Device For Correction Inconsistencies In Walls or Ceilings

Abstract

Inconsistencies in walls or ceilings are formed when the walls and/or ceiling are out of level or square. This device compensates for the inconsistencies in walls and ceilings by providing a level and/or square surface to which wallboard or backer board may be attached.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 61/836,825 filed on 19 Jun. 2013, which is incorporated in its entirety by this reference.

FIELD OF THE INVENTION

This invention relates to a new device and method for correcting inconsistencies in walls and/or ceilings which are out of level or square, specifically a device and method of using the device that enables the user to correct for the inconsistencies and provide a level or square surface upon which to attach wallboard or backer board for walls and/or ceilings.

BACKGROUND OF THE INVENTION

In modern construction methods, a building or room is usually framed with wood or steel studs. Drywall is then mounted upon the studs to form the finished interior space. However, these studs are not often laid true; ceiling studs or joists may not be perfectly horizontal, and wall studs may not be perfectly vertical. Oftentimes an entire wall or ceiling may be out of alignment, and each stud may be out of alignment by a differing amount. When drywall or similar material is laid on top of these non-true studs, the drywall or other material may simply be trimmed to absorb the imperfection, and the defect will not be especially noticeable.

However, when laying tile, cabinetry, or similar interior finishing materials on a wall or ceiling that is not square or level, it becomes much more labor-intensive to compensate for the imperfection. Imperfections become more problematic when installing finished work, such as cabinets, countertops, backsplashes, appliances, and tile work. When laying tile, it is possible to have the row of tiles adjacent to the wall or ceiling absorb the imperfection. However, the lines of the tile then give an observer a reference to compare against, and the imperfections of the join becomes much more obvious. Leaving the defective wall in place is then undesirable. There are several methods available in the art to correct for this problem. However, all of them are either labor-intensive, expensive, and/or cause additional problems.

In one method of correcting for non-true studs (either wall or ceiling), an individual may remove the current drywall mounted to joists of the ceiling or to studs of a wall. They may then attach a new wood or steel stud to the side of the existing stud or joist, commonly another 2×4 stud, offset such that the attachment face of the new stud is properly true in the desired orientation. However, this causes several problems. Standard 2×4 boards are often not straight or are warped, and so adding a new one does not fix the problem. Additionally, lumber is expensive, and if significant correction is required it can add unanticipated cost to the project, leading to cost overruns and exceeding the budgeted funds. Thirdly, in standard construction, wall studs are spaced to create regular 16-inch on-center gaps between each stud. Plumbing, insulation, electrical, ducting, and other internal components are typically sized to fit that standard gap. By reducing the gap by the width of the added stud (typically 1.5-2″), extra time and labor is required to re-size the interior pieces.

Alternately, one may use furring shims to correct the surface alignment of a stud or joist. These furring shims are essentially strips of cardboard, 1.5″ wide, 4 feet long, and 1/16th of an inch thick. One or more furring shims are mounted to the face that must be trued; multiple layers are required, and each is cut to a different length to fill the angled gap. However, this must be done with precision, and becomes time-consuming if multiple studs or joists must be fixed in this manner.

In U.S. patent application Ser. No. 12/832,175, we are taught a method for correcting edgewise deviations, when framing limber is crooked and presents a cupped edge instead of a flat edge upon which wallboard is intended to be mounted. However, the device described in the '175 Patent App. is only intended to provide a plane surface for warped studs and is not intended to correct for imperfections in the placement of the stud or rafter, such as when it has been secured at other than right angles.

There exists a need in the construction and remodeling industry for a simple, easy-to-use, and cost effective device that can correct for any imperfection in the square of level of a stud or ceiling joist, which simultaneously provides a flat surface upon which wall board or backer board may be attached.

BRIEF SUMMARY OF THE INVENTION

The present invention provides a device, and method of using said device, for providing a square or level surface upon which to attach wallboard or backer board when the base wall or ceiling is out of level or square.

As used herein, the terms “out of true”, “out of plane”, and “out of square” are interchangeable and refer to when a stud or joist is not at right angles to the adjacent wall, floor, or ceiling.

