Construction element and method of manufacturing the construction element

Abstract

A construction element (100, 200) is disclosed The construction element (100, 200) comprises a first flange member (112, 212) comprising a first material and a second flange member (114, 214) comprising a second material. Each of the first flange member (112, 212) and the second flange member (114, 214) comprises a front surface (116, 216) facing each other and a rear surface (118, 218) non-facing each other. The construction element (100, 200) further comprises a plurality of web members (130, 230). Each web member (132, 232) comprises a third material and is adapted to be coupled to the first flange member (112, 212) and the second flange member (114, 214) by a pair of brackets (150, 250) comprising a fourth material. The first material and the second material are non-metallic materials, and the fourth material comprises metal. Further, a method (800) of manufacturing the construction element (100, 200) is disclosed.

Description

[0001] CONSTRUCTION ELEMENT AND METHOD OF MANUFACTURING THE CONSTRUCTION ELEMENT

[0002] TECHNICAL FIELD

[0003]

[0001] The present disclosure relates to the field of a construction element, in particular, to a lightweight construction element having a plurality of a web members spaced at a predetermined distance from each other. Particularly, the present disclosure relates to a composite construction element having two flange members comprised of a first and second material, respectively spaced apart and coupled together with a plurality of web members comprised of a third material.

[0004] BACKGROUND

[0005]

[0002] The information in this section merely provides background information related to the present disclosure and may not constitute prior art(s) for the present disclosure.

[0006]

[0003] In today’s world, partition walls consisting of gypsum plaster boards or equivalent construction panels are widely used. Said walls comprise construction elements, for example made of sheet metal, that serves as a carrier structure for the construction panels used to construct partition walls. Typically, multiple such construction elements are placed at a predetermined spacing such that the construction panels can be installed and affixed. One of the construction elements is embodied as a profile element that comprises a web region and at least one flange region such that the at least one flange region can be brought into engagement with construction panels in order to fix the construction panels to the flange region and thereby form the wall. The profile element acts as a means through which most of the forces imposed on the wall are diverted away, generally along a longitudinal direction of the profile element.

[0007]

[0004] Conventional construction elements may comprise a central region which is the web with two flanges rising from either side of the web. Typically, such construction elements are formed from one piece of metal, for example low-carbon steel, and weigh about 1.5kg to 1.7kg for a height of around 3 meter to 3.6 meter. Constructional elements made of metal are extensively used to build partition walls and ceilings with gypsum plaster boards. However, metal emits more CO2 emission compared to gypsum plaster boards starting from the mining and production to the final product development of steel. Although, steel is 100% recyclable material, it consumes significant energy during recycling too. Therefore, a significant portion of the CO2 footprint of a partition wall is due to the metal construction elements used. It is thus imperative to reduce metal usage and increase the usage of sustainable materials for lightweight construction applications.

[0008]

[0005] Accordingly, there remains a need in the domain for an improved composite construction element that has suitable weight, strength (e.g., minimizes the chances of buckling under heavy load conditions), and uses a reduced amount of metal without significantly increasing the cost.

[0009] SUMMARY

[0010]

[0006] The one or more shortcomings of the prior art are overcome by the construction element, and method of manufacture of a construction element as claimed herein, and additional advantages are provided through the provision of the system / assembly / method as claimed in the present disclosure. Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure.

[0011]

[0007] Pursuant to an aspect of the present disclosure, in an embodiment, a construction element is disclosed. The construction element comprises a first flange member comprising a first material and a second flange member comprising a second material. Each of the first flange member and the second flange member comprises a front surface facing each other and a rear surface non-facing each other. The construction element further comprises a plurality of web members. Each web member comprises a third material and is adapted to be coupled to the first flange member and the second flange member by a pair of brackets comprising a fourth material. The first material and the second material are non-metallic materials, and the fourth material comprises at least one of metal, plastics or thermoplastics.

[0012]

[0008] In another non-limiting embodiment of the present disclosure, the first material and the second material comprise at least one of wood, bamboo, cardboard, polymers, natural fiber composites, plastics, thermoplastic, plaster board, cement board, magnesium oxide board or fiber reinforced composites.

[0013]

[0009] In another non-limiting embodiment of the present disclosure, the first material and the second material are substantially the same material.

[0014]

[0010] In another non-limiting embodiment of the present disclosure, the fourth material comprises steel or aluminum. [Oil] In another non-limiting embodiment of the present disclosure, the web members are spaced at a distance of 50 to 300 mm.

[0015]

[0012] In another non-limiting embodiment of the present disclosure, the pair of brackets comprises a first ‘L-shaped’ bracket adapted to be coupled to the web member and the front surface of the first flange member by an adhesive, fastener, welding or deformation of the first ‘L-shaped’ bracket which penetrates into the web member and / or into the front surface of the first flange member. Further, the pair of brackets comprises a second ‘L-shaped’ bracket adapted to be coupled to the web member and the front surface of the second flange member by an adhesive, fastener, welding or deformation of the second ‘L-shaped’ bracket which penetrates into the web member and / or into the front surface of the second flange member. The first ‘L-shaped’ bracket and the second ‘L-shaped’ bracket are configured to couple the web member to the first flange member and the second flange member, respectively.

[0016]

[0013] In another non-limiting embodiment of the present disclosure, the third material of the web member comprises at least one of wood, bamboo, cardboard, natural fiber composites, polymers, plastics, thermoplastic, plaster board, cement board, magnesium oxide board or fiber reinforced composites.

[0017]

[0014] In another non-limiting embodiment of the present disclosure, the web member comprises a web plate having a length measured along a distance of separation between the first flange member and the second flange member. The length of the web plate is less than the distance of separation between the first flange member and the second flange member.

[0018]

[0015] In another non-limiting embodiment of the present disclosure, the pair of brackets comprises a first coupling bracket configured to be coupled to the front surface of the first flange member by an adhesive, fastener, welding or deformation of the first coupling bracket which penetrates into the front surface of the first flange member. Further, the pair of brackets comprises a second coupling bracket configured to be coupled to the front surface of the second flange member by an adhesive, fastener, welding or deformation of the second coupling bracket which penetrates into the front surface of the second flange member. Each of the first coupling bracket and the second coupling bracket defines one or more apertures that facilitate coupling the web member to the first flange member and the second flange member.

[0019]

[0016] In another non-limiting embodiment of the present disclosure, the web member comprises a ‘C-shaped’ web member having a plate and first and second walls transverse to the plate. The first wall of the web member is adapted to be received in the first coupling bracket, and the second wall of the web member is adapted to be received in the second coupling bracket for coupling the web member to the first flange member and the second flange member.

[0020]

[0017] In another non-limiting embodiment of the present disclosure, the first wall and the second wall of the web member are configured to snap-fit, weld, fasten, crimp or clinch into the first coupling bracket and the second coupling bracket, respectively.

[0021]

[0018] In another non-limiting embodiment of the present disclosure, the first and second walls of the web member and the one or more apertures of the first and second coupling brackets have interference fit or transition fit therebetween.

