (the weighted sound reduction index) is at least 45 dBThermal transmittance (U-value) of less than 0.15 W / m2K

[0133] The composite material is a lighter weight material than steel. Advantageously, the light weight support structure of the present invention may be easier to install in building applications, thereby minimising time and overall labour costs. For example, a 3.7m long steel stud with a substantially C-shaped cross section weighed 1 ,6kg, compared to the same length of a composite material stud with a similar C-shaped cross section, which weighed 1 ,2kg.

[0134] The composite material is advantageously an electrical insulator, in contrast to steel. Therefore, the support structure of the present invention is beneficial as a steel stud alternative in situations in which an electrical conductor is undesirable.

[0135] Advantageously, the composite material does not expand with heat, unlike steel, which will expand in length, surface area and volume with temperature. The composite material is inert to a broad range of chemicals, and so may be compatible with other building materials.

[0136] Advantageously, the composite material will not corrode or rust, and so is a favourable alternative to steel in harsh environments, such as structures adjacent to marine environments.

[0137] The composite material can be pressed into sheets of a desired thickness and molded and / or cut into many different shapes. Sheets of the composite material may be molded into the same shape as traditional steel studs. In this way, the support structure of the present disclosure is compatible with and will seamlessly integrate with existing construction systems. Advantageously, established construction practices can be maintained to allow for successful implementation in diverse construction projects.

[0138] In particular, in some examples, the support structure may be used as a stud in the construction of buildings. Studs are elongate structures with a substantially C- shaped, a U-shaped, or optionally an H-shaped cross-section.

[0139] The sheets of the composite material may be molded into the same profile as a traditional steel stud. For example, in an embodiment of the invention, the support structure may be an elongate structure with a substantially C-shaped, optionally a substantially U- shaped, and / or optionally a substantially H-shaped cross-section (see for example, Figure 1 ). The desired profile for the support structure may be achieved by bending the edges of the composite material sheet around a mold using heat and pressure.

[0140] In some examples, the support structure may be a stud with a substantially C- shaped cross section, wherein the weight ratio of hemp derived material to resin is from 90:10 to 80:20, and wherein the hemp fibres and hemp shives are in substantially equal weight %. One support structure may be connected with another support structure, for example by splicing, to extend the length of the support structure.

[0141] The support structure comprising the composite material may meet the relevant industry standards (as of 1 January 2024), such as EN13501-1 (which relates to a reaction to fire classification procedure for all construction products & building elements), BS6001 (which is an environmental and sustainability standard) and BS EN ISO 14001 (which relates to a standard used to assess the status of an organisation's environmental management system against defined requirements).

[0142] The support structure of the present invention has the advantage that it may be adapted to not only meet current industry standards but also may be adaptable to future regulatory changes in the construction industry.

[0143] The support structure of the present dsiclosure may be used for a support for walls in buildings, and also outside of the construction industry for packaging material, decorative panels, and / or fencing and fencing posts.

[0144] The structural support may be used as a sustainable packaging material, through reuse and recycling.

[0145] The structural support may be used in interior design. The ability to add colour and its sustainability makes the composite material suitable for interior or exterior design applications.

[0146] The structural support may be used as an alternative to traditional materials in the manufacture of sustainable furniture, due to its eco-friendly and durable nature. The structural support may be used in the development of other sustainable structures, such as fencing and fencing posts.

[0147] Further, as herein disclosed, the composite material may be formed into other structural shapes, such as panels, moldings, or other architectural features which are low in maintenance and have a high aesthetic appeal.

[0148] In another aspect of the invention, there is provided a process for making the support structure comprising the composite material according to the first aspect of the invention, comprising, mixing the hemp derived material and the resin to form a hemp-resin mix; applying heat and pressure to form a sheet of composite material; and allowing the composite material to cure; and optionally allowing the composite material to cool to room temperature.

[0149] The required heat and pressure to form a sheet of composite material will vary depending on the resin used and the quantity of hemp derived material used. For example, the heat applied may be between 140 and 250 °C and the pressure applied may be between 500 and 1000 kPa to the hemp-resin mix, and may be for a time period of between 1 and 4 minutes.

[0150] The hemp derived material may be dried before use so that there is substantially between 4 and 8 weight % water content. The hemp derived material may be thoroughly mixed with the resin so that the hemp derived material is dispersed substantially evenly throughout the resin, to achieve a consistent quality and material strength.

[0151] The hemp derived material may be sprayed with the resin, for example by using a rotary sprayer. This may help the resin to thoroughly penetrate into the hemp fibres and hemp shives. The hemp derived material may be sprayed with the resin before the hemp derived material is mixed with the resin.

