DRYWALL REPAIR PLUG AND METHOD

Abstract

A drywall repair device includes an elongated plank. The elongated plank includes a body with back end and a tapered front end. The elongated plank also includes a cylindrical puck positioned at a central portion of the elongated plank between the back end and tapered front end. The cylindrical puck has a diameter corresponding with a width of the elongated plank. The drywall repair device includes a plug having a frustoconical shape. The drywall repair device also includes a tensioner removably coupled to the cylindrical puck and the plug. The tensioner is adapted to apply a tension to a back surface of the cylindrical puck to retain the elongated plank in a hole in a drywall panel and to guide the plug into the hole of the drywall panel.

Description

FIELD

The present disclosure relates to construction and repair devices and, more particularly, to drywall construction and repair devices and methods.

BACKGROUND

Repair of drywall is typically performed by applying a drywall mud, or patch compound, in the hole to perform a patch repair. 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.

As can be seen, there is a need for apparatus and methods that address the above drawbacks.

SUMMARY

In one aspect of the present disclosure, a drywall repair device includes an elongated plank. The elongated plank includes a body with back end and a tapered front end. The elongated plank also includes a cylindrical puck positioned at a central portion of the elongated plank between the back end and tapered front end. The cylindrical puck has a diameter corresponding with a width of the elongated plank. The drywall repair device includes a plug having a frustoconical shape. The drywall repair device also includes a tensioner removably coupled to the cylindrical puck and the plug. The tensioner is adapted to apply a tension to a back surface of the cylindrical puck to retain the elongated plank in a hole in a drywall panel and to guide the plug into the hole of the drywall panel.

In another aspect of the present disclosure, a method of drywall repair includes inserting an elongated plank into a hole in a drywall panel. The elongated plank includes a body with back end and a tapered front end. The elongated plank also includes a cylindrical puck positioned at a central portion of the elongated plank between the back end and tapered front end. The cylindrical puck has a diameter corresponding with a width of the elongated plank. The method includes positioning the cylindrical puck in the hole by manipulating a tensioner removably coupled to the cylindrical puck. Further, the method includes inserting a plug into the hole using the tensioner as a guide. Additionally, the method includes securing the elongated plank to an interior surface of the drywall panel with a first fastener extending through a front surface of the drywall panel. The method includes securing the plug to the elongated plank with a second fastener extending through a front surface of the plug.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a drywall repair apparatus including a plank and plug, according to aspects of the present disclosure;

FIG. 2 is a perspective view of the drywall repair apparatus of FIG. 1 showing hole right sizing, according to aspects of the present disclosure;

FIG. 3 is a perspective view of the drywall repair apparatus taken along line 3-3 in FIG. 2, according to aspects of the present disclosure;

FIG. 4 is a perspective view of the drywall repair apparatus of FIG. 1 showing a tensioner cable, according to aspects of the present disclosure;

FIG. 5 is a section view of the drywall repair apparatus of FIG. 1 showing the plank being placed behind the drywall, according to aspects of the present disclosure;

FIG. 6 is a section view of the drywall repair apparatus of FIG. 1 showing the plank being positioned behind the drywall, according to aspects of the present disclosure;

FIG. 7 is a section view of the drywall repair apparatus of FIG. 1 showing the plug being added, according to aspects of the present disclosure;

FIG. 8 is a section view of the drywall repair apparatus of FIG. 1 showing the plug in place, according to aspects of the present disclosure; and

FIG. 9 is a section view of the drywall repair apparatus of FIG. 1 showing a completed repair, according to aspects of the present disclosure.

DETAILED DESCRIPTION OF THE DISCLOSURE

The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the disclosure. 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 disclosure, since the scope of the disclosure is best defined by the appended claims.

As discussed above, 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.

Broadly, an embodiment of the present disclosure provides a drywall repair apparatus and method that quickly and easily repairs holes in drywall enabling users to produce professional results. The drywall repair apparatus includes two pieces, a plug, and a plank. The drywall repair apparatus is a tool that “right sizes” the damaged hole, inserts the plank into the hole which provides an anchor into which the plug is attached. The resulting repair surface requires only a thin layer of joint compound to smooth out the damaged area. The repair is quick, easy, and results in a professionally smooth surface with a sturdy repair that is as strong, if not stronger, than the original drywall.

