WO2012079119A1

WO2012079119A1 - Hollow wall repair apparatus

Info

Publication number: WO2012079119A1
Application number: PCT/AU2011/001610
Authority: WO
Inventors: Kerry Petersen
Original assignee: Kerry Petersen
Priority date: 2010-12-15
Filing date: 2011-12-14
Publication date: 2012-06-21

Abstract

An apparatus for repairing a hole in a sheet of cladding including, a generally rigid base attached to a foldable support member, the support member extendable outwardly from the base and being movable between a folded position and a generally fiat array, a locating member graspable by a user and releasably attached to the base, and a locking means for fixing the support member relative the base, wherein the base and support member In the folded position are insertable through said hole, whereafter the support member is expanded and attached to a rear surface of said sheet of cladding, the locating member being detached from the base whereupon a curable filter being applied to fill said hole, wherein the support member provides a barrier to support the flowable filler to permit curing.

Description

Hollow well repair apparatus

FIELD OF THE INVENTION

The present Invention relates to a hollow wall repair apparatus and in one aspect relates an expandable apparatus for repairing a hole in a sheet of cladding, such as plasterboard.

BACKGROUND OF THE INVENTION

The repair of holes in wall and roof plasterboard cladding is typically undertaken during renovation, repairing damage and when the layout of a room is being altered. Typically the hole results from accidental damage or from the removal of a power point, down light, or ceiling fan.

Typically to repair a small hole in plasterboard cladding the edges of the hole are cleaned with any broken or lose plaster and paper removed. A piece of plasterboard slightly larger than the hole is cut so that it can be inserted through the hole. This often requires the enlargement of the hole by cutting a slot to either side. A small hole is then cut in the centre of plasterboard patch to attach a piece of string or a nail is pushed into the centre of plasterboard patch. Contact adhesive, plaster or cornice cement is then applied to the plasterboard patch, which is then inserted through the hole and positioned so that the plasterboard patch affixes to the rear of the plasterboard cladding. The string or nail is pulled to ensure that the patch sticks to the back of the cladding. Subsequent coats of plaster are then applied to fill the hole.

Alternatively, repair tape is applied over the hole and plaster is applied to the surface to conceal to hole. The plaster is then sanded so that there is minimal protrusion of the plaster outwardly from the wall. There are a number of problems with the existing methods of repairing holes in plasterboard. Previously available methods require a degree of expertise that may not be possessed by the person repairing the wall. Furthermore, where tape is used, the method results in the plaster creating a protruding area on the wan. This protruding lump can be quite conspicuous on the ceiling, in a walkway, or when the surface is painted a dark colour such as on a feature wall. It should be appreciated that any discussion of the prior art throughout the specification is included solely for the purpose of providing a context for the present invention and should in no way be considered as an admission that such prior art was widely known or formed part of the common general knowledge In the field as it existed before the priority date of the application.

SUMMARY OF THE INVENTION

In one aspect the Invention could generally be understood to comprise an apparatus for repairing a hole in a sheet of generally rigid material including a support member that may be inserted through said hole and expanded or enlarged to engage with and fix to a rear surface of said sheet, wherein the support member provides rear backing for a flowabie filler applied to fill said hole.

In one form the support member may be moved between a folded or collapsed position and a generally flat layout wherein the support member has a reduced width when in the folded position to permit the support member to be inserted through the hole.

The support member may be folded or collapsible in a number of way, such as, but not limited to a plurality of hinged faces, a concertina arrangement fan configuration or separate members alignable to form a generally flat array.

In another aspect of the invention but not necessarily the broadest or only aspect, there is proposed an apparatus for repairing a hole in a sheet of cladding including, a generally rigid base attached to a foldable support member, the support member extendable outwardly from the base and being movable between a folded position and a generally flat array, a locating member graspable by a user and reJeasably attached to the base, and a locking means for fixing the support member relative the base, wherein the base and support member in the folded position are intertable through said hole, whereafter the support member is expanded and attached to a rear surface of said sheet of cladding, the locating member being detached from the base whereupon a curable filler being applied to fill said hole, wherein the support member provides a barrier to support the flowabie filler to permit curing. The support member may include a plurality of faces hlngedr/ interconnected, wherein the plurality of faces can be folded to reduce the circumference of the support member. In this way the support member can be folded so that it can be inserted through the hole and then expanded into a generally fiat configuration to be attached to the rear of the cladding.

