BACKGROUND OF THE INVENTION

Field: This invention relates generally to the field of repairing relatively large holes in hollow building walls or mounting items, such as electrical boxes, in hollow building walls such as plasterboard walls.

State of the Art: In modern times, the vast majority of interior walls are formed by first erecting a series of two by four studs in parallel relation into a vertical lattice. Plasterboard, fiberboard, paneling, or similar sheet material is then nailed, screwed, glued, or otherwise fastened to the studs to complete the wall structure. With plasterboard, taping and plastering of the joints between sheets of plasterboard, sanding, and painting then make the wall structure smooth and aesthetically pleasing to the eye. Where the wall structure divides interior rooms, the plasterboard or similar interior sheet material is secured to both sides of the lattice so that interior walls are formed on both sides of the wall structure. Where the wall structure forms both an interior and exterior wall, in many instances plasterboard or similar interior sheet material is secured to the interior side of the lattice while exterior sheet material is secured to the exterior side of the lattice. In some instances, an intermediate material may be secured to the exterior side of the lattice with brick, siding, or other material forming an exterior wall secured to such intermediate material. In some instances where concrete, brick, or similar material is used for the exterior wall or foundation wall, the exterior side of the stud lattice may be secured to or merely abut such wall. In other instances, furring strips may be attached to such exterior walls to serve as the lattice for the mounting of the interior wall. In any case, such walls may be referred to as hollow walls because with such walls, two outer sheets of material are connected to opposing side faces of the studs of the lattice and a space is formed between the sheet material on each side of the lattice. Thus, the sheet material on each

side of the lattice forms a wall having an exposed front face and an unexposed rear face toward the lattice. The unexposed rear face of a wall is spaced from and confronts the unexposed rear face of the wall on the other side of the lattice which forms a spaced, confronting surface to the unexposed rear face of the opposite wall.

The method described of erecting walls is a substantial time saver, as well as money saver, over the previously used lath and plaster or screen and plaster walls which were comparatively difficult and uneconomical to build. While plasterboard walls are easier to build and less expensive than other type plaster walls, the plasterboard walls generally are not as durable or as structurally sound as the predecessor plaster walls. For example, it is not uncommon to accidentally open a door with too much force resulting in the doorknob of the door or a hook or similar protrusion attached to the door breaking a hole through the plasterboard between the supporting studs. Further, furniture or other items may be knocked against such walls with enough force to cause relatively large holes therein.

While small holes in plasterboard, such as those formed by nails, tacks, and the like, are easily repaired, larger holes, such as those formed by doorknobs, are much more difficult to patch. Because of the substantially hollow interior of the wall structure, there is no support or foundation to hold the plaster with which the repair is to be made. Consequently, a number of devices have been used in the prior art to provide a foundation for the repair plaster. Each of these devices has proved to have a number of disadvantages. One of the prior art devices consists of a nonadhesive, paper like tape which is stretched over the hole to be repaired, the ends thereof being wetted to form a weak bond with the wall to hold the tape in place. While many manufacturers produce a tape similar to that described, these tapes are usually collectively known as perfatape. Although generally serving as an adequate foundation for holes no bigger than a few inches in diameter, perfatape does not provide the structural integrity necessary to hold enough plaster required to repair a larger hole.

Wire mesh screens are also known and used in the art, although such have proven to have unacceptable disadvantages as well. While wire mesh screens generally provide adequate structural strength, such screens are difficult to position in place within the hole to be repaired, and thus may slide about or even fall out of the hole as the plaster is applied thereto. Furthermore, plaster can seep and ooze through the screen elements, thereby wasting significant amounts of plaster. Thus, the use of wire screens can be disadvantageous in the repair of holes in plasterboard walls.

Another problem with the hollow wall structures described is that it is difficult to mount items such as electrical boxes for electrical outlets or electrical switches in such walls. Generally a stud in the lattice behind the wall must be located, an opening for the electrical box cut into the wall adjacent the stud, and the electrical box mounted securely to the stud. It is sometimes necessary to make several holes in a wall before a stud is located, and the location of the box is dictated by the location of the stud. An attempt has been made to provide an electrical box that can be mounted in an opening in a hollow wall not adjacent a stud by providing a means extending from the box to sandwich and clamp the plasterboard material at the side of the receiving opening in the plasterboard, but such box is difficult to mount securely.

