SPACER FOR INTERCONNECTING ADJACENT ELONGATED MEMBERS, A METHOD FOR MANUFACTURING THE SAME, AND A METHOD AND A USE OF SAID SPACER

Abstract

A spacer for interconnecting in a frame structure, adjacent elongated members. Said spacer comprises: a main member having opposite ends, at least one first attachment plate, and a at least one second attachment plate, the at least one first attachment plate being adapted to be secured to one of the opposite ends of the main member, and the at least one second attachment plate being adapted to be secured to the other of the opposite ends, wherein the at least one first attachment plate is adapted to cooperate with at least one fastener for fastening the same to one of the adjacent elongated members, wherein the at least one second attachment plate is adapted to cooperate with at least one fastener for fastening the same to the other of the adjacent elongated members, wherein the main member has a length and a width, the length corresponding to a distance separating the adjacent elongated members, the width being close to the width of the adjacent elongated members, wherein the main member is further provided with at least one portion comprising an opening obstructed by a corresponding removable element fastened to the main member by at least one breakable member, and wherein when the at least one breakable member is broken, the element is removed to give access to the opening. Also, a method for manufacturing the spacer, a method of use of said spacer and a use of said spacer.

Claims

1. A spacer for interconnecting in a frame structure, adjacent elongated members having a determined width and maintaining a determined distance between said adjacent elongated members, wherein said spacer comprises: a main member having opposite ends, at least one first attachment member and at least one second attachment member, wherein the at least one first attachment member is secured to one of the opposite ends of the main member, and the at least one second attachment member is secured to the other of the opposite ends, wherein the at least one first attachment member is adapted to cooperate with at least one first fastener for fastening the same to one of the adjacent elongated members, wherein the at least one second attachment member is adapted to cooperate with at least one second fastener for fastening the same to the other of the adjacent elongated members, wherein the main member has a length corresponding to the determined distance between the adjacent elongated members, and a width which is close to the width of the adjacent elongated members, and wherein the main member is further provided with at least one removable knock-out portion substantially covering or closing at least one corresponding opening provided in the main member.

2. The spacer according to claim 1, wherein the at least one first attachment member forms a first attachment plate, and the at least one second attachment member forms a second attachment plate.

3. The spacer according to claim 2, wherein the at least one first attachment plate is further provided with at least one fastening opening adapted to receive and cooperate with the at least one first fastener, and wherein the at least one second attachment plate is further provided with at least one second fastening opening adapted to receive and cooperate with the at least one second fastener.

4. The spacer according to claim 2, wherein the at least one first fastener makes an integral part of the at least one first attachment plate, and wherein the at least one second fastener makes an integral part of the second attachment plate.

5. The spacer according to claim 1, wherein the at least one removable knock-out portion and a portion of the main member corresponding to the corresponding opening are joined together by at least one breakable member or by at least one weakened line.

6. The spacer according to claim 1, wherein the main member, the at least one first attachment member and the at least one second attachment member are made of a material selected from the group consisting of metallic materials, fiberglass materials, plastic materials, and composite materials.

7. The spacer according to claim 6, wherein the main member, the at least one first attachment member and the at least one second attachment member are made of a sheet of metal.

8. The spacer according to claim 1, wherein the main member, the at least one first attachment member, and the at least one second attachment member are further provided with reinforcing portions and/or reinforcing members.

9. The spacer according to claim 7, wherein the main member further comprises at least one reinforcing portion and/or at least one reinforcing member; wherein the at least one first attachment member is at least one first attachment plate, wherein the at least one second attachment member is at least one second attachment plate, wherein the main member, the reinforcing members, the at least one first attachment plate and the at least one second attachment plate are obtained by cutting and folding corresponding portions of a single sheet of metal having an upper face and a lower face; and wherein the single sheet of metal is a sheet of steel, said sheet of steel having a gauge varying from 18 to 25.

10. The spacer according to claim 9, wherein the at least one first fastener makes an integral part of the at least one first attachment plate, wherein the at least one second fastener makes an integral part of the at least one first attachment plate.

11. The spacer according to claim 9, wherein the at least one first attachment plate is further provided with at least one first fastening opening adapted to receive and cooperate with the at least one first fastener, wherein the at least one second attachment plate is further provided with at least one second fastening opening adapted to receive and cooperate with the at least one second fastener, wherein the at least one first fastener is part of at least one first fastening system comprising a L-shaped elongated element provided with a first portion having a first end and a second end opposite to the first end, and a second portion having a first end and a second end opposite to the first end, the first end of the first portion being connected to the at least one first attachment plate, the first portion defining a connector between the at least one first attachment plate and the second portion, the second end of the first portion and the first end of the second portion being connected to form a shoulder at the L-shaped elongated element, the second end of the second portion being sharpened, and the second portion defining the at least one first fastener, the L-shaped elongated element being movable from a raised position where the second end of the second portion is positioned above the at least one first fastening opening, to a lowered position where the at least one first fastener is adapted to engage via the at least one first fastening opening a corresponding adjacent elongated member of the frame structure; and wherein the at least one second fastener is part of at least one second fastening system comprising a L-shaped elongated element provided with a first portion having a first end and a second end opposite to the first end, and a second portion having a first end and a second end opposite to the first end, the first end of the first portion being connected to the at least one second attachment plate, the first portion defining a connector between the at least one second attachment plate and the second portion, the second end of the first portion and the first end of the second portion being connected to form a shoulder at the L-shaped elongated element, the second end of the second portion being sharpened, and the second portion defining the at least one second fastener, the L-shaped elongated element being movable from a raised position where the second end of the second portion is positioned above the at least one second fastening opening, to a lowered position where the at least one second fastener is adapted to engage via the at least one second fastening opening a corresponding adjacent elongated member of the frame structure.

12. The spacer according to 11, wherein the L-shaped elongated element of the at least one first fastening system is obtained by punching out a portion of the at least one first attachment plate, and wherein the L-shaped elongated element of the at least one second fastening system is obtained by punching out a portion of the at least one second attachment plate.

13. The spacer according to claim 9, wherein the at least one first attachment plate is further provided with at least one first fastening opening adapted to receive and cooperate with the at least one first fastener, and wherein the at least one second attachment plate is further provided with at least one second fastening opening adapted to receive and cooperate with the at least one fastener.

14. The spacer according to claim 9, wherein the at least one removable knock-out portion and the corresponding opening are joined together by at least one breakable member or at least one weakening line.

15. The spacer according to claim 9, wherein the main member, the at least one first attachment plate, and the at least one second attachment plate are further provided with the at least one reinforcing portion.

16. The metal spacer according to claim 9, wherein the at least one removable knock-out portion has a determined size and shape to allow receiving or passing therethrough an element or an article having a cross section of similar size and shape.

17. A method for the manufacturing of the spacer defined in claim 1, wherein said method at least comprises a step of forming the main member, the at least one first attachment member, the at least one second attachment member, and the at least one removable knock-out portion covering or closing the at least one corresponding opening provided in the main member.

18. A method according to claim 17, wherein when the spacer is made of a sheet of metal, said method at least comprises the steps of: cutting the sheet of metal having an upper face and a lower face, to define the main member, the at least one first attachment plate and the at least one second attachment plate; and stamping with a die at least one portion of the main member to define the at least one removable knock-out portion covering or closing the at least one corresponding opening provided in the main member.

19. The method according to claim 18, wherein said method further comprises a step of folding the sheet of metal to form the main member, the at least one first attachment plate and the at least one second attachment plate.

20. The method according to claim 18, wherein said method further comprises a step of stamping at least one portion of the main member to define at least one reinforcing embossment defining the at least one reinforcing portion.

21. A method for interconnecting adjacent elongated members, said method comprising a step of positioning the spacer defined in claim 1 between the adjacent elongated members, to have its reinforcement members substantially co-planar with each of corresponding edges of the adjacent, elongated members, and fastening the at least one first attachment member and the at least one second attachment member to corresponding adjacent elongated members.