The locking means may be a clamp having an expanded portion for bearing respectively on opposite faces of the support member, so that when drawn together the expanded portions clamp the support member in said flat array.

The face or faces may include apertures extending therethrough to provide a binding site and assist in curing of the filler.

The locating member may be elongate and the fotdab!e support member having a central aperture wherein the elongate locating member extends therethrough and is attached to the base.

In one form the elongate locating member may be a shaft that is release biy attached to the base. An end of the shaft may include a thread that cooperateE with an opposing threaded aperture in the base. The length of the shaft will permit the user to grasp the locating member to position the support member within the hole.

The upper surface of the support member may include an adhesive that permits the support member to be attached to the rear of the cladding. Alternatively an adhesive, plaster or double sided tape may be applied to the support member to enable fixing.

A1 least a portion of the base is preferably stiff and provides rigidity to the expanded support member. This means that the support member can be constructed from a semi-flexible material that can be manipulated so that it can be inserted in through the hole. The base in one form includes a generally circular rigid plate and a central upstand that is engagable with the locking means. The outer surface of the upstand may include a thread that cooperates with an opposing threaded locking means in the form of a nut The upstand may also include said opposing threaded aperture in the base that cooperates with the threaded end of the shaft. The support member may be attached to the base by way of two hinged arms and the locating member may pass through a central opening in the support member. In this way the locating member that is attached to the base can be used to draw the base against the underside of the support member. The locking means is then used to fix the support member relative to the base and the locating member removed to provide a generally planar support member affixed to the rear of the cladding.

In one form the locking means may be a threaded nut that b sHdabte down the shaft of the locating means and engagable with an opposing threaded projection on the base. The nut may include an annular flange or washer that extended outwardly to abut with the upper surface of the support member to damp it to the base.

The shaft may include a projection or thread to engage with the nut In this way the apparatus can be supplied as a complete unit without having to attach any additional components. Accordingly, in use the support member can be manipulated to block the hole and the locking means can be slide down the shaft to fix the support member relative the base. Once the support member is attached to the cladding the locating member can simply be removed and disposed of.

In an alternate form the locking means comprise an annular flange with a threaded depending projection. The depending projection engages with an opposing threaded annular aperture in nut that is attached to the underside of rigid plate of the base. A hexagon shaped member may be attached to the upper surface of annular flange to enable a user to tighten the locking means.

The locking means may also be a pin or a bayonet fitting that engages with the support member or base, or therebetween. The apparatus may also be provided in a kit including, plaster, an applicator and sand paper.

The apparatus may be constructed from plastic, metal, combination thereof, or any other type of suitable material.

In another aspect of the invention there is proposed a method of repairing a hole in a sheet of cladding, including the steps of.

InserUng a generally rigid base attached to a foldable support member of a repair apparatus in through said hole;

using an elongate locating member release My attached to said base and positioned to extend outwardly through said hole, to locate the support member adjacent a rear surface of the sheet of cladding;

moving the support member into an expanded configuration;

fixing the support member relative the base using a locking means of the repair apparatus, whereby the support member is positioned in a generally flat array; attaching the support member to said rear surface of the sheet of cladding;

disengaging the locating member from the base; and

applying a flowable and curable filler to the hole, wherein the expanded support member provides a barrier to support said filler.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated In and constitute a part of this specification, illustrate several implementations of the invention and, together with the description and claims, serve to explain the advantages and principles of the invention. In the drawings.

