Abstract:
A shim holder includes 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. Also disclosed is a 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. Further disclosed is a 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.

Description:
BACKGROUND 
       [0001]    1. Field 
         [0002]    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. 
         [0003]    2. Background Information 
         [0004]    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. 
         [0005]    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. 
         [0006]    Existing shim technology is believed to have significant limitations and shortcomings. Thus, a need exists for the present invention. 
         [0007]    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. 
       BRIEF SUMMARY 
       [0008]    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. 
         [0009]    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. 
         [0010]    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. 
         [0011]    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. 
         [0012]    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. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING 
         [0013]    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. 
           [0014]      FIG. 1  is a front view of an embodiment of a shim holder of the present invention. 
           [0015]      FIG. 2  is a front view of another embodiment of the shim holder. 
           [0016]      FIG. 3A  illustrates an embodiment of a method of using a shim holder, of the present invention. 
           [0017]      FIG. 3B  is a flow chart of an embodiment of the method of using a shim holder. 
           [0018]      FIG. 4  is a front view of yet another embodiment of the shim holder of the present invention. 
           [0019]      FIG. 5  is a back view of the shim holder shown in  FIG. 4 . 
           [0020]      FIG. 6  is a side view of the shim holder. 
           [0021]      FIG. 7  is a front view of the shim holder. 
           [0022]      FIG. 8  is a back view of the shim holder. 
           [0023]      FIG. 9  is a perspective view of the shim holder. 
           [0024]      FIG. 10  is a front view of the shim holder with a shim deployed in the holder. 
           [0025]      FIG. 11  is a perspective view from the back of the shim holder with a pair of shims deployed therein. 
           [0026]      FIG. 12  is a perspective view from the front of the shim holder. 
           [0027]      FIG. 13  is a side view of the shim holder. 
           [0028]      FIG. 14  is a front view of still another embodiment of the shim holder of the present invention. 
           [0029]      FIG. 15  is a front view of the shim holder of  FIG. 14 , with a pair of shims inserted therein. 
           [0030]      FIG. 16  is a back view of the shim holder. 
           [0031]      FIG. 17  is a side view of the shim holder. 
           [0032]      FIG. 18  is a front view of still another embodiment of the shim holder of the present invention. 
           [0033]      FIG. 19  is a back view of the shim holder of  FIG. 18  with a shim inserted therein. 
           [0034]      FIG. 20  is a front view of a further embodiment of the shim holder of the present invention. 
           [0035]      FIG. 21  is a perspective view of the shim holder of  FIG. 20 . 
           [0036]      FIG. 22  is a further perspective view of the shim holder. 
           [0037]      FIG. 23  is a front view of still a further embodiment of the shim holder of the present invention. 
           [0038]      FIG. 24  is a perspective view of the shim holder of  FIG. 23  with a shim inserted therein. 
           [0039]      FIG. 25  is a front view of yet a further embodiment of the shim holder of the present invention, with a shim inserted therein. 
           [0040]      FIG. 26  is a perspective view of the shim holder of  FIG. 25 , again with a shim inserted therein. 
           [0041]      FIG. 27  is a front view of yet another embodiment of the shim holder of the present invention, with a shim inserted therein. 
           [0042]      FIG. 28  is a perspective view of still another embodiment of the shim holder of the present invention, with a shim inserted therein. 
           [0043]      FIG. 29  is a front view of yet another embodiment of the shim holder of the present invention, with a shim inserted therein. 
           [0044]      FIG. 30  is a perspective view of the shim holder of  FIG. 29 , again with a shim inserted therein. 
           [0045]      FIGS. 31-34  illustrate an alternative embodiment of the shim and shimming technology of the present invention, involving an adjustable wedge system. 
           [0046]      FIGS. 35 and 36  another alternative embodiment of the shim system of the present invention. 
           [0047]      FIG. 37  illustrates still another alternative embodiment of the shim system of the present invention. 
           [0048]      FIGS. 38 and 39  illustrate yet another alternative embodiment of the shim system of the present invention 
           [0049]      FIG. 40  illustrates a further alternative embodiment of the shim system of the present invention 
       