Referring now to FIGS. 1-9, FIG. 1 illustrates a drywall repair apparatus including an elongated plank 10 and a plug 18, according to aspects of the present disclosure. While FIG. 1 illustrates examples of components of the drywall repair apparatus, additional components can be added and existing components can be removed and/or modified.

As illustrated, the elongated plank 10 includes a body 11 with a tapered end 12. A cylindrical puck 13 is formed at a central portion of the body 11 and protrudes from a front surface and a back surface of the elongated plank 10. Preferably the cylindrical puck 13 is positioned along an intermediate portion of the body 11 of the elongated plank 10. The body 11, including the tapered end 12, can also include a beveled edge surface 15. The tapered end 12 and beveled edge 15 are configured to clean and size the hole in the drywall 28 as part of the repair process, as illustrated in FIGS. 2 and 3. The drywall repair apparatus including the elongated plank 10 and the plug 18 can be made of any suitable materials, such as plastics, wood, composites, and the like.

The cylindrical puck 13 has a diameter equal to the lateral width of the plank 10. The puck 13 is a solid cylinder molded into the plank and vertically positioned so that it protrudes evenly from both top and bottom surfaces of the plank. Each equally elevated protrusion is such that the combined height of the protrusion and the height of the plug 18 does not exceed the thickness of the standard drywall, for example, drywall 28 as illustrated in FIG. 6. For example, the elevation of the cylindrical puck 13 from the surface of the elongated plank 10 and the plug 18 is selected to position the top front face of the plug 18 at a depth of approximately ⅛ inch from a front surface of the drywall 28. Accordingly, the combined elevation of the cylindrical puck 13 and plug 18 may be ⅛ inch less than a thickness of the drywall 28 that is in need of repair, more preferably 1/16″.

The cylindrical puck 13 includes one or more channels 14, for example, two channels, that extend from a front surface to a back surface of the cylindrical puck 13. As illustrated in FIG. 4, the channels 14 are configured to receive a tensioner 24. The tensioner 24 is removably coupled to the cylindrical puck 13. The tensioner 24 is adapted to allow the elongated plank 10 to be positioned on an inner surface of the drywall 28. Additionally, tensioner 24 is adapted to retain the drywall repair device 10 against an inner surface of the drywall 28 such that the plug 18 can be attached to the elongated plank 10 and fasteners 26 may be received in the elongated plank 10 and the plug 18. In the non-limiting embodiment shown, the tensioner 24 can be a cable that allows the user to position the elongated plank 10 in the hole during installation.

The plug 18 is configured to be inserted into the hole in the drywall 28, thereby filling the hole after positioning the elongated plank 10. As illustrated in FIG. 1, the plug 18 frustoconical shape that tapers from a front surface of the plug 18 to rear surface of the plug 18. The plug 18 includes one or more channels 20, for example, two channels, that extend from a front surface to a back surface of the plug. As illustrated in FIGS. 7-9, the channels 20 are configured to receive a tensioner 24. The plug 18 also includes a tapered fastener channel 22 that extends from the front surface to the back surface. The tapered fastener channel 22 is configured to receive a fastener 26 to couple the plug to the elongated plank 10. The tapered inner surface of the tapered fastener channel 22 is positioned at the front surface of the plug 18 such that the fastener 26 can be recessed into the plug 18.

A method of repairing a hole in a drywall surface is illustrated in FIGS. 2-9. In a first step, as illustrated in FIGS. 2 and 3, the tapered end 12 is utilized to clean and size a hole or other damage in drywall 28. A distal end of the tapered end 12 is inserted into the hole and the elongated plank 10 is rotated back and forth along a longitudinal axis of the elongated plank 10. As the drywall repair device 10 is rotated, the beveled edge 15 scrapes the drywall material. The elongated plank 10 is progressively urged into the hole to be repaired until the hole has been sized to the lateral width of elongated plank 10.