22. The method according to claim 21, wherein when the spacer is metal spacer made of a sheet of metal and comprising a main member having opposite ends, at least one first attachment plate and at least one second attachment plate, wherein the at least one first attachment plate is secured to one of the opposite ends of the main member, wherein the at least one second attachment plate is secured to the other of the opposite ends, wherein the at least one first attachment plate is adapted to cooperate with at least one first fastener for fastening the same to one of the adjacent elongated members, wherein the at least one second attachment plate is adapted to cooperate with at least one second fastener for fastening the same to the other of the adjacent elongated members, wherein the main member has a length corresponding to the determined distance between the adjacent elongated members, and a width which is close to the width of the adjacent elongated members, and wherein the main member is further provided with at least one removable knock-out portion substantially covering or closing at least one corresponding opening provided in the main member, wherein the main member, the reinforcing members, the at least one first attachment plate and the at least one second attachment plate are obtained by cutting and folding corresponding portions of a single sheet of metal having an upper face and a lower face; and wherein the single sheet of metal is a sheet of steel having a gauge varying from 18 to 25; said method comprising a step of positioning the metal spacer between the adjacent elongated members, to have its reinforcement members substantially co-planar with each of corresponding edges of the adjacent, elongated members, and fastening the at least one first attachment plate and the at least one second attachment plate to corresponding adjacent elongated members.

Description

[0131] The present invention will be better understood with reference to the following drawings:

[0132] FIG. 1 represents a perspective view of a sheet of metal provided with sections that will define a first embodiment of a metal spacer;

[0133] FIG. 2 represents the first embodiment of the metal spacer according to the invention;

[0134] FIG. 3 represents a variant of the metal spacer of FIG. 2 where the breakable members are replaced by a weakening line.

[0135] FIG. 4 represents the metal spacer of FIG. 2 further provided with optional fittings 41a and 41c.

[0136] FIG. 5 represents a cross sectional view of the spacer of FIG. 4 (further provided with optional fitting 41b), positioned between posts 101 and 101′.

[0137] FIG. 6 represents a top view of the metal spacer of FIG. 5 with panels further enclosing said metal spacer within the adjacent elongated members and to substantially prevent air circulation between the metal spacer, the adjacent elongated members and the panels.

[0138] FIG. 7 represents a cross-sectional view of the spacer of FIG. 3 according to line VII-VII.

[0139] FIG. 8 represents a partial view of the metal spacer of FIG. 2 where the opening 13 have been replaced by a plurality of tongue-shaped nails 14, or the openings 15 have been replaced by a plurality of tongue-shaped nails 16.

[0140] FIG. 9 represents a perspective view of a fitting 41a or 41c appearing in the metal spacer of FIG. 4.

[0141] FIG. 10 represents a perspective view of a sheet of metal provided with sections of a second embodiment of a metal spacer (designed for use with «C» channel metal posts);

[0142] FIG. 11 represents a perspective view of the second embodiment of the metal spacer;

[0143] FIG. 12 represents a variant of the metal spacer of FIG. 11 where the breakable members are replaced by a weakening line.

[0144] FIG. 13 represents a cross-sectional view according to XIII-XIII of the metal spacer of FIG. 12;

[0145] FIG. 14 represents a cross-sectional view of the metal spacer of FIG. 12 when positioned between a pair of «C» channel posts, and with an electric wires and a metal pipe passing through the openings of said metal spacer;

[0146] FIG. 15 represents a top view of the metal spacer of FIG. 14 with panels further enclosing said metal spacer within the adjacent elongated members to substantially prevent air circulation between the metal spacer, the adjacent elongated members and the panels.

[0147] FIG. 16 represents the third embodiment of a spacer according to the invention;

[0148] FIG. 17 represents a cross-sectional view of the spacer of FIG. 16 according to line XVII-XVII; and

[0149] FIG. 18 represents a cross-sectional view of the spacer of FIG. 16 according to line XVIII-XVIII, with removable elements removed.

[0150] FIG. 19 represents a perspective view of a fourth embodiment of a metal spacer.

[0151] FIG. 20 represents a top plan view of the fourth embodiment of FIG. 19.

[0152] FIG. 21 represents a side elevational view of the fourth embodiment of FIG. 19.

[0153] FIG. 22 represents a end elevational view of the fourth embodiment of FIG. 19.

[0154] FIG. 23 represents a perspective view of a fifth embodiment with openings (i.e. with removable elements not present).

[0155] FIG. 24 represents a top plan view of the fifth embodiment of FIG. 23.

[0156] FIG. 25 represents a side elevational view of the fifth embodiment of FIG. 23.

[0157] FIG. 26 represents a end elevational view of the fifth embodiment of FIG. 23.

[0158] FIG. 27 represents a cross sectional view of the spacer of FIG. 19 (further provided with optional fitting).

[0159] FIG. 28 represents a top view of the metal spacer of FIG. 19 with panels further enclosing said metal spacer within the adjacent elongated members and to substantially prevent air circulation between the metal spacer, the adjacent elongated members and the panels.

[0160] FIG. 29 represents a cross sectional view of the spacer of FIG. 23 (further provided with optional fitting 41b).

[0161] FIG. 30 represents a top view of the metal spacer of FIG. 23 with panels further enclosing said metal spacer within the adjacent elongated members and to substantially prevent air circulation between the metal spacer, the adjacent elongated members and the panels.

DETAILED DESCRIPTION OF PREFERRED ASPECTS THE INVENTION

[0162] Referring to the drawings, the invention relates to a spacer 3, 303 or 1003 (a metal spacer for positioning between posts), a spacer 303 (a metal spacer for positing between metallic «C» channel posts) or a spacer 603 (a non-metallic spacer for positioning between posts).

Metal Spacer 3 According to a First Preferred Aspect of the Invention

[0163] As mentioned above, with reference to FIGS. 1 to 9 the drawings, the metal spacer 3 is intended for interconnecting adjacent elongated members 101, 101′ of a frame structure. Examples of the adjacent elongated members 101, 101′ may consist of posts of a frame structure (e.g. wooden posts, metal posts, wooden joists, metal joists, etc.). The frame structure is generally further covered with covering material (e.g. panels of wood, sheetrock, etc.) to form a wall, a floor, a ceiling, a roof, etc.

[0164] The metal spacer 3 comprises: a main member 5, reinforcing members 7a and 7b, a first attachment plate 9, and a second attachment plate 11. The main member 5 has a length L and a width W, the length L corresponding to a distance separating the elongated members 101, 101′, and the width W being close to the width of the elongated members 101, 101′,

[0165] The reinforcing member 7a is connected to (preferably makes an integral part of) the main member 5 along the junction 8a. The reinforcing member 7b is connected to (preferably makes an integral part of) the main member 5 at the junction 8b. More preferably, reinforcing members 7a and 7b substantially extend along the whole length L of the main member 5, and they may have a height H that will contribute to strengthen the main member 5, preferably a height varying from 0.1 inch to few inches, much more preferably from 0.1 inch to 2 inches.

[0166] The first attachment plate 9 is connected to (preferably makes an integral part of) the main member 5 along the junction 10, and the second attachment plate 11 is connected to (preferably makes an integral part of) the main member 5 along the junction 12.

[0167] The first attachment plate 9 is adapted to cooperate with at least one fastener for fastening the same to one of the adjacent elongated members 101. Preferably at least one opening, preferably two openings 13, are provided in the first attachment plate 9. These openings 13 are adapted to be engaged by fastener (e.g. a screw, a nail, etc.) further engaging elongated member 101.

[0168] The second attachment plate 11 is adapted to cooperate with at least one fastener for fastening the same to the elongated members 101′. Preferably at least one opening, preferably two openings 15, are provided in the first attachment plate 11. These openings 15 are adapted to be engaged by fastener (e.g. a screw, a nail, etc.) further engaging the elongated member 101′.

