METHOD AND APPARATUS FOR SHIMMING OUT A WALL

Abstract

An apparatus for shimming out a wall comprises a furring strip including an adhesive suitable for adhering to a wall component on at least a portion of at least one side of the furring strip. The furring strip comprises a thickness of between about one-eighth of an inch and about one and one-half of an inch. The furring strip comprises a width of between about three-quarters of an inch and about one and one-half of an inch. The furring strip comprises a length of between about three feet and about eight feet.

Description

RELATED APPLICATIONS

This application claims the benefit of U.S. provisional application No. 60/926,882 filed on Apr. 30, 2007 entitled “Method and Apparatus for Shimming Out a Wall,” which hereby is incorporated by reference into this application.

TECHNICAL FIELD

The present invention relates to tile installations, and in particular, to an adhesive furring strip used to provide a uniform surface beneath a tile backer unit for a tile installation.

BACKGROUND OF THE INVENTION

The use of tile for interior finishing has been known for some time. One particular known use of tile is for shower installations in bathrooms, for example. One problem faced by tile installers is the need to create a waterproof layer to contain the water to prevent damage to the underlying surface. To overcome this difficulty, a shower pan or other waterproof membrane is typically provided before the tile is installed. The waterproof membrane can come in a variety of shapes and materials. For example, the waterproof membrane may be provided as a substantially waterproof sheet. Other waterproof membranes are known in the art, such as copper. Typically, the waterproof membrane is provided on the floor and is angled and sloped towards a drain to ensure that any water that seeps through the tile is removed. The waterproof membrane typically extends from the floor and up the wall for a pre-determined distance.

A backer unit, such as a sheet of cement board, is typically provided over the waterproof membrane. FIG. 2 shows a backer unit installed over the waterproof membrane according to the prior art. The backer unit usually substantially covers the entire wall on which the tiles are to be installed. Therefore, the backer unit extends down and over the waterproof membrane on the portion of the wall that the waterproof membrane extends to and is attached to the wall studs (wood or metal) for the remainder of the wall. The backer unit provides a number of benefits including a uniform surface. The tiles are then typically installed directly on the backer unit.

A problem in the past has been creating a uniform surface for the backer unit to attach. This is because waterproof membranes range in thicknesses, but are typically between about one-sixteenth of an inch and one and one-half of an inch. Therefore, a gap exists between the two or more surfaces that the backer unit covers. The present invention overcomes this and other problems and an advance in the art is achieved.

SUMMARY OF THE INVENTION

An apparatus for shimming out a wall is provided according to an embodiment of the invention. The apparatus comprises a furring strip including a thickness of between about one-sixteenth of an inch and about one and one-half of an inch. The furring strip comprises a width of between about three-quarters of an inch and about one and one-half of an inch. The furring strip comprises a length of between about three feet and about eight feet. An adhesive suitable for adhering to a wall component is included on at least a portion of at least one side of the furring strip.

An apparatus for shimming out a wall is provided according to an embodiment of the invention. The apparatus comprises a flexible furring strip including a thickness of between about one-sixteenth of an inch and about one and one-half of an inch. The flexible furring strip comprises a width of between about three-quarters of an inch and about six inches. An adhesive suitable for adhering to a wall component is provided on at least a portion of at least one side of the strip.

A method for shimming out a wall prior to installing tile is provided according to an embodiment of the invention. The method comprises positioning a furring strip on a wall component above a waterproof membrane, the waterproof membrane having a pre-determined thickness. Positioning the furring strip on the wall component creates a substantially uniform planar surface between the furring strip and the waterproof membrane. The furring strip includes a thickness of between about one-sixteenth of an inch and about one and one-half of an inch. The furring strip includes a width of between about three-quarters of an inch and about one and one-half of an inch. The furring strip includes an adhesive on at least a portion of at least one side of the furring strip. The method further comprises affixing the furring strip to the wall component by placing a side of the furring strip including the adhesive onto the wall component. The furring strip provides a substantially coplanar surface with the waterproof membrane.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a cross section of a shower prior to installing a backer unit.