Figure 1 is a perspective view of a first embodiment of the hole repair

apparatus of the present invention In a partially folded configuration;

Figure 2a is a perspective view of the hole repair apparatus of figure 1 in a partially expanded configuration;

Figure 2b is a perspective view of the hole repair apparatus of figure 1 in a completely expanded configuration illustrating the movement of the locking means;

Figure 3 is a side cross-sectional view of a hole in a hollow wall illustrating the insertion of the hole repair apparatus of figure 1 into the hole;

Figure 4 is a side cross-sectional view of a hole in a hoHow wall illustrating the attachment of the hole repair apparatus, removal of the elongate locating member and the application of a flowabie filler into the hole;

Figure s is a perspective view of a second embodiment of the hole repair apparatus in a partially folded configuration; Figure 6 is a side view of the hole repair apparatus of figure 5 illustrating removal of the locating member;

Figure 7 Is a side view of the locking means of figure 5 illustrating the

attachment to the base;

Figure 8 is a top view of the hole of figure 3 prior to the application of the ftowable filler;

Figure 9 is a perspective view of a third embodiment of the hole repair

apparatus, illustrating a fanlike support member.

Figure 10 is a perspective view of a fourth embodiment of the hole repair

apparatus illustrating a collapsible support member;

Figure 11 is a side view of a fifth embodiment of the hole repair apparatus

illustrating a push in bolt; and

Figure 12 is a side view of the hole repair apparatus of figure 11 affixed to the rear of the cladding. DETAILED DESCRIPTION OF THE ILLUSTRATED AND EXEMPLIFIED EMBODIMENTS

Similar reference characters indicate corresponding parts throughout the drawings. Dimensions of certain parts shown in the drawings may have been modified and/or exaggerated for the purposes of clarity or illustration. Referring to the drawings for a more detailed description, a hole repair apparatus 10 is illustrated, demonstrating by way of examples arrangements in which the principles of the present Invention may be employed. As illustrated in figure 1 , the hole repair apparatus 10 for repairing a hole 12 in a sheet of cladding 14 Includes, a backing member 16 comprising a base 18 attached to a support member 20. The support member 20 is extendable outwardly from the base 18 and movable between a folded or collapsed position and a generally flat array, as illustrated in figures 1 to 2b. An elongate locating member 22 is releasably attached to the base 18, and a locking means 24 for fixing the support member 20 relative to the base 18 siidably engages the locating member 22 as indicated by arrow 28 in figure 2b. The base 18 and support member 20, in a collapsed position as illustrated in figure 1 , can be inserted through the hole 12. The locating member 22 can be grasped by a user and the support member 20 expanded in the direction of arrows 28 as lluBtrated in figure 2a into a generally flat configuration so that it can be attached to a rear surface 30 of said sheet of cladding 14, as further illustrated in figure 4. The locating member 22 can then be disengaged from the base In the direction of arrow 32 in figure 4, and a curable filler 34 applied to fill said hole 12 in the direction of arrow 36. As the reader will now appreciate the expanded support member 20 providing a barrier as shown in figure 8 to support the fiowabto filler 34 to permit curing thereof.

As further illustrated in the figures, in particular figures 1 , 4 and 8, the locating member 22 comprises a shaft 38 having a generally circular cross sectional profile and a threaded portion 40 at one end that cooperates with an opposing threaded aperture 42 in the base 18. The length of the shaft 38 permits a user to grasp the locating member 22 to position the backing member 16 within the hole 12.

In one possible embodiment, as Illustrated In figures 1 to 2b, the support member 20 includes a plurality of faces 50, 52, 54, 56, 58, 60 hingedly

interconnected 62. The plurality of faces can be folded to reduce the circumference of the support member 20 as illustrated in figure 1 and inserted through the hole 12. Once through the hole the support member can be expanded into a generaly flat configuration as illustrated in figures 2b and 4 to be attached to the rear 30 of the cladding 14.

The faces include apertures 64 extending therethrough to provide a binding site and assist In curing of the filler. The upper surface 68 of the support member 20 may include an adhesive that permits the support member 20 to be attached to the rear of tile cladding. Alternatively an adhesive, plaster or double sided tape may be applied to the support member to enable fixing.

In one embodiment the base 18 comprises a generally circular rigid plate 70 and a central projection 72 that is engagable with the locking means 24. The outer surface of the upstand includes a thread that cooperates with an opposing threaded a nut 74 of the locking means 24. The rigid plate 70 provides rigidity to the expanded support member once positioned within the hole 12. The support member 20 Is attached to the rigid plate 70 by way of two hinged arms 76, 78 and the locating member 22 pass through a central opening 80 in the support member 20. In this way the locating member 22 can be used to draw the rigid plate 70 against the underside of the support member 22. As illustrated in the figures the hinged arms 76, 78 may be attached to the underside of faces 50 and 56 however the reader will appreciate that this is only one way of providing a backing member and other way may be practiced without departing from the scope of the invention.