[0169] Alternatively, as illustrated in FIG. 8, the openings 13 of the attachment plate 9 and/or the openings 15 of the attachment plate 11 may be replaced by a plurality of teeth or tongue-shaped nails 14, 16 obtained by any appropriate means well known in the art, preferably by die stamping of the attachment plate 9 and/or the attachment plate 11. This alternative may be advantageous when the elongated members are wood posts. Then, the carpenter only has to drive said teeth or tongue-shaped nails in the wood posts with a hammer (e.g. the attachment plate 9 or 11 is struck with the hammer). In such case the first attachment plate 9 and the second attachment plate 11 may be optionally slightly inclined to ease the positioning of the spacer 3 between elongated members (101, 101′) made of wood.

[0170] The main member 5 is further provided with at least one portion comprising an opening covered or closed by a corresponding removable element fastened to the main member by at least one breakable member. As illustrated in the drawings, three distinct portions 31a, 31b and 31c comprising corresponding openings 33a, 33b and 33c respectively covered or closed by corresponding removable elements 35a, 35b and 35c. The removable element 35a is fastened to the main member 3 by breakable members 37a, the removable element 35b is fastened to the main member 3 by breakable members 37b, and the removable element 35c is fastened to the main member 3 by breakable members 37c. Alternatively, as illustrated in FIGS. 3 and 7 of the drawings, the removable elements 35a, 35b and 35c are respectively fastened to the corresponding portions 31a, 31b and 31c by a weakening line 36a, 36b and 36c. Each of the weakening line 36a, 36b and 36c is formed by thinning a part of the distinct portions 31a, 31b and 31c.

[0171] When the removable element 35a is removed, access is given to the opening 33a. The removable element 35a is removed by breaking the breakable members 37a by any appropriate means. As an example, a pair of pliers or a screwdriver can be used to break the breakable members 37a, to remove or punch out the removable element and to open the opening 33a. Alternatively, when a weakening line 36a is provided, the removable element 35a is knocked out with any appropriate tool allowing to impact the removable element 35a, and break the weakening line 36a. As an example, the removable element 35a may be struck by the blade of a screw driver.

[0172] When the removable element 35b is removed, access is given to the opening 33b. The removable element 35b is removed by breaking the breakable members 37b by any appropriate means. As an example, a pair of pliers or a screwdriver can be used to break the breakable members 37b, to remove or punch out the removable element and to open the opening 33b. Alternatively, when a weakening line 36b is provided, the removable element 35b is knocked out with any appropriate tool allowing to impact the removable element 35b, and break the weakening line 36a. As an example, the removable element 35b may be struck by the blade of a screw driver

[0173] When the removable element 35c is removed, access is given to the opening 33c. The removable element 35c is removed by breaking the breakable members 37c by any appropriate means. As an example, a pair of pliers or a screwdriver can be used to break the breakable members 37c, to remove or punch out the removable element and to open the opening 33c. Alternatively, when a weakening line 36c is provided, the removable element 35c is knocked out with any appropriate tool allowing to impact the removable elements 35c, and break the weakening line. As an example, the removable element 35b may be struck by the blade of a screw driver

[0174] Of course, any one of the removable elements 35a, 35b and 35c may be knocked out before or after positioning of the spacer 3 between the adjacent elongaged members 101, 101′.

[0175] Optionally, any one of the openings 33a, 33b and 33c may be further provided conventional plastic fitting allowing to pass therethrough electric wires and/or other pipings. As illustrated, optional fittings 41a and 41c are PVC fittings currently used in the field of electric boxes. Said fittings 41a and 41c are sized to be just press fit in any one of the openings 33a and 33c. Non limitative examples of fittings 41a and 41c may be those commercialized under the tradename LOOMEX CONNECTOR. Also, optional fitting 41b may be of any type suitable to fit within the opening 33b. Optional fitting 41b can be made of any suitable plastic material, such as PVC. Of course, any other type of fitting or connectors can be used. Fittings 41a, 41b and 41c are useful to prevent electric wires, pipings or elements to be damaged due to a direct contact with the metal spacer. Also, they are useful to preferably minimize and/or more preferably prevent air of flowing across the spacer 3.

Manufacture of the Metal Spacer 3

[0176] With reference to FIG. 1, there is represented a sheet of steel 1 (obtained from a larger sheet of steel) having a gauge of about 18 and cut out to define different parts of a metal spacer 3. The metal spacer 3 comprises a main member 5, reinforcing members 7a and 7b, a first attachment plate 9 and a second attachment plate 11.

[0177] According to another embodiment of the invention, the metal spacer 3 may be preferably obtained according to a process comprising the following steps:

[0178] Step 1: Cutting from a sheet of steel, the sheet of metal 1 having an upper face and a lower face, and provided with portions defining the main member 5, the reinforcing members 7a and 7b, the first attachment plate 9 and the second attachment plate 11.

[0179] The cutting of the sheet of metal can be made with any appropriate tools well known to persons skilled in the art of sheet metal working. Preferably, the sheet of metal may be steel sheet having a gauge varying from 18 to 25, preferably a gauge of about 18. More preferably, the sheet of steel is a gauge 18 galvanized steel sheet.

[0180] Step 2: Stamping the main member 5 to define portions 31a, 31b and 31c comprising openings 33a, 33b and 33c covered or closed by removable elements 35a, 35b and 35c fastened to the main member 5 by four breakable members 37a, four breakable members 37b and four breakable members 37c, or alternatively fastened to the main member 5 by the weakening lines 36a, 36b and 36c.

[0181] Optionally, the openings 13 and 15 of the tongue-shaped nails 14 and 16 can be made in a step 2a by stamping portions of the sheet of metal 1 corresponding to the first attachment plate 9 and the second attachment plate 11. More preferably, this stamping can be made by any appropriate means, before or after step 2, or more preferably simultaneously with step 2.

[0182] Step 3: Folding the reinforcing members 7a along the junction line 8a, and folding the reinforcing member 7b along the junction line 8b, to form a «U» channel with the upper face of the main member 5. The folding can be made with any appropriate tools well known to persons skilled in the art of sheet metal working.

[0183] Step 4: Folding the first attachment 9 along the junction line 10, and the second attachment plate 11 along the junction line 12. Again, the folding can be made with any appropriate tools well known to persons skilled in the art of sheet metal working.

[0184] Optionally, steps 1, 2, 2a, 3 and 4 can be made in any order. Also, two or several of said steps can be made simultaneously. Also, two or more of said steps 1, 2, 2a, 3 and 4 may be carried out simultaneously. Also, stamping and folding steps may be carried out according to any appropriate techniques well known in the art.

[0185] The metal spacer 3 has a determined width W and length L. The length L corresponds to the standard distances between adjacent joists or posts of a frame structure, and the width W corresponds to the width of said joists or posts (i.e corresponding to the thickness of the frame structure (not considering the thickness of any covering materials fixed thereto). Example of the width W and length L may vary from 10.5 inches to 22.5 inches. Example of the height H may vary from 0.1 to few inches, preferably from 1 to 2 inches, more preferably about 2 inches.

[0186] When necessary, any one of the removable elements 35a, 35b and 35c can be removed to give access to the openings 33a, 33b and 33c. To do so, as mentioned above, any one of the removable elements 35a, 35b and 35c can be removed by breaking the corresponding breakable members 37a, 37b and 37c. or the weakening lines 36a, 36b and 36c.This operation can be made using a pair of pliers, a screwdriver, etc..

[0187] Optionally, as mentioned above, the plastic fittings 41a, 41b and 41c are conventional plastic fittings. They are positioned within the corresponding openings 33a, 33b and 33c by any appropriate means, preferably manually.

Method and Use of the Metal Spacer 3 for Interconnecting Adjacent Elongated Members of a Frame Structure

[0188] With reference to FIGS. 5 and 6, there is represented a metal spacer 3 as illustrated in FIG. 4, positioned between posts 101 and 101′. The metal spacer 3 is fastened to the posts 101, 101′ with screws 103 engaging the first attachment plate 9 and the post 101, and screws 103′ engaging the second attachment plate 11 and the post 101′.

[0189] Optionally, if the metal spacer 3 is provided with tongue-shaped nail 14, 16 as illustrated in FIG. 8, said tongue-shaped nails 14, 16 are driven in post 101, 101′ with a hammer. The hammer merely hits the first attachment plate 9 and the second attachment plate 11 to drive the tongue-shaped nails 14, 16 in the post 101, 101′.