    
    
     DETAILED DESCRIPTION 
       [0050]    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. 
         [0051]    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. 
         [0052]      FIG. 1  shows an embodiment of a shim holder  10  of the present invention. The shim holder  10  has a body which is unitary and preferably thin, substantially flat in a normal state, and flexible. The body is preferably constructed of a flexible plastic material. 
         [0053]    The body  10  includes a center panel or region  11 , a pair of middle panels  12   a  and  b,  and a pair of outer or end panels  13   a  and  b.  The middle panels  12  are separated from the center panel  11  by slots or channels  20   a  and  b  in the side (relative to the drawing in  FIG. 1 ). Channels  20   a  and  20   a ′ (prime) are preferably aligned with each other and extend equidistantly from the sides, as do the channels  20   b  and  20   b ′. Regions or area  21   a  and  b  between the slots  20  couple the center panel  11  to the middle panels  12 . The outer or end panels  13  are separated from their respective middle panels  11  by slots or channels  25   a  and  b  in the side (relative to the drawing in  FIG. 1 ). Regions or area  26   a  and  b  between the slots  25  couple the center panel  11  to the middle panels  12 . Slots  25  are also preferably aligned and of equivalent dimensions. Slots or channels  30   a  and  b  are preferably disposed in middle panels  12   a  and  b  respectively. The slots  25  are preferably centered in the panels  12 . 
         [0054]    The side of the body shown in  FIG. 1  has adhesive members  13   a  and  b  disposed on the outer panels  13   a  and  b  respectively. The opposite side of the body (not shown) may optionally have one or more adhesive members. 
         [0055]    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. 
         [0000]    
       
         
               
               
               
               
             
           
               
                   
                   
               
             
             
               
                   
                 “A” 
                 1½ 
                 inches (in.) 
               
               
                   
                   
                 (2.0 
                 cm.) 
               
               
                   
                 B 
                 ⅞ 
                 in. 
               
               
                   
                 C 
                  10/16 
                 in. 
               
               
                   
                 D 
                  1/16 
                 in. 
               
               
                   
                 E 
                  1/16 
                 in. 
               
               
                   
                 F 
                 1⅛ 
                 in. 
               
               
                   
                 G 
                 2¼ 
                 in 
               
               
                   
                 H 
                 3⅜ 
                 in. 
               
               
                   
                 I 
                  9/16 
                 in. 
               
               
                   
                 J 
                  9/16 
                 in. 
               
               
                   
                 K 
                 R ⅛ 
                 in. 
               
               
                   
                 L 
                 R 1/32 
                 in. 
               
               
                   
                 M 
                 ¾ 
                 in. 
               
               
                   
                 N 
                 ¾ 
                 in. 
               
               
                   
                 X 
                 4½ 
                 in. 
               
               
                   
                 Y 
                 4½ 
                 in. 
               
               
                   
                   
               
             
          
         
       
     
         [0056]      FIG. 2  is a front view of another embodiment of the shim holder  100 . It is constructed and arranged substantially similar to the shim holder  10  of  FIG. 1 , comprising a body with a center panel  110 , middle panels  111   a  and  b,  and outer panels  112   a  and  b.  By way of illustrating alternative, non-limiting, structural dimensions, those for shim holder  100  are as follows. 
         [0000]    
       
         
               
               
               
               
             
           
               
                   
                   
               
             
             
               
                   
                 “O” 
                 4⅜ 
                 inches (in.) 
               
               
                   
                 P 
                 4⅜ 
                 in. 
               
               
                   
                 Q 
                 1½ 
                 in. 
               
               
                   
                 R 
                 1 17/32 
                 in. 
               
               
                   
                 S 
                  13/16 
                 in. 
               
               
                   
                 T 
                 ⅝ 
                 in. 
               
