Patent Publication Number: US-2006010817-A1

Title: Drywall patch kit

Description:
PRIORITY  
      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  
      1. Field of the Invention  
      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.  
      2. Background Information  
      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™. 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.  
      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.  
      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.  
      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.  
      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  
      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.  
      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.  
      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.  
      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.  
      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.  
      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  
       FIG. 1  shows an assembly view of the items of the present preferred embodiment of the invention.  
       FIG. 2  shows a hole in a wall.  
       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.  
       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.  
       FIG. 5  shows the patch of the present invention in place upon a surface that has been prepared.  
       FIG. 6  shows a detailed side view of the patch of the present invention in place upon a surface. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS  
      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.  
       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 (½) 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 ½″, ⅝″ and ¾″.  
      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.  
      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.  
      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.  
      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.  
      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.  
      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.