AU2019280035A1

AU2019280035A1 - Improved Spacer

Info

Publication number: AU2019280035A1
Application number: AU2019280035A
Authority: AU
Inventors: Mariana Lai; Warren Stewart; Giuseppe Timi
Original assignee: CSR Building Products Ltd
Current assignee: CSR Building Products Ltd
Priority date: 2019-04-16
Filing date: 2019-12-12
Publication date: 2020-11-05

Abstract

An improved spacer is disclosed for positioning a sheet in a spaced relationship relative to framework that supports the sheet in use. The spacer is elongate and extends between first and second opposite ends. The spacer comprises at least one 5 leg located at one of the ends. The leg is arranged for positioning the end in a spaced relationship relative to the framework. 11959812_1 (GHMatters) P110604.AU.1 120 110 130 160 140 10 Figure 1 150 -- 160 .40 100 Figure 2 119 110 112 114 Figure 117 28479_1 (GHMatters) P110604.AU 1/8

Description

120 110 130

160 140

10 Figure 1

150 -- 160

.40 Figure 2 100

119

110 112

114 Figure 117

28479_1 (GHMatters) P110604.AU

1/8

IMPROVED SPACER TECHNICAL FIELD

An improved spacer is disclosed that can be attached to an existing framework (e.g. to the purlins, studs, etc. of roofing and wall framework, etc.). The spacer enables sheets (such as roof or wall sheets), panels, board, cladding, etc. (hereafter collectively referred to as "sheets") to then be attached to the framework via the spacer. The spacer functions, inter alia, to provide space for insulation placed over or against the framework and underneath the sheets. The spacer may prevent such insulation from being unduly compressed or crushed. The spacer may also provide a cavity for services etc.

BACKGROUND ART

Roofs on large and small buildings typically comprise of purlins or rafters. Framework (e.g. roof purlins or rafters) may be fixed across the beams and at spaced intervals. A safety mesh is typically attached to the framework for larger roofs but may not be present for smaller roofs. Roof sheets are then screwed into the framework or attached by other known means such as via a clip lock mechanism. It is often a requirement to provide suitable insulation in the roof area. Insulating material in roll form is laid over the framework and the roof sheets are then attached. The insulating material can comprise aluminium foil and PE bubble insulation, glasswool insulation and the like.

Insulation may also be employed within external or internal walls in a building. Again, wall sheets, panels, board, etc. are then fixed with respect to the wall framework (such as to the studs, posts, plates, etc.), thereby retaining the insulation within the wall cavity.

A disadvantage with the conventional approach is that the insulation material is compressed between the framework and the sheets. For insulation material to achieve its proper insulating rating it needs to be in its recovered, or uncompressed form. Compressed or crushed insulation reduces insulation efficiency.

11959760_1 (GHMaters) P110604.AU.1

Roofing spacers are known in the art that are employed between the roofing framework and the roof sheets so as to prevent insulation material from being compressed. Examples are shown in each of AU 2017251813 and AU 2017101373.

Problems with the use of existing spacers can arise during installation, particularly at height, where a roof installer may be subjected to wind, difficult roof slopes, etc. If the spacer is difficult to position and affix, this can lead to occupational hazards and can slow down the roof sheet installation process. Further, if the roofing framework is not sufficiently level, such existing spacers can prove to be difficult to install, for example without causing damage to the spacer or associated supports used in conjunction with the spacer. It may then become difficult to attach roof sheets to the spacer, or to attach the spacer to the framework, which can lead to hazards for the installer and slow down roof sheet installation.

The above references to the background art do not constitute an admission that the art forms part of the common general knowledge of a person of ordinary skill in the art. The above references are also not intended to limit the application of the spacer as disclosed herein.

SUMMARY

Disclosed herein in a first aspect is spacer for positioning a sheet in a spaced relationship relative to framework that supports the sheet in use. The spacer can space the sheets from the framework so as to e.g. prevent insulation material from being compressed. Whilst the spacer finds particular use in roofing applications (i.e. to position a roof sheet in a spaced relationship relative to roofing framework), it should be understood that the spacer can be employed in a variety of other sheet-spacing applications including, for example, the spacing of sheets that are affixed with respect to internal and external walls, etc. As an alternative or additional to preventing insulation material from being compressed, the spacer may function to provide a cavity within a

11959760_1 (GHMatters) P110604.AU.1 roof, wall, etc. (i.e. between the sheets and framework). This cavity may be employed to accommodate services such as electrical, cabling, wiring, water, gas, etc.

The spacer as disclosed herein is elongate and extends between first and second opposite ends. The spacer comprises at least one leg located at one of the ends. This leg is arranged for positioning the end in a spaced relationship relative to the framework. The spacer may however comprise any number of legs located between its first and second ends, for positioning the spacer in a relationship relative to the framework, the number and location of spacer legs depending on the particular requirements of the framework or the sheets.

The spacer further comprises opposing elongate walls, and elongate flanges, each flange extending for a length of a respective elongate wall, and each flange projecting laterally outwards of its respective elongate wall. The opposing elongate walls give the spacer the form of an inverted channel section (e.g. that may be stacked, overlapped, etc.). Such a channel profile may also provide enhanced structural properties to the spacer, even when formed of a relatively light gauge sheet material (e.g. galvanised steel sheet, aluminium sheet, etc.).

The leg of the spacer, similarly to the elongate body of the spacer, comprises opposing leg walls, and leg flanges that each extend for a length of its respective leg wall, with each leg flange projecting laterally outwards of its respective leg wall.

In accordance with the present disclosure, the leg flanges are joined to respective elongate wall flanges in a manner such that a respective flanking web is formed at the join between each leg flange and its respective wall flange. The flanking webs "flank" each leg flange and its respective wall flange and represent an improvement over prior art spacers. Further, it has been found that provision of flanking webs, joining the elongate spacer body to the leg, can impart significant strength benefits to the spacer in use.

In an embodiment, each flanking web may be configured to diverge from its respective leg flange and wall flange, adjacent the join between the leg flange and wall flange. The

11959760_1 (GHMatters) P110604.AU.1 divergence can form a corner that is flared at the join between the leg and wall flanges. Such flared leg joins can provide a larger amount of flange material at the comer of the bend between the spacer body and leg and can thus reduce (or accommodate) the degree of stress concentration at the corner when the spacer is subjected to loading, for example, by roofing sheets, and/or by the weight of the roofing installer during installation. By providing flanking webs on either side of the spacer, the join between the leg and the elongate spacer can be strengthened, improving the structural integrity of the spacer, whilst obviating the need for use of heavier-gauge sheet materials (i.e. that may otherwise be required to form spacers of similar structural integrity, absent such flanking webs).

In some embodiments, each flanking web may be configured to deform laterally outwards of its respective leg and wall flanges. The deformation may then return towards the comer so as to in part define the flared corner.

In some embodiments, the spacer may further comprise an elongate web. The opposing elongate walls may each extend from a respective elongate side of the web. Correspondingly, the leg may further comprise a leg web. The leg walls may each extend from a respective side of the leg web. The leg may extend from (e.g. it may be connected to) each of the opposing elongate walls. The presence of the elongate web and opposing elongate walls may give the spacer the form of an inverted channel section (e.g. that may be stacked, overlapped, etc.). Such a channel profile may also provide enhanced structural properties to the spacer, even when formed of a relatively light gauge sheet material (e.g. galvanised steel sheet, aluminium sheet, etc.).

In some embodiments, the spacer may be configured such that it does not comprise a leg located at an opposite end of the spacer. In such embodiments, the end not having a spacer leg may be configured for other purposes, such as engaging with supporting structures, or other like spacers. For example, each wall flange may further comprise one or more discrete securing formations formed therein, adjacent the spacer opposite end. These securing formations may, for example, take the form of discrete, spaced lugs that are press-formed or cut into each flange. Each securing formation may be arranged

11959760_1 (GHMatters) P110604.AU.1 to releasably secure the spacer opposite end at a starter support. The starter support may be able to be pre-arranged and/or secured at the framework. Alternatively, the starter support may be able to be pre-arranged and/or secured or at the spacer.

