U.S. patent application number 15/071351 was filed with the patent office on 2016-09-22 for drywall repair kit and method.
The applicant listed for this patent is AC (Macao Commercial Offshore) Limited. Invention is credited to Richard M. Davidian, Lauren Spratte.
Application Number | 20160273235 15/071351 |
Document ID | / |
Family ID | 56896910 |
Filed Date | 2016-09-22 |
United States Patent
Application |
20160273235 |
Kind Code |
A1 |
Davidian; Richard M. ; et
al. |
September 22, 2016 |
DRYWALL REPAIR KIT AND METHOD
Abstract
A repair kit for repairing a damaged area of a workpiece,
includes an arbor having an abutment surface, and a cutting member
removably coupled to the arbor. The cutting member has a sidewall
with a first end and a second end, an end cap coupled to the first
end of the side wall and abutting the abutment surface of the
arbor, a plurality of cutting elements coupled to the second end of
the sidewall, and a retention feature defined by the sidewall. The
cutting member is rotatable by the arbor to cut a hole in the
workpiece. The retention feature is configured to engage the
workpiece as the cutting member cuts the hole to secure the cutting
member within the hole.
Inventors: |
Davidian; Richard M.;
(Pickens, SC) ; Spratte; Lauren; (Decatur,
GA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
AC (Macao Commercial Offshore) Limited |
Macau |
|
MO |
|
|
Family ID: |
56896910 |
Appl. No.: |
15/071351 |
Filed: |
March 16, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62133795 |
Mar 16, 2015 |
|
|
|
62256379 |
Nov 17, 2015 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B23B 2251/60 20130101;
B23B 51/0426 20130101; B23B 2226/57 20130101; E04G 23/0207
20130101 |
International
Class: |
E04G 23/02 20060101
E04G023/02; B23B 51/04 20060101 B23B051/04 |
Claims
1. A repair kit for repairing a damaged area of a workpiece, the
repair kit comprising: an arbor having an abutment surface; and a
cutting member removably coupled to the arbor, the cutting member
including a side wall having a first end and a second end, an end
cap coupled to the first end of the side wall and abutting the
abutment surface of the arbor, a plurality of cutting elements
coupled to the second end of the side wall, and a retention feature
defined by the side wall, the cutting member being rotatable by the
arbor to cut a hole in the workpiece, wherein the retention feature
is configured to engage the workpiece as the cutting member cuts
the hole to secure the cutting member within the hole.
2. The repair kit of claim 1, wherein the retention feature
includes a thread that extends circumferentially around the side
wall.
3. The repair kit of claim 2, wherein the thread is positioned
closer to the first end of the side wall than to the second end of
the side wall
4. The repair kit of claim 1, wherein the cutting member defines a
plurality of drive apertures in the end cap, wherein the arbor
includes a plurality of drive protrusions extending from the
abutment surface, and wherein the plurality of drive apertures
receives the plurality of drive protrusions such that the arbor
rotationally drives the cutting member.
5. The repair kit of claim 1, wherein the arbor includes a grip
extending from a surface of the arbor opposite the abutment surface
for manually turning the arbor.
6. The repair kit of claim 1, further comprising a pilot drill bit
coupled to the arbor, wherein the pilot drill bit extends from the
abutment surface along a central axis of the arbor, and wherein the
end cap of the cutting member defines a central aperture that
provides clearance for the pilot drill bit.
7. The repair kit of claim 1, wherein the abutment surface of the
arbor extends radially beyond the end cap of the cutting member to
form a lip.
8. The repair kit of claim 1, further comprising a guide member
couplable to the workpiece over the damaged area, wherein the guide
member is sized to be received within a cavity defined by the side
wall of the cutting member.
9. The repair kit of claim 8, wherein the guide member includes a
central projection that extends axially away from the end cap of
the cutting member, and wherein the central projection is pressable
into the workpiece to connect the guide member to the
workpiece.
10. The repair kit of claim 9, further comprising a pilot drill bit
coupled to the arbor, wherein the pilot drill bit extends from the
abutment surface along a central axis of the arbor, and wherein the
central projection of the guide member defines an aperture that
provides clearance for the pilot drill bit.
11. A method for repairing a damaged area of a workpiece with a
repair kit including an arbor and a cutting member removably
coupled to the arbor, the arbor having an abutment surface, the
cutting member having a side wall, an end cap coupled to a first
end of the side wall and abutting the abutment surface of the
arbor, and a plurality of cutting elements coupled to a second end
of the side wall, the method comprising: rotating the arbor to
drive the cutting member about a central axis of the arbor; cutting
a hole in the workpiece with the cutting member; engaging the
workpiece with the cutting member as the hole is cut to secure the
cutting member within the hole; disconnecting the arbor from the
cutting member; and leaving the cutting member in the workpiece to
plug the hole.
