Patent Application
20060213135
The present invention is directed to an adjustable shim for positioning a closure unit in a rough opening, and in particular, to an installation system and method for a closure unit.
One of the more time consuming jobs in the construction and restoration fields is the setting (i.e. installing, leveling, and plumbing) of closures such as doors, windows, side lights, transoms, gable air vents, portals, skylights, etc., in rough structural openings, such as the rough opening 10 illustrated in
Installers typically use wooden shims placed and sometime driven in the gap between the closure frame or jamb and the wall studs that form the rough opening. A level is used during this process to confirm the positioning of the jamb in the opening and re-adjustment of the shims is made as necessary to complete the installing, leveling and plumbing process. Levels are used on closures that have a flat vertical or horizontal side or sides. A plumb line is used on closures where a level is ineffective, such as a circular or oval closure.
Although the wooden shim is still the dominant means today for installing closures, it does have some limitations including: (1) the method of installing with wood shims is very time consuming; (2) wood shims are difficult to use on rounded surfaces (i.e. circular, oval-portals, stained glass ovals, etc.); (3) wood shims often interfere with complete sealing of the window to the rough opening; and (4) wood shims can slip out of place during installation of the closure unit.
U.S. Pat. No. 5,655,343 (Seals) discloses an adjustable shim that attaches to a window or a door jamb at the construction site. Flanges 160, 170 are bent around the jamb and attached thereto with fasteners. As best illustrated in
U.S. Pat. No. 5,692,350 (Murphy, Jr.) discloses a spring shim for windows and doors. The spring shim of Murphy is in an expanded configuration prior to installation of the window or door in the rough opening.
U.S. Pat. Nos. 4,713,922 (Ingold); 4,731,965 (Jensen); 5,054,250 (Foss); and 6,018,916 (Henry) disclose variations on conventional shims.
The present invention is directed to an adjustable shim for positioning a closure unit in a rough opening. The present invention is also directed to an installation system and method for a closure unit.
One embodiment is directed to a system for installing a closure unit in a rough opening. The closure unit includes a frame with a perimeter edge and at least one longitudinal recess extending along at least a portion of the perimeter edge. An attachment member on an adjustable shim is releasably coupled with the longitudinal recess. The adjustable shim includes at least one deformable leg having a first end and a second end is coupled to the attachment member. An elongated member coupled to the deformable leg in a compact configuration such that displacement of the elongated member relative to the attachment member in a first direction deforms the deformable leg into an expanded configuration. The adjustable shim is substantially located within the perimeter edge of the closure unit in the expanded configuration. The elongated member can be notched strap, such as on a cable tie, a threaded member, or a variety of other structures adapted to apply a force on the deformable legs.
Another embodiment of the present invention is directed to a system for installing a closure unit in a rough opening. The closure unit has a frame with a perimeter edge and at least one longitudinal recess extending along at least a portion of the perimeter edge. An attachment member on the adjustable shim is releasably coupled with the longitudinal recess. The adjustable shim includes at least one deformable leg having a first end and a second end coupled to the attachment member and a threaded member coupled to the deformable leg in a compact configuration. Rotation of the threaded member in a first direction deforms the leg into an expanded configuration, wherein the adjustable shim is substantially retained within the perimeter edge in both the compact and expanded configurations.
The longitudinal recess preferably extends substantially around the perimeter edge of the closure unit. The attachment member preferably slidingly engages with the longitudinal recess. In one embodiment, the attachment member forms a snap-fit relationship with the longitudinal recess. At least one locking mechanism proximate the attachment member is optionally used to secure the adjustable shim relative to the longitudinal recess. The adjustable shim is preferably attached to the closure unit at a location remote from the rough opening, such as for example at a manufacturing facility.
The deformable leg can be elastically or plastically deformable. The deformable leg can be metal, plastic, or a composite thereof. In one embodiment, the deformable leg is a pair of deformable legs located on opposite sides of the threaded member. The deformable leg is preferably constructed from a sheet material.
Rotation of the threaded member in the first direction causes the first end to displace toward the second end. Rotation of the threaded member in a second direction opposite from the first direction causes the first end to displace away from the second end. The threaded member is preferably coupled proximate the first and second ends of the deformable leg. The threaded member includes at least one adjustment interface, such as for example a Phillips or hex headed member, at a distal end thereof. In the preferred embodiment, the adjustment interface is compatible with conventional tools, such as for example, flat-head or Phillips screwdrivers, hex-headed tools, and the like.
The adjustable shim is preferably located between an interior sealing plane and an exterior sealing plane associated with the closure unit. The adjustable shim is accessible through one or both of the interior or exterior sealing planes associated with the closure unit.
