Note: Descriptions are shown in the official language in which they were submitted.
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TITLE OF THE INVENTION
Method and implements for erecting walls including a plurality of wall
components.
FIELD OF THE INVENTION
(0001] The present invention relates to the general field of
construction work, and is particularly concerned with a method and implements
to erect walls including a plurality of wall components.
BACKGROUND OF THE INVENTION
(0002] A traditional method for erecting walls including a plurality of
wall components, such as bricks, includes laying a first layer of wall
components and subsequently adding a layer of mortar on top of the first layer
of wall components. Then, a second layer of wall components is positioned
over the first layer and mortar is added again on top of the second layer.
Usually, mortar is also inserted between the wall components and many layers
of wall components are laid on top of each other, as described hereinabove,
and the mortar is left to dry. When the mortar is dried, the wall has a
relatively
strong structural integrity.
(0003] However, the wall is typically relatively fragile while the mortar
is drying. Accordingly, typically only a limited number of layers of wall
components are laid and the mortar is left to dry before adding further wall
components on top of these layers. If the wall is relatively tall, a
relatively large
amount of time is wasted waiting for the mortar to dry.
(0004] In addition, laying the bricks requires some skill in order for
the work to be done properly. Also, labor costs associated with brick laying
are
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relatively high. In fact, the costs associated with a brick wall are mainly
due to
labor costs.
(0005] With this traditional method, laying of walls having a curved
external surface is relatively awkward. Also, there is a need to have a
foundation on which to lay the bricks, and since the bricks are maintained on
top of each other, there is a need to have relatively wide bricks, and
therefore
relatively wide foundations. Obviously, such foundations add to the cost of
erecting a building.
[0006] The freeze and thaw cycle present in many climates can
damage the mortar and may render the wall fragile. In this case, there is a
need to rapidly repair the wall, as there is a risk that the wall will fall
apart.
[0007] In addition to this traditional technique, a few implements
have been devised to hold wall components, such as bricks, together prior to
the addition of mortar. Typically, mortar is required as these implements are
only used to position the wall elements at relatively fixed distances
therebetween. Also, since these devices only typically connects the wall
elements together, but do not connect the wall to any other structure, the
wall
thereby erected is relatively fragile if no mortar is inserted between the
wall
components.
(0008] Another problem with both the use of previously provided
implements and with the traditional methods described herein above, is that
laying wall components around windows is a relatively awkward procedure.
[0009] Against this background, there exists a need in the industry to
provide a new and improved method and implements to erect walls including a
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plurality of wall components.
OBJECTS OF THE INVENTION
(0010] An object of the present invention is therefore to provide
improved method and implements to erect walls including a plurality of wall
components
SUMMARY OF THE INVENTION
[0011] In a first broad aspect, the invention provides, in combination,
a first and a second wall component and a connector for connecting the first
and second wall components. The first and second wall components are
substantially elongated, each of the first and second wall components
including
respective first and second ends defining respective first and second end
surfaces. The first and second wall components have respectively first and
second substantially elongated and substantially longitudinal wall components
apertures. The connector includes a base and a first projection extending
substantially outwardly from the base, the first projection being insertable
between the first end surface of the first wall component and the second end
surface of the second wall component. A second projection for engaging the
first wall component aperture extends substantially outwardly from the base. A
distance between the first and second projections is substantially smaller
than
a distance between the first aperture and the first end surface of the first
wall
component.
[0012] Advantageously, the connector allows a relatively unskilled
user to connect together wall components at a predetermined distance
therebetween relatively easily. In addition, the connector improves the
structural rigidity of a wall including the connector. The connector also
facilitates the erection of curved walls.
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[0013] In a variant, the connector further includes a third projection
for engaging the second wall component aperture. The third projection extends
substantially outwardly from the base. A distance between the third and second
projections is substantially smaller than a distance between the second
aperture and the second end surface of the second wall component.
[0014] A non-limiting example of the wall components is a brick
including a wall component aperture extending therethrough. The wall
component aperture is of substantially oval and substantially uniform cross-
section.