For example, when the starter support is pre-secured at the framework, the securing formations of the spacer may be arranged to releasably engage with the starter support. On the other hand, the starter support may first be releasably secured at the spacer second end, and then secured to the framework. The starter support can take the place of a leg for a first-to-be-positioned spacer at the second "legless" end of the first-to-be positioned spacer. The starter support may take the form of a starter saddle onto which the second end of the spacer can locate. The starter support may have a form such that it can support the spacer second end thereat against lateral movement.

In some embodiments, each elongate wall flange may comprise a pair of discrete securing formations, or lugs, formed therein. In use an upper end of the starter support may be located at the pair of discrete securing formations. In this way, the starter support may be aligned with and secured to the spacer. The securing lugs may also allow for the starter support to be secured to the spacer prior to installation of the spacer at the framework. For example, this can enable a roofing installer to attach the starter support-spacer assembly to the framework as a unit, which may be an advantage in situations of complex installations, where installing multiple separate components to the framework may be difficult.

In some embodiments, the elongate web of the spacer can comprise one or more apertures therethrough. The one or more web apertures may be located adjacent to the flange securing formations. In use, the web apertures may be configured to enable one or more fasteners to be passed through the web of the spacer and through the underlying starter support, which may allow the starter support to be secured to the framework. When the starter support is secured to the framework in this way, the spacer second end may accordingly become secured to the framework.

In some embodiments, the starter support may be configured to engage with each elongate flange of the spacer and/or with the securing formations. Such engagement can

11959760_1 (GHMatters) P110604.AU.1 enable the spacer to be pivoted on the starter support in use. For example, this can allow a roofing installer to simply engage an end of the spacer with the starter support and then allow the spacer to pivot under gravity (e.g. by dropping/releasing the spacer first end) until the leg of the spacer locates with the framework. A spacer able to pivot on its starter support may be installed in a more efficient, controlled and safe manner.

In some embodiments, the starter support may be in the form of a generally triangular section. An apex portion of the triangular section may be configured to engage in use with the elongate flange of the spacer and/or with the securing formations. A triangular support section may provide both an efficient pivot point for the spacer, and may also contribute to the structural integrity of the starter support (e.g. a triangular profile offers greater resistance to compression). Such a triangular shape may impart sufficient additional strength to the starter support to allow for starter supports (and thereby spacers) of increased height to be used, without the need for the use of stronger or heavier materials. Such a triangular shape may allow a roofing installer to stand on the spacer at its second end, without compromising the structural integrity of the starter support and/or of the spacer.

In some embodiments, the apex portion of the triangular support may comprise an aperture. The apex aperture may be configured to align in use with the one or more web apertures of an overlying spacer. This can enable the one or more fasteners, such as screws, to be passed through the web aperture(s) and the apex aperture of the starter support, allowing the triangular support to be secured to the framework. In particular, the aligned apertures of the spacer and starter support may allow for the fasteners to be accessed by the roofing installer, even after the spacer has been placed over the starter support, which may aid in both installation and disassembly, as necessary.

In some embodiments, the starter support may comprise one or more strengthening formations formed therein. Such strengthening formations may take the form of ribs, gussets or indentations for example, and may be formed along the base, walls and/or corners of the starter support. Again, such strengthening formations may impart sufficient additional strength to the starter support to allow for starter supports (and

11959760_1 (GHMatters) P110604.AU.1 thereby spacers) of increased height to be used, and to allow a roofing installer to stand on the spacer at its second end, without compromising the structural integrity of the starter support and/or of the spacer.

In some embodiments, the at least one leg may extend from the spacer end so as to form a substantially acute angle with an elongate axis of the spacer (i.e. an axis that extends between the first and second opposite ends of the spacer). For example, this acute angle between the leg and the elongate body of the spacer may be in the order of approximately 85 to 89 degrees and can provide a reduction in the in-use forces that act on the leg (e.g. at the attachment points between the leg and the end of the spacer) during positioning of the spacer on the framework, as set out in further detail below. In particular, the acute leg bend angle may reduce the forces applied to the spacer as the spacer is rotated into position to locate the leg at the framework (i.e. prior to the leg reaching its intended -90-degree fixed position with respect to the framework).

The realisation that spacers having a leg located at an end of the spacer can be enhanced by the provision of flared leg joins and acute leg bend angles is both surprising and unexpected. Prior art spacers employing 90-degree leg bend angles and typically simple leg-to-spacer joining arrangements can be less robust and may not be suitable in situations where roofing framework is not sufficiently level. In such cases, conventional spacers can prove to be difficult to install, for example without causing damage to the spacer or associated supports used in conjunction with the spacer, as described further herein. It may then become difficult to attach roof sheets to the spacer, or to attach the spacer to the framework, which can lead to hazards for the installer and slow down roof sheet installation. Further, such strengthened spacers may allow for greater leg lengths and/or thinner gauge spacer material to be employed than for conventional spacers. Longer spacer legs can provide increased space between the spacer and the framework for additional insulation, services, etc.

Because the improved spacer embodiments as disclosed herein can work cooperatively with a like, adjacent spacer, one leg per spacer has also been found to be sufficient in many cases, where a multi-leg conventional spacer may otherwise have been required, for example, where heavy roof sheets are employed. In other words, the leg of a given

11959760_1 (GHMatters) P110604.AU.1 spacer may support an adjacent spacer and so on along a framework to support increased loads on/spans of the spacers. Further, because the leg can be located at just one end, it may allow for the overlapping as well as stacking of adjacent spacers.

In some embodiments, the spacer may be arranged for receiving at one end, an opposite end of a like spacer, with the at least one leg of the first spacer being able to support the opposite end of the like spacer in the spaced relationship relative to the framework. In other words, in addition to supporting the first end of a given spacer, the leg of the given spacer can support the second end of an adjacent spacer, and so on along a framework. Further, because the leg can also support the adjacent spacer, this can result in insulation being less compressed in use and/or can provide the afore-mentioned cavity. Thus, the one leg may support adjacent or overlapping ends of adjacent spacers.

When it is stated herein that the spacer receives thereat a second end of a like spacer, it is intended that this like spacer second end may be received at the spacer first end, or may be received somewhere along the spacer (i.e. intermediate its first and second ends). In the latter case, the adjacent spacers can overlap. This ability to overlap has certain benefits, including enabling spacer stackability, but also allowing for a shortened overall length of spacers (e.g. at the end of a run of spacers located at a framework, as set forth hereafter).

In some embodiments, the at least one leg located at said one end of the spacer may extend in a manner that defines an opening at said one end of the spacer. The opposite end of the like spacer may be received in the opening. Thus, the second end of the like spacer may be received in the opening, whereby the spacers may be arranged end-to end. By enabling the second end of the like spacer to be received therein, the opening can allow for spacer installation in a relatively quick, safe, reliable, repeatable and easy manner, in that the opening can facilitate rapid spacer-to-spacer alignment. Each such opening can also allow for multiple like spacers to be progressively installed in series across the framework, and for sheets to thus be sequentially installed. Each such installed sheet can also allow e.g. an installer to stand thereon and to be supported

11959760_1 (GHMatters) P110604.AU.1 thereby as a next spacer is placed in the opening of an installed spacer, and then positioned at the framework, and so on.

In some embodiments, one or more formations may be provided in the elongate web of the spacer. Each formation may be adapted to enable a sheet to be secured with respect to the spacer (e.g. by use of a clip-bearing assembly, which can facilitate rapid securing of a sheet to the spacer).

