US20060059829A1

US20060059829A1 - Wall patch system

Info

Publication number: US20060059829A1
Application number: US11/066,166
Authority: US
Inventors: James Flynn
Original assignee: Individual
Current assignee: Individual
Priority date: 2004-09-17
Filing date: 2005-02-28
Publication date: 2006-03-23

Abstract

A wall patch repair system for a hole comprising of at least one backing member that is mounted to patch member, a securing means applied to the backing member to secure the backing member and patch member in the hole, a positioning means for positioning the patch member and the backing member in the hole and adding additional pressure to the wall patch system while the securing means is activated.

Description

FIELD OF THE INVENTION

This invention relates in general to a patch for a damaged wall or ceiling and more particularly to a wall or ceiling patch system that provides for patches that may be applied to holes of various sizes by inserting the patch through holes in sheetrock, drywall board and other wall surfaces.

BACKGROUND OF THE INVENTION

Most homes and buildings that are constructed today have walls and ceilings that are constructed using vertical studs and horizontal ceiling joists and drywall or plasterboard nailed between the studs and ceiling joists. Unfortunately, wall and ceiling surfaces such as plasterboard or drywall damage easily when they are bumped into inadvertently. Also electrical, plumbing or other home repairs often require that a hole be formed into the drywall. As such the drywall must be patched to repair any hole in the drywall. Historically as holes in drywall have been difficult to replace, an entire sheet of drywall was often used since it was too difficult to replace a smaller section. Due to the expense involved in having to remove an entire sheet of drywall prior art patching systems have been devised to address some of the problems.
For example, U.S. Pat. No. 6,508,040 issued on Jan. 21, 2003 to Nelson relates to a hole patching device including mechanism for covering an opening on an interior surface of a wall, the covering mechanism being formed of a generally rigid material and being at least two inches in diameter; mechanism for guiding the covering mechanism through the opening, which may include a slit cut from a center of the covering mechanism to an outer edge of the covering mechanism; mechanism for securing the covering mechanism to the interior surface of the wall to define a pocket; an insert for filling the pocket; and a hardenable material spread over the insert and pocket smoothable with the wall and a method of use.
U.S. Pat. No. 4,989,385 which issued on Feb. 5, 1991 to McCullough relates to a device for repairing a hole in a plasterboard wall formed of a flat relatively thin, stiff coverboard, an insulation board secured by adhesive to the coverboard rear surface, the insulation board being dimensioned less than the coverboard leaving a clear space around the peripheral of the coverboard rear surface, the insulation board being dimensioned to be received in the hole to be repaired, and screws or adhesive for securing the coverboard rear surface peripheral clear space to the wall to thereby retain the insulation board in the hole with the coverboard completely covering the hole.
U.S. Pat. No. 6,607,621 which issued on Aug. 19, 2003 to Swanson relates to a wall patch which includes a body with a lower surface and an upper surface. An adhesive is located on the lower surface to secure the wall patch to a wall surface. The upper surface is ready-to-paint and can also be pre-textured, if desired. A center reinforcement can be a rigid plastic or metal wall patch, or a flexible plastic or fibered paper wall patch, without a textured upper surface. A method for repairing a hole in a wall includes placing a wall patch over the hole and directly painting the upper surface of the wall patch. The method can further include placing a center reinforcement over the hole before applying the wall patch.
U.S. Pat. No. 6,347,496 which issued on Feb. 19, 2002 to Pinkins relates to a wall repair system for repairing holes in drywall panels without furring strips or screws. The wall repair system includes a patch assembly adapted for fitting through a small hole in a dry wall panel, the patch assembly having a front surface with a perimeter edge, the front surface being adapted for coupling to a back surface of a drywall panel after the patch member is fitted through the hole, and a handle member which is couplable to a central portion of the patch assembly for facilitating insertion of the patch assembly through the hole in the drywall panel and subsequent coupling of the perimeter edge of the front surface of the patch assembly to the back surface of the drywall panel.
U.S. Pat. No. 6,209,277 which issued on Apr. 3, 2001 to DiGate relates to a wallboard repair clip which includes a patch wallboard receiving structure for contacting inner and outer surfaces of a patch wallboard, an existing wallboard receiving member and a securing structure.
Thus, a wall patch system which does not require an entire sheet of drywall to be replaced, doesn't require extensive patching or filling, can work in corners, around electrical sockets, on the vertical or horizontal, can have no limitation with respect to the size of the patch, is economical, can be installed and adhered in one step is desirable.