FIG. 2 shows a cross section of a prior art shower with a backer unit.

FIG. 3 shows a furring strip according to an embodiment of the invention.

FIG. 4 shows another furring strip according to an embodiment of the invention.

FIG. 5 shows a cross section of a shower with the furring strip installed according to an embodiment of the invention.

FIG. 6 shows a cross section of a shower with the furring strip and a backer unit installed according to an embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1-6 and the following description depict specific examples to teach those skilled in the art how to make and use the best mode of the invention. For the purpose of teaching inventive principles, some conventional aspects have been simplified or omitted. Those skilled in the art will appreciate variations from these examples that fall within the scope of the invention. Those skilled in the art will appreciate that the features described below can be combined in various ways to form multiple variations of the invention. As a result, the invention is not limited to the specific examples described below, but only by the claims and their equivalents.

FIG. 1 shows a partial cross sectional view of a shower 100. The shower 100 includes a wall component 101, a mortar bed 102, and a waterproof membrane 103. In many applications tile or an additional mortar bed would cover the flooring over the waterproof membrane 103, however, the additional layer has not been shown for the purpose of clarity.

Typically, when installing a tile shower, one of the concerns is water damage to the underlying surface. In order to minimize and/or eliminate water damage, a mortar bed, such as mortar bed 102 is installed above the existing floor. Mortar bed 102 is provided with an inclined slope directed towards a floor drain (not shown). A recommended slope is approximately one-quarter of an inch per foot. The slope of the mortar bed 102 shown in FIG. 1 is exaggerated and is not shown to scale for the purpose of clarity.

Installed above the mortar bed 102 is a waterproof membrane 103. Waterproof membranes are known in the art and are typically made out of a substantially flexible material. However, other more rigid membranes are known and may be used. The particular type of waterproof membrane used is not important for the present invention and should not be a limiting aspect of the invention.

The waterproof membrane 103 substantially covers the floor of the shower 100 and extends up the wall component 101 a pre-determined distance. The waterproof membrane 103 extends up the wall component 101 between approximately four inches and one foot, in most cases. However, the waterproof membrane 103 could extend up the wall component 101 any desired distance. The edge of the waterproof membrane 103 creates a gap 104 between the inner edge of the waterproof membrane and the wall component 101. The distance of the gap 104 varies depending on the particular waterproof membrane 103 used, but can range from about one-sixteenth of an inch to about one-quarter of an inch or more. In applications where the waterproof membrane 103 comprises a waterproof sheet, the waterproof membrane 103 may need to be folded over, thus doubling the distance of the gap 104.

The tile of the shower 100 needs to be applied to a substantially flat surface. The wall component 101 may only consist of a series of wall studs (metal or wood). The wall studs are typically spaced along the wall at pre-determined distances. Therefore, in many applications, a backer unit needs to be installed over the wall component 101 to create a substantially flat surface.

FIG. 2 shows a prior art partial cross sectional view of the shower 100 with a backer unit 205. Once the waterproof membrane 103 is installed, but prior to installing the tile, a backer unit 205 is installed on the wall component 101. According to one embodiment of the invention, the backer unit 205 comprises a cement board. However, other backer units are known in the art and may be used. The backer unit 205 is provided to create a uniform surface to apply the tile to. A problem exists, however, because typically the backer unit 205 is affixed directly to the wall component 101, which as mentioned, may comprise a series of wall studs. The backer unit 205 typically extends down and over the waterproof membrane 103.

