WALL REPAIR SYSTEM

Abstract

A wall repair system is disclosed. The wall repair system includes a patch and a rigid patch support having a proximal end and a distal end. The rigid patch support having a length substantially equal to the gap between a first inner surface and a second inner surface of the wall being repaired. The distal end has at least one wall engagement member capable of securing the distal end to second inner surface. The system also includes means for securing the patch to the proximal end of the rigid patch support.

Description

FIELD OF THE INVENTION

The present invention relates to repairing damaged walls, and more specifically to repairing damaged drywall walls, particularly drywall walls damaged by a door knob or similarly sized object.

DESCRIPTION OF THE RELATED ART

In the late 1940's the use of gypsum board panels, typically referred to as “sheetrock” or “drywall”, became the preferred building material for interior walls and partitions in most types of buildings in the United States, primarily because of the relatively low cost of material and installation. These panels are essentially made of a hardened plaster-like gypsum material which is sandwiched between sheets of paper or cardboard material. Sheetrock panels, which can by cut to size using only a utility knife, are typically nailed or screwed to spaced wooden studs or joists to provide a flat wall or ceiling surface which spans these wooden supporting members, leaving the space between the studs or joists hollow behind the wall surface. The surface of a sheetrock wall is typically finished by filling irregularities and indentations, such as those in the areas where nails or screws have been driven through the face of the panel. The slight gaps between panels are similarly filled and taped over using paper tape which is sufficiently wide to bridge the gap between panels and which is held in place by the filler material. The filler is “drywall compound,” a mud-like material which is smoothed into place and allowed to dry and harden. However, even the dried filler material has relatively little structural integrity and provides primarily the cosmetic benefit of a smooth wall or ceiling surface. The filler material by itself also has a tendency to shrink somewhat while drying and is therefore susceptible to cracking, particularly where it is used in large quantities or in thick layers.

Sheetrock panels installed in this manner serve well for interior use as walls and ceilings. A typical interior wall will have two external wall surfaces, each wall surface being the external surface of one of two parallel sheetrock panels which are spaced apart and secured to opposite sides of the wooden studs.

The primary drawback to using sheetrock material is that it is easily damaged by a sudden blow applied to a small area, such as that which may be caused by the protruding door knob of a swinging door. The material is also susceptible to being puncturing by sharp objects. Also, removal or relocation of an electrical outlet or switch box during remodeling may leave a hole that must be filled or covered.

A simple, easy to use and inexpensive method for repairing holes in sheetrock walls to restore the damaged or missing part of the wallboard, has eluded inventors, drywall professionals, handymen-homeowners, and building maintenance personnel, for as long as such materials have been in common use. Such repair can be relatively difficult, especially in the most common situation where the hole is located over the void between two wall studs and extends completely through the drywall into this void. In such a situation, and particularly if the hole is greater than about one (1) inch in diameter, the use of any semi-liquid or paste-like hardening filler material such as drywall compound, plaster, or spackling compound is generally not practical, since the void behind the hole provides no support for the filler, thus allowing the filler to fall through into the hollow space behind the hole. Additionally, there often exists an air pressure differential between the void inside the wall and the room. This air pressure differential can push the filler into or out of the hole. Previously, similar difficulties have arisen in connection with using a solid patching material such as a piece of wood or drywall since there has been no convenient way of both positioning the patch flush with the outer face of the wall surface and supporting it in place.

Over time, various methods and systems have been developed to attempt to repairs holes in drywall. One of the most common methods involves stuffing wadded up newspapers, cloths, or other similar items into the hole and then covering the hole with filler compound with the hope that the wadded up material will provide enough support for the filler compound to set and seal the hole. Another common method involves removing a large enough section of the damaged drywall to allow the patch to be nailed or screwed into the surrounding studs or joists.

