Abstract:
A device for patching wall holes caused by a doorknob or other item impact, which device is assembled in situ between the injured wall member and an adjacent rear wall member. A master plate having a circular opening with four ninety-degree apart radiating outward slots, is adhered to the interior face of the injured wall over the opening. Two inter-engageable body sections each having a tongue are centrally inter-engaged at right angles and retained by placement of a disk designated the central section having a central internal cross-shaped cutout over the engaged tongues. The disk bearing engaged body sections are recessed into the master plate up to the tongues, rotated and locked into position between the wall members. Spackle or plaster is applied, allowed to dry, and then painted/papered to yield a non-discernable repair is applied, allowed to dry and then painted or papered over to yield a non-discernible repair.

Description:
FIELD OF THE INVENTION  
       [0001]     This application pertains to a device for filling in a hole in a gypsum board wall member to retain a spackled patch.  
       BACKGROUND OF THE INVENTION  
       [0002]     Due to negligence, accidents, or anger people find from time to time that a doorknob being opened inwardly smashes into the adjacent wall often making at least an indentation and often a hole in the wall member. Such holes are difficult to patch, as there is a no base for Spackle to stick to. The device of this invention fits in the hole between the injured front interior wall member and the rear wall member of the wall to provide a substrate for receipt of Spackle such that the hole can be completely filled in and painted or papered over as needed.  
         [0003]     There is also a need to fill in holes even bigger than a conventional doorknob. This device permits holes as large as six inches in diameter to be filled in prior to spackling.  
         [0004]     It is a first object to define a device to fill in a hole made by a doorknob.  
         [0005]     It is a second object to provide a device that is mounted between an interior injured wall member and the wall member spaced away adjacent thereto.  
         [0006]     It is a third object to provide a device that permits the user to fill a hole in the wall between a void front wall member and its sister spaced away interior member.  
         [0007]     It is a fourth object to provide a device that permits the hole from a doorknob impression to be readily filled in.  
         [0008]     It is a fifth object to provide a support for Spackle for the repair of apertures in a wall having been injured by projectile such as a fist, a fast-moving doorknob or even a bullet.  
         [0009]     The device of this invention indeed serves as a base for the repair of such holes in an interior gypsum board wall. And a novice can carry out the job.  
         [0010]     The invention accordingly comprises the device possessing the features, properties, the selection of components which are amplified in the following detailed disclosure, and the scope of the application of which will be indicated in the appended claims.  
         [0011]     For a fuller understanding of the nature and objects of the invention, reference should be made to the following detailed description, taken in conjunction with the accompanying drawings.  
       SUMMARY OF THE INVENTION  
       [0012]     A device for filling the hole in the interior gypsum board wall member to retain a spackled patch. The device is formed from four members made of various materials such as but not limited to plywood, sheets plastic, chipboard, water resistant corrugated board and cardboard, and artists&#39; board assembled in a specific fashion and of specific dimensions for two of the members. A first member, designated the master plate, is adhered to the interior of the injured wall, followed by the insertion through the master plate of two body members each of which is a tongue bearing centrally inter-engaged body section, having a an interlocking disk thereon. The so engaged body members with disk thereon are designated a material receiver. The disk carrying engaged members (material receiver) is rotated into a secure position. Spackle or plaster is added; paper or paint is applied to yield a non-discernible repair.  
         [0013]     It is a first object to provide a low cost, easy to install wall hole repair device.  
         [0014]     It is a second object to provide a wall hole repair device that yields an invisible repair once paint or wallpaper is applied.  
         [0015]     Other objects of the invention will in part be obvious and will in part appear hereinafter.  
     
    
     BRIEF DESCRIPTION OF FIGURES  
       [0016]      FIG. 1  is a front plan view of the master plate body portion.  
         [0017]      FIG. 2  is a plan view of the circular front central section of this invention.  
         [0018]      FIG. 3  is a plan view of the body member A.  
         [0019]      FIG. 4  is a plan view of the body member B.  
         [0020]      FIG. 5  is a rear plan view of the master plate.  
         [0021]      FIG. 6  is a side elevation of the inventive device disposed in a wall.  
         [0022]      FIG. 7  is a rear perspective device of the assembled invention of this application.  
         [0023]      FIG. 8  is a front perspective view of the assembled invention of this application.  