In one such embodiment, the one or more formations may comprise one or more (further) apertures through the web. The one or more apertures may be configured for enabling a clip-bearing assembly to be arranged at and secured to the web. Such a clip bearing assembly can facilitate rapid securing of a sheet to the spacer (e.g. the clip bearing assembly may be adapted to the push-fitting of roof sheets with respect to a framework).

The clip-bearing assembly may be arranged to be secured to the web via one or more fasteners. In some embodiments, the one or more fasteners may each be configured so as to pass through to the framework to secure both the clip-bearing assembly and the spacer to the framework. This can speed up installation and can also decrease the overall number of fasteners required.

In another such embodiment, the one or more formations may comprise one or more (further) deformations in the web. The one or more deformations may be additional or alternative to the one or more (further) apertures. Each such deformation can enable a respective fastener to pass through the spacer web (e.g. each deformation may take the form of a pilot point or a pilot hole for a self-tapping or self-drilling fastener). Again, the one or more fasteners may each be able to pass through to the framework to secure the spacer to the framework. Thus, when a given sheet is to be secured to the spacer via one or more fasteners, each such fastener may pass through the sheet, through a respective deformation, and through to the framework. Again, this can speed up installation, and decrease the overall number of fasteners required.

Thus, as set forth above, the spacer may be configured such that a lesser number of separate fasteners may be required for spacer and sheet installation.

11959760_1 (GHMatters) P110604.AU.1

In another aspect there is disclosed herein a spacer for positioning a sheet in a spaced relationship relative to framework that supports the sheet in use. The spacer is elongate and extends between first and second opposite ends. The spacer comprises at least one leg located at one of the ends. This leg is arranged for positioning the end in a spaced relationship relative to the framework. The spacer further comprises opposing elongate walls and elongate flanges. Each flange extends for a length of a respective elongate wall and each flange projects laterally outwards of its respective elongate wall.

Each elongate wall flange also comprises a pair of discrete securing formations formed therein. As set forth above, an upper end of a starter support is able to locate at the pair of discrete securing formations. The discrete securing formations will be described in further detail hereafter.

In some embodiments, the spacer of this other aspect may be otherwise as defined above for the first aspect.

In a further aspect there is disclosed a starter support for positioning a spacer in a spaced relationship relative to framework that supports the spacer in use. The starter support can support an end of a first spacer that does not comprise a leg at that end, so as to maintain the spaced relationship between the first spacer and the framework. In other words, the starter support can take the place of a leg for a first-to-be-positioned spacer at its opposite "legless" end. For example, the starter support may take the form of a starter saddle onto which the second end of the spacer can locate. The starter saddle may be configured to support the spacer second end against lateral movement.

When e.g. the starter support is used at a roof, the starter support can comprise an in-use upper end that is configured to engage with the spacer. This upper end can enable the spacer to be pivoted on the starter support in use, as described further herein. The starter support can also comprise an in use lower end that is configured to engage with the framework. The starter support lower end can be secured to the framework by means of

11959760_1 (GHMatters) P110604.AU.1 fasteners e.g. screws, bolts, etc. either before or after the first spacer is located at the starter support.

In some embodiments, the support may be in the form of a generally triangular section. The upper end of the triangular support may comprise an apex portion of the triangular section. The apex portion of the triangular support can provide an effective pivot point, on which the spacer may be pivoted - e.g. as the spacer is positioned relative to the framework.

In some embodiments, the apex portion of the triangular support may comprise an aperture. The apex aperture can be configured to align in use with one or more corresponding apertures formed in an overlying spacer, as set forth herein. This can enable one or more fasteners to be passed through the spacer aperture(s) and the apex aperture, for enabling the triangular support to be secured to the framework. This can in turn secure the spacer to the framework.

In some embodiments, the starter support can comprise one or more strengthening formations formed therein, for example in the form of ribs, gussets or indentations, etc. as described herein.

In some embodiments, the spacer used with the starter support of the further aspect may be configured as set forth above in the first and other aspects.

Also disclosed herein is a spacer system for positioning a sheet in a spaced relationship relative to framework that supports the sheet in use. The system can comprise a spacer, the spacer being as set forth above in the first and other aspects. The system can also comprise a starter support as set forth above in the further aspect.

Also disclosed herein is a method for forming a spacer, the spacer being as set forth above. The method as disclosed herein can enable the spacer to be formed from a single

11959760_1 (GHMatters) P110604.AU.1 sheet of material (e.g. from a single "blank"). The sheet material may comprise a suitable metal (e.g. galvanised steel sheet, aluminium sheet, etc.).

The method comprises bending and/or folding a section of sheet material to define the elongate spacer as extending between the first and second opposite ends. The method also comprises bending the elongate spacer at one of the ends so as to form the at least one leg. In other words, the same sheet can be used to form both the spacer and leg. The leg may thus be integrally formed with the spacer. This can considerably simplify spacer manufacture, and hence reduce its cost to manufacture. In some embodiments, prior to bending and/or folding the section of sheet material, the method may comprise forming a discrete cut through the sheet. The discrete cut may be located adjacent to one end of the spacer, once the section of sheet material has been bent and/or folded to define the spacer as extending between the first and second ends. The section of sheet material may also be bent adjacent to the discrete cut, so as to form the leg. Thus, the discrete cut can define an opening at the end of the resultant spacer.

The method also comprises deforming the elongate wall flanges and leg flanges so as to form the respective flanking web at the join between each leg flange and its respective wall flange. The flanking web can also be integrally formed with the rest of the spacer.

In some embodiments, the method may also comprise deforming and/or cutting the section of sheet material to define the one or more formations or deformations therein. The one or more formations or deformations may be as set forth above.

Also disclosed herein is a method for forming a starter support, the starter support being as set forth above. The method as disclosed herein can enable the starter support to be formed from a single sheet of material (e.g. from a single "blank"). The sheet material may comprise a suitable metal (e.g. galvanised steel sheet, aluminium sheet, etc.).

The method comprises bending and/or folding a section of sheet material to define the starter support. The method may also comprise cutting the section of sheet material so

11959760_1 (GHMatters) P110604.AU.1 as to form the aperture. The method may further comprise deforming the section of sheet material so as to form the strengthening formations.

Also disclosed herein is a method for arranging a spacer and a starter support. The spacer and the starter support may be as set forth above. The method can enable positioning of a plurality of further spacers and one or more sheets in a spaced relationship relative to framework, the sheet(s) supported by the spacers in use.

The method comprises arranging a starter support at the framework. The method further comprises arranging a first spacer at the starter support. In this regard, the starter support may be secured to the framework by means of a fastener, such as a screw, before the spacer is arranged at the starter support, or in some cases, after the spacer has been arranged at the starter support.

The method further comprises pivoting the first spacer on the starter support, until the leg of the first spacer locates at the framework. Along with the starter support, the leg can support the spacer and maintain a spaced relationship of the first spacer relative to the framework. As above, such an installation method can result in a quick, safe, reliable and easy methodology, and can facilitate rapid spacer-to-spacer alignment.

In some embodiments, the first spacer may be arranged at the starter support, prior to the starter support being arranged at the framework. Again, this may allow for an efficient installation of a spacer-starter support assembly at the framework, rather than installing each component separately.

In some embodiments, the method may further comprise arranging a second like spacer, such that the opposite (second) end of the second spacer is located in the opening at the first end of the first spacer. It is to be understood that the like spacer opposite end may be received at the spacer first end (e.g. in the opening), or it may be received somewhere along the spacer (i.e. intermediate its first and second ends). In the latter case, the adjacent spacers can overlap. This ability to overlap has certain benefits, including spacer stackability, but also allows for a shortened overall length of spacers e.g. at the end of a run of spacers located at a framework.