SUMMARY OF THE INVENTION

An object of one aspect of the present invention is to provide an improved wall patch system for repairing a hole.
In accordance with one aspect of the present invention there is provided a wall patch repair system for a hole comprising of at least one backing member that is mounted to patch member, a securing means applied to the backing member to secure the backing member and patch member in the hole, a positioning means for positioning the patch member and the backing member in the hole and adding additional pressure to the wall patch system while the securing means is activated. The orientation and number of the members to one another depends on the location of the hole to be patched. The patch member is sized to fit flush into the desired hole to be patched.
Conveniently, the wall patch system may be used in a variety of ways, namely for an accidental puncture in a drywall surface, an accidental puncture in the corner of a wall, or for rewiring locations for instance around an electrical receptacle or in a re-plumbing situation. Preferably, the backing member is mounted to the patch member at a location that provides the appropriate pressure and securement best suited to the type of patch being used. Conveniently, the positioning means may include a cord allowing for the suspension of the wall patch system into the hole as well as the positioning of the patch member in the hole and an additional pressure member such as a shim.
Advantages of the present invention are an economical and speedy system to repair drywall using compatible material, the system is simple, environmentally friendly and results in little waste, can be used in different capacities, namely for accidental punctures, in rewiring or re-plumbing, comes in a variety of sizes and allows the user to work within the wall cavity.