               
                   
                 U 
                  5/16 
                 in 
               
               
                   
                 V 
                  5/16 
                 in. 
               
               
                   
                 W 
                 1 5/16 
                 in. 
               
               
                   
                 W′ (Prime) 
                  9/16 
                 in. 
               
               
                   
                   
               
             
          
         
       
     
         [0057]      FIGS. 3A  and B illustrates an embodiment of a method  200  of using a shim holder, of the present invention, to install a building element, for example a door  210 , in a structure, for example a wall  215 . The first step  230  involves selecting a shim holder for example shim holder  10  describe above. The second step of this embodiment of the method involves activating  231  shim holder  10   a  by removing release liners  35  to expose adhesive  34  of elements  13   a  and  b.  The shim holder  10   a  is then oriented and placed  232  at a predetermined position on the jamb  220  of the door  210 . The next step of the process  200  involves loading  233  the holder  10  with one or more shims  225 . One shim  225   a  is aligned with insertion edge  226   a  and moved between the holder body  10  and the jamb  220 . The body  10  flexes to create an insertion pocket  227  that accommodates all of the shim  225   a  that is inserted by the user. A further shim  225   b  may be inserted, wholly or partly, in the opposite direction beginning at edge  226   b.  Still further shims or portions of shims may be inserted by the user as necessary or desired leveling. 
         [0058]    The process  200  is repeatable for additional shim holders  10   b,    10   c,    10   d  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. 
         [0059]      FIGS. 4-13  disclose yet another embodiment of the shim holder  300  of the present invention. The holder  300  comprises first (outer) and second (inner) members  315   a  and  315   b  respectively, and elastomeric ties  317  (preferably rubber or polymeric bands). An adhesive element (including adhesive strip  319  and release liner  320 ) is disposed on the outer surface of inner member  315   b,  for connection to a jamb. 
         [0060]    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: 
         [0000]    
       
         
               
               
               
               
             
           
               
                   
                   
               
             
             
               
                   
                 “X” 
                 5¼ 
                 inches (in.) 
               
               
                   
                 Y 
                 2 
                 in. 
               
               
                   
                 A 
                 3¼ 
                 in. 
               
               
                   
                 B 
                 1 
                 in. 
               
               
                   
                 C 
                  1/16 
                 in. 
               
               
                   
                 D 
                 ⅛ 
                 in. 
               
               
                   
                 E 
                 ¼ 
                 in 
               
               
                   
                 F 
                 ¼ 
                 in. 
               
               
                   
                   
               
             
          
         
       
