U.S. patent application number 11/184471 was filed with the patent office on 2006-01-19 for drywall patch kit.
Invention is credited to Jack R. Shull.
Application Number | 20060010817 11/184471 |
Document ID | / |
Family ID | 35597951 |
Filed Date | 2006-01-19 |
United States Patent
Application |
20060010817 |
Kind Code |
A1 |
Shull; Jack R. |
January 19, 2006 |
Drywall patch kit
Abstract
A kit for repairing holes in drywall having two principal
components, a patch itself and a moistening device for attaching
the patch to the surface upon which the patch is intended to be
placed. The patch containing an inner portion configured for
insertion within an opening and an outer portion configured to
attach and connect with the wall upon which the patch is placed.
The moistening device, preferably a form of spray on texture
provides a means for adhering the patch to the surface upon which
it is placed and also provides a means for covering the patch so as
to blend with the surrounding surfaces.
Inventors: |
Shull; Jack R.; (Star,
ID) |
Correspondence
Address: |
DEREK H. MAUGHAN;DYKAS, SHAVER & NIPPER, LLP
PO BOX 877
BOISE
ID
83701-0877
US
|
Family ID: |
35597951 |
Appl. No.: |
11/184471 |
Filed: |
July 19, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60589405 |
Jul 19, 2004 |
|
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Current U.S.
Class: |
52/514 ;
52/742.1 |
Current CPC
Class: |
E04G 23/0203 20130101;
E04G 23/0207 20130101 |
Class at
Publication: |
052/514 ;
052/742.1 |
International
Class: |
E02D 37/00 20060101
E02D037/00 |
Claims
1. A drywall repair kit, said kit comprising: a patch, said patch
comprised of a base, said base having an outer periphery and an
elevated inner portion, said elevated inner portion extending
generally upward from said base, said elevated portion configured
to have the same general thickness of the wall into which the patch
is to be placed; a pattern, said pattern having an outer ring
configured to have the same general dimensions as said outer
periphery of said base, said outer ring defining an aperture, said
aperture configured to receive said elevated inner portion of said
patch therein; a moistening agent said moistening agent configured
to provide moisture to said outer periphery of said base so as to
adhere said outer periphery to a surface being repaired.
2. The drywall repair kit of claim 1 wherein said moisturizing
agent is an adhesive texturing component.
3. The drywall repair kit of claim 1 wherein said moisturizing
agent is sprayed on.
4. The drywall repair kit of claim 1 further comprising painting
materials.
5. The drywall repair kit of claim 1 further comprising a cutting
device for cutting a hole having the same dimensions as the
aperture portion of said template.
6. A method for patching a hole in a drywall surface, utilizing a
kit, said kit comprised of a patch, said patch having a base, said
base having an outer periphery and an inner portion, said inner
portion integrally connected to a filler portion, said filler
portion extending generally upward from said inner portion of said
base, said filler portion configured to have the same general
thickness of the wall into which the patch is to be placed; and a
frame, said frame having an outer ring configured to have the same
general dimensions as said outer periphery of said base, said outer
ring defining an aperture, said aperture configured to receive said
filler portion therein, said method comprising the steps of:
placing said frame upon said drywall surface in a position wherein
the aperture completely surrounds the area to be patched; tracing
the outline of the aperture in this location; cutting the drywall
along the traced outline to form a desired opening; placing the
inner portion of the patch into the desired opening; and adhering
the base to the drywall.
Description
PRIORITY
[0001] This application is a non-provisional application which
claims the priority date from the provisional application entitled
DRYWALL PATCH KIT filed by Jack R. Shull on Jul. 19, 2004 with
application Ser. No. 60/589,405, the disclosure of which is
incorporated by reference.
DESCRIPTION OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention generally refers to methods and
devices for performing home repairs and more particularly for
methods and devices for repairing and patching drywall.
[0004] 2. Background Information
[0005] Many modern structures include gypsum panels or drywall as a
component for forming walls in which insulation, wiring and other
items are stored. An example of such a device is sold by the USG
Corporation under the trade name SHEETROCK.TM.. Gypsum panels are
smoother, more sound proof and more economically accessible than
other types of wall coverings. In addition, this material after
placement, can be prepared, textured and painted so as to provide
wall and ceiling surfaces that are aesthetically pleasing. While
this material provides various advantages, there are also various
disadvantages to this material.
[0006] One of these problems arises when a strong force is placed
against the wall. Gypsum panels can be broken easily, and when it
is broken, the wall from which the gypsum panel is made can have a
large hole. Another problem that exists is that when gypsum panels
get wet the wall can deform and bend. When these and other
instances occur, the gypsum panels must be repaired. Gypsum panels
can be repaired in various ways, however; typically repairing one
of these panels includes cutting sections from a wall in such a way
that a stud can be accessed and then replacing the entire section
by replacing another section of gypsum panel in that location. This
method of repair can be time consuming and costly as areas that are
significantly larger than the hole that needs to be repaired must
be removed so as to accommodate the replacement portion.
[0007] In the past a variety of different devices and methods have
been utilized to attempt to improve and ease this problem. One
method and device is taught in U.S. Pat. No. 4,620,407. This device
teaches the use of a template having saw guides or diagonal slots.