In the next step, as illustrated in FIG. 4, the tensioner 24 can then be routed through channels 14 to prepare the elongated plank 10 for installation in drywall 28. The tensioner 24 is routed so that free ends of the tensioner 24 protrude from the front surface of the cylindrical puck 13 and the tensioner 24 is retained against the back surface of the cylindrical puck 13.

As illustrated in FIGS. 5 and 6, the elongated plank 10 can then be inserted into the cleaned and sized hole in the drywall 28. While the elongated plank 10 is inserted into the cleaned and sized hole the user utilizes the free ends of the tensioner 24 to prevent the elongated plank 10 from falling into the cavity behind the drywall 28. Once the elongated plank 10 is positioned within the cavity, the tensioner 24 is drawn to position the cylindrical puck 13 within the cleaned and sized hole, as shown in FIG. 6. Tension is applied to the tensioner 24 to retain the cylindrical puck 13 in abutment with an interior surface of the drywall 28 surrounding the cleaned and sized hole.

As illustrated in FIG. 7, the plug 18 is inserted into the hold in the drywall 28 using the tensioner 24. That is, the ends of the tensioner 24 are inserted into the channels 20 of the plug 18 such that the back surface of the plug 18 is positioned towards the drywall 28. The plug 18 can then be fed along the tensioner 24 into the hole in the drywall 28 while applying tension with the tensioner 24, as illustrated in FIG. 8.

As illustrated in FIG. 9, while tension is applied to the tensioner 24, the fasteners 26 are drilled through the drywall 28 and into the ends of the elongated plank 10. The fasteners 26 are tightened to retain the elongated plank 10 in position in abutment with the interior surface of the drywall 28 with the cylindrical puck 13 positioned within, and preferably centered in the cleaned and sized hole. The plug 18 is then secured to the elongated plank 10 with a fastener 26 drilled through the fastener channel 22 into a starter hole 16 in the cylindrical puck 13. The fastener 26 is tightened until the fastener 26 is recessed in the tapered channel 22 of the plug 18. As it is being recessed into the drywall hole, the plug 18 pulls the ragged edges of the hole underneath is tapered edges and rests below the exterior surface of the drywall 28. For example, ⅛ inch below the drywall exterior surface, preferably 1/16 inch.

Once the elongated plank 10 and the plug 18 have been secured with the fasteners 26, the user may then withdraw the tensioner 24 from the plug 18 and the cylindrical puck 13. For example, a free end of the tensioner 24 is pulled to withdraw the tensioner 24 from the plug 18 and the cylindrical puck 13. Alternatively, the free end of the tensioner 24 may be pushed within the interior cavity behind the drywall 28. As shown in FIG. 9, the user may apply a drywall compound 30 to the surface of the drywall 28, covering the fasteners 26 and filling any gaps left by the plug 18. A stronger bond may be achieved by pressing the drywall compound 30 such that it is urged into the channels 20 of the plug 18.

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 plug 18 fills the drywall hole, eliminating the need for numerous layers of joint compound to fill the ½″ void created by the hole. The elongated plank 10 is anchored to the inside of the drywall and creates an anchor for attaching the plug using a common drywall screw. The drywall repair apparatus reduces the number of joint compound layers required and eliminates the need for professional technique of broad feathering around the hole to hide the repair. The drywall repair apparatus also, provides a solid backing inside the drywall that is hidden and results in a long lasting and strong repair. Additionally, the plug 18, once attached, eliminates ragged edges created during the “right sizing” of the hole and provides a much cleaner surface to receive the drywall joint compound.

As used in the description herein and throughout the claims that follow, “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise. Also, as used in the description herein and throughout the claims that follow, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise. While the above is a complete description of specific examples of the disclosure, additional examples are also possible. Thus, the above description should not be taken as limiting the scope of the disclosure which is defined by the appended claims along with their full scope of equivalents.