[0190] A metal piping 121 may be passed through the opening 33b, and electric wires 131a and 131c are passed through the fittings 41a and 41c. Also, optionally, as preferably illustrated, a fitting 41b may be positioned in the opening 33b to prevent contact of the metal piping with the main portion 5, and also to minimize and more preferably prevent air of flowing via the opening 33b.

[0191] As illustrated in FIG. 6, the metal spacer 3 minimize the possibility of having air flowing between said metal spacer 3, posts 101 and 101′ and covering materials 151 and 151′ (e.g. gypsum plates). Also, in the frame structure, posts 101 and 101′ may be secured to other metal spacers 3′ and 3″. Indeed, there is no openings between the spacer 3 and the posts 101, 101′ and the covering materials 151, 151′.

Metal Spacer 303 According to a First Preferred Aspect of the Invention

[0192] As mentioned above, with reference to FIGS. 10 to 15 of the drawings, the metal spacer 303 is intended for interconnecting adjacent elongated members 301, 301′ of a frame structure. Examples of the adjacent elongated members 301, 301′ may consist of «C» channel metal posts.

[0193] The metal spacer 303 comprises: a main member 305, reinforcing embossments 306a and 306b, reinforcing members 307a and 307b, a first attachment plate 309, and a second attachment plate 311. The main member 305 has a length L′ and a width W′, the length L′ corresponding to a distance separating the elongated members 301, 301′, the width being close to the width of the elongated members 301, 301′.

[0194] The reinforcing member 307a is connected to (preferably makes an integral part of) the main member 305 along the junction 308a. The reinforcing member 307b is connected to (preferably makes an integral part of) the main member 305 at the junction 308b. More preferably, reinforcing members 307a and 307b substantially extend along the whole length L of the main member 305, and they may have a height H′ that will contribute to strengthen the main member 5, preferably a height varying from 0.1 inch to few inches, much more preferably from 0.1 inch to 2 inches.

[0195] The first attachment 309 is connected to (preferably makes an integral part of) the main member 305 along the junction 310, and the second attachment plate 311 is connected to (preferably makes an integral part of) the main member 305 along the junction 312. Preferably, the first attachment 309 and a portion 305a of the main member 305 has a width W′.sub.1 that is slightly smaller than the width W′ of the member 305 to allow an easy housing of the same within the «C» channel of the post 301. Also, optionally, notches 305b may be further provided to receive the ends of the «C» of the «C» channel metal post 301.

[0196] The first attachment plate 309 is adapted to cooperate with at least one fastener for fastening the same to one of the adjacent elongated members 301. Preferably at least one opening, preferably two openings 313, are provided in the first attachment plate 309. These openings 313 are adapted to be engaged by fastener (e.g. a screw, a nail, etc.) which are adapted to further engage the elongated member 301.

[0197] The second attachment plate 311 is adapted to cooperate with at least one fastener for fastening the same to the elongated members 301′. Preferably at least one opening, preferably two openings 315, are provided in the first attachment plate 311. These openings 315 are adapted to be engaged by fastener (e.g. a screw, a nail, etc.) which are adapted to further engage the elongated member 301′.

[0198] The main member 305 is further provided with at least one portion comprising an opening covered or closed by a corresponding removable element fastened to the main member by at least one breakable member. As illustrated in the drawings, three distinct portions 331a, 331b and 331c comprising corresponding openings 333a, 333b and 333c respectively obstructed by corresponding removable elements 335a, 335b and 335c. The removable element 335a is fastened to the main member 305 by breakable members 337a, the removable element 335b is fastened to the main member 305 by breakable members 337b, and the removable element 335c is fastened to the main member 305 by breakable members 337c. Alternatively, as illustrated in FIGS. 12 and 13 of the drawings, the removable elements 335a, 335b and 335c are respectively fastened to the main member 305 by a weakening line 336a, 336b and 336c. Each of the weakening line 336a, 336b and 336c is formed by thinning a part of the distinct portions 31a, 31b and 31c.

[0199] When the removable element 335a is removed, access is given to the opening 333a. The removable element 335a is removed by breaking the breakable members 337a by any appropriate means. As an example, a pair of pliers or a screwdriver can be used to break the breakable members 337a, to remove or punch out the removable element and to open the opening 333a. Alternatively, when a weakening line 336a is provided, the elements 335a is knocked out with any appropriate tool allowing to impact the removable elements 335a, and break the weakening line 336a. As an example, the removable element 335a may be struck by the blade of a screw driver.

[0200] When the removable element 335b is removed, access is given to the opening 333b. The removable element 335b is removed by breaking the breakable members 337b by any appropriate means. As an example, a pair of pliers or a screwdriver can be used to break the breakable members 337b, to remove or punch out the removable element and to open the opening 333b. Alternatively, when a weakening line 336b is provided, the elements 335b is knocked out with any appropriate tool allowing to impact the removable elements 335b, and break the weakening line 336b. As an example, the removable element 335b may be struck by the blade of a screw driver.

[0201] When the removable element 335c is removed, access is given to the opening 333c. The removable element 335c is removed by breaking the breakable members 337c by any appropriate means. As an example, a pair of pliers or a screwdriver can be used to break the breakable members 337c, to remove or punch out the removable element and to open the opening 333c. Alternatively, when a weakening line 336c is provided, the elements 335c is knocked out with any appropriate tool allowing to impact the removable elements 335c, and break the weakening line 336c. As an example, the removable element 335c may be struck by the blade of a screw driver.

[0202] Of course, any one of the removable elements 335a, 335b and 335c may be knocked out before or after positioning of the spacer 303 between the adjacent elongaged members 301, 301′.

[0203] Optionally, any one of the openings 333a, 333b and 333c may be further provided conventional plastic fitting allowing to pass therethrough electric wires and/or other pipings. As illustrated, optional fittings 341a and 341c are PVC fittings currently used in the field of electric boxes. Said fittings 341a and 341c are sized to be just press fit in any one of the openings 333a and 333c. Non limitative examples of fittings 341a and 341c may be those commercialized under the tradename LOOMEX CONNECTOR. Also, optional fitting 341b may be of any type suitable to fit within the opening 333b. Optional fitting 341b can be made of any suitable plastic material, such as PVC. Of course, any other type of fitting or connectors can be used. Fittings 341a, 341b and 341c are useful to prevent electric wires, pipings or elements to be damaged due to a direct contact with the metal spacer. Also, they are useful to preferably minimize and/or more preferably prevent air of flowing across the spacer 3.

[0204] Optionally, in a way similar to the alternative illustrated in FIG. 8, the first attachment plate 309 and the second attachment plate 311 may be provided with tongue-shaped nails which are similar to tongue-shaped nails 14 and 16 illustrated in said FIG. 8,

Manufacture of the Metal Spacer 303

[0205] With reference to FIG. 10, there is represented a sheet of steel 301 (obtained from a larger sheet of steel) having a gauge of about 18 and cut out to define different parts of a metal spacer 303. The metal spacer 303 comprises a main member 305, reinforcing members 307a and 307b, reinforcing embossments 306a and 306b, a first attachment plate 309 and a second attachment plate 311. Reinforcing embossments 306a and 306b contribute to increase the stiffness of the metal spacer 303.

[0206] According to the second embodiment of the invention, the metal spacer 303 may be preferably obtained according to a process comprising the following steps:

[0207] Step 1: Cutting from a sheet of steel, the sheet of metal 301 having an upper face and a lower face, and provided with portions defining the main member 305, the reinforcing members 307a and 307b, the first attachment plate 309 and the second attachment plate 311.

[0208] The cutting of the sheet of metal can be made with any appropriate tools well known to persons skilled in the art of sheet metal working. Preferably, the sheet of metal may be steel sheet having a gauge varying from 18 to 25, preferably a gauge of about 18. More preferably, the sheet of steel is a gauge 18 galvanized steel sheet.