11959760_1 (GHMatters) P110604.AU.1

The method may further comprise pivoting the second spacer around its opposite end until the leg of the second spacer locates at the framework to support the first end of the second spacer in the spaced relationship relative to the framework.

As above, such an installation method can result in a quick, safe, reliable and easy methodology, and can facilitate rapid spacer-to-spacer alignment.

In some embodiments, prior to arranging the second spacer, the first spacer may be secured to the framework by one or more fasteners. This securement can then enable a sheet to be secured to the first spacer. An installer may e.g. then stand safely and securely on this sheet when installing the next (e.g. second, third, etc.) spacer, and so on across the framework.

In some embodiments, once the second spacer has been arranged at the framework, a third like spacer may be arranged such that the opposite (second) end of the third spacer is located at the second spacer. The third spacer may then be pivoted around its opposite end until the leg of the third spacer locates at the framework. This procedure can be repeated along the framework (e.g. along a given purlin or stud), until the framework has been spanned by a number of spacers arranged end-to-end.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments will now be described by way of example only, with reference to the accompanying drawings in which:

Figure 1 is a top perspective view of a spacer 100 in accordance with an embodiment.

Figure 2 is an underside perspective view of the spacer 100.

Figure 3 is an enlarged top view detail of the spacer 100.

Figure 4 is another enlarged top view detail of the spacer 100.

Figure 5 is an enlarged view of a first opposite "female" end 130 of an embodiment of the spacer 100".

11959760_1 (GHMatters) P110604.AU.1

Figure 6A is a schematic view of a starter saddle 200 in accordance with an embodiment.

Figure 6B illustrates the starter saddle 200 of Figure 6A in use.

Figure 6C is a perspective view of the framework, including purlins P and safety mesh M.

Figure 6D is a series of views of a starter support 200', in accordance with another embodiment.

Figure 6E is an enlarged top view detail of a spacer 100" in accordance with another embodiment.

Figure 6F is a series of schematic top and side views of the spacer 100"', engaging with a starter saddle 200 and a starter saddle 200'.

Figure 7 is a first top perspective view of two spacers 100 and 100A in a partially inter-connected configuration.

Figure 8 is a second top perspective view of two spacers 100 and 100A in an inter-connected configuration.

Figure 9 is a side schematic view of two spacers 100 and 100A in a partially inter-connected configuration, similar to Figure 7, during use in e.g. a roofing system.

Figures 1OA to 1OC illustrate side schematic views of respective roofing systems having two spacers 100 and 1OOA in an inter-connected configuration, similar to Figure 8, during use in the respective roofing systems.

Figure 1OD & 1OE illustrate spacers in use, with roof sheets attached to roof clip-bearing assemblies mounted on the spacers.

Figures 11A & 11B respectively show perspective and plan views of a spacer 10 0 1v in accordance with another embodiment, with location dimples formed on the elongate flanges, proximal the male end.

11959760_1 (GHMatters) P110604.AU.1

DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS

In the following detailed description, reference is made to accompanying drawings which form a part of the detailed description. The illustrative embodiments described in the detailed description, depicted in the drawings and defined in the claims, are not intended to be limiting. Other embodiments may be utilised and other changes may be made without departing from the spirit or scope of the subject matter presented. It will be readily understood that the aspects of the present disclosure, as generally described herein and illustrated in the drawings can be arranged, substituted, combined, separated and designed in a wide variety of different configurations, all of which are contemplated in this disclosure.

Referring firstly to Figures 1 to 4, a first embodiment of a spacer 100 is illustrated. The illustrated spacer 100 can position a roof sheet R in a spaced relationship relative to framework (e.g. a purlin P) that is positioned below the roof sheet. However, it should be understood that the spacer 100 can be employed in a variety of other sheet-spacing applications including, for example, the spacing of sheets that are affixed with respect to internal and external walls, etc.

The illustrated spacer 100 is shown in use with framework, typically in the form of purlins P and optionally safety mesh M (see Figure 6C). The illustrated spacer 100 is employed for spacing roof sheets away from the framework. This allows insulation, such as insulation blankets, to be positioned over the purlins/mesh (i.e. see Figures 6C, 1OD & 10E) and in an uncompressed manner under the sheets. In other words, the spacer 100 provides sufficient space to enable the insulation blankets to retain their expanded state in a roof (i.e. to retain their insulation (R') rating). However, as above, the spacer 100 can alternatively or additionally be employed to provide a cavity within a roof, wall, etc. (i.e. between the sheets and framework). This cavity may be employed to accommodate services such as electrical, cabling, wiring, water, gas, etc. Hereafter, the spacer will primarily be described in relation to the spacing of roof sheets away from roofing framework.

11959760_1 (GHMatters) P110604.AU.1

The spacer 100 takes the form of an elongate member 110 that extends between two opposed ends. A first of the opposed ends takes the form of a female end 130, and a second of the opposed ends takes the form of a male end 120. The male end 120 defines a type of tongue 140 at that end. The spacer 100 has a simple and easy-to-manufacture configuration in that it can be readily formed from sheet material. In the embodiments depicted in the drawings, the spacer comprises only one leg 160 that is located at the female end 130, though other forms are possible, whereby further (e.g. one or more) legs may be located along the length of the spacer. In the embodiments depicted in the drawings, the leg 160 is connected to the elongate member 110 (e.g. it can be integrally formed therewith). The leg 160 is arranged for positioning the female end 130 in a spaced relationship relative to framework in use.

The leg 160, together with the elongate member 110, defines an opening 150 at the female end 130. As described in greater detail below (i.e. see Figures 7 & 8), the tongue 140 of an adjacent, like spacer 100A can be received and located in the opening 150 of an installed spacer 100. This can enable easy end-to-end alignment of adjacent spacers across a framework.

As also described in greater detail below, the spacer 100 is configured such that, instead of locating the tongue 140 of an adjacent spacer in the opening 150 of an installed spacer 100, the adjacent spacer can overlap the installed spacer (i.e. such that the tongue of the adjacent spacer locates over the installed spacer intermediate its female and male ends). This can be particularly useful at the end of a "run" of end-to-end spacers at a framework, where the final region to be spaced is shorter than the spacer length. Such overlapping can also facilitate spacer stacking as described hereafter.

Whether the tongue of the adjacent spacer is located in the opening 150 or is overlapped, the leg 160 is in each case able to support the male end 120 of the like spacer 100A in the spaced relationship with respect to the framework. Thus, the one leg 160 is able to support adjacent ends 130 and 120 of each of the adjacent spacers 100, 1OOA in the spaced relationship relative to the framework, resulting in insulation being less compressed in use and/or providing a cavity between the sheet(s) and framework.

11959760_1 (GHMatters) P110604.AU.1

Referring now to the embodiment illustrated in Figures 3 and 4 in particular, the elongate member 110 is formed to comprise an elongate web 112 that extends along the length of elongate member 110. First and second opposing elongate walls 114 and 116 each extend from a respective elongate side of the web 112. In use, the web 112 and first and second elongate walls 114 and 116 give the elongate member 110 the form of an inverted channel section, contributing to its structural integrity, and enabling overlapping and stacking of adjacent spacers. In other forms however, the spacer may not comprise an elongate web, for example, the space may be formed such that the first and second elongate walls are angled to meet and connect at an elongate ridge spanning the first and second opposing ends, giving the elongate member the form of an inverted triangular section. Typically, the walls 114, 116 outwardly diverge from one another, producing a spacer that has a trapezoidal cross-section when an elongate web 112 is present. Again, this divergence can enable overlapping and stacking and can contribute to (i.e. it can enhance) the shape of the opening 150 so as to more easily receive and to better guide therein the tongue of the like spacer 100A in use (see Figures 7 and 8).