As shown in FIG. 2, affixing the backer unit 205 directly to the wall component 101 forces the backer unit to bend in order to clear the waterproof membrane 103. It should be understood that FIG. 2 is exaggerated for the purpose of clarity and the backer unit 205 may not bend to the extent shown. It is important to ensure that the backer unit 205 extends beyond the edge of the waterproof membrane 103 to prevent water damage to the underlying surface. Additionally, unnecessary contact between the backer unit 205 and the waterproof membrane 103 should be avoided as the waterproof membrane can be delicate and rip easily. Because the backer unit 205 is forced to bend in order to clear the waterproof membrane 103, the tile does not have a substantially flat surface to apply to, and instead has a substantially curved surface. The present invention overcomes the problems outlined above.

FIG. 3 shows a furring strip 306 according to an embodiment of the invention. The furring strip 306 comprises a thickness 308, which is between about one-sixteenth of an inch and about one and one-half of an inch. The thickness 308 can be varied according to the size of the waterproof membrane 103, for example. The furring strip 306 comprises a width 309, which is between about three-quarters of an inch and about one and one-half of an inch, depending on the size of wall component 101. The furring strip 306 comprises a length 307, which is typically between about three feet and about eight feet.

The furring strip 306 can be used to shim out a wall prior to installing the backer unit 205. According to an embodiment of the invention, the furring strip 306 includes adhesive 310 on at least a portion of at least one side. While different types of adhesive may be used, it is preferred to use an adhesive 310 suitable for adhering to the wall component 101. The adhesive 310 may be capable of holding the furring strip 206 to the wall component 101. In some embodiments, the adhesive 310 may be strong enough to hold both the furring strip 306 and the backer unit 205 to the wall component 101. However, according to one embodiment of the invention, the adhesive 310 only needs to temporarily hold the furring strip 306 to the wall component 101 long enough for the backer unit 205 to be installed. This is because in some embodiments, the backer unit 205 is installed using fasteners that attach to the wall component 101 by going substantially through the furring strip 306. Therefore, according to an embodiment of the invention, the furring strip 306 should be capable of having a fastener go through without cracking or breaking.

According to an embodiment of the invention, the furring strip 306 is provided with a removable backing 311, which substantially covers the adhesive 310. The removable backing 311 may be provided to prevent the adhesive 310 from adhering to unwanted surfaces during handling, for example. The removable backing 311 can be removed substantially immediately prior to installing the furring strip 306 onto the wall component 101. According to one embodiment, the removable backing 311 creates a non-permanent bond with the adhesive 310. Therefore, the removable backing 311 adheres to the adhesive 310, but can be easily removed, for easy installation.

According to an embodiment of the invention, the furring strip 306 is substantially rigid. However, it should be understood that the furring strip could also be flexible (See FIG. 4). The furring strip 306 may be made out of a number of materials. However, the furring strip 306 should be made of a material that is capable of shimming out a wall, but may withstand penetration from a fastener (not shown) without cracking or breaking.

The furring strip 306 may be provided with a plurality of perforations 312 spaced along the furring strip 306 at pre-determined intervals. The perforations 312 may be provided to allow the furring strip 306 to be shortened simply by breaking along the perforations 312. While only one set of perforations are shown, it should be understood that multiple sets could be provided.

FIG. 4 shows another furring strip 406 according to an embodiment of the invention. The furring strip 406 is similar to the furring strip 306, however, the furring strip 406 is substantially flexible and provided as a continuous strip on a roll 413 and may be cut into desired lengths. The furring strip 406 comprises a thickness 408, which is between about one-sixteenth of an inch and about one and one-half of an inch. The furring strip 406 comprises a width 409, which is between about three-quarters of an inch and about one and one-half of an inch.

The furring strip 406 includes an adhesive (not shown), similar to the adhesive 310 on the furring strip 306, on at least a portion of at least one side. The furring strip 406 can also include a removable backing 411 to prevent the adhesive from adhering to the back side of the furring strip 406 when rolled up.

The furring strip 406 can be made out of a number of flexible materials. Whatever material is chosen, it should be flexible enough to roll up on roll 413, yet sturdy enough to shim out a wall and withstand penetration from a fastener. Use of both the furring strip 306 and 406 will be discussed below.

