MECHANICALLY TENSIONED WALL PATCH

Abstract

This invention is an apparatus for repairing a hole in a surface with an adhesive mesh repair patch that is mechanically tensioned inward by a tensioning pin that is attached to a slat, and a method of using the same.

Description

FIELD OF INVENTION

[0001] This invention relates to the method and apparatus for repairing a hole in a sheet, plate, board, fiberglass, wood, or drywall with an adhesive mesh repair patch. More particularly, the invention relates to a method and apparatus of mechanically tensioning a mesh repair patch such that the repair patch is indented into the hole to be patched by a tensioning pin.

BACKGROUND

[0002] Since the advent of the drywall, and its prolific use in the construction of structures, methods and devices have been created to repair damaged portions of a drywall. Generally, there are two common types of reparable damage to a drywall: a small hole or crack; or a large hole. Large holes are typically repaired by cutting out the damaged section of the wall, placing a back board behind the cut-out hole and filling the cut-out hole with a comparable sized piece of drywall. The edges of the cut-out are then taped with paper drywall tape or fiberglass tape, and filled in and covered with drywall compound.

[0003] Very small holes and cracks may often be repaired with just the use of drywall compound, by layering the drywall compound over the hole or crack and then sanding it down to smooth it with the rest of the wall.

[0004] For holes that are too large to use just the drywall compound or too small to warrant the use of the cut-out and replace method, a mesh repair patch, or a mesh laminated and centered onto a smaller piece of metal, as disclosed in U.S. Pat. No. 4,135,017, issued to Hoffman, is frequently used. A mesh repair patch is a small piece of mesh, typically made out of round fiberglass threads, which is placed over the hole in the drywall. The mesh repair patch provides a workable surface for the drywall compound to adhere to in repairing the damage, but can leave an unsightly bulge, or fall away completely from the wall due to the weight of the drywall compound. Alternatively, metal laminate plates are rigid enough to support more weight, but leave an unsightly bulge that is difficult to float out and hide due to the increased thickness of the metal.

[0005] There are numerous references that disclose devices and methods for repairing holes in walls, boards, sheets, plates, fiberglass, wood, or drywall using a mesh repair patch. For example, U.S. Pat. No. 7,380,382 ("the '382 patent"), issued to Daniel R. Hansen, the same inventor of the present invention, discloses a laminate mesh repair patch that has an adhesive located on one side of the fiberglass mesh adhered and centered onto a smaller separate sheet of dry, water hardenable cement on the front. The mesh repair patch of the '382 patent is placed over the hole, the sides of the patch adhere to the sides of the hole, and the cement is wetted, allowed to set for about 5 minutes becoming partially rigid, but still movable, and then pushed inward to form an indentation. After the indentation sets relatively hard, drywall compound is applied to make a smooth repair. The partially rigid cement on the front of the mesh repair patch allowed the mesh laminate to be manually indented into the hole by pushing it inward with a hand or finger.

[0006] Although the '382 patent was a vast improvement over using the standard mesh repair patch, or metal laminate patches, without the dry, water hardenable cement on the front, it did not entirely overcome the problem of providing a repair patch devoid of an unsightly bulge. Specifically, the '382 patent had a mesh repair patch thinner than the popular metal laminate patch, but thicker than a fiberglass mesh patch devoid of a metal plate. The '382 patent requires that the user spray water over the patch once it is affixed over the hole and onto the wall, and rubbed with a hand to mix the plaster. With the addition of water, the '382 patch will sometimes slide off the wall, or in cold weather, will not stick at all. Also, if the plaster on the patch is not wetted and rubbed properly, a larger, unsightly bulge may be created. Finally, it can take 20 or 30 minutes, depending on atmospheric conditions, for the patch disclosed in the '382 patent to set hard enough to complete the repair. This is a significant downside for professionals in need of an instant repair.