As used herein the term “out of plumb” specifically refers to a wall stud which is not perfectly vertical or does not present a perfectly vertical surface upon which to mount wall board or backer board.

As used herein, the term “out of level” specifically refers to a floor or ceiling joist which is not perfectly horizontal.

As used herein the term “stud” can refer to any beam or beam-like object used in framing of a house, room, building, or other structure, including but not limited to 2×4 wooden boards, 2×6 wooden boards, steel studs, or other framing materials. The term “stud”, while typically meant to refer to 2×4 boards used to frame walls of a structure, should also be taken to include ceiling and floor joists unless clearly limited by the context.

One object of the present invention is to provide a shim device that corrects for out-of-true studs in walls or ceilings.

Another object of the present invention is to provide a shim device that presents a flat face upon which wallboard and/or backer board may be mounted.

When remodeling existing structures, it becomes important to work around existing electrical wiring, plumbing, and/or other lines which extend through the frame walls or ceilings. Any corrections or attachments must avoid the existing lines. Accordingly, a further object of the present invention is to provide a shim device that does not interfere with or may easily be modified to accommodate existing or future electrical, plumbing, and/or other lines.

Specifically, this invention comprises a shim comprised of a mounting face and a flat face which are at right angles to each other, the flat face being on a flange that is equal to or less than the width of the frame member to which it attaches, such that the mounting face can be fixed to the out of true stud or joist providing a flat face upon which wall board or backer board may be attached.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a lateral view of one embodiment of the shim, depicting one method of installing the device on a stud which is out of plumb.

FIG. 2 is an enlarged isometric view of one embodiment of the shim, showing a plurality of attachment holes.

FIG. 3 is an enlarged lateral view of one embodiment of the shim, showing a method of attaching said shim to a stud.

FIG. 4 is a partial, cut-away view of a wall, showing shims of the present invention attached to several out-of-plumb studs, as would be used when correcting the angle of an entire wall.

FIG. 5 is a cross-section view showing how wallboard is to be attached to the flat face of the shim.

DETAILED DESCRIPTION OF THE INVENTION

The following description of the preferred embodiments of the invention is not intended to limit the scope of the invention to the preferred embodiments, but rather to enable any person having ordinary skill in the art to make and use the invention. As used in the specification and the claims, the singular articles “a”, “an”, and “the” should be understood to include plural referents unless clearly limited by the context.

The invention described herein is intended to be used both in new construction and in remodeling existing construction. When remodeling, older building codes, natural shifting, damage, settling, and/or other causes can lead studs and walls to become out of alignment. Even in new construction, it is common to find studs out of true when framing is completed and interior finishing work begins. In many cases, an entire wall will have been built out of plane, and each stud may be out of plane by different degrees compared to adjacent studs.

FIG. 1 shows one embodiment of the shim 10 attached on to an out-of-true stud 30. In this embodiment, the shim 10 is 8 feet long, the same length as a standard 2×4 stud 30, such that it extends the entire distance between the double top plate 32 and the bottom sill plate 34. The angle between the shim 10 and the subfloor 36 should be exactly 90°.

FIG. 2 depicts an enlarged view of one preferred embodiment of the shim 10 of this invention, shown in relation to an out-of-true stud 30. In this preferred embodiment, the shim 10 has a mounting face 20 which is positioned along one side of the stud 30. The mounting face 20 is shaped in a conventional truss configuration 22, which allows the shim 10 to be easily cut and positioned around electrical, plumbing, and/or other utility lines. The mounting face also includes a plurality of attachment holes 26, with which one can fasten the mounting face 20 to the stud 30 via any desired fastening technique, for example a screw. The mounting face 20 also contains a near border 28 which attaches at right angles to a flange 12 which includes the flat face 14 on which wall board or other interior finishing may be attached.

FIG. 3 depicts an enlarged view of one preferred embodiment of the shim 10 attached to an out of true stud 30 or ceiling joist. In this embodiment, the mounting face 20 comprises a truss configuration 22 with a plurality of cutout holes 24, a plurality of attachment holes 26, and a near border 28 to which the flange 12 connects. The shim 10 is secured to the stud 30 or joist by way of screws 40 through only the attachment holes 26 that overlap the side face of the stud 30 or joist.

