WALL ASSEMBLY, COMPONENTS, AND METHODS FOR MANUFACTURE AND INSTALLATION THEREOF

Abstract

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

Description

FIELD OF THE INVENTION

The present invention generally relates to wall assemblies and components thereof for mounting a wall in a residential or commercial building space, as well as methods for manufacturing components of the wall assembly, and methods of installing the wall assembly in a residential or commercial building space.

BACKGROUND

The installation of walls in a residential or commercial building space can typically involve a time-consuming and detailed manual labor process, which may take several hours, and even days, to complete, using the skills of relatively highly-trained and specialized workers with the technical proficiency to complete the intensive and painstaking steps. Typical steps in a wall installation process can include, for example, an initial step of forming a wall frame including supporting studs, installing electrical and plumbing lines in the frame, fitting insulation to the frame, hanging multiple sheets of drywall, typically gypsum-containing drywall sheets, on the supporting studs of the wall frame, and carrying out the numerous and times-consuming steps needed to finish the drywall to provide a visually appealing wall with appropriate characteristics. For example, in addition to carefully aligning and hanging individual drywall sheets at appropriate positions on the supporting studs of the wall frame, the drywall may be finished to remove the appearance of cracks or gaps that exist between the drywall sheets and/or at corners of the wall, such as via the labor intensive steps of taping, prepping for and applying joint compound to any gaps and/or other irregularities, followed by sanding and priming the drywall. It is typically only after the wall has thus been installed and finished to conceal any gaps or other irregularities resulting from the hanging of the drywall sheets that the wall can be painted or another finish such as wallpaper or finish board can be applied.

A problem with such conventional techniques is that the process tends to be expensive and time consuming, which reduces the efficiency with which commercial and residential spaces can be built. Also, the conventional techniques require that installation and any finishing techniques be performed in situ on the finished wall, meaning that any special finishing processes performed to enhance the aesthetics of the wall must be performed at each of the individual locations where the walls are installed. It can also be the case that walls installed via conventional installation techniques may be lacking in qualities such as sufficiently high fire resistance, UV resistance, moisture resistance, pest resistance, acoustic dampening, compressive and/or tensile strength, and other properties.

Accordingly, there remains a need for wall installation techniques and materials that are relatively time and cost efficient. There also remains a need for wall installation techniques and materials that provide for improved wall aesthetics, and improved properties such as fire resistance, moisture resistance, and other desirable properties.

SUMMARY

Aspects of the disclosure relate to a wall for mounting in a residential or commercial building space, the wall having a wall body having an upper region configured to be laterally supported at one or more upper surfaces thereof to maintain the wall body in a substantially upright position, and a lower region configured to be laterally supported at one or more lower surfaces thereof to maintain the wall body in a substantially upright position. The wall body has a unitary body having a molded material.

According to one aspect, a lateral support for a wall assembly for mounting a wall in a commercial or residential building space is provided. The lateral support includes an engagement portion configured to engage a surface of an upper or lower region of a wall body. The lateral support can include a unitary body having a molded material, and the lateral support comprising a fire rating according to International Building Code (IBC) Chapter 7 of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours.

Further aspects of the disclosure provide a wall assembly for mounting a wall in a residential or commercial building space. The wall assembly has a wall body having an upper region configured to be laterally supported at one or more upper surfaces thereof to maintain the wall body in a substantially upright position, and a lower region configured to be laterally supported at one or more lower surfaces thereof to maintain the wall body in a substantially upright position. The wall assembly further has at least one lateral support comprising an engagement portion configured to engage the one or more upper surfaces of the upper region or one or more lower surfaces of the lower region of the wall body. The wall body has a unitary body having a molded material. The wall assembly having the wall as mounted with the at least one lateral support in a residential or commercial building comprises a fire rating according to International Building Code (IBC) Chapter 7 of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours.

In yet another aspect of the disclosure, a method of manufacturing a piece of a wall assembly for mounting a wall in a residential or commercial space is provided. The method includes providing a mold in the shape of the piece, providing a mixture of MgO, MgCl₂ and water in the mold, curing the mixture to form a material by the reaction of MgO, MgCl₂ and water, and optionally, machining one or more channels, grooves, notches, and/or indentations into the piece.

In yet another aspect, a method of installing a wall using a wall assembly for mounting the wall in a residential or commercial space is provided. The method includes mounting at least one lateral support within the residential or commercial space, providing a wall body having upper and lower regions, and engaging one or more of an upper or lower surface of the upper or lower region of the wall body with the at least one lateral support. The at least one lateral support engages the wall body at one or more of the upper and lower regions to support the wall body in a substantially upright position in the residential or commercial space.

In yet another aspect, a wall board for a residential or commercial building space is provided. The wall board includes a tensile strength layer comprising a mesh material, and a magnesium-containing layer, wherein a surface of the magnesium-containing layer is optionally textured to provide a textured surface of the wall board.

According to yet another embodiment, an exterior wall for an exterior of a residential or commercial building is provided. The exterior wall includes a wall body having a first side adapted to be exposed to an exterior of the residential or commercial building, and a second opposing side facing an interior space of the commercial building. The wall body has an upper region configured to be connected to one or more roof joists of the residential or commercial building, and a lower region configured to be connected to a foundation of the residential or commercial building. The wall body has a unitary body made of a molded material, the unitary body extending between and including the upper and lower regions.

These and other aspects of the invention are further disclosed in the detailed description and examples which follow.

BRIEF DESCRIPTION OF THE DRAWINGS

The following drawings form part of the present specification and are included to further demonstrate certain aspects of the present invention. The invention may be better understood by reference to one or more of these drawings in combination with the detailed description of specific embodiments presented herein.

FIG. 1A is a perspective view of an embodiment of a wall for mounting in a residential or commercial building space, according to aspects of the invention.

FIG. 1B is a perspective view of embodiments of lateral supports for supporting a wall in a residential or commercial building space, according to aspects of the invention.

FIG. 1C is a perspective view of an embodiment of a wall assembly including a wall and lateral supports, for mounting the wall in a residential or commercial building space, according to aspects of the invention.

FIGS. 2A-2C, 3A-3C and 4A-4C are embodiments of wall assemblies for mounting a wall in a residential or commercial building space, according to aspects of the invention.

FIGS. 5A-5C are embodiments of a wall for mounting in a residential or commercial space, according to aspects of the invention.

FIG. 6A is an embodiment of a wall board having a magnesium containing material, with a removable substrate, according to aspects of the invention.

FIG. 6B is an embodiment of a natural fiber mesh, according to aspects of the invention.

DETAILED DESCRIPTION OF THE INVENTION

Aspects of the disclosure relate to a wall assembly for mounting a wall in a residential or commercial building space, as well as component thereof, including walls and upper and/or lower lateral supports, as well as methods of installing the wall with the wall assembly, methods of manufacturing components of the wall assembly, as well as a finished wall product comprising the wall assembly.

According to one aspect, referring to FIGS. 1A, 1B and 1C, a wall assembly 100 comprises a wall 102 having a wall body 104, and at least one lateral support 106 to support the wall body 104. According to one embodiment, the wall 102 comprises a wall body 104 having an upper region 108a configured to be laterally supported at one or more upper surfaces 110a of the upper region 108a, such as to maintain the wall body 104 in a substantially upright position. In yet another embodiment, the wall 102 comprises a wall body 104 having a lower region 108b configured to be laterally supported at one or more lower surfaces 110b of the lower region 108b, such as to maintain the wall body 104 in a substantially upright position. Referring to FIGS. 1B-1C, in one embodiment the at least one lateral support 106 of the wall assembly 100 may comprise, for example, one or more of an upper lateral support 106a configured to support at least a portion of the upper region 108a of the wall body 104, and a lower lateral support 106b configured to support at least a portion of the lower region 108b of the wall body. The at least one lateral support 106 may thus engage the wall body 104 to align and position the wall body, for example to provide a substantially upright wall 102 mounted in a commercial or residential building space.

In one embodiment, the at least one lateral support 106 comprises one or more of an upper and lower lateral support 106a,106b that provide the primary support to maintain the wall body 104 in the substantially upright position. That is, in certain aspects the upper and/or lower lateral support 106a,b may together and/or alone primarily support the wall body in the substantially upright position, without requiring a further lateral support at an intermediate point between the upper and lower regions 108a, 108b of the wall body. For example, in one embodiment one or more upper lateral supports 106a may primarily support the wall body, whereas in another embodiment one or more lower lateral supports 106b may primarily support the wall body, and in yet another embodiment, one or more upper and lower lateral supports 106a,b may cooperate to primarily support the wall body in the substantially upright position. In one embodiment, the wall body is supported substantially without a lateral support disposed between the upper and lower lateral supports 106a, 106b, that is without a lateral support at a mid-region along the vertical height of the wall body, although in certain embodiments a further lateral support at a mid-region could be provided. According to certain aspects, by primarily supporting the wall body with at least one of the upper and lower lateral supports 106a, 106b, the mounting of the wall in the residential or commercial building space can be greatly simplified to improve the efficiency and reduce the cost of wall installation.

In one embodiment, the wall assembly 100 comprises a wall body 104 that is a unitary body, such as a unitary body formed of a molded material. By “unitary body” it is meant that the wall body 104 is formed of a single piece, as opposed to being formed of multiple segments. That is, the wall body 104 may form a single, unitary body of material that is can be supported by the at least one lateral support 106 to provide a mounted wall in a substantially upright position. In one embodiment, the wall body 104 comprises a unitary body that is configured to extend between upper and lower lateral supports 106a, 106b. In another embodiment, the wall body 104 comprises a unitary body that is capable of extending substantially from a floor to a ceiling of a residential or commercial building space, or may otherwise have a sufficient vertical height such that only a single wall body is required to traverse the vertical dimension of the commercial or residential building space. For example, in one embodiment, the wall body may be a unitary body having a vertical height H as defined between top and bottom sides 112a, 112b of the wall body 104, of at least 4 feet, such as at least 6 feet, at least 8 feet, and/or at least 10 feet. According to yet another embodiment, the wall 102 may comprise one or a plurality of wall bodies 104 that are joined together side by side to cover a horizontal dimension of the residential or commercial building space. For example, the wall 102 can comprise one or more wall bodies 104 having a width Was defined between opposing lateral sides 114a, 114b of the wall body 104 of at least 1 foot, at least 2 feet, at least 4 feet, and/or at least 6 feet. That is, the wall 102 can comprise one or more wall bodies 104 having lateral sides 114a, 114b that are adjacent and/or abut one another to form the horizontal dimension of the wall 102.

According to one embodiment, one or more of the wall assembly 100, wall body 102, and the at least one lateral support 106 are configured to provide an enhanced fire resistance and/or fire safety. For example, in one embodiment, at least one of wall body 102 and at least one lateral support 106 can comprise a fire rating according to International Building Code (IBC) Chapter 7 of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours. For example, in one embodiment, at least one of the wall body 102 and at least one lateral support 106 can comprise a fire rating according to Underwriter Laboratories (UL) standard number 263 (Standard for Fire Tests of Building Construction and Materials) of at least 1 hour, at least 2 hours, at least 3 hours, and/or even at least 4 hours. In another embodiment, the wall assembly 100 and/or finished wall comprising the wall assembly 100 as mounted in a residential or commercial building space can comprise a fire rating according to International Building Code (IBC) Chapter 7 of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours, and/or a fire rating according to Underwriter Laboratories (UL) standard number 263 (Standard for Fire Tests of Building Construction and Materials) of at least 1 hour, at least 2 hours, at least 3 hours, and/or even at least 4 hours. The enhanced fire rating of the wall assembly 100 and/or components thereof can provide for enhanced safety of the residential and/or commercial buildings in which the wall assembly is used. According to certain aspects, and without limitation, the enhanced fire safety can be imparted by the materials used to form the wall assembly and/or components thereof, and the configuration of the wall assembly 100 can also promote fire resistance.