[0007] Several references, including U.S. Pat. Nos. 4,406,107 ("the '107 patent"), 6,317,952 ("the '952 patent"), and 5,033,949 ("the '949 patent"), disclose wall repair devices that provide a stable surface on which to apply a drywall compound to repair a hole in a wall. However, none of these references incorporate an easy to use mesh repair patch and each and every one of these references involves the use of a very complex device or method that is difficult to use or perform. For example, the '107 patent, issued to Schoonbeck discloses a wall repair device that is comprised of two discs connected with a center bolt and nut. The larger of the two discs must be larger than the hole to be repaired and is adhered to the back of the wall. The smaller disc must be smaller than the hole to be repaired. The smaller disc is positioned along the bolt and is locked in place just rearward of the hole. The front and smaller disc acts as a stable platform for drywall compound to be applied. Although the device disclosed in the '107 patent could potentially aid in the repair of a drywall hole, the device is very complex and is extremely limited. Specifically, there is no easy way to modify the discs to fit the randomly sized hole that may need to be repaired. Additionally, it is hard to imagine how the large disc fits through the hole in the first place since it must necessarily be larger than the hole.

[0008] The '952 patent discloses a device that includes a flexible plastic plate, which is bigger than the hole to be repaired and is pushed to the inside of the wall and then pulled back against the back side of the wall using a plastic zip key like device. The zip key is attached to a plastic rod, which is positioned on the outside of the wall and securely holds the plate in place. The problem with this device is that the plastic rod is in the way when the user fills the hole with plaster or drywall compound. Additionally, once the drywall compound hardens, the plastic zip key must be cut away as close to the hardened plaster as possible and removed from the patching assembly along with the plastic rod. Accordingly, an additional coat of drywall compound is required to complete the repair and cover the zip key.

[0009] The '949 patent discloses a back disc that is held in place in a hole by a bolt while drywall compound is filled in the hole. Before the compound is set, a front dam is attached to the bolt, and the back disc is forced forward, which causes the compound to press forward against the dam. The problem with this device is that it is extremely complicated to use and requires the user to hold the back in place while the drywall compound is applied.

[0010] Thus, what is needed is to provide a tensioned mesh repair patch that is less complex than the prior art and much easier to use.

SUMMARY OF THE INVENTION

[0011] To minimize the limitations in the prior art, and to minimize other limitations that will become apparent upon reading and understanding the present specification, the present invention is a method and apparatus of mechanically tensioning a mesh repair patch such that the repair patch is indented into the hole to be patched by tensioning pin.

[0012] One embodiment of the invention is a surface repair patch comprising: a patch; a tension pin; and a slat. The patch is affixed to and substantially covers a front side of a hole in a surface. The slat is inserted into the hole in a surface and is affixed to a back side of the surface on an outer edge of the hole. Preferably, the tension pin has a head end and a free end. The head end of the tension pin is attached to the patch. The free end of the tension pin is attached to the slat such that the head end is pulled toward the slat, which causes the patch to inwardly indent. Preferably, the slat has one or more apertures into which the free end is inserted. Alternatively, the invention may include a plurality of slat connectors that are slidably connected to the slat and are adjustable along the length of the slat. Preferably it is these slat connectors that are used to affix the slat to the back side of the surface on an outer edge of the hole. Typically, the patch is a flat fiberglass thread mesh repair patch that is adhesively affixed to the front side of the hole. Preferably the slat is plastic and scored for easily adjusting the size of the slat. Alternatively, the slat may be wood and the tension pin may be a nail or a screw. Preferably the surface is a drywall and the hole is a hole in the drywall. The adhesive is preferably a very strong anti-slip type adhesive that will stand up against the force that the tensioning pin puts on the mesh screen. Typically drywall tapes and patches used in the field of drywall are of the pressure sensitive type that easily allows for removing and repositioning the device many times with little loss in adhesive quality. There are many types of anti-slip or permanent adhesives that are acrylic, organic, water based, etc., commonly used in other industries such as, manufacturers of automobiles. These types of adhesives are not used in the drywall industry. As the tension pin is pushed or turned inward, there is a force created that wants to pull the mesh away from the wall at the source of the adhesive bond between the wall surface and the adhesive mesh. For the patch to create a superior flush finish the adhesive needs to partially or completely hold the mesh in place to remove the slack in the patch to have proper tensioning on the fiberglass threads much like the strings on a guitar.

