Patent Publication Number: US-2023134908-A1

Title: Methods and apparatus for repairing walls

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     Embodiments of the invention relates generally to methods and systems for repairing a wall. More particularly, the invention relates to a foldable plate that can be inserted inside a wall and positioned to provide a support for applying plaster, joint compound, spackle or other wall repair spreads in a hole in a wall. 
     2. Description of Prior Art and Related Information 
     The following background information may present examples of specific aspects of the prior art (e.g., without limitation, approaches, facts, or common wisdom) that, while expected to be helpful to further educate the reader as to additional aspects of the prior art, is not to be construed as limiting the present invention, or any embodiments thereof, to anything stated or implied therein or inferred thereupon. 
     Holes can be formed in a wall through various manners and can be presented in various sizes. Conventional wall repair kits include a patch or tape that one applies across the hole. Then, a compound is applied over the patch or tape, sanded and painted. 
     It such repair kits, one must apply enough compound to cover the patch or tape, so that it does not show, yet cannot apply too much compound as to provide a bulge in the wall. Further, with such patches or tapes, it is difficult to make the repair have any substantial thickness, so that the wall repair area becomes a region susceptible to further damage. These conventional methods do not permit the compound placed over the hole to be even close to the thickness of the original wall. 
     In view of the foregoing, there is a need for systems and methods for repairing walls that can overcome the deficiencies of conventional methods. 
     SUMMARY OF THE INVENTION 
     Embodiments of the present invention provide a wall repair system comprising a backer board configured to be inserted into a hole in a wall, the wall having an outer side facing a living space and a back side facing an opposite wall back side of an opposite wall, the wall and the opposite wall forming a wall space therebetween; and a pressure generating means for pressing at least a portion of the backer board against the back side of the wall about at least a portion of a periphery of the hole. 
     Embodiments of the present invention further provide a wall repair system comprising a backer board configured to be inserted into a hole in a wall, the wall having an outer side facing a living space and a back side facing an opposite wall back side of an opposite wall, the wall and the opposite wall forming a wall space therebetween; and a pressure generating means for pressing at least a portion of the backer board against the back side of the wall about at least a portion of a periphery of the hole. 
     Embodiments of the present invention further provide a method for repairing a hole in a wall comprising inserting a backer board into the hole in the wall, the backer board having at least one threaded opening therethrough; threading at least one screw into the at least one threaded opening; positioning the backer board in a desired position to press against at least a portion of an outer periphery of the hole on a back side of the wall; turning the screw to cause a distal end thereof to press against a wall opposite the wall with the hole, thus securing the backer board in the desired position; and building up repair material in the hole, against the backer board. 
     These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Some embodiments of the present invention are illustrated as an example and are not limited by the figures of the accompanying drawings, in which like references may indicate similar elements. 
         FIG.  1    shows a wall having a hole therein for which the repair system of the present invention may be applied; 
         FIG.  2    illustrates a wall repair system according to an exemplary embodiment of the present invention; 
         FIG.  3    illustrates a wall repair system having a backer piece, according to another exemplary embodiment of the present invention; 
         FIG.  4    illustrates the insertion of the wall repair system of  FIG.  2    into a hole in a wall; 
         FIG.  5    illustrates the inflation of the wall repair system of  FIG.  2    to provide a backer for repair compound to be placed in the hole; 
         FIG.  6    illustrates a backer board usable with the wall repair system of the present invention, showing how the backer board may be scored to permit easy reduction in size; 
         FIGS.  7 A through  7 D  illustrate views of a threaded backer board for wall repair; 
         FIG.  8    illustrates a side view of the threaded backer board disposed in a wall; 
         FIG.  9    illustrates a side view of the threaded backer board installed in a wall that is ready for patching; 
         FIGS.  10 A and  10 B  illustrate views showing combining multiple ones of the threaded backer boards of  FIGS.  7 A through  7 B , for large surface area wall repairs; 
         FIG.  11    illustrates a perspective view of a wall repair system having retention protrusions according to an exemplary embodiment of the present invention; and 
         FIG.  12    illustrates a side view of the wall repair system of  FIG.  11   . 
     
    
    
     Unless otherwise indicated illustrations in the figures are not necessarily drawn to scale. 