     
         [0061]    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. 
         [0062]    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  FIG. 6 . 
         [0063]      FIGS. 14-17  show of still another embodiment of the shim holder  400  of the present invention. The shim holder  400  is constructed of a flexible, preferably polymeric material and has a thin, flat, substantially sheet-like, configuration as shown. The body  400  has slot array  401  of a predetermined configuration. An adhesive connector  402  is disposed on one side of the body  400 , preferably centrally. 
         [0064]    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 . 
         [0065]      FIGS. 18 and 19  disclose still another embodiment of the shim holder  500  of the present invention. The shim holder  500  is also constructed of a flexible material and has a thin, flat, substantially sheet-like, configuration as shown. The body  500  also has slot array  501  of an alternative, predetermined configuration. An adhesive connector (not shown) is disposed on one side of the body  500 , preferably centrally. 
         [0066]    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 . 
         [0067]      FIGS. 20-22  show a further embodiment of the shim holder  600  of the present invention. The holder  600  comprises first (outer) and second (inner) members  601   a  and  601   b  respectively, and elastomeric ties  603  (preferably rubber or polymeric bands). An adhesive element (not shown) is disposed on the outer surface of inner member  601   b,  for connection to a jamb. The members  601  are constructed of a polymeric material and have predetermined configurations as shown. In use, the shim holder  600  is deployed by adhesively connecting it to a jamb and inserting one or more shims  603  between the members  601   a  and  b.    
         [0068]      FIGS. 23 and 24  disclose still a further embodiment of the shim holder  700  of the present invention. The holder  700  comprises coupled, first (outer) and second (inner) members  701   a  and  701   b  respectively. An adhesive element (not shown) is disposed on the outer surface of inner member  701   b,  for connection to a jamb. The members  701  are constructed of a polymeric material and have predetermined configurations as shown. In use, the shim holder  700  is deployed by adhesively connecting it to a jamb and inserting one or more shims  702  between the members  701   a  and  b  to thereby form a flexible insertion and holding passage  703 . 
         [0069]      FIGS. 25 and 26  show yet a further embodiment of the shim holder  800  of the present invention, with a shim inserted therein. The holder  800  comprises coupled, first (outer) and second (inner) members  801   a  and  801   b  respectively. An adhesive element (not shown) is disposed on the outer surface of inner member  801   b,  for connection to a jamb. The members  801  are constructed of a flexible material and have predetermined configurations as shown. In use, the shim holder  800  is deployed by adhesively connecting it to a jamb and inserting one or more shims  802  between the members  801   a  and  b  to thereby form a flexible insertion and holding passage  803 . 
         [0070]      FIG. 27  discloses yet another embodiment of the shim holder  900  of the present invention, with a shim  902  inserted therein. The holder  900  comprises first (outer) and second (inner) members  901   a  and  901   b  respectively, which are coupled by connectors  904 . An adhesive element (not shown) is disposed on the outer surface of inner member  901   b,  for connection to a jamb. The members  901  are constructed of a flexible material and have predetermined configurations as shown. In use, the shim holder  900  is deployed by adhesively connecting it to a jamb and inserting one or more shims  902  between the members  901   a  and  b  to thereby form a flexible insertion and holding passage  903 . 
         [0071]      FIG. 28  show still another embodiment of the shim holder  1000  of the present invention, with a shim  1002  inserted therein. The holder  1000  comprises first (outer) and second (inner) members  1001   a  and  1001   b  respectively, which are coupled by connector  1004 . An adhesive element (not shown) is disposed on the outer surface of inner member  1001   b,  for connection to a jamb. The members  1001  are constructed of a flexible material and have predetermined configurations as shown. In use, the shim holder  1000  is deployed by adhesively connecting it to a jamb and inserting one or more shims  1002  between the members  1001   a  and  b  to thereby form a flexible insertion and holding passage  1003 . 
         [0072]      FIGS. 29 and 30  disclose yet another embodiment of the shim holder  1100  of the present invention, with a shim  1102  inserted therein. The holder  1100  comprises first (outer) and second (inner) members  1101   a  and  1101   b  respectively, and elastomeric ties  1103  (preferably rubber or polymeric bands). An adhesive element (not shown) is disposed on the outer surface of inner member  1101   b,  for connection to a jamb. The members  1101  are constructed of a flexible material and have predetermined configurations as shown. The shim holder  1100  is deployed by adhesively connecting it to a jamb and inserting one or more shims  1102  between the members  1101 . 
         [0073]      FIGS. 31-34 ,  35 - 36 ,  37 ,  38 - 39  and  40  show alternative embodiments  1200 ,  1300 ,  1400 ,  1500  and  1600  respectively of the shim and shimming technology of the present invention, involving an adjustable wedge system. These arrangements involve shim or wedge elements which are coupled together and adjustable via a mechanical adjustment element, for example a screw element (preferably a tapered screw), so that the shims spread apart or move closer. The arrangements are connectable to a frame or jamb, for example via an adhesive so that they attach quickly, stay in place, and may be used in a stacking or other combination. The arrangements may be constructed of a durable, light weight material such as plastic. Such material is resistant to deterioration and mold. They provide an adjustable, stable and self aligning unit that is easy, fast and accurate to use. 
         [0074]    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. 
         [0075]    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. 
         [0076]    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.