[0013] In another embodiment of the invention the apertures have one or more pawls and the tension pin has a plurality of teeth. In this manner the plurality of teeth of the tension pin ratchet past the one or more pawls of the one or more apertures. The pawls prevent the tension pin from sliding back out of the apertures.

[0014] In another embodiment of the invention the tension pin has one or more nodes. These nodes slide through the apertures such that the tension pin is restricted from sliding back out of the apertures.

[0015] Another embodiment of the invention is a method of applying a repair patch to a hole in a surface, preferably comprising the steps of: affixing a slat to a back side of a surface on an outer edge of the hole; affixing a patch to a front side of the hole; providing a tension pin, wherein the tension pin has a head end and a free end; attaching the head end of the tension pin to the patch; attaching the free end of the tension pin to the slat; using the tension pin to mechanically indent the patch toward the slat; wherein the slat has one or more apertures; wherein free end is attached to the slat by inserting the free end into the one or more apertures; wherein the slat is further comprised of a first slat connector and a second slat connector; wherein the first slat connector and the second slat connector are slidably connected to the slat and are slidably adjustable along a length of the slat; wherein the slat connectors are used to affix slat to the back side of the surface on an outer edge of the hole; sliding the first slat connector and the second slat connector to opposite ends of the slat so that the slat connectors are spaced just wider than the hole; affixing the first slat connector and the second slat connector to the back side of the surface on an outer edge of the hole; wherein the one or more apertures have one or more pawls; wherein the tension pin has a plurality of teeth; inserting the tension pin into the one or more apertures such that the plurality of teeth of the tension pin ratchet past the one or more pawls of the one or more apertures; wherein the tension pin is prevented from sliding back out of the one or more apertures by the one or more pawls; indenting and tensioning the patch towards the slat by pushing the tension pin into the one or more apertures; wherein the patch is a flat fiberglass mesh repair patch; and preferably, applying a drywall compound on the indented and tensioned patch.

[0016] Alternatively, the method includes: wherein the tension pin has a one or more nodes; inserting the tension pin into the one or more apertures such that the one or more nodes of the tension pin slide past the one or more apertures; and wherein the tension pin is restricted from sliding back out of the one or more apertures; indenting and tensioning the patch towards the slat by pushing the tension pin into the one or more apertures; and wherein the patch is a flat fiberglass mesh repair patch.

[0017] Other embodiments of the invention include the use of two or more slats. The slats may be telescoping so that a smaller product can be packaged and sold. Alternatively, the one or more slats may have a pin interface or slider that accepts and/or engages with the pin.

[0018] In another embodiment of the invention, the slat, connectors, or pin interface slider engages with an interior wall beam or the inside of an opposite dry wall.

[0019] Alternatively, the engagement mechanism for the connectors can be spikes or hooks, rather than an adhesive.

[0020] In another embodiment of the invention, the tension pin may be attached to an interior structure of the wall or an opposite drywall board. Alternatively, the tension pin may have a large flat head that is turned around, covered with an adhesive, and attached to an interior backside of the opposite drywall inside of the hole so that the sharp tip protrudes outside the hole that is to be repaired. An adhesively coated mesh is applied over the hole with the tension pin puncturing the center of the patch. A tension disk is pushed inward tightening the mesh, like a cable tie, holding the mesh tight. The tip of the tensioning pin may be cut flush, as close to the mesh as possible, and filled. This embodiment is especially useful with hollow core doors and fiberglass shower repairs. Epoxy resins, plastic, or plastic fillers, such as Bondo® can be used instead of plaster or drywall compound.