The adjustable shim in the expanded configuration creates opposing forces simultaneously acting on the perimeter edge of the closure unit and the rough opening. The expanded configuration spans the gap between the perimeter edge and the rough opening. The width of the closure unit and the adjustable shim in the compact configuration is preferably less than a width of the rough opening.
In one embodiment, finish trim is attached to an interior surface of the closure unit generally around the perimeter edge. A foam material can optionally be used to attach the closure unit to the rough opening.
The present invention is also directed to a method of installing a closure unit in a rough opening. A longitudinal recess is formed in at least a portion of a perimeter edge of a frame on the closure unit. An attachment member on an adjustable shim is releasably coupled to the longitudinal recess so that the adjustable shim is substantially retained within the perimeter edge. The adjustable shim is configured in a compact configuration. The closure unit is positioned in the rough opening. The adjustable shim is deformed to an expanded configuration that creates opposing forces simultaneously acting on the perimeter edge and the rough opening sufficient to suspend the closure unit in the rough opening.
The method typically includes attaching a plurality of adjustable shims to the closure unit at a manufacturing facility, prior to delivery of the closure unit to the installation site. The method optionally includes sliding the adjustable shim along the longitudinal recess to the desired location. Once the closure unit is suspended in the rough opening using the adjustable shims, the frame is attached to the rough opening using foam, fasteners, or a combination thereof.
In one embodiment, the method includes attaching finish trim to an interior surface of the closure unit generally around the perimeter edge before positioning the closure unit in the rough opening. The adjustable shim and/or finish trim is preferably attached to the closure unit at a remote location.
a is a perspective view of an adjustable shim in accordance with an embodiment of the present invention.
b is a top view of the adjustable shim of
c is an end view of the adjustable shim of
d is an end view of the adjustable shim of
a is a side view of an adjustable shim in the compact configuration in accordance with the present invention.
b is a side view of the adjustable shim of
a is a side view of an alternate adjustable shim in accordance with the present invention.
b is a side view of the alternate adjustable shim of
c is an enlarged partial sectional view of the head and strap of
The present invention is directed to a system for installing a closure unit in a rough opening. The present system includes the use of an adjustable shim reliably attached to the closure unit, preferably at a remote location, such as a manufacturing facility. The remote location refers to any location other than the site of the rough opening. As used herein, “closure” or “closure unit” refer to a structure that mounts in a rough opening of a building structure, such as for example doors, fixed or movable windows, side lights, transoms, gable air vents, portals, skylights, and the like.
Located generally between the exterior sealing plane 34 and the interior sealing plane 36 of the closure unit 30 is a perimeter edge 38. The perimeter edge 38 includes one or more surfaces on the perimeter of the closure unit 30 that extend between the exterior and interior sealing planes 34, 36. As used herein, “perimeter edge” refers to one or more surfaces located between interior and exterior sealing planes of a closure unit.
The perimeter edge 38 preferably includes one or more longitudinal recesses 40. One or more adjustable shims 50 are releasably attached or coupled to the longitudinal recess 40, preferably along each side of the closure unit 30. The adjustable shims 50 can preferably be attached and detached from the recess 40 without the use of tools. In one embodiment, the adjustable shims 50 are adapted to form a snap-fit relationship with the longitudinal recess 40.
In the preferred embodiment, the adjustable shims 50 are releasably attached to the closure unit 30 at a location remote from the rough opening 10, such as a manufacturing facility. The closure unit 30 is preferably packaged and shipped with the adjustable shims 50 pre-attached. Alternatively, some or all of the adjustable shims 50 can be snap-fit into the longitudinal recess 40 at the installation site.
a through 3d illustrate one embodiment of the adjustable shim 50 in accordance with the present invention. The adjustable shim 50 includes an attachment member 52. In the illustrated embodiment, the attachment member 52 includes a flange 54 with a rounded distal end 56. The attachment member 52 preferably forms a snap-fit relationship with the longitudinal recess 40 (See e.g.,
In the preferred embodiment, the attachment member 52 permits the adjustable shim 50 to slidingly engage with the longitudinal recess 40. The sliding relationship between the longitudinal recess 40 and the attachment member 52 permits the installer to position the adjustable shims 50 at the optimum locations along the perimeter edge 38 to install the closure 30 in the rough opening 10. As used herein, “snap fit” refers to a positive engagement by substantially elastic deformation of two generally interengaging components.
The adjustable shim 50 includes elongated member 60 with an adjustment interface 62. In the illustrated embodiment, the elongated member 60 is a threaded member. The adjustment interface 62 may comprise a structure that can mechanically couple with a variety of specialty or conventional tools, such as for example a flat head screw drive, a Phillips screw drive, a torx wrench, a hex wrench, a socket wrench, and the like.