         [0024]      FIG. 9  is a top perspective view of the assembled invention.  
         [0025]      FIG. 10  is a rear perspective view of the installed invention in a wall.  
         [0026]      FIG. 11  is a front perspective view of the assembled installed invention.  
         [0027]      FIG. 12  is a view of an alternative construction of the master plate.  
         [0028]      FIG. 13  is a perspective view of several of two body members formed as an integrated unit as by casting.  
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0029]     The device  10  of this invention is intended to serve as a support for spackle in the repair of an interior gypsum wall board that has an aperture therein due to the door handle having impacted against the wall member, for such reasons as the failure of anger management, accident or due to negligence.  
         [0030]     In this patent application the term interior wall refers to two closely spaced wall members, each usually made of gypsum board. The device of this invention as described fits between the two spaced gypsum board members of the wall.  
         [0031]     In  FIG. 1 , a sheet of artists&#39; foam board or the suitable material cut to the desired size is designated as the master plate, 15  is seen on its obverse side. This side may be made distinguishable from the reverse side by providing for the presence of the score line  28 , which, if present, is scribed from the outer edge of the plate  15 , through the center of either pair of rectangular openings  17  the purpose for which will be discussed infra. The center opening  16  of the master plate is about two inches in diameter, is seen which opening communicates with a series of small rectangular openings  17  disposed at each of the 90 degree positions around the center opening. These four slots  17  radiate outwardly from the opening  16 , ninety degrees apart. Disposed adjacent to each pair of rectangular openings  16  is a piece of self adhesive tape  19  approximately 1 inch by 1.5 inches. A peelable cover sheet  20  is disposed over each adhesive layer to prevent the glue from sticking to other than the desired surface, which in this case is a piece of gypsum board. As will also be discussed infra in the section of this application dealing with installation. The overall size of the artist foam board or other board is not critical, but should be between about 4.75 to 6 inches for ease of packaging and ease of use.  
         [0032]     In  FIG. 2  the central section is seen. This section is a piece of artist foam board  18  that has been removed from the master plate  15  and modified. The central section  18  has a central internal x-shaped cutout therein designated  38 .  
         [0033]     In  FIGS. 3 and 4 , the body members,  12 , 13  comprising the mating planar tongue bearing body sections  21  and  23  are seen. These are die cut sections also of artists&#39; foam board that are of the same physical dimensions. The width of each of  21  and  23  designated  21 W and  23 W respectively may be about 2.5 inches, while the depth of each  21 D and  23 D respectively may be about 3 inches, though the depth excludes the tongue to be discussed next.  
         [0034]     The depth measurements of  21 D and  23 D constitute the distance from the inside of the broken front wall (re the wall to be repaired) measured to the inside surface of the spaced adjoining area or room interior wall, minus the thickness of the master plate  15 . This is the measurement for both the 2×4-studded walls and 2×6-studded walls.  
         [0035]     Each body member&#39;s body section has a centrally disposed rectangular tongue that is contiguous with and attached to the respective front edge  27 , 29  per  FIG. 4 , respectively of the width of the body section. Such tongues  22 , 25  are in the same respective plane as each of the body sections and are about ½ inch in depth and 1 inch in width, which is a smaller diameter than the width of the body section. The two body sections differ in that section  21  has an inwardly directed slot  24  on the rear width edge opposite its tongue directed parallel to the side edges; while body section  25  has an inwardly directed slot  26  on the front edge through the tongue into the body. Both slots  24 , 26  are of equal extension. When engaged, the two body sections are vertically engaged along their central axis to form a plus sign (+) shaped unit;  
         [0036]     In  FIG. 5 , the reverse side of the master plate  15  is seen. Here the score line  28  is not seen. Only the center opening and the communicating little 90 degrees apart rectangular slots or openings are seen.  
         [0037]     In  FIG. 6 , a side elevational view of an assembled unit of this invention is seen. The two-interlocked body sections  21 , 23  are assembled to form a cross, and the two outer edges of each of the body sections are disposed within a respective slot  17 . The central section or disk  18  seen in  FIG. 2  is disposed via its cross opening  38  upon the crossed tongues  22 , 25  and rests on the respective front edges  27 , 29  of the body sections  21 ,  23 . The respective crossed tongues protrude through the T-slot  31  in central section  18 . When the disk is placed on the plus sign (+) crossed body sections, a material receiver is defined.  