(0015] In a second broad aspect, the invention provides a wall. The
wall includes a plurality of wall components arranged generally in a plurality
of
layers and a plurality of connectors each for interconnecting a first, a
second
and a third wall component from the plurality of wall components. Each of the
connectors connects the first wall component to the second wall component so
that the first and second wall components are at a predetermined side-by-side
spacing distance relative to each other. The connector connects the third wall
component to both the first and second wall components, the third wall
component being in a superposed relationship relative to the first and second
wall components with the connector provided between the third wall component
and both the first and second wall components. An interconnector connects at
least two connectors from the plurality of connectors for substantially
preventing a relative movement between the at least two connectors.
[0016] In some embodiments of the invention, the wall has a
structural integrity large enough to be erected without the use of mortar or
any
other bonding material.
[0017] In a third broad aspect, the invention provides a method for
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assembling a wall including a plurality of layers of wall components, the
method
comprising the steps of:
[0018] a) superposing above each other the plurality of layers of wall
components; and
[0019] b) securing to each other the plurality of layers of wall
components by interconnecting a plurality of wall components through
connectors, each wall component from the plurality of wall components being
included in a respective layer from the plurality of layers of wall
components.
[0020] In a fourth broad aspect, the invention provides a connector
for connecting first and second substantially elongated wall components, each
wall components having respective first and second ends defining respective
first and second end surfaces, the first and second wall components having
respectively first and second substantially elongated and substantially
longitudinal wall components apertures. The connector includes: a base, a
first
projection extending substantially outwardly from the base, the first
projection
being insertable befinreen the first end surface of the first wall component
and
the second end surface of the second wall component, and a second projection
for engaging the first wall component aperture, the second projection
extending
substantially outwardly from the base. A distance between the first and second
projections is substantially smaller than a distance between the first
aperture
and the first end surface of the wall component.
[0021] Other objects, advantages and features of the present
invention will become more apparent upon reading of the following non-
restrictive description of preferred embodiments thereof, given by way of
example only with reference to the accompanying drawings.
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BRIEF DESCRIPTION OF THE DRAWINGS
(0022] In the appended drawings:
(0023] Figure 1 is a perspective view of a partially assembled wall
including a plurality of layers of wall components, a plurality of connectors
connecting the wall components together, and an interconnector
interconnecting the layers of wall components;
[0024] Figure 2 is a perspective exploded view of a connector of
Figure 1 into which an interconnector is inserted and connecting together
three
wall components;
[0025] Figure 3A illustrates the connection of two wall components
by the connector of Figure 1 at a first distance therebetween;
[0026] Figure 3B illustrates the connection of two wall components
by the connector of Figure 1 at a second distance therebetween;
[0027] Figure 3C illustrates the connection of two wall components
by the connector of Figure 1 at a third distance therebetween;
[0028] Figure 4 illustrates in a perspective exploded view the
connection of wall components to window contour components defining a
window aperture; and
[0029] Figures 5, 6, 7 and 8 illustrate in perspective views alternative
connectors.
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[0030] Figure 9 illustrates in perspective view the use of a spacer in
conjunction with a connector from Figure 1.
DETAILED DESCRIPTION
[0031] Figure 1 illustrates a wall 10 including a plurality of layers 12
of wall components 14. The wall components 14 within each layer 12 are
interconnected by connectors 16. The connectors 16 further connect wall
components 14 from adjacent layers 12. Interconnectors 18 interconnect some
of the connectors 16.
[0032] In some embodiments of the invention, attachments 20 allow
to attach or otherwise secure a connector 16 to an external structure adjacent
to the connector 16 to which they are attached. In a specific embodiment of
the
invention shown in the drawings, the adjacent structure is a frame of a house
including wooden boards or any other suitable structure. In this case, the
attachment 20 is secured to the wooden boards through screws, nails or to any
suitable attachment method.
[0033] In other embodiments of the invention, the frame of the
house includes any other suitable components. In yet other embodiments of
the invention, the attachment 20 is secured to any other suitable external
structure that is external and adjacent to the wall 10.