Additionally, various U.S. patents have been issued on systems and methods of repairing damaged wallboard. For example, U.S. Pat. No. 3,936,988, discloses a repair device used to restore a damaged dry wallboard, wherein a 2.5 inch or larger hole is cut out from the damaged wall. A cut out piece of wallboard of slightly smaller dimensions than the hole is used to effect the restoration in conjunction with the repair device. The repair device consists of a wallboard support member that inserts through the hole to be secured onto the inside surface of a rear drywall. The cut out piece of wallboard is secured to the board support member. A plurality of clip members are affixed onto the cutout piece of wallboard, wherein the clip members engage an inside surface of the damaged wall board. The cut out piece of wallboard is recessed inward from the front face of the damaged drywall. A user plasters material into the recess and onto the cut out piece of wallboard. The clip members and board support member become an integral part of the restored wallboard.

Another example is found in U.S. Pat. No. 5,269,861, which discloses a structure and method for repairing a damaged section in a sheetrock wall or ceiling comprising removal of the damaged section by cutting out a specifically-sized section of the wall surrounding the damaged section, providing a like-size, tight-fitting replacement section in the cutout area, providing a combination of fabric strips impregnated with an unactivated fast-setting plaster or cementitious material, providing a water-based glue, coating the edges of the replacement section and the cutout area with the water-based glue, activating the cementitious material, positioning fabric strips on the back side of the replacement patch with ends of the strips extending beyond each edge of the replacement patch, inserting the replacement section of sheetrock into the cutout area and manipulating it into flush alignment with the wall surface by manually gripping the patch assembly using the extended portions of the plaster impregnated strips, flattening the extended portions of the strips against the wall surface, allowing the cementitious material and water-based glue to harden, and trimming away exposed portions of the strips on the wall surface, thus creating a securely bonded integral patched part of the sheetrock, which restores the panel to near its original strength and finish.

Unfortunately, each of these systems and methods do not provide sufficient support of the repaired area to resist being damaged again. As mentioned above, one of the common causes of damage to drywall is door knob strikes. Since it is more likely than not that the door knob will strike the repaired area again, the repaired area needs to be able to resist being damaged again. Using the methods and systems described above, the repaired area is weaker, not stronger, than the original undamaged wall in that area.

Accordingly, there remains a need for a wall repair system that adequately supports the patch and results in the repaired area being stronger than the original, undamaged wall in that area. There also remains a need for a wall repair system that provides sufficient support of the repaired area to resists being damaged again.

SUMMARY

In view of the deficiencies described above, it is an object of the present invention to provide a wall repair system that adequately supports the patch and results in the repaired area being stronger than the original, undamaged wall in that area.

It is a further object of the present invention to provide a wall repair system that provides sufficient support of the repaired area to resists being damaged again.

The present invention is a wall repair system. The wall repair system includes a patch and a rigid patch support having a proximal end and a distal end. The rigid patch support having a length substantially equal to the gap between a first inner surface and a second inner surface of the wall being repaired. The distal end has at least one wall engagement member capable of securing the distal end to second inner surface. The system also includes means for securing the patch to the proximal end of the rigid patch support.

Preferably, the patch is made from drywall having a desired shape for the patch. In various preferred embodiments, the patch is a substantially circular disc of drywall.

The wall engagement members can include at least one spike suitable for penetrating the second inner surface of the second wall portion of the wall being repaired and firmly securing the rigid patch support to the second inner surface.

The means for securing the patch to the proximal end of the rigid patch support can include a screw, such as a common drywall screw. In other various preferred embodiments, the patch can be secured to the proximal end of the rigid patch support with an adhesive.

The wall repair system of the present invention can be used according to the following process. First, the damaged section is cut out from the first wall portion, if needed, thus forming a hole in the first wall portion. Next, the rigid patch support is inserted into the hole and the distal end of the rigid patch support is secured to the second inner surface of the second wall portion using at least one wall engagement member. Now the patch is inserted into the hole and the patch is secured to the rigid patch support using any of the techniques described above. Lastly, the interface between the patch and the first wall portion is finished off.

Once installed, the wall repair system of the present invention is stronger than the original, undamaged, wall in the area of the repair. This result is achieved through the use of the rigid patch support to hold the patch in place and brace the patch against further impacts, a result not achieved by other wall repair systems.

Other features and advantages of the invention will be apparent from the following detailed description taken in conjunction with the following figures, wherein like reference numerals represent like features.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 shows a wall repair system according to the present invention.

FIG. 2 shows and alternate embodiment of a wall repair system according to the present invention.