     The invention and its various embodiments can now be better understood by turning to the following detailed description wherein illustrated embodiments are described. It is to be expressly understood that the illustrated embodiments are set forth as examples and not by way of limitations on the invention as ultimately defined in the claims. 
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS AND BEST MODE OF INVENTION 
     The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well as the singular forms, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. 
     Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one having ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein. 
     In describing the invention, it will be understood that a number of techniques and steps are disclosed. Each of these has individual benefit and each can also be used in conjunction with one or more, or in some cases all, of the other disclosed techniques. Accordingly, for the sake of clarity, this description will refrain from repeating every possible combination of the individual steps in an unnecessary fashion. Nevertheless, the specification and claims should be read with the understanding that such combinations are entirely within the scope of the invention and the claims. 
     In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be evident, however, to one skilled in the art that the present invention may be practiced without these specific details. 
     The present disclosure is to be considered as an exemplification of the invention, and is not intended to limit the invention to the specific embodiments illustrated by the figures or description below. 
     As is well known to those skilled in the art, many careful considerations and compromises typically must be made when designing for the optimal configuration of a commercial implementation of any system, and in particular, the embodiments of the present invention. A commercial implementation in accordance with the spirit and teachings of the present invention may be configured according to the needs of the particular application, whereby any aspect(s), feature(s), function(s), result(s), component(s), approach(es), or step(s) of the teachings related to any described embodiment of the present invention may be suitably omitted, included, adapted, mixed and matched, or improved and/or optimized by those skilled in the art, using their average skills and known techniques, to achieve the desired implementation that addresses the needs of the particular application. 
     Broadly, embodiments of the present invention provide a wall repair system that includes a balloon that can be inflated within a wall space behind a hole in the wall. The balloon, or, as described below, a backer board attached to the balloon, can provide a surface for placement or build up of wall repair compound so that the repaired wall has substantially the same thickness of the original wall and so that no tape or patch needs to be placed on top of the wall along any location surrounding the hole. In some embodiments, the backer board can have one or more threaded holes therethrough where a threaded rod can be inserted into the threaded holes to contact a wall surface opposite the hole, causing the backer board to stay in place against the back side of the wall having the hole therein, thus blocking all or a part of the hole. 
     Referring to  FIGS.  1  through  3   , a balloon  10  can include a fill port  12  having a straw  14  extending therefrom. The balloon  10  may be designed so that the straw  14  may be used to fill the balloon  10 . When the straw  14  is removed from the balloon  10 , the balloon  10  may remain inflated. In other words, the air fill port  12  of the balloon may be self-sealing upon removal of the straw  14 . The air fill port  12  can include various mechanisms for providing a self-sealing balloon  10  as may be known in the art. For example, a deformable plastic piece may fit around the fill port of the balloon  10 , where insertion of the straw  14  may cause the fill port to open around the straw, permitting inflation of the balloon  10 . When the straw  14  is removed, the resilient material may close the fill port to prevent deflation. The straw  14  may be any elongated tubular member and may be flexible, rigid, straight, bent, or combinations thereof. 
     In some embodiments, the balloon  10  may be self-filling and be sealed with certain chemicals that create a gaseous product reaction to permit inflation of the balloon upon contact of the chemicals. For example, the balloon may include a first chamber having baking soda and a second chamber with citric acid, vinegar, or the like, so that, when the chambers are combined, the balloon self-inflates. 
     The system may include a backer board  16  attached to a portion of the exterior of the balloon  10 . The backer board  16  may be size adjustable by various means, such as scoring or marking of cut lines, so that the backer board  16  may be sized to be, at least on one dimension, smaller than the hole  32  in the wall  30 , permitting the backer board  16  to be inserted with the deflated balloon  10  into the hole  32  as shown in  FIG.  4   . When the balloon  10  is inflated inside the wall space  18 , the backer board  16  can be aligned to provide a more firm backing for building up the wall repair. The backer board  16  may be made from various materials, such as cardboard, paperboard, plastic, wood, metal, or the like. Typically, the backer board  16  may be relatively rigid, at least more rigid than the balloon  10 , for example. In some embodiments, rather than being attached to the balloon  10 , the backer board  16  may be a separate piece that may be inserted during or after balloon inflation. 