[0209] Step 2: Stamping the main member 305 to define portions 331a, 331b and 331c comprising openings 333a, 333b and 333c covered or closed by removable elements 335a, 335b and 335c fastened to the main member 305 by four breakable members 337a, four breakable members 337b and four breakable members 337c, or alternatively fastened to the main member 305 by the weakening lines 336a, 336b and 336c. Simultaneously with step 2 or according to a separate stamping step 2b carried out before or after step 2, reinforcing embossments 306a and 306b are formed.

[0210] More preferably, stamping and folding steps may be carried out according to any appropriate techniques well known in the art.

[0211] Step 3: Folding the reinforcing members 307a along the junction line 308a, and folding the reinforcing member 307b along the junction line 308b, to form a «U» channel with the upper face of the main member 305. The folding can be made with any appropriate tools well known to persons skilled in the art of sheet metal working.

[0212] Step 4: Folding the first attachment 309 along the junction line 310, and the second attachment plate 311 along the junction line 312. Again, the folding can be made with any appropriate tools well known to persons skilled in the art of sheet metal working.

[0213] Optionally, steps 1, 2, 2b, 3 and 4 can be made in any order. Also, two or several of said steps can be made simultaneously.

[0214] If alternative tongue-shaped nails are provided in the first attachment plate 309 and the second attachment plate 311, said tongue-shaped nails are obtained by die-stamping of said first attachment plate 309 and second attachment plate 311.

[0215] The metal spacer 303 has a determined width W′ and length L′. The length L′ corresponds to the standard distances between the bottom of the «C» channel of the elongated «C» channel metal post 301, and the back of the «C«channel of the elongated «C» channel metal post 301′. Also, the cutting step 1 is adjusted to have the width L′ corresponding to the width of the elongated «C» channel metal post, except for a portion 305a of the main member 305, and the first attachment plate 309, which have a width W′.sub.1 that is slightly smaller than W′ to allow an easy housing of the portion 305a and the first attachment plate 309 within the «C» channel of the elongated «C» channel metal post 301; and have notches 305b are provide to receive the ends of the «C» of the «C» channel of the elongated «C» channel metal post 301. Preferably, the width W′, the width may vary from 3.5 inches to 5.5 inches, and the length L′ may vary from A to B, with A representing 12 inches−(a thickness of the metal sheet forming the adjacent elongated «C» channel metal post/2) and with B representing 24 inches−(a thickness of the metal sheet forming adjacent elongated «C» channel metal posts/2). An example of the length L′ when each of the adjacent elongaged «C» channel metal posts are made from a sheel of steel having gauge 18 (i.e. 0.0478 inch thick), said length L′ may vary from 11.9522 inches to 23.9522 inches. Example of the height H′ may vary from 0.1 to few inches, preferably from 1 to 2 inches, more preferably about 2 inches.

[0216] When necessary, any one of the removable elements 335a, 335b and 335c can be removed to give access to the openings 333a, 333b and 333c. To do so, as mentioned above, any one of the removable elements 335a, 335b and 335c can be removed by breaking the corresponding breakable members 337a, 337b and 337c, or the weakening lines 336a, 336b and 336c.This operation can be made using a pair of pliers, a screwdriver, etc..

[0217] Optionally, as mentioned above, the plastic fittings 341a, 341b and 341c are conventional plastic fittings similar to plastic fittings 41a, 41b and 41c defined above concerning metal spacer 3. They are positioned within the corresponding openings 333a, 333b and 333c by any appropriate means, preferably manually.

[0218] Method and use of the metal spacer 303 for interconnecting adjacent elongated members of a frame structure

[0219] With reference to FIGS. 14 and 15, there is represented a metal spacer 303 as illustrated in FIG. 12, positioned between posts 301 and 301′. The metal spacer 303 is fastened to the post 301 with screws, preferably metal screws 303, engaging the first attachment plate 309 and the post 301, and screws, preferably metal screws 303′, engaging the second attachment plate 311 and the post 301′.

[0220] A metal piping 421 may be passed through the opening 333b, and electric wires 431a and 431c may be passed through the fittings 341a and 341c. Optionally, as illustrated, a fitting 341b may be positioned in the opening 333b to avoid direct contact of the metal pipe with the main member 305, and prevent air flow by said opening 333b. Fittings 341a, 341b and 341c are similar to fittings 41a, 41b and 41c of the metal spacer 3.

[0221] As illustrated in FIG. 15, the metal spacer 303 minimize the possibility of having air flowing between said metal spacer 303, posts 301 and 301′ and covering materials 451 and 451′ (e.g. gypsum plates). Indeed, there is no openings between the spacer 303 and the posts 301, 301′ and the covering materials 451, 451′. Also, in the frame structure, posts 301 and 301′ may be secured to other metal spacers 303.

[0222] Optionally, If tongue-shaped nails are provided in the first attachment plate 309 and the second attachment plate 311, said tongue-shaped nails are driven in post 301, 301′ with a hammer. The hammer merely hits the first attachment plate 309 and the second attachment plate 311 to drive the tongue-shaped nails in the post 301, 301′,

Non-Metallic Spacer 603 According to a Third Preferred Aspect of the Invention

[0223] As mentioned above, with reference to FIGS. 16 to 18 of the drawings, the non-metallic spacer 603 is intended for interconnecting adjacent elongated members similar adjacent elongated members 101, 101′ illustrated for spacer 3. Examples of the adjacent elongated members may consist of wood posts.

[0224] The non-metallic spacer 603 comprises: a main member 605 reinforcing members 607a and 607b, a first attachment plate 609, and a second attachment plate 611. The main member 605 has a length L″ and a width W″, the length L″ corresponding to a distance separating the adjacent elongated members of the frame structure (i.e. similar to the elongated members 101 and 101′), the width L′ being close to the width of the elongated members. More preferably, reinforcing members 607a and 607b substantially extend along the whole length L of the main member 605, and they may have a height H″ that will contribute to strengthen the main member 605, preferably a height varying from 0.1 inch to few inches, much more preferably from 0.1 inch to 2 inches. According to a further preferred embodiment, the thickness of the main member 605, the reinforcing members 607a and 607b, the first attachment plate 609 and/or the second attachment plate 611 may vary from 0.1 inch to 1 inch, preferably from 0.1 inch to 0.75 inch, more preferably from 0.25 inch to 0.5 inch or 0.125 inch to 0.375 inch.

[0225] The reinforcing member 607a is connected to (preferably makes an integral part of) the main member 605 along the junction 608a. The reinforcing member 607b is makes an integral part of the main member 605 at the junction 608b.

[0226] The first attachment plate 609 makes an integral part of the main member 605 along the junction 610, and the second attachment plate 611 is connected to (preferably makes an integral part of) the main member 605 along the junction 612.

[0227] The first attachment plate 609 is adapted to cooperate with at least one fastener for fastening the same to one of the adjacent elongated members. Preferably at least one opening, preferably two openings 613, are provided in the first attachment plate 609. Each of these openings 613 is adapted to be engaged by a fastener (e.g. a screw, a nail, etc.) in order to further engage the corresponding elongated member.

[0228] The second attachment plate 611 is adapted to cooperate with at least one fastener for fastening the same to the adjacent elongated member. Preferably at least one opening, preferably two openings 615, are provided in the second attachment plate 611. Each of these openings 615 is adapted to be engaged by a fastener (e.g. a screw, a nail, etc.) in order to further engage the corresponding elongated member.

[0229] The main member 605 is further provided with at least one portion comprising an opening obstructed by a corresponding removable element fastened to the main member by at least one breakable member. As illustrated in FIGS. 16 to 18 of the drawings, the removable elements 635a, 635b and 635c are respectively fastened to the main member 605 by the weakening lines 363a, 363b and 363c. Each of the weakening line 336a, 336b and 336c is formed by thinning a part of the distinct portions 331a, 331b and 331c.

[0230] When the removable element 635a is removed, access is given to the opening 633a. The removable element 635a is removed by breaking the weakening line 363a. To do so, the removable element 635a is knocked out with any appropriate tool allowing to impact the removable elements 635a, and break the weakening line 363a. As an example, the removable element 635a may be struck by the blade of a screw driver.