The locking means 24 in one embodiment comprises a threaded nut 74 that is slkJable down the shaft 38 of the locating means 22 in the direction of arrow 26 and engagable with the opposing threaded projection 72 of the base. The nut 74 may include an annular flange 82 that extended outwardly to abut with the upper surface 68 of the support member 20 to damp it against the rigid plate 70. The locking means 24 thereby fixes the support member 20 relative the base 18, and the locating member 22 is then removed to provide a generally planar backing member affixed to the rear of the cladding.

The shaft 38 may include a projection 84 or thread to engage with the nut 74. In this way the apparatus 10 can be supplied as a complete unit without having to attach components. Accordingly, in use the backing member 16 can be manipulated to block the hole 12 and the locking means 24 can be slide down the shaft 38 to fix the support member 20 relative the base 18. Once the support member 18 is attached to the cladding the locating member 22 can be simply removed and discarded.

In an alternate embodiment, as illustrated in figure 5, the locking means 24 comprise an annular flange 82 with a threaded depending projection 90. The depending projection 90 engages with an opposing threaded annular aperture 92 in nut 94 that is attached to the underside of rigid plate 70. The locking means 24 slidabfy engages shaft 38 and the elongate locating member 22 is provided with a handle 96 at an upper end to be grasped by a user. A hexagon shaped member 98 is attached to the upper surface of annular flange 62 to enable the user to tighten the locking means 24.

As illustrated in figure 6, because the nut 94 is positioned below the rigid plate 70 it does not protrude into the hole. Accordingly the second embodiment is useful in filling hole where the sheet of cladding 14 is relatively thin or the user wants to ensure a premium finish.

Figure 7 illustrates the configuration of the locking means 24 and its attachment with the base 18. As the reader will appreciate depending projection 90 engages with threaded annular aperture 92, to fix the annular flange 82 against the support member 20. Furthermore the thread portion 40 of shaft 38 engages with threaded aperture 42 that is separated from annular aperture 92 by way of upstand 100. The reader should appreciate that the nut 94 blind ended and the upstand is attached to the blind end of the nut 94. This thereby forms two upwardly open apertures 92, 100 that can engages with locking means 24 and shaft 38 respectively.

Figure 9 illustrates an alternate embodiment of the repair apparatus 10 wherein the support member 20 comprises a tanlike arrangement The shaft 38 reversibly engages an aperture 102 in central portion 104 of the support member 20. The panels 106, 108, 110 are configured to spread out around central portion 104 in the direction of arrow 114 to produce a generally circular disc that can then be affixed to the rear of a plasterboard sheet. The panel 110 includes an aperture 112 that can be used to expand the support member 20.

Figure 10 illustrates still another embodiment of the repair apparatus 10 wherein the support member is collapsible and comprises hinged panels 116, 118, 120 and 122. As the locking means 24 Is pushed down the shaft 38 it bears upon the collapsed support member 20 thereby moving it into an expanded configuration.

In another embodiment, as illustrated in figures 11 and 12, the locking means 24 comprises a push in bolt that is configured to engage with an outwardly open chamber 130 in the base 18, As illustrated in figure 11 the backing member 18 is inserted through the hole 12 and expanded such that the support member is position against the rear surface 30 of the sheet of cladding 14. The push in bolt is then moved into frictional engagement within the outwardly open chamber 130 and the locating member can then be removed as discussed above.

It should be appreciate that other types of connections means could be used to position the base 18 and support member 20 in a fixed arrangement, for instance a bayonet male/female arrangement or a pin could also be used. The skilled addressee will now appreciate the advantages of the illustrated invention. The hole repair apparatus 10 can be used by home renovators and unskilled homeowners to repairs hole in plasterboard and the like. The apparatus 10 can be provided In different sizes and shapes for different applications. Furthermore the apparatus 10 can be provided as part of a kit for the repair of holes.