BRIEF DESCRIPTION OF THE DRAWINGS

A detailed description of the preferred embodiments are provided herein below by way of example only and with reference to the following drawings, in which:
FIG. 1 is a front view of a hole in a wall.
FIG. 2 in a perspective view, illustrates a wall patch system in accordance with a preferred embodiment of the present invention being sized against the hole illustrated in FIG. 1.
FIG. 3 in a side view, illustrates the patch member being traced over the hole of FIG. 1.
FIG. 4 in a front view illustrates the size of the patch member traced onto the wall around the hole of FIG. 1.
FIG. 5A in a front view illustrates the outline of the patch being cut to provide a hole that matches in size to that of the patch member.
FIG. 5B in a side view illustrates an alternative in cutting the hole in the drywall while using a jigsaw.
FIG. 6 in a front plan view illustrates the new hole that matches the size of the patch member.
FIG. 7 in a front plan view illustrates the removal of any burrs from the edge of the new hole.
FIG. 8A in a perspective view illustrates the insertion of the wall patch system into the hole of FIG. 7.
FIG. 8B in a side view illustrates the insertion of the wall patch system into the hole of FIG. 7.
FIG. 8C in a front view illustrates the insertion of the wall patch system into the hole of FIG. 7.
FIG. 8D in a front view illustrates the securement of the wall patch system in the hole of FIG. 7.
FIG. 8E in a side view illustrates the securement of the wall patch system into the hole of FIG. 7.
FIG. 9A in a front view illustrates the securement of the wall patch system into the hole of FIG. 7.
FIG. 9B in a front view illustrates the securement of the wall patch system into the hole of FIG. 7.
FIG. 9C in a front view illustrates the securement of the wall patch system into the hole of FIG. 7.
FIG. 9D in a side view illustrates the securement of the wall patch system into the hole of FIG. 7.
FIG. 9E in a front view illustrates the securement of the wall patch system into the hole of FIG. 7.
FIG. 9F in a front view illustrates the securement of the wall patch system in the hole of FIG. 7.
FIG. 9G in a front view illustrates the finishing treatment of the wall patch system in the hole of FIG. 7.
FIG. 10A in a front view illustrates the insertion of wall patch system into the hole of FIG. 7.
FIG. 10B in a front view illustrates the insertion of wall patch system into the hole of FIG. 7.
FIGS. 11A-B illustrates an alternative method of positioning the wall patch system in the hole.
FIGS. 12A-C illustrates an alternative method of securing the wall patch system in the hole.
FIG. 13 is a perspective view of hole in the corner of a wall.
FIG. 14 in a perspective view illustrates the wall patch system as illustrated in a second preferred embodiment of the present invention applied to the hole of FIG. 13 for outlining.
FIG. 15 is a front view of the completion of the outline of the patch member from the corner wall patch system.
FIG. 16 is front view of a hole exposed from cutting the outline of the patch member.
FIG. 17 is a perspective view of the insertion of the wall patch system into the hole of FIG. 15.
FIG. 18 is a front view of the securement of the wall patch system into the hole of FIG. 15.
FIG. 19 is a side view of the location of the drywall stud.
FIG. 20 in a perspective view illustrates the wall patch system of the third preferred embodiment of the present invention being outlined over the electrical receptacle switch.
FIG. 21 in a front view illustrates the outline of the hole to be cut.
FIG. 22 in a front view illustrates the hole resulting from cutting out the outline.
FIG. 23 in a perspective view illustrates the ability to position any additional wiring.
FIG. 24 in a front view illustrates the insertion of the electrical receptacle.
FIG. 25 in a side view illustrates the positioning of the wall patch system while the receptacle and wiring positioning is finalized.
FIG. 26 in a perspective view illustrates the securement of the wall patch system around the receptacle.
FIG. 27 in a perspective view illustrates the securement of the wall patch system around the receptacle.
In the drawings, preferred embodiments of the invention are illustrated by way of example. It is to be expressly understood that the description and drawings are only for the purpose of illustration and as an aid to understanding, and are not intended as a definition of the limits of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to FIGS. 1-12 there is provided a wall patch repair system 10 for a hole 12 comprising of at least one backing member 14 that is mounted to a patch member 16, a securing means 18 applied to the backing member 14 to secure the backing member 14 and patch member 16 in the hole 12, a positioning means 19 for positioning the patch member 16 and the backing member 14 in the hole 12 and adding additional pressure to the wall patch system 10 while the securing means 18 is activated.
More specifically, the backing member 14 and the patch member 16 may be made from drywall or similar material that can be sized to patch various sized holes 17 or punctures in walls. The backing member 14 may consist of one member 20 or multiple members depending on the location of the puncture. The backing member 14 has a front face 22 and a back fac 24. The patch member 16 has a front face 26 and a back face 28. Furthermore, only a portion 30 of the front face 22 of the backing member 14 is mounted or secured to the back face 28 or side of the patch member 16, thereby providing a portion of the front face 22 of the backing member 14 that can engage the back side of the drywall in need of repair. This configuration allows for the backing member 14 to provide support to the patch member 16 when positioned in the hole 12. The securing means 18 may be an appropriate form of glue 32 that adheres the front face 22 of the backing member 14 to the backside of the drywall thereby positioning the patch member securely in the hole 12 in question. The positioning means 19 may comprise by way of example only, a string or cord 34 that is attached to the patch member 16 and a shim 36. The positioning means 19 therefore allows for the backing member 14 and patch member 16 to be lowered into the hole 12 and then positioned in the hole 12 to allow the securing means 18 or glue to activate and secure the backing member 14 and the patch member 16. Furthermore the positioning means 19 allows for additional pressure to be applied to the wall patch system 10 while the securing means 18 cures therefore allowing for a tight seal of the wall patch system 10 to the drywall. This type of patch 10 is used when the puncture in the drywall is anywhere. This design of patch can be practically used between standard building 2×4 or 2×6 wall studs, and 4 inches up to the distance between each stud. The backing member 14 and the patch member 16 may also be a unitary piece of drywall having a configuration described above.