The elongate member 110 also includes elongate flange portions 117 and 119 that respectively project laterally outwards from the opposing walls 114 and 116. The flange portions 117 and 119 can provide further structural integrity to the spacer, and can also function as the attachment point of a respective leg 160 to the female end 130 of the elongate member 110. Also, as shown in Figure 1OD, the flange portions 117 and 119 can in use rest on an underlying insulation layer I that is positioned at the framework to provide an air gap between this layer and the elongate web 112 (i.e. a gap into which fasteners can pass when introduced through the web).

Referring particularly to the spacer embodiment 100" illustrated in Figure 5, it will be seen that the leg 160 extends from each of the first and second walls 114 and 116 to define the opening 150 as locating adjacent to an end edge 112A of the web 112 and adjacent to sloping edge portions 154 and 156 of walls 114 and 116. More particularly, the leg 160 is formed integrally with the flange portions 117 and 119. The leg can thus be seen as a continuation of the elongate member 110, but cut at web edge 112A and edge portions 154 and 156, and yet remaining connected via the flange portions 117 and

11959760_1 (GHMatters) P110604.AU.1

119, and then bent into the "acute" orientation as shown in Figure 5. This configuration helps to simplify manufacture of the spacer.

Figure 5 shows that the leg 160 is bent to form an acute angle 157 with the elongate axis of walls 114 and 116, producing a leg bend angle of approximately 85 to 89 degrees. This acute angle 157 between the leg 160 and the elongate member 110 or body of the spacer, can provide significant advantages over existing spacers having substantially vertical legs. In this regard, the acute angle 157 provides for a reduction in the forces that act on the leg (e.g. at the attachment points between the leg and the end of the spacer) during positioning of the spacer on the framework, as set out in further detail below. In particular, the acute leg bend angle reduces the forces applied to the spacer as the spacer is rotated into position to locate the leg 160 at the framework (i.e. during the period before the leg reaches its intended -90-degree fixed position with respect to the framework).

The leg 160 comprises an upstanding wall 164 (i.e. a "leg web") that is flanked by opposed side walls 166 and 168. Each of the opposed side walls 166 and 168 comprises a respective flange portion 167 and 169. The leg flange portions 167, 169 are left intact (i.e. not cut) so as to form integrally with the flange portions 117 and 119 of the walls 114 and 116. In this way, the leg 160 is integrally connected to the female end 130 of the spacer 100.

Figure 5 illustrates that the resultant leg 160 also comprises an edge 161 located at an upper distal end of the leg upstanding wall 164. This edge 161 on a first spacer 100 is in use able to support the tongue 140 of the second spacer 100A - i.e. when the latter is interconnected with the first spacer 100 (as illustrated in Figures. 7 & 8) or when the latter overlaps the first spacer 100.

As illustrated in Figure 5, the elongate wall flange portions 117, 119 join their respective leg flange portions 167, 169, forming a flanking web 158 at the comer of the bend between the leg 160 and the elongate member 110. The flanking web comprises deformations 159, that diverge from each of the respective flange portions, adjacent the corner of the bend between the leg 160 and the elongate member 110. These

11959760_1 (GHMatters) P110604.AU.1 deformations 159 progressively reduce in the degree of their divergence from the planes of their respective flange portions, as they return to meet at the comer of the leg bend, forming a flared corner portion 162 at the corner of the bend between the leg 160 and the elongate member 110.

The flared comer portion 162, by virtue of its shape, provides a larger amount of flange material at the comer of the bend than would be provided by a 'simple' corner. The flared corner portion 162 thus reduces the degree of stress concentration (i.e. accommodates a greater amount of stress) at the corner when the spacer is subjected to loading, for example, by roofing sheets, or by the weight of the roofing installer during installation. This serves to strengthen the join between the leg 160 and the elongate member 110, improving the structural integrity of the spacer. In particular, such a flared comer greatly enhances the strength of spacers having the acute bend angle illustrated in Figure 5.

Such a strengthened comer arrangement allows for greater spacer leg lengths to be employed (i.e. providing more space between the framework and the roofing sheets), whilst maintaining sufficient structural integrity of the spacer, without the need for heavier gauge sheet material to form the spacer. Thus, the flanking web corner arrangement can reduce both cost and weight of the spacers.

The realisation that integrally formed spacers having a leg located at an end of the spacer can be significantly strengthened in use by the provision of flared leg joins and acute leg bend angles is both surprising and unexpected. Prior art spacers employing 90-degree leg bend angles and typically simple leg-to-spacer joining arrangements are less robust and may not be suitable in situations where roofing framework is not sufficiently level. In such cases, conventional spacers can prove to be difficult to install, for example without causing damage to the spacer or associated supports used in conjunction with the spacer, as described further herein. It may then become difficult to attach roof sheets to the spacer, or to attach the spacer to the framework, which can lead to hazards for the installer and can slow down roof sheet installation. Because the strengthened one-legged spacer embodiments as disclosed herein can work

11959760_1 (GHMatters) P110604.AU.1 cooperatively with a like, adjacent spacer, one leg has also been found to be sufficient in many cases (whereas a multi-leg conventional spacer may have otherwise been required); such as in applications requiring spacers of greater leg height (i.e. more space required between the framework and the roofing sheets). In other words, the leg 160 of a given spacer 100 can support the male end 120 of an adjacent spacer 1OA, and so on along a framework. Further, because the leg 160 can be located at just one end, it can allow for the overlapping as well as stacking of adjacent spacers prior to use.

Further, by enabling the tongue 140 of the like spacer 100A to be received in the opening 150 or to overlap the spacer 100 somewhere along its length, this can allow for spacer installation at a framework in a relatively quick, safe, reliable and easy manner. The spacer configuration, including the configuration of the opening 150, can facilitate rapid spacer-to-spacer alignment. The opening 150 can also allow for multiple like spacers to be progressively installed in series across the framework, and for sheets to thus be sequentially installed. A roof sheet installer can stand on installed sheets to be safely supported as a next spacer is placed in the opening of an installed spacer. As described below, the installer can simply drop the next spacer into place on the framework, and then secure it to the framework using fasteners.

In the spacer embodiments of Figures 1-8, the web 112 also includes one or more formations in the form of pilot holes 115 that are arranged along the length of the web 110. Each pilot hole 115 is adapted for receiving a self-tapping fastener therethrough to enable the spacer 100 to be fastened to an adjacent framework (e.g. to a purlin or stud, etc.) during use. These holes can also be used to secure a roof clip assembly A to the spacer. These roof clip assemblies A are illustrated in more detail in Figures 9 and1OA 1OE.

Figures 7 to 1OE show how the tongue 140 and the opening 150 allow two spacers 100 and 100A to be inter-connected during use. Specifically, the tongue 140 of the second spacer 100A is received and secured within the opening 150 of a first, installed spacer 100 in a kind of push-fit, thereby inter-connecting the first and second spacers 100 and 1OOA end-to-end. For example, a roof sheet installer is able to stand on an installed roof

11959760_1 (GHMatters) P110604.AU.1 sheet R that is supported by multiple parallel installed spacers 100. The installer is safely supported on roof sheet R and, from a standing position, is then able to insert the tongue 140 of a next spacer 100A in the opening 150 of each installed spacer 100. The installer may position the tongue 140 of spacer 100A into the opening 150 of spacer 100 without needing to bend down.

Having inserted the tongue, the installer can simply drop spacer 100A, and it then pivots around its male end 120 located at the leg 160 and into place on the framework - i.e. with the leg 160 of the next spacer 100A locating at the framework. The spacer 100A can then be secured to the framework (e.g. purlin, stud, etc.) by one or more fasteners.

Returning again to Figure 5, it will be seen that the opening 150 is in part defined by the edge 112A of the web 112 and by the sloping edge portions 154 and 156 of the walls 114 and 116 respectively. The taper 141 of the tongue 140 can engage with and be guided down the sloping edge portions 154 and 156 during insertion of the tongue 140 into the opening 150, to provide a guide mechanism for tongue insertion.