FIGS. 3-7 show the process of repairing a damaged wall using a wall repair system according to the present invention.

FIG. 8 shows a side view of a completed wall repair using a wall repair system according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

While this invention is susceptible of embodiments in many different forms, there are shown in the drawings and will herein be described in detail, preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated.

The present invention is a wall repair system. The wall repair system of the present invention is best suited to repair a damaged section of a wall constructed using conventional construction techniques. Wall of this type are shown in FIGS. 3-8. Walls constructed using conventional construction techniques have a first wall portion 200, usually of drywall, which has a first outer surface 202 and a first inner surface 204. There is also a second wall portion 210, also usually of drywall, which has a second outer surface 212 and a second inner surface 214. A gap 225 exists between the first inner surface 204 and the second inner surface 214. The gap 225 is created by studs 220, which form the framework for the wall and onto which the first wall portion 200 and the second wall portion 210 are affixed. In the United States, studs 220, and thus the gap 225, typically are 3.5 inches wide.

The wall repair system, as shown in FIG. 1, includes a patch 100 and a rigid patch support 110 having a proximal end 112 and a distal end 114. The rigid patch support 110 having a length substantially equal to the gap 225 between the first inner surface 204 and the second inner surface 214. The distal end 114 has at least one wall engagement member 120 capable of securing the distal end 114 to second inner surface 214. The system also includes means for securing the patch 100 to the proximal end 112 of the rigid patch support 110. In various preferred embodiments, the length of rigid patch support 110 may be adjustable to account for variations in the thicknesses of the gap 225 and the first wall portion 200.

Preferably, the patch 100 is made from drywall having a desired shape for the patch 100. In various preferred embodiments, the patch 100 is a substantially circular disc of drywall. On other various preferred embodiments, the patch 100 can be rectangular, triangular, or square in shape, or can have any other desired shape.

The wall engagement member 120 or members 120 can include at least one spike suitable for penetrating the second inner surface 214 into the second wall portion 210 and firmly securing the rigid patch support 110 to the second inner surface 214. In various preferred embodiments, the wall engagement member 120 can include a screw 130, as shown in FIG. 2. Preferably screw 130 would be located along the centerline of the rigid patch support 110. In other various preferred embodiments, the wall engagement member 120 can be selectively removed from the rigid patch support, which, among other things, permits test fitting of the wall repair system.

The means for securing the patch 100 to the proximal end 112 of the rigid patch support 110 can include a screw 140, such as a common drywall screw. In various preferred embodiments, the patch 100 can include preformed hole 102 for receiving the screw 140. Also, the proximal end 112 of the rigid patch support 110 can have a hole 104 for receiving the screw 140. Optionally, screw 140 can be used as a handle for holding and or positioning the rigid patch support 110 during installation. In other various preferred embodiments, the patch 100 can be secured to the proximal end 112 of the rigid patch support 100 with an adhesive. Other securing means known in the art may also be used.

In various preferred embodiments, one or more layers of tape 105, cloth, or other similar material can be applied around the perimeter of the patch 100 to ensure a tight fit of the patch 100 into the hole 240. Additionally, this tape 105 can also seal any air gaps between the patch 100 and the hole 240 and thus prevent or minimize any effects on plaster or compound used to finish the wall repair caused by an air pressure differential between the gap 225 and the first outer surface 202.

The wall repair system of the present invention can be used according to the process shown in FIGS. 3-7. First, the damaged section 230 is cut out from the first wall portion 200, if needed, thus forming a hole 240 in the first wall portion 200. The patch 100 can be used as a template for tracing the perimeter of the patch 100 to indicate where to cut out the damaged section 230. This insures that the hole 240 will be substantially the same size and shape as the patch 100, which will further facilitate fitting the patch 100 into the hole 240 later on.

Next, the rigid patch support 110 is inserted into the hole 240 and the distal end 114 of the rigid patch support 110 is secured to the second inner surface 214 of the second wall portion 210 using at least one wall engagement member 120. If needed, the length of the rigid patch support 110 may be adjusted.

Now the patch 100 is inserted into the hole 240 and the patch 100 is secured to the rigid patch support 110 using any of the techniques described above. In various preferred embodiments, any air gaps between the patch 100 and the hole 240 can be sealed with one or more layers of tape 105, cloth, or similar material wrapped around the perimeter of the patch 100.