[0034] Referring to Figures 1, 2, 3A, 3B and 3C, the connectors 16
keep the layers 12 away from each other at a predetermined distance. The
predetermined distance is determined in a specific embodiment of the invention
by a thickness of a base 24 of the connector 16.
[0035] Also, the connectors 16 allow spacing from each other the
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wall components 14 in a given layer 12 at a predetermined distance from each
other. In specific embodiments of the invention, the predetermined distance is
a variable distance. In other words, in these embodiments the predetermined
distance is selected by an intended user from a range of distances.
[0036] An example of a suitable wall component 12 is a brick.
However, it is within the scope of the invention to have any other suitable
wall
component.
(0037] The interconnectors 18 (not shown in Figures 3A, 3B and 3C)
interconnect the connectors 16 interposed between adjacent layers 12 of the
wall 10. Therefore, the interconnectors 18 help in improving the structural
integrity and rigidity of the wall 10.
[0038] In some embodiments of the invention, the connectors 16, the
attachments 20 and the interconnectors 18 give a structural rigidity to the
wall
sufficient for the wall 10 to be erected without the use of a binding
material,
such as mortar. Then, if needed, the bonding material is added between the
wall components 14 for esthetic purposes. However, in other embodiments of
the invention, mortar is inserted between the wall components 14 to also
improve the structural rigidity of the wall 10.
(0039] Referring to Figure 1, in some embodiments of the invention,
the wall 10 is laid on a foundation 26. An example of a suitable foundation 26
is a concrete foundation. However, any other foundation is usable in
conjunction with the invention in other embodiments.
[0040] In a specific embodiment of the invention, as better shown in
Figure 2, the wall components 14 take the form of substantially elongated
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parallelepiped-shaped bricks including an aperture 28 extending therethrough.
The aperture 28 is of a substantially oval cross-section and the cross-section
is
substantially uniform through the aperture. The aperture 28 is for receiving
the
connectors 16 and the interconnectors 18 and is substantially elongated and
substantially longitudinally oriented. Each wall component 14 has first and
second ends 15 and 17 defining respective first and second end surfaces 19
and 21.
[0041] Figure 2 illustrates in more details one of the connectors 16.
The connector 16 includes a base 24, intercomponent projections 30 extending
substantially outwardly from the base 28, the intercomponent projections being
insertable between wall components 14 from the same layer 12, and
intracomponent projections 32 for engaging the wall component apertures 28,
the intracomponent projections 32 extending substantially outwardly from the
base 24.
[0042] The intercomponent projections 30 and the intracomponent
projections 32 allow connecting wall components 14 in the same layer 12 at the
variable distance therebetween. To that effect, a distance between an
intercomponent projection 30 and an adjacent intracomponent projection 32 is
substantially smaller than a distance between an end surface 19 or 17 and the
wall component aperture 28 of each wall component 14.
[0043] In some embodiments of the invention, as shown in Figure 2,
the connector 16 includes two intercomponent projections 30 and four
intracomponent projections 32. However, it is within the scope of the
invention
to have any other suitable number of projections.
[0044] Referring to Figure 3A, a specific use of the connector 16 is
shown. This use will be better explained by referring to two specific wall
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components 14, namely wall components 14A and 14B.
[0045] As shown in Figures 2 and 3A, the connector 16 includes a
panel 29 defining first and second substantially opposed support surfaces 34
and 36. The support surface 34 contacts the wall component 14A and 14B,
while the support surface 36 contacts a wall component 14 from a layer 12
superposed to a layer 12 including the wall components 14A and 14B. The
projections 30 and 32 extend from the support surface 36 and are inserted
within the aperture 28 of the wall component 14 from the layer 12 superposed
to the layer 12 including the wall components 14A and 14B. A peripheral wall
42 connects the support surfaces 34 and 36.
(0046] One of the intercomponent projections 30 of the connector 16
is inserted between the wall components 14A and 148, while two
intracomponent projections 32 extending from the support surface 34 are
inserted respectively within the apertures 28 of the wall component 14A and
the
wall component 14B.