FIG. 4 depicts a partial cut-away view of a wall which has been finished using the device and preferred method of use described herein. Each out of true stud 30 has a shim 10 secured to it as described herein. The shim 10 extends to the top of the stud 30, nearly touching the double top plate 32. The wallboard 38 is attached to the shims 10 by self-tapping screws 42.

FIG. 5 depicts a cross-section view of one method of use. The shim 10 is attached to the out of true stud 30 such that the flange 12 presents a vertical flat face upon which to mount the wall board 38. Where the deviation of the stud 30 from the flange 12 is less, depicted here on the bottom of the drawing, the self-tapping screws 42 can penetrate through the wall board 38 and the flange 12 into the stud 30 beneath. Where the deviation is greater, depicted here at the top of the diagram, the self-tapping screws 42 do not reach the stud 30. In the embodiment pictured, there is no truss configuration on the mounting face.

In the present invention, the shim 10 may be mounted to a stud 20 to square a wall. The shim 10 may also be mounted to a joist to square or level a ceiling. To mount the shim 10 to the stud 30 or joist, one first holds the mounting face 20 against the side of the stud 30. Then, one moves the shim 10 relative to the stud 30 to position the flat face 14 as desired, for example perpendicular to level. Then one fastens the mounting face 20 of the shim 10 to the stud 30 via any desired fastening technique. In one embodiment, the fastening technique may use screws 40 through the plurality of attachment holes 26. In another embodiment, the shim 10 may further include a fastener tab like the one described in '175 Patent Application, which would allow the user to quickly and temporarily secure the shim 10 to the stud 30 or joist, freeing up both hands for retrieving and installing more permanent attachments such as screws 40.

Once the shim 10 is mounted to the stud 30, one may then mount a panel of wallboard 38 sheet rock or drywall to the flat face 14. With the wallboard 38 mounted to the stud 30 via the shim 10, the wallboard 38 should then be square and/or level with the floor and thus make it easier for the person laying tile or other finishing work on the walls and/or adjacent walls, floor, and/or ceiling to quickly lay the tile and/or other finishing work adjacent to the corrected wall.

The shim 10 may be manufactured out of any desired material capable of withstanding the loads encountered while in use. For example, in the preferred and other embodiments, the shim 10 may be made of a metal such as sheet metal. In other embodiments, the shim 10 may be composed of a composite material, such as layers of woven fiberglass joined with adhesive. In still other embodiments, the shim 10 may include wood. In further embodiments, the shim 10 may be comprised of polymers. In still further embodiments, the shim 10 may be comprised of any other architecturally-compatible material or combination of materials. In the preferred embodiment, the shim should be constructed out of a flat steel, between 3-gauge and 36-gauge steel, preferably between 11-gauge and 20-gauge thickness, such that it is strong enough for the intended purpose and yet thin enough to cut with commonly available equipment such as tin snips.

The mounting face 20 of the shim 10 may be configured as desired. In the preferred embodiment, the mounting face 20 includes a truss configuration 22 with a plurality of cut-out holes 24 and a plurality of attachment holes 26. The truss configuration 22 provides structural strength while allowing for easy fitting to existing shapes. However, the mounting face 20 may contain a plurality of cut out shapes in addition to or instead of the desired triangles, including but not limited to circles, squares, rectangles, and/or other regular and/or irregular polygon shapes and/or combination of shapes. In other embodiments, the mounting face 20 may be a solid material such as a plate or sheet, with a plurality of attachment holes 26 but no cutout holes. In another embodiment, the mounting face 20 may be a solid material such as a plate or sheet, with neither cutout holes nor attachment holes, and the mounting face 20 must be secured to the stud 30 using self-tapping screws 42 or another appropriate attachment method.