[0022]

[0019] In another non-limiting embodiment of the present disclosure, the ‘C-shaped’ web member comprises at least one of metal, polymers, plastics or thermoplastics; preferably the ‘C-shaped’ web member comprises steel or aluminum.

[0023]

[0020] In another non-limiting embodiment of the present disclosure, the first coupling bracket and the second coupling bracket are made of sheet metal.

[0024]

[0021] In another non-limiting embodiment of the present disclosure, the construction element is a drywall stud.

[0025]

[0022] In another non-limiting embodiment of the present disclosure, the construction element has a ‘C-shaped’, ‘I-shaped’ or ‘H-shaped’ profile.

[0026]

[0023] Pursuant to another aspect of the present disclosure, in an embodiment, a drywall partition having a framing assembly is disclosed. The drywall partition comprises a first horizontal framing member fixed to a floor, and a second horizontal framing member substantially parallel to and spaced from the first horizontal framing member and fixed to a ceiling. The drywall partition further comprises a plurality of construction elements as defined above and spaced vertically and mounted to the first horizontal framing member at a bottom end thereof and to the second horizontal framing member at a top end thereof, and at least one construction panel. Each construction element of the plurality of construction elements is mounted such that the first and second flange members of the construction elements abut and support a surface of the construction panel, when the at least one construction panel is fixed to one or either side of the framing assembly.

[0027]

[0024] Pursuant to yet another aspect of the present disclosure, in an embodiment, a method of manufacturing a construction element is disclosed. The method comprises providing a first flange member comprising a first material and a second flange member comprising a second material. Each of the first flange member and the second flange member comprises a front surface facing each other. The method further comprises coupling the front surface of the first flange member to the front surface of the second flange member by a plurality of web members comprising a third material. Each web member of the plurality of web members is coupled to the first flange member and the second flange member by a pair of brackets comprising a fourth material. The first material and the second material are non-metallic materials, and the fourth material comprises metal.

[0028]

[0025] In another non-limiting embodiment of the present disclosure, wherein coupling the front surface of the first flange member to the front surface of the second flange member comprises coupling a first ‘L-shaped’ bracket to a web plate of the web member and to the first flange member by an adhesive, fastener, welding, clinching or crimping which forms at least one deformation of the first ‘L-shaped’ bracket which penetrates into the web member and the front surface of the first flange member, and coupling a second ‘L-shaped’ bracket to the web plate of the web member and to the second flange member by an adhesive, fastener, welding, clinching or crimping which forms at least one deformation of the second ‘L-shaped’ bracket which penetrates into the web member and the front surface of the second flange member.

[0029]

[0026] In another non-limiting embodiment of the present disclosure, wherein coupling the front surface of the first flange member to the front surface of the second flange member comprises coupling a first coupling bracket to the front surface of the first flange member by an adhesive, a fastener, welding, clinching or crimping which forms at least one deformation of the first coupling bracket which penetrates into the front surface of the first flange member, coupling a second coupling bracket to the front surface of the second flange member by an adhesive, a fastener, welding, clinching or crimping which forms at least one deformation of the second coupling bracket which penetrates into the front surface of the second flange member, and inserting a first wall and a second wall of the web member into one or more apertures of the first coupling bracket and the second coupling bracket, respectively.

[0030]

[0027] In another non-limiting embodiment of the present disclosure, wherein inserting the first and second walls of the web member into the one or more apertures of the first and second coupling brackets comprises snap-fitting the first wall and the second wall of the web member into the first coupling bracket and the second coupling bracket, respectively.

[0028] In another non-limiting embodiment of the present disclosure, wherein the first and second materials comprise at least one of wood, bamboo, cardboard, natural fiber composites, polymers, plastics, thermoplastic, plaster board, cement board, magnesium oxide board or fiber reinforced composites, the third material comprises at least one of wood, bamboo, cardboard, natural fiber composites, polymers, plastics, thermoplastic, plaster boards, cement boards, magnesium oxide board, fiber reinforced composites, steel, or aluminum, and the fourth material comprises at least one of metal, plastics or thermoplastics.

[0031]

[0029] Within the scope of the present disclosure, the construction element of the present disclosure is a composite ‘C-shaped’, ‘I-shaped’ or ‘H-shaped’ beam that includes nonmetal and metal sheets. The construction element of the present disclosure is more sustainable than steel frames due to reduced metal content and therefore reduced carbon footprint.

[0032]

[0030] According to the present disclosure, metal is cold-formed steel or aluminium sheets and nonmetal is wood, bamboo, cardboard, natural fiber composites, polymers, plastics, thermoplastic, plaster board, cement board, magnesium oxide board, or fiber reinforced composites. Connections between first and fourth materials, and between third and fourth materials are either by mechanical or adhesive joining. Composite ‘C- shaped’, ‘I-shaped’ or ‘H-shaped’ beams take full advantage of the material strength, high section modulus, and stability. This composite ‘C-shaped’, ‘I-shaped’ or ‘H- shaped’ beam structures have the benefits of reducing the amount of metal used and the carbon footprint of the construction element.

[0033]

[0031] It is to be understood that the aspects and embodiments of the disclosure described above may be used in combination with each other. Several of the aspects and embodiments may be combined together to form a further embodiment of the disclosure.

[0034]

[0032] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

[0035] BRIEF DESCRIPTION OF FIGURES

[0036]

[0033] The novel features and characteristics of the disclosure are set forth in the description. The disclosure itself, however, as well as a preferred mode of use, further objectives, and advantages thereof, will best be understood by reference to the following description of an illustrative embodiment when read in conjunction with the accompanying drawings. One or more embodiments are now described, by way of example only, with reference to the accompanying drawings wherein like reference numerals represent like elements and in which:

[0037]

[0034] FIG. 1 illustrates an exemplary construction element, in accordance with a first embodiment of the present disclosure;

[0038]

[0035] FIG. 2 illustrates an exploded view of the construction element of FIG. 1, in accordance with the first embodiment of the present disclosure;

[0039]

[0036] FIG. 3 illustrates a side view of the construction element of FIG. 1, in accordance with the first embodiment of the present disclosure;

[0040]

[0037] FIG. 4 illustrates an exemplary construction element, in accordance with a second embodiment of the present disclosure;

[0041]

[0038] FIG. 5 illustrates an exploded view of the construction element of FIG. 4, in accordance with the second embodiment of the present disclosure;

[0042]

[0039] FIG. 6 illustrates a side view of the construction element of FIG. 4, in accordance with the second embodiment of the present disclosure;

[0043]

[0040] FIG. 7 illustrates a dry wall partition, in accordance with an embodiment of the present disclosure; and

[0044]

[0041] FIG. 8 illustrates a flow chart depicting a method for manufacturing the construction element of FIGS. 1 to 6, in accordance with an embodiment of the present disclosure.

[0045]

[0042] Skilled artisans will appreciate that elements in the drawings are illustrated for simplicity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the drawings may be exaggerated relative to other elements to help to improve understanding of embodiments of the present disclosure.

[0046] DETAILED DESCRIPTION

[0047]

[0043] While the disclosure is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the FIGS, and will be described in detail below. It should be understood, however that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure as defined by the appended claims.

