Wall panel construction and repair method and apparatus

Abstract

A wall repair and construction method and structure using foam, such as expanding foam, to fill large gaps and holes, and then top coating with plaster. The foam provides a strong, rapidly-cured support structure, and the plaster provides an attractive finish surface. Thus, holes can be repaired in substantially less time than conventionally, and maintain substantial strength. Additionally, construction of walls can be performed rapidly.

1 . A method of constructing a finished wall with a continuous planar face, the method comprising:
 (a) joining at least two sheets of wall material to at least one wall support member, thereby forming a void at least at the junction of said at least two sheets;   (b) applying a foam material in said void, said foam material occupying a significant portion of the void; and   (c) applying over said foam material a curing plaster paste that adheres to the foam material and, when cured, forms a continuous finished planar face with the sheets.   
   
   
       2 . The method in accordance with  claim 1 , further comprising cutting said foam material to conform the foam material to a volume slightly smaller than the void. 
   
   
       3 . A finished wall with a continuous planar face, the wall comprising:
 (a) at least two sheets of wall material joined to at least one wall support member, the junction of said at least two sheets forming a void;   (b) a foam material mounted in said void, said foam material occupying a significant portion of the void; and   (c) plaster mounted over and adhered to said foam material to form a continuous finished planar face with the sheets.   
   
   
       4 . A method of constructing a finished wall with a continuous planar face, the wall including a first sheet and a second, substantially parallel, sheet, the first and second sheets separated to form a gap therebetween in which at least wall support members are interposed and attached to said first and second sheets, the method comprising:
 (a) inserting a fluent material in the gap through a void formed through at least the first sheet, said material expanding to form a foam material extending from attachment to the second sheet to attachment to the first sheet at the void; and   (b) applying over said foam material a curing plaster paste that adheres to at least the foam material and, when cured, forms a continuous finished planar face with the sheets.   
   
   
       5 . The method in accordance with  claim 4 , further comprising cutting the foam material to form a concave foam material surface that is recessed from the finished planar face of the sheets. 
   
   
       6 . The method in accordance with  claim 4 , further comprising mounting at least one bridging member in the gap for preventing the fluent material from falling away from the void. 
   
   
       7 . The method in accordance with  claim 6 , further comprising compressing said at least one bridging member, inserting the bridging member in the gap and releasing the bridging member to expand and contact the first and second sheets. 
   
   
       8 . The method in accordance with  claim 6 , further comprising attaching the bridging member to the second sheet. 
   
   
       9 . The method in accordance with  claim 8 , further comprising attaching the bridging member to the first sheet. 
   
   
       10 . The method in accordance with  claim 6 , wherein the step of inserting the fluent material further comprises placing the fluent material in a vessel (e.g., cup) and resting the vessel on said at least one bridging member. 
   
   
       11 . The method in accordance with  claim 10 , further comprising removably mounting a planar panel to the first sheet over the void, substantially parallel to the continuous planar face of the first sheet, for restricting the fluent material from flowing out of the void. 
   
   
       12 . The method in accordance with  claim 11 , further comprising removing the planar panel from the first sheet. 
   
   
       13 . A finished wall with a continuous planar face, the wall including a first sheet and a second, substantially parallel, sheet, the first and second sheets separated to form a gap therebetween in which at least wall support members are interposed and attached to said first and second sheets, the wall comprising:
 (a) a foam mounted in the gap and at least partially occupying a void formed through at least the first sheet, said foam extending from attachment at the second sheet to the void; and   (b) a cured plaster forming a layer over said foam and at least part of the first sheet, said plaster adhering to the foam and at least part of the first sheet, thereby forming a continuous finished planar face.   
   
   
       14 . The wall in accordance with  claim 13 , wherein the foam forms a concave surface that is recessed from the finished planar face of the sheets. 
   
   
       15 . The wall in accordance with  claim 13 , further comprising at least one bridging member mounted in the gap for supporting the foam. 
   
   
       16 . The wall in accordance with  claim 15 , wherein at least one bridging member is compressed in the gap and expanded to contact the first and second sheets. 
   
   
       17 . The wall in accordance with  claim 15 , wherein the bridging member is attached to the second sheet. 
   
   
       18 . The wall in accordance with  claim 17 , wherein the bridging member is attached to the first sheet.