US20200071946A1

US20200071946A1 - Wall Repair Patch

Info

Publication number: US20200071946A1
Application number: US16/554,524
Authority: US
Inventors: Taj Johnson
Original assignee: Individual
Current assignee: Individual
Priority date: 2018-08-28
Filing date: 2019-08-28
Publication date: 2020-03-05

Abstract

A wall repair patch is capable of repairing a hole in drywall in just a few minutes. A wall-textured top surface provides a visual appearance similar to the rest of the wall. The base is threaded and the top has a slotted or cross-shaped socket or another receiver for a screw drive system, allowing the patch to be screwed into a wall. The base is hollow and tapered, and the diameter of the top surface is greater than the diameter of the base at the latter's broadest part. Various diameters of base and top surface may be used in order to accommodate the repair of walls containing different sized holes. The length of the base is generally greater than the thickness of a drywall panel, but a length less than the thickness of drywall may be used when needed to avoid penetrating a wall stud.

Description

RELATED APPLICATION

This application claims priority to U.S. Provisional Patent Application Ser. No. 62/723,980 for “Wall Repair Patch,” filed Aug. 28, 2018, and currently co-pending.

FIELD OF THE INVENTION

The present invention pertains generally to a patch for use in wall repair. More particularly, the present invention pertains to an insert for covering a hole in a wall. The present invention is particularly, but not exclusively, useful as a patch to repair holes in drywall.

BACKGROUND OF THE INVENTION

Interior walls in buildings, and especially homes, in the United States are usually made with drywall. Drywall generally comes in four foot by eight foot panels, at a thickness of one-half or five-eighths of an inch, although other sizes and thicknesses are available.
The use of drywall provides many benefits, including speedy installation, but drywall walls are also easily damaged. Small holes in drywall are often repaired with spackling paste, while larger holes are repaired with a mesh patch or a drywall patch. A patch, whether made of wire mesh or drywall, is typically covered with joint compound. Larger holes may need wood supports installed, and joint tape may need to be applied before the joint compound.
Spackling paste and joint compound need at least twenty-four hours to dry before sanding (if necessary) and painting or texturing. If more than one coat is required, the repair time is increased accordingly.
In light of the above, it would be advantageous to provide an apparatus and method for repairing drywall that would eliminate the need for spackling paste or joint compound.

SUMMARY OF THE INVENTION

Disclosed is a wall repair patch capable of repairing a hole in drywall in just a few minutes. The patch comprises a wall-textured top surface on top of a threaded base. The top surface is configured to receive an installation tool such as a Phillips screwdriver tip or, in some embodiments, a spanner or “pig nose” screwdriver tip, to facilitate insertion of the base into a wall. In preferred embodiments, the base is hollow and tapered, and the diameter of the top surface is greater than the greatest diameter of the base.
In order to accommodate the repair of walls containing different sized holes, various embodiments comprise various diameters of base and top surface. Moreover, in some preferred embodiments, the length of the base is greater than the thickness of drywall. For example, one embodiment comprises a base approximately one inch long. This allows the wall repair patch to penetrate completely through the sheet of drywall.
In other preferred embodiments, the length of the base is slightly less than the thickness of drywall. For example, one embodiment comprises a base approximately three-eighths of an inch long. This allows the wall repair patch to be inserted into a drywall panel mounted over a stud without contacting the stud itself.
In use, a wall repair patch with a base diameter equal to or greater than the width of the hole to repair is selected. The wall repair patch is also selected according to the desired length of the base; a user may select a wall repair patch with a base less than one-half inch long if the hole overlaps a stud. Or, a user may select a wall repair patch with a base greater than one-half inch (or greater than five-eighths of an inch if the damage is in five-eighths inch thick drywall) if the hole is not over a stud.
Once the appropriate sized wall repair patch is selected, it is placed over the hole in the wall and inserted into the wall with a rotational motion using an appropriate installation tool.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features of this invention, as well as the invention itself, both as to its structure and its operation, will be best understood from the accompanying drawings, taken in conjunction with the accompanying description, in which similar reference characters refer to similar parts, and in which:

FIG. 1 illustrates the insertion of a wall repair patch into a hole in a wall;

FIG. 2 is a side view of a wall repair patch showing respective sizes of the base and top surface, and an axis of rotation of the patch;

FIG. 3 is a bottom view of a wall repair patch showing the hollow center of the base;