FIG. 5 shows a cross sectional view of the shower 100 including the present invention. The shower 100 as shown in FIG. 5 is similar to the shower 100 as shown in FIGS. 1 & 2; however, the furring strip 306 is included. While furring strip 306 is shown, it should be understood that furring strip 406 could be used and the figures and discussion below only refer to furring strip 306 for the purpose of clarity.

As shown in FIG. 5, the furring strip 306 can be affixed to the wall component 101, for example. In embodiments in which the wall component 101 comprises a series of wall studs (wood or metal), the furring strip 306 can comprise a width 309 approximately equal to the width of the wall stud. However, it should be understood that the width 309 of the furring strip 306 could be greater or less than the width of the wall stud.

According to an embodiment of the invention, the adhesive 310 is used to at least temporarily adhere to the wall component 101. According to another embodiment, the adhesive 310 can substantially permanently adhere the furring strip 306 to the wall component 101. Because the furring strip 306 is provided with an adhesive, application is much faster, easier, and cleaner than if the furring strip did not have the adhesive. According to an embodiment of the invention, the removable backing 311 can be removed, exposing the adhesive 310, and the furring strip 306 can be affixed to the wall component 101.

The furring strip 306 is shown affixed to the wall component 101 above the waterproof membrane 103. Although a small gap is shown in FIG. 5, in some embodiments, the furring strip 306 substantially abuts the waterproof membrane 103.

According to an embodiment of the invention, the furring strip 306 comprises a thickness 308 approximately equal to the thickness of the waterproof membrane 103, providing a substantially uniform planar surface that is substantially coplanar with the waterproof membrane 103. According to another embodiment of the invention, the furring strip 306 can comprise a thickness 308 greater than the thickness of the waterproof membrane 103. In this embodiment, the furring strip 306 will extend slightly beyond the waterproof membrane 103. It is important that the furring strip 306 comprise a thickness 308 which is at least as thick as the waterproof membrane 103.

FIG. 6 shows the shower 100 with both the furring strip 306 and the backer unit 205. As shown, providing the furring strip 306 has a number of advantages. One advantage to providing the furring strip 306 is that the backer unit 205 can be affixed on top of the furring strip 306, which extends from the wall component at least as far out as the waterproof membrane 103. Because the furring strip 306 extends at least as far as the waterproof membrane 103, the backer unit 205 does not bend in order to clear the waterproof membrane 103. By providing the furring strip 306, the backer unit 205 can form a substantially flat surface for the tile.

Another advantage of providing the furring strip 306 is that the backer unit 205 can be kept out of contact with the waterproof membrane 103, thus reducing the chance that the backer unit 205 will puncture the waterproof membrane 103. To ensure that the backer unit 205 does not damage the waterproof membrane 103, in some embodiments, the furring strip 306 comprises a thickness 308 which is greater than the waterproof membrane 103.

The backer unit 205 can be affixed to the furring strip 306 in a similar way in which the backer unit 205 is typically affixed to the wall component. Because the furring strip 306 is penetrable, the backer unit 205 may be affixed using fasteners, such as nails, screws, bolts, etc. In some embodiments, the furring strip 306 may also be provided with adhesive 310 on the side exposed to the backer unit 205. In these embodiments, the adhesive 310 may be used to affix the backer unit 205 directly to the furring strip 306. The particular method of affixing the backer unit 205 is not important for purposes of the present invention and should not limit the scope of the invention.

The detailed descriptions of the above embodiments are not exhaustive descriptions of all embodiments contemplated by the inventors to be within the scope of the invention. Indeed, persons skilled in the art will recognize that certain elements of the above-described embodiments may variously be combined or eliminated to create further embodiments, and such further embodiments fall within the scope and teachings of the invention. It will also be apparent to those of ordinary skill in the art that the above-described embodiments may be combined in whole or in part to create additional embodiments within the scope and teachings of the invention.