The wall assembly and/or components thereof may further comprise other advantages, such as by virtue of the materials used to form the wall assembly and/or components thereof. In one embodiment, at least one of the components and/or the entirety of the wall assembly 100 can be formed from a building material comprising a magnesium-containing material. For example, at least one of the wall body 104, and at least one lateral support 106 can be formed from a building material comprising a magnesium-containing material. In one embodiment, the building material comprises a material having one or more of magnesium oxide, magnesium chloride, and magnesium oxychloride, formed from the reaction of MgO, MgCl₂ and water. For example, the material can comprise a magnesium oxy-chloride material. In yet another embodiment, the building material can comprise a material that is formed by combining MgO with MgCl₂ in a weight ratio that is sufficient to provide for a chemical reaction of MgO and MgCl2 in a curing process that forms a final bonded solid product. According to one embodiment, the MgO-containing material may impart fire resistance because it is a natural fire-extinguishing agent, and can inhibit combustion, as well as thermal insulation.

According to yet another embodiment, at least one and even all of the components for the wall assembly 100 can comprise a building material that is other than an MgO-containing material, or can comprise components containing an MgO-containing material in combination with components that comprise a material other than the MgO-containing material, according to a desired combination. That is, according to one embodiment, the wall assembly 100 and/or components thereof comprise the overall profile and/or structure shapes and/or functions described herein, independently of a composition of the wall assembly 100 or components thereof. Furthermore, while in certain embodiments, components of the wall assembly may comprise a fire-resistance material, in yet another embodiment, one or more components of the wall assembly 100 comprise materials that have little or no fire resistance, either in combination with other components that do have substantial fire-resistance, or the entire wall assembly 100 may be made of materials having little fire-resistance, for example when the wall assembly is to be used in an environment having low fire risk, or when a decorative material having low fire-resistance is to be used as a component of the wall assembly, among other embodiments. For example, in one embodiment, in a case where a risk of fire is low, materials may be used for the components of the wall assembly that are relatively more cost-effective than fire-resistant materials, such as relatively inexpensive metal tracks instead of more highly fire-resistant materials. That is, according to one embodiment, the wall assembly 100 and/or components thereof comprise the overall profile and/or structure shapes and/or functions described herein, independently of whether or not a fire-resistant composition of the wall assembly 100 or components thereof is provided.

According to yet another embodiment, at least one and even all of the components for the wall assembly 100 can comprise a building material that has voids and/or spaces therein, such as for example those formed by addition of a foaming agent during preparation of the building material. In one embodiment, one or more of the components or even all of the components comprises a plurality of voids therein, such that the density of the component is sufficiently low to allow it to be buoyant when immersed in water. Furthermore, in one embodiment, the foaming agent comprises less than 10%, less than 8%, less than 6%, less than 5%, and/or less than 3% benzene, formaldehyde or other carcinogen. In one embodiment, the foaming agent comprises substantially no benzene, formaldehyde or other carcinogen. In one embodiment, component is made from the building material and poured as a slurry mixture. A foaming agent can be used in the slurry to create air bubbles in the mixture. This forms numerous singular micro bubbles, so the resulting formed component is relatively light.

In one embodiment, one or more components for the wall assembly 100 comprise a tensile strength material to impart increased strength to the component. For example, the tensile strength material can comprise any one or more of horse hair, carbon fiber, type 1 collagen fibrils, bamboo mesh, natural fiber mesh, burlap mesh, wood fiber mesh, wood chips, natural fibers, plant fibers, wood fibers, cellulose, PVA fibers, acrylic fibers, AR glass fiber, alpha gypsum additive, polymer modified gypsum, pozzolans, fumed silica, metakaolin, liquid polymers including but not limited to acrylic emulsion polymer, powdered polymers, calcium aluminum sulfate crystals, portland cement, plasticizers, epoxies including epoxy putties, casting epoxies, composite epoxies, PVA fibers, fiberglass mesh, alkali resistant glass fibers, and alkali resistant scrim. In one embodiment, the mesh material comprises a woven bamboo mesh, as shown for example in FIG. 6B, having interleaving bamboo fibers, the bamboo fibers having a diameter of less than 1 about 1 cm, 0.5 cm, 0.05 cm, and even less than 1 mm. In another embodiment, the interleaving bamboo fibers have first fibers extending in a first primary direction, and second fibers extending primarily in a second direction, the first and second fibers being interwoven with one another to form a matrix of the first and second fibers, and wherein the bamboo mesh extends across at least 50%, at least 75%, at least 80% and event at least 95% of the area of the wall body.

Furthermore, according to one embodiment, the building material comprises a higher content by weight of the magnesium-containing material than gypsum, and/or can comprise a higher content by weight of the magnesium-containing material than concrete, and/or a higher content by weight of the magnesium-containing material than cement. That is, in one embodiment, the building material can comprise a higher content by weight of magnesium-containing material that any other single material in the building material.

The wall assembly 100 and/or components thereof may provide certain advantages. For example, one or more and even all components of the wall assembly as well as the wall assembly itself, can comprise at least one of moisture resistance, UV resistance, termite resistance, acoustic dampening, a relatively low coefficient of expansion and/or contraction, and a relatively high compressive strength, tensile strength, and/or resistance to bending and impact. With respect to moisture-resistance, the components and/or assembly may be stable in water, and moisture-resistance agents can also be added to further improve resistance to water and moisture. Also, good sound insulation may be provided in certain aspects by providing the voids and/or pores in the building materials, to block the passage of sound. The materials may also allow for simple cutting with a wood saw, and is capable of holding nails and screws, as well as adhesives, and can provide fast installation. The inorganic magnesium-containing material is also resistant to pests such as termites. Furthermore, in one embodiment the building material used for the components for the wall assembly has a good thermal conductivity, such as a thermal conductivity of no more than 0.040 W/m·K, no more than 0.036 W/m·K and/or no more than 0.04 W/m·K.

Referring again to FIGS. 1A, 1B, and 1C, in one embodiment the wall body 104 for the wall assembly 100 comprises one or more features formed in an upper surface 110a of the upper region 108a of the wall body that are configured to engage a lateral support 106. For example, the one or more features can comprise one or more of a notch, groove, indentation and/or channel formed in the upper surface of the upper region that is configured to engage a lateral support 106. In the embodiment as shown in FIG. 1A, the wall body 104 comprises inner and outer sides 116a, 116b, with the inner side of the wall body having at least one channel 118 formed in a section of the inner surface located in the upper region of the wall body, the at least one channel being configured to engage with a lateral support 106. In one embodiment, the at least one channel 118 extends along at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, at least 95%, and/or substantially entirely along a horizontal length of the wall body. In yet another embodiment, the wall body comprises an overhang 120 that is configured to engage the lateral support, and that hangs at least partly over an opening of the at least one channel 118 formed in the wall body, and wherein the overhang extends along at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, at least 95%, and/or substantially entirely along a horizontal length of the wall body.

Referring to FIGS. 1B and 1C, in one embodiment at least one lateral support 106 is provided that comprises an engagement portion that is configured to engage and support one or more of the upper and lower regions 108a, 108b of the wall body 104, to support the wall body in a substantially upright position. In the embodiments as shown in FIGS. 1B and 1C, upper and lower lateral supports are provided 106a, b, that cooperatively engage and at least partly support the wall body in an upright position in the residential or commercial building space. In one embodiment, the upper lateral support 106a can be attached to a ceiling 125 or upper wall of the residential or commercial building space, although in some embodiments the upper lateral support 106a can be suspended below a ceiling or upper wall. The lower lateral support 106b can be positioned along a floor 127 or base of the residential or commercial building space. The upper lateral support 106a comprises an upper track having an upper longitudinal beam portion 120a and a wall engagement portion 122. The wall engagement portion 122 can comprise a projection 124 that extends outwardly from a periphery of the upper longitudinal beam portion 120 along at least a part of a length of the upper longitudinal beam portion 120.

According to at least one embodiment, the wall engagement portion 122 is configured to engage the channel 118 of the wall body 104. For example, the projection 124 of the wall engagement portion 122 of the upper track can comprises a ledge extending outwardly from the upper longitudinal beam portion, and may further comprise an upturned lip 128 at a periphery of the ledge that is configured to engage the wall body 104. In one embodiment, the projection of the wall body engagement portion extends along at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, at least 95%, and/or substantially entirely along a length of the upper longitudinal beam portion. According to yet another embodiment, the wall body is configured to be attached to one or more lateral supports via an adhesive, and/or the one or more lateral supports are configured to be attached to a structure such as a ceiling or floor of the residential or commercial building space via an adhesive. In yet another embodiment, wherein the wall body is configured to be attached to one or more lateral supports without an adhesive.

Referring to FIG. 1C, in one embodiment, the projection 124 of the wall engagement portion 122 is configured to interlock with the at least one channel 118 formed in the wall body. For example, the projection 124 of the wall engagement portion 124 can be configured to interlock with the at least one channel 118 formed in the wall body 104 via a tongue-in-groove mechanism. In yet another embodiment, the wall body 104 comprises interior channel surfaces defining the at least one channel, and the projection 124 of the wall engagement portion 122 is configured to engage one or more interior channel surfaces of the at least one channel 118 in the wall body. Furthermore, referring to FIG. 1C, in one embodiment the wall body comprises at least one overhang that hangs at least partly over an opening of the at least one channel formed in the wall body, the overhang 130 extending along a least a portion of a length of the channel 118, and the upper track comprises a projection 124 of the wall engagement portion 122 having a ledge extending outwardly from the upper longitudinal beam portion 120a, and an upturned lip 128 at a periphery of the ledge that is configured to engage the wall body 104, wherein an interior surface of the upturned lip, an upper surface of the ledge, and peripheral surface of the upper longitudinal beam portion cooperate to form a longitudinal groove 132 in the upper track, and the projection 124 is configured to engage the at least one channel 118 such that an upper surface of the at least one channel 118 rests against an upper surface of the upturned lip 128, and the overhang 130 extends at least partly into the groove 132 formed in the upper track between the upturned lip of the ledge and peripheral surface of the upper longitudinal beam portion.

In the embodiment as shown in FIGS. 1B and 1C, the lower lateral support 106b comprises a lower track comprising a lower longitudinal beam portion 120b and a support portion 134 configured to at least partly support the lower region of wall body. For example, as shown in FIGS. 1B and 1C, the support portion 134 can engage a notch 136 formed in the lower region 108b of the wall body 104, and may comprise a complementary shape to engage the notch 136 and support the wall body. In the embodiment as shown in FIG. 1C, the notch 136 extends along at least a portion, and optionally the entire horizontal width, of the wall body, and engages a stepped support portion 134 of the lower lateral support 106b.

In one embodiment, the wall assembly 100 comprises only an upper lateral support 106a or only a lower lateral support 106b, but not both. In other embodiments, both upper and lower supports are provided. In yet another embodiment, the upper and/or lower lateral supports 106a, 106b may be configured to support a plurality of wall bodies 104 thereon, such as for example when a plurality of wall bodies are engaged on an upper and/or lower lateral support 106a, 106b comprising a lengthy track that is configured to engage multiple wall bodies mounted side by side along the length of the track. Conversely, in another embodiment, each wall body 104 may be configured to be supported by a plurality of upper lateral supports 106a and/or lower lateral supports 106b, such as when a plurality of individual lateral supports are provided to support the upper and/or lower regions of a single wall body. Combinations of lateral supports 106 and wall bodies, including various different mechanisms for engaging and supporting the wall body 104, are also included herein. Furthermore, in the embodiments as shown in FIGS. 1B-1C, the upper and lower supports 106a, 106b are configured to support wall bodies mounted on opposing sides of the supports 106a, 106b, and may optionally provide a space in between such opposing wall bodies where various components such as wiring, insulation, electrical components, etc., may be provided. According to suitability, a plurality of lateral supports 106 may be provided to allow for a support structure for several wall bodies 104 across a residential or commercial building space, so as to form a final wall having a desired total horizontal width across the space.