12. The method of claim 11, wherein the abutment surface of the
arbor extends radially beyond the end cap of the cutting member to
form a lip, and wherein cutting the hole includes driving the
cutting member axially into the workpiece until the lip engages the
workpiece.
13. The method of claim 11, wherein the cutting member defines a
plurality of drive apertures in the end cap, wherein the arbor
includes a plurality of drive protrusions extending from the
abutment surface, wherein rotating the arbor to drive the cutting
member includes receiving the plurality of drive protrusions in the
plurality of drive apertures, and wherein disconnecting the arbor
from the cutting member includes withdrawing the plurality of
driving protrusions from the plurality of drive apertures.
14. The method of claim 11, wherein the cutting member includes a
thread extending circumferentially around the side wall, and
wherein engaging the workpiece with the cutting member includes
engaging with the workpiece with the thread as the cutting member
cuts the hole.
15. The method of claim 11, further comprising: applying spackle
over the hole and the cutting member to create a spackled area;
sanding the spackled area to be flush with an adjacent surface of
the workpiece; and applying a coating to the spackled area of the
workpiece.
16. The method of claim 11, further comprising: selecting a guide
member sized to sufficiently cover the damaged area of the
workpiece; positioning the guide member over the damaged area; and
guiding the cutting member to cut the hole at the damaged area of
the workpiece using the guide member.
17. The method of claim 16, wherein guiding the cutting member
includes receiving the guide member within a cavity defined by the
side wall of the cutting member.
18. The method of claim 16, wherein the guide member includes a
central projection that extends axially away from the end cap of
the cutting member, and wherein positioning the guide member over
the damaged area includes pressing the central projection into the
workpiece.
19. A plug for plugging a hole in a workpiece, the plug comprising:
a flat disc-shaped body having a plane and a central axis
perpendicular to the plane; a plurality of resilient members, each
of the resilient members at least partially formed by a slot
defined in the body and extending from an outer circumference of
the body toward the central axis; and a gripping tooth extending
from each of the resilient members at the outer circumference of
the body, wherein each of the resilient members is movable from an
original position to a deflected position when a force is applied
to allow the plug to be inserted into the hole, and wherein the
resilient members return to the original position when the force is
removed such that the gripping teeth engage the workpiece to secure
the plug within the hole.
20. The plug of claim 19, wherein each of the plurality of
resilient members is flexed radially inward towards the central
axis when the force is applied to reduce a diameter of the
body.
21. The plug of claim 19, wherein the slot associated with each
resilient member has a first portion that extends from the outer
circumference towards the central axis and a second portion that
extends from the first portion towards the outer circumference to
define an L-shaped slot.
22. The plug of claim 19, wherein each of the plurality of
resilient members is flexed out of the plane when the force is
applied.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent
Application No. 62/133,795, filed on Mar. 16, 2015; and U.S.
Provisional Patent Application No. 62/256,379, filed on Nov. 17,
2015, the entire contents of all of which are incorporated by
reference herein.
FIELD OF INVENTION
[0002] The present invention relates to drywall repair kits and,
more particularly, to drywall repair kits including hole saws.
BACKGROUND
[0003] Hole saws are typically used to cut large holes in drywall,
wood, plastic or a similar material that would be otherwise
difficult for a drill bit. Hole saws cut circular holes in
workpieces, resulting in plugs. Therefore, hole saws can cut larger
holes that would otherwise be difficult for a drill bit. A hole saw
is sometimes used to cut a hole in drywall where damage has
occurred. After the hole is cut, a separate preformed plug similar
in diameter to the hole saw may be inserted into the hole and
plastered over in order to repair the drywall.
SUMMARY
[0004] The present invention provides, in one aspect, a repair kit
for repairing a damaged area of a workpiece. The repair kit
includes an arbor having an abutment surface, and a cutting member
removably coupled to the arbor. The cutting member includes a side
wall having a first end and a second end, an end cap coupled to the
first end of the side wall and abutting the abutment surface of the
arbor, a plurality of cutting elements coupled to the second end of
the side wall, and a retention feature defined by the side wall.
The cutting member is rotatable by the arbor to cut a hole in the
workpiece. The retention feature is configured to engage the
workpiece as the cutting member cuts the hole to secure the cutting
member within the hole.