     The backer board  16  may be solid or may include a plurality of holes therethough for permitting the repair compound to engage there with. The backer board  16  may include a plurality of scores  18  to permit easy size adjustment. In some embodiments, as shown in  FIG.  6   , the scores may be arranged in concentric circles. 
     Referring back to  FIGS.  1 ,  4  and  5   , in use, the balloon  10  may be inflated within the wall space  34  so that either an outer edge  20  of the balloon  10 , or a backer board  16 , can be aligned with a back side (interior to the wall) portion  22  of the wall  30  at the location of the hole  32 . Thus, the inflated balloon  10 , or the backer board  16 , provides a backing to receive repair compound thereagainst. If conventional repair compound, such as joint compound or spackle, is used on a hole in the wall, as the hole fills with the repair compound, much of the compound can push out beyond the back surface of the wall and simply fall within the wall space. With the repair system of the present invention, a stop is provided to retain repair compound and this stop is positioned at or near a back surface of the wall. In this manner, when the repair is complete, the repaired section will have substantially the same thickness of the rest of the original wall and the repaired area may be smoothed or sanded to be flush with the surrounding wall, since there is no material added about the perimeter of the hole on the wall. 
     The wall repair system may be used to repair virtually any sized hole in a wall, provided that it is large enough to permit insertion of the balloon therein. Typically, the wall repair system may be used to repair holes from about 1 inch to about 8 inches, for example. 
     In the above embodiment, the inflated balloon provides pressure for itself or a backer board to receive the build-up of the wall repair compound. Referring to  FIGS.  7 A through  9   , in some embodiments, a threaded backer board  70  can include one or more female threaded through openings  72 . A screw  74  may be inserted into the through openings. The screw  74  may be long enough to permit the screw to contact an opposite wall  76  within the wall space  34 , thus pushing the threaded backer board  70  against the back side portion  22  of the wall  30  with the hole  32 . An opposite wall contacting side of the screw  74  may have an enlarged head  80  to provide a large surface area to push against the opposite wall  76  during use. The enlarged head  80  may be integral with the screw  74  or may be attached to the screw  74  during use and after threading the screw  74  into the threaded opening  72 . In some embodiments, the enlarged head  80  may be positioned on the back side of the backer board  70  so that the screw, when inserted through the threaded opening  72 , can automatically engage the enlarged head  80  and separate the enlarged head  80  from the back side of the backer board  70 . In this manner, the backer board  70  may be inserted into the hole, without the screw  74  installed, and then the screw  74  can be inserted. The handle  86 , described below, may be used to hold the backer board  70  in place while the screw  74  is inserted. Such a configuration may be especially useful for the larger size board, as shown in  FIGS.  10 A and  10 B . 
     The hole facing side  82  of the screw  74  can include a screw engaging shape  84 A, such as Phillips-head shape, to permit a screwdriver to turn the screw  74  or may include a handle  84  for turning the screw  74  by hand. The length of the screw  74  may be pre-sized to fit within standard wall openings. For example, the screw  74  may be from about 3.25 to about 3.75 inches in length for a standard 2×4 wall construction. Other screw lengths may be provided for other wall widths. 
     The threaded backer board  70  may include hinges  87 , or similar structure, to permit folding of the threaded backer board  70 . Typically, the hinges  87  may permit folding one or more sides of the threaded backer board  70  outward (toward the hole when the threaded backer board  70  is inserted into place behind the hole in the wall), but not inward (toward the opposite wall  76  in the wall space  34 ) so that, as the screw  74  is tightened, causing the threaded backer board  70  to push against at least a portion of the inner perimeter of the hole, the one or more hinged sides do not bent inward. In some embodiments, the hinges  87  may be living hinges formed along the length of the backer board  70 . In some embodiments, the hinges  87  may be formed in a V-shape to permit the hinged parts to fold toward the front of the device, but not in the opposite direction. 
     In some embodiments, protrusions  90  may extend on from a back side  91  of the device, as shown in  FIG.  11   . The protrusions  90  may be disposed on each of the hinged parts (such has hinged parts  92 ,  93 ) on opposite sides of the hinge  87  such that, if the hinged parts  92 ,  93  are pushed to bend into their back side  91 , the protrusions  90  can contact each other to prevent this backward bending. 