In the preferred method of use, the truss configuration 22 combined with the preferred 11-20 gauge steel allows the user to quickly and easily use standard equipment such as tin snips to cut out sections of the mounting face 20 of the shim 10 in order to accommodate existing and/or future utility lines, such as electrical, plumbing, and/or other utility lines. In alternate embodiments of the method, any saw with a metal-cutting blade, metal power shears, or any other device designed to cut metal, or other appropriate tool may be used.

In the preferred embodiment, the flange 12, which includes the flat face 14, extends 90° from the rail or near border 28 of the mounting face 20 to form an “L” shape with the mounting face 20. In another embodiment, the flange 12 may extend from the rail or near border 28 of the mounting face 20 to form a “T” shape with the mounting face 20.

In the preferred embodiment, the flat face 14 is a solid material. In the preferred method of use, self-tapping screws 42, screws that have a drill bit-like tip and are manufactured to screw straight into steel, are used to attach the drywall, backer board, or other wall board 38 to the flat face 14 of the shim 10 once the shim 10 is mounted to the stud 30. In other methods of use, the screws are long enough to penetrate through the shim 10 to the stud 30 below, however, the extra length is not necessary. In other methods of use, any other appropriate securing device may be used to attach the wallboard 38 to the shim 10.

In the preferred embodiment, the shim 10 may be sized as desired. In one preferred embodiment, the width of the flat face 14 is 1.5 inches and the width of the mounting face 20 is 3 inches, and as such the device is sized to fit a standard 2×4 framing stud. In other embodiments, the shim 10 may be sized to fit 2×6 studs or any other size of stud commonly used in framing. In the preferred embodiment, the flat face 14 and the mounting face 20 should be oriented at 90° from each other, and the corner between the flat face 14 and the mounting face 20 should comprise the least possible radius allowed by the material.

The shim may also be provided in various lengths as desired. For example, in the preferred and other embodiments, the shim 10 includes a length that is at least 90% of the length of the stud 30. In other embodiments, the shim is provided in 8 foot (96″) lengths, as that is the typical floor-to-ceiling height in modern construction. In another embodiment the shim can be provided in 1 foot lengths, and multiple shims may be used end-to-end over a non-standard distance. In still other embodiments, the shim 10 may be provided in lengths greater than 8 feet, including but not limited to 10 feet, 12 feet, and 16 feet.

In all methods of use, the shim 10 may be cut to shorter lengths if desired or if required to fit the space to be corrected. In the preferred method of use and materials, the shim 10 may be cut to length by tin snips. In an alternate method of use, the shim 10 may be cut by any other standard construction equipment, including but not limited to a saw, a saw with a metal-cutting blade, metal power shears, or any other equipment appropriate for the material. In alternate methods of use multiple shims may be used end-to-end in order to correct a deviation over a distance which is longer than the shim 10. Being able to cut the shim 10 short or use multiple shims to cover a longer distance is especially useful for correcting linear deviations in ceiling studs or joists. In modern construction, walls are a standard height. However, ceilings may be any length or width, depending on the space available, and do not conform to standard dimensions. Therefore being able to easily customize the length of a shim 10 is especially useful.

In the preferred method of use, the user would first identify the section of the out of true stud 30 that is furthest out of plumb. Then the shim 10 is placed parallel with the stud 30, such that the mounting face 20 is flush with one side of the stud 30 and the inner face of the flange 12 is in contact with the portion of the front face of the stud 30 that is furthest out of plumb or level, and held in place manually. The shim 10 is then adjusted, preferably by rotating and/or sliding the mounting face 20 along the side of the stud 30 until the flat face 14 of the shim 10 is plumb or level as desired. The mounting face 20 of the shim 10 is then secured to the stud 30 using screws 40 through the attachment holes 26. However, any other method of placing and attaching the shim 10 to the stud 30 such that the flat face 14 ends up plumb or level is an acceptable method of use.