SUMMARY OF THE INVENTION

According to the invention, a device is provided for placement and securement over an opening in a wall of a hollow wall structure. If the opening is an undesired hole in the wall, the device forms a backing over the opening or hole so that the hole can be repaired. If the opening is to receive an item to be securely installed in the opening, such as an electrical box, the device may form the item, such as an electrical box, to be installed. In such case, a portion of the device may extend through the opening a desired distance, for example, to be flush with the interior surface of the wall.

The device includes a housing sized to pass through the opening with abutting means cooperable with the housing for abutting the rear face of the wall when the device is in

desired position over the opening to prevent the device from passing through the opening. Means for extending an extension means cooperable with the housing is included for extending the extension means from the housing to contact a surface spaced from and confronting the rear face of the wall when the device is installed to securely hold the device in an installed position over the opening in the wall and between the confronting surface and the rear face of the wall. If the invention is configured as a wall repair device, the abutting means may take the form of a plate which extends over the hole to serve as a backing for patching material. If the invention is configured as an electrical box or other item to be installed in an opening in a wall, the housing may take the form of the items to be positioned in the opening in the wall with the abutting means extending therefrom.

In a preferred form of the invention used to provide a backing for repairing holes in a wall of a hollow wall structure wherein two outer sheets of wall material are connected to opposing side faces of each of a series of studs, a rigid mounting plate having top and bottom faces forms the abutting means. The housing, in the form of a first hollow cylinder which forms a cavity, is secured to the mounting plate and has the extension means in the form of a second hollow cylinder disposed within the cavity of the first cylinder so as to be in telescoping relationship therewith. A means for extending the extension means is provided in the form of an advancing structure for selectively drawing the second cylinder outwardly through the top portion of the first cylinder to an extended position, such that the top portion of the second cylinder contacts the interior face of one of the two outer sheets of a standard plasterboard wall structure. The bottom portion of the first cylinder contacts the top face of the mounting plate, the bottom face of the mounting plate contacting the rear face of the other of the two outer sheets of the plasterboard wall to substantially cover a hole therein. The bottom portion of the first hollow cylinder is preferably hingedly connected to the top face of the mounting plate such that the first cylinder is brought into a position normal to the mounting plate when the second cylinder is drawn outwardly

by the advancing structure.

Also, it is presently preferred that the advancing structure include a locking structure for maintaining the second cylinder in the extended position relative to the first cylinder after being drawn outwardly. Advantageously, the advancing structure includes a pair of oppositely disposed longitudinal channels in the second hollow cylinder, each channel having a length less than the length of the second hollow cylinder; a first peg disposed transversely in the cavity of the first cylinder in the top portion thereof such that the first peg is slidably received in the channels of the second cylinder; a second peg disposed transversely in the cavity of the second cylinder in the bottom portion thereof near the channels; and an electrical tie looped about both the first and second pegs such that a tensile or pulling force on the free end thereof causes a tightening of the loop which forces the first and second pegs together, which, in turn, forces the first and second cylinders into the extended position. In use, the mounting plate and related advancing structure are inserted through a hole in a wall to be repaired. This may require the cutting of slots in one or both sides of the hole through which the mounting plate can be inserted. The cylinder will usually be in a folded condition relative to the plate during this insertion operation to facilitate such insertion. After insertion through the hole, the mounting plate is maneuvered to at least substantially cover the hole to be repaired as the operator grasps the free end of the looped tie upon which the tensile force is to be applied. When the plate is in desired position over the hole, tensile force is applied by pulling the free end of the looped tie, thereby causing the telescoping members to advance to the extended position, and thus anchoring the plate in position against the interior faces of the outer sheets of the plasterboard wall in which the hole to be repaired is located. At this point, a layer of patching plaster is applied to the mounting plate in the hole, the layer of plaster having an approximate thickness of one of the outer sheets, in a manner well known in the art to repair the hole.

