Apparatus, method and kit for dustless repair of a damaged wallboard

Abstract

An apparatus, method and kit for dustless repair of a damaged wallboard. The apparatus having an insertion rod which engages a patching element and an insertion brace for inserting the patching element and insertion brace through a hole in the wallboard and adhering the patching element to an inner surface of the wallboard. A dustless method is then provided for patching the hole without producing any environmentally harmful dust. The kit includes all necessary materials for repairing a hole in the wallboard using the dustless method according to this invention.

We claim:  
     
         1 . An apparatus for repairing a hole in a wallboard, comprising: 
 an insertion rod having an insertion end portion;    a patching element engageable with the insertion end portion, said patching element made of a deformable material and having a surface area greater than an area of the hole; and    an insertion brace engageable with the insertion end portion.    
     
     
         2 . The apparatus of  claim 1  wherein the insertion rod comprises a handle positioned on a handle end portion of the insertion rod.  
     
     
         3 . The apparatus of  claim 1  further comprising an adhesive applied to a front surface of the patching element.  
     
     
         4 . The apparatus of  claim 3  further comprising a release sheet positioned on the adhesive.  
     
     
         5 . The apparatus of  claim 1  wherein the patching element comprises a styrene polymer.  
     
     
         6 . The apparatus of  claim 5  wherein the patching element has a gauge of about 0.010 to about 0.10.  
     
     
         7 . The apparatus of  claim 1  wherein the insertion brace comprises a styrene polymer.  
     
     
         8 . The apparatus of  claim 7  wherein the insertion brace has a gauge of about 0.010 to about 0.15.  
     
     
         9 . The apparatus of  claim 1  further comprising an adhesive applied to a front surface of the insertion brace.  
     
     
         10 . The apparatus of  claim 9  further comprising a release sheet positioned on the adhesive.  
     
     
         11 . The apparatus of  claim 1  wherein the patching element forms an aperture.  
     
     
         12 . The apparatus of  claim 1  wherein the patching element is threadedly engaged with the insertion rod.  
     
     
         13 . A method for repairing a hole in a wallboard, comprising the steps of: 
 providing a patching element having a surface area greater than an area of the hole;    engaging the patching element with an insertion end portion of an insertion rod;    engaging an insertion brace with the insertion end portion of the insertion rod;    inserting the insertion brace and the patching element into the hole;    mounting the patching element to an inner surface of the wallboard;    applying a first layer of a filler material to the patching element;    wet-sanding the first layer; and    smoothing an outer surface of the first layer with a smoothing surface.    
     
     
         14 . The method of  claim 13  further comprising the steps of: 
 applying a second layer of the filler material to the first layer;  
 wet-sanding the second layer; and  
 smoothing an outer surface of the second layer with a smoothing surface.  
 
     
     
         15 . The method of  claim 13  wherein during the mounting step, a front surface of the patching element is adhered to the inner surface of the wallboard.  
     
     
         16 . The method of  claim 13  further comprising the step of mounting the insertion brace to the patching element.  
     
     
         17 . The method of  claim 16  wherein a front surface of the insertion brace is adhered to a back surface of the patching element.  
     
     
         18 . The method of  claim 13  further comprising the step of disengaging the insertion brace and the patching element from the insertion end portion before the first layer of filler material is applied to the patching element.  
     
     
         19 . The method of  claim 13  further comprising the step of disengaging the insertion brace and the patching element from the insertion end portion after the first layer of filler material is applied to the patching element.  
     
     
         20 . The method of  claim 19  further comprising the step of at least partially drying the first layer before disengaging the insertion brace and the patching element from the insertion end portion.  
     
     
         21 . The method of  claim 13  wherein the wet-sanding step comprises wetting the outer surface of the first layer with a sponge to keep the outer surface of the first layer wet and sanding the outer surface of the first layer with a sanding screen.  
     
     
         22 . A kit for repairing a hole in a wallboard, comprising: 
 an insertion rod having a threaded insertion end portion;    a flexible patching element forming an aperture for threaded engagement with the insertion end portion of the insertion rod, the patching element comprising a styrene polymer which can be cut to an appropriate shape corresponding to the hole in the wallboard, and having an adhesive applied to a front surface;    an insertion brace forming an aperture for threaded engagement with the insertion end portion of the insertion rod, the insertion brace adherable to a back surface of the patching element for supporting the patching element as the patching element is adhered to an inner surface of the wallboard;    a wet-sanding system; and    a smoothing surface.