FIG. 4 is a top view of a wall repair patch showing the textured top surface and various receivers for installation tools;

FIG. 5 is a partial cross-sectional view of a wall with two embodiments of a wall repair patch inserted;

FIG. 6 illustrates an installation tool for a preferred embodiment of a drive system of a wall repair patch;

FIG. 7 illustrates a method of repairing a hole in a wall using a wall repair patch of the present invention;

FIG. 8 is a perspective view of an alternative embodiment of a wall repair patch showing a base diameter similar to the top surface diameter and a thread that terminates in a toothed portion proximate the top surface; and

FIG. 9 is a side view of the wall repair patch of FIG. 8.

DETAILED DESCRIPTION

Referring initially to FIG. 1, a damaged wall 10 is shown. Wall 10 has a hole 12 that can be repaired with a wall repair patch 100. In order to repair the wall 10, patch 100 is pushed in direction 14 into the wall, while being rotated in direction 16.
Referring now to FIG. 2, a side view of wall repair patch 100 is shown. Patch 100 comprises a top surface 102 and a threaded base 104. In preferred embodiments, top surface 102 is smooth or has a texture 106 matching a common wall texture.
In preferred embodiments of wall repair patch 100 top surface 102 has a plastic substrate 108 where the top surface 102 will sit against the wall 10. In some preferred embodiments, substrate 108 has one or more adhesive elements 109 that aid in adhering wall repair patch 100 to a wall 10. In an exemplary preferred embodiment, two adhesive elements 109 are on substrate 108 opposite each other on either side of base 104. In one embodiment, adhesive elements 109 are adhesive dots, such as those sold under the brand name GLUE DOTS. In another embodiment, adhesive elements 109 are peel-and-stick adhesives, which have a peel-off cover that is removed before wall repair patch 100 is placed on a wall 10.
Top surface 102 has an upper thickness 110 and a substrate 108 thickness 112 that, combined, are small compared to the thickness of a drywall panel. In particular, thicknesses 110 and 112 are kept small in preferred embodiments in order to minimize the visibility of wall patch 100 when placed in a wall 10.
Base 104 has threads 114 which catch on the interior of the wall 10 to hold the patch 100 in place. Base 104 is also tapered at taper angle 116 for more efficient and effective insertion into the wall 10. Base 104 has a primary diameter 117, defined as the diameter of base 104 where it joins with top surface 102 at substrate 108; primary diameter 117 is the largest measurement of the diameter of base 104, and the diameter decreases in length with distance away from the top surface 102.
Base 104 has a length 118 which varies between embodiments. In some preferred embodiments, length 118 is greater than five-eighths of an inch in order to allow base 104 to penetrate completely through a wall 10 made of drywall. In one such embodiment, length 118 is one (1) inch, or approximately one (1) inch. In other preferred embodiments, length 118 is less than one-half inch in order to prevent base 104 from passing completely through a wall 10 made of drywall. In one such embodiment, length 118 is three-eighths of an inch, or approximately three-eighths of an inch. Top surface 102 has a diameter 119 greater than the primary diameter 117 of base 104.
In order to use the wall repair patch 100, the end 120 of the base 104 is placed against the wall 10 around the hole 12, and driven around axis 121 into the wall 10.
Referring now to FIG. 3, a bottom view of wall patch 100 is shown. In a preferred embodiment, base 104 forms a threaded, tapered tube comprising a plastic perimeter at its end 120 around a hollow center 122. An exemplary configuration of adhesive elements 109 is shown, wherein two (2) adhesive elements 109 are placed on substrate 108 on opposite sides of base 104.
Referring now to FIG. 4, a top view of wall repair patch 100 is shown. Preferred embodiments of top surface 102 of patch 100 have a texture 106 to match a wall with which patch 100 will be used. Some embodiments have a smooth texture, while others have orange peel, knockdown, or popcorn textures.
Some preferred embodiments of wall patch 100 also have an installation tool receiver 130, configured to receive a flat-bladed or Phillips screwdriver. Installation tool receiver 130 allows the wall patch 100 to be inserted into a wall 10 using a screwdriver. Alternative preferred embodiments use an alternate installation tool receiver system comprising two holes 132A and 132B, in a manner substantially similar to a “spanner” or “pig nose” screw drive, instead of installation tool receiver 130. Another embodiment uses three holes 134A, 134B, and 134C arranged as if they were vertices on an equilateral triangle. The use of holes 132A and 132B may be smaller in diameter yet provide ample torque while providing the advantage of less visibility than other screw drives, such as installation tool receiver 130.
Referring now to FIG. 5, the placement of wall patches 100 in a wall is illustrated. A wall patch 100A fills a hole 12 in a wall 10. Wall patch 100A has a base 104 length 118A longer than the thickness of the drywall into which it is inserted, allowing it to pass completely through wall 10. Wall patch 100B, on the other hand, has a base 104 length 118B shorter than the thickness of the drywall of wall 10, in order to avoid damaging stud 18 when it is inserted into wall 10.