BRIEF DESCRIPTION OF THE DRAWINGS The best modes presently contemplated for carrying out the invention in actual practice are shown in the accompanying drawings in which: Figure 1, is a rear perspective view of an embodiment of the invention used as a device for repairing holes in walls and shown in a position where the telescoping members are advancing to an extended position;

Figure 2(a) , a side elevational view of the embodiment of Figure 1 shown positioned against a wall to be repaired with the base and extension means in folded condition prior to actuation of the advancing structure;

Figure 2(b) , a side elevational view similar to Figure 2(a) , but showing the telescoping members as they are being unfolded and advanced to an extended position;

Figure 2(c), a side elevational view similar to Figures 2(a) and 2(b) showing the telescoping members in the extended position wherein both outer sheets of a typical plasterboard wall are contacted by the device to anchor the device in place; Figure 3, a front elevational view of the embodiment of Figure 1 in the installed position and prepared to receive patching plaster;

Figure 4, a side elevational view of the telescoping members; , Figure 5, a top plan view of the telescoping members of Figure 4;

Figure 6(a), an end elevation of the outer telescoping member of Figure 5 looking from the left of Fig. 5;

Figure 6(b), an end elevation of the inner telescoping member of Figure 5 looking from the left of the inner member in Fig. 5;

Figure 7(a), a vertical section of the embodiment of Figure 1 illustrating the structure for advancing the telescoping members in a position prior to actuation thereof; Figure 7(b) , a vertical section similar to Figure 7(a) , but showing the structure for advancing the telescoping members in the actuated, position with the telescoping members in extended position;

Figure 8(a) , a side elevational view of the head and

6a channel portions of an electrical tie usable with the invention;

Figure 8(b) , a front elevational view of the electrical

7 tie of Figure 8 (a) ;

Figure 9, a fragmentary end elevation showing the telescoping members in operable position;

Figure 10, a front perspective view of a different embodiment of the invention used as a device for installing an electrical box in a hollow wall structure showing the device in an installed position in a wall with portions of the wall broken away;

Figure 11, a vertical section taken on the line 11-11 of Figure 10;

Figure 12, a longitudinal section through the device of Figure 10 but showing the device only partially inserted into the receiving opening in the wall and prior to actuation of the telescoping members; Figure 13, a longitudinal section similar to that of Figure 12, but showing the device received in the receiving opening;

Figure 14, a rear perspective view of a device similar to that of Figure 1, but showing a different embodiment of telescoping members;

Figure 15, a fragmentary vertical section taken on the line 15-15 of Figure 14; and

Figure 16, a fragmentary longitudinal section taken on the line 16-16 of Figure 14.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS As shown in Figures 1-9, a presently preferred embodiment of the invention for use in repairing holes in hollow wall structures, generally designated 10, comprises a rigid mounting plate 12, a first hollow cylinder 14, a second hollow cylinder 16 disposed within the first cylinder 14 so as to be in telescoping relationship therewith, and an advancing structure 18 for selectively drawing the second cylinder 16 outwardly through the first cylinder 14 such that the top end of the second cylinder 16 contacts the rear face 32, Figure 2(c), of one of two outer sheets 24 of a hollow wall structure 26 to be repaired. The plasterboard wall structure 26 includes two outer sheets of plasterboard 24 connected to opposing side faces 30 of each of a series of studs 28. Each sheet 24 has an

8 exposed front face 32(a) and an unexposed rear face 32. The bottom end of the first cylinder 14 contacts the mounting plate 12, which in turn contacts the rear face 32 of the other of the two outer sheets 24 to substantially cover a hole 34 therein. The rear face 32 of the sheet 24 which is contacted by second cylinder 16 forms a surface confronting rear face 32 of the wall sheet 24 having hole 34 therein.

The rigid mounting plate 12 may be made of various structural materials. Masonite board has been found satisfactory, however, fiber board, particle board, press board, plywood, or plastic may be used.

As shown, the rigid mounting plate 12 has a top face 20 and a bottom face 22 and includes an aperture 23 drilled or otherwise formed through the approximate center thereof. The top face 20 of rigid mounting plate 12 contacts the bottom end of the first hollow cylinder 14, as will be explained hereafter. The bottom face 22 of the rigid mounting plate 12, in use, contacts the rear face of one of the outer sheets 24 of the plasterboard wall structure 26, as best seen in Figures 2(a)-2(c) .