[0048]

[0044] Before describing detailed embodiments, it may be observed that the novelty and inventive step of the present disclosure resides in a construction element, a dry wall partition, and a method of manufacturing the construction element. It is to be noted that a person skilled in the art can be motivated from the present disclosure and modify the various embodiments of the construction element, the drywall partition, and the method. However, such modifications should be construed within the scope of the present disclosure. Accordingly, the drawings are showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having benefit of the description herein.

[0049]

[0045] In the present disclosure, the term “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any embodiment or implementation of the present subject matter described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments.

[0050]

[0046] The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a device that comprises a list of components does not include only those components but may include other components not expressly listed or inherent to such setup or device. In other words, one or more elements in a system or apparatus proceeded by “comprises... a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.

[0051]

[0047] The terms like “at least one” and “one or more” may be used interchangeably or in combination throughout the description.

[0052]

[0048] Pursuant to an embodiment, a construction element is disclosed. The construction element comprises a first flange member comprising a first material and a second flange member comprising a second material. Each of the first flange member and the second flange member comprises a front surface facing each other and a rear surface non-facing each other. The construction element further comprises a plurality of web members. Each web member comprises a third material and is adapted to be coupled to the first flange member and the second flange member by a pair of brackets comprising a fourth material. The first material and the second material are non-metallic materials, and the fourth material comprises at least one of metal, plastics or thermoplastics. The first material and the second material comprise at least one of wood, bamboo, cardboard, natural fiber composites, polymers, plastics, thermoplastic, plaster board, cement board, magnesium oxide board or fiber reinforced composites. The fourth material comprises steel or aluminum. In an embodiment, the first material and the second material are substantially the same material. Further, the web members are spaced at a distance of 50 to 300 mm.

[0053]

[0049] The pair of brackets comprises a first ‘L-shaped’ bracket adapted to be coupled to the web member and the front surface of the first flange member by an adhesive, fastener, welding or deformation of the first ‘L-shaped’ bracket which penetrates into the web member and / or into the front surface of the first flange member. Further, the pair of brackets comprises a second ‘L-shaped’ bracket adapted to be coupled to the web member and the front surface of the second flange member by an adhesive, fastener, welding or deformation of the second ‘L-shaped’ bracket which penetrates into the web member and / or into the front surface of the second flange member. The first ‘L-shaped’ bracket and the second ‘L-shaped’ bracket are configured to couple the web member to the first flange member and the second flange member, respectively. The third material of the web member comprises at least one of wood, bamboo, cardboard, natural fiber composites, polymers, plastics, thermoplastic, plaster boards, cement boards, magnesium oxide board or fiber reinforced composites. In an embodiment, the web member comprises a web plate having a length measured along a distance of separation between the first flange member and the second flange member. The length of the web plate is less than the distance of separation between the first flange member and the second flange member.

[0054]

[0050] In an embodiment, the construction element is a drywall stud. The construction element has a ‘C-shaped’, ‘l-shaped’ or ‘H-shaped’ profile.

[0055]

[0051] Pursuant to another embodiment, a construction element is disclosed. The construction element comprises a first flange member comprising a first material and a second flange member comprising a second material. Each of the first flange member and the second flange member comprises a front surface facing each other and a rear surface non-facing each other. The construction element further comprises a plurality of web members. Each web member comprises a third material and is adapted to be coupled to the first flange member and the second flange member by a pair of brackets comprising a fourth material. The first material and the second material comprise at least one of wood, bamboo, cardboard, natural fiber composites, polymers, plastics, thermoplastic, plaster board, cement board, magnesium oxide board or fiber reinforced composites. The fourth material comprises at least one of metal, plastics or thermoplastics. In an embodiment, the first material and the second material are substantially the same material. Further, the web members are spaced at a distance of 50 to 300 mm.

[0056]

[0052] In an embodiment, the pair of brackets comprises a first coupling bracket configured to be coupled to the front surface of the first flange member by an adhesive, fastener, welding or deformation of the first coupling bracket which penetrates into the front surface of the first flange member. Further, the pair of brackets comprises a second coupling bracket configured to be coupled to the front surface of the second flange member by an adhesive, fastener, welding or deformation of the second coupling bracket which penetrates into the front surface of the second flange member. Each of the first coupling bracket and the second coupling bracket defines one or more apertures that facilitate coupling the web member to the first flange member and the second flange member. Further, the web member comprises a ‘C-shaped’ web member having a plate and first and second walls transverse to the plate. The first wall of the web member is adapted to be received in the first coupling bracket, and the second wall of the web member is adapted to be received in the second coupling bracket for coupling the web member to the first flange member and the second flange member. The first wall of the web member is adapted to be received in the one or more apertures of the first coupling bracket, and the second wall of the web member is adapted to be received in the one or more apertures of the second coupling bracket for coupling the web member to the first flange member and the second flange member. The first wall and the second wall of the web member are configured to snap-fit into the first coupling bracket and the second coupling bracket, respectively. Alternatively, the first wall and the second wall of the web member are configured to be welded, fastened, crimped or clinched into the first coupling bracket and the second coupling bracket, respectively. The first and second walls of the web member and the one or more apertures of the first and second coupling brackets have interference fit or transition fit therebetween. The ‘C-shaped’ web member comprises at least one of metal, polymers, plastics or thermoplastics; preferably the ‘C-shaped’ web member comprises steel or aluminum. The first coupling bracket and the second coupling bracket are made of sheet metal.

[0057]

[0053] In an embodiment, the construction element is a drywall stud. The construction element has a ‘C-shaped’, ‘I-shaped’ or ‘H-shaped’ profile.

[0054] Pursuant to a further aspect of the present disclosure, in an embodiment, a drywall partition having a framing assembly is disclosed. The drywall partition comprises a first horizontal framing member fixed to a floor, and a second horizontal framing member substantially parallel to and spaced from the first horizontal framing member and fixed to a ceiling. The drywall partition further comprises a plurality of construction elements as defined above and spaced vertically and mounted to the first horizontal framing member at a bottom end thereof and to the second horizontal framing member at a top end thereof, and at least one construction panel. Each construction element of the plurality of construction elements is mounted such that the first and second flange members of the construction elements abut and support a surface of the construction panel, when the at least one construction panel is fixed to one or either side of the framing assembly.

[0058]

[0055] Pursuant to yet another embodiment, a method of manufacturing a construction element is disclosed. The method comprises providing a first flange member comprising a first material and a second flange member comprising a second material. Each of the first flange member and the second flange member comprises a front surface facing each other. The method further comprises coupling the front surface of the first flange member to the front surface of the second flange member by a plurality of web members comprising a third material. Each web member of the plurality of web members is coupled to the first flange member and the second flange member by a pair of brackets comprising a fourth material. The first material and the second material are non-metallic materials, and the fourth material comprises metal.