[0231] When the removable element 635b is removed, access is given to the opening 633b. The removable element 635b is removed by breaking the weakening line 363b. To do so, the removable element 635b is knocked out with any appropriate tool allowing to impact the removable elements 635b, and break the weakening line 363b. As an example, the removable element 635b may be struck by the blade of a screw driver.

[0232] When the removable element 635c is removed, access is given to the opening 633c. The removable element 635c is removed by breaking the weakening line 363c. To do so, the removable element 635c is knocked out with any appropriate tool allowing to impact the removable elements 635c, and break the weakening line 363c. As an example, the removable element 635c may be struck by the blade of a screw driver.

[0233] Optionally, any one of the openings 633a, 633b and 633c may be further provided conventional plastic fittings allowing to pass therethrough electric wires and/or other pipings. Said plastic fittings are preferably similar to those of the first embodiment of the invention (i.e. metallic spacer 3).

Manufacture of the Non-Metallic Spacer 603

[0234] The non-metallic spacer 603 is obtained by moulding of a plastic material in a mold. Said plastic material advantageously further contains additives such as flame retardant, etc. The moulding can be carried out according to any appropriate moulding techniques well known to persons skilled in the art.

[0235] The molded non-metallic spacer 603 has an upper face and a lower face, and is provided with portions defining the main member 605, the reinforcing members 607a and 607b, the first attachment plate 609 and the second attachment plate 611. Preferably, any kind the plastic or composite material can be used, especially fiber glass, or preferably HDPE comprising additives such flame retardant.

[0236] The non-metallic spacer 603 has a determined width W″ and length L″. The length L″ corresponds to the standard distances between joists or posts, and the width W″ corresponds to the width of said joists or posts (i.e. corresponding to the thickness of the frame structure (i.e. not considering the thickness of any covering materials fixed to said frame structure). Examples of the standard distances may vary from 10.5 inches to 22.5 inches. Example of the height H″ may vary from 0.1 to few inches, preferably from 1 to 2 inches, more preferably about 2 inches. Examples of the thickness of the main member 605, the reinforcing members 607a and 607b, the first attachment plate 609 and/or the second attachment plate 611 may vary from 0.1 inch to 1 inch, preferably from 0.1 inch to 0.75 inch, more preferably from 0.25 inch to 0.5 inch or 0.125 inch to 0.375 inch, much more preferably about 0.25 inch.

[0237] When necessary, any one of the removable elements 635a, 633b and 635c can be removed to give access to the openings 633a, 633b and 633c. To do so, as mentioned above, any one of the removable elements 635a, 635b and 635c can be removed by breaking the corresponding breakable lines 636a, 636b and 636c. These breakable lines are obtained by thinning a portion of the spacer 603 between the main portion 631a, 631b and 631c and the removable elements 635a, 635b and 635c. This operation can be made using a pair of pliers and/or a screwdriver.

[0238] Optionally, conventional plastic fittings may be positioned within the openings 633a, 633b and 633c to allow passing therethrough electric wires and/or other pipings. Any type of fittings can be used. These fittings may be positioned within the corresponding openings 633a, 633b and 633c manually when necessary.

Method and Use of the Non-Metallic Spacer 603 for Interconnecting Adjacent Elongated Members of a Frame Structure

[0239] The non-metallic spacer 603 can be used in a way similar to the one concerning the spacer 3.

Metal Spacer 703 According to a Fourth Preferred Aspect of the Invention

[0240] With reference to FIGS. 19 to 22, 27 and 28 of the drawings, a fourth preferred embodiment of the invention is illustrated. This fourth preferred embodiment refers to a metal spacer 703 which is similar to an alternative embodiment of the spacer 3 illustrated in FIG. 8, and intended for interconnecting adjacent elongated members 701, 701′ of a frame structure. The adjacent elongated members 701, 701′ may consist of posts of a frame structure (e.g. wooden posts), The frame structure is generally further covered with covering material (e.g. panels of wood, sheetrock, etc.) to form a wall, a floor, a ceiling, a roof, etc.

[0241] The metal spacer 703 comprises: a main member 705, reinforcing members 707a and 707b, a first attachment plate 709, and a second attachment plate 711. The main member 705 has a length L.sup.iv and a width W.sup.iv, the length L.sup.iv corresponding to a distance separating the elongated members 701, 701′, and the width W.sup.iv being close to the width of the elongated members 701, 701′. The length L.sup.iv may be of any appropriate length, preferably about 14.5 inches, and the width W.sup.iv may be of any appropriate width, preferably about 3.5 inches.

[0242] The reinforcing member 707a is connected to (preferably makes an integral part of) the main member 705 along the junction 708a. The reinforcing member 707b is connected to (preferably makes an integral part of) the main member 705 at the junction 708b. More preferably, reinforcing members 707a and 707b substantially extend along the whole length L.sup.iv of the main member 705, and they may have a height H.sup.iv that will contribute to strengthen the main member 705, preferably a height varying from 0.1 inch to few inches, much more preferably from 0.1 inch to 2 inches, and even more preferably about 0.71 inch.

[0243] The first attachment plate 709 is connected to (preferably makes an integral part of) the main member 705 along the junction 710, and the second attachment plate 711 is connected to (preferably makes an integral part of) the main member 5 along the junction 712.

[0244] The first attachment plate 709 is adapted to cooperate with at least one fastener for fastening the same to one of the adjacent elongated members 701.

[0245] Preferably at least one opening, preferably two openings 713, are provided in the first attachment plate 709. Preferably, the attachment plate 709 has a width similar to the one of the main member 705 (preferably about 3.5 inches), and any suitable height (preferably about 2 inches).

[0246] The second attachment plate 711 is adapted to cooperate with at least one fastener for fastening the same to one of the adjacent elongated members 701. Preferably at least one opening, preferably two openings 715, are provided in the second attachment plate 709. Preferably, the first attachment plate 709 has a width similar to the one of the main member 705 (preferably about 3.5 inches), and any suitable height (preferably about 2 inches).

[0247] Preferably, all constitutive parts of the metal spacer 703 are made from a single sheet of metal, more particularly a single sheet of steel, and much more preferably a single sheet of galvanized steel. The sheet of metal may be of any appropriate gauge, preferably from 18 to 25, more preferably 18 or 20, more preferably 20.

[0248] Each openings 713 is further provided with a L-shaped elongated element 714 provided with a first portion 714a having a first end and a second end opposite to the first end, and a second portion 714b having a first end and a second end opposite to the first end. The first end of the first portion 714a is connected to the at least one first attachment plate 709, the first portion 714a defining a connector between the at least one first attachment plate 709 and the second portion 714b, the second end of the first portion 714a and the first end of the second portion 714b being connected to form a shoulder 714c at the L-shaped elongated element. The second end of the second portion 714b is sharpened and defines at least one first fastener 803. The L-shaped elongated element 714 is movable from a raised position where the second end of the second portion is positioned above the at least one first fastening opening 713, to a lowered position where the at least one first fastener 803 is adapted to engage via the at least one first fastening opening a corresponding adjacent elongated member 701 of the frame structure. Each L-shaped elongated element 714 can be obtained by any appropriate means well known in the art, preferably by die stamping of the attachment plate 709.

[0249] Each openings 715 is further provided with a L-shaped elongated element 716 provided with a first portion 716a having a first end and a second end opposite to the first end, and a second portion 716b having a first end and a second end opposite to the first end. The first end of the first portion 716a is connected to the at least one second attachment plate 711, the first portion 716a defining a connector between the at least one second attachment plate 711 and the second portion 716b, the second end of the first portion 716a and the first end of the second portion 716b being connected to form a shoulder 716c at the L-shaped elongated element. The second end of the second portion 716b is sharpened and defines at least one first fastener 803′. The L-shaped elongated element 716 is movable from a raised position where the second end of the second portion is positioned above the at least one first fastening opening 715, to a lowered position where the at least one first fastener 803′ is adapted to engage via the at least one first fastening opening 715 a corresponding adjacent elongated member 701′ of the frame structure. Each L-shaped elongated element 716 can be obtained by any appropriate means well known in the art, preferably by die stamping of the attachment plate 711.