The surfaces of each wall patch 100A and 100B are textured to match the texture 20 of wall 10. This allows wall patches 100A and 100B to blend in with wall 10, thereby increasing their aesthetic appeal. Some embodiments of wall patch 100 are smooth, and not only blend in better with smooth walls, but can be textured, painted, or wallpapered in the same or similar manner to the texturing of a wall 10.
Referring now to FIG. 6, a driver for a drive system using a plurality of holes is shown and generally designated 200. Driver 200 comprises a handle 210 which is grasped by a user to operate the driver 200. A shank 212 extends outward from one end of handle 210, and terminates in at least two (2) tips 214. In a “pig nose” or “spanner” embodiment, two (2) tips 214 are present. In a “triangle” embodiment, driver 200 has three (3) tips. Other numbers of tips are used for other drive systems.
Referring now to FIG. 7, a method of repairing a hole in a wall is illustrated and generally designated 300. Method 300 begins with the step 310 of measuring the hole in the wall. The measurement taken is generally the greatest end-to-end distance of the hole. For example, if the hole spans a greater distance vertically than horizontally, a measurement of the vertical length is preferred over the horizontal length. If a diagonal measurement would be even greater, the diagonal measurement is preferred.
Next step 312 is providing a wall repair patch 100 as described above in conjunction with FIGS. 1 through 5. More particularly, the wall repair patch has a top surface 102, a drive system, and a threaded base 104. Various embodiments of step 312 comprise the provision of the various embodiments of wall repair patch 100. More particularly, a wall repair patch 100 is selected with a base 104 having a primary diameter 117 equal to or greater than the measurement taken in step 310. In some embodiments of the method 300, wall repair patch 100 is also selected to have a texture 106 matching the texture of the wall to be repaired.
Step 314 is placing the end 120 of the base 104 against the wall and particularly around the hole to be repaired. Step 316 is the inserting a driver 200 corresponding to the drive system of patch 100 into patch 100. A Phillips or flathead screwdriver may be used with wall patches 100 that comprise corresponding drive systems. It will be apparent to a person of ordinary skill in the art that step 314 and step 316 may be performed in any order, according to a user's preference.
Step 318 is rotating the driver 200 while applying pressure against the wall repair patch 100 until patch 100 is fully inserted into the wall and top surface 102 is placed against the wall. In one embodiment, the driver 200 and patch 100 are rotated counterclockwise. However, the direction of rotation depends on the direction of threads 114, and so varies between embodiments.
Once the patch 100 is fully inserted into the wall, step 320 is removing the driver 200 from patch 100. At this point, the hole has been repaired, although a user may perform additional steps for cosmetic purposes, such as spackling or otherwise covering any observable details of the drive system of patch 100.
Referring now to FIG. 8, an alternative preferred embodiment of a wall repair patch 400 has a tapered base 404 with a diameter 417 such that the threads 414 extend substantially even with the diameter 419 of the top surface 402. Moreover, threads 414 terminate near the top surface 402 in a toothed configuration, with teeth 440 facilitating the insertion of patch 100 into drywall. As shown, base 404 also has a hollow center 422.
Referring now to FIG. 9, a side view of the alternative preferred embodiment of wall repair patch 400 of FIG. 8 is shown, illustrating the similarity between the base diameter 417 extended by threads 414, and the top surface diameter 419. In variants of the illustrated embodiment, top surface 402 is textured as described above with respect to other embodiments. Base 404 is formed with a first portion 404A and a second portion 404B. First portion 404A is formed with a first taper angle 405A which narrows the diameter of the base away from the top surface 402. The taper angle 405A ranges from 20 to 90 degrees, with a typical angle of 80 degrees. Second portion 404B is formed with a second taper angle 405B that ranges from 0 to 90 degrees, with a typical angle of 45 degrees. The taper angles 405A and 405B facilitate the insertion of the device 400 into the damaged portion of a wall by allowing insertion with the smaller diameter portion which, when threaded in accordance with this invention into the wall, advances the increasing diameter into the damaged wall to secure device 400 in position.
Also shown from this figure is the relationship between the thickness 407 and length 408 of threads 414 and teeth 440. In a preferred embodiment, the thickness 407 of threads and teeth 414 and 440 ranges from 0.05 to 0.2 inches, and the length 408 ranges from 0.05 to 0.7 inches. In a preferred embodiment, the thickness 407 is 0.08 inches, and the length 408 is 0.4 inches; other lengths and thicknesses 408 and 407 are fully contemplated herein and do not depart from the present invention. In a preferred embodiment, the device 400 is formed with a thickness 407 and length 408 ratio range of between 1:20 and 1:3.
Additional embodiments combining the various features described herein in connection with each exemplary embodiment are also fully contemplated.
While there have been shown what are presently considered to be preferred embodiments of the present invention, it will be apparent to those skilled in the art that various changes and modifications can be made herein without departing from the scope and spirit of the invention.