[0047] In a specific use, as seen on Figure 3C, one of the
intercomponent projection 30 separates the wall components 14A and 14B at a
first predetermined distance therebetween. To that effect, the wall components
14A and 14B both contact the intercomponent projection 16 extending from the
support surface 34.
[0048] As can be seen in Figures 3A and 3B, two wall components
14A and 14B within the same layer 12 do not necessarily abut the
intercomponent projection 30 that is inserted therebetween. Indeed, if a
distance between the projections 32 and the projection 30 is sufficient, and
if
the apertures 28 of the wall components 14A and 14B are suitably shaped, the
wall components 14A and 14B are positionable at a variable distance
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therebetween.
(0049] At a maximal distance between the wall components 14A and
14B, as shown in Figure 3A, intracomponent projections 32 contact extremities
of the apertures 28 of the wall components 14A and 14B. In that configuration,
the intercomponent projection 30 inserted between the wall components 14A
and 14B does not contact these wall components 14A and 14B. At a minimal
distance between the wall components 14A and 14B, the situation is as
described hereinabove with respect to Figure 3C.
(0050] At an intermediate distance shown in Figure 3B, both the
intracomponent and intercomponent projections 32 and 30 do not contact the
extremities of the apertures 28 and the end surfaces 19 and 21 of the wall
components 14A and 14B.
(0051] In some embodiments of the invention, the intracomponent
projections 32 frictionally engage the apertures 28. In this embodiment, the
connectors 16 improve the structure rigidity of the wall 10 as opposed to a
situation wherein the connectors do not frictionally engage the apertures. In
other embodiments of the invention however, the projections 32 do not engage
the apertures 28 and are simply inserted within the apertures 28.
(0052] Turning back to Figures 3A, 3B and 3C, the intercomponent
projections 30 include two substantially planar abutment surfaces 33 and 35
for
abutting the wall components 14A and 14B when these wall components 14A
and 14B are positioned at the minimal distance with respect to each other. The
abutment surfaces 33 and 35 are substantially perpendicular to the support
surface 34.
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(0053] The intracomponent projections 32 are substantially
cylindrical with a longitudinal axis substantially perpendicular to the
support
surfaces 34 and 36. In a specific embodiment of the invention, the projections
32 extending from the surface 34 are substantially collinear with the
projections
32 extending from the support surface 36. Also, the longitudinal axis of the
intracomponent projections 32 is substantially perpendicular to the support
surfaces 34 and 36.
[0054) In some embodiments of the invention, two collinear
intracomponent projections 32 and the base 24 define a connector aperture 40
extending therethrough. However, in alternative embodiments of the invention,
the intracomponent projections 32 do not define apertures extending
therethrough.
[0055] In some embodiments of the invention, some or all of the
connectors 16 include a respective attachment 20 or 20' extending
substantially
outwardly from the connector 16. In some embodiments of the invention, as
seen in Figures 5, fi and 7, an attachment 20' extends integrally from
connectors 16', which are described in further details hereinbelow, while in
other embodiments of the invention, as shown in Figure 2, an attachment 20 is
detachable from the connectors 16.
[0056] Depressions 44 are defined within the support surfaces 34
and 36 of the connector 16, the depressions 44 being defined around
respective intracomponent projections 32 and extending to the peripheral wall
42. The depressions 44 are for receiving the attachments 20. To that effect,
the attachments 20 each define an attachment aperture 46.
[0057] A specific example of an attachment 20, which is substantially
L-shaped, is shown in Figure 2. More specifically, the attachment 20 includes
a
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substantially L-shaped bracket that includes first and second substantially
perpendicular bracket portions 50 and 52. The bracket portion 50 is attachable
to the external structure while the aperture 46 is provided in the second
bracket
portion 52. Therefore, the second bracket portion 52 is received within the
depression 44.
[0058] The connector 16 includes markings and indicia 54 provided
on the peripheral wall 42. The indicia 54 allow positioning of the wall
components 14A and 14B at the predetermined distance from each other, as
seen in Figures 3A, 3B and 3C.
[0059] In some embodiments of the invention, the indicia 54 take the
form of substantially rectilinear grooves engraved within the peripheral wall.
