Patent Application
20100058678
1. Field
The present invention relates, generally, to building construction apparatus and methods. More particularly, the invention relates to building tools or accessories, and to methods of using such tools or accessories by carpenters or workers. Most particularly, the invention relates to a shim system, apparatus and methods. The invention is especially suitable for use in installing doors, windows and other building elements in new or existing construction.
2. Background Information
A shim is a thin and often tapered or wedged piece of material, used to fill small gaps or spaces between objects. Shims are typically used to support, adjust for better fit, or provide a level surface for doors, windows and other building elements. In carpentry or joinery, shims are typically small pieces of wood which are inserted into spaces or gaps between boards for alignment of doors, windows and the like.
An example use of shims in carpentry is in the installation of a pre-hung door. A pre-hung door is a door that is already hanging in its own frame (jambs). It is a fully self-contained unit. The main parts of a pre-hung door are door slab, hinges, and a frame. Typically, the entire unit (jambs and door) are installed at once. The unit is set it in a preformed opening and shims are used on either side of the head jamb to squeeze the unit into the opening. The hinge-side jamb is made at least level or perhaps a little higher than the strike-side jamb. Shims are inserted underneath the hinge jamb if it is not at least level. With the door open, the hinge-side jamb is shimmed until it is straight and plumb using a level and placement of shims behind the hinges. Typically, a pair of shims points in opposite directions to create a flat surface. Nails are placed through the jamb, through the shims, and into the framing. Next, the door is closed and shimming is placed under the strike-side jamb until there is an even gap between the door and the head jamb (i.e. the head jamb is level). Shims are placed behind the strike-side jamb until it is also straight and plumb. Using the door itself as a guide, shimming is placed until there is an even gap between the door and the strike-side jamb. Nails are placed through the jamb and shims and into the framing. The head jam is then shimmed and secured.
Existing shim technology is believed to have significant limitations and shortcomings. Thus, a need exists for the present invention.
All U.S. patents and patent applications, and all other published documents mentioned anywhere in this application are hereby incorporated by reference in their entirety.
The present invention provides a shim system, apparatus, article and methods which are practical, reliable, accurate and efficient, and which are believed to fulfill a need and to constitute an improvement over the background technology.
In one aspect, the invention provides a shim holder including a body having a center panel, a pair of middle panels connected to the center panel, and a pair of outer panels connected to the middle panels and adapted to be fixed to a surface to be shimmed. The body is unitary, thin, substantially flat in a normal state, and flexible. Adhesive elements are disposed on the outer panels to fix the holder to the surface to be shimmed.
In another aspect, the invention provides shim holder including an outer member; an inner member for contact with a surface to be shimmed; and at least one elastomeric connecter for connecting the outer member to the inner member. An adhesive element is disposed on the inner member for fixing the inner member to the surface to be shimmed.
In a further aspect, the invention provides method of attaching a shim to a surface to be shimmed including the steps of providing a shim holder, attaching the shim holder to the surface to be shimmed, and loading at least one shim to the shim holder.
The aspects, features, advantages, benefits and objects of the invention will become clear to those skilled in the art by reference to the following description, claims and drawings.
The present invention, and the manner and process of making and using it, will be better understood by those skilled in the art by reference to the following drawings.
The installation of doors, windows and other such building elements or features, involves placing the element into a rough opening in the construction. The construction may be new or remodel and it may be residential, commercial or industrial. After placement, the element must be oriented so that it is plumb, level and square. This almost universally involves adjustment and securement by using shims, typically wedge shaped wooden shims. The shims are placed between the rough opening framing member (i.e. stud) and the frame (i.e. jamb) of the element.
The present invention provides a technology for improving the shimming process by way of a holder for such shims or, in some embodiments, an adjustable shim assembly.
The body 10 includes a center panel or region 11, a pair of middle panels 12a and b, and a pair of outer or end panels 13a and b. The middle panels 12 are separated from the center panel 11 by slots or channels 20a and b in the side (relative to the drawing in
The side of the body shown in
The body 10 and panels 11-13 are shown to have rectangular configurations with substantially rectilinear (straight line) peripheral edges and radiused corners. In the embodiment shown, preferred dimensions are as follows. Other dimensions may be used by those skilled in the art and are within the purview of the invention.
The process 200 is repeatable for additional shim holders 10b, 10c, 10d and the like at further positions on the jamb 200 as desired by the user. The shims 225 may be adjusted and trimmed as necessary during leveling and door 210 installation. The door 210 may be secured, for example by inserting nails or other fasteners (not shown) through the holders 10 and shims 225 and into the jambs 220. Shimming may be used on one or both vertical jambs or the horizontal jamb.
The members 315 are constructed of a polymeric material and have predetermined configurations as shown. In the embodiment shown, preferred (but non-limiting) dimensions are as set forth below:
The inner and outer members 315 each preferably have a center region 325 and end regions 326 which are flexible with respect to the center region 325 to facilitate insertion of shims 330 at the ends.
The shim holder 300 is deployed by adhesively connecting it to a jamb and inserting one or more shims 330 between the members 315 as shown in
In use, the holder 400 is connected to a jamb via the connector 402, and one or more shims 403 are inserted as shown into the array 401 to form, by way of the combination of the array 401 design and flexible body, an insertion and holding passage 404.
In use, the holder 500 is connected to a jamb and one or more shims 502 are inserted as shown into the array 501 to form, by way of the combination of the array 501 design and flexible body, an insertion and holding passage 503.
Although the embodiments of the apparatus and methods of the invention are described in terms of up, down, vertical, horizontal, transverse (lateral), longitudinal, and the like, it should be understood that variations from the absolute vertical, horizontal, transverse, and longitudinal are also within the scope of the present invention.
Although the apparatus/method has been described in connection with the field of carpentry, it can readily be appreciated that it is not limited solely to such field, and can be used in other fields.
The embodiments above are chosen, described and illustrated so that persons skilled in the art will be able to understand the invention and the manner and process of making and using it. The descriptions and the accompanying drawings should be interpreted in the illustrative and not the exhaustive or limited sense. The invention is not intended to be limited to the exact forms disclosed. While the application attempts to disclose all of the embodiments of the invention that are reasonably foreseeable, there may be unforeseeable insubstantial modifications that remain as equivalents. It should be understood by persons skilled in the art that there may be other embodiments than those disclosed which fall within the scope of the invention as defined by the claims. Where a claim, if any, is expressed as a means or step for performing a specified function it is intended that such claim be construed to cover the corresponding structure, material, or acts described in the specification and equivalents thereof, including both structural equivalents and equivalent structures, material-based equivalents and equivalent materials, and act-based equivalents and equivalent acts.