[0021] In another embodiment of the invention, the slat or connectors may be attached to the interior of the wall by screwing and countersinking two or more hollow wall plastic anchors through the wall and then attaching the slat or connectors to the anchors. Alternatively, the portion of the wall anchor that protrudes inward can accept a bungee cord, plastic cable tie, turnbuckle, spring, rubber band, plastic or metal band with holes, which can be stretched or extended inside the hole from one wall anchor to the other. This device located between the wall anchors may be manually tightened by twisting or winding the device until properly tensioned, if additional tension is necessary. The center of the device can be made to accept a mechanical tensioning device such as a tensioning pin to pull the mesh inward tightening the patch.

[0022] In another embodiment of the invention, the tension patch can be made in a roll to cover long channels created in walls for installing cable, electrical wiring, plumbing, etc. Multiple slats may be installed along the inside of the wall channel at reasonable intervals (20-50 cm, as needed). The rolled mesh is then applied over the entire channel. Multiple solid rods can be attached with a tension pin starting from one slat to the next and tightened until the mesh is pulled inward creating an indentation along the entire channel and then the long strip of mesh is covered with plaster.

[0023] Another embodiment of the invention takes into account pipes protruding from the inside of the wall to the outside of the wall for plumbing, such as angle stops under a sink, or interior fire sprinklers, which sometimes have holes in the wall that need to be repaired around the pipe. The mesh may be cut with an appropriate size hole in the patch, and a slit from the hole to one side of the mesh to position the patch around the pipe and against the wall covering the hole. A round disk tension device with a hinge on one side is opened and snapped snuggly into place around the pipe and slid forward toward the mesh until the mesh is properly tensioned and indented beyond the outside surface of the wall. The disk may have teeth that protrude into the mesh to anchor and affix the disk to the mesh. This keeps the disk from sliding inside the hole without the mesh and from slipping by the disk during installation. The patch is then completed with drywall compound.

[0024] In another embodiment, of the invention the mesh patch, rather than being completely coated with adhesive on a back side, is only coated on a rim of the patch. This allows better penetration of the drywall compound into the mesh, which, when hardened, provide a stronger repair.

[0025] In another embodiment of the invention, only one end of the slat is attached to the interior of the wall. Alternatively, the slat may use a clip to non-adhesively attach to the rim of the hole to be repaired.

[0026] In another embodiment of the invention, the tensioning pin and slat may provide magnetic attraction to tension the mesh between them.

[0027] It is an object of the present invention to overcome the limitations of the prior art.

[0028] Another object of this invention is to provide a mechanically tensioned wall patch that is simple, easy to use, professional grade, and inexpensive.

[0029] One of the problems that the present invention solves is how to indent and hold steady a mesh wall patch that is strong enough to support the weight of a drywall compound so that it can be used to smoothly repair a hole in a surface, such as dry wall.

BRIEF DESCRIPTION OF THE DRAWINGS

[0030] FIG. 1 is an illustration of a perspective view of one embodiment of the invention and shows the patch applied to a hole.

[0031] FIG. 2 is an illustration of a cross-section view of one embodiment of the invention and shows the patch mechanically indented and tensioned.

[0032] FIG. 3 is an illustration of a perspective view of a slat and tension pin of one embodiment of the invention.

[0033] FIG. 4 is an illustration of a side perspective view of a slat and tension pin of one embodiment of the invention and shows the tension pin with nodes.

[0034] FIG. 5 is an illustration of a perspective view of a slat with a pawl and tension pin with teeth of one embodiment of the invention.

[0035] FIG. 6 is an illustration of a perspective view of one embodiment of the invention and shows a wood slat and a screw.

[0036] FIG. 7 is an illustration of a cross-section view of one embodiment of the invention.

[0037] FIG. 8 is an illustration of a cross-section view of one embodiment of the invention and shows the hole after it is repaired.

DETAILED DESCRIPTION OF THE DRAWINGS

[0038] In the following detailed description of various embodiments of the invention, numerous specific details are set forth in order to provide a thorough understanding of various aspects of one or more embodiments of the invention. However, one or more embodiments of the invention may be practiced without some or all of these specific details. In other instances, well-known methods, procedures, and/or components have not been described in detail so as not to unnecessarily obscure aspects of embodiments of the invention.