Thus, although specific embodiments of, and examples for, the invention are described herein for illustrative purposes, various equivalent modifications are possible within the scope of the invention, as those skilled in the relevant art will recognize. The teachings provided herein can be applied to other furring strips and applications, and not just to the embodiments described above and shown in the accompanying figures. Accordingly, the scope of the invention should be determined from the following claims.

Claims

1. An apparatus for shimming out a wall, said apparatus comprising:

a furring strip including a thickness of between about one-sixteenth of an inch and about one and one-half of an inch, a width of between about three-quarters of an inch and about one and one-half of an inch, and a length of between about three feet and about eight feet;

an adhesive suitable for adhering to a wall component included on at least a portion of at least one side of the furring strip.

2. The apparatus of claim 1, wherein the furring strip includes a plurality of perforations spaced along the length of the furring strip at pre-determined distances and wherein the plurality of perforations allow the furring strip to be shortened by breaking the furring strip along the plurality of perforations.

3. The apparatus of claim 1, wherein the furring strip is flexible and suitable to be rolled and unrolled.

4. The apparatus of claim 1, further comprising a removable backing substantially covering the adhesive.

5. The apparatus of claim 1, wherein the furring strip has substantially the same width as a wall stud.

6. The apparatus of claim 1, wherein the furring strip is penetrable.

7. An apparatus for shimming out a wall, said apparatus comprising:

a flexible furring strip including a thickness of between about one-sixteenth of an inch and about one-eighth of an inch and a width of between about one and one-half of an inch and about six inches; wherein an adhesive suitable for adhering to a wall component is included on at least one side of the strip.

8. The apparatus of claim 7, wherein the flexible furring strip is suitable to be rolled and unrolled.

9. The apparatus of claim 7, further comprising a removable backing substantially covering the adhesive.

10. The apparatus of claim 7, wherein the furring strip can be cut to a desired length.

11. The apparatus of claim 7, wherein the furring strip has a width substantially the same as the width of a wall stud.

12. The apparatus of claim 7, wherein the furring strip is penetrable.

13. The apparatus of claim 7, wherein the furring strip includes a plurality of perforations spaced along the length of the furring strip at pre-determined distances and wherein the plurality of perforations allow the furring strip to be shortened by breaking the furring strip along the plurality of perforations.

14. A method for shimming out a wall prior to installing tile, the method comprising:

positioning a furring strip on a wall component above a waterproof membrane, having a pre-determined thickness, to create a substantially uniform planar surface between the furring strip and the waterproof membrane, with the furring strip including a thickness of between about one-sixteenth of an inch and about one and one-half of an inch, a width of between about three-quarters of an inch and about one and one-half of an inch, wherein the furring strip includes an adhesive on at least a portion of at least one side of the furring strip; affixing the furring strip to the wall component by placing a side of the furring strip including the adhesive onto the wall component, with the furring strip providing a substantially coplanar surface with the waterproof membrane.

15. The method of claim 14, wherein the furring strip has a thickness substantially equal to the pre-determined thickness of the waterproof membrane.

16. The method of claim 14, wherein the furring strip has a length of between about three feet and about eight feet.

17. The method of claim 14, wherein the furring strip comprises a flexible furring strip and the method further comprises unrolling the flexible furring strip and cutting the flexible furring strip at the desired length.

18. The method of claim 14, further comprising providing a removable backing substantially covering the adhesive.

19. The method of claim 14, wherein the furring strip has a width substantially the same as the width of a wall stud.

20. The method of claim 14, wherein the furring strip is penetrable.

21. The method of claim 14, wherein the furring strip includes a plurality of perforations spaced along the length of the furring strip at pre-determined distances and wherein the plurality of perforations allow the furring strip to be shortened by breaking the furring strip along the plurality of perforations.