         [0038]      FIG. 7  illustrates the reverse side of the master plate  15  and the crossed interconnected main sections  21  and  23  having the master plate  15  disposed thereon. The master plate  15  is placed thereon from the bottom of the edge of the main sections that do not have a tongue, by aligning the four 90 degrees spaced slots with the crossed body sections,  21 ,  23 . When installation is to transpire, this should be done from the obverse side of the master plate  15 .  
         [0039]     In  FIG. 8 , the device of this invention is seen in a partially assembled condition, but not in an in-wall environment. The front or obverse face of the master plate  15  is seen with the self-adhesive tabs  19  still covered over. Plate  15  is spaced back from the edge of the disk  18 . During installation it,  18  is disposed a distance back from the front edges of members  21  and  23  and placed thereon in the hole in the gypsum board.  
         [0040]     It is also to be seen that while in  FIG. 8  the assembly of the two members shown in  FIGS. 3 and 4  have been carried out, and the center section has been placed thereover. It is also within the scope of the invention to mold the two members,  18   21 ,and  23 , with the center section thereon, as one preformed member. See  FIG. 13  wherein the preformed unitary structure  101  has its three components designated in the  100  series numbers,  118 , 121 , and  123  respectively.  
         [0041]     While the unitary structure  101  falls within the scope of the invention as to utilization, a different packaging is required but with less assembly by the user.  
         [0042]      FIG. 9  is a mirror image of  FIG. 6  and need not be discussed further.  
         [0043]      FIG. 10 , is a view that simulates a wall thickness. Designator  30 B stands for the backside of the gypsum board wall  30  having a hole  32  therein to be repaired. Surrounding the hole  32  is a pair of spaced studs  36 , 40 , which is present. A cross beam  41  may be disposed, but need not be, between the two studs aforementioned. Device  10  is seen through the pseudo wall  42 , which is spaced from the front wall&#39;s backside  30 B. The pseudo wall here  42  is a sheet of clear acrylic that simulates the second spaced piece of gypsum board, which helps define the space  44  between the two gypsum board sheets making up a wall thickness of a room.  
         [0044]     The right side part of  FIG. 10  illustrates a previously installed unit of this invention as seen from within the wall between the opposed gypsum boards, in front of back wall shown here as being clear. Reference will be made back to  FIG. 10  at the completion of the discussion of the individual figures.  
         [0045]      FIG. 11  illustrates the front side of the wall  30 , namely  30 A. Thus, the busted in segment of the wall  30  as designated  32  in the left of  FIG. 10  is seen on the right in  FIG. 11 . The position of the previously installed unit of the invention  10  is also reversed from  FIG. 10  to  FIG. 11 . The relative position of the master plate  15  subsequent to installation is visible in  FIG. 10 . As can be seen, the master plate and the disk are coplanar post installation.  
         [0046]     In  FIG. 12  the master plate  115  is seen. Here the entire surface of the foam board or other material  118  is covered over by an adhesive layer  119 . The cutaway lines reveal the presence of the underlying layer  118 . The central opening  116  has the 4 90 degree apart radiating outwardly slots  117 . A peelable cover layer to protect the adhesive from unintentional contact would be used but is not shown.  
         [0047]     In  FIG. 13 , the two body sections are seen in perspective formed as an integral unit,  121  as by casting or molding of resin with three legs instead of four. In addition it may also be possible to have the disk or central section also integrally molded in place on the unified body section  121  and such is contemplated by this invention.  
       Installation  
       [0048]     In order to set up the device of this invention within its work environment,—between two spaced sections of gypsum board, a set of steps must be carried out, though not necessarily in the same order as recited. After removing the adhesive cover layers  20 , the master plate  15  is folded along the score line  28 , if present, and disposed through the opening equivalent to  32  where the hole was made as by a doorknob impact, or a punch or other mode into the front wall member  30  to require a repair to be made. The master plate with its circular opening and four ninety degree apart radiating outward slots is held through the center opening  16  with a pair of fingers, and then opened such that the four uncovered adhesive tabs face the operator. The plate is brought toward the viewer to make contact between the exposed adhesive tabs and the wall  30 B to attach the master plate  15  into position.  