[0039] While multiple embodiments are disclosed, still other embodiments of the present invention will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the invention. As will be realized, the invention is capable of modifications in various obvious aspects, all without departing from the spirit and scope of the present invention. Accordingly, the screen shot figures, and the detailed descriptions thereof, are to be regarded as illustrative in nature and not restrictive. Also, the reference or non-reference to a particular embodiment of the invention shall not be interpreted to limit the scope of the invention.

[0040] In the following description, certain terminology is used to describe certain features of one or more embodiments of the invention. For instance, the term "drywall compound" refers to any substance that can be used to patch a hole in a wall or other surface, including, but not limited to, any putty, spackle, mud, joint compound, plastic, resin, plaster, veneer plaster, plaster of paris, or other mixture of water, limestone, expanded perlite, ethylene-vinyl acetate polymer, gypsum, and/or attapulgite.

[0041] FIG. 1 is an illustration of a perspective view of one embodiment of the invention and shows the patch applied to a hole. As shown in FIG. 1, the invention is a tensioned repair patch for a hole 5 in wall 10 and is preferably comprised of a patch 20, adhesive 22, indent 23, drywall compound 24, slat 40, tension pin 50, and apertures 60. Slat 40 is inserted into hole 5 and affixed to the back side of the wall on the outer edge of the hole. Slat 40 is preferably made out of plastic, but it may be made out of any natural or synthetic material, including wood, without deviating from the scope of the invention. Back 40 is preferably adhesively affixed to the back side of the wall with a strong and permanent adhesive. However, any fastening means may be used, including, but not limited to straps, zip-ties, chains, clips, binders, bungees, cords, ropes, strings, cables, fasteners, staples, hook and loop, friction, bands, latches, stitches, snaps, wenches, glue, other natural or synthetic chemical adhesives, adhesive tape, heat bonding, chemical bonding, crimps, clamps, or ultrasonic welding, without deviating from the scope of the invention. Indeed, although a strong permanent adhesive is the preferred way to adhere, affix, attach, or connect the present invention to the wall or surface to be repaired, it should be understood that any attachment or connection means may be used.

[0042] FIG. 1 shows how patch 20 is preferably adhesively affixed over hole 5 such that the entire hole is covered. As shown in FIG. 1, patch 20 is preferably a thin fiberglass thread mesh repair patch. The mesh repair patch may be pre-cut patch or cut from a large roll of mesh. Tension pin 50 is inserted through patch 20 and into one of the apertures 60 in slat 40. As tension pin 50 is pushed further into apertures 60, patch 20 is mechanically tensioned and indented towards slat 40, forming indent 23. After patch 20 has been indented, a drywall compound 24 is applied to complete the repair of the hole. The tensioned and indented patch 20 allows a smoother and faster repair on the hole to be performed.

[0043] Although patch 20 is preferably a fiberglass mesh repair patch, it should be understood that patch 20 may be made out of any material and may be solid non-mesh patch without deviating from the scope of the invention. In a non-limiting example, patch 20 may be drywall tape or reinforced tape.

[0044] FIG. 2 is an illustration of a cross-section view of one embodiment of the invention and shows the patch mechanically indented and tensioned. As shown in FIG. 1, the invention is a tensioned repair patch for a hole 5 in wall 10 and is preferably comprised of a patch 20, adhesive 22, indent 23, drywall compound 24, slat 40, tension pin 50, slat connectors 100. FIG. 2 shows how slat connectors 100 have a flat surface 101 that is affixed to a back side of the wall 10 via adhesive 103. Slat connector 100 is preferably adhesively affixed to the back side of the wall 10. However, any connection means may be used. Alternatively, the slat 40 may be directly attached to the back side of the wall 10. FIG. 2 also shows how slat connector 100 preferably includes an encompassing portion 102 that allows the slat connector 100 to slidably connect and move along the length of slat 100.