[0250] Elements 714, 716 may have any appropriate shape, as far as they can be driven by any appropriate means into the corresponding posts 701, 701′ of the frame structure (preferably with a hammer of the type commonly use by carpenters). said posts 701, 701′ being made of wood or any other material suitable for carpentry

[0251] Preferably, the second portion 714b and its sharpened end, and the second portion 716b and its sharpened end are respectively engaged in the post 701 and 701′ by any appropriate means, such as by striking the shoulder 714c and 716c with the head of the hammer of a carpenter. Preferably, the second end of the second portion 716b is sharpened. Also, preferably, the first attachment plate 709 and the second attachment plate 711 may be optionally slightly inclined to ease the positioning of the spacer 703 between elongated members (701, 701′) made of wood.

[0252] The main member 705 is further provided with at least one portion comprising an opening covered or closed by a corresponding removable element fastened to the main member by at least one breakable member. As illustrated in the drawings, three distinct portions 731a, 731b and 731c comprising corresponding openings 733a, 733b and 733c respectively covered or closed by corresponding removable elements 735a, 735b and 735c. The removable element 735a is fastened to the main member 703 by a weakening line 736a, 736b and 736c. Each of the weakening line 736a, 736b and 736c is formed by thinning a part of the distinct portions 731a, 731b and 731c.

[0253] When the removable element 735a is removed, access is given to the opening 733a. The removable element 735a can be removed by breaking the weakening line 736a. As an example, the removable element 735a may be knocked out by any appropriate tool allowing to impact the removable element 735a, and break the weakening line 736a. Preferably, the removable element 735a may be struck by the blade of a screwdriver.

[0254] When the removable element 735b is removed, access is given to the opening 733b. The removable element 735b can be removed by breaking the weakening line 736b. As an example, the removable element 735b may be knocked out by any appropriate tool allowing to impact the removable element 735b, and break the weakening line 736a. Preferably, the removable element 735b may be struck by the blade of a screwdriver

[0255] When the removable element 735c is removed, access is given to the opening 733c. The removable element 735c is removed by breaking the weakening line 736c. As an example, the removable element 735c may be knocked out by any appropriate tool allowing to impact the removable elements 735c, and break the weakening line. Preferably, the removable element 735b may be struck by the blade of a screw driver.

[0256] Of course, any one of the removable elements 735a, 735b and 735c may be knocked out before or after positioning of the spacer 703 between the adjacent elongaged members 701, 701′.

[0257] Optionally, any one of the openings 733a, 733b and 733c may be further provided with a corresponding fitting allowing to pass therethrough electric wires and/or other pipings. Such fitting may be similar to those described in connection with the first embodiment of the invention illustrated in FIGS. 4 to 6 and 9.

[0258] Manufacture of the metal spacer 703

[0259] The metal spacer 703 is manufacture in a way similar to the manufacture of the metal spacer 3, as defined above.

[0260] According to another embodiment of the invention, the metal spacer 703 may be preferably obtained according to a process comprising the following steps:

[0261] Step 1: Cutting sheet of metal, said sheet of metal having an upper face and a lower face, and being provided with portions defining the main member 705, the reinforcing members 707a and 707b, the first attachment plate 709 and the second attachment plate 711.

[0262] The cutting of the sheet of metal can be made with any appropriate tools well known to persons skilled in the art of sheet metal working. Preferably, the sheet of metal may be steel sheet having a gauge varying from 18 to 25, preferably a gauge of about 18 or 20, more preferably 20. More preferably, the sheet of metal is a sheet of steel, more preferably a sheet of galvanized steel having a gauge of about 20.

[0263] Step 2: Stamping the main member 705 to define portions 731a, 731b and 731c comprising openings 733a, 733b and 733c covered or closed by removable elements 735a, 735b and 735c fastened to the main member 705 by weakening lines 736a, 736b and 736c.

[0264] Step 3: Stamping of the first attachment plate 709 and the second attachment plate 711, to form the openings 713 and 715, the L-shaped elongated elements 714, 716 and the sharpening of the second end of the second portions 714b and 716b. More preferably, this stamping can be made by any appropriate means, before or after step 2, or more preferably simultaneously with step 2.

[0265] Step 4: Folding the reinforcing members 707a along the junction line 708a, and folding the reinforcing member 707b along the junction line 708b, to form a «U» channel with the upper face of the main member 705. The folding can be made with any appropriate tools well known to persons skilled in the art of sheet metal working.

[0266] Step 5: Folding the first attachment 709 along the junction line 710, and the second attachment plate 711 along the junction line 712. Again, the folding can be made with any appropriate tools well known to persons skilled in the art of sheet metal working.

[0267] Optionally, steps 1 to 5 can be made in any order. Also, two or several of said steps can be made simultaneously. Also, two or more of said steps 1 to 5 may be carried out simultaneously. Also, stamping and folding steps may be carried out according to any appropriate techniques well known in the art.

[0268] Preferably, the metal spacer 703 has a determined width W.sup.iv and length L.sup.iv. The length L.sup.iv corresponds to the standard distances between adjacent joists or posts of a frame structure, and the width W.sup.iv corresponds to the width of said joists or posts (i.e. corresponding to the thickness of the frame structure (not considering the thickness of any covering materials fixed thereto). Example of the width W.sup.iv and length L.sup.iv may vary from 10.5 inches to 22.5 inches. Example of the height H.sup.iv may vary from 0.1 to few inches, preferably from 1 to 2 inches, more preferably about 2 inches.

[0269] When necessary, any one of the removable elements 735a, 735b and 735c can be removed to give access to the openings 733a, 733b and 733c. To do so, as mentioned above, any one of the removable elements 735a, 735b and 735c can be removed by breaking the weakening lines 736a, 736b and 736c.This operation can be made using a pair of pliers, a screwdriver, etc.

[0270] Optionally, as mentioned above, plastic fittings may be positioned within the corresponding openings 733a, 733b and 733c by any appropriate means, preferably manually.

Method and Use of the Metal Spacer 703 for Interconnecting Adjacent Elongated Members 701, 701′ of a Frame Structure

[0271] With reference to FIGS. 27 and 28, there is represented a metal spacer 703 as illustrated in FIGS. 19 to 23, positioned between posts 701 and 701′. The metal spacer 703 is fastened to the posts 701, 701′ by driving the sharpened end of the second section 714b, 716b through the openings 713, 715 and the posts 701, 701′. To do so, the shoulder 714b, 716b are struck by the head of a hammer of a carpenter.

[0272] A metal piping 821 may be passed through the opening 733b, and electric wires 831a and 831c are passed through the fittings 741a and 741c. Also, optionally, as preferably illustrated, a fitting 741b may be positioned in the opening 733b to prevent contact of the metal piping with the main portion 705, and also to minimize and more preferably prevent air of flowing via the opening 733b.

[0273] As illustrated in FIG. 28, the metal spacer 703 minimize the possibility of having air flowing between said metal spacer 703, posts 701 and 701′ and covering materials 851 and 851′ (e.g. gypsum plates). Also, in the frame structure, posts 701 and 701′ may be secured to other metal spacers 703′ and 703″. Preferably, there is no openings between the spacer 703 and the posts 701, 701′ and the covering materials 851, 851′.

Metal Spacer 1003 According to a Fifth Preferred Aspect of the Invention

[0274] As mentioned above, with reference to FIGS. 23 to 26, 29 and 30 of the drawings, the metal spacer 1003 is intended for interconnecting adjacent elongated members 1001, 1001′ of a frame structure. Examples of the adjacent elongated members 1001, 1001′ may consist of posts of a frame structure (e.g. wooden posts, metal posts, wooden joists, metal joists, etc.). The frame structure is generally further covered with covering material (e.g. panels of wood, sheetrock, etc.) to form a wall, a floor, a ceiling, a roof, etc.