[0005] The present invention provides, in another aspect, a method
for repairing a damaged area of a workpiece with a repair kit that
includes an arbor and a cutting member removably coupled to the
arbor. The arbor has an abutment surface. The cutting member has a
side wall, an end cap coupled to a first end of the side wall and
abutting the abutment surface of the arbor, and a plurality of
cutting element coupled to a second end of the side wall. The
method includes rotating the arbor to drive the cutting member
about a central axis of the arbor, cutting a hole in the workpiece
with the cutting member, and engaging the workpiece with the
cutting member as the hole is cut to secure the cutting member
within the hole. The method further includes disconnecting the
arbor from the cutting member, and leaving the cutting member in
the workpiece to plug the hole.
[0006] The present invention provides, in yet another aspect, a
plug for plugging a hole in a workpiece. The plug includes a flat
disc-shaped body having a plane and a central axis perpendicular to
the plane, and a plurality of resilient members. Each of the
resilient members is at least partially formed by a slot defined in
the body that extends from an outer circumference of the body
toward the central axis. The plug further includes a gripping tooth
extending from each of the resilient members at the outer
circumference of the body. Each of the resilient members is movable
from an original position to a deflected position when a force is
applied to allow the plug to be inserted into the hole. The
resilient members return to the original position when the force is
removed such that the gripping teeth engage the workpiece to secure
the plug within the hole.
[0007] Other features and aspects of the invention will become
apparent by consideration of the following detailed description and
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a perspective view of a drywall repair kit in
accordance with an embodiment of the invention, the drywall repair
kit including a hole saw assembly and a guide member.
[0009] FIG. 2 is an exploded perspective of the drywall repair kit
of FIG. 1.
[0010] FIG. 3 is a perspective view of an arbor of the hole saw
assembly of FIG. 1.
[0011] FIG. 4 is a perspective view of a cutting member of the hole
saw assembly of FIG. 1.
[0012] FIG. 5 is a perspective view of the guide member of FIG.
1.
[0013] FIG. 6 illustrates a method of repairing a damaged portion
of drywall using the drywall repair kit of FIG. 1.
[0014] FIG. 7 is a perspective view of a drywall repair kit in
accordance with another embodiment of the invention, the drywall
repair kit including a hole saw assembly and a guide member.
[0015] FIG. 8 is an exploded perspective view of the drywall repair
kit of FIG. 7.
[0016] FIG. 9 is another exploded perspective view of the drywall
repair kit of FIG. 7.
[0017] FIG. 10 is a perspective view of an auxiliary plug.
[0018] FIG. 11 is another perspective view of the auxiliary plug of
FIG. 10.
[0019] FIG. 12 is a perspective view of an auxiliary plug in
accordance with another embodiment of the invention.
[0020] Before any embodiments of the invention are explained in
detail, it is to be understood that the invention is not limited in
its application to the details of construction and the arrangement
of components set forth in the following description or illustrated
in the following drawings. The invention is capable of other
embodiments and of being practiced or of being carried out in
various ways. Also, it is to be understood that the phraseology and
terminology used herein is for the purpose of description and
should not be regarded as limiting.
DETAILED DESCRIPTION
[0021] FIGS. 1-2 illustrate a drywall repair kit 10 for repairing a
punctured hole or damaged area of a workpiece (e.g., drywall). The
illustrated kit 10 includes a cutting assembly or hole saw assembly
14 and a guide member 18. The assembly 14 includes an arbor 22, a
pilot drill bit 26, and a cutting member 30. The arbor 22 and the
pilot drill bit 26 are couplable to a drill (not shown) for
rotation about an axis of rotation A. In some embodiments, the
arbor 22 and the pilot drill bit 26 may be coupled to the drill via
a chuck. The drill may be a power drill, a manually turned rotary
hand drill or any similar tool capable of transferring rotational
power to the arbor 22. The cutting member 30, or hole saw, is
removably coupled to the arbor 22 and is driven by the arbor 22 to
cut a circular hole out of the drywall around the damaged area. The
cutting member 30 also acts as a plug and remains in the circular
hole when the arbor 22 and the drill are disconnected.
[0022] With reference to FIGS. 2-3, the arbor 22 includes a back
piece 34 having an abutment face 42. The arbor 22 also defines a
bore 38 extending through the back piece 34. The bore 38 is
concentric with the axis A. The arbor 22 has drive protrusions 46
that extend outwardly from the abutment face 42 parallel to the
axis A. In the illustrated embodiment, there are four drive
protrusions 46 that are equally spaced circumferentially around the
bore 38 about the axis A. The pilot drill bit 26 is received within
the bore 38 of the arbor 22 and extends outwardly from the abutment
face 42 along the axis A. In alternate embodiments, the arbor 22
and the pilot drill bit 26 may be formed as one piece, and fewer or
more drive protrusions 46 may be used.