[0059]

[0056] In an embodiment, coupling the front surface of the first flange member to the front surface of the second flange member comprises coupling a first ‘L-shaped’ bracket to a web plate of the web member and to the first flange member by an adhesive, fastener, welding, clinching or crimping which forms at least one deformation of the first ‘L-shaped’ bracket which penetrates into the web member and / or the front surface of the first flange member, and coupling a second ‘L-shaped’ bracket to the web plate of the web member and to the second flange member by an adhesive, fastener, welding, clinching or crimping which forms at least one deformation of the second ‘L-shaped’ bracket which penetrates into the web member and / or the front surface of the second flange member.

[0060]

[0057] Further, in an embodiment, coupling the front surface of the first flange member to the front surface of the second flange member comprises coupling a first coupling bracket to the front surface of the first flange member by an adhesive, a fastener, welding, clinching or crimping which forms at least one deformation of the first coupling bracket which penetrates into the front surface of the first flange member, coupling a second coupling bracket to the front surface of the second flange member by an adhesive, a fastener, welding, clinching or crimping which forms at least one deformation of the second coupling bracket which penetrates into the front surface of the second flange member, and inserting a first wall and a second wall of the web member into one or more apertures of the first coupling bracket and the second coupling bracket, respectively.

[0061]

[0058] In an embodiment, inserting the first and second walls of the web member into the one or more apertures of the first and second coupling brackets comprises snapfitting the first wall and the second wall of the web member into the first coupling bracket and the second coupling bracket, respectively.

[0062]

[0059] The first and second materials comprise at least one of wood, bamboo, cardboard, natural fiber composites, polymers, plastics, thermoplastic, plaster board, cement board, magnesium oxide board or fiber reinforced composites, the third material comprises at least one of wood, bamboo, cardboard, natural fiber composites, polymers, plastics, thermoplastic, plaster boards, cement boards, magnesium oxide board, fiber reinforced composites, steel, or aluminum, and the fourth material comprises steel or aluminum.

[0063]

[0060] Pursuant to preferred embodiments, the first and second material is wood, third material is wood, or aluminum or steel and the fourth material is metal.

[0064]

[0061] Reference will now be made to the exemplary embodiments of the present disclosure, as illustrated in the accompanying drawings. Wherever possible, same numerals will be used to refer to the same or like parts. Embodiments of the disclosure are described in the following paragraphs with reference to FIGS. 1 to 8. In FIGS. 1 to 8, the same element or elements which have same functions are indicated by the same reference signs.

[0065]

[0062] Referring to FIGS. 1 to 3, in accordance with a first embodiment of the present disclosure, a construction element (100) is disclosed. Without limiting the scope of protection of the present disclosure, the construction element (100) may be a composite construction element (100). The construction element (100) may be embodied to comprise a ‘C-shaped’ profile, ‘I-shaped’ profile or ‘H-shaped’ profile. In an exemplary embodiment of the present disclosure, without limiting the scope of protection, the construction element (100) may be a drywall stud that may serve as a carrier structure for the construction of walls using gypsum plaster boards.

[0066]

[0063] Referring to FIGS. 1 and 3, the construction element (100) may comprise a pair of flanges (110) that may be connected to each other by a plurality of web members (130). The pair of flanges (110) may comprise a first flange member (112) and a second flange member (114). Further, the construction element (100) may comprise a plurality of brackets (150) that facilitate coupling a respective web member (132) of the plurality of web members (130) to each flange, i.e., the first flange member (112) and the second flange member (114), of the pair of flanges (110). In the exemplary embodiment of FIG. 1, the construction element (100) comprises two web members (132) that connect the pair of flanges (110). In said exemplary embodiment, the construction element (100) comprises two pairs of brackets (150), each pair of which couples the respective web member (132) to the pair of flanges (110). In accordance with the present disclosure, in the exemplary embodiment shown in FIGS. 1 to 3, the first flange member (112) may be made of a first material, the second flange member (114) may be made of a second material, the plurality of web members (130) may be made of a third material, and the pairs of brackets (150) may be made of a fourth material. Without limiting the scope of protection of the present disclosure, the first material and the second material may substantially be the same material. In an embodiment, the pairs of brackets (150) may be made of metallic material and the pair of flanges (110), i.e., the first and second flange members (112, 114), and the plurality of web members (130) may be made of non-metallic material.

[0067]

[0064] Still referring to FIGS. 1 to 3, the construction element (100) comprises the first flange member (112) and the second flange member (114). Each of the first flange member (112) and the second flange member (114) comprises a front surface (116) facing each other and a rear surface (118) non-facing each other. In an embodiment of the present disclosure, the plurality of web members (130) is configured to couple the front surface (116) of the first flange member (112) with the front surface (116) of the second flange member (114). In an embodiment of the present disclosure, each of the first flange member (112) and the second flange member (114) may be embodied as a cuboidal planks or sheets and may be made of the first material and the second material, respectively. The first and second materials may comprise, but not limited to, at least one of wood, bamboo, cardboard, natural fiber composites, polymers, plastics, thermoplastic, plaster board, cement board, magnesium oxide board or fiber reinforced composites. Pursuant to this embodiment, the first and second material preferably may comprise wood.

[0068]

[0065] Referring to FIG. 3, each web member (132) of the plurality of web members (130) may be embodied as a web plate (134) that extends between the first flange member (112) and the second flange member (114) to couple the first flange member (112) with the second flange member (114). In the exemplary embodiment shown in FIGS. 1 to 3, each web member (132) may be made of the third material that comprises, but not limited to, at least one of wood, bamboo, cardboard, natural fiber composites, polymers, plastics, thermoplastic, plaster boards, magnesium oxide board, cement boards or fiber reinforced composites. Pursuant to this embodiment, the web member preferably may be made of wood. In an embodiment, a length of the web plate (134) of the web member (132) may be measured along a distance of separation between the first flange member (112) and the second flange member (114). The length of the web plate (134) may be less than the distance of separation between the first flange member (112) and the second flange member (114).

[0069]

[0066] A person skilled in the art can readily comprehend that the difference between the distance of separation between the first flange member (112) and the second flange member (114) and the length of the web plate (134) may be compensated by the dimensions and design of the pair of brackets (150) that facilitate coupling the web plate (134) with the first flange member (112) and the second flange member (114). In an embodiment, the web members (132) may be spaced at a distance of 50 to 300 mm along the length of the construction element (100), i.e., along the length of the first flange member (112) and the second flange member (114), as shown in FIGS. 1 and 2.

[0067] As discussed above, each web member (132) is coupled to the first flange member (112) and the second flange member (114) by the respective pair of brackets (150). The pair of brackets (150) may be made of the fourth material that comprises, but non-limited to, steel or aluminum or plastics or thermoplastics. Pursuant to this embodiment, the fourth material is preferably metal. Without limiting the scope of protection, the pair of brackets (150) may be manufactured by one of sheet metal bending process, roll forming process, or extrusion process. Referring to FIGS. 2 and 3, the pair of brackets (150) may comprise a first ‘L-shaped’ bracket (152) and a second ‘L-shaped’ bracket (154). Each of the first ‘L-shaped’ bracket (152) and the second ‘L- shaped’ bracket (154) may be made of the fourth material that comprises, but nonlimited to, steel or aluminum. The first and second ‘L-shaped’ brackets (152, 154) are configured to couple the web member (132) with the front surfaces (116) of the first flange member (112) and the second flange member (114), respectively.