     In some embodiments, as shown in  FIGS.  11  and  12   , pointed protrusions  95  may be disposed on a front side  94  of the device and on the back side  96  of the enlarged head  80 . The protrusions  95  on the front side  94  of the device can extend into the back side (interior to the wall) portion  22  of the wall  30  on which there is a hole (see  FIGS.  8  and  9   ). The protrusions  95  on the enlarged head  80  may extend into the opposite wall  76  (see  FIGS.  8  and  9   ). The protrusions  95  can help secure the device in place while the screw is tightened. 
     The threaded backer board  70  may be scored to permit size adjustment and may include one or more hinged features to permit folding of the board for insertion and allowing for opening of the hinged features within the wall space. In use, the screw  74  may provide a handle to hold the threaded backer board  70  in the proper orientation for placement thereof. 
     In some embodiments, the threaded backer board  70  may include a pressure sensitive adhesive with a removable backing strip. The threaded backer board  70  may be inserted into the wall space  34 , the removable backing strip may be removed, and at least a portion of the threaded backer board  70  may adhere to the back side of the wall about at least a portion of the periphery of the hole. Such adhesive may hole the threaded backer board  70  in place while the user tightens the one or more screws to more securely hold the threaded backer board  70  in place. 
     In some embodiments, a handle  86  may pivotably extend from a surface of the backer board  70 . As shown, the handle  86  may be formed from a section of the backer board  70  where the handle attaches at a hinged region  88  that is adjacent the threaded opening  72 . In use, the user can hold the backer board by the handle  86  to keep the backer board  70  against the inside of the wall while the screw  74  is turned to secure the backer board  70  in place. A stopper  90  may be formed along one edge of an opening  92  formed when the handle  86  is moved outward from the surface of the backer board. The stopper  90  can prevent the handle  86  from being pushed outward from a back side of the backer board  70 . 
     As shown in  FIGS.  10 A and  10 B , the backer board  70 A can be formed in various sizes. In some embodiments, multiple screws  72  may be used to support the backer board  70 A in place, as shown. One or more hinges  94  can be provided to permit bending of the backer board  70 A in a manner similar to that described above. 
     One in place, handle  84  of the backer board  70 ,  70 A can be removed. Typically, the screw  72  is sized so that the screw end, once the handle  84  is removed, is covered by the wall patch added to the hole in the wall against the backer board  70 ,  70 A. In some embodiments, the screw  72  may be scored to be broken off once the backer board  70 ,  70 A is in position. 
     All the features disclosed in this specification, including any accompanying abstract and drawings, may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features. 
     Claim elements and steps herein may have been numbered and/or lettered solely as an aid in readability and understanding. Any such numbering and lettering in itself is not intended to and should not be taken to indicate the ordering of elements and/or steps in the claims. 
     Many alterations and modifications may be made by those having ordinary skill in the art without departing from the spirit and scope of the invention. Therefore, it must be understood that the illustrated embodiments have been set forth only for the purposes of examples and that they should not be taken as limiting the invention as defined by the following claims. For example, notwithstanding the fact that the elements of a claim are set forth below in a certain combination, it must be expressly understood that the invention includes other combinations of fewer, more or different ones of the disclosed elements. 
     The words used in this specification to describe the invention and its various embodiments are to be understood not only in the sense of their commonly defined meanings, but to include by special definition in this specification the generic structure, material or acts of which they represent a single species. 
     The definitions of the words or elements of the following claims are, therefore, defined in this specification to not only include the combination of elements which are literally set forth. In this sense it is therefore contemplated that an equivalent substitution of two or more elements may be made for any one of the elements in the claims below or that a single element may be substituted for two or more elements in a claim. Although elements may be described above as acting in certain combinations and even initially claimed as such, it is to be expressly understood that one or more elements from a claimed combination can in some cases be excised from the combination and that the claimed combination may be directed to a subcombination or variation of a subcombination. 
     Insubstantial changes from the claimed subject matter as viewed by a person with ordinary skill in the art, now known or later devised, are expressly contemplated as being equivalently within the scope of the claims. Therefore, obvious substitutions now or later known to one with ordinary skill in the art are defined to be within the scope of the defined elements. 
     The claims are thus to be understood to include what is specifically illustrated and described above, what is conceptually equivalent, what can be obviously substituted and also what incorporates the essential idea of the invention.