[0023] The arbor 22 also includes a pair of projections 50
extending from a rear surface 44 of the back piece 34 opposite the
abutment face 42. The projections 50 are configured to be manually
grasped and turned about the axis A in the absence of a drill or
other driving tools. In the illustrated embodiment, the projections
50 include two crescent-shaped projections extending radially
outward from the bore 38. The projections 50 are circumferentially
spaced apart 180 degrees about the axis A. In other embodiments,
the arbor 22 may include other projection configurations that form
grips for manually turning the hole saw assembly 14.
[0024] With reference to FIGS. 2 and 4, the cutting member 30
includes an annular side wall 54 and an end cap or back wall 58.
The annular wall 54 extends from the back wall 58 at a first,
proximal end 62 to a second, distal end 66. In some embodiments,
the annular wall 54 tapers inwardly toward the axis A from the
first, proximal end 62 to the second, distal end 66. The back wall
58 and the annular wall 54 define a cavity 70. The second end 66 of
the annular wall 54 has a series of cutting teeth 74. The annular
wall 54 also defines four slots 78 that are equally spaced
circumferentially around the annular wall 54. The teeth 74 and the
slots 78 are cutting elements that allow the cutting member 30 to
function like a conventional hole saw.
[0025] The illustrated annular wall 54 also defines a retention
feature 82. In the illustrated embodiment the retention feature 82
includes grooves or threads 82 extending circumferentially around
the annular wall 54. The threads 82 are configured to engage the
drywall as the cutting member 30 cuts into the drywall, thereby
securing and retaining the cutting member 30 within the circular
hole cut by the cutting member 30 so that the arbor 22 may be
disconnected and removed. In the illustrated embodiment, the
threads 82 are positioned closer to the first end 62 of the annular
wall 54 than to the second end 66. In some embodiments, the threads
82 may be replaced with any projection extending outwardly from the
annular wall 54 to engage the drywall and secure the cutting member
30 within the circular hole cut by the cutting member 30.
[0026] The back wall 58 defines a central aperture 86 sized to
receive the pilot drill bit 26. The back wall 58 also defines drive
apertures 90 equally spaced around the central aperture 86 and
corresponding to the drive protrusions 46 of the arbor 22. The
drive apertures 90 are configured to receive the drive protrusions
46 (as shown in FIG. 1). In alternate embodiments, the drive
apertures 90 and the drive protrusions 46 may be spaced radially
farther from the axis A (i.e., closer to the outer diameter of the
back wall 58), as shown in FIGS. 7-9. In further alternate
embodiments, the drive apertures 90 and the drive protrusions 46
may be arranged in any configuration or pattern. In further
alternate embodiments, the drive apertures 90 may be blind
recesses. In further alternate embodiments, the drive protrusions
46 may be located on the cutting member 30, and the drive apertures
90 may be located on the arbor 22. In addition, the illustrated
back wall 58 defines through holes 94 spaced around the central
aperture 86. The through holes 94 help retain a joint or surfacing
compound (e.g., spackle), applied over the circular hole cut out of
the drywall and on the back wall 58 of the cutting member 30.
[0027] As previously mentioned, the arbor 22 is coupled to a drill
for rotation about the axis A, and the cutting member 30 is
removably coupled to the arbor 22. As shown in FIGS. 1-2, the
central aperture 86 and the drive apertures 90 of the cutting
member 30 receive the drill bit 26 and the drive protrusions 46 of
the arbor 22 so that the cutting member 30 is coaxial with the axis
A of the arbor 22. Additionally, the back wall 58 of the cutting
member 30 abuts the abutment face 42 of the back piece 34. The back
piece 34 extends radially outward past the annular wall 54 of the
cutting member 30, such that the abutment face 42 of creates an
annular flange or lip 96 (FIG. 1) that inhibits the cutting member
30 from being driven too deep into the drywall while cutting. The
drive protrusions 46 engage the drive apertures 90 of the cutting
member 30 as the arbor 22 is rotated by the drill, thus driving the
cutting member 30 about the axis A. The cutting member 30 is held
in engagement with the drive protrusions 46 as force is applied
along the axis A in a direction of arrow F (FIG. 1) (e.g., toward
the drywall) to drive the cutting member 30 deeper into the drywall
until cutting is complete. However, the cutting member 30 may be
removed from the arbor 22 by axially sliding the drive protrusions
46 out of the drive apertures 90 and the cutting member 30 off the
drill bit 26 in a direction opposite the direction F (e.g., away
from the drywall).