Likewise, it will also be seen that the opening 150 is in part defined by the upper edge portion 161 of the wall 164 of leg 160. Additionally, respective upper portions of each of the leg side walls 166 and 168 include sloping edges 163 and 165 which also define the opening and which slope downwardly from edge portion 161 to the joint of flanges 117, 167 and 119, 169. As best shown in Figure 7, the upper edge portion 161 and sloping edges 163 and 165 also provide a guide mechanism for directing the diagonally oriented tongue 140 of the second spacer 100A into the opening 150 of the first spacer 100.

These respective guiding mechanisms around the opening 150 allow a roof installer to safely, easily, reliably and speedily position the tongue 140 of spacer 1OOA into the opening 150 of spacer 100A in a diagonal orientation (i.e. from a standing position). They also help to facilitate pivoting in an arc of the male end 120 of spacer 100A about the leg 160 and female end 130 of spacer 100 when released by the roof installer.

Once the second spacer 100A has been installed, it will be seen in Figure 8 that the flange portions 117, 119 at the male end 120 of spacer 100A abut at 118 the flange

11959760_1 (GHMatters) P110604.AU.1 portions 117, 119 at the female end 130 of the spacer 100. Thus, a snug, generally flush joint results.

Referring now to Figures 11A and 1IB, the joins that are defined between the elongate web 112 and the opposing elongate walls 114 and 116 can comprise a number of spacer formations D defined therein (e.g. that are press-formed therein prior to or during bending of the walls). The spacer formations D can alternatively be formed just in the web 112, or just in the walls 114 and 116. The spacer formations D can aid in storage and transport of the spacers prior to use, acting to prevent stacked spacers from nesting too tightly (e.g. which may result in adjacent spacers fastening to each other), and making it easier to unpack the spacers for use. Further, the spacer formations D can improve air flow between stacked spacers in storage, aiding drying in the event of water ingress and helping to prevent corrosion.

The installation procedure, including spacer fastening to the framework, will now be described with particular reference to Figures 6A to 6C, 9 and 10A to 10E. The method of inter-connecting adjacent spacers can be repeated across a framework (e.g. along the line of each of the purlins or studs thereof, etc.).

In an initial step, an insulating layer I is positioned above the framework (Fig. 6C), which may be in the form of a series of parallel purlins P that have a safety (fall) mesh M extending across the space therebetween. The insulating layer I is typically in the form of a roll of insulating (e.g. glasswool) material that is rolled out over the framework P. The safety mesh M also helps to hold the insulating layer I positioned over the space between the framework P and the roof sheets R.

Referring now to Figures 6A and 6B, an embodiment of a spacer male end support, in the form of a starter saddle 200, is located over the insulating layer I adjacent to a starting end of the framework (e.g. above each of the parallel purlins or studs at one side of the roof, wall, etc.). The saddle 200 takes the place of a leg for a first-to-be positioned spacer at its male end 120. As specifically illustrated in Fig. 6B, the starter saddle 200 comprises a base web 202 which sits on the insulating layer I and which can then be screwed down into an underlying purlin P, such as through one or more (e.g. up

11959760_1 (GHMatters) P110604.AU.1 to three) screw holes 203 formed through the base web 202, depending on the installation method used. A central such hole can be employed where the saddle 200 is screw-secured from the top, whereas the side such holes 203 can be employed where the saddle 200 has been pre-attached to the spacer 100, and an installer is then screw securing from the side.

The starter saddle 200 also comprises opposing walls 204, 206 which extend up from the base web 202. Each wall has a rebate 208 defined along its upper edge, with the rebate sized to receive therein the flange portions 117 and 119 of the overlying spacer 100. The opposing side walls 210, 212 of the rebate 208 are also half-diamond shaped to project inwardly of the rebate. Thus, the flange portions 117 and 119 of the overlying spacer 100 must be slid in under the side walls 210, 212, or press-fit down into the rebate in use. This helps to secure the starter saddle 200 adjacent to a spacer male end 120.

The starter saddle 200 further comprises gussets 213 formed at the joints between the base web 202 and the opposing walls 204, 206. These gussets 213 stiffen and strengthen the base web-to-opposing wall joins, helping the saddle 200 to resist deflection and to support a load, including the roofing installer's weight during use.

Each starter saddle 200 thus maintains a spaced relationship of the spacer male end 120 above the framework. With the starter saddle 200 e.g. screwed into place, the first spacer 100 may now be positioned and then fastened into place, and then subsequent spacers 1OA, 1OB, 1OOC, etc. may then be positioned and fastened into place, end-to end along the framework. This provides for the required spacing between the roof sheets and the framework for receipt of the insulation layer I therein.

As illustrated in the embodiment of Figure 6D, the starter saddle can be in the form of a triangular-section support 200'. The triangular support comprises a base web 202' which sits on the insulating layer I and which can then be screwed down into an underlying purlin P, such as through one or more (e.g. up to three) screw holes 203' formed through the base web 202', depending on the installation method used. A central such hole 201' can be employed where the triangular saddle 200' is screw-secured from

11959760_1 (GHMatters) P110604.AU.1 the top, whereas the side such holes 203' can be employed where the saddle 200' is to be pre-attached to the spacer 100, with an installer then screw-securing from the side.

The starter saddle 200' also comprises opposing walls 204', 206' which each extend upwards in an angled fashion from the base web 202', to meet above the screw holes 203' of the base web 202', forming an apex portion 205' of the triangular support 200'. Each wall has a rebate 208' defined along its upper edge, the rebate located within the apex portion 205', with the rebate sized to receive therein the flange portions 117 and 119 of the overlying spacer 100. The opposing side walls 210', 212' of the rebate 208' are also half-diamond shaped to project inwardly of the rebate 208'. Thus, the flange portions 117 and 119 of the overlying spacer 100 must be slid in under the side walls 210', 212', or press-fit down into the rebate in use. This helps to secure the starter saddle 200' adjacent to a spacer male end 120.

The starter saddle 200' further comprises gussets 213' formed at the joints between the base web 202' and each of the opposing walls 204', 206'. The starter saddle 200' also comprises indented channels 214' formed in the underside of the base web 202' and terminating adjacent the gussets 213', to further provide strength to the support 200'. The apex portion 205' comprises an aperture 207', formed by cutting an elongate slot into each of the opposing side walls 204', 206'. The saddle aperture 207' aligns above the central screw hole 201' and, when a spacer is fitted into the rebate 208' as described above, a web aperture 209 of the spacer (as illustrated in the spacer embodiments of Figures 6E and 6F) aligns with the underlying saddle aperture 207' and saddle central screw hole 201', to allow a fastener such as a screw to be passed through from above. This allows the starter saddle 200' to be secured to the framework by at least the central screw hole 201', even after a spacer has been fitted over the saddle. Alternatively, a screw may be passed through the spacer web 209 and saddle 207' apertures, prior to the starting saddle being arranged at the framework.

The triangular saddle 200', having apex portion 205' engaging with an overlying spacer, allows for the overlying spacer to be pivoted on the triangular starter saddle (i.e. the apex portion acts as a pivot point). This arrangement allows an installer, after having

11959760_1 (GHMatters) P110604.AU.1 arranged the spacer end over the starter support, to simply drop the spacer, with the leg automatically locating with the underlying framework, the opposite end being guided by the starter saddle to help prevent lateral movement of the spacer.