The plasterboard wall structure 26, as mentioned, comprises a series of studs 28, which generally are standard two-by-four timbers aligned vertically in parallel relationship to each other. Each stud 28 includes two side faces 30 to which the sheets 24 of plasterboard or other material forming the walls are securely attached, as with nails, screws or the like. Referring now to Figure 2(c), the bottom face 22 of the rigid mounting plate 12 is secured against the rear face 32 of the sheet 24 in which the hole 34 to be repaired is located. The first hollow cylinder 14 may be constructed of any durable, lightweight, structural material. Advantageously, the first hollow cylinder 14 is constructed of a standard polyvinyl chloride (PVC) pipe which is cut to an appropriate length. As shown, the first hollow cylinder 14 has a top portion 36 and a bottom portion 38, the hollowed interior portion of the first hollow cylinder 14 forming a cavity 40.

As best seen in Figure 4-6, the first hollow cylinder 14 includes a peg 42 disposed transversely in the cavity 40 in the top portion 46 thereof. The ends of the peg 42 are securely

9 attached to the walls of the first hollow cylinder 14, as shown. Advantageously, the bottom portion 38 of the first hollow cylinder 14 has beveled inside edges 45 in order to fractionally hold the second hollow cylinder 16 therein without other means. See Figures 4 and 5.

In the preferred embodiment of the present invention illustrated in Figures 1-9, the bottom portion 38 of the first hollow cylinder 14 includes a molded plastic hinge 41 for hingedly connecting the first hollow cylinder 14 to the top face 20 of the mounting plate 12. See Figures 1 and 9. The hinge 41 allows the first hollow cylinder 14 to be brought into an unfolded position normal to the mounting plate 12 when the second hollow cylinder 16 is drawn outwardly by the advancing structure 18. Alternatively, the bottom portion 38 of the first hollow cylinder 14 may be rigidly attached to the top face 20 of the mounting plate 12.

The second hollow cylinder 16 is constructed of a material similar or identical to that forming the first hollow cylinder 14. The outside diameter of the second hollow cylinder 16 is slightly less than the inside diameter of the first hollow cylinder 14, and thus the second hollow cylinder 16 may easily fit within the cavity 40 of the first hollow cylinder 14 in telescoping relationship. The beveled inside edge 45 in the bottom potion 38 if the first hollow cylinder 14 decrease the inside diameter thereof such that the first hollow cylinder 14 and second hollow cylinder 16 frictionally grip each other and thereby remain together unless influenced by an external force. As best seen in Figure 5, the second hollow cylinder 16 includes a pair of oppositely disposed, longitudinal channels 44, each channel 44 having a length "a", which, as shown, extends from a top portion 46 into a bottom portion 48 of the second hollow cylinder 16. The length "a" of each channel 44 is less than the length of the second hollow cylinder 16. The channels 44 each have a width "b", which is slightly greater than the diameter of the peg 42 disposed in the top portion 46 of the first hollow cylinder 14. Thus, the peg 42 in the top portion 46 of the first hollow cylinder 14 may be slidably received in the channels 44 of the second hollow cylinder 16. The second hollow cylinder 16 includes a peg 50 which is

10 similar in all respects to the peg 42 in the first hollow cylinder 14. As illustrated, the peg 50 is disposed transversely in the cavity 52 formed by the hollowed interior portion of the second hollow cylinder 16 in the bottom portion 48 thereof near the channels 44.

Advantageously, the peg 50 has a longitudinal axis which is parallel to a transverse axis intersecting both channels 44. Thus, when the second hollow cylinder 16 is placed within the first hollow cylinder 14 in telescoping relationship thereto, the pegs 42 and 50 are parallel to each other, the peg 42 being engaged by the channels 44 such that the second hollow cylinder 16 cannot be drawn completely out of the first hollow cylinder 14, as best illustrated in Figures 7(a) and 7(b).

The advancing structure 18 comprises the peg 42 in the first hollow cylinder 14 and the peg 50 in the second hollow cylinder 16. Further, the advancing structure 18 comprises an electrical or similar tie 54 which is looped about both the peg 42 and the peg 50 such that a tensile or pulling force on the first, or free, end 66 of the electrical tie 54 causes a tightening of the loop which forces the peg 42 and the peg 50 together. This action is best illustrated in Figures 7(a) and 7(b) in combination.

The electrical tie 54 is well known in the art and is commonly used to. attach electrical wires or cables to a supporting structure. One skilled in the art will recognize, however, that alternative devices may be used without departing from the scope of the invention. The preferred electrical tie 54 is best illustrated in Figures 8(a) and 8(b).