[0028] With reference to FIGS. 2 and 5, the guide member 18 is
formed as a circular disc with a central projection 88 that extends
axially outwardly. The guide member 18 defines a central aperture
92 extending through the projection 88. The central aperture 92 of
the guide member 18 is sized to provide clearance for the pilot
drill bit 26. In the illustrated embodiment, the central aperture
92 is approximately equal in size to the central aperture 86 of the
cutting member 30, but may be any size that allows the drill bit 26
to pass therethrough. The guide member 18 has an outer diameter
that is similar to, but no greater than, an inner diameter of the
annular wall 54 of the cutting member 30, such that the guide
member 18 fits within the cavity 70 of the cutting member 30. The
guide member 18 is configured to be coupled to the drywall, by
pressing the projection 88 into the drywall, to cover a damaged
area. In alternate embodiments, the guide member 18 may include
teeth, pins, gripping members, adhesive or the like to secure the
guide member 18 to the drywall. In further alternate embodiments,
the guide member 18 may include holes configured to receive screws
to couple the guide member 18 to the drywall. The guide member 18
further defines a plurality of large holes 98 equally spaced around
the central aperture 86. The large holes 98 reduce the weight and
material of the guide member 18. The holes 98 may also be used to
view the damaged area through the guide member 18 as the guide
member 18 is coupled to the drywall to make sure the damaged area
is properly covered.
[0029] In operation of the drywall repair kit 10, when the cutting
member 30 is coupled to the arbor 22, the drill bit 26 is inserted
through the central aperture 92 of the guide member 18 to center
the cutting member 30 on the guide member 18 about the axis A. The
cutting member 30 is then rotated about the axis A until the drive
apertures 90 align to receive the drive protrusions 46. Once
aligned, the drill may be powered to rotate the cutting member 30
about the axis A and begin cutting the hole in the drywall. The
guide member 18 fits within the cavity 70 to guide and align the
cutting member 30 and keep the cutting member 30 straight. Applying
force axially along the axis A drives the cutting member 30 deeper
into the drywall until the annular flange 96 formed by the back
piece 34 abuts the drywall, thereby inhibiting further movement of
the assembly 14 into the drywall. As the assembly 14 cuts into the
drywall, the threads 82 of the cutting member 30 engage the drywall
to secure the cutting member 30 within the circular hole in the
drywall. Once the cutting member 30 is secured in the circular
hole, the drill bit 26 and the drive protrusions 46 are axially
withdrawn from the central aperture 86 of the cutting member 30 and
the drive apertures 90, leaving the cutting member 30 within the
circular hole as a plug.
[0030] FIG. 6 illustrates a method for repairing a damaged area 304
(e.g., a hole) in drywall 300 using the drywall repair kit 10 of
FIGS. 1-5. In step 1000, the damaged area 304 is observed in the
drywall 300. In step 1010, the guide member 18 is applied to the
drywall 300 to cover the damaged area 304. The guide member 18 is
coupled to the drywall 300 by pressing the projection 88 into the
drywall 300. The guide member 18 may be centered on the damaged
area 304 or may be slightly offset relative to the damaged area
304, depending on the location of studs or other environmental
considerations.
[0031] In step 1020, the arbor 22 and the cutting member 30 are
coupled to a drill 306. The drill bit 26 is aligned in the central
aperture 92 of the guide member 18. The drill 306 is then powered
so that the cutting member 30 cuts a circular cut hole 308 in the
drywall 300 around the guide member 18. As the cutting member 30
cuts into the drywall 300, the threads 82 of the cutting member 30
engage the drywall 300 to secure the cutting member 30 within the
hole 308.
[0032] In step 1030, the drill 306 and the arbor 22 are axially
withdrawn and removed from the cutting member 30, leaving the hole
308 plugged by the cutting member 30.
[0033] In step 1040, the hole 308 and the cutting member 30 are
spackled over. The spackle 312 is left to dry. In step 1050, once
the spackle 312 has dried, the spackle 312 is sanded flush with a
surface of the drywall 300. In step 1060, paint (or other coatings)
is applied over the sanded area of spackle 316 that is covering the
cutting member 30 and the hole 308. Depending on the type of
workpiece being repaired, one or more of the steps 1040, 1050, 1060
may be omitted. For example, it may not be necessary to spackle and
sand a non-drywall workpiece that is being repaired with the kit
10.
[0034] The cutting member 30 can have different diameters to allow
for repair of larger or smaller damaged areas. For example, in some
embodiments, the cutting member 30 may have a diameter of 2.5
inches, and in some embodiments the cutting member 30 may have a
diameter of 4 inches, allowing for the repair of damaged areas that
have a max width of 2.5 inches or 4 inches, respectively. However,
the cutting member 30 may also be of any diameter between 2.5
inches and 4 inches, any diameter smaller than 2.5 inches, or any
diameter larger than 4 inches. The other components of the drywall
repair kit 10, such as the arbor 22 and the guide member 18, may be
sized accordingly.