The strengthened triangular support provides additional structural integrity to the starter support over a greater range of spacer pivot angles than, for example, the starter saddle 200. As such, the starter support 200' can be used to support spacers of greater leg length (i.e. which provide an increased spacing between sheets and the framework) such as illustrated in Figure 6F. Referring to Figure 6E, it can be seen that the elongate flanges 117, 119 of a further spacer embodiment 100"' can be provided with a number of discrete securing formations in the form of lug pairs 302. These pairs are located proximal the spacer male end 120. The lug pairs 302 can also be press-formed therein prior to or during bending of the flanges, and protrude from the underside of the flanges 117, 119. The lug pairs 302 function to locate with respect to, and to thereby engage with, the opposing rebates 208 of the starter saddle 200 or 200' (referring to Figures 6A, 6D and 6F). Thus, the lug pairs 302 locate and secure the spacer male end 120, but also help resist the spacer male end from sliding-out of the rebates 208. This interference further contributes to securement of the spacer 100"'in the starter saddle 200 or 200'. The lugs 302 also allow for the starter saddle 200 or 200' to be initially secured to the spacer (i.e. instead of the starter saddle first being secured to the framework). Thus, the starter saddle-spacer assembly is able to then be attached to the framework as a single unit. Hence, the securing lugs 302 provide installers with additional installation options, speeding-up sheet installation, particularly in non-standard applications or non standard framework arrangements.

Turning now to Figures 11A and 1lB (and as can be seen in Figure 6E), it will be seen that the elongate flanges 117, 119 of a further spacer embodiment 100' can be provided with a number of discrete support formations in the form of location dimple pairs 300. These pairs are located proximal the spacer male end 120. The dimple pairs 300 can be press-formed therein prior to or during bending of the flanges, and protrude from the underside of the flanges 117, 119. The dimple pairs 300 can function to locate with respect to, and to thereby interfere with, the starter saddle 200 (Figure 6A). Thus, they

11959760_1 (GHMatters) P110604.AU.1 locate and also help resist the spacer male end 120 from sliding-out of the rebates 208. This interference further contributes to securement of the spacer 100" in the starter saddle 200.

As illustrated by Figure 9, and Figures 10A to 1OC, a first spacer 100 may be secured to the framework (purlin P) by one, two or three fasteners F. The fasteners F may each take the form of an elongate self-tapping roof screw. The length of each fastener F is optimised to a given spacer. Typically, the first spacer 100 is secured by the fasteners F to a purlin P before arranging the second spacer 1OA, etc. Figures 9 and 10A show a three-screw option, whereas Figure 1OB shows a two-screw option, and Figure 1OC shows a one-screw option.

Where a roof clip-bearing assembly is to be employed, roof clips C and/or a roof clip bearing assembly A are typically fastened to each roof spacer prior to positioning each roof sheet above the framework P. Whilst single clips may be secured to a spacer, each by a respective fastener, typically a roof clip-bearing assembly A having a plurality of clips already secured thereto is employed. The roof clips C and/or a roof clip-bearing assembly A can be used for push-fitting roof sheets R onto the spacers 100 as best shown in Figures 9 & 1OD to E. They provide for a "concealed" means of fastening of roof sheets.

Having now secured the first spacer 100 to the purlin P, the tongue 140 of a diagonally oriented second spacer 100A is then positioned into the opening 150 of spacer 100. During such installation, the installer initially gently pushes (i.e. to begin insertion of) the tongue 140 into the opening 150. Once fully inserted, the installer then simply releases spacer 1OA, with this spacer then pivoting around the female end 130 and leg 160 of spacer 100, in alignment with and such that its leg then locates over the purlin P. There is no need for a separate alignment step for the spacer 1OA. In this regard, both its insertion and pivoting is guided by the configuration of opening 150, as set forth in the guiding mechanism outlined above. This considerably simplifies and expedites spacer mounting to a roof structure.

11959760_1 (GHMatters) P110604.AU.1

Having been so inter-connected, the spacers 100, 1OA, 1OB, etc. are positioned and aligned upon the framework P, and do not move relative to each other but rather tend to remain in position. Thus, a roof installer has the option of connecting two or more of the spacers, using the above mentioned connecting methodology, before fastening each of the spacers to the underlying framework.

Where the inter-connected spacers 100, 10OA, 1OB, etc. have a combined length that is greater than the expanse of the framework P, a final spacer, e.g. 1OOX can, instead of having its tongue 140 located in the opening 150 of a penultimate installed spacer, overlap the penultimate installed spacer (i.e. such that the tongue of the final spacer locates over the penultimate installed spacer intermediate its female and male ends). This can enable an even finishing of a "run" of end-to-end spacers at the framework P (e.g. such that the leg 160 of the final spacer locates on a final end member of the framework).

Typically, the spacer is formed from sheet material, for example, it may be cut, pressed formed and/or bent from sheet metal (e.g. a galvanised or a Zn-Al coated steel sheet, aluminium sheet, etc.). The spacer may be formed in a manufacturing method that comprises the following steps:

A. supporting the sheet material and forming discrete cuts through and deformations in the sheet. The cuts can correspond to the opening 150 and the apertures/holes 209, 115; the deformations can correspond to the optional formations 302, 300, etc.

B. sectioning the sheet of material (with the discrete cuts and deformations therein) to produce a blank that is ready for press-forming/bending (i.e. to form the elongate member 110 and leg 160). Note - step B. can be performed before step A.

C. where deformations 300, 302 and flanking web 158 are required in the spacer, these can be press-formed therein (e.g. prior to step D such as during step A, or as part of step D).

11959760_1 (GHMatters) P110604.AU.1

D. bending and/or folding the section of sheet (blank), such as by a press-forming operation, to define the web 112, the first and second walls 114, 116, the flange portions 117, 119 and the corresponding walls 166, 168 and flanges 167, 169 on the leg 160.

E. bending the elongate member 110 adjacent to the discrete cut so as to form the leg 160, and such that the leg extends down and generally at a right angle to the elongate member 110.

As set forth above, whilst the spacer has been primarily described with reference to its application in roofing, the spacers can be used in walls, partitions, etc. that may require insulation that needs to be maintained in an expanded state, and/or to provide cavities for services, etc.

Variations and modifications may be made to the process previously described without departing from the spirit or ambit of the disclosure.

In the claims which follow and in the preceding summary, except where the context requires otherwise due to express language or necessary implication, the word "comprising" and variations is used in the sense of "including", that is, the features may be associated with further features in various embodiments.

11959760_1 (GHMatters) P110604.AU.1

Claims

1. A spacer for positioning a sheet in a spaced relationship relative to framework that supports the sheet in use, the spacer being elongate and extending between first and second opposite ends, the spacer comprising at least one leg located at one of the ends, whereby the leg is arranged for positioning the end in a spaced relationship relative to the framework, the spacer further comprising opposing elongate walls, and elongate flanges, each flange extending for a length of a respective elongate wall, and each flange projecting laterally outwards of its respective elongate wall;

wherein the leg comprises opposing leg walls, and leg flanges that each extend for a length of its respective leg wall, with each leg flange projecting laterally outwards of its respective leg wall; and

wherein the leg flanges are joined to respective elongate wall flanges in a manner such that a respective flanking web is formed at the join between each leg flange and its respective wall flange.

2. A spacer according to claim 1, wherein each flanking web is configured to diverge from its respective leg flange and wall flange, adjacent the join between the leg flange and wall flange, the divergence forming a corner that is flared at the join between the leg and wall flanges.

3. A spacer according to claim 2, wherein each flanking web is configured to deform laterally outwards of its respective leg and wall flanges, the deformation then returning towards the corner so as to in part define the flared corner.

4. A spacer according to any one of claims 1 to 3, the spacer further comprising an elongate web wherein the opposing elongate walls each extend from a respective elongate side of the web, and wherein the leg further comprises a leg web and the leg walls each extend from a respective side of the leg web.