[0275] The metal spacer 1003 comprises: a main member 1005, reinforcing members 1007a and 1007b, a first attachment plate 1009, and a second attachment plate 1011. The main member 1005 has a length L″ and a width W″, the length L″ corresponding to a distance separating the elongated members 1001, 1001′, and the width W′ being close to the width of the elongated members 1001, 1001′. The length L″ may be of any appropriate length, preferably about 14.5 inches, and the width W′ may be of any appropriate width, preferably about 3.5 inches.

[0276] The reinforcing member 1007a is connected to (preferably makes an integral part of) the main member 1005 along the junction 1008a. The reinforcing member 1007b is connected to (preferably makes an integral part of) the main member 1005 at the junction 1008b. More preferably, reinforcing members 1007a and 1007b substantially extend along the whole length L″ of the main member 1005, and they may have a height H″ that will contribute to strengthen the main member 1005, preferably a height varying from 0.1 inch to few inches, much more preferably from 0.1 inch to 2 inches, and even more preferably about 0.71 inch.

[0277] The first attachment 1009 is connected to (preferably makes an integral part of) the main member 1005 along the junction 1010, and the second attachment plate 1011 is connected to (preferably makes an integral part of) the main member 1005 along the junction 1012.

[0278] The first attachment plate 1009 is adapted to cooperate with at least one fastener for fastening the same to one of the adjacent elongated members 1001. Preferably at least one opening, preferably five openings 1013, are provided in the first attachment plate 1009. These openings 1013 are adapted to be engaged by fastener (e.g. a screw, a nail, etc.) further engaging elongated member 1001. Said openings 1013 may be of any appropriate size. As an example, the openings 1013 may have a diameter of 13/64 inch.

[0279] The second attachment plate 1011 is adapted to cooperate with at least one fastener for fastening the same to the elongated members 1001′. Preferably at least one opening, preferably five openings 1015, are provided in the second attachment plate 1011. These openings 1015 are adapted to be engaged by fastener (e.g. a screw, a nail, etc.) further engaging the elongated member 1001′. Said openings 1015 may be of any appropriate size. As an example, the openings 1015 may have a diameter of 13/64 inch.

[0280] Preferably, all constitutive parts of the metal spacer 1003 are made from a single sheet of metal, more particularly a single sheet of steel, and much more preferably a single sheet of galvanized steel. The sheet of metal may be of any appropriate gauge, preferably from 18 to 25, more preferably 18 or 20, more preferably 20.

[0281] The main member 1005 is illustrated with opening not covered or closed by a corresponding removable element fastened to the main member 1005 by at least one breakable member or weakening line. Of course, main member 1005 may be further provided with such removable elements similar to those illustrated in any one of FIGS. 1 to 7 and 10 to 15.

[0282] Optionally, any one of the openings 1033a, 1033b and 1033c may be further provided conventional fitting 1041a, 1041b and 1041c which are similar to those described in the embodiment of FIGS. 4 to 6 and 9, in order to allowing passing therethrough electric wires and/or other pipings.

Manufacture of the Metal Spacer 1003

[0283] The metal spacer 1003 is manufactured in a way similar to the manufacture of the metal spacer 3.

[0284] According to another embodiment of the invention, the metal spacer 1003 may be preferably obtained according to a process comprising the following steps:

[0285] Step 1: Cutting a sheet of metal, said the sheet of metal having an upper face and a lower face, and being provided with portions defining the main member 1005, the reinforcing members 1007a and 1007b, the first attachment plate 1009 and the second attachment plate 1011.

[0286] The cutting of the sheet of metal can be made with any appropriate tools well known to persons skilled in the art of sheet metal working. Preferably, the sheet of metal may be steel sheet having a gauge varying from 18 to 25, preferably a gauge of about 18 or 20, more preferably 20. More preferably, the sheet of metal is a sheet of steel, more preferably a sheet of galvanized steel having a gauge of about 20.

[0287] Step 2: Stamping the main member 1005 to define portions comprising openings 1033a, 1033b and 1033c eventually covered or closed by removable elements fastened to the main member 1005 by weakening lines.

[0288] Step 3, the openings 1013 and 1015 are made by stamping portions of the sheet of metal corresponding to the first attachment plate 1009 and the second attachment plate 1011. More preferably, this stamping can be made by any appropriate means, before or after step 2, or more preferably simultaneously with step 2.

[0289] Step 4: Folding the reinforcing members 1007a along the junction line 1008a, and folding the reinforcing member 1007b along the junction line 1008b, to form a «U» channel with the upper face of the main member 1005. The folding can be made with any appropriate tools well known to persons skilled in the art of sheet metal working.

[0290] Step 5: Folding the first attachment 1009 along the junction line 1010, and the second attachment plate 1011 along the junction line 1012. Again, the folding can be made with any appropriate tools well known to persons skilled in the art of sheet metal working.

[0291] Optionally, steps 1 to 5 can be made in any order. Also, two or several of said steps can be made simultaneously. Also, two or more of said steps 1 to 5 may be carried out simultaneously. Also, stamping and folding steps may be carried out according to any appropriate techniques well known in the art.

[0292] The metal spacer 1003 has a determined width W.sup.v and length L.sup.v. The length L″ corresponds to the standard distances between adjacent joists or posts of a frame structure, and the width W′ corresponds to the width of said joists or posts (i.e. corresponding to the thickness of the frame structure (not considering the thickness of any covering materials fixed thereto). Example of the width W′ and length L″ may vary from 10.5 inches to 22.5 inches. Example of the height H″ may vary from 0.1 to few inches, preferably from 1 to 2 inches, more preferably about 2 inches.

[0293] In a way similar to the embodiment of spacer 303 of FIGS. 10 to 15, the spacer 1003 is provided with removable elements 1035a, 1035b and 1035c which are similar to removable elements 35a, 35b and 35c. Said removable elements 1035a, 1035b and 1035c are fastened to a corresponding portion of the openings 1033a, 1033b and 1033c with breakable members similar to breakable members 337a to 337c, or preferably weakening lines 1036a, 1036b and 1036c which are similar to weakening lines 336a, 336b and 336c. When necessary, any one of the eventual removable elements 1035a, 1035b and 1035c can be removed to give access to the openings 1033a, 1033b and 1033c. To do so, as mentioned above, any one of the removable elements can be removed by breaking the corresponding weakening lines. This operation can be made in a way similar to what is defined in previous embodiments of the invention, preferably using a pair of pliers, a screwdriver, etc..

[0294] Optionally, as mentioned above, the fittings 1041a, 1041b and 1041c are conventional plastic fittings. They are positioned within the corresponding openings 1033a, 1033b and 1033c by any appropriate means, preferably manually.

Method and Use of the Metal Spacer 1003 for Interconnecting Adjacent Elongated Members of a Frame Structure

[0295] With reference to FIGS. 29 and 30, there is represented a metal spacer 1003 as illustrated in FIGS. 23 to 26, positioned between posts 1001 and 1001′. The metal spacer 1003 is fastened to the posts 1001, 1001′ with screws 1003 engaging the first attachment plate 1009 and the post 1001, and screws or nails, preferably 1003′, engaging the second attachment plate 1011 and the post 1001′.

[0296] A metal piping 1121 may be passed through the opening 1033b, and electric wires 1131a and 1131c are passed through the fittings 1041a and 1041c. Also, optionally, as preferably illustrated, a fitting 1041b may be positioned in the opening 1033b to prevent contact of the metal piping with the main portion 1005, and also to minimize and more preferably prevent air of flowing via the opening 1033b.

[0297] As illustrated in FIG. 30, the metal spacer 1003 minimize the possibility of having air flowing between said metal spacer 1003, posts 1001 and 1001′ and covering materials 1151 and 1151′ (e.g. gypsum plates). Also, in the frame structure, posts 1001 and 1001′ may be secured to other metal spacers 1003′ and 1003″. Preferably, there is no openings between the spacer 1003 and the posts 1001, 1001′ and the covering materials 1151, 1151′.

[0298] The above description of the embodiments should not be interpreted in a limiting manner since other variations, modifications and refinements are possible within the scope of the present invention. Accordingly, it should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form varying modes of the disclosed invention. The scope of the invention is defined in the appended claims and their equivalents.