[0035] FIGS. 7-9 illustrate another drywall repair kit 10a. With
the exception of some minor distinctions, the drywall repair kit
10a of FIGS. 7-9 is substantially similar to the drywall repair kit
10 of FIGS. 1-5. Like components and features are identified with
like reference numerals plus the letter "a" and will not be
described again in detail. The manner of operation of the drywall
repair kit 10a of FIGS. 7-9 is identical to that described above in
connection with the drywall repair kit 10 of FIGS. 1-5. In
addition, the method for repairing a damaged area (e.g., a hole) in
drywall using the drywall repair kit 10a of FIGS. 7-9 is identical
to the method for repairing a damaged area using the drywall repair
kit 10 of FIGS. 1-5, as shown in FIG. 6. Therefore, only
differences between the two embodiments will be described in
detail.
[0036] With reference to FIGS. 7-9, the cutting member 30a includes
a single thread 82a that extends circumferentially around the
annular wall 54a of the cutting member 30a. Similar to the threads
82 of the cutting member 30 of FIGS. 1, 2, and 4, the thread 82a
engages the drywall as the cutting member 30a cuts into the
drywall, thereby retaining the cutting member 30a within the
circular hole cut by the cutting member 30a once the arbor is
removed. The single thread 82a on the cutting member reduces the
possibility of the cutting member 30a grinding into the drywall
compared to a cutting member with multiple threads.
[0037] With continued reference to FIGS. 7-9, the drive apertures
90a of the cutting member 30a are spaced farther away radially from
the axis A, nearer the annular wall 54a. The corresponding drive
protrusions 46a of the arbor 22a are also spaced farther away
radially from the axis A. Additionally, although not shown, the
drywall repair kit 10a of FIGS. 7-9 may include a pilot drill bit
similar to the pilot drill bit 26 of FIGS. 1 and 5.
[0038] FIGS. 10-11 illustrate an auxiliary plug 100 that may be
included in the drywall repair kit 10 of FIGS. 1-5 and used to plug
holes cut in the drywall by the cutting member 30 or a similarly
sized hole saw. The auxiliary plug 100 is typically used when an
obstruction (e.g., a stud) inhibits the cutting member 30 from
being fully inserted into the hole, and thus, flush with the
surface of the drywall. The auxiliary plug 100, may be part of the
drywall repair kit 10 or an independent component that is used
separately or in combination with other hole saws or drywall repair
kits. Although described with reference to, and as part of, the
drywall repair kit 10 of FIGS. 1-5, the auxiliary plug 100 may also
be included in, or used with, the drywall repair kit 10a of FIGS.
7-9.
[0039] The auxiliary plug 100 includes a generally flat disc shaped
body 104 having a central axis B. The body 104 defines a pair of
slots 108 that each extend from an outer circumference 106 of the
body 104 to form a pair of flexible resilient members 112 on the
body 104. In the illustrated embodiment, the slots 108 are
generally L-shaped, but may alternatively have other shapes or
configurations. Specifically, each of the illustrated slots 108 has
a first portion 108A that extends from the outer circumference 106
generally towards the center of auxiliary plug 100, and a second
portion 108B that extends from an end of the first portion 108A
towards the outer circumference 106 to form an "L" shape. Each of
the resilient members 112 has a flexible portion 122 between an end
of the second portion 108B of the slot 108 and the outer
circumference 106. The flexible portions 122 connect each of the
resilient members 112 to the rest of the body 104. The resilient
members 112 and the pair of slots 108 are configured with the
flexible portion 122 to allow the resilient members 112 to flex
radially inwards.
[0040] In the illustrated embodiment, the resilient members 112
each have a cylindrical projection 116 axially extending from the
body 104. The cylindrical projections 116 each have a recess 120
for receiving, for example, a thumb and a finger of a user,
respectively, for squeezing the resilient members 112 radially
inward. In particular, a user can insert his/her thumb and finger
into the recesses 120 and then squeeze his/her thumb and finger
together. This action causes the resilient members 112 to flex or
bend about the flexible portions 122 radially inwards toward the
center of the body 104 (e.g., in the direction of arrows C in FIG.
11). As the resilient members 112 move toward the center, the
members 112 collapse the slots 108 and reduce the outer diameter of
the body 104.