FIGS. 2A-2C, 3A-3C and 4A-4C demonstrate further embodiments of a wall assembly 100 and components therefore. In FIGS. 2A-2C, various “mechanical” means of providing support for the wall body 104 are demonstrated. For example, referring to FIG. 2A, in one embodiment, the wall body 104 and/or upper lateral support 106a can comprise a mechanical mechanism 138 configured to connect the upper surface 110a of the upper region 108a of the wall body 104 to the upper lateral support 106a, and/or the same and/or similar mechanical mechanism 138 can be provided to connect the lower surface 110b of the lower region 108b of the wall body 104 to the lower lateral support 106b. The mechanical mechanism 138 can comprise, for example, a clip, hasp, catch, hook, buckle, or other fastener, and may further connect to a connector extending from an upper region 108a of the wall body 104. Referring to the example as shown in FIG. 2B, the mechanical means as shown is similar to that in FIGS. 1A-1B, but the groove 132 formed by the ledge and upturned lip 128 has an angle that tightens towards the surface of the ledge (e.g., extends upwardly from the ledge at an angle), and thus can in certain embodiments provide an even more secure fit of the overhang 130 of the wall body in the groove 132. In the embodiment as shown in FIG. 2C, the mechanical means can comprise a flexible and/or movable panel 140 that is capable of catching at least a portion of the upper region 108a of the wall body and retaining it adjacent the body of the lateral support. For example, the panel 140 can comprise a unidirectional clip that is capable of flexing in one direction to allow a portion of the wall body to pass the clip, but does not flex in the opposite direction such that the wall body is retained by the clip adjacent the body of the lateral support 106. Furthermore, while the embodiments as depicted in FIGS. 2A-2C show upper lateral supports 106a, the mechanical mechanisms described and shown for the upper lateral supports 106a can also be provided as a part of a lower lateral support 106b to support the lower region 108b of the wall body 104. Alternatively, the lateral support structures 2A-2C can also be provided in combination with other lateral support structures.

In the embodiments as shown in FIGS. 2A-2C, the lateral support 106 is configured to laterally support a wall body on a single side of the lateral support. However, in the embodiments as shown in FIGS. 1A-1C, the lateral support 106 is configured to support a wall body on both opposing sides of the lateral support 106. As yet another option, lateral supports that support a wall body on only a single side can be provide on opposing sides of one another, such that a first wall body is supported by a first lateral support on a first side, and a second wall body is supported by a second lateral support on a second side that is opposing the first side. Furthermore, in the embodiments as shown in FIGS. 3A-3C, first and second lateral supports 106 are provided to support a single wall body 104 therebetween. In the embodiments as shown in FIGS. 4A-4C, a single lateral support 106 is provided to support a single wall body 104, with the single wall body having opposing surfaces that face out to the residential building space.

Referring to FIGS. 3A-3C, embodiments are shown having first and second upper lateral supports 106a1, 106a2 that are configured to cooperatively laterally support an upper region 108a of the wall body 104. Furthermore, the first and second upper lateral supports 106a1, 106a2 are configured to contact opposing upper surfaces 110a1, 110a2 of the wall body 104 to support the wall body in the substantially upright position. In the embodiment as shown in FIG. 3A, a channel 142 is formed in the ceiling 125 of the residential or commercial building space, and the upper region of the wall body 104 is inserted into the channel, such that the adjacent ceiling portions serve as the first and second upper lateral supports 106a1, 106a2. In the embodiment as shown in FIG. 3B, an upper lateral support 106a is provided and attached to the ceiling 125, where the upper lateral support 106a comprises first and second upper lateral supports 106a1, 106a2 that cooperatively engage the opposing upper surfaces 110a1 and 110a2 of the wall body. In this embodiment, the upper lateral supports 106a1 and 106a2 comprise a longitudinal beam portion 120a which may optionally be attached to a ceiling 125, and a support portion 144 that extends downwardly from the longitudinal beam portion and along a portion of the upper region 108a of the wall body, to cooperatively hold the upper region between the upper lateral supports 106a1, 106a2. In the embodiment as shown in FIG. 3C, the upper lateral supports 106a1 and 106a2 similarly hold an upper region 108a of the wall body 104 therebetween, but do so between longitudinal beam portions and without the separate support region of FIG. 3B. Furthermore, as with FIGS. 2A-2C discussed above, the structures described and shown in FIGS. 3A-3C for the upper lateral supports 106a can also be provided as a part of a lower lateral support 106b to support the lower region 108b of the wall body 104, with the structures simply being inverted to accommodate support of the lower region 108b, as opposed to upper region 108a, of the wall body 104. Alternatively, the lateral support structures 3A-3C can also be provided in combination with other lateral support structures.

In the embodiments as shown in FIGS. 4A-4C, a single lateral support structure 106 is provided to support a wall body 104. In the embodiments as shown in FIGS. 4A-4B, the lateral support 106 braces opposing inner and outer surfaces 110a1, 110a2 at the upper region 108a of the wall body 104. That is, in the embodiment as shown in FIG. 4A, the thickness of the wall body 104 as measured between the opposing inner and outer surface 110a1, 110a2 is configured to be accommodated by the lateral support, such as via insertion into a longitudinal channel 146 formed in a lower surface of the lateral support 106. In the embodiment as shown in FIG. 4B, a thickness of the upper region 108a of the wall body is similarly inserted into a channel 14 formed in a lower surface of the lateral support 106. However, in this embodiment, the lateral support does not accommodate an entire thickness between the opposing wall surfaces in the channel, but instead the wall body comprises a cap portion 148 at a top of the wall body that is thinner than a remainder of the wall body thickness, and that is sized to fit in the channel 146. In this embodiment, the portions of the lateral support 106 about channel opening may abut and/or be adjacent to an upper surface of the wall body that is stepped down from the cap portion 148. In FIG. 4C, the lateral support 106 comprises an upper longitudinal beam portion 120a, and the wall body 104 has a channel 150 formed in a top 112a thereof, with the thickness of the longitudinal beam portion being such that it can be inserted into and accommodated in the channel 150. Furthermore, as with FIGS. 2A-2C and 3A-3C discussed above, the structures described and shown in FIGS. 4A-4C for the upper lateral supports 106a can also be provided as a part of a lower lateral support 106b to support the lower region 108b of the wall body 104, with the structures simply being inverted to accommodate support of the lower region 108b, as opposed to upper region 108a, of the wall body 104. Alternatively, the lateral support structures 4A-4C can also be provided in combination with other lateral support structures.

The embodiments of FIGS. 5A-5C depict wall bodies 104 having different configurations. In the embodiment as shown in FIG. 5A, the wall body 104 comprises one or more compartments and/or recesses 152 formed therein and optionally having one or more panels 154 to at least partially cover said one or more compartments and/or recesses. For example, the one or more compartments and/or recesses 152 may be provided to accommodate electrical wiring, plumbing, and/or other structures that may be stored and/or concealed therein. In one embodiment, the one or more compartments and/or recesses has a horizontal length that extends substantially across a horizontal length of the wall body between first and second opposing lateral sides of the wall body, for example to allow access and/or storage of one or more of electrical wiring and/or plumbing traversing the entire lateral length of the wall body. In yet another embodiment, the panel 154 can comprise a wall board having a layer of magnesium-containing material on a substrate, as is described in further detail herein.

According to yet another embodiment, the wall body can comprise substantially 90° corners at one or more and even both of the upper and lower regions. In yet another embodiment, the wall body comprises at least one of opposing back surface and front surfaces that is substantially planar, and/or does not comprise any of grooves, channels, recesses and/or compartments formed therein.

In the embodiment as shown in FIG. 5B, the wall body 104a is configured to cooperate with a second wall body 104b to form a finished wall upon completion of mounting of the wall, and optionally the finished wall can comprise a space between the first and second wall bodies 104a, 104b, and/or the wall bodies 104a, 104b may be flush with one another. The first and second wall bodies 104a, 104b thus form opposing wall portions that provide the opposing sides of the finished wall. In one embodiment, the first and second wall bodies 104a, 104b are spaced apart from one another to provide a space therebetween that is of adequate size to accommodate electrical wiring, plumbing, insulation, or other structures suitable for storing within and/or routing through walls. In the embodiment as shown in FIG. 5C, the wall body 104 optionally comprises one or more conduits 156 embedded therein, and extending from a first side of the wall body to a second side of the wall body, such as from a top 112a to a bottom 112b of the wall body 104. The wall bodies 104 as shown in the embodiments of FIGS. 5A-5C may be provided as a part of a wall assembly 100 with a lateral support 106 such as any of those described herein, and/or depicted in any of FIGS. 1A-1C, 2A-2C, 3A-3C and/or 4A-4C.

According to a further aspect, a method of manufacturing a component of a wall assembly for mounting a wall in a residential or commercial building space is provided. In one embodiment, the method comprises providing a mold in the shape of the component to be formed, such as a wall body or lateral support. The method further comprises providing a mixture of MgO, MgCl₂ and water in the mold, optionally with any of the other additives described above, such as a foaming agent or tensile strength agent. The mixture can be cured in the mold, for example via application of heat, and/or UV, as well as by other methods, to form a molded building material by the reaction of MgO, MgCl₂ and water. Once the molded building material is formed, the material may optionally be machined or otherwise worked to form one or more channels, grooves, notches and/or indentations therein, for example to provide features that are capable of engaging a wall body to a lateral support, and including any of the features described herein. For example, once the molded building material has been prepared in the shape of the wall body 104, one or more channels can be machined therein to provide the structure as shown in the embodiment depicted in FIGS. 1A-1C. Furthermore, for a molded building material prepared in the shape of an upper lateral support, one or more grooves could be machined therein as in the embodiment as shown in FIGS. 1A-1C. According to one aspect, the shape of the mold in which the mixture is cured determines the shape of the resulting component. For example, for a mold having a shape corresponding to a wall body, the resulting molded component will have a wall body shape, whereas for a mold in the shape of a lateral support, the resulting molded component will have a lateral support shape.

In one embodiment, the molded material thus prepared by curing the mixture of building materials in the mold in the shape of the intended component thus provides a component that is a unitary body, in that the molded material is in the shape of the intended component. For example, a wall body comprising a unitary body may be provided, and a lateral support comprising a unitary body may be provided. In the case of the wall body, the unitary body may have a shape and size that is adequate for the unitary body to extend from either a lower lateral support and/or floor, to an upper lateral support and/or ceiling, as a single piece. That is, the vertical height of the wall body may correspond to a single piece, as opposed to multiple pieces. In some embodiments, the wall body may comprise a unitary body having dimensions that span the vertical height, but may also have additional components such as panels or compartments added to the unitary body that spans the vertical distance, for example as shown in FIG. 5A.

Furthermore, in one embodiment, the molded component can be further worked to provide a final finish to the component. For example, one or more surfaces of the component can be finished to provide at least one surface that is textured, patterned, molded, painted, sculpted and/or wall-papered. In one embodiment, for a component comprising a wall body, at least one surface of the wall body can be finished to provide an aesthetically pleasing wall surface that is viewable upon installation. The lateral supports can also be finished and/or decorated, and may for example be finished with trim or crown molding. According to one aspect, as the wall body and lateral supports can be finished before installation, the finishing process can be performed with greater accuracy and efficiency, thus increasing the capability of providing aesthetically attractive wall and wall assembly surfaces, and well as increasing the ability to reproduce and scale up the production of specific finishes.

In yet another embodiment, a method of installing a wall using a wall assembly for mounting the wall in a residential or commercial space is provided. The method can generally comprise mounting at least one lateral support within the residential or commercial space, providing a wall body having upper and lower regions, and engaging one or more of an upper or lower surface of the upper or lower region of the wall body with the at least one lateral support, such that the at least one lateral support engages the wall body at one or more of the upper and lower regions to support the wall body in a substantially upright position in the residential or commercial space. For example, in one embodiment, the method can comprise mounting at least one upper lateral support towards a top region and/or to the ceiling of the residential or commercial space, and mounting at least one lower lateral support towards a bottom region and or on the floor of the residential or commercial space, and engaging the upper and lower regions of the wall body with the upper and lower lateral supports. In one embodiment, for example as shown in FIGS. 1A-1C, the method can comprise engaging the wall body with the at least one lateral support substantially without requiring an adhesive and/or metal connector therebetween. Furthermore, the method can comprise mounting a plurality of wall bodies using the at least one lateral support and/or a plurality of lateral supports, such as either side-by-side or on opposing sides of the at least one lateral support and/or plurality of lateral supports.