Lastly, the interface between the patch 100 and the first wall portion 200 is finished off. This can be accomplished by using joint or filling compound to seal the perimeter of the patch 100 to the edge of the hole 240 and sealing any openings between the two. Once dried, sanded, painted or otherwise finished, the repaired area should be indistinguishable from the remainder of the first wall portion 200.

Once installed, the wall repair system of the present invention is stronger than the original, undamaged, wall in the area of the repair. This result is achieved through the use of the rigid patch support 110 to hold the patch 100 in place and brace the patch against further impacts, a result not achieved by other wall repair systems.

While specific embodiments have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the invention and the scope of protection is limited by the scope of the accompanying claims.

Claims

1. A wall repair system for a wall comprising a first wall portion having a first outer surface and a first inner surface and a second wall portion having a second outer surface and a second inner surface, wherein a gap exists between said first inner surface and said second inner surface, and wherein a damaged section exists in said first wall portion, said wall repair system comprising:

a patch,

a rigid patch support having a proximal end and a distal end, said rigid patch support having a length substantially equal to said gap between said first inner surface and said second inner surface,

wherein said distal end has at least one wall engagement member capable of securing said distal end to said second inner surface, and

means for securing said patch to said proximal end of said rigid patch support.

2. The wall repair system according to claim 1, wherein a length of said rigid patch support is adjustable.

3. The wall repair system according to claim 1, wherein said patch comprises drywall in a desired shape.

4. The wall repair system according to claim 1, wherein said patch comprises a substantially circular disc of drywall.

5. The wall repair system according to claim 1, wherein said at least one wall engagement member comprises at least one spike.

6. The wall repair system according to claim 1, wherein said at least one wall engagement member comprises at least one screw.

7. The wall repair system according to claim 1, wherein said means for securing said patch to said proximal end of said rigid patch support comprises a screw.

8. The wall repair system according to claim 7, wherein said patch comprises a hole for receiving said screw.

9. The wall repair system according to claim 7, wherein said proximal end of said rigid patch support comprises a hole for receiving said screw.

10. The wall repair system according to claim 8, wherein said proximal end of said rigid patch support comprises a hole for receiving said screw.

11. The wall repair system according to claim 1, wherein said means for securing said patch to said proximal end of said rigid patch support comprises an adhesive.

12. The wall repair system according to claim 1, further comprising sealing means for wrapping around a perimeter of said patch.

13. The wall repair system according to claim 12, wherein said sealing means comprises tape.

14. The wall repair system according to claim 12, wherein said sealing means comprises cloth.

15. A method of repairing a damaged section of a wall comprising a first wall portion having a first outer surface and a first inner surface and a second wall portion having a second outer surface and a second inner surface, wherein a gap exists between said first inner surface and said second inner surface, and wherein said damaged section exists in said first wall portion, said method comprising the steps of:

cutting said damaged section from said first wall portion, forming a hole in said first wall portion,

inserting a rigid patch support into said hole, wherein said rigid patch support has a proximal end and a distal end, said rigid patch support having a length substantially equal to said gap between said first inner surface and said second inner surface,

securing said rigid patch support to said second inner surface of said second wall portion,

inserting said patch into said hole,

securing said patch to said rigid patch support, and

finishing an interface between said patch and said first wall portion.

16. The method of repairing a damaged section of a wall according to claim 15, further comprising using said patch as a template, tracing a perimeter of said patch to mark a location for said hole prior to cutting said damaged section from said first wall portion.

17. The method of repairing a damaged section of a wall according to claim 15, wherein securing said patch to said rigid patch support comprises securing said patch to said rigid patch support with a screw.

18. The method of repairing a damaged section of a wall according to claim 15, wherein securing said patch to said rigid patch support comprises securing said patch to said rigid patch support with an adhesive.

19. The method of repairing a damaged section of wall according to claim 15 further comprising sealing any air gaps between said patch and said hole via wrapping a perimeter of said patch with a sealing means.

20. The method of repairing a damaged section of wall according to claim 19, wherein said sealing means comprises tape.