[0041] The illustrated auxiliary plug 100 further includes three
gripping teeth 124 extending from the outer circumference 106 of
the auxiliary plug 100. In the illustrated embodiment, the gripping
teeth 124 are evenly circumferentially spaced around the outer
circumference 106 (e.g., about 120 degrees apart about the central
axis of the body 104). Each of the resilient members 112 includes
at least one of the gripping teeth 124 adjacent the corresponding
slot 108 on the outer circumference 106. Another one of the
gripping teeth 124 is located on the outer circumference 106
equidistant from the gripping teeth 124 on the resilient members
112. In addition, similar to the cutting member 30, the illustrated
body 104 defines through holes 128. The through holes 128 help to
retain spackle applied over the circular hole cut out of the
drywall and the body 104 of the auxiliary plug 100.
[0042] The auxiliary plug 100 may have different diameters to allow
for repair of larger or smaller damaged areas. The diameters may
correspond to the diameter of the cutting member 30 or another hole
saw. The diameter may be the same as the cutting member 30 or
slightly larger to provide for a tight fit within the hole in the
drywall cut out by the cutting member 30. For example, the
auxiliary plug 100 may have a diameter of about 2.5 inches or about
4 inches, allowing for the repair of damaged areas that have a max
width of 2.5 inches or 4 inches, respectively. However, the
auxiliary plug 100 may also be of any diameter between 2.5 inches
and 4 inches, or of any diameter smaller than 2.5 inches or larger
than 4 inches.
[0043] In operation, the auxiliary plug 100 is typically used when
the cutting member 30 cannot fully be received within the hole cut
in the drywall due to an obstruction such that the back wall 58 of
the cutting member 30 is not flush with the surface of the drywall.
The obstruction is typically a material that is too hard to be cut
by the cutting member 30 (e.g., a wooden or metal stud), but in
some instances the obstruction may be undesirable to cut for
structural or aesthetic reasons. Once the hole has been cut in the
drywall, the cutting member 30 is removed from the hole along with
the guide member 18. If the threads 82 of the cutting member 30 are
engaged with the drywall, the cutting member 30 is removed by
rotating the cutting member 30 in a direction opposite the cutting
direction to disengage the threads 82.
[0044] After the cutting member 30 is removed, a user selects an
auxiliary plug 100 of appropriate size for the hole. The user then
inserts a thumb and a finger into a corresponding one of the
recesses 120 of the resilient members 112 of the auxiliary plug
100. The resilient members 112 are squeezed together such that the
resilient members 112 deflect inwardly towards one another to
reduce the diameter of the auxiliary plug 100. The diameter of the
auxiliary plug 100 is reduced in order to fit within the hole. This
is due to the diameter of the auxiliary plug 100 being
approximately the same as, or slightly larger than, the diameter of
the cutting member 30. The auxiliary plug 100 is then inserted into
the hole in the drywall. The resilient members 112 are then
released, allowing the flexible portions 122 to spring back, such
that the resilient members 112 move towards their original
position. As the resilient members 112 deflect radially outward,
the outer circumference 106 and the gripping teeth 124 engage the
hole in the drywall to secure the auxiliary plug 100 within the
hole.
[0045] The method of using the drywall repair kit 10 shown in FIG.
6 is similar to a method that includes and uses the auxiliary plug
100. Therefore, only the differences between the methods will be
explained in detail. Step 1000, step 1010, and step 1020 remain the
same as the method described above in which the auxiliary plug 100
is not used. Step 1030 is also similar; however, the hole saw 30
and the guide member 18 are removed once the hole 308 is made in
the drywall 300. In an additional step, between step 1030 and step
1040, the auxiliary plug 100 is inserted into the hole 308 as
described in detail above. Once the auxiliary plug 100 is secured
within the hole 308, the auxiliary plug 100 and the hole 308 are
spackled over and left to dry, similar to step 1040 in which the
cutting member 30 remains in the hole 308. Step 1050 and step 1060
remain the same, in which the spackle 312 is sanded flush with the
surface of the drywall 300 before applying paint.
[0046] FIG. 12 illustrates another auxiliary plug that may be
included in the drywall repair kit 10 of FIGS. 1-5 and used to plug
holes cut in the drywall by the cutting member 30 or a similarly
sized hole saw. The auxiliary plug 200 is typically used when an
obstruction (e.g., a stud) inhibits the cutting member 30 from
being fully inserted into the hole and flush with the surface of
the drywall. The auxiliary plug 200 may be part of the drywall
repair kit 10 or an independent component that is used separately
or in combination with other hole saws or drywall repair kits.
Although described with reference to, and as part of, the drywall
repair kit 10 of FIGS. 1-5, the auxiliary plug 100 may also be
included in, or used with, the drywall repair kit 10a of FIGS.
7-9.