[0152] Compression manufacturing methods may be used to form the sheets of composite material. For example, the hemp-resin mix may be compressed from around 100mm down to around 3mm. These compression manufacturing methods allow for mass production, offering advantages in terms of speed and scalability compared to traditional manufacturing processes of construction materials.

[0153] The sheet of the composite material may have any thickness according to the desired use. For example, in an embodiment of the invention, the sheet may have a thickness of between 1 and 15mm, optionally between 1 and 10mm, optionally between 2 and 6mm, and further optionally between 3 and 5mm. Further optionally, the sheet may have a thickness of 3mm or less.

[0154] In some examples, the sheet of composite material may have a length of up to 1 ,5m, optionally up to 2.5m, and further optionally up to 4.5m. The compression manufacturing methods may be adjusted so that a sheet of composite material may be made into any appropriate size according to the desired use. For example, compression manufacturing methods and compression moulding techniques may be used to produce the structure support stud in particular dimensions to be used in the construction industry such as 94mm x 47mm x 3000mm, with minimum thickness of between 3 and 5mm.

[0155] It is advantageous that the composite material may be easily compressed into sheets and / or moulded into different shapes, and then can be melted down again, all without requiring high temperatures required for moulding steel.

[0156] As herein disclosed, the composite material may also be moulded into different shapes without necessarily first being made into a sheet.

[0157] The process for making the support structure according to the first aspect of the invention may further comprise: applying heat of between 140 and 250 °C to soften the sheet of the composite material; applying pressure to bend the sheet of the composite material around a mould; and allowing the composite material to cool to room temperature to form the support structure. In some examples, a stud may be manufactured according to the process of the second aspect of the invention.

[0158] In some examples, the hemp-based wall stud may be manufactured using specific material compositions to achieve desired properties. The non-woven matt used in the composite material may comprise a combination of hemp and wool fibers in precise ratios. For instance, a 600 g / m2 non-woven matt may be composed of 85% hemp fibers and 15%wool fibers. This composition may provide a balance of strength and flexibility to the final product.

[0159] In some embodiments, an additional layer of 100% wool fibers with a weight of 180 g / m2 may be incorporated into the composite structure. This pure wool layer may enhance the thermal insulation properties of the wall stud while also contributing to moisture management within the material.

[0160] The hemp shives, which form a significant portion of the composite material, may be added in a specific quantity to achieve the desired density and structural properties. For example, 480 grams of hemp shives may be used per unit area of the wall stud. This precise amount of hemp shives may contribute to the overall strength, lightweight nature, and insulation properties of the finished product.

[0161] In some examples, the ratio of hemp fibers to hemp shives may be adjusted to optimize the performance characteristics of the wall stud. For instance, a higher proportion of hemp fibers may increase the tensile strength of the composite, while a higher proportion of hemp shives may enhance its compressive strength and thermal insulation properties.

[0162] The binder material used to impregnate the composite may also be applied in specific quantities. In some examples, the binder may constitute 20% to 30% of the total weight of the wall stud. This range may allow for sufficient bonding between the hemp and wool fibers and the hemp shives, while maintaining the desired flexibility and environmental benefits of the bio-based material.

[0163] In some exmaples, additives such as fire retardants or water-repellent agents may be incorporated into the composite in precise amounts. For example, a fire retardant may be added at 0.5% to 2% by weight of the total composite material to enhance the fire resistance of the wall stud without significantly altering its other properties.

[0164] In some aspects, the environmental impact of the hemp-based wall stud may be assessed through a comprehensive life cycle assessment (LCA) approach. This analysis may consider various environmental impact categories throughout the product's lifecycle, from raw material extraction to end-of-life scenarios.

[0165] The hemp-based wall stud may demonstrate lower environmental impacts compared to traditional steel studs in several key areas. For instance, the global warming potential (GWP) of the hemp-based stud may be reduced due to the carbon sequestration properties of hemp during its growth phase. Additionally, the production process for hemp-based studs may consume less energy compared to steel stud manufacturing, potentially leading to lower fossil resource depletion and reduced emissions.

[0166] In some cases, the use of organic fertilizers in hemp cultivation may further decrease the environmental footprint of the wall stud. The selection of renewable energy sources for manufacturing processes may also contribute to improved environmental performance across multiple impact categories.

[0167] The hemp-based wall stud may offer advantages in terms of freshwater ecotoxicity and marine ecotoxicity compared to steel alternatives. This may be attributed to the reduced need for mining and processing of metal ores, which can have significant impacts on aquatic ecosystems.

[0168] When integrated into building systems, the hemp-based wall studs may contribute to overall reductions in embodied carbon. For example, in a typical multi-story office building, the use of hemp-based studs in place of steel studs for internal non-load bearing walls may result in substantial carbon emission reductions.