In some cases, it may be necessary to adjust the plumb or level of an entire wall or face by attaching at least one shim to each stud or joist within that face. In one method of use, a shim 10 is attached to the stud 30 that is furthest to either the left or the right side of the wall and the shim 10 is adjusted until the flat face 14 is plumb or vertical. Then a second shim 10 is attached to the stud 30 that is furthest to the other side of the wall and adjusted until plumb. In one method of use, a straight edge which is at least as long as the distance between the first two shims 10 is placed against the two flat faces 14. Then shims 10 are attached to the remaining studs 30, one at a time, and adjusted to plumb against the straight edge. In an alternate method of use, one string, line, or other flexible material may be tied, clipped, or otherwise attached to the top of the first shim 10 and the top of the second shim 10 such that it marks a straight line between the two shims 10. A second string may then be attached between the bottom of the first shim 10 and the bottom of the second shim 10. More shims 10 may then be attached to the remaining studs 30, one at a time, and adjusted until both plumb and level to the marking strings. This method ensures that all shims 10 are on the same plane in addition to being in plumb.

The invention disclosed herein has been described in terms of preferred, alternate, and optional embodiments, all of which meet the objectives of the present invention as described above, and which provide a device for correcting inconsistencies in walls and/or ceilings by providing a flat and level or square surface upon which wall board and/or backer board may be attached. One of ordinary skill in the art may contemplate variations of, modifications of, and alterations to the present invention which do not differ from the scope and spirit of the invention. It is therefore intended that the invention not be limited by any of the preferred embodiments described herein but only by the claims.

Claims

1. A device for correcting inconsistencies in walls or ceilings, comprising:

a. A mounting face which is capable of being attached to a stud, joist, or other framing member; and

b. A flat face which is capable of being attached to wallboard, backer board, or other interior finishing material; wherein

c. The mounting face and the flat face are joined at right angles to each other along their longer edges.

2. The device of claim 1, wherein said mounting face further comprises:

a. A truss configuration;

b. A plurality of openings;

c. A plurality of attachment holes; and

d. A solid border on the edge which connects to the framing member

3. The device of claim 1, wherein the device is sized to fit a standard framing member.

4. The device of claim 3, wherein the device is essentially equal in length to the framing member to which it is attached.

5. The device of claim 3, wherein the device is shorter than the framing member to which it is attached

6. The device of claim 3, wherein the device is specifically sized to fit a 2×4 framing stud.

7. The device of claim 6, wherein the mounting face is between 2 and 4 inches wide and the flat face is between 1 and 2 inches wide.

8. The device of claim 7, wherein the mounting face is preferably 3.0 inches wide and the flat face is 1.5 inches wide.

9. The device of claim 1, wherein the mounting face and the flat face form an “L” shape in cross-section.

10. The device of claim 1, wherein the mounting face and the flat face form a “T” shape in cross-section.

11. The device of claim 1 which is a metal shim.

12. The metal shim of claim 11, wherein the metal shim is comprised of between 3-gauge and 36-gauge thickness steel.

13. The metal shim of claim 12, wherein the metal shim is preferably comprised of between 11-gauge and 20-gauge thickness steel.

14. A method of compensating for inconsistencies in walls and/or ceiling by using at least one shim, the steps of the method comprising:

a. Identifying the section of a framing member that is furthest out of plumb or level;

b. Placing the mounting face of said shim along the side of said framing member;

c. Adjusting the flat face of said shim to plumb or level by sliding and/or rotating said entire shim along said mounting face; and

d. Securing said mounting face to said framing member;

e. Wherein said shim comprises a mounting face and a flat face which are joined at right angles along their longer edges.

15. The method of claim 14, the steps of the method further comprising:

a. Placing the mounting face of the shim along the side of the framing member such that the inner face of the flange contacts the portion of the stud that is furthest out of plumb or level; and

b. Adjusting the flat face of the shim to plumb or level by sliding or rotating the entire shim around the contact point between the stud and the inner face of the flange.

16. The method of claim 14, wherein said shim is comprised of 11-gauge to 20-gauge thickness steel.

17. The method of claim 16, wherein said metal shim is sized to fit a standard framing member such as a 2×4 stud

18. The method of claim 17, wherein said metal shim is preferably 3 inches wide on the mounting face, 1.5 inches wide on the flat face, and 7.5-8 feet long.