In one embodiment for installing a wall using the wall assembly corresponding to the embodiment shown in FIGS. 1A-1C, the method can comprise attaching an upper track to a ceiling of the residential or commercial building space, the upper track comprising an upper longitudinal beam portion and a wall engagement portion, the wall engagement portion comprising a projection that extends outwardly from a periphery of the upper longitudinal beam portion along at least a part of a length of the upper longitudinal beam portion. The method further comprises attaching a lower track to a floor of the residential or commercial building space, the lower track comprising a lower longitudinal beam portion and a support portion configured to at least partly support a lower region of wall body. The method further comprises providing a wall comprising a wall body having an upper region and a lower region, and inner side and outer sides with opposing inner and outer side surfaces, the inner side of the wall body having at least one channel formed in a section of the inner surface located in the upper region of the wall body, the at least one channel being configured to engage with the wall body engagement portion of the upper track, and engaging the wall body engagement portion of the upper track with the at least one channel in the upper region of the wall body. The method comprises positioning the lower region wall of the body with respect to the support portion of the lower track such that the upper track and lower track cooperatively engage and at least partly support the wall body in an upright position in the residential or commercial building space.

According to yet another embodiment, a wall board 300 for a residential or commercial building space can be provided, that includes the magnesium containing material, as shown for example in FIG. 6A. The wall board 300 can serve as a part of a finished wall, and/or may substitute for and/or cooperate with the wall body described above. For example, the wall board 300 may be used to form the panel 154 described above that covers a compartment and/or recess in the wall body. In one embodiment, the wall board 300 comprises, a tensile strength layer 306 comprising a mesh material, and a magnesium-containing layer 304, and/or may comprise multiple such tensile strength layers 306 and magnesium-containing layers 304 in a multi-layer structure, optionally with other layers. In one embodiment, a surface of the magnesium-containing layer is optionally textured to provide a textured surface of the wall board. For example, in one embodiment the surface of the magnesium containing layer 304 is textured by layering the magnesium-containing material and tensile strength material on a removable substrate 302 having a textured surface, and removing the removable substrate after the layer of magnesium containing material has at least partially dried on the surface, thereby transferring any texture of the removable substrate 302 to the surface of the layer 304 of magnesium-containing material that was in contact with the removable substrate. In one embodiment, the removable substrate layer comprises one or more of a PVC plate, urethane-epoxy plate, rubber plate, silicone plate, a metal plate, and a ceramic plate. Other methods for forming a texture on the surface of the layer of magnesium-containing material can also be provided. The magnesium-containing layer and/or tensile strength layers may be any of those otherwise described herein for the wall building material. In one embodiment, the mesh material comprise a woven bamboo mesh, for example as shown in FIG. 6A, having interleaving bamboo fibers, the bamboo fibers having a diameter of less than 1 about 1 cm, 0.5 cm, 0.05 cm, and even less than 1 mm. In one embodiment, the wall board comprises interleaving bamboo fibers have first fibers 308A extending in a first primary direction, and second fibers 308B extending primarily in a second direction, the first and second fibers being interwoven with one another to form a matrix of the first and second fibers, and wherein the bamboo mesh extends across at least 50%, at least 75%, at least 80% and event at least 95% of the area of the wall board. In one embodiment, the magnesium containing layer comprises a material having one or more of magnesium oxide, magnesium chloride, and magnesium oxychloride, formed from the reaction of MgO, MgCl₂ and water. In one embodiment, the wall board is formed by layering the tensile strength material and a wet mixture of magnesium-containing material on the substrate, and allowing the mixture of magnesium-containing material to dry. In yet another embodiment, the layer of magnesium-containing material is textured by a relief-patterning method including placing the wet mixture of magnesium-containing material in contact with a textured surface or material, allowing the magnesium-containing material to dry, and removing the textured surface or material. The layer of magnesium-containing material may also be textured by any other method described herein. In one embodiment, the wall board comprises a fire rating according to International Building Code (IBC) Chapter 7 of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours, and/or a fire rating according to Underwriters Laboratory (UL) standard number 263 (Standard for Fire Tests of Building Construction and Materials) of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours.

According to yet another embodiment, the wall 102 may be capable of serving as an exterior wall for a commercial or residential building. For example, the wall 102 can comprise a wall body 104 having a first side 116a adapted to be positioned facing an interior space of a residential or commercial building, and a second opposing side 116b that is adapted to be exposed to an exterior of the residential or commercial building. The wall body 104 can further comprise an upper region 108a and a lower region 108b that are configured to position and stabilize the wall body in a substantially upright position. For example the upper region 108a can be configured to be connected to one or more roof joists of the residential or commercial building, and the lower region 108b configured to be connected to a foundation of the residential or commercial building. As for the embodiments of the wall body 104 discussed above, the exterior wall 102 can comprise a wall body 104 having a unitary body of a molded material, with the molded material including any of the materials described herein, such as for example the magnesium-containing material, and as made by any of the methods described herein. As with any of the other embodiments described herein the unitary body may extend between and include the upper and lower regions 108a, 108b, for example such that the wall body is substantially entirely formed of the unitary body. Furthermore, the exterior wall 102 may optionally and/or alternatively be installed and/or maintained substantially upright by using any of the lateral supports and/or other mechanisms described herein. In one embodiment, the exterior wall 102 may be adapted for use as an exterior wall of a single family home or condo. The exterior wall can, in certain embodiments, have a height as defined between opposing top and bottom sides of the wall body of at least 6 feet, at least 8 feet, and/or at least 10 feet, and a width as defined between opposing lateral sides of the wall body of at least 1 foot, at least 2 feet, at least 4 feet, at least 6 feet, at least 10 feet, at least 15 feet and/or at least 20 feet. Other embodiments and aspects as described elsewhere herein for the wall and/or wall body, such as for example methods of manufacture, use, installation and composition of the wall, may also be incorporated into the exterior wall and its manufacture, installation, composition and use.

Embodiments of the disclosure are described herein for purposes of further describing aspects of the invention, but the invention is not intended to be limited thereto.

Embodiment 1: A wall for mounting in a residential or commercial building space, the wall comprising a wall body having: an upper region configured to be laterally supported at one or more upper surfaces thereof to maintain the wall body in a substantially upright position; and a lower region configured to be laterally supported at one or more lower surfaces thereof to maintain the wall body in a substantially upright position, wherein the wall body comprises a unitary body having a molded material.

Embodiment 2: The wall according to any preceding Embodiment, wherein the wall body comprises a fire rating according to International Building Code (IBC) Chapter 7 of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours.

Embodiment 3: The wall according to any preceding Embodiment, wherein the wall body comprises a fire rating according to Underwriters Laboratory (UL) standard number 263 (Standard for Fire Tests of Building Construction and Materials) of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours.

Embodiment 4: The wall according to any preceding Embodiment, wherein the wall body comprises at least one of moisture resistance, UV resistance, termite resistance, acoustic dampening, a relatively low coefficient of expansion and/or contraction, and a relatively high compressive strength, tensile strength, and/or resistance to bending and impact.

Embodiment 5: The wall according to any preceding Embodiment, wherein the wall body comprises a thermal conductivity of no more than 0.040 W/m·K, no more than 0.036 W/m·K and/or no more than 0.04 W/m·K.

Embodiment 6: The wall according to any preceding Embodiment, wherein the wall body comprises a plurality of voids therein, such that the density of the wall body is sufficiently low to allow the wall body to be buoyant when immersed in water.

Embodiment 7: The wall according to any preceding Embodiment, wherein the wall body comprises a height as defined between opposing top and bottom sides of the wall body of at least 6 feet, at least 8 feet, and/or at least 10 feet, and a width as defined between opposing lateral sides of the wall body of at least 1 foot, at least 2 feet, at least 4 feet and/or at least 6 feet.

Embodiment 8: The wall according to any preceding Embodiment, wherein the wall body optionally further comprises one or more compartments, channels and/or recesses formed therein.

Embodiment 9: The wall according to any preceding Embodiment, wherein the wall body comprises substantially 90° corners at one or more and even both of the upper and lower regions.

Embodiment 10: The wall according to any preceding Embodiment, wherein the wall body comprises at least one of opposing back surface and front surfaces that is substantially planar, and/or does not comprise any of grooves, channels, recesses and/or compartments formed therein.

Embodiment 11: The wall according to any preceding Embodiment, wherein the wall body comprises one or more compartments and/or recesses formed therein and optionally having one or more panels to cover said one or more compartments and/or recesses.

Embodiment 12: The wall according to Embodiment 11, wherein the one or more compartments and/or recesses has a horizontal length that extends substantially across a horizontal length of the wall body between first and second opposing lateral sides of the wall body.

Embodiment 13: The wall according to Embodiment 11, wherein the panel comprises a wall board having a layer of magnesium-containing material.

Embodiment 14: The wall according to Embodiment 11, wherein the wall body optionally comprises one or more conduits embedded therein, and extending from a first side of the wall body to a second side of the wall body.

Embodiment 15: The wall according to Embodiment 14, wherein the conduits are vertical conduits extending from a top to a bottom of the wall body.

Embodiment 16: The wall according to any preceding Embodiment, wherein the wall body is configured to cooperate with a second wall body to form a finished wall upon completion of mounting of the wall, and optionally wherein the finished wall comprises a space between the wall body and second wall body, or the wall body and second wall body are flush with one another.

Embodiment 17: The wall according to any preceding Embodiment, wherein the wall body comprises one or more of a notch, groove, indentation and/or channel formed in the upper surface of the upper region that is configured to engage a lateral support.

Embodiment 18: The wall according to any preceding Embodiment, wherein the wall body comprises a mechanical mechanism configured to connect an upper surface of the upper region to a lateral support.

Embodiment 19: The wall according to any preceding Embodiment, wherein a thickness of the wall body as measured between inner and outer surfaces is configured to be accommodated by one or more lateral supports that laterally support the wall body by bracing the opposing inner and outer surfaces at the upper region of the wall body.

Embodiment 20: The wall according to any preceding Embodiment, wherein the wall body is configured to be attached to one or more lateral supports via an adhesive, and/or the one or more lateral supports are configured to be attached to a structure such as a ceiling or floor of the residential or commercial building space via an adhesive.

Embodiment 21: The wall according to any preceding Embodiment, wherein the wall body is configured to be attached to one or more lateral supports without an adhesive.

Embodiment 22: The wall according to any preceding Embodiment, wherein the wall body is formed from a building material comprising a magnesium-containing material.

Embodiment 23: The wall according to Embodiment 22, wherein the wall body comprises a material having one or more of magnesium oxide, magnesium chloride, and magnesium oxychloride, formed from the reaction of MgO, MgCl₂ and water.

Embodiment 24: The wall according to Embodiment 22, wherein the material is formed by combining MgO with MgCl₂ in a weight ratio that is sufficient to provide for a chemical reaction of MgO and MgCl2 in a curing process that forms a final bonded solid product.

Embodiment 25: The wall according to Embodiment 22, wherein the material further comprises a tensile strength material comprising any one or more of horse hair, carbon fiber, type 1 collagen fibrils, bamboo mesh, natural fiber mesh, burlap mesh, wood fiber mesh, wood chips, natural fibers, plant fibers, wood fibers, cellulose, PVA fibers, acrylic fibers, AR glass fiber, alpha gypsum additive, polymer modified gypsum, pozzolans, fumed silica, metakaolin, liquid polymers including but not limited to acrylic emulsion polymer, powdered polymers, calcium aluminum sulfate crystals, portland cement, plasticizers, epoxies including epoxy putties, casting epoxies, composite epoxies, PVA fibers, fiberglass mesh, alkali resistant glass fibers, and alkali resistant scrim.

Embodiment 26: The wall according to Embodiment 25, wherein the mesh material comprises a woven bamboo mesh having interleaving bamboo fibers, the bamboo fibers having a diameter of less than 1 about 1 cm, 0.5 cm, 0.05 cm, and even less than 1 mm.

Embodiment 27: The wall according to Embodiment 26, wherein the interleaving bamboo fibers have first fibers extending in a first primary direction, and second fibers extending primarily in a second direction, the first and second fibers being interwoven with one another to form a matrix of the first and second fibers, and wherein the bamboo mesh extends across at least 50%, at least 75%, at least 80% and event at least 95% of the area of the wall body.

Embodiment 28: The wall according to Embodiment 22, wherein the material comprises voids and/or spaces formed by the addition of a foaming agent to in preparing the material.