[0169] The end-of-life phase of hemp-based studs may align with circular economy principles, as the organic components may be more readily recyclable or biodegradable compared to steel alternatives. This characteristic may contribute to reduced waste and environmental impact associated with building demolition or renovation.

[0170] In some embodiments, sensitivity analyses may be conducted to identify opportunities for further reducing the environmental impacts of hemp-based wall studs. These analyses may consider variables such as transportation distances, energy sources, and raw material sourcing to optimize the product's environmental performance.

[0171] The environmental benefits of hemp-based wall studs, combined with their structural and fire-resistant properties, may contribute to achieving green building certifications and meeting sustainability goals in construction projects. This holistic approach to building material selection may offer architects and builders a comprehensive solution that balances performance and environmental considerations.

[0172] Specific exemplary examples are provided hereafter, however, more general application of the methods described below are considered within the scope of the present disclosure.EXAMPLES

[0173] Example 1 - Hemp shiv and hemp hurd are dried with heat and in a vacuum, to obtain dried hemp shiv and dried hemp hurd with a maximum of between 4 and 8 weight % water. The thermoplastic resin AcForm® Power 2889 X (produced by BASF in 2024) is heated to between 150 and 175°C to obtain a flowing liquid and to ensure best mechanical performance. 42.5 weight % of dried hemp shiv and 42.5 weight % of dried hemp fibres are mixed with the heated liquid thermoplastic resin in a mixer and mixed until the hemp fibres and hemp shives are substantially evenly dispersed within the thermoplastic resin, to obtain the hemp-resin mix.

[0174] The hemp-resin mixture is compressed using a heated hydraulic press (or alternatively a double belt press) from around 100mm to obtain the composite material as sheets with around 3mm thickness. The composite material sheets are softened by heating to around 140°C and the sheets compressed around a mould to form C-profile shaped studs.

[0175] Example 2 - Hemp shiv and hemp fibres are dried with heat and in a vacuum, to obtain dried hemp shiv and dried hemp fibres with a maximum of between 4 and 8 weight % water. The thermoplastic resin AcForm® Power 2888 (produced by BASF in 2024) is heated to between 150 and 175°C to obtain a flowing liquid and to ensure best mechanical performance. 245.5g of dried hemp fibres are evenly distributed over a flat surface and sprayed with 43g of the AcForm® Power 2888 resin to obtain a hemp fibre-resin mix. 245.5g of dried hemp shives are thoroughly mixed with 43g of the AcForm® Power 2888 resin to obtain a hemp shiv-resin mix and evenly distributed over the layer of hemp fibres.

[0176] The hemp-resin mixture is compressed using a heated hydraulic press (or alternatively a double belt press) from around 100mm to obtain the composite material as sheets with around 3mm thickness. The composite material sheets are softened by heating to around 140°C and the sheets compressed around a mould to form C-profile shaped studs, such as that shown in Figure 1 .

[0177] Hereafter a plurality of items are provided. These items are exemplary items and are not intended to limit the scope of the disclosure, the invention is defined by the appended claims.

[0178] Item 1 comprises a hemp-based wall stud comprising: a composite material formed from hemp fibers and hemp shives; a binder material impregnating said composite material; wherein said hemp-based wall stud has a C-shaped profile; and wherein said hempbased wall stud has a density sufficient for structural use in wall construction.

[0179] Item 2 comprises the hemp-based wall stud of item 1 , wherein the composite material comprises 50% to 95% by weight of the wall stud. Item 3 comprises the hemp-based wall stud of item 1 or 2, wherein the binder material comprises 5% to 50% by weight of the wall stud. Item 4 copmrises the hemp-based wall stud of any one of items 1 to 3, wherein the binder material comprises a thermosetting resin. Item 5 comprises the hemp-based wall stud of any one of items 1 to 4, further comprising a fire retardant. Item comprises the hemp-based wall stud of any one of items 1 to 5, wherein the density of the wall stud is between 600 kg / m3 and 1200 kg / m3.

[0180] Item 7 comprises a method of manufacturing a hemp-based wall stud, the method comprising: combining hemp fibers and hemp shives to form a composite material; impregnating the composite material with a binder; pressing the impregnated composite material into a board; and shaping the board into a C-shaped profile.

[0181] Item 8 comprises the method of item 7, further comprising applying heat during the pressing step. Item 9 comprises the method of item 7 or 8, wherein shaping the board comprises feeding the board through a haul-off machine. Item 10 comprises the method of any one of items 7 to 9, further comprising adding a fire retardant to the composite material. Item 11 comprises the method of any one of items 7 to 10, wherein the binder comprises a thermosetting resin.