The foregoing disclosure encompasses multiple distinct examples with independent utility. While these examples have been disclosed in a particular form, the specific examples disclosed and illustrated above are not to be considered in a limiting sense as numerous variations are possible. The subject matter disclosed herein includes novel and non-obvious combinations and sub-combinations of the various elements, features, functions and/or properties disclosed above both explicitly and inherently. Where the disclosure or subsequently filed claims recite “a” element, “a first” element, or any such equivalent term, the disclosure or claims is to be understood to incorporate one or more such elements, neither requiring nor excluding two or more of such elements. As used herein regarding a list, “and” forms a group inclusive of all the listed elements. For example, an example described as including A, B, C, and D is an example that includes A, includes B, includes C, and also includes D. As used herein regarding a list, “or” forms a list of elements, any of which may be included. For example, an example described as including A, B, C, or D is an example that includes any of the elements A, B, C, and D. Unless otherwise stated, an example including a list of alternatively-inclusive elements does not preclude other examples that include various combinations of some or all of the alternatively-inclusive elements. An example described using a list of alternatively-inclusive elements includes at least one element of the listed elements. However, an example described using a list of alternatively-inclusive elements does not preclude another example that includes all of the listed elements. And, an example described using a list of alternatively-inclusive elements does not preclude another example that includes a combination of some of the listed elements. As used herein regarding a list, “and/or” forms a list of elements inclusive alone or in any combination. For example, an example described as including A, B, C, and/or D is an example that may include: A alone; A and B; A, B and C; A, B, C, and D; and so forth. The bounds of an “and/or” list are defined by the complete set of combinations and permutations for the list.

It should be understood, of course, that the foregoing relates to exemplary embodiments of the disclosure and that modifications can be made without departing from the spirit and scope of the disclosure as set forth in the following claims.

Claims

1. A drywall repair device, comprising: an elongated plank comprising: a body with back end and a tapered front end; anda cylindrical puck positioned at a central portion of the elongated plank between the back end and tapered front end, the cylindrical puck having a diameter corresponding with a width of the elongated plank;a plug having a frustoconical shape; anda tensioner removably coupled to the cylindrical puck and the plug, the tensioner being adapted to apply a tension to a back surface of the cylindrical puck to retain the elongated plank in a hole in a drywall panel and to guide the plug into the hole of the drywall panel.

2. The drywall repair device of claim 1, wherein the diameter is selected to correspond with a size of the hole to be repaired.

3. The drywall repair device of claim 1, wherein a top surface of the cylindrical puck is elevated at a height from a top surface of the elongated plank such that when combined with a height of the plug is approximately ⅛ inch less than a thickness of the drywall panel and a bottom surface of the cylindrical puck is elevated at a height from a bottom surface of the elongated plank such that when combined with the height of the plug is approximately 2 mm less than the thickness of the drywall panel.

4. The drywall repair device of claim 1, wherein the plug comprises one or more channels extending from a front surface of the plug to a back surface of the plug and the one or more channels are configured to receive the tensioner.

5. The drywall repair device of claim 1, wherein the plug comprises a tapered fastener channel extending from a front surface of the plug to a back surface of the plug and the tapered fastener channel is configured to receive a fastener to couple the plug to the elongated plank.

6. The drywall repair device of claim 1, wherein the cylindrical puck comprises one or more channels extending from a front surface of the cylindrical puck to the back surface of the cylindrical puck and the one or more channels are configured to receive the tensioner.

7. The drywall repair device of claim 1, wherein the body of the elongated plank further comprises a beveled edge defined along a side edge of at least the tapered end.

8. A method of drywall repair, comprising: inserting drywall repair device in claim 1 andpositioning the cylindrical puck in the hole by manipulating a tensioner removably coupled to the cylindrical puck;inserting a plug into the hole using the tensioner as a guide;securing the elongated plank to an interior surface of the drywall panel with a first and second fastener extending through a front surface of the drywall panel; andsecuring the plug to the elongated plank with a third fastener extending through a front surface of the plug; and pulling ragged edges of the hole under a tapered edge as it is being tightened against the plank.

9. The method of claim 8, the method further comprising: removing the tensioner from the cylindrical puck and the plug.

10. The method of claim 8, the method further comprising: applying a drywall compound to an exterior surface of the drywall panel to cover the front surface of the plug, the first fastener, the second fastener, and third fastener.

11. The method of claim 8, the method further comprising: cleaning and sizing the hole by inserting the tapered front end of the elongated plank into the hole; androtating the elongated plank about a longitudinal axis and urging the elongated plank into the hole until the hole has a width corresponding to the width of the elongated plank.