         [0049]     By folding the master plate such that the glue containing sections move away from each other, the four cover plates may be removed prior to disposition through opening  32 , this way contact of one adhesive tab with another such tab is avoided.  
         [0050]     After the master plate is positioned affixed to wall  30 B, the two body sections A and B, designated  21  and  23  are inter-engaged and placed into the four slots  17 , moving rearwardly part way away from the user. Disk  18  is placed over the crossed body sections A and B to yield a material receiver. The rearward journey of the two inter-engaged body sections with the disk is restarted and continued until impact is made with wall  41 . This point in time should coincide with the location of the disk almost approaching a coplanar status with the master plate  15 . The crossed tongues should be the only parts of the two inter-engaged body sections now visible.  
         [0051]     Using two fingers, on the two tongues, the inter-engaged body sections, are rotated about 45 degrees, once the front edges  27  and  29  clear the slots  17 , to lock the main body sections between the two pieces of gypsum board constituting the injured wall member and the rear wall member of the wall. See  FIG. 10 , right side. The rearward travel to the inter-locked body sections is continued until the disk  18  becomes coplanar with the body section. See  FIG. 11 . Note the lack of coordination in  FIG. 11  of the two tongues and the slots  17 . Once the device  10  is locked into position, such that it cannot fall rearwardly down into the void between the two spaced gypsum board wall members, Spackle or plaster can be applied over the disk and the showing portion of the master plate. These serve as a backer plate for the reception of the Spackle or plaster and as a permanent brace to strengthen and resist future impacts from a doorknob. Once filled and dried, the spackle or plaster does not require feathering and can be sanded and painted to complete the repair of the impacted doorknob or fist, or other source of the hole. Reference is made to designator  35  in  FIG. 11 , which illustrates a completed repair.  
         [0052]     It is believed that other step orders can be carried out to place device  10  between the spaced sheets of gypsum board, though more difficulty may be encountered in doing so.  
         [0053]     While artists&#39; foam board has been mentioned as the preferred material for the structure, other materials such as sheet styrene or other plastic may be employed for all sections as will as chipboard, plywood, and cardboard. A waxed corrugated board to prevent swelling from the moisture of the Spackle may also be utilized for all parts of the invention.  
         [0054]     Any latex paint or oil paint may be applied to the patch created by the use of this device.  
         [0055]     Earlier, it has been indicated that the device  10  is suitable for the repair of holes having a diameter as large as about six inches. This is based upon two facts. First, the most common diameter for doorknobs found in the USA is about two inches in diameter. Thus, if the hole radiates out from a central point of impact, an allowance of an extra two inches of damage to the left and right of the knob yields or six inch diameter circle. Accordingly, the master plate  15  has been sized preferably at 6×6 inches before folding in anticipation of such possible drywall crackages. Obviously, the master plate can be enlarged laterally to cover larger spans up to perhaps sixteen inches wide, but with the same depth.  
         [0056]     In the discussion supra concerning  FIG. 1 , an alternative mode of construction is seen in the side view  FIG. 12 . Here a self-adhesive layer  119  is disposed over the entire master plate  115 . The self-adhesive layer  119  is overlaid with a peel off cover layer  120 . Such a variant can be produced by a spraying technique for the adhesive layer  119  rather than having the tab  19  laid in place by hand or machine. This format works for a four-legged unit as well as the three-legged unit shown.  
         [0057]     Other modes of attachment of the master plate are also contemplated, such as a layer of removable adhesive overlaid on the master plate  15  though one having a stronger adhesive quality than is used on Post-it® notes is needed. Removable adhesive is suggested or slow drying adhesive to compensate for errors of the person doing the repairs.  
         [0058]     Previous reference has been made to a score line. This line may be actually required, depending upon the material employed of the master plate. The benefit of having a score line is that a fold generally along such a line as desired is ensured. In certain materials, due to the preexistence of the ¼ hour opening and the center opening, a true fold may be easily accomplished. Such is not the case however wherein the substrate for the master plate  15  is sheet plastic, or a plywood segment. Card stock or corrugated board should fold easily in contrast without the need for a true score line  28 .  
         [0059]     While in general the same material will be used for all of the elements of this invention, they need not be so manufactured.  
         [0060]     Since certain changes may be made in the described apparatus without departing from the scope of the invention herein involved, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.