[0070]

[0068] As shown in FIGS. 2 and 3, each of the first ‘L-shaped’ bracket (152) and the second ‘L-shaped’ bracket (154) comprises a first leg (156) and a second leg (158) extending substantially perpendicular to the first leg (156), thereby forming an ‘L- shaped’ profile. The first legs (156) of the first ‘L-shaped’ bracket (152) and the second ‘L-shaped’ bracket (154) may couple to a top surface (136) of the web plate (134) and the second legs (158) of the first ‘L-shaped’ bracket (152) and the second ‘L-shaped’ bracket (154) may couple to the respective front surface (116) of the first flange member (112) and the second flange member (114), thereby coupling the web member (132) with the first flange member (112) and the second flange member (114) of the construction element (100). The first ‘L-shaped’ bracket (152) and the second ‘L- shaped’ bracket (154) may be coupled to the web plate (134) and the first and second flange members (112, 114) by an adhesive, fastener, welding or deformation defined in the first and second ‘L-shaped’ brackets (152, 154). In an embodiment, the first leg (156) and the second leg (158) of the first ‘L-shaped’ bracket (152) may be coupled to the top surface (136) of the web plate (134) and the front surface (116) of the first flange member (112) by the adhesive, fastener, welding or deformation of the first ‘L-shaped’ bracket (152) which penetrates into the web member (132) and / or into the front surface (116) of the first flange member (112). Similarly, the first leg (156) and the second leg (158) of the second ‘L-shaped’ bracket (154) may be coupled to the top surface (136) of the web plate (134) and the front surface (116) of the second flange member (114) by the adhesive, fastener, welding or deformation of the second ‘L-shaped’ bracket (154) which penetrates into the web member (132) and / or into the front surface (116) of the second flange member (114).

[0071]

[0069] Referring to FIGS. 4 to 6, in accordance with a second embodiment of the present disclosure, a construction element (200) is disclosed. Without limiting the scope of protection of the present disclosure, the construction element (200) may be a composite construction element (200). The construction element (200) may be embodied to comprise a ‘C-shaped’ profile, ‘l-shaped’ profile or ‘H-shaped’ profile. In an exemplary embodiment of the present disclosure, without limiting the scope of protection, the construction element (200) may be a drywall stud that may serve as a carrier structure for the construction of walls using gypsum plaster boards.

[0070] Referring to FIGS. 4 and 6, the construction element (200) may comprise a pair of flanges (210) that may be connected to each other by a plurality of web members (230). The pair of flanges (210) may comprise a first flange member (212) and a second flange member (214). Further, the construction element (200) may comprise a pair of brackets (250) that facilitate coupling a respective web member (232) of the plurality of web members (230) to each flange, i.e., the first flange member (212) and the second flange member (214), of the pair of flanges (210). In the exemplary embodiment of FIG. 4, the construction element (200) comprises two web members (232) that connect the pair of flanges (210). In said exemplary embodiment, the construction element (200) comprises two pairs of brackets (250), each pair of which couples the respective web member (232) to the pair of flanges (210). In accordance with the present disclosure, in the exemplary embodiment shown in FIGS. 4 to 6, the first flange member (212) may be made of a first material, the second flange member (214) may be made of a second material, the plurality of web members (230) may be made of a third material, and the pairs of brackets (250) may be made of a fourth material. Without limiting the scope of protection of the present disclosure, the first material and the second material may substantially be the same material. In an embodiment, the plurality of web members (230) and the pairs of brackets (250) may be made of metallic material and the pair of flanges (210), i.e., the first flange member (212) and the second flange member (214), may be made of non -metallic material.

[0072]

[0071] Still referring to FIGS. 4 to 6, the construction element (200) comprises the first flange member (212) and the second flange member (214). Each of the first flange member (212) and the second flange member (214) comprises a front surface (216) facing each other and a rear surface (218) non-facing each other. In an embodiment of the present disclosure, the plurality of web members (230) is configured to couple the front surface (216) of the first flange member (212) with the front surface (216) of the second flange member (214). In an embodiment of the present disclosure, each of the first flange member (212) and the second flange member (214) may be embodied as cuboidal planks or sheets and may be made of the first material and the second material, respectively. The first and second materials may comprise, but not limited to, at least one of wood, bamboo, cardboard, natural fiber composites, polymers, plastics, thermoplastic, plaster board, cement board, magnesium oxide board or fiber reinforced composites. Pursuant to this embodiment, the first and second material preferably may comprise wood.

[0072] Referring to FIGS. 5 and 6, each web member (232) of the plurality of web members (230) may be embodied as a ‘C-shaped’ web member (232). The ‘C-shaped’ web member (232) may have a plate (234) and a first wall (236) and a second wall (238) that extend transversely to the plate (234). The ‘C-shaped’ web member (232) is configured to couple the first flange member (212) with the second flange member (214) of the construction element (200). In the exemplary embodiment shown in FIGS. 4 to 6, each ‘C-shaped’ web member (232) may be made of the third material that comprises, but not limited to, least one of metal, polymers, plastics or thermoplastics; preferably the ‘C-shaped’ web member comprises steel or aluminum. Pursuant to this embodiment, the third material is preferably steel or aluminum. Without limiting the scope of protection, metal ‘C-shaped’ web member (232) may be manufactured by one of sheet metal bending process, roll forming process, or extrusion process; ‘C-shaped’ web members comprising polymers, plastics or thermoplastics may be manufactured by extrusion moulding. In an embodiment, the web members (232) may be spaced at a distance of 50 to 300 mm along the length of the construction element (200), i.e., along the length of the first flange member (212) and the second flange member (214), as shown in FIGS. 4 and 5.

[0073]

[0073] As discussed above, each web member (232) is coupled to the first flange member (212) and the second flange member (214) by the respective pair of brackets (250). The pair of brackets (250) may be made of the fourth material that comprises, but non-limited to, steel or aluminum. Referring to FIGS. 5 and 6, the pair of brackets (250) may comprise a first coupling bracket (252) and a second coupling bracket (254). Each of the first coupling bracket (252) and the second coupling bracket (254) may be made of the fourth material that comprises, but non-limited to, at least one of metal, plastics or thermoplastics or steel or aluminum. Pursuant to this embodiment, the fourth materials preferably metal. The first and second coupling brackets (252, 254) are configured to couple the ‘C-shaped’ web member (232) with the front surfaces (216) of the first flange member (212) and the second flange member (214), respectively. In an embodiment, the first coupling bracket (252) and the second coupling bracket (254) may be made of sheet metal.