Embodiment 29: The wall according to Embodiment 28, wherein the foaming agent comprises less than 10%, less than 8%, less than 6%, less than 5%, and/or less than 3% benzene, formaldehyde or other carcinogen.

Embodiment 30: The wall according to Embodiment 29, wherein the foaming agent comprises substantially no benzene, formaldehyde or other carcinogen.

Embodiment 31: The wall according to Embodiment 22, wherein the material comprises a higher content by weight of the magnesium-containing material than gypsum.

Embodiment 32: The wall according to Embodiment 22, wherein the material comprises a higher content by weight of the magnesium-containing material than concrete.

Embodiment 33: The wall according to Embodiment 22, wherein the material comprises a higher content by weight of the magnesium-containing material than cement.

Embodiment 34: The wall according to any preceding Embodiment, wherein at least one of the outer and inner surfaces of the wall body is textured, patterned, molded, painted, sculpted and/or wall-papered.

Embodiment 35: A finished and installed building wall comprising the wall according to any preceding Embodiment.

Embodiment 36: A wall assembly comprising the wall of any preceding Embodiment, and further comprising at least one upper lateral support configured to laterally support the upper region of the wall body, wherein the wall assembly comprises a fire rating according to International Building Code (IBC) Chapter 7 of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours.

Embodiment 37: The wall assembly according to Embodiment 36, wherein the wall assembly comprises a fire rating according to Underwriters Laboratory (UL) standard number 263 (Standard for Fire Tests of Building Construction and Materials) of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours.

Embodiment 38: The wall assembly according to Embodiment 37, wherein the upper lateral support comprises an engagement portion with a mechanical connector to mechanically connect the upper lateral support to the upper region of the wall body.

Embodiment 39: The wall assembly according to Embodiment 38, wherein the upper lateral support comprises a clip to connect to a connector extending from an upper region of the wall body.

Embodiment 40: The wall assembly according to Embodiment 38, wherein the upper lateral support comprises a projection that extends outwardly at a periphery of the lateral support to engage the wall body.

Embodiment 41: The wall assembly according to Embodiment 38, wherein the upper lateral support comprises a projection with a ledge at a periphery of the lateral support having an upturned lip, and wherein the wall body comprises at least one channel formed in an inner surface of the upper region that is configured to engage with the projection.

Embodiment 42: The wall assembly according to Embodiment 41, wherein the upturned lip extends upwardly from the ledge at an angle.

Embodiment 43: The wall assembly according to Embodiment 38, wherein the upper lateral support comprises a groove, notch, indentation and/or channel to engage an upper region of the wall body.

Embodiment 44: The wall assembly according to Embodiment 38, wherein the upper lateral support is configured to engage a groove, notch, indentation and/or channel formed in an upper region of the wall body.

Embodiment 45: The wall assembly according to Embodiment 38, comprising first and second upper lateral supports that are configured to cooperatively laterally support an upper region of the wall body.

Embodiment 46: The wall assembly according to Embodiment 38, wherein the first and second upper lateral supports are configured to contact opposing upper surfaces of the wall body.

Embodiment 47: The wall assembly according to Embodiment 38, wherein the lateral support comprises a track having a beam portion and an engagement portion.

Embodiment 48: The wall assembly according to Embodiment 38, further comprising a lower lateral support configured to laterally support the lower region of the wall body.

Embodiment 49: A lateral support for a wall assembly for mounting a wall in a commercial or residential building space, the lateral support comprising: an engagement portion configured to engage a surface of an upper or lower region of a wall body, the lateral support comprising a unitary body having a molded material, and the lateral support comprising fire rating according to International Building Code (IBC) Chapter 7 of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours.

Embodiment 50: The lateral support according to Embodiment 49 comprising a fire rating according to Underwriters Laboratory (UL) standard number 263 (Standard for Fire Tests of Building Construction and Materials) of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours.

Embodiment 51: The lateral support according to any of Embodiments 49-50, wherein the lateral support comprises an upper lateral support to engage the upper region of the wall body.

Embodiment 52: The lateral support according to Embodiment 51, wherein the upper lateral support has an engagement portion having a mechanical connector to mechanically connect the upper lateral support to the upper region of the wall body.

Embodiment 53: The lateral support according to Embodiment 51, wherein the upper lateral support comprises a clip to connect to a connector extending from an upper region of the wall body.

Embodiment 54: The lateral support according to Embodiment 51, wherein the upper lateral support comprises a projection that extends outwardly at a periphery of the upper lateral support to engage the wall body.

Embodiment 55: The lateral support according to Embodiment 51, wherein the upper lateral has a projection with a ledge at a periphery of the lateral support having an upturned lip, and wherein the wall body comprises at least one channel formed in an inner surface of the upper region that is configured to engage with the projection.

Embodiment 56: The lateral support according to Embodiment 55, wherein the upturned lip extends upwardly from the ledge at an angle.

Embodiment 57: The lateral support according to Embodiment 51, wherein the upper lateral support comprises a groove, notch, indentation and/or channel to engage the upper region of the wall body.

Embodiment 58: The lateral support according to Embodiment 51, wherein the upper lateral support is configured to engage a groove, notch, indentation and/or channel formed in an upper region of the wall body.

Embodiment 59: The lateral support according to Embodiment 51, wherein the upper lateral support comprises a first lateral support that is configured to cooperatively laterally support the upper region of the wall body with a second upper lateral support.

Embodiment 60: The lateral support according to Embodiment 59, wherein the first and second upper lateral supports are configured to contact opposing upper surfaces of the wall body.

Embodiment 61: The lateral support according to Embodiment 49, wherein the lateral support comprises a track having a beam portion and an engagement portion.

Embodiment 62: The lateral support according to Embodiment 49, wherein the lateral support comprises a lower lateral support configured to laterally support the lower region of the wall body.

Embodiment 63: A lateral support assembly for supporting a wall mounted in a commercial or residential building space, the lateral support assembly comprising at least one lateral support according to Embodiment 49.

Embodiment 64: The lateral support assembly according to Embodiment 63, comprising an upper lateral support to support the upper region of the wall body, and a lower lateral support to support the lower region of the wall body.

Embodiment 65: The lateral support according to Embodiment 49, wherein the lateral support comprises at least one of moisture resistance, UV resistance, termite resistance, acoustic dampening, a relatively low coefficient of expansion and/or contraction, and a relatively high compressive strength, tensile strength, and/or resistance to bending and impact.

Embodiment 66: The lateral support according to Embodiment 49, wherein the lateral support comprises a thermal conductivity of no more than 0.040 W/m·K, no more than 0.036 W/m·K and/or no more than 0.04 W/m·K.

Embodiment 67: The lateral support according to Embodiment 49, wherein the lateral support comprises a plurality of voids therein, such that the density of the lateral support is sufficiently low to allow the lateral support to be buoyant when immersed in water.

Embodiment 68: The lateral support according to Embodiment 49, wherein the lateral support is configured to support a wall body having a height as defined between opposing top and bottom sides of the wall body of at least 6 feet, at least 8 feet, and/or at least 10 feet, and a width as defined between opposing lateral sides of the wall body of at least 1 foot, at least 2 feet, at least 4 feet and/or at least 6 feet.

Embodiment 69: The lateral support according to Embodiment 49, wherein the lateral support is optionally further configured to support a wall body comprises one or more compartments, channels and/or recesses formed therein.

Embodiment 70: The lateral support according to Embodiment 49, wherein the lateral support is configured to support a wall body comprising substantially 90° corners at one or more and even both of the upper and lower regions.

Embodiment 71: The lateral support according to Embodiment 70, wherein the lateral support is configured to support a wall body that comprises at least one of opposing back surface and front surfaces that is substantially planar, and/or does not comprise any of grooves, channels, recesses and/or compartments formed therein.

Embodiment 72: The lateral support according to Embodiment 70, wherein the lateral support is configured to support a wall body comprising one or more compartments and/or recesses formed therein and optionally having one or more panels to cover said one or more compartments and/or recesses.

Embodiment 73: The wall according to Embodiment 72, wherein the one or more compartments and/or recesses has a horizontal length that extends substantially across a horizontal length of the wall body between first and second opposing lateral sides of the wall body.

Embodiment 74: The wall according to Embodiment 72, wherein the panel comprises a wall board having a layer of magnesium-containing material.

Embodiment 75: The lateral support according to Embodiment 70, wherein the lateral support is optionally configured to support a wall body comprising one or more conduits embedded therein, and extending from a first side of the wall body to a second side of the wall body.

Embodiment 76: The lateral support according to Embodiment 75, wherein the lateral support is configured to support a wall body having conduits that are vertical conduits extending from a top to a bottom of the wall body.

Embodiment 77: The lateral support according to Embodiment 49, wherein the lateral support is configured to further support a second wall body to form a finished wall upon completion of mounting of the wall, and optionally wherein the lateral support is configured to support a finished wall having a space between the wall body and second wall body, or a finished wall where the wall body and second wall body are flush with one another.

Embodiment 78: The lateral support according to Embodiment 49, wherein the lateral support is configured to support a wall body having one or more of a notch, groove, indentation and/or channel formed in the upper surface of the upper region that is configured to engage the lateral support.

Embodiment 79: The lateral support according to Embodiment 49, wherein the lateral support is configured to support a wall body having a mechanical mechanism configured to connect an upper surface of the upper region to the lateral support.

Embodiment 80: The lateral support according to Embodiment 49, wherein lateral support is configured to laterally support the wall body by bracing the opposing inner and outer surfaces at the upper region of the wall body.

Embodiment 81: The lateral support according to Embodiment 49, wherein the wall body is configured to be attached to one or more lateral supports via an adhesive, and/or the one or more lateral supports are configured to be attached to a structure such as a ceiling or floor of the residential or commercial building space via an adhesive.

Embodiment 82: The lateral support according to Embodiment 49, wherein the wall body is configured to be attached to one or more lateral supports without an adhesive.

Embodiment 83: The lateral support according to Embodiment 49, wherein the lateral support is formed from a building material comprising a magnesium-containing material.

Embodiment 84: The lateral support according to Embodiment 83, wherein the lateral support comprises a material having one or more of magnesium oxide, magnesium chloride, and magnesium oxychloride, formed from the reaction of MgO, MgCl₂ and water.

Embodiment 85: The lateral support according to Embodiment 84, wherein the material is formed by combining MgO with MgCl₂ in a weight ratio that is sufficient to provide for a chemical reaction of MgO and MgCl2 in a curing process that forms a final bonded solid product.

Embodiment 86: The lateral support according to Embodiment 84, wherein the material further comprises a tensile strength material comprising any one or more of horse hair, carbon fiber, type 1 collagen fibrils, bamboo mesh, natural fiber mesh, burlap mesh, wood fiber mesh, wood chips, natural fibers, plant fibers, wood fibers, cellulose, PVA fibers, acrylic fibers, AR glass fiber, alpha gypsum additive, polymer modified gypsum, pozzolans, fumed silica, metakaolin, liquid polymers including but not limited to acrylic emulsion polymer, powdered polymers, calcium aluminum sulfate crystals, portland cement, plasticizers, epoxies including epoxy putties, casting epoxies, composite epoxies, PVA fibers, fiberglass mesh, alkali resistant glass fibers, and alkali resistant scrim.

Embodiment 87: The lateral support according to Embodiment 86, wherein the mesh material comprises a woven bamboo mesh having interleaving bamboo fibers, the bamboo fibers having a diameter of less than 1 about 1 cm, 0.5 cm, 0.05 cm, and even less than 1 mm.

Embodiment 88: The lateral support according to Embodiment 87, wherein the interleaving bamboo fibers have first fibers extending in a first primary direction, and second fibers extending primarily in a second direction, the first and second fibers being interwoven with one another to form a matrix of the first and second fibers, and wherein the bamboo mesh extends across at least 50%, at least 75%, at least 80% and event at least 95% of the area of the wall body.

Embodiment 89: The lateral support according to Embodiment 84, wherein the material comprises voids and/or spaces formed by the addition of a foaming agent to in preparing the material.

Embodiment 90: The lateral support according to Embodiment 89, wherein the foaming agent comprises less than 10%, less than 8%, less than 6%, less than 5%, and/or less than 3% benzene, formaldehyde or other carcinogen.