In operation the exterior wall surface of the drywall wall patch system 10 is used as a template around the hole 12 to be repaired. This repair is done by placing the exterior surface face of the drywall wall patch 10 over the hole 12 to be repaired and drawing a line on the drywall surface 40 from the top side of the patch, down to the bottom edge of the exterior wall portion of the patch, while still holding the patch 10 against the wall. The same is done on the other side of the patch 10, then turn the patch 10 to the lines just drawn and join those lines, both top and bottom.
This will form an outline to be cut on the drywall 40 around the damaged parts on the wall. The drywall 40 is then cut on the outside edge of the line just drawn; cutting straight into the drywall at right angles using either a drywall knife of fine toothed jigsaw blade 42 attached to a jigsaw or other cutting device. Cutting on the other edge of the outlined allows the patch 10 to fit snugly into its own peripheral dimensions. Care should be taken not to go beyond the borders of the outline, especially in the corners. Test fit by using the surface face of the patch 10 by placing it gently into the hole 12 just cut, do not use force. The patch 10 should slide easily in and out of the hole. Remove patch 10. Remove any burrs from edge of hole 12, inside and out with drywall knife or other cutting device. Do not tear off drywall paper from interior of drywall hole. Cut off paper burrs with drywall knife or other cutting device. Place fingers in hold and feel around edges for any debris and remove debris.
The interior surface of wall 10 should be dry and dust free. Using a paper to paper, paper to cardboard or paper to wood glue 18, spread interior edges of hole 12 with glue 18 to a depth equal or more than the interior edges of the drywall 40 wall patch 10. Spread the same type of glue 14 onto the interior drywall wall patch surfaces. The glue 18 should not be excessive, but cover all of the surfaces mentioned. At this point the drywall wall patch is ready to be inserted into the hole 12. Holding onto the longer piece of string 34, drop drywall wall patch 10 into hole 12. Lift patch 10 up to area on the inside glued portion of the interior wall 40 and line up glued interior portions of patch 10, then pull patch 10 into hole 12 firmly for adhesion. Have shims 36 ready for use. Slide one shim 36 under knotted portion of string 34 on patch all the way across to other side of patch 10 and onto the drywall 40. Both sides of the shim 36 should bridge the seams of the patch. Take the second shim 30 and slide it under the first shim 36; slide it all the way across the patch 10 to bridge both seams 42. Push seams together to tighten string 34, which will pull patch 10 firmly onto glue on interior area of drywall 40. String 34 should have no play at all when the shims 36 are in place. Leave to dry for allotted time of glue 18. Seams 42 around shims 36 may be filled with plaster while glue 18 dries. Do not plaster over shims 36. When allotted time for glue 18 to dry has elapsed, remove shims 36 by cutting string 34 beside knot. Remove shims 36. Remove string by pulling longest portion, letting the short end come through holes. Finish plastering where the shims 36 were.
Referring to FIGS. 13-18, using the same method as the open patch described above, the corner patch 50 is used as a template. The corner patch 50 is inverted and pushed into the corner wall 52 covering the hole 12, or where the drywall is to be opened up. A line is then drawn down one side of the patch 50, from the ceiling on the drywall 52. A second line is then drawn on the drywall 52 on the drywall 52 using the bottom edge of the patch 50 as a guide. Lift patch 50 away and join the two lines at 90°. Cut on the outside edge of lines, straight down into the drywall at 90° to the drywall 52. Cut the ceiling wall drywall from the edge just cut to the corner, then cut down from that corner to join the cut at bottom. Remove the damages drywall 52 or pieces cut gently.
At this point the ceiling plate and wall stud will be exposed. Remove any nails or screws, in portion exposed, from ceiling plate and wall stud. Clean off any debris. Size and fit in the same manner as open wall patch. Apply glue 18 to exposed ceiling plate and wall stud. Apply glue 18 to inside area of drywall 52 where drywall wall patch interior will meet wall. Apply glue 18 to interior drywall wall patch 50 section. Insert drywall w all patch 50 with drywall wall patch interior section first, allowing the interior part of the patch 50 to slip down behind drywall 52. Gently push patch 50 into corner secure with three nails or drywall screws in ceiling plate and wall stud. Slide shims under string in same manner open drywall patch.
Referring to FIGS. 19-29, as in the open wall drywall patch and the corner ceiling wall drywall wall patch, the same system is applied to electrical outlets and switches. House renovations or alterations sometimes require, because of certain design plans, new electrical outlets or switches to be installed in existing walls. Electricians have no trouble putting in these devices, however, the remaining drywall damage and the work required after such work has been done can be expensive and tedious. The electrical outlet/switch drywall patch 60 gives a clean, simple, fast, and inexpensive solution to this problem.
When the individual has decided where the outlet or switch is to be placed, the wall stud for that location is found. A small hole is then cut into the drywall flush to the edge of the stud. Using the electrical outlet/switch patch 60 as a template, put the surface face of the patch 60 against the wall and line up the lines on each arm of the patch with the flush drywall and stud. Starting from the first arm line on the inside portion of the arm, draw a line around the patch 60 until you come to the patch extension and then join the top and bottom lines. Without removing the patch 60 or your hand holding the patch, do the same to the other patch arm.
The template is now complete. Cut arms of template out first by using a drywall knife or other cutting device. Cut on the outside line of the template at a right angle to the blade and the drywall. Use a fine toothed blade on a jigsaw to cut out the rest of the template. Clean away burrs and debris from arm area. Invert patch 60 and test fit patch 60 in hole just cut. Do not use force. Patch 60 should move in and out of hole easily with no interference.
Install receptacle box onto stud. The receptacle top and bottom and side attached to stud should be exactly flush with drywall and top and bottom of arm cutouts. Wires may be put through receptacle prior to installing interior receptacle. Place glue onto face of drywall at rear. Do not use force. Apply glue to back inner wall facing portion of patch. Insert patch into hole (see FIG. 26) and allow arms of receptacle with cutouts to fall over receptacle knobs. Pull string firmly once fit has been accomplished. Secure arms with nails or drywall screws. Place shims in same manner as open and corner patches. Referring to FIGS. 12 a, 12 b and 12 c, this method can be used on all patches as a means of sealing.
Other variations and modifications of the invention are possible. All such modifications or variations are believed to be within the sphere and scope of the invention as defined by the claims appended hereto.