[0047] With reference to FIG. 12, the auxiliary plug 200 includes a
generally flat disc-shaped body 204 having a plane and a central
axis B perpendicular to the plane in a center of the body 204. The
body 204 has an outer circumference 206. The auxiliary plug 200
further includes flexible resilient members 212 circumferentially
spaced evenly about the center axis (e.g., about 30 degrees apart
about the central axis of the body 204). In the illustrated
embodiment, the plug 200 includes twelve flexible resilient members
212, but may alternatively include fewer or more flexible members
12. Each of the resilient members 212 is defined in the body 204 by
a pair of slots 208 that extend from the outer circumference 206 of
the body 204 generally towards the center of the body 204. Each of
the resilient members 212 is connected to the body 204 by a
flexible portion 222. The resilient members 212 are configured with
the flexible portions 222 to allow the resilient members 212 to
flex out of the plane with the remainder of the body 204.
Specifically, as a force is applied to each of the resilient
members 212, the resilient member 212 deflects to a deflected
position in which the resilient member 212 is deformed out of the
plane of the body 204 generally towards the central axis B (e.g.,
in the direction of arrow D in FIG. 9). When the force is removed,
the resilient member 212 springs back to the original position, in
which the resilient member 212 lies in the plane of the body
204.
[0048] In the illustrated embodiment, each of the resilient members
212 has a gripping tooth 224. Each gripping tooth 224 extends
radially outward at a distal end of each of the resilient members
212 so as to protrude from the outer circumference 206 of the body
204. In addition, similar to the auxiliary plug 100 of FIGS. 10-11,
the illustrated body 204 defines through holes 228. The through
holes 228 help to retain spackle applied over the circular hole cut
out of the drywall and the body 204 of the auxiliary plug 200.
[0049] Similar to the auxiliary plug 100 of FIGS. 10-11, the
auxiliary plug 200 of FIG. 12 may have different diameters to allow
for repair of larger or smaller damaged areas. The diameters may
correspond to the diameter of the cutting member 30 or another hole
saw. The diameter may be the same as the cutting member 30 or
slightly larger to provide for a tight fit within the hole in the
drywall cut out by the cutting member 30. For example, the
auxiliary plug 200 may have a diameter of about 2.5 inches or about
4 inches, allowing for the repair of damaged areas that have a max
width of 2.5 inches or 4 inches, respectively. However, the
auxiliary plug 200 may also be of any diameter between 2.5 inches
and 4 inches, or of any diameter smaller than 2.5 inches or larger
than 4 inches.
[0050] In operation, similar to the auxiliary plug 100 of FIGS.
10-11, the auxiliary plug 200 is used when the cutting member 30 is
unable to act as a plug, for example, when the cutting member 30
cannot be fully received within the hole cut in the drywall. Once
the cutting member 30 is removed from the hole, a user selects an
auxiliary plug 200 of appropriate size for the hole. The auxiliary
plug 200 is then aligned with the hole and inserted into the hole
in the drywall by pushing on the auxiliary plug 200, thereby
applying an axial force generally along the central axis. As the
body 204 of the auxiliary plug 200 is inserted into the hole, the
teeth 224 extending from each of the resilient members 212 engage
the drywall around the edge of the hole causing the resilient
members 212 to flex and deflect away from the body 204 to allow the
auxiliary plug 200 to be inserted into the hole. Once the auxiliary
plug 200 is fully inserted into the hole, the resilient members 212
spring back to their original position, such that the resilient
members 212 lie in the plane of the body 204 and the teeth 224 of
the resilient members 212 engage the drywall to secure the
auxiliary plug 200 within the hole.
[0051] The method of repairing a damaged area (e.g., a hole) in
drywall using the drywall repair kit 10, 10a in combination with
the auxiliary plug 200 of FIG. 12 is identical to the method for
repairing a damaged area using the drywall repair kit 10, 10a with
the auxiliary plug 100 of FIGS. 10-11, as described above. One
simply uses the auxiliary plug 200 of FIG. 12 in place of the
auxiliary plug 100 of FIGS. 10-11.
[0052] Additionally, each of the components of the drywall repair
kit 10 of FIGS. 1-5, the drywall repair kit 10a of FIGS. 7-9, and
the auxiliary plugs 100, 200 of FIGS. 10-12 may be formed out of
plastic, composites, metal or any other suitable material for
cutting drywall. It should be noted that the individual components
may be formed out of different materials. For example, the cutting
member 30 may be formed out of metal, while the auxiliary plugs
100, 200 may be formed out of plastic. Additionally, although, the
present application specifically refers to repairing drywall, it
should be readily apparent that the kits 10, 10a may also be used
to repair other types of workpieces, such as wood, composite
material or the like.
[0053] Although the invention has been described in detail with
reference to certain preferred embodiments, variations and
modifications exist within the scope and spirit of one or more
independent aspects of the invention as described. Various features
and advantages of the invention are set forth in the following
claims.
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