Embodiment 91: The lateral support according to Embodiment 90, wherein the foaming agent comprises substantially no benzene, formaldehyde or other carcinogen.

Embodiment 92: The lateral support according to Embodiment 84, wherein the material comprises a higher content by weight of the magnesium-containing material than gypsum.

Embodiment 93: The lateral support according to Embodiment 84, wherein the material comprises a higher content by weight of the magnesium-containing material than concrete.

Embodiment 94: The lateral support according to Embodiment 84, wherein the material comprises a higher content by weight of the magnesium-containing material than cement.

Embodiment 85: The lateral support according to Embodiment 49, wherein an external surface of the wall lateral support is textured, patterned, molded, painted, sculpted and/or wall-papered.

Embodiment 86: A wall assembly for mounting a wall in a residential or commercial building space, the wall assembly comprising: a wall body having: an upper region configured to be laterally supported at one or more upper surfaces thereof to maintain the wall body in a substantially upright position; and a lower region configured to be laterally supported at one or more lower surfaces thereof to maintain the wall body in a substantially upright position; and at least one lateral support comprising an engagement portion configured to engage the one or more upper surfaces of the upper region or one or more lower surfaces of the lower region of the wall body, wherein the wall body comprises a unitary body having a molded material, and wherein the wall assembly comprising the wall as mounted with the at least one lateral support in a residential or commercial building comprises a fire rating according to International Building Code (IBC) Chapter 7 of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours.

Embodiment 87: The wall assembly according to Embodiment 86 comprising a fire rating according to Underwriters Laboratory (UL) standard number 263 (Standard for Fire Tests of Building Construction and Materials) of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours.

Embodiment 88: The wall assembly according to Embodiment 86, wherein one or more of the wall body and the at least one lateral support comprises at least one of moisture resistance, UV resistance, termite resistance, acoustic dampening, a relatively low coefficient of expansion and/or contraction, and a relatively high compressive strength, tensile strength, and/or resistance to bending and impact.

Embodiment 89: The wall assembly according to Embodiment 86, wherein one or more of the wall body and the at least one lateral support comprises a thermal conductivity of no more than 0.040 W/m·K, no more than 0.036 W/m·K and/or no more than 0.04 W/m·K.

Embodiment 90: The wall assembly according to Embodiment 86, wherein one or more of the wall body and at least one lateral support comprises a plurality of voids therein, such that the density thereof is sufficiently low to allow the wall body to be buoyant when immersed in water.

Embodiment 91: The wall assembly according to Embodiment 86, wherein the wall body comprises a height as defined between opposing top and bottom sides of the wall body of at least 6 feet, at least 8 feet, and/or at least 10 feet, and a width as defined between opposing lateral sides of the wall body of at least 1 foot, at least 2 feet, at least 4 feet and/or at least 6 feet.

Embodiment 92: The wall assembly according to Embodiment 86, wherein the wall body optionally further comprises one or more compartments, channels and/or recesses formed therein.

Embodiment 93: The wall assembly according to Embodiment 92, wherein the wall body comprises substantially 90° corners at one or more and even both of the upper and lower regions.

Embodiment 94: The wall assembly according to Embodiment 93, wherein the wall body comprises at least one of opposing back surface and front surfaces that is substantially planar, and/or does not comprise any of grooves, channels, recesses and/or compartments formed therein.

Embodiment 95: The wall assembly according to Embodiment 94, wherein the wall body comprises one or more compartments and/or recesses formed therein and optionally having one or more panels to cover said one or more compartments and/or recesses.

Embodiment 96: The wall according to Embodiment 95, wherein the one or more compartments and/or recesses has a horizontal length that extends substantially across a horizontal length of the wall body between first and second opposing lateral sides of the wall body.

Embodiment 97: The wall according to Embodiment 95, wherein the panel comprises a wall board having a layer of magnesium-containing material.

Embodiment 98: The wall assembly according to Embodiment 95, wherein the wall body optionally comprises one or more conduits embedded therein, and extending from a first side of the wall body to a second side of the wall body.

Embodiment 99: The wall assembly according to Embodiment 96, wherein the conduits are vertical conduits extending from a top to a bottom of the wall body.

Embodiment 100: The wall assembly according to Embodiment 86, further comprising a second wall body configured to cooperate with the wall body to form a finished wall upon completion of mounting of the wall, and optionally wherein the finished wall comprises a space between the wall body and second wall body, or the wall body and second wall body are flush with one another.

Embodiment 101. The wall assembly according to Embodiment 86, wherein the wall body comprises one or more of a notch, groove, indentation and/or channel formed in the upper surface of the upper region that is configured to engage a lateral support.

Embodiment 102: The wall assembly according to Embodiment 86, wherein one or more of the wall body and at least one lateral support comprises a mechanical mechanism configured to connect an upper surface of the upper region of the wall body to the lateral support.

Embodiment 103: The wall assembly according to Embodiment 86, wherein a thickness of the wall body as measured between inner and outer surfaces is configured to be accommodated by the at least one lateral support by bracing the opposing inner and outer surfaces at the upper region of the wall body.

Embodiment 104: The wall assembly according to Embodiment 86, wherein the wall body is configured to be attached to one or more lateral supports via an adhesive, and/or the one or more lateral supports are configured to be attached to a structure such as a ceiling or floor of the residential or commercial building space via an adhesive.

Embodiment 105: The wall assembly according to Embodiment 86, wherein the wall body is configured to be attached to one or more lateral supports without an adhesive.

Embodiment 106: The wall assembly according to Embodiment 86, wherein one or more of the wall body and the at least one lateral support is formed from a building material comprising a magnesium-containing material.

Embodiment 107: The wall assembly according to Embodiment 106, wherein one or more of the wall body and the at least one lateral support comprises a material having one or more of magnesium oxide, magnesium chloride, and magnesium oxychloride, formed from the reaction of MgO, MgCl₂ and water.

Embodiment 108: The wall assembly according to Embodiment 107, wherein the material is formed by combining MgO with MgCl₂ in a weight ratio that is sufficient to provide for a chemical reaction of MgO and MgCl2 in a curing process that forms a final bonded solid product.

Embodiment 109: The wall assembly according to Embodiment 106, wherein the material further comprises a tensile strength material comprising any one or more of horse hair, carbon fiber, type 1 collagen fibrils, bamboo mesh, natural fiber mesh, burlap mesh, wood fiber mesh, wood chips, natural fibers, plant fibers, wood fibers, cellulose, PVA fibers, acrylic fibers, AR glass fiber, alpha gypsum additive, polymer modified gypsum, pozzolans, fumed silica, metakaolin, liquid polymers including but not limited to acrylic emulsion polymer, powdered polymers, calcium aluminum sulfate crystals, portland cement, plasticizers, epoxies including epoxy putties, casting epoxies, composite epoxies, PVA fibers, fiberglass mesh, alkali resistant glass fibers, and alkali resistant scrim.

Embodiment 110: The wall assembly according to Embodiment 109, wherein the mesh material comprises a woven bamboo mesh having interleaving bamboo fibers, the bamboo fibers having a diameter of less than 1 about 1 cm, 0.5 cm, 0.05 cm, and even less than 1 mm.

Embodiment 111: The wall assembly according to Embodiment 110, wherein the interleaving bamboo fibers have first fibers extending in a first primary direction, and second fibers extending primarily in a second direction, the first and second fibers being interwoven with one another to form a matrix of the first and second fibers, and wherein the bamboo mesh extends across at least 50%, at least 75%, at least 80% and event at least 95% of the area of the wall body.

Embodiment 112: The wall assembly according to Embodiment 107, wherein the material comprises voids and/or spaces formed by the addition of a foaming agent to in preparing the material.

Embodiment 113: The wall assembly according to Embodiment 112, wherein the foaming agent comprises less than 10%, less than 8%, less than 6%, less than 5%, and/or less than 3% benzene, formaldehyde or other carcinogen.

Embodiment 114: The wall assembly according to Embodiment 113, wherein the foaming agent comprises substantially no benzene, formaldehyde or other carcinogen.

Embodiment 115: The wall assembly according to Embodiment 107, wherein the material comprises a higher content by weight of the magnesium-containing material than gypsum.

Embodiment 116: The wall assembly according to Embodiment 107, wherein the material comprises a higher content by weight of the magnesium-containing material than concrete.

Embodiment 117: The wall assembly according to Embodiment 107, wherein the material comprises a higher content by weight of the magnesium-containing material than cement.

Embodiment 118: The wall assembly according to Embodiment 86, wherein a surface of one or more of the wall body and at least one lateral support is textured, patterned, molded, painted, sculpted and/or wall-papered.

Embodiment 119: A finished and installed building wall comprising the wall assembly according to Embodiment 86.

Embodiment 120: The wall assembly according to Embodiment 86, wherein the at least one lateral support comprises an upper lateral support to engage the upper region of the lateral body.

Embodiment 121: The wall assembly according to Embodiment 120, wherein the upper lateral support comprises an engagement portion with a mechanical connector to mechanically connect the upper lateral support to the upper region of the wall body.

Embodiment 122: The wall assembly according to Embodiment 120, wherein the upper lateral support comprises a clip to connect to a connector extending from an upper region of the wall body.

Embodiment 123: The wall assembly according to Embodiment 120, wherein the upper lateral support comprises a projection that extends outwardly at a periphery of the lateral support to engage the wall body.

Embodiment 124: The wall assembly according to Embodiment 120, wherein the upper lateral support comprises a projection with a ledge at a periphery of the lateral support having an upturned lip, and wherein the wall body comprises at least one channel formed in an inner surface of the upper region that is configured to engage with the projection.

Embodiment 125: The wall assembly according to Embodiment 124, wherein the upturned lip extends upwardly from the ledge at an angle.

Embodiment 126: The wall assembly according to Embodiment 120, wherein the upper lateral support comprises a groove, notch, indentation and/or channel to engage an upper region of the wall body.

Embodiment 127: The wall assembly according to Embodiment 120, wherein the upper lateral support is configured to engage a groove, notch, indentation and/or channel formed in an upper region of the wall body.

Embodiment 128: The wall assembly according to Embodiment 120, comprising first and second upper lateral supports that are configured to cooperatively laterally support the upper region of the wall body.

Embodiment 129: The wall assembly according to Embodiment 128, wherein the first and second upper lateral supports are configured to contact opposing upper surfaces of the wall body.

Embodiment 130: The wall assembly according to Embodiment 86, wherein the lateral support comprises a track having a beam portion and an engagement portion.

Embodiment 131: The wall assembly according to Embodiment 86, comprising an upper lateral support to support the upper region of the wall body and a lower lateral support to laterally support the lower region of the wall body.

Embodiment 132: A method of manufacturing a piece of a wall assembly for mounting a wall in a residential or commercial space, the method comprising: providing a mold in the shape of the piece; providing a mixture of MgO, MgCl₂ and water in the mold; curing the mixture to form a material by the reaction of MgO, MgCl₂ and water; and optionally, machining one or more channels, grooves, notches, and/or indentations into the piece.

Embodiment 133: The method of Embodiment 132, wherein the piece comprises at least one of a wall body and a lateral support.

Embodiment 134: The method of Embodiment 132, wherein curing the mixture provides a unitary body of the material formed by the reaction of MgO, MgCl₂ and water.

Embodiment 135: The method of Embodiment 132 further comprising providing a tensile strength material to the mixture, the tensile strength material comprising any one or more of horse hair, carbon fiber, type 1 collagen fibrils, bamboo mesh, natural fiber mesh, burlap mesh, wood fiber mesh, wood chips, natural fibers, plant fibers, wood fibers, cellulose, PVA fibers, acrylic fibers, AR glass fiber, alpha gypsum additive, polymer modified gypsum, pozzolans, fumed silica, metakaolin, liquid polymers including but not limited to acrylic emulsion polymer, powdered polymers, calcium aluminum sulfate crystals, portland cement, plasticizers, epoxies including epoxy putties, casting epoxies, composite epoxies, PVA fibers, fiberglass mesh, alkali resistant glass fibers, and alkali resistant scrim.

Embodiment 136: The method according to Embodiment 135, wherein the mesh material comprises a woven bamboo mesh having interleaving bamboo fibers, the bamboo fibers having a diameter of less than 1 about 1 cm, 0.5 cm, 0.05 cm, and even less than 1 mm.