Claims

I claim:

1. A wall repair patch, comprising:

a top surface having a plastic substrate configured for placement against a wall comprising drywall; and

a threaded base tapered for effective insertion into the wall,

wherein the top surface has a thickness sufficiently small to minimize the visibility of the wall repair patch when the wall repair patch is placed in the wall.

2. The wall repair patch as recited in claim 1, further comprising adhesive elements attached to the substrate.

3. The wall repair patch as recited in claim 1, wherein the threaded base comprises a length greater than five-eighths of an inch.

4. The wall repair patch as recited in claim 1, wherein the threaded base comprises a length less than one-half inch.

5. The wall repair patch as recited in claim 1, further comprising an installation tool receiver configured to receive an installation tool.

6. The wall repair patch as recited in claim 5, wherein the installation tool receiver is configured to receive an installation tool based on a spanner screw drive.

7. The wall repair patch as recited in claim 1, wherein the top surface comprises a texture to match the wall.

8. The wall repair patch as recited in claim 7, wherein the texture is selected from the group consisting of an orange peel texture, a knockdown texture, and a popcorn texture.

9. A system for repairing a hole in drywall, comprising:

a wall repair patch, comprising:

a top surface having a plastic substrate configured for placement against a wall comprising drywall;

a threaded base tapered for effective insertion into the wall; and

an installation tool receiver, and

an installation tool configured to be received by the installation tool receiver in order to install the wall repair patch in a wall comprising drywall.

10. The system for repairing a hole in drywall as recited in claim 9, wherein the installation tool is based on a spanner screw drive.

11. The system for repairing a hole in drywall as recited in claim 9, wherein the threaded base is hollow.

12. The system for repairing a hole in drywall as recited in claim 9, wherein the top surface comprises a texture to match the wall.

13. The system for repairing a hole in drywall as recited in claim 12, wherein the texture is selected from the group consisting of an orange peel texture, a knockdown texture, and a popcorn texture.

14. The system for repairing a hole in drywall as recited in claim 9, wherein the plastic substrate has two adhesive elements positioned opposite each other.

15. A method for repairing a hole in drywall, comprising:

measuring a hole in a wall;

providing a wall repair patch, comprising:

a threaded base tapered for effective insertion into the wall; and

an installation tool receiver,

wherein the threaded base has a diameter at least equal to the measurement of the hole;

providing an installation tool;

placing an end of the threaded base against the wall and at least partially within the hole;

inserting the installation tool into the installation tool receiver;

rotating the installation tool while applying pressure until the top surface is against the wall; and

removing the installation tool.

16. The method for repairing a hole in drywall as recited in claim 15, wherein the step of measuring the hole comprises taking the greatest end-to-end distance.

17. The method for repairing a hole in drywall as recited in claim 15, wherein the installation tool is based on a spanner screw drive.

18. The method for repairing a hole in drywall as recited in claim 15, wherein the top surface comprises a texture to match the wall.

19. The method for repairing a hole in drywall as recited in claim 15, wherein the threaded base is hollow.

20. The method for repairing a hole in drywall as recited in claim 15, wherein the plastic substrate has two adhesive elements positioned opposite each other.