In the illustrated embodiment, the threaded member 60 includes a single adjustment interface 62 at a distal end of the threaded member 60. Alternatively, the threaded member 60 may include a first and second adjustment interfaces 62 at opposite ends from each other (see e.g.,
Coupled to the threaded member 60 is at least one deformable leg 64 having a first end 66 and second end 68. The deformable leg 64 may be made of metal, plastic, fiberglass, or a composite thereof. The deformable leg 64 is preferably formed from a sheet material. The deformable leg 64 is either elastically or plastically deformable.
In the illustrated embodiment, sleeve 70 is attached to the deformable leg 64 near the first end 66 and sleeve 72 is attached to the deformable leg 64 near the second end. In the illustrated embodiment, the sleeve 70 has internal threads that correspond to the threads on the threaded member 60. Alternatively, the sleeve 72 can include internal threads.
b illustrates a positioning mechanism 74 proximate the attachment member 52. The positioning mechanism 74 is optionally used to secure the adjustable shim 50 to the closure unit 30 at a particular location along the longitudinal recess 40. In the illustrated embodiment, the positioning mechanism 74 includes a pair of holes, which can receive nails, screws, or the like. Alternatively, the positioning member 74 can be a pointed protrusion stamped through the second end 68.
a and 4b illustrate operation of the adjustable shim 50 in accordance with the present invention. Prior to operation, the legs 64 are in a substantially compact configuration, as illustrated in
Rotation of the adjustment interface 62 causes the threaded member 60 to rotate in the threaded sleeve 70. Since rotation of the threaded sleeve 70 is restricted by the legs 64, rotation of the threaded member 60 in the first direction causes the first end 66 to displace toward the second end 68. As best illustrated in
a illustrates yet another embodiment of the adjustable shim 250 in accordance with the present invention. In the illustrated embodiment, the adjustable shim 250 includes an attachment member 252 connected at a first end 263 of a deformable leg 264. First end 266 of elongated member or strap 265 is coupled to second end 270 of the deformable leg 264. Second end 268 of the strap 265 is slidingly engaged in opening 269 in head 267. The head 267 may be attached to the attachment member 252 by adhesives, welding, fasteners or a variety of other techniques. Alternatively, the attachment member 252 may be integrally molded with the head 267 as a single component.
As best illustrated in the enlarged partial sectional view of
b illustrates the operation of the adjustable shim 250. Prior to operation, the deformable leg 264 is preferably in a compact configuration, such as illustrated in
Rotation of the adjustment interface 106 causes the adjustable shim 100 to expand, creating opposing forces 108, 110 between the rough opening 10 and the perimeter edge 38 of the closure unit 30. The opposing forces 108, 110 operate to suspend the closure unit 30 in the desired position within the rough opening 10. A plurality of adjustable shims 100 are preferably adjusted until the closure unit 30 is properly positioned, level and tightly secured in the rough opening 10. The legs 114 of the adjustable shim 100 are preferably elastically deformable so that the installer can reduce the forces 108, 110 by counter-rotating the adjustment interface as needed. Alternatively, the legs 114 are plastically deformable.
The adjustable shims 100 are preferably located between the exterior sealing plane 34 and the interior sealing plane 36. Consequently, the present adjustable shims 100 do not interfere with whatever sealing material is positioned in the gap 112 between the perimeter edge 38 and the rough opening 10. In one embodiment, foam material 120 is sprayed into the gap 112 to form a weather-tight seal and/or to securely attach the closure unit 30 in the rough opening 10. As illustrated in
In the illustrated embodiment, the closure unit 30 further includes a finish trim 124 attached to an interior surface 126 of the closure unit 30, generally around the perimeter edge 38. The finish trim 124 is preferably attached to the interior surface 126 at location remote from the rough opening 10 prior to installation of the closure unit 30, such as a manufacturing factory. This embodiments permits the finish trim 124 to be factory installed and a factory finish applied prior to the closure unit 30 being shipped to the installation site.
In the illustrated embodiment, the threaded member 154 has an adjustment interface 162, 164 at each end. This configuration permits the installer to operate the adjustable shim 150 from either the inside 166 or outside 168 of the closure unit 30.
Rotation of the threaded member 154 causes the coiled material 152 to deform to an expanded configuration, which creates opposing compressive forces 170, 172 between the outer perimeter 38 and the rough opening 10.
Again, the adjustable shims 150 are preferably located between the exterior sealing plane 34 and the interior sealing plane 36. Consequently, the present adjustable shims 150 do not interfere with whatever sealing material is positioned in the gap 112 between the perimeter edge 38 and the rough opening 10. The adjustable shim 250 of
Patents and patent applications disclosed herein, including those cited in the Background of the Invention, are hereby incorporated by reference. Other embodiments of the invention are possible. It is to be understood that the above description is intended to be illustrative, and not restrictive. Many other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.