Embodiment 137: The method according to Embodiment 136, wherein the interleaving bamboo fibers have first fibers extending in a first primary direction, and second fibers extending primarily in a second direction, the first and second fibers being interwoven with one another to form a matrix of the first and second fibers, and wherein the bamboo mesh extends across at least 50%, at least 75%, at least 80% and event at least 95% of the area of the wall body.

Embodiment 138: The method of Embodiment 132, wherein the method comprises adding a foaming agent to the mixture to form voids and/or spaces in the cured material.

Embodiment 138: The method according to Embodiment 138, wherein the foaming agent comprises less than 10%, less than 8%, less than 6%, less than 5%, and/or less than 3% benzene, formaldehyde or other carcinogen.

Embodiment 139: The method according to Embodiment 139, wherein the foaming agent comprises substantially no benzene, formaldehyde or other carcinogen.

Embodiment 140: The method according to Embodiment 132, wherein the material comprises a higher content by weight of the magnesium-containing material than gypsum.

Embodiment 141: The method according to Embodiment 132, wherein the material comprises a higher content by weight of the magnesium-containing material than concrete.

Embodiment 142: The method according to Embodiment 132, wherein the material comprises a higher content by weight of the magnesium-containing material than cement.

Embodiment 143: The method according to Embodiment 132, further comprising finishing one or more surfaces of the piece to provide at least one surface that is textured, patterned, molded, painted, sculpted and/or wall-papered.

Embodiment 144: The method according to Embodiment 132, wherein the cured mixture of the material comprises a fire rating according to International Building Code (IBC) Chapter 7 of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours.

Embodiment 145: The method according to Embodiment 144, wherein the material comprises a fire rating according to Underwriters Laboratory (UL) standard number 263 (Standard for Fire Tests of Building Construction and Materials) of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours.

Embodiment 146: A method of installing a wall using a wall assembly for mounting the wall in a residential or commercial space, the method comprising: mounting at least one lateral support within the residential or commercial space; providing a wall body having upper and lower regions; and engaging one or more of an upper or lower surface of the upper or lower region of the wall body with the at least one lateral support, wherein the at least one lateral support engages the wall body at one or more of the upper and lower regions to support the wall body in a substantially upright position in the residential or commercial space.

Embodiment 147: The method according to Embodiment 146, comprising mounting at least one upper lateral support towards a top region of the residential or commercial space, and mounting at least one lower lateral support towards a bottom region of the residential or commercial space, and engaging the upper and lower regions of the wall body with the upper and lower lateral supports.

Embodiment 148: The method according to Embodiment 146, comprising engaging the wall body with the at least one lateral support substantially without requiring an adhesive and/or metal connector.

Embodiment 149: The method according to Embodiment 146, comprising mounting a plurality of wall bodies using the at least one lateral support and/or a plurality of lateral supports.

Embodiment 150: A finished wall installed according to the method of Embodiment 146, wherein the finished wall comprises a fire rating according to International Building Code (IBC) Chapter 7 of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours.

Embodiment 151: The finished wall according to Embodiment 150 comprising a fire rating according to Underwriters Laboratory (UL) standard number 263 (Standard for Fire Tests of Building Construction and Materials) of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours.

Embodiment 152: A wall board for a residential or commercial building space, the wall board comprising: a tensile strength layer comprising a mesh material; and a magnesium-containing layer, wherein a surface of the magnesium-containing layer is optionally textured to provide a textured surface of the wall board.

Embodiment 153: The wall board according to Embodiment 152, wherein the wall board is prepared by layering the tensile strength layer and magnesium containing layer on a removable substrate layer.

Embodiment 154: The wall board according to Embodiment 153, wherein the removable substrate comprises one or more of a PVC plate, urethane-epoxy plate, a metal plate, and a ceramic plate.

Embodiment 155: The wall board according to Embodiment 152, wherein the mesh material comprises a woven bamboo mesh having interleaving bamboo fibers, the bamboo fibers having a diameter of less than 1 about 1 cm, 0.5 cm, 0.05 cm, and even less than 1 mm.

Embodiment 156: The wall board according to Embodiment 155, wherein the interleaving bamboo fibers have first fibers extending in a first primary direction, and second fibers extending primarily in a second direction, the first and second fibers being interwoven with one another to form a matrix of the first and second fibers, and wherein the bamboo mesh extends across at least 50%, at least 75%, at least 80% and event at least 95% of the area of the wall board.

Embodiment 157: The wall board according to Embodiment 152, wherein the magnesium containing layer comprises a material having one or more of magnesium oxide, magnesium chloride, and magnesium oxychloride, formed from the reaction of MgO, MgCl₂ and water.

Embodiment 158: The wall board according to Embodiment 152, wherein the wall board is formed by layering the tensile strength material and a wet mixture of magnesium-containing material on the substrate, and allowing the mixture of magnesium-containing material to dry.

Embodiment 159: The wall board according to Embodiment 152, wherein the layer of magnesium-containing material is textured by placing the wet mixture of magnesium-containing material in contact with textured surface or material, allowing the magnesium-containing material to dry, and removing the textured surface or material.

Embodiment 160: The wall board according to Embodiment 152, wherein the layer of magnesium containing material is textured by layering the magnesium-containing material and tensile strength material on a removable substrate having a textured surface, and removing the removable substrate after the layer of magnesium containing material has at least partially dried on the surface, thereby transferring the texture of the removable substrate to the surface of the layer of magnesium-containing material.

Embodiment 161: The wall board according to Embodiment 152, wherein the wall board comprises a fire rating according to International Building Code (IBC) Chapter 7 of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours.

Embodiment 162: The finished wall according to Embodiment 152 comprising a fire rating according to Underwriters Laboratory (UL) standard number 263 (Standard for Fire Tests of Building Construction and Materials) of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours.

Embodiment 162: An exterior wall for the exterior of a residential or commercial building, the wall comprising: a wall body having a first side adapted to be exposed to an exterior of the residential or commercial building, and a second opposing side facing an interior space of the commercial building, the wall body comprising: an upper region configured to be connected to one or more roof joists of the residential or commercial building; and a lower region configured to be connected to a foundation of the residential or commercial building, wherein the wall body comprises a unitary body having a molded material, the unitary body extending between and including the upper and lower regions.

Embodiment 163: The exterior wall according to Embodiment 162, wherein the exterior walls is adapted for use as an exterior wall of a single family home.

Embodiment 164: The exterior wall according to Embodiment 162, wherein the exterior wall has a height as defined between opposing top and bottom sides of the wall body of at least 6 feet, at least 8 feet, and/or at least 10 feet, and a width as defined between opposing lateral sides of the wall body of at least 1 foot, at least 2 feet, at least 4 feet, at least 6 feet, at least 10 feet, at least 15 feet and/or at least 20 feet.

Embodiment 165: The exterior wall according to Embodiment 164, wherein the wall body comprises a fire rating according to International Building Code (IBC) Chapter 7 of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours.

Embodiment 166: The exterior wall according to Embodiment 164, wherein the wall body comprises a fire rating according to Underwriters Laboratory (UL) standard number 263 (Standard for Fire Tests of Building Construction and Materials) of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours.

Embodiment 167: The exterior wall according to Embodiment 164, wherein the wall body comprises at least one of moisture resistance, UV resistance, termite resistance, acoustic dampening, a relatively low coefficient of expansion and/or contraction, and a relatively high compressive strength, tensile strength, and/or resistance to bending and impact.

Embodiment 168: The exterior wall according to Embodiment 164, wherein the wall body comprises a thermal conductivity of no more than 0.040 W/m·K, no more than 0.036 W/m·K and/or no more than 0.04 W/m·K.

Embodiment 169: The exterior wall according to Embodiment 164, wherein the wall body comprises a plurality of voids therein, such that the density of the wall body is sufficiently low to allow the wall body to be buoyant when immersed in water.

Embodiment 170: The exterior wall according to Embodiment 164, wherein the wall body comprises substantially 90° corners at one or more and even both of the upper and lower regions.

Embodiment 171: The exterior wall according to Embodiment 164, wherein the wall body comprises at least one of opposing back surface and front surfaces that is substantially planar, and/or does not comprise any of grooves, channels, recesses and/or compartments formed therein.

Embodiment 172: The exterior wall according to Embodiment 164, wherein the wall body comprises one or more compartments and/or recesses formed therein and optionally having one or more panels to cover said one or more compartments and/or recesses.

Embodiment 173: The exterior wall according to Embodiment 172, wherein the one or more compartments and/or recesses has a horizontal length that extends substantially across a horizontal length of the wall body between first and second opposing lateral sides of the wall body.

Embodiment 174: The exterior wall according to Embodiment 173, wherein the panel comprises a wall board having a layer of magnesium-containing material.

Embodiment 175: The exterior wall according to Embodiment 164, wherein the wall body optionally comprises one or more conduits embedded therein, and extending from a first side of the wall body to a second side of the wall body.

Embodiment 176: The exterior wall according to Embodiment 175, wherein the conduits are vertical conduits extending from a top to a bottom of the wall body.

Embodiment 177: The wall according to Embodiment 164, wherein the wall body is configured to cooperate with a second wall body to form a finished wall upon completion of mounting of the wall, and optionally wherein the finished wall comprises a space between the wall body and second wall body, or the wall body and second wall body are flush with one another.

Embodiment 178: The exterior wall according to Embodiment 164, wherein the wall body is formed from a building material comprising a magnesium-containing material.

Embodiment 179: The exterior wall according to Embodiment 178, wherein the wall body comprises a material having one or more of magnesium oxide, magnesium chloride, and magnesium oxychloride, formed from the reaction of MgO, MgCl₂ and water.

Embodiment 180: The exterior wall according to Embodiment 178, wherein the material is formed by combining MgO with MgCl₂ in a weight ratio that is sufficient to provide for a chemical reaction of MgO and MgCl2 in a curing process that forms a final bonded solid product.

Embodiment 181: The exterior wall according to Embodiment 178, wherein the material further comprises a tensile strength material comprising any one or more of horse hair, carbon fiber, type 1 collagen fibrils, bamboo mesh, natural fiber mesh, burlap mesh, wood fiber mesh, wood chips, natural fibers, plant fibers, wood fibers, cellulose, PVA fibers, acrylic fibers, AR glass fiber, alpha gypsum additive, polymer modified gypsum, pozzolans, fumed silica, metakaolin, liquid polymers including but not limited to acrylic emulsion polymer, powdered polymers, calcium aluminum sulfate crystals, portland cement, plasticizers, epoxies including epoxy putties, casting epoxies, composite epoxies, PVA fibers, fiberglass mesh, alkali resistant glass fibers, and alkali resistant scrim.

Embodiment 182: The exterior wall according to Embodiment 181, wherein the mesh material comprises a woven bamboo mesh having interleaving bamboo fibers, the bamboo fibers having a diameter of less than 1 about 1 cm, 0.5 cm, 0.05 cm, and even less than 1 mm.

Embodiment 183: The exterior wall according to Embodiment 182, wherein the interleaving bamboo fibers have first fibers extending in a first primary direction, and second fibers extending primarily in a second direction, the first and second fibers being interwoven with one another to form a matrix of the first and second fibers, and wherein the bamboo mesh extends across at least 50%, at least 75%, at least 80% and event at least 95% of the area of the wall body.

Embodiment 183: The exterior wall according to Embodiment 178, wherein the material comprises voids and/or spaces formed by the addition of a foaming agent to in preparing the material.

Embodiment 184: The exterior wall according to Embodiment 183, wherein the foaming agent comprises less than 10%, less than 8%, less than 6%, less than 5%, and/or less than 3% benzene, formaldehyde or other carcinogen.

Embodiment 185: The exterior wall according to Embodiment 184, wherein the foaming agent comprises substantially no benzene, formaldehyde or other carcinogen.

Embodiment 186: The exterior wall according to Embodiment 178, wherein the material comprises a higher content by weight of the magnesium-containing material than gypsum.

Embodiment 187: The exterior wall according to Embodiment 178, wherein the material comprises a higher content by weight of the magnesium-containing material than concrete.

