Shim device

Abstract

Composites, products made from composites and method of producing same are provided. The present invention includes an injection moldable product made from a composite material at least composed of balanced mixture of thermoplastics and fibrous components. The injection moldable product is formed into a body that has a wedge-shape, a shim-shape or the like wherein the body includes one or more cored regions extending though at least a portion thereof.

What is claimed is: 
     
         1 . A composite shim comprising:
 a shim-shaped body having a length, a width and a depth, the depth gradually increasing from a first end of the body to a second end of the body, the body further including a plurality of discrete cavities, each cavity defining a width and a depth, wherein the plurality of discrete cavities collectively define a width that is approximately 64% of the width of the body.   
     
     
         2 . The composite shim of  claim 1  wherein the body includes a fiber-reinforced base material, the fiber-reinforced base material including a fibrous component and a thermoplastic component. 
     
     
         3 . The shim of  claim 1 , wherein the plurality of discrete cavities are positioned along the shim up to about two thirds of a length of the body. 
     
     
         4 . The shim of  claim 1 , wherein the plurality of discrete cavities are structured and positioned so as to enable the composite shim to be secured while minimizing an amount of force exerted to the shim, thereby halting propagation of splitting caused by securing the composite shim through piercing at least one of the discrete cavities of the shim. 
     
     
         5 . The composite shim of  claim 1 , wherein the body includes a thermoplastic component that is selected from the group consisting of polyethylene, polyesters, polystyrene, polycarbonate, polyvinylchloride, poly (methyl methacrylate), nylon, copolymers thereof and mixtures thereof. 
     
     
         6 . The composite shim of  claim 1 , wherein the body includes a fibrous component that is selected from the group consisting of synthetic fiber, carbon fiber, a cellulosic material, natural fiber, wood flour, birch wood flour, maple wood flour, spruce wood flour, pine wood flour, fir wood flour, rice hull, peanut shells, recyclable wood waste, recyclable paper, flax sheeve and combinations thereof. 
     
     
         7 . The composite shim of  claim 1 , wherein the body includes a thermoplastic component and a fibrous component, the thermoplastic component ranges from about 30% to about 70% by weight of the composite shim and the fibrous component ranges from about 30% to about 70% by weight of the composite shim. 
     
     
         8 . The composite shim of  claim 1 , wherein the body is formed of a component selected from the group consisting of a binder, a coloring agent, a scent agent, an ultraviolet light stabilizer, a filler, a natural filler, a heat stabilizer, an antioxidant, a foaming agent, a fungicide and combinations thereof. 
     
     
         9 . The composite shim of  claim 1 , wherein the plurality of discrete cavities are positioned in rows across the width of the body and two or more of the rows include three discrete cavities. 
     
     
         10 . The composite shim of  claim 1 , wherein the length of the body does not exceed about twelve inches and the width does not exceed about 1.5 inches. 
     
     
         11 . The composite shim of  claim 1 , wherein the plurality of discrete cavities are tapered. 
     
     
         12 . The composite shim of  claim 1 , wherein the body includes a first side and a second side opposite the first side, wherein the plurality of discrete cavities extend from the first side through a portion of the body to a distance from the second side that is approximately 0.06 inches. 
     
     
         13 . The composite shim of  claim 12 , wherein the depth of the body at the first end is approximately 0.035 inches and the depth of the body at the second and is approximately 0.280 inches. 
     
     
         14 . The composite shim of  claim 1 , wherein each of the plurality of discrete cavities are tapered at an angle of about eight degrees. 
     
     
         15 . The composite shim of  claim 1 , wherein the plurality of discrete cavities are spaced apart from one another along the length of the body by approximately 0.456 inches. 
     
     
         16 . The composite shim of  claim 1 , wherein each of the plurality of discrete cavities is cylindrical and has a diameter of approximately 0.32 inches. 
     
     
         17 . The composite shim of  claim 1 , wherein the body includes a first side and a second side opposite the first side defining the depth of the body, each of the plurality of cavities extending from the first side through a portion of the body to a cavity depth that is less than 80% of the depth of the body. 
     
     
         18 . The composite shim of  claim 17 , wherein the cavity depth for each of the plurality of discrete cavities is greater than 66% of the depth of the body.