[0182] Item 12 comprises a wall assembly system comprising: one or more hemp-based wall studs according to anyone of items 1 to 5; and at least one wall panel attached to said one or more hemp-based wall studs.

[0183] Item 13 coomprises the wall assembly system of item 12, wherein the at least one wall panel comprises a gypsum board. Item 14 comprises the wall assembly system of item 12 or 13, further comprising a horizontal track for securing the one or more hemp-based wall studs. Item 15 comprises the wall assembly system of any one of items 12 to 14, wherein the one or more hemp-based wall studs are spaced at intervals of 400 mm to 600 mm.

Claims

CLAIMS1. A support structure comprising a composite material, wherein the composite material comprises: at least 50 weight % of hemp derived material; and at least 15 weight % of resin.

2. A support structure according to claim 1 , wherein the hemp derived material comprises hemp fibres and / or hemp shives.

3. A support structure according to claim 1 , wherein the hemp derived material consists of hemp fibres and / or hemp shives.

4. A support structure according to any preceding claim, wherein the composite material comprises at least 70 weight %, optionally at least 85 weight %, and further optionally at least 90 weight % of the hemp derived material.

5. A support structure according to claims 1 to 3, wherein the weight ratio of hemp derived material to resin is from 98:2 to 60:40, optionally from 95:5 to 70:30, and further optionally from 90:10 to 80:20.

6. A support structure according to any preceding claim, wherein the composite material comprises hemp fibres and hemp shives in substantially equal weight %.

7. A support structure according to any preceding claim, wherein the hemp fibres are arranged in random directions and distributed substantially homogeneously throughout the composite material.

8. A support structure according to any one of claims 1 to 6, wherein the hemp fibres are arranged substantially in one direction and distributed substantially homogeneously throughout the composite material.

9. A support structure according to any preceding claim, wherein the average length of a hemp fibre is between 30 and 100mm, and optionally between 50 and 80mm.

10. A support structure according to any preceding claim, wherein the resin comprises a bio resin, and wherein the bio resin is substantially derived from renewable biological sources.11 . A support structure according to claim 10, wherein the bio resin is substantially free from formaldehyde.

12. A support structure according to any preceding claim, wherein the resin comprises one or more selected from acForm® Power 2888, acForm® Power 2889 X,ACRODUR®, MDI (melamine-urea-formaldehyde) resin, and transfurans PFA (perfluoroalkoxy copolymer) resin.

13. A support structure according to any preceding claim, wherein the resin is a thermoplastic resin, and optionally wherein the thermoplastic resin is recyclable.

14. A support structure according to any preceding claim, wherein the composite material may be melted down and reformed into a new support structure.

15. A support structure according to any preceding claim, wherein the composite material additionally comprises one or more additives selected from biocides, pigments, surfactants, water repellents, antifoaming agents, intumescents, hardeners, and / or flame retardants.

16. A support structure according to any preceding claim, wherein the composite material has a physical property which is equal to or better than the same physical property in light-gauge steel, and wherein the physical property is selected from Young’s modulus, tensile strength, compressive strength, acoustic measurement (Rw), and / or thermal transmittance (U-value).

17. A support structure according to any preceding claim, wherein the support structure is an elongate structure with a substantially C-shaped, a substantially U-shaped, and / or a substantially H-shaped cross-section.

18. A support structure according to any preceding claim, for use as a stud in the construction of buildings.

19. A support structure according to claim 18, wherein the support structure is a stud with a substantially C-shaped cross-section, wherein the weight ratio of hemp derived material to resin is from 90:10 to 80:20, and wherein the hemp fibres and hemp shives in substantially equal weight %.

20. A support structure according to any preceding claim, wherein the support structure is used as a support for walls in buildings, packaging material, decorative panels, and / or fencing and fencing posts.21 . A support structure comprising two or more layers of composite material, in which each layer substantially comprises either hemp fibres or hemp shives.

22. A process for making the support structure comprising the composite material according to any one of claims 1 to 21 , comprising: mixing the hemp derived material and the resin to form a hemp-resin mix; applying heat and pressure to the hemp-resin mix to form a sheet of composite material;allowing the composite material to cure; and optionally allowing the composite material to cool to room temperature.

23. A process according to claim 22, wherein the sheet has a thickness of between 1 and 10mm, optionally between 2 and 6mm, and further optionally between 3 and 5mm, and optionally wherein the sheet has a length of up to 1 ,5m, optionally up to 2.5m, and further optionally up to 4.5m.

24. The process for making the support structure according to claim 22 or 23, further comprising: applying heat to soften the sheet of the composite material; applying pressure to bend the sheet of the composite material around a mould; and allowing the composite material to cool to room temperature to form the support structure.

25. A stud manufactured according to the process according to any one of claims 22 to

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