In
other alternative embodiments of the invention, the indicia 54 include a
substantially rectilinear raised design over the peripheral wall.
[0060] The interconnector 18 extends through the apertures 28 of
the wall components 14 and through the connector apertures 40 of the
connectors 16. Therefore, the interconnectors 18 solidify the wall components
together.
[0061] The interconnectors 18 each include a substantially
elongated rod 60. The rod 60 is substantially cylindrical. However, it is
within
the scope of the invention to have rods having any other suitable shape. The
rod 60 is shaped to be substantially snugly received within the connector
apertures 40.
[0062] In some embodiments of the invention, the interconnector
includes a plurality of rods 60. Each rod 60 is included in a respective
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interconnector portion. The rod 60 defines a male segment 62 and a female
segment 64. The male segment 62 is defined at an extremity of the rod 60 and
the female segment 64 is defined at the other extremity of the rod 60. The
male segment 62 of one of the rods 60 is for engaging the female segment 64
of another of the rods 60. To that effect, an outside diameter of the male
segment 62 is substantially smaller than an inside diameter of the female
segment 64.
[0063] In some embodiments of the invention, the rod 60 defines a
rod aperture 66 extending therethrough. However, in other embodiments of the
invention, the rod 60 does not define an aperture and is instead a solid piece
of
material.
[0064] Referring to Figure 8, there is shown that in some
embodiments of the invention, a connector 16" similar to the connector 16 is
included in the wall 10. The connector 16" is substantially similar to the
connector 16, except that no protrusions 32 and 30 extend from the support
surface 34. Therefore, the connector 16" is positionable onto the foundation
26
of the wall 10. In some embodiments of the invention, the base 24 of the
connector 16" does not define an aperture, and therefore the connector 16"
receives the interconnector through the intercomponent projections 32 and the
interconnector abuts the base 24.
[0065] In some embodiments of the invention, the connector 16"
defines connector apertures extending therethrough and therefore the
interconnectors engage the foundation in a foundation aperture (not shown in
the drawings).
[0066] As shown in Figure 1, in some embodiments of the invention,
the wall 10 includes a window aperture 70. The window aperture 70 is defined
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by at least one window contour component 77 and is for receiving a window
(not shown). The window contour components 77 are connected to adjacent
wall components 14 through window connectors 116.
(0067] One of the window connector 116 and one of the window
contour component 77 are better illustrated on Figure 4. The window contour
component 77 is substantially elongated and includes a substantially
longitudinal indentation 79. In the specific embodiment of the invention shown
in the drawings, the window contour component 77 is substantially
parallelepiped-shaped and includes six substantially planar walls 81 a, 81 b,
81 c,
81 d, 81 a and 81 f. The indentation 79 extends along substantially a whole
length of the wall 81a. However, in alternative embodiments of the invention,
the window contour component 77 is of any suitable shape and the indentation
79 is configured in any other suitable manner.
[0068] The window connector 160 is very similar to the connector
16, except that half of the base and finro of the intracomponent projections
32
are not present in this connector 160. Therefore, a single intercomponent
protrusion 130, generally corresponding to the two intercomponent protrusions
30 in the connector 16, is defined in the connector 160. The intercomponent
projection 130 is for engaging the indentation 79.
(0069] In some embodiments of the invention, it is advantageous to
have a wall 10 including half-wall components 14' in proximity to the window
contour elements 77. The half-wall components 14' are similar to what is
obtained by cutting in half one of the wall components 14 in a plane
substantially perpendicular to the longitudinal axis of the wall components
14.
The half-wall components 14' help in preserving an offset between the wall
components 14 of adjacent layers 12.
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[0070] In use, a foundation 26 of the house is first built in any
suitable manner. Then, the connectors 16" are laid onto this foundation 26. In
alternative embodiments of the invention, the connectors 16" are laid into
cavities defined within the foundation. In yet other embodiments of the
invention, the foundation 26 is a concrete foundation and the connectors 16"
are simply pushed into unsolidified concrete while erecting the foundation 26.