[0074]

[0074] As shown in FIGS. 5 and 6, each of the first coupling bracket (252) and the second coupling bracket (254) may be embodied to be formed of three portions, namely a first portion (256a), a second portion (256b) and a third portion (256c). Without limiting the scope of protection, the first and second coupling brackets (252, 254) may be manufactured by one of sheet metal bending process, roll forming process, or extrusion process. In an embodiment, the second portion (256b) is arranged between the first portion (256a) and the third portion (256c) and may be contained in a first plane that is parallel to a second plane containing the first and third portions (256a, 256c). Each of the first coupling bracket (252) and the second coupling bracket (254) defines one or more apertures (258) at segments where the first portion (256a) meets the second portion (256b), and the second portion (256b) meets the third portion (256c). In an embodiment, the first portion (256a) and the third portion (256c) are connected to the second portion (256b) at the end regions of the second portion (256b) such that the apertures (258) are defined in the regions where the first portion (256a) and the third portion (256c) are not connected to the second portion (256b).

[0075]

[0075] In an embodiment of the construction element (200), each of the first coupling bracket (252) and the second coupling bracket (254) may be coupled to the first flange member (212) and the second flange member (214), respectively, by an adhesive, fastener, welding or deformation defined in the first coupling bracket (252) and the second coupling bracket (254). The first portion (256a) and the third portion (256c) of the first coupling bracket (252) may be coupled to the front surface (216) of the first flange member (212) by the adhesive, fastener, welding or deformation of the first coupling bracket (252) which penetrates into the front surface (216) of the first flange member (212). Similarly, the first portion (256a) and the third portion (256c) of the second coupling bracket (254) may be coupled to the front surface (216) of the second flange member (214) by the adhesive, fastener, welding or deformation of the second coupling bracket (254) which penetrates into the front surface (216) of the second flange member (214). Further, one or more apertures (258) of the first coupling bracket (252) and the second coupling bracket (254) may receive the first and second walls (236, 238), respectively, of the ‘C-shaped’ web member (232) to couple the web member (232) with the first flange member (212) and the second flange member (214) of the construction element (200).

[0076]

[0076] Referring to FIGS. 5 and 6, for coupling the web member (232) to the first flange member (212) and the second flange member (214) in the construction element (200), the first wall (236) of the web member (232) is adapted to be received in the one or more apertures (258) of the first coupling bracket (252), and the second wall (238) of the web member (232) is adapted to be received in the one or more apertures (258) of the second coupling bracket (254). In accordance with the present disclosure, the first wall (236) and the second wall (238) of the web member (232) are configured to snap-fit into the first coupling bracket (252) and the second coupling bracket (254), respectively. In an embodiment, the first and second walls (236, 238) of the web member (232) and the one or more apertures (258) of the first and second coupling brackets (252, 254) may have interference fit or transition fit therebetween for coupling the web member (232) to the first flange member (212) and the second flange member (214) in the construction element (200). As shown in FIG. 5, in an embodiment, each of the first wall (236) and the second wall (238) of the ‘C-shaped’ web member (232) may comprise a stopper (240) for locking the ‘C-shaped’ web member (232) with the first coupling bracket (252) and the second coupling bracket (254).

[0077]

[0077] Referring to FIG. 7, a drywall partition having a framing assembly (10) is illustrated. The drywall partition may comprise a first horizontal framing member (20) fixed to a floor (21), and a second horizontal framing member (30) substantially parallel to and spaced from the first horizontal framing member (20) and fixed to a ceiling (31). The drywall partition may further comprise a plurality of construction elements spaced vertically and mounted to the first horizontal framing member (20) at a bottom end thereof and to the second horizontal framing member (30) at a top end thereof. In an embodiment, a construction element of the plurality of construction elements used in the framing assembly (10) may have structural and functional configurations similar to the construction element (100) or the construction element (200) as described above. Although, the exemplary embodiment of FIG. 7 illustrates the construction element (100) in the framing assembly (10); however, without deviating from the scope of protection of the present disclosure, the construction element (200) may also be used in the framing assembly (10).

[0078]

[0078] The drywall partition further comprises at least one construction panel (35). In accordance with the present disclosure, each construction element (100, 200) of the plurality of construction elements (100, 200) is mounted such that the first and second flange members (112, 114, 212, 214) of the construction elements (100, 200) abut and support a surface of the construction panel (35), when the at least one construction panel (35) is fixed to one or either side of the framing assembly (10).

[0079]

[0079] Referring to FIG. 8, a method (800) for manufacturing the construction element (100, 200) of FIGS. 1 to 6 is disclosed. At step (802), the method (700) for manufacturing the construction element (10, 200) comprises providing the first flange member (112, 212) comprising of the first material and the second flange member (114, 214) comprising of the second material. Within the scope of protection of the present disclosure, each of the first flange member (112, 212) and the second flange member (114, 214) comprises the front surface (116, 216) facing each other and the rear surface (118, 218) non-facing each other. The first and second materials may comprise, but not limited to, at least one of wood, bamboo, cardboard, natural fiber composites, polymers, plastics, thermoplastic, plaster board, cement board, magnesium oxide board or fiber reinforced composites.

[0080]

[0080] At step (804), the method (800) further comprises coupling the front surface (116, 216) of the first flange member (112, 212) to the front surface (116, 216) of the second flange member (114, 214) by the plurality of web members (130, 230) comprising the second material. In accordance with the present disclosure, each web member (132, 232) of the plurality of web members (130, 230) is coupled to the first flange member (112, 212) and the second flange member (114, 214) by the pair of brackets (150, 250) made of the fourth material. The fourth material may comprise, but not limited to, metal or plastic or thermoplastic. Referring to FIGS. 1 to 3, for the construction element (100), the first and second flange members (112, 114) are made of the first material and the second material, respectively, that comprises, but not limited to, at least one of wood, bamboo, cardboard, natural fiber composites, polymers, plastics, thermoplastic, plaster board, cement board, magnesium oxide board or fiber reinforced composites, the plurality of web members (130) are made of the third material comprising, but not limited to at least one of wood, bamboo, cardboard, natural fiber composites, polymers, plastics, thermoplastic, plaster boards, cement boards, magnesium oxide board or fiber reinforced composites, and the pair of brackets (150) are made of the fourth material comprising, but not limited to, steel or aluminum. Pursuant to FIGS. 1 to 3, the first, second and third material are preferably wood, and the fourth material is preferably metal.

[0081]

[0081] Further, referring to FIGS. 4 to 6, for the construction element (200), the first and second flange members (212, 214) are made of the first material and the second material, respectively, that comprises, but not limited to, at least one of wood, bamboo, cardboard, natural fiber composites, polymers, plastics, thermoplastic, plaster board, cement board, magnesium oxide board or fiber reinforced composites, the plurality of web members (230) are made of the third material comprising, but not limited to steel or aluminum, and the pair of brackets (250) are made of the fourth material comprising, but not limited to, metal or plastic or thermoplastic. Pursuant to FIGS. 4 to 6, the first and second material are preferably wood, third material is preferably steel or aluminum and the fourth material is preferably metal.