This template is used to cut out portions of the damaged wall
portion and to cut new sections of drywall which have sloped sides
and which sit within the wall itself. The problem that this device
creates is that seams or gaps are left at the margins where the
patch is fitted into the wall. While this may be patched with
plaster or another compound, this plaster must be allowed to dry,
after which the patch must be sanded and leveled and textured to
approximate the surface of the wall in which the patch has been
placed. In many of these instances, these patches are still
noticeable several years after they have been put into place
because of the differences in textures. This same problem is also
associated with a variety of other types of patching methods and
systems wherein the patching systems which are utilized produce
patches which fit improperly or which require substantial
additional measures such as plastering and sanding in order to fill
the gaps in which the devices are placed.
[0008] The present invention solves this problem by providing a
patch kit that is simple and easy to use, and allows a user to
simply, easily and efficiently repair and replace portions of a
damaged gypsum wallboard. While the present invention is described
in the context of a drywall repair kit, it is to be distinctly
understood that the invention may be variously embodied for use
with other types of material, and to incorporate a variety of other
modifications and other novel features.
[0009] Additional objects, advantages and novel features of the
invention will be set forth in part in the description which
follows and in part will become apparent to those skilled in the
art upon examination of the following or may be learned by practice
of the invention. The objects and advantages of the invention may
be realized and attained by means of the instrumentalities and
combinations particularly pointed out in the appended claims.
SUMMARY OF THE INVENTION
[0010] The present invention is a kit for repairing holes in
drywall. The kit is made up of two principal components, however,
it is to be distinctly understood that a variety of other accessory
components and pieces can also be included within the kit of the
present invention and are contemplated within the scope of the
invention. The principal pieces of the kit of the present invention
are the patch itself and the spray on texturing material which is
sold with the patches. In the preferred embodiment of the invention
the device is utilized together with a spray on texturing product
which allows the patch to obtain the same texture as the wall in
which the patch is placed.
[0011] The patch portion of the present invention is made up of a
patch that contains an outer portion and an inner portion. The
outer portion is comprised of a thin piece of material such as the
backing portion of the material which is attached to the gypsum
drywall. The inner portion contains a portion of drywall having a
desired thickness. In the preferred embodiment of the invention
these patches are held within a frame which protects the patch from
damage. This frame can also be utilized to serve as a pattern for
cutting the hole in the wall board that is to be replaced so as to
further increase the ease of use of the invention.
[0012] To use the present invention the area that is to be repaired
is prepared. This is done by finding the size of the opening that
is to be repaired and selecting the patch of the appropriate size.
A variety of different sized patches may be made according to the
needs of the user. Once the size of the patch that is to be used
has been selected, the opening around the hole that is to be
patched is enlarged sufficiently so as to receive the preselected
patch therein. Once this opening has been enlarged, the areas
surrounding the patch are preferably sanded so as to remove a layer
of material from the wall approximately as thick as the backing
layer of the patch. Once these steps have been performed the patch
is simply placed within the cut out opening, and the edges of the
devices are wetted so as to form these items against the wall
itself. In the preferred embodiment the can of spray texture
provides sufficient moisture so as to adhere the outer portions of
the patch to the surface upon which the device is placed. In
addition, the spray on texture which is utilized in the present
embodiment also contains a texture material which can be splattered
in place or smoothed over so as to match the surfaces of the other
surrounding walls. Once dried this material can then be painted
according to the needs and necessities of the user.
[0013] The present invention presents a substantial advantage over
the prior art in that this invention enables a party to obtain a
substantially superior result in patching holes in drywall as
compared to the other devices, products and methods which exist in
the prior art.
[0014] The purpose of the foregoing Abstract is to enable the
United States Patent and Trademark Office and the public generally,
and especially the scientists, engineers, and practitioners in the
art who are not familiar with patent or legal terms or phraseology,
to determine quickly from a cursory inspection, the nature and
essence of the technical disclosure of the application. The
Abstract is neither intended to define the invention of the
application, which is measured by the claims, nor is it intended to
be limiting as to the scope of the invention in any way.
[0015] Still other objects and advantages of the present invention
will become readily apparent to those skilled in this art from the
following detailed description wherein I have shown and described
only the preferred embodiment of the invention, simply by way of
illustration of the best mode contemplated by carrying out my
invention. As will be realized, the invention is capable of
modification in various obvious respects all without departing from
the invention. Accordingly, the drawings and description of the
preferred embodiment are to be regarded as illustrative in nature,
and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 shows an assembly view of the items of the present
preferred embodiment of the invention.
[0017] FIG. 2 shows a hole in a wall.
[0018] FIG. 3 shows the use of the pattern of the present invention
being utilized to remove the portion of wall that is to be repaired
so as to allow placement of the patch in the opening.
[0019] FIG. 4 shows the patch of the present invention ready for
placement within the aperture which has been opened and prepared
for use of the patch.
[0020] FIG. 5 shows the patch of the present invention in place
upon a surface that has been prepared.
