The present invention relates to drywall, and more particularly to apparatus and methods for repairing holes in drywall.
Repair of drywall is typically performed by applying a drywall mud, or patch compound, in the hole to perform a patch repair. However, for larger holes, this often requires multiple applications of the drywall mud while permitting the mud an opportunity to completely dry between applications, causing unnecessary delays in performing a simple repair.
Even when properly dried, mud applications to larger holes often do not have sufficient structural integrity because the mud does not have a suitable bonding interface with the drywall and there is often an absence of wall structural support behind the mud. Consequently, the patch may release from the drywall when the patch is sanded for a smooth wall surface prior to refinishing or when moistened with the paint during refinishing.
Other drywall repair products provide a fibrous patch that is affixed to the outside surface of the drywall. The finished repair is not solid as there is no backing behind the fibrous patch. Also, because the patch adds elevation to the drywall surface, this increases the area needed to feather the repair so that it blends into the wall. Feathering is a professional drywall technique that most homeowners are not able to do well, resulting in a subpar repair.
Some other types of drywall repair devices mount to inside of the drywall, creating a solid backing but do not fill the ½″ deep void created by the hole. The void needs to be filled with multiple ⅛″ layers of joint compound each of which, as indicated previously, must dry before the next layer is applied. Drying time between layers is approximately 4 hours. Thus, four ⅛″ layers will take 16 hours to complete the repair.
As can be seen, there is a need for improved apparatus and methods for performing a drywall repair.
In one aspect of the present invention, a drywall repair device, for repairing a hole in a drywall panel is disclosed. The drywall repair device includes an elongate plank having a front surface, a back surface, a first end, a second end, and a point defined at one of the first end and the second end. A cylindrical puck has a top surface elevated from the front surface. The cylindrical puck has a diameter corresponding with a width of the elongate plank. A tensioner is removably coupled to the cylindrical puck. The tensioner is adapted to apply a tension to the top surface of the cylindrical puck to retain the drywall repair device in the hole in the drywall panel.
In some embodiments, the diameter is selected to correspond with a size of the hole to be repaired.
In some embodiments, the top surface is elevated at a height that is approximately ⅛ inch less than a thickness of the drywall panel.
In some embodiments, the device also includes an aperture defined in the top surface of the cylindrical puck. The tensioner is removably received in the aperture. The tensioner may be a cable.
In other embodiments, a beveled edge is defined along a side edge of the point.
In other aspects of the invention, a method of repairing a hole in a drywall panel is disclosed. The method includes inserting a drywall repair device into the hole in the drywall panel. The drywall repair device has a point defined at a first end of an elongate plank having a front surface, a back surface. A cylindrical puck has a top surface elevated from the front surface and has a diameter corresponding with a width of the elongate plank. The cylindrical puck is positioned in the hole by manipulating a tensioner removably coupled to the cylindrical puck. At least the first end of the elongate plank is secured to an interior surface of the drywall panel with a fastener extending through a front surface of the drywall panel.
In some embodiments, the method includes removing the tensioner from the cylindrical puck.
In some embodiments, the method also includes applying a drywall compound to an exterior surface of the drywall panel surrounding the hole to cover the top surface of the cylindrical puck and the fastener.
In other embodiments, an outward tension is applied to the tensioner to retain the drywall repair device in the hole while securing the fastener.
In yet other embodiments, the method includes cleaning and sizing the hole by inserting the point extending from a front end of the elongate plank into the hole. The elongate plank is rotated about a longitudinal axis while urging the elongate plank into the hole until the hole has a width corresponding to a width of the elongate plank.
These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description, and claims.
The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense but is made merely for the purpose of illustrating the general principles of the invention.
Broadly, embodiments of the present invention provides a puck and plank drywall repair device that can be installed in less than two minutes. More importantly, the drywall repair device requires only one layer of joint compound to conceal the repair in the wall surface and does not require broad feathering technique to hide the repair site.
As seen in reference to the drawings, the drywall repair device 10 that includes an elongate plank portion 12 and a cylindrical puck portion 14 protruding from a surface of the plank 12. Preferably the cylindrical puck 14 is positioned along an intermediate portion of the plank 12. At least one end of the plank 12 includes a pointed tip 15. The pointed tip 15 may also include a beveled edge surface 16. The pointed end 15 and beveled edge 16 are configured to clean and size the hole in the drywall 22 as part of the repair process.
The plank 12 has a lateral width that corresponds with a diameter of the puck 14 and a size of hole to be repaired. The elevation of the puck 14 from the surface of the plank 12 is selected to position the top front face of the puck 14 at a depth of ⅛ inch from a front surface of the drywall 22. Accordingly, the elevation of the puck 14 may be ⅛ inch less than a thickness of the drywall 22 that is in need of repair, more preferably 1/16″. The drywall repair device 10 can be made of any suitable materials, such as plastics, wood, composites, and the like.
One or more apertures 18 are defined in a top face of the puck 14. The apertures are configured to receive a tensioner 20. The tensioner 20 is removably coupled to the puck 14. The tensioner 20 is adapted to retain the drywall repair device 10 against an inner surface of the drywall 22 such that a fastener 26 may be received in the plank 12. In the non-limiting embodiment shown, the tensioner 20 may be a cable 20 that allows the user to position the drywall repair device 10 in the hole during installation.
A method of repairing a hole in a drywall surface is illustrated in
The cable 20 may then be routed through the apertures 18 to prepare the drywall repair device 10 for installation in the wall. The cable 20 is routed so that free ends of the cable 20 protrude from the outer face of the puck 14 and the cable 20 is retained against an interior surface of the puck 14, such as seen in
The drywall repair device 10 may then be inserted into the cleaned and sized hole 24 in the drywall 22. While the drywall repair device 10 is inserted into the cleaned and sized hole 24 the user utilizes the free ends of the cable 20 to prevent the drywall repair device 10 from falling into the cavity behind the wall surface 22, as seen in
Once the drywall repair device 10 is positioned within the cavity, the cable 20 is drawn to position the puck 14 within the cleaned and sized hole 24, as shown in
While tension is applied to the cable 20, a drywall fastener 26 is drilled through the drywall 22 and into the ends of the plank 12. The drywall fastener 26 is tightened to retain the plank 12 in position in abutment with the interior surface of the drywall 22 with the puck 14 positioned within, and preferably centered in the cleaned and sized hole 24, as shown in reference to
Once the drywall repair device 10 has been secured with the fastener 26, the user may then withdraw the cable 20 from the apertures 18 in the puck 14 as shown in
As seen in
Unlike other repair devices/techniques, this integrated device is both a tool for preparing the hole and an integral part of the finished repair. The puck fills the drywall hole, eliminating the need for numerous layers of joint compound to fill the ½″ void created by the hole. Because the puck and plank are a single plastic device, the plank is anchored to the inside of the drywall, thereby holding the puck in place. The device reduces the number of joint compound layers required, eliminates the need for professional technique of broad feathering around the hole to hide the repair. It also, provides a solid backing inside the drywall that is hidden and results in a long lasting and strong repair
It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.
This application claims the benefit of priority of U.S. provisional application No. 63/050,084 filed Jul. 9, 2020, the contents of which are herein incorporated by reference.
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Number | Date | Country | |
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Number | Date | Country | |
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63050084 | Jul 2020 | US |