[0082]

[0082] Further, according to the method (800) of the present disclosure, in an embodiment, referring to FIGS. 1 to 3 and 8, coupling the front surface (116) of the first flange member (112) to the front surface (116) of the second flange member (114) comprises coupling the first ‘L-shaped’ bracket (152) to the web plate (134) of the web member (132) and to the first flange member (112) by the adhesive, fastener, welding, clinching or crimping which forms at least one deformation of the first ‘L-shaped’ bracket (152) which penetrates into the web member (132) and / or the front surface (116) of the first flange member (112). Further, coupling the front surface (116) of the first flange member (112) to the front surface (116) of the second flange member (114) comprises coupling the second ‘L-shaped’ bracket (154) to the web plate (134) of the web member (132) and to the second flange member (114) by the adhesive, fastener, welding, clinching or crimping which forms at least one deformation of the second ‘L- shaped’ bracket (154) which penetrates into the web member (132) and / or the front surface (116) of the second flange member (114).

[0083]

[0083] Further, according to the method (800) of the present disclosure, in another embodiment, referring to FIGS. 4 to 6 and 8, coupling the front surface (216) of the first flange member (212) to the front surface (216) of the second flange member (214) comprises coupling the first coupling bracket (252) to the front surface (216) of the first flange member (212) by the adhesive, fastener, or crimping which forms at least one deformation of the first coupling bracket (252) which penetrates into the front surface (216) of the first flange member (212). Further, coupling the front surface (216) of the first flange member (212) to the front surface (216) of the second flange member (214) comprises coupling the second coupling bracket (254) to the front surface (216) of the second flange member (214) by the adhesive, fastener, or crimping which forms at least one deformation of the second coupling bracket (254) which penetrates into the front surface (216) of the second flange member (214). Furthermore, coupling the front surface (216) of the first flange member (212) to the front surface (216) of the second flange member (214) comprises inserting the first wall (236) and the second wall (238) of the web member (232) into the one or more apertures (258) of the first coupling bracket (252) and the second coupling bracket (254), respectively.

[0084]

[0084] Further, in an alternate embodiment according to the method (800) of the present disclosure, referring to FIGS. 4 to 6 and 8, coupling the front surface (216) of the first flange member (212) to the front surface (216) of the second flange member (214) comprises inserting the first wall (236) and the second wall (238) of the web member (232) into the one or more apertures (258) of the first coupling bracket (252) and the second coupling bracket (254), respectively. Alternatively, welding, fastening, clinching or crimping the first wall (236) and the second wall (238) of the web member (232) to the first coupling bracket (252) and the second coupling bracket (254), respectively. Subsequently, coupling the front surface (216) of the first flange member (212) to the front surface (216) of the second flange member (214) by coupling the first coupling bracket (252) and second coupling bracket (254) to the front surface (216) of the first flange member (212) and coupling the front surface (216) of the second flange member (214), respectively by the adhesive, fastener, or crimping which forms at least one deformation of the first coupling bracket (252) which penetrates into the front surface (216) of the first flange member (212).

[0085]

[0085] According to the method (800) of the present disclosure, inserting the first and second walls (236, 238) of the web member (232) into the one or more apertures (258) of the first and second coupling brackets (252, 254) comprises snap-fitting the first wall (236) and the second wall (238) of the web member (232) into the first coupling bracket (252) and the second coupling bracket (254), respectively.

[0086]

[0086] Within the scope of the present disclosure, the construction element (100, 200) of the present disclosure is a composite ‘C-shaped’, ‘I-shaped’ or ‘H-shaped’ beam that includes nonmetal and metal sheets. The construction element (100, 200) of the present disclosure is lighter in weight compared to the conventional construction elements, more sustainable than steel frames, and can be easy to install for drywall applications.

[0087] According to the present disclosure, metal is cold-formed steel or aluminium sheets and nonmetal is wood, bamboo, cardboard, natural fiber composites, polymers, plastics, thermoplastic, plaster board, cement board, magnesium oxide board or fiber reinforced composites. Connections between first and fourth materials, and between third and fourth materials are either by mechanical or adhesive joining. Composite ‘C- shaped’, ‘I-shaped’ or ‘H-shaped’ beams take full advantage of the material strength, high section modulus, and stability. These composite ‘C-shaped’, ‘I-shaped’ or ‘H- shaped’ beam structures have the benefits of reducing the amount of metal used and the carbon footprint of the construction element.

[0087]

[0088] The various embodiments of the present disclosure have been described above with reference to the accompanying drawings. The present disclosure is not limited to the illustrated embodiments; rather, these embodiments are intended to fully and completely disclose the subject matter of the disclosure to those skilled in this art. In the drawings, like numbers refer to like elements throughout. Thicknesses and dimensions of some components may be exaggerated for clarity.

[0088]

[0089] Herein, the terms “attached”, “connected”, “interconnected”, “contacting”, “mounted”, “coupled” and the like can mean either direct or indirect attachment or contact between elements, unless stated otherwise.

[0089]

[0090] Well-known functions or constructions may not be described in detail for brevity and / or clarity. As used herein the expression “and / or” includes any and all combinations of one or more of the associated listed items.

[0090]

[0091] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises”, “comprising”, “includes” and / or “including” when used in this specification, specify the presence of stated features, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, operations, elements, components, and / or groups thereof.

[0091]

[0092] While considerable emphasis has been placed herein on the particular features of this disclosure, it will be appreciated that various modifications can be made, and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other modifications in the nature of the disclosure or the preferred embodiments will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.

[0092] REFERENCE NUMERALS

[0093]

[0094] EQUIVALENTS:

[0095]

[0093] The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

[0096]

[0094] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and / or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.

[0097]

[0095] Any discussion of documents, acts, materials, devices, articles and the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.

[0098]

[0096] The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher / lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.

Claims

CLAIMS1. A construction element (100, 200), comprising: a first flange member (112, 212) comprising a first material; a second flange member (114, 214) comprising a second material, each of the first flange member (112, 212) and the second flange member (114, 214) comprises a front surface (116, 216) facing each other and a rear surface (118, 218) non-facing each other; and a plurality of web members (130, 230), each web member (132, 232) comprising a third material and adapted to be coupled to the first flange member (112, 212) and the second flange member (114, 214) by a pair of brackets (150, 250) comprising a fourth material, wherein the first material and the second material are non-metallic materials, and the fourth material comprises at least one of metal, plastics or thermoplastics.

2. The construction element (100, 200) as claimed in claim 1, wherein the first material and the second material comprise at least one of wood, bamboo, polymers, plastics, thermoplastic, cardboard, natural fiber composites, plaster boards, cement boards, magnesium oxide board or fiber reinforced composites.

3. The construction element (100, 200) as claimed in claim 1, wherein the first material and the second material are substantially the same material.

4. The construction element (100, 200) as claimed in claim 1, wherein the fourth material comprises steel or aluminum.

5. The construction element (100, 200) as claimed in claim 1, wherein the web members (132, 232) are spaced at a distance of 50 to 300 mm.

6. The construction element (100) as claimed in claim 1, wherein the pair of brackets (150) comprises:a first ‘L-shaped’ bracket (152) adapted to be coupled to the web member (132) and the front surface (116) of the first flange member (112) by an adhesive, fastener, welding or deformation of the first ‘L-shaped’ bracket (152) which penetrates into the web member (132) and / or into the front surface (116) of the first flange member (112); and a second ‘L-shaped’ bracket (154) adapted to be coupled to the web member (132) and the front surface (116) of the second flange member (114) by an adhesive, fastener, welding or deformation of the second ‘L-shaped’ bracket (154) which penetrates into the web member (132) and / or into the front surface (116) of the second flange member (114), wherein the first ‘L-shaped’ bracket (152) and the second ‘L-shaped’ bracket (154) are configured to couple the web member (132) to the first flange member (112) and the second flange member (114), respectively.