Embodiment 188: The exterior wall according to Embodiment 178, wherein the material comprises a higher content by weight of the magnesium-containing material than cement.

Embodiment 189: The exterior wall according to Embodiment 1164, wherein at least one of the outer and inner surfaces of the wall body is textured, patterned, molded, painted, sculpted and/or wall-papered.

Although illustrative embodiments of the present invention have been described herein, it should be understood that the invention is not limited to those described, and that various other changes or modifications may be made by one skilled in the art without departing from the scope or spirit of the invention.

Claims

1. A wall for mounting in a residential or commercial building space, the wall comprising: a wall body having: an upper region configured to be laterally supported at one or more upper surfaces thereof to maintain the wall body in a substantially upright position; anda lower region configured to be laterally supported at one or more lower surfaces thereof to maintain the wall body in a substantially upright position,wherein the wall body comprises a unitary body having a molded material.

2. The wall according to claim 1, wherein the wall body comprises a fire rating according to International Building Code (IBC) Chapter 7 of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours.

3. The wall according to any preceding claim, wherein the wall body comprises a fire rating according to Underwriters Laboratory (UL) standard number 263 (Standard for Fire Tests of Building Construction and Materials) of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours.

4. The wall according to any preceding claim, wherein the wall body comprises at least one of moisture resistance, UV resistance, termite resistance, acoustic dampening, a relatively low coefficient of expansion and/or contraction, and a relatively high compressive strength, tensile strength, and/or resistance to bending and impact.

5. The wall according to any preceding claim, wherein the wall body comprises a thermal conductivity of no more than 0.040 W/m·K, no more than 0.036 W/m·K and/or no more than 0.04 W/m·K.

6. The wall according to any preceding claim, wherein the wall body comprises a plurality of voids therein, such that the density of the wall body is sufficiently low to allow the wall body to be buoyant when immersed in water.

7. The wall according to any preceding claim, wherein the wall body comprises a height as defined between opposing top and bottom sides of the wall body of at least 6 feet, at least 8 feet, and/or at least 10 feet, and a width as defined between opposing lateral sides of the wall body of at least 1 foot, at least 2 feet, at least 4 feet and/or at least 6 feet.

8. The wall according to any preceding claim, wherein the wall body optionally further comprises one or more compartments, channels and/or recesses formed therein.

9. The wall according to any preceding claim, wherein the wall body comprises substantially 90° corners at one or more and even both of the upper and lower regions.

10. The wall according to any preceding claim, wherein the wall body comprises at least one of opposing back surface and front surfaces that is substantially planar, and/or does not comprise any of grooves, channels, recesses and/or compartments formed therein.

11. The wall according to any preceding claim, wherein the wall body comprises one or more compartments and/or recesses formed therein and optionally having one or more panels to cover said one or more compartments and/or recesses.

12. The wall according to any preceding claim, wherein the one or more compartments and/or recesses has a horizontal length that extends substantially across a horizontal length of the wall body between first and second opposing lateral sides of the wall body.

13. The wall according to any preceding claim, wherein the panel comprises a wall board having a layer of magnesium-containing material.

14. The wall according to any preceding claim, wherein the wall body optionally comprises one or more conduits embedded therein, and extending from a first side of the wall body to a second side of the wall body.

15. The wall according to any preceding claim, wherein the conduits are vertical conduits extending from a top to a bottom of the wall body.

16. The wall according to any preceding claim, wherein the wall body is configured to cooperate with a second wall body to form a finished wall upon completion of mounting of the wall, and optionally wherein the finished wall comprises a space between the wall body and second wall body, or the wall body and second wall body are flush with one another.

17. The wall according to any preceding claim, wherein the wall body comprises one or more of a notch, groove, indentation and/or channel formed in the upper surface of the upper region that is configured to engage a lateral support.

18. The wall according to any preceding claim, wherein the wall body comprises a mechanical mechanism configured to connect an upper surface of the upper region to a lateral support.

19. The wall according to any preceding claim, wherein a thickness of the wall body as measured between inner and outer surfaces is configured to be accommodated by one or more lateral supports that laterally support the wall body by bracing the opposing inner and outer surfaces at the upper region of the wall body.

20. The wall according to any preceding claim, wherein the wall body is configured to be attached to one or more lateral supports via an adhesive, and/or the one or more lateral supports are configured to be attached to a structure such as a ceiling or floor of the residential or commercial building space via an adhesive.

21. The wall according to any preceding claim, wherein the wall body is configured to be attached to one or more lateral supports without an adhesive.

22. The wall according to any preceding claim, wherein the wall body is formed from a building material comprising a magnesium-containing material.

23. The wall according to any preceding claim, wherein the wall body comprises a material having one or more of magnesium oxide, magnesium chloride, and magnesium oxychloride, formed from the reaction of MgO, MgCl2 and water.

24. The wall according to any preceding claim, wherein the material is formed by combining MgO with MgCl2 in a weight ratio that is sufficient to provide for a chemical reaction of MgO and MgCl2 in a curing process that forms a final bonded solid product.

25. The wall according to any preceding claim, wherein the material further comprises a tensile strength material comprising any one or more of horse hair, carbon fiber, type 1 collagen fibrils, bamboo mesh, natural fiber mesh, burlap mesh, wood fiber mesh, wood chips, natural fibers, plant fibers, wood fibers, cellulose, PVA fibers, acrylic fibers, AR glass fiber, alpha gypsum additive, polymer modified gypsum, pozzolans, fumed silica, metakaolin, liquid polymers including but not limited to acrylic emulsion polymer, powdered polymers, calcium aluminum sulfate crystals, portland cement, plasticizers, epoxies including epoxy putties, casting epoxies, composite epoxies, PVA fibers, fiberglass mesh, alkali resistant glass fibers, and alkali resistant scrim.

26. The wall according to any preceding claim, wherein the mesh material comprises a woven bamboo mesh having interleaving bamboo fibers, the bamboo fibers having a diameter of less than 1 about 1 cm, 0.5 cm, 0.05 cm, and even less than 1 mm.

27. The wall according to any preceding claim, wherein the interleaving bamboo fibers have first fibers extending in a first primary direction, and second fibers extending primarily in a second direction, the first and second fibers being interwoven with one another to form a matrix of the first and second fibers, and wherein the bamboo mesh extends across at least 50%, at least 75%, at least 80% and event at least 95% of the area of the wall body.

28. The wall according to any preceding claim, wherein the material comprises voids and/or spaces formed by the addition of a foaming agent to in preparing the material.

29. The wall according to any preceding claim, wherein the foaming agent comprises less than 10%, less than 8%, less than 6%, less than 5%, and/or less than 3% benzene, formaldehyde or other carcinogen.

39. The wall according to any preceding claim, wherein the foaming agent comprises substantially no benzene, formaldehyde or other carcinogen.

40. The wall according to any preceding claim, wherein the material comprises a higher content by weight of the magnesium-containing material than gypsum.

41. The wall according to any preceding claim, wherein the material comprises a higher content by weight of the magnesium-containing material than concrete.

42. The wall according to any preceding claim, wherein the material comprises a higher content by weight of the magnesium-containing material than cement.

43. The wall according to any preceding claim, wherein at least one of the outer and inner surfaces of the wall body is textured, patterned, molded, painted, sculpted and/or wall-papered.

44. A finished and installed building wall comprising the wall according to any preceding claim.

45. A wall assembly comprising the wall of any preceding claim, and further comprising at least one upper lateral support configured to laterally support the upper region of the wall body, wherein the wall assembly comprises a fire rating according to International Building Code (IBC) Chapter 7 of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours.

46. The wall assembly according to claim 45, wherein the wall assembly comprises a fire rating according to Underwriters Laboratory (UL) standard number 263 (Standard for Fire Tests of Building Construction and Materials) of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours.

47. The wall assembly according to any of claims 45-46, wherein the upper lateral support comprises an engagement portion with a mechanical connector to mechanically connect the upper lateral support to the upper region of the wall body.

48. The wall assembly according to according to any of claims 45-47, wherein the upper lateral support comprises a clip to connect to a connector extending from an upper region of the wall body.

49. The wall assembly according to according to any of claims 45-48, wherein the upper lateral support comprises a projection that extends outwardly at a periphery of the lateral support to engage the wall body.

50. The wall assembly according to according to any of claims 45-49, wherein the upper lateral support comprises a projection with a ledge at a periphery of the lateral support having an upturned lip, and wherein the wall body comprises at least one channel formed in an inner surface of the upper region that is configured to engage with the projection.

51. The wall assembly according to according to any of claims 45-50, wherein the upturned lip extends upwardly from the ledge at an angle.

52. The wall assembly according to according to any of claims 45-51, wherein the upper lateral support comprises a groove, notch, indentation and/or channel to engage an upper region of the wall body.

53. The wall assembly according to any of claims 45-52, wherein the upper lateral support is configured to engage a groove, notch, indentation and/or channel formed in an upper region of the wall body.

54. The wall assembly according to any of claims 45-53, comprising first and second upper lateral supports that are configured to cooperatively laterally support an upper region of the wall body.

55. The wall assembly according to any of claims 45-54, wherein the first and second upper lateral supports are configured to contact opposing upper surfaces of the wall body.

56. The wall assembly according to any of claims 45-55, wherein the lateral support comprises a track having a beam portion and an engagement portion.

57. The wall assembly according to any of claims 45-56, further comprising a lower lateral support configured to laterally support the lower region of the wall body.

58. A lateral support for a wall assembly for mounting a wall in a commercial or residential building space, the lateral support comprising; an engagement portion configured to engage a surface of an upper or lower region of a wall body,the lateral support comprising a unitary body having a molded material, and the lateral support comprising fire rating according to International Building Code (IBC) Chapter 7 of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours.

59. A lateral support assembly for supporting a wall mounted in a commercial or residential building space, the lateral support assembly comprising at least one lateral support according to claim 58.

60. A wall assembly for mounting a wall in a residential or commercial building space, the wall assembly comprising: a wall body having: an upper region configured to be laterally supported at one or more upper surfaces thereof to maintain the wall body in a substantially upright position; anda lower region configured to be laterally supported at one or more lower surfaces thereof to maintain the wall body in a substantially upright position; andat least one lateral support comprising an engagement portion configured to engage the one or more upper surfaces of the upper region or one or more lower surfaces of the lower region of the wall body,wherein the wall body comprises a unitary body having a molded material, and wherein the wall assembly comprising the wall as mounted with the at least one lateral support in a residential or commercial building comprises a fire rating according to International Building Code (IBC) Chapter 7 of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours.

61. A finished and installed building wall comprising the wall assembly according to claim 60.

62. A method of manufacturing a piece of a wall assembly for mounting a wall in a residential or commercial space, the method comprising: providing a mold in the shape of the piece;providing a mixture of MgO, MgCl2 and water in the mold;curing the mixture to form a material by the reaction of MgO, MgCl2 and water; andoptionally, machining one or more channels, grooves, notches, and/or indentations into the piece.

63. A method of installing a wall using a wall assembly for mounting the wall in a residential or commercial space, the method comprising: mounting at least one lateral support within the residential or commercial space;providing a wall body having upper and lower regions; andengaging one or more of an upper or lower surface of the upper or lower region of the wall body with the at least one lateral support,wherein the at least one lateral support engages the wall body at one or more of the upper and lower regions to support the wall body in a substantially upright position in the residential or commercial space.

64. A finished wall installed according to the method of claim 63, wherein the finished wall comprises a fire rating according to International Building Code (IBC) Chapter 7 of at least 1 hour, at least 2 hours, at least 3 hours and/or at least 4 hours.

65. A wall board for a residential or commercial building space, the wall board comprising: a tensile strength layer comprising a mesh material; anda magnesium-containing layer,wherein a surface of the magnesium-containing layer is optionally textured to provide a textured surface of the wall board.

66. An exterior wall for the exterior of a residential or commercial building, the wall comprising; a wall body having a first side adapted to be exposed to an exterior of the residential or commercial building, and a second opposing side facing an interior space of the commercial building, the wall body comprising: an upper region configured to be connected to one or more roof joists of the residential or commercial building; anda lower region configured to be connected to a foundation of the residential or commercial building,wherein the wall body comprises a unitary body having a molded material, the unitary body extending between and including the upper and lower regions.