[0021] FIG. 6 shows a detailed side view of the patch of the
present invention in place upon a surface.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] While the invention is susceptible of various modifications
and alternative constructions, certain illustrated embodiments
thereof have been shown in the drawings and will be described below
in detail. It should be understood, however, that there is no
intention to limit the invention to the specific form disclosed,
but, on the contrary, the invention is to cover all modifications,
alternative constructions, and equivalents falling within the
spirit and scope of the invention as defined in the claims.
[0023] FIGS. 1-6 show the present invention and the method of using
the present invention to patch holes in drywall. Referring first to
FIG. 1, the system of the present invention includes a patch 10.
This patch 10 is made up of a base 12 which is generally flat in
nature and is preferably made of the same material that is
connected to the back portion drywall. Typically this is paper or a
thin cardboard type of material, however this material is modified
according to the needs and necessities of the user. A generally
centrally located elevated inner portion 16 is located upon the
base and defines an outer periphery 16 around the base 12 itself.
In the preferred embodiment of the invention the elevated portion
of the invention is configured to have a pre-selected thickness
equal to the thickness of the gypsum panel that is to be replaced.
The exact thickness of the sheetrock that is to be replaced varies
according to location, local building codes and other factors.
However, for purposes of the preferred embodiment, the thickness of
the extended portion is made from a one half (1/2) inch thick
gypsum panel. While in the preferred embodiment the elevated
portion 16 of the patch 12 has a thickness of one half inch, it is
to be distinctly understood that the invention is not limited
thereto but may be of any thickness including the standard
thickness 1/2'', 5/8'' and 3/4''.
[0024] The patch portion 10 has an outer periphery 14 that is
significantly thinner than the elevated portion 16. The patch 10 is
configured for storage and sale with a frame 18 which can also
serve as a pattern for opening holes of the appropriate size within
the surface to be repaired. The frame or pattern 18 is configured
to lie over the patch so as to form one generally square unit. The
frame 18 preferably corresponds in shape to the perimeter portions
of the patch and defines an aperture 22, which is dimensioned to
have the same dimensions as the elevated portion 16 of the patch
10. When not in use, the two pieces 10, 18 may be placed together
so as to form a single piece. This configuration provides support
for the patch 10 and prevents the patch 10 and the frame 18 from
being broken.
[0025] The invention also includes a moistening agent 24. In the
preferred embodiment of the invention this moistening agent is
texturing material, preferably the kind that is sprayed on to a
surface. In this kit embodiment, this device is a can of premixed
spray which can be utilized to spray and cover a surface. This
material acts to wet the base 12 and cause the base or backing 12
to adhere to the surface upon which the patch 10 of the present
invention is being used. In addition to these materials various
other embodiments of the kits may include other materials such as a
knife, small saw or other cutting device 27 as well as paint 26 in
various packaged forms.
[0026] To use the present invention, the area that is to be
repaired must first be prepared. This is usually done by finding
the size of the opening that is to be repaired and selecting the
patch 10 of the appropriate size. A variety of different sized
patches 10 may be made according to the needs of the user. Once the
size of the patch 10 that is to be used has been selected, the
opening around the hole that is to be patched is enlarged
sufficiently so as to receive the preselected patch 10 therein.
Once this opening has been enlarged, the areas surrounding the
patch 10 are preferably sanded so as to remove a layer of material
from the wall approximately as thick as the backing layer 12 of the
patch 10. Once these steps have been performed the patch 10 is
simply placed within the cut out opening, and the outer periphery
14 of the devices are wetted so as to form these items against the
wall itself. In the preferred embodiment the can of spray texture
24 provides sufficient moisture so as to adhere the outer portions
of the patch to the surface upon which the device is placed. In
addition, the spray on texture which is utilized in the present
embodiment also contains a texture material which can be splattered
in place or smoothed over so as to match the surfaces of the other
surrounding walls. Once dried, this material can then be painted
according to the needs and necessities of the user.
[0027] The present invention presents a substantial advantage over
the prior art in that this invention enables a party to obtain a
substantially superior result in patching holes in drywall as
compared to the other devices, products and methods which exist in
the prior art.
[0028] Once the patch has been inserted within the wall, and the
patch and the wall have sufficiently bonded together, the patched
portion of the wall surface may be finished in a conventional
manner by applying texture and/or paint to these surfaces so as to
form and correct these surfaces in such a way that the patch and
the wall into which the patch has been inserted appear as a unified
whole. To assist a user in bringing this result, various items may
also be sold with the patch and pattern as a part of a patching
kit. Examples of items that might be utilized include, but are not
limited to, spray texture, adhesive, paint, knives for cutting,
pencils for marking and other items that a user might find useful
in the application of such a device as long as the device provides
sufficient moisture so as to allow the outer peripheral portion of
the patch to adhere to wall surface against which the peripheral is
placed.
[0029] While there is shown and described the present preferred
embodiment of the invention, it is to be distinctly understood that
this invention is not limited thereto but may be variously embodied
to practice within the scope of the following claims. From the
foregoing description, it will be apparent that various changes may
be made without departing from the spirit and scope of the
invention as defined by the following claims.
* * * * *