Claims

1. A patch system for repairing a hole in a surface comprising:

a) at least one backing member having a front side and a back side the front side engaging the surface;

b) a patch member adapted to fit the hole, having a front side and a back side, the back side being mounted to a portion of the front side of the backing member;

c) a securing means adapted to secure the front side of the backing member to the surface and the patch member in the hole; and

d) a removable positioning means adapted to attach to the backing member and the patch member for positioning the patch member and the backing member in the hole while the securing means fits the patch member into the hole.

2. A patch system for repairing a hole in a surface as claimed in claim 1 wherein the patch member is made from drywall sized to accurately fit the size of hole.

3. A patch system for repairing a hole in a surface as claimed in claim 1 wherein the backing member is made from drywall and mounted to the patch member whereby a second portion of the front side of the backing member engages the inside of the surface during securement.

4. A patch system for repairing a hole in a surface as claimed in claim 1 wherein the securing means is an adhesive.

5. A patch system for repairing a hole in a surface as claimed in claim 1 wherein the adhesive is a paper to paper, paper to cardboard, or paper to wood glue.

6. A patch system for repairing a hole in a surface as claimed in claim 1 wherein the positioning means is a string attached to both the backing member and the patch member and at least one shim positioned against the surface and between the string and the patch member.

7. A patch system for repairing a hole in a surface as claimed in claim 1 wherein the patch system is used in a wall.

8. A patch system for repairing a hole in a surface as claimed in claim 1 wherein the patch system is used in a ceiling.

9. A patch system for repairing a hole in a surface as claimed in claim 1 wherein the patch system is used in a corner.

10. A patch system for repairing a hole in a surface as claimed in claim 1 wherein the patch system is used in a ceiling.

11. A patch system for repairing a hole in a surface as claimed in claim 1 wherein the system is used for an electrical receptacle installation.

12. A method of repairing a hole in a surface having an inside and an outside using a patch system comprising:

a) placing a patch member having a front side, a back side and adapted to fit the hole over the hole;

b) tracing the patch member over the hole onto the surface;

c) cutting out the traced hole to expose edges of the hole in the surface;

d) applying a securing means to the edges of the hole, the inside of the surface and to at least one backing member having a front side and a back side, the securing means applied to a portion of the front face of the backing member;

e) inserting into the hole the backing member and the patch member using a removable positioning means to lower the backing member and patch member into the hole;

f) positioning the patch member into the hole;

g) engaging the securing means between the inside surface and the front side of the backing member, and the edges of the hole and the patch member; and

h) removing the removable positioning means from the patch member and the backing member.

13. A method for repairing a hole as claimed in claim 11 wherein the positioning means is a string attached through the patch member and backing member, and at least one shim whereby the shim is positioned between the string and the front side of the patch member to rest against the outside surface thereby applying pressure to the patch member during securement.

14. A method for repairing a hole as claimed in claim 11 further comprising filling in a seam in between the patch member and the outside surface to provide a smooth surface.

15. A method for repairing a hole as claimed in claim 11 further comprising removing the string and the shims from the patch member.

16. A method for repairing a hole as claimed in claim 11 wherein the method is used for a wall.

17. A method for repairing a hole as claimed in claim 11 wherein the method is used for a corner in a wall.

18. A method for repairing a hole as claimed in claim 11 wherein the method is used for a ceiling.

19. A method for repairing a hole as claimed in claim 11 wherein the method is used for an electrical receptacle installation.