[0045] FIG. 2 shows how the tension pin 50 preferably includes a head end 51, a free end 52, and a plurality of nodes 55. The tension pin 50 is preferably attached to the patch 20 such that the head end rests on a front side of the patch 20. It should be understood that the tension pin 50 may engage with the patch 20 in any manner so long as the tension pin 50 indents the patch 20 towards the slat 40. The free end 52 of the tension pin is inserted into one of the apertures 60 (shown in FIG. 1). The tension pin is pushed or even forced into one of the apertures such that one or more of the nodes 55 slide past the aperture. This ratcheting effect causes the patch 20 to indent inwards towards the slat. Preferably the nodes restrict the ability of the tension pin to slide back out of the apertures. Although only one tension pin is shown, it should be understood that any number of tension pins may be used.

[0046] FIG. 2 shows the more flexible the patch 20 is the greater the need to provide tension to the patch so that a smooth layer of drywall compound may be applied. FIG. 2 shows how a user has started to fill indent 23 with drywall compound 24.

[0047] FIG. 3 is an illustration of a perspective view of a slat and tension pin of one embodiment of the invention. FIG. 3 shows that the slat 40 preferably has two slat connectors 100 that are slidable along the length of slat 40. In this manner the slat connectors may be positioned just wider than the hole that is being repaired. Slat connectors 100 preferably have flat surface 101, and encompassing portions 102. FIG. 3 also shows how slat 40 preferably has a plurality of apertures 60 running along its length. In this manner, the slat is able to accept the insertion of one or more tension pins 50 anywhere along its length. As shown in FIG. 3, the tension pin is preferably inserted between the two slat connectors. Finally, FIG. 3 shows how tension pin 50 preferably has a head end 51, a free end 52, and nodes 55. The free end is inserted into one of the apertures 60 and the nodes allow the user to ratchet the tension pin 50 into the apertures 60 without having the tension pin 50 slide back out of the apertures 60.

[0048] FIG. 4 is an illustration of a side perspective view of a slat and tension pin of one embodiment of the invention and shows the tension pin with nodes. FIG. 4 shows tension pin 50 inserted into slat 40 with slat connector 100 behind tension pin 50. FIG. 4 shows how node 55 is restricting the ability of tension pin 50 from sliding back out of the aperture.

[0049] FIG. 5 is an illustration of a perspective view of a slat with a pawl and tension pin with teeth of one embodiment of the invention. FIG. 5 shows another embodiment of the invention with tension pin 150 and slat 45. FIG. 5 shows how slat 45 may include scores 175. The scores 175 allow the user to easily trim or snap off portions of the slat 45 to make slat 45 shorter and better fit into to the outside edge of the hole.

[0050] FIG. 5 also shows how tension pin 150 may have a plurality of teeth 155 and apertures 61 have a pawl 63. In this embodiment, the teeth 155 ratchet past pawl 63 when tension pin 150 is inserted into apertures 61 and the pawl prevents tension pin 150 from being withdrawn from apertures 61.

[0051] FIG. 5 also shows how slat connector 100 preferably has an adhesive 103 that is applied to flat surface 101. This allows the slat to be quickly and permanently attached to the back side edge of the hole.

[0052] Preferably, the slat is made of a lightweight but strong plastic, but it should be understood that the tension pin may be made from any natural or synthetic material, including but not limited to: metal; metal alloy; wood or other fibrous plant product such as hemp, paper, or cardboard; glass; composite materials such as graphite, fiberglass, boron, or aramid fibers; admixtures of plastic resins combined with metal, metal alloy, wood or other fibrous plant product, glass, or composite materials; plastic; animal materials such as wool, bone, or hardened leather; or any combination of these materials, without departing from the scope of the present invention.

[0053] The tension pin preferably has nodes or teeth. However, the tension pin may be any device that is insertable into or attachable to the slat apertures or the slat itself, including but not limited to, cable ties, screws, nails, bolts, studs, bits, cord, rope, and pins.