Various features of the invention have been particularly shown and described in connection with the exemplified embodiments of the invention, however, it must be understood that these particular arrangements merely illustrate and that the invention is not limited thereto. Accordingly the invention can include various modifications, which fall wtthin the spirit and scope of the invention. For the purpose of the specification the word "comprise" or "comprising* means "including but not limited to".

Claims

THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

1. An apparatus for repairing a hole in a sheet of generally rigid material including a support member that may be inserted through said hole and expanded or enlarged to engage with and fix to a rear surface of said sheet, wherein the support member provides rear becking for a ftowable filler applied to fill said hole.

2. The apparatus in accordance with claim 1 wherein the support member Is movable between a folded or collapsed position and a generally flat layout, wherein the support member has a reduced width when in the folded position to permit the support member to be inserted through the hole.

3. An apparatus for repairing a hole in a sheet of cladding including, a

generally rigid base attached to a foldabte support member, the support member extendable outwardly from the base and being movable between a folded position and a generally flat array, a locating member graspable by a user and releasably attached to the base, and a locking means for fixing the support member relative the base, wherein the base and support member in the folded position are intertable through said hole, whereafter the support member is expanded and attached to a rear surface of said sheet of cladding, the locating member being detached from the base whereupon a curable filler being applied to fill said hole, wherein the support member provides a barrier to support the flowable filler to permit curing.

4. The apparatus in accordance with any one of claims 1 to 3 wherein the support member includes a plurality of faces hingedty interconnected, wherein the plurality of faces can be folded to reduce the circumference of the support member.

5. The apparatus in accordance with claim 3 or 4 wherein the locking means is a damp having an expanded portion for bearing respectively on opposite faces of the support member, so that when drawn together the expanded portions clamp the support member in said flat array.

6. The apparatus in accordance with claim 4 wherein the face or faces include apertures extending therethrough to provide a binding site and assist in curing of the filler.

7. The apparatus in accordance with any one of claims 3 to 6 wherein the locating member Is an elongate shaft, the foldabie support member having a central aperture wherein the elongate shaft extends therethrough and is releasably attached to the base.

8. The apparatus in accordance with any one of claims 3 to 7 wherein a portion of the base is stiff and provides rigidity to the expanded support member.

9. The apparatus in accordance with any one of claims 3 to 8 wherein the support member is attached to the base by way of two hinged arms and the locating member passes through a central opening in the support member.

10. The apparatus in accordance with any one of claims 3 to 9 wherein the locking means is a threaded nut that Is slkJable down the shaft of the locating means and engagabte with an opposing threaded projection on the base, the locking means including an annular flange or washer that extended outwardly to and abuts with the upper surface of the support member to damp it to the base.

11. The apparatus in accordance with any one of claims 3 to 10 wherein the shaft includes a projection or thread at an upper end to engage with the threaded nut prior to use, wherein the threaded nut can be slid or rotated off the projection or thread once the support member has been inserted through the hole to bear upon the top of the support member to move the same into the expanded position.

12. The apparatus in accordance with any one of claims 3 to 9 wherein the locking means comprise an annular flange with a threaded depending projection, the depending projection engages with an opposing threaded annular aperture in a nut that is attached to the underside of rigid plate of the base.

13. The apparatus In accordance with any one of claims 3 to 9 wherein the locking means Is a pin or bayonet fitting that engages with the support member or base, or therebetween.

14. A kit including the apparatus in accordance with any one of claims 1 to 13, quantity of plaster, an applicator and sand paper.

15. A method of repairing a hole in a sheet of cladding, including the steps of: inserting a generally rigid base attached to a foldable support member of a repair apparatus in through said hole;

using an elongate locating member releasaWy attached to said base and positioned to extend outwardly through said hole, to locate the support member adjacent a rear surface of the sheet of cladding:

moving the support member into an expanded configuration;

fixing the support member relative the base using a locking means of the repair apparatus, whereby the support member is positioned in a generally flat array;

attaching the support member to said rear surface of the sheet of cladding; disengaging the locating member from the base; and

applying a flowable and curable filer to the hole, wherein the expanded support member provides a barrier to support said filter.