7. The construction element (100) as claimed in claim 6, wherein the third material of the web member (132) comprises at least one of wood, bamboo, polymers, plastics, thermoplastic, cardboard, natural fiber composite, plaster boards, cement boards, magnesium oxide board or fiber reinforced composites.

8. The construction element (100) as claimed in claim 6, wherein the web member (132) comprises a web plate (134) having a length measured along a distance of separation between the first flange member (112) and the second flange member (114), and the length of the web plate (134) is less than the distance of separation between the first flange member (112) and the second flange member (114).

9. The construction element (200) as claimed in claim 1, wherein the pair of brackets (250) comprises: a first coupling bracket (252) configured to be coupled to the front surface (216) of the first flange member (212) by an adhesive, fastener, welding or deformation of the first coupling bracket (252) which penetrates into the front surface (216) of the first flange member (212); and a second coupling bracket (254) configured to be coupled to the front surface (216) of the second flange member (214) by an adhesive, fastener,welding or deformation of the second coupling bracket (254) which penetrates into the front surface (216) of second flange member (214), each of the first coupling bracket (252) and the second coupling bracket (254) defines one or more apertures (258) that facilitate coupling the web member (232) to the first flange member (212) and the second flange member (214).

10. The construction element (200) as claimed in claim 9, wherein the web member (232) comprises a ‘C-shaped’ web member (232) having a plate (234) and first and second walls (236, 238) transverse to the plate (234), the first wall (236) of the web member (232) is adapted to be received in the first coupling bracket (252), and the second wall (238) of the web member (232) is adapted to be received in the second coupling bracket (254) for coupling the web member (232) to the first flange member (212) and the second flange member (214).

11. The construction element (200) as claimed in claim 10, wherein the first wall (236) and the second wall (238) of the web member (232) are configured to snap-fit, weld, fasten, crimp or clinch into the first coupling bracket (252) and the second coupling bracket (254), respectively.

12. The construction element (200) as claimed in claim 11, wherein the first and second walls (236, 238) of the web member (232) and the one or more apertures (258) of the first and second coupling brackets (252, 254) have interference fit or transition fit therebetween.

13. The construction element (200) as claimed in claim 10, wherein the ‘C-shaped’ web member (232) comprises at least one of metal, polymers, plastics or thermoplastics.

14. The construction element (200) as claimed in claim 10, wherein the ‘C-shaped’ web member (232) comprises steel or aluminum.

15. The construction element (200) as claimed in claim 9, wherein the first coupling bracket (252) and the second coupling bracket (254) are made of sheet metal.

16. The construction element (100, 200) as claimed in claim 1, wherein the construction element (100, 200) is a drywall stud.

17. The construction element (100, 200) as claimed in claim 1, wherein the construction element (100, 200) has a ‘C-shaped’, ‘I-shaped’ or ‘H-shaped’ profile.

18. A drywall partition having a framing assembly (10) comprising: a first horizontal framing member (20) fixed to a floor (21); a second horizontal framing member (30) substantially parallel to and spaced from the first horizontal framing member (20) and fixed to a ceiling (31); a plurality of construction elements (100, 200) as claimed in any one of claims 1 to 16, spaced vertically and mounted to the first horizontal framing member (20) at a bottom end thereof and to the second horizontal framing member (30) at a top end thereof; and at least one construction panel (35), wherein each construction element (100, 200) of the plurality of construction elements (100, 200) is mounted such that the first and second flange members (112, 114, 212, 214) of the construction elements (100, 200) abut and support a surface of the construction panel (35), when the at least one construction panel (35) is fixed to one or either side of the framing assembly (10).

19. A method (800) of manufacturing a construction element (100, 200), the method (800) comprising: providing a first flange member (112, 212) comprising a first material and a second flange member (114, 214) comprising a second material, each of the first flange member (112, 212) and the second flange member (114, 214) comprises a front surface (116, 216) facing each other; and coupling the front surface (116, 216) of the first flange member (112, 212) to the front surface (116, 216) of the second flange member (114, 214) bya plurality of web members (130, 230) comprising a third material, wherein each web member (132, 232) of the plurality of web members (130, 230) is coupled to the first flange member (112, 212) and the second flange member (114, 214) by a pair of brackets (150, 250) comprising a fourth material, wherein the first material and the second materials are non-metallic materials, and the fourth material comprises metal.

20. The method (800) as claimed in claim 19, wherein coupling the front surface (116) of the first flange member (112) to the front surface (116) of the second flange member (114) comprises: coupling a first ‘L-shaped’ bracket (152) to a web plate (134) of the web member (132) and to the first flange member (112) by an adhesive, a fastener, welding, clinching or crimping which forms at least one deformation of the first ‘L-shaped’ bracket (152) which penetrates into the web member (132) and / or the front surface (116) of the first flange member (112); and coupling a second ‘L-shaped’ bracket (154) to the web plate (134) of the web member (132) and to the second flange member (114) by an adhesive, fastener, welding, clinching or crimping which forms at least one deformation of the second ‘L-shaped’ bracket (154) which penetrates into the web member (132) and / or the front surface (116) of the second flange member (114).

20. The method (800) as claimed in claim 19, wherein coupling the front surface (216) of the first flange member (212) to the front surface (216) of the second flange member (214) comprises: coupling a first coupling bracket (252) to the front surface (216) of the first flange member (212) by an adhesive, a fastener, welding, clinching or crimping which forms at least one deformation of the first coupling bracket (252) which penetrates into the front surface (216) of the first flange member (212); coupling a second coupling bracket (254) to the front surface (216) of the second flange member (214) by an adhesive, a fastener, welding, clinching or crimping which forms at least one deformation of the second coupling bracket (254) which penetrates into the front surface (216) of the second flange member (214); andinserting a first wall (236) and a second wall (238) of the web member (232) into one or more apertures (258) of the first coupling bracket (252) and the second coupling bracket (254), respectively.

22. The method (800) as claimed in claim 21, wherein inserting the first and second walls (236, 238) of the web member (232) into the one or more apertures (258) of the first and second coupling brackets (252, 254) comprises: snap-fitting the first wall (236) and the second wall (238) of the web member (232) into the first coupling bracket (252) and the second coupling bracket (254), respectively.

23. The method (800) as claimed in claim 19, wherein the first and second materials comprise at least one of wood, bamboo, polymers, plastics, thermoplastic, cardboard, natural fiber composites, plaster board, cement board, magnesium oxide board or fiber reinforced composites; the third material comprises at least one of wood, bamboo, polymers, plastics, thermoplastic, cardboard, natural fiber composite, plaster boards, cement board, magnesium oxide board, fiber reinforced composites, steel, or aluminum; and the fourth material comprises at least one of metal, plastics or thermoplastics.

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