[0054] FIG. 6 is an illustration of a perspective view of one embodiment of the invention and shows a wood slat and a screw. As shown in FIG. 6, the invention for patching a hole 5 in wall 10 may be comprised of patch 20, adhesive 22, slat 41, and tension pin 250. FIG. 6 shows that tension pin 250 may be a screw and slat 41 may be made out of wood. Indent 23 is formed as tension pin 250 is screwed into slat 41, which may or may not have apertures. Tension pin 250 may be comprised of a washer and a screw. The screw is threaded through the center of the washer and the washer provides additional surface area for tension pin 250 to indent the patch 20 as the tension pin is screwed into slat 41.

[0055] FIG. 7 is an illustration of a cross-section view of one embodiment of the invention. As shown in FIG. 7, the invention for patching a hole 5 in wall 10 may be comprised of patch 20, adhesive 22, indent 23, slat 41, slat connectors 105, and tension pin 250. FIG. 7 shows how slat connectors 105 are attached to the back side of wall 10, just outside the edge of hole 5, by adhesive 103. FIG. 7 also shows how tension pin 250 has a head end 251 and free end 252. Head end 251 tensions and indents patch 20 as free end 252 is screwed into slat 41.

[0056] Because the patch 20 is held firmly in place by the anchored tension pin 252, the present invention is less cumbersome and requires fewer steps and less drying and curing time to complete a repair project, which makes it superior to the prior art.

[0057] FIG. 8 is an illustration of a cross-section view of one embodiment of the invention and shows the hole after it is repaired. As shown in FIG. 8, the invention for patching a hole 5 in wall 10 may be comprised of a patch 20, adhesive 22, tension pin 250, drywall compound 800, and paint 801. FIG. 8 shows how a drywall compound may be smoothly applied to hole 5, completely repairing hole 5. The drywall compound covers patch 20, tension pin 250 and head end 251 when applied. Typically, a layer of paint 801, which is not part of the claimed invention and is shown in broken-line form, is applied over the smooth drywall compound to complete the repair.

[0058] The foregoing description of the preferred embodiment of the invention has been presented for the purposes of illustration and description. While multiple embodiments are disclosed, still other embodiments of the present invention will become apparent to those skilled in the art from the above detailed description, which shows and describes illustrative embodiments of the invention. As will be realized, the invention is capable of modifications in various obvious aspects, all without departing from the spirit and scope of the present invention. Accordingly, the detailed description is to be regarded as illustrative in nature and not restrictive. Also, although not explicitly recited, one or more embodiments of the invention may be practiced in combination or conjunction with one another. Furthermore, the reference or non-reference to a particular embodiment of the invention shall not be interpreted to limit the scope the invention. It is intended that the scope of the invention not be limited by this detailed description, but by the claims and the equivalents to the claims that are appended hereto.

Claims

1. A surface repair patch comprising: a patch; a tension pin; and wherein said patch is affixed to and substantially covers a front side of a hole in a surface; wherein said tension pin has a head end and a free end; wherein said head end of said tension pin is attached to said patch; wherein said free end of said tension pin is attached to an interior structure within said hole, such that said head end is pulled toward said interior structure, which causes said patch to inwardly indent.

2. The surface repair patch of claim 1, further comprising: a slat; wherein said slat is inserted into said hole and is affixed to a back side of said surface on an outer edge of said hole; wherein said free end of said tension pin is attached to said slat such that said head end is pulled toward said slat, which causes said patch to inwardly indent.

3. The surface repair patch of claim 2, wherein said slat has one or more apertures; and wherein said free end is attached to said slat by inserting said free end into said one or more apertures.

4. The surface repair patch of claim 3, further comprising a plurality of slat connectors; wherein said plurality of slat connectors are slidably connected to said slat and are slidably adjustable along a length of said slat; wherein said slat connectors are used to affix said slat to said back side of said surface on said outer edge of said hole.

5. The surface repair patch of claim 4, wherein said patch is a fiberglass thread mesh repair patch that is adhesively affixed to said front side of said hole.

6. The surface repair patch of claim 5, wherein said slat is plastic and is scored.

7. The surface repair patch of claim 4, wherein said one or more apertures have one or more pawls; wherein said tension pin has a plurality of teeth; wherein said plurality of teeth of said tension pin ratchet past said one or more pawls of said one or more apertures; and wherein said tension pin is prevented from sliding back out of said one or more apertures by said one or more pawls.