11959760_1 (GHMaters) P110604.AU.1

5. A spacer according to any one of claims 1 to 4, wherein the spacer is configured to not comprise a leg located at an opposite end to said one end of the spacer, and wherein each wall flange further comprises one or more discrete securing formations formed therein, adjacent the spacer opposite end, each securing formation arranged to releasably secure the spacer opposite end at a starter support, the starter support able to be pre-arranged at the framework or at the spacer.

6. A spacer according to claim 5, wherein each elongate wall flange comprises a pair of discrete securing formations formed therein, and wherein in use an upper end of the starter support is able to locate at the pair of discrete securing formations.

7. A spacer according to any one of claims 5 to 6, when dependent on claim 4, wherein the elongate web comprises one or more apertures, the one or more web apertures being located adjacent to the flange securing formations, each web aperture configured to enable one or more fasteners to be passed therethrough, for enabling the starter support to be secured to the framework.

8. A spacer according to any one of claims 5 to 7, wherein the starter support is configured to engage with each elongate flange of the spacer and/or the securing formations, so as to enable the spacer to be pivoted on the starter support in use.

9. A spacer according to claim 8, wherein the starter support is in the form of a generally triangular section, an apex portion of the triangular section being configured to engage in use with the elongate flange of the spacer and/or with the securing formations.

10. A spacer according to claim 9, when claim 8 is dependent on claim 7, wherein the apex portion of the triangular support comprises an aperture, the apex aperture configured to align in use with the one or more web apertures,

11959760_1 (GHMaters) P110604.AU.1 to enable the one or more fasteners to be passed through the apex aperture, for enabling the triangular support to be secured to the framework.

11. A spacer according to any one of claims 5 to 10, wherein the starter support comprises one or more strengthening formations formed therein.

12. A spacer according to any one of the preceding claims, wherein the at least one leg extends from the spacer end so as to form a substantially acute angle with an elongate axis of the spacer that extends between the first and second opposite ends.

13. A spacer according to any one of the preceding claims, wherein the spacer is arranged for receiving, at said one end, an opposite end of a like spacer, whereby the at least one leg of the spacer is able to support the opposite end of the like spacer in the spaced relationship relative to the framework.

14. A spacer according to claim 13, wherein the at least one leg located at said one end of the spacer extends in a manner that defines an opening at said one end of the spacer, with the opposite end of the like spacer able to be received in the opening, whereby the spacers are able to be arranged end-to-end.

15. A spacer according to claim 4, or any one of claims 5 to 14 when dependent on claim 4, wherein one or more formations are provided in the elongate web of the spacer, each formation adapted to enable a sheet to be secured with respect to the spacer.

16. A spacer according to claim 15, wherein the one or more formations comprise:

i. one or more apertures through the web, the one or more apertures configured for enabling a clip-bearing assembly to be arranged at and secured to the web;

ii. one or more deformations in the web, each deformation enabling a respective fastener to pass through the web.

11959760_1 (GHMaters) P110604.AU.1

17. A spacer for positioning a sheet in a spaced relationship relative to framework that supports the sheet in use, the spacer being elongate and extending between first and second opposite ends, the spacer comprising at least one leg located at one of the ends, whereby the leg is arranged for positioning the end in a spaced relationship relative to the framework, the spacer further comprising opposing elongate walls, and elongate flanges, each flange extending for a length of a respective elongate wall, and each flange projecting laterally outwards of its respective elongate wall;

wherein each elongate wall flange comprises a pair of discrete securing formations formed therein, and wherein in use an upper end of a starter support is able to locate at the pair of discrete securing formations.

18. A spacer as claimed in claim 17, the spacer being otherwise as defined in any one of claims 1 to 16.

19. A starter support for positioning a spacer in a spaced relationship relative to framework that supports the spacer in use, the starter support comprising an in-use upper end configured to engage with said spacer so as to enable the spacer to be pivoted on the starter support in use, and an in use lower end configured to engage with said framework.

20. A starter support according to claim 19, wherein the starter support is in the form of a generally triangular section, the in-use upper end of the starter support comprising an apex portion of the triangular section.

21. A starter support according to claim 20, wherein the apex portion of the triangular section comprises an aperture, the aperture of the apex configured to align in use with one or more corresponding apertures formed in said spacer, the alignment enabling one or more fasteners to be passed through the apex aperture, for enabling the triangular section to be secured to the framework.

11959760_1 (GHMaters) P110604.AU.1

22. A starter support according to any one of claims 19 to 21, wherein the starter support comprises one or more strengthening formations formed therein.

23. A starter support as claimed in anyone of claims 19 to 22, wherein said spacer is as defined in any one of claims I to 18.

24. A spacer system for positioning a sheet in a spaced relationship relative to framework that supports the sheet in use, the system comprising:

- a spacer as defined in any one of claim 1 to 18;

- a starter support as defined in any one of claim 19 to 22.

25. A method for forming a spacer as set forth in any one of claims 1 to 18, the method comprising:

- bending and/or folding a section of sheet material to define the elongate spacer as extending between the first and second opposite ends;

- bending the elongate spacer at one of the ends so as to form the at least one leg;

- bending and/or folding the elongate spacer to define the opposing elongate wall flanges and leg flanges;

- deforming the elongate wall flanges and leg flanges so as to form the respective flanking web at the join between each leg flange and its respective wall flange.

26. A method according to claim 25, wherein prior to bending and/or folding, the section of sheet material has a discrete cut formed through the sheet, with the discrete cut located adjacent to one end once the section of sheet material has been bent and/or folded to define the spacer as extending between the first and second ends, and wherein the section of sheet material is also bent

11959760_1 (GHMaters) P110604.AU.1 adjacent to the discrete cut so as to form the leg, such that the discrete cut defines an opening at the end of the resultant elongate spacer.

27. A method according to any one of claims 25 to 27, the method further comprising deforming and/or cutting the section of sheet material to define the one or more formations or deformations therein, with the one or more formations or deformations being as set forth in any one of claims 5 to 22.

28. A method for forming a starter support as set forth in any one of claims 19 to 23, the method comprising:

- bending and/or folding a section of sheet material to define the starter support;

- when dependent on any one of claims 21 to 23, cutting the section of sheet material so as to form the aperture;

- when dependent on any one of claims 22 or 23, deforming the section of sheet material so as to form the strengthening formations.

29. A method for arranging a spacer and a starter support, the spacer as set forth in any one of claims 1 to 18, the starter support as set forth in any one of claims 19 to 23, the method enabling positioning of a plurality of further spacers, and one or more sheets in a spaced relationship relative to framework, the sheet(s) supported by the spacers in use, the method comprising:

- arranging a starter support at the framework;

- arranging a first spacer at the starter support;

- pivoting the first spacer on the starter support, such that the leg of the first spacer locates at the framework and maintains a spaced relationship of the first spacer relative thereto.

11959760_1 (GHMaters) P110604.AU.1

30. A method according to claim 29, wherein the first spacer is arranged at the starter support, prior to the starter support being arranged at the framework.

31. A method according to any one of claims 29 or 30, wherein the spacer is as set forth in any one of claims 14 to 18, the method further comprising:

- arranging a second like spacer, such that the opposite end of the second spacer is located in the opening at the end of the first spacer;

- pivoting the second spacer around its opposite end until the leg of the second spacer locates at the framework to support the opposite end of the second spacer in the spaced relationship relative to the framework.

32. A method according to any one of claims 29 to 31, wherein, prior to arranging the second spacer, the first spacer is secured to the framework by one or more fasteners.

33. A method according to claim 31 or 32, wherein, once the second spacer has been arranged at the framework, a third like spacer is arranged such that the opposite end of the third spacer is located at the second spacer, and the third spacer is then pivoted around its opposite end until the leg of the third spacer locates at the framework, and so forth until the framework has been spanned by a number of spacers arranged end-to-end, whereby sheet(s) are then able to be arranged at and secured to the plurality of spacers secured to the framework.

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