(0071] Then, a layer 12 of wall components 14 is laid.
Subsequently, a layer of connectors 16 is laid onto the layer 12 of wall
components 14. A distance between the wall components 14 of this layer 12 is
adjusted at a predetermined distance as illustrated in Figures 3A, 3B and 3C.
Each of the connectors 16 engages a respective aperture 28 within the wall
components 14 of the first layer 12.
[0072] Afterward, a second layer 12 of wall components 14 is laid
onto the first layer. The wall components 14 of the second layer 12 are offset
from the wall component 14 of the first layer and spaced apart at the
predetermined distance. This offset is such that each of the connectors 16 on
top of the first layer of wall components 16 engages two wall components 16 of
the second layer 12, as described hereinabove.
(0073] Additional layers 12 of wall components 14 are laid on top of
each other as described with respect to the first and second layers 12 of wall
components 14. When the wall has reached a height substantially equal to a
length of one of the rods 60, a rod 60 is inserted into the connectors 16 and
the
apertures 28 that are substantially aligned. Then, if required, more layers of
connectors 16 and wall components 14 are added, as described hereinabove.
Rods 60 are also added, as described hereinabove.
[0074] In some embodiments of the invention, the wall 10, built as
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described, is left as is without the use of a bonding material. However, in
alternative embodiments of the invention, a binding material, such as mortar,
for example, is inserted in between the wall components.
[0075] The rods 60 substantially prevent the connectors 16, and
consequently in some embodiments of the invention the wall components 14,
from moving with respect to each other. Accordingly, a structural rigidity of
the
wall 10 is greatly improved. This allows erecting the whole wall 10 without
requiring the use of mortar or any other binding material, which is only
applied
after a complete assembly of the wall 10. Therefore, there is no need to wait
for
the binding material to dry after laying a few layers of wall components,
which
greatly diminishes a time taken to erect the wall 10.
[0076] In addition, an increased structural rigidity of the wall 10
contributes to an improved earthquake resistance of the wall 10 and reduces
risks that the wall 10 becomes damaged through any other cause and falls.
[0077] In specific embodiments of the invention, the attachments 20
are inserted onto connectors 16 that are aligned with the wood planks and
beams of the structure of the house, thereby allowing attaching these
connectors to this structure to further solidify the wall 10.
[0078] Therefore, the wall 10 and its various components allow
erecting the wall 10 without using the mortar and subsequently, to add the
mortar which has mainly an esthetic function.
(0079] In some embodiments of the invention, the wall is not a
straight wall and is instead curved. This curvature is relatively easy to
achieve
with the wall components 14 and the connectors 16 because of the rounded
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nature of the intracomponent projections 32 and of the apertures 28.
[0080] Figures 5 to 7 illustrate alternatives connectors 16', 16a and
16b which are similar respectively to the connectors 16, 16" and 116, except
that the attachment 20 is replaced in these connectors 16', 16a and 16b by an
attachment 20' extending integrally from a respective base 24', 24a and 24b.
[0081] Figure 9 illustrates an alternative embodiment of the invention
including spacers 200. The spacers 200 are insertable between a connector 16
and a wall component 14 to vary a distance between two wall components 14
included in adjacent layers 12 connected by this connector 16. This allows an
intended user to vary a distance between layers 12, either uniformly
throughout
a wall or to form a pattern with the layers 12.
[0082] In addition, the spacers 200 allow leveling the wall
components 14 within a layer 12. To that effect, a number of spacers 200 used,
which may include the use of zero spacers (the absence of a spacer), is
selected so that the wall components within a level 12 are substantially level
with respect to each other.
[0083] As shown on Figure 9, in a specific embodiment of the
invention, the spacer 200 is substantially annular and insertable onto the
intracomponent projections 32. In addition, the spacer 200 is shaped to be
received within the depressions 44. However, in alternative embodiments of the
invention, the spacer 200 adopts any other suitable configuration.
[0084] Although the present invention has been described
hereinabove by way of preferred embodiments thereof, it can be modified,
without departing from the spirit and nature of the subject invention as
defined
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