8. The surface repair patch of claim 4, wherein said tension pin has one or more nodes; wherein said one or more nodes of said tension pin slide through said one or apertures such that said tension pin is restricted from sliding back out of said one or more apertures.

9. The surface repair patch of claim 2, wherein said tension pin is a screw and wherein said slat is wood.

10. The surface repair patch of claim 2, wherein a drywall compound is applied to said patch.

11. The surface repair patch of claim 2, wherein said surface is a drywall.

12. A drywall mesh repair patch comprising: a patch; a tension pin; a slat; two slat connectors; wherein said two slat connectors are slidably connected to said slat and are slidably adjustable along a length of said slat; wherein said slat is inserted into a hole in a drywall surface and wherein said slat connectors are adhesively affixed to said back side of said surface on an outer edge of said hole; wherein said patch is a fiberglass thread mesh repair patch; wherein said patch is adhesively affixed to and substantially covers a front side of said hole; wherein said tension pin has a head end, a free end, and a plurality of teeth; wherein said slat has one or more apertures; wherein said one or more apertures have one or more pawls; wherein said head end of said tension pin is attached to said patch; wherein said free end of said tension pin is inserted into said one or more apertures and wherein said plurality of teeth of said tension pin ratchet past said one or more pawls of said one or more apertures; wherein said tension pin is prevented from sliding back out of said one or more apertures by said one or more pawls; and wherein said head end is pulled toward said slat as said free end is inserted into said one or more apertures, which causes said patch to inwardly indent; and wherein a drywall compound is applied to said indented patch.

13. A method of applying a repair patch to a hole in a surface, comprising the steps of: affixing a slat to a back side of said surface on an outer edge of said hole; affixing a patch to a front side of said hole; providing a tension pin, wherein said tension pin has a head end and a free end; attaching said head end of said tension pin to said patch; attaching said free end of said tension pin to said slat; using said tension pin to mechanically indent said patch toward said slat.

14. The method of applying a repair patch to a hole in a surface of claim 13, wherein said slat has one or more apertures; and wherein said free end is attached to said slat by inserting said free end into said one or more apertures.

15. The method of applying a repair patch to a hole in a surface of claim 14, wherein said slat is further comprised of a first slat connector and a second slat connector; wherein said first slat connector and said second slat connector are slidably connected to said slat and are slidably adjustable along a length of said slat; wherein said slat connectors are used to affix slat to said back side of said surface on an outer edge of said hole; sliding said first slat connector and said second slat connector to opposite ends of said slat so that said slat connectors are spaced just wider than said hole; affixing said first slat connector and said second slat connector to said back side of said surface on said outer edge of said hole.

16. The method of applying a repair patch to a hole in a surface of claim 15, wherein said one or more apertures have one or more pawls; wherein said tension pin has a plurality of teeth; inserting said tension pin into said one or more apertures such that said plurality of teeth of said tension pin ratchet past said one or more pawls of said one or more apertures; and wherein said tension pin is prevented from sliding back out of said one or more apertures by said one or more pawls.

17. The method of applying a repair patch to a hole in a surface of claim 16, further comprising the steps of: indenting and tensioning said patch towards said slat by pushing said tension pin into said one or more apertures.

18. The method of applying a repair patch to a hole in a surface of claim 17, wherein said patch is a flat fiberglass mesh repair patch.

19. The method of applying a repair patch to a hole in a surface of claim 14, wherein said tension pin has a one or more nodes; inserting said tension pin into said one or more apertures such that said one or more nodes of said tension pin slide past said one or more apertures; and wherein said tension pin is restricted from sliding back out of said one or more apertures.

20. The method of applying a repair patch to a hole in a surface of claim 19 further comprising the steps of: indenting and tensioning said patch towards said slat by pushing said tension pin into said one or more apertures; and applying a drywall compound to indented and tensioned patch.

Images