The electrical tie 54 is self locking and includes a single direction head 56 and a channel 58 which includes a series of transversely disposed slots 60. Within the head 56 is a tab 62 which includes a nipple 64 for engaging the slots

60 in the channel 58.

As illustrated in Figure 8(a), the tab 62 is disposed so as to allow movement of the first end 66 of the electrical tie 54 which has been looped about pegs 42 and 50 to be inserted into the second end 68, which includes the head 56. As shown, the tab 62 will move downwardly out of the way of the slots 60 in the channel 58 as the first end 66 is pulled through the

11 head 56 in a direction which decreases the size of the loop. In contrast, if the first end 66 is pulled in a direction which increases the size of the loop, the tab 62 will not move and the nipple 64 will remain engaged in one of the slots 60. This configuration allows for limitation of movement of the first end 66 through the second end 68 to a single direction, and is in this manner self-locking. Thus, when a tensile or pulling force has been applied to the first end 66 of electrical tie 54 such that the pegs 42 and 50 are brought closer together, the pegs 42 and 50 will remain in this position. In this manner, the telescoping first and second hollow cylinders 14 and 16, respectively, in conjunction with the mounting plate 12, abut against the interior faces 32 of the two outer sheets 24 of the plasterboard wall structure 26 to anchor the mounting plate 12 in position over a hole 34.

The embodiment of the invention illustrated in Figs 1-9 is used as a device to help repair holes in hollow walls. In use, the device 10, including the first and second hollow cylinders 14 and 16, respectively, and the advancing structure 18, is inserted through the hole 34 to be repaired. This may require enlarging the hole 34 by cutting two slots 70 and 72 in opposing sides thereof, Figure 3. During this step, cylinders 14 and 16 will advantageously be in folded position against plate 12 as shown in Figure 2(a) . The device 10 is then maneuvered into the position shown in Figure 2(a) , wherein the bottom face 22 of the mounting plate 12 is flush against the rear face 32 of the sheet 24 of wall material in which the hole 34 is located, thereby substantially covering the hole 34. The user may advantageously grip the free end 66 of the electrical tie 54, which protrudes through the aperture 23 in the mounting plate 12, to hold the device 10 while guiding the device 10 into position with his or her fingers.

Once the device 10 is properly positioned over the hole 34, a tensile or pulling force is exerted on the free end 66 of the electrical tie 54 to actuate the advancing structure 18. Responsive thereto, the action illustrated in Figures 2(a)-2(c) occurs. Namely, the hollow cylinders 14 and 16 are brought into an unfolded position normal to the mounting plate 12,

12 while at the same time telescoping outwardly into a locked extended position such that the top portion 46 of the second hollow cylinder 16 contacts one of the outer sheets 24 and the bottom portion 38 of the first hollow cylinder 14 contacts the top face 20 of the mounting plate 12, the bottom face 22 of the mounting plate 12 contacting the other of the two outer sheets 24.

Because the advancing structure 18 is self-locking, as explained, the telescoping hollow cylinders 14 and 16 are self- supporting and thus remain anchored in this position. At this point, the free end 66 of the electrical tie 54 is cut off near where it protrudes through the aperture 23 in the mounting plate 12. A standard plaster material (not shown) is then prepared and applied to the bottom face 22 of the mounting plate 12 in a manner which is well known in the art. This plaster material should completely fill the remainder of the hole 34, mounting plate 12 serving as a foundation or backing for the plaster material.

In the embodiment of the invention illustrated in Figures 1-9, the first hollow cylinder forms a housing of the invention. The mounting plate 12 forms an abutting means cooperable with the housing for abutting the rear face of the wall with the hole or opening therein when the device is in desired position over the hole to prevent the device from passing through the hole. The second hollow cylinder forms an extension means cooperable with the housing or first hollow cylinder for selective extension therefrom. The advancing structure forms a means for extending the extension means or second hollow cylinder from the housing or first hollow cylinder to contact the rear face of the wall sheet 24 confronting the wall sheet with the hole therein so that the device is held securely in an installed position over the hole and between the confronting surface and the rear face of the wall with the hole therein. Figures 14-16 illustrate an alternative embodiment of a device of the invention for use in repairing holes in hollow walls. In such embodiment, a housing 75 is hingedly secured by hinge 76 to a mounting plate 77 which serves as an abutting means to abut the rear face 78 of a wall 79 to cover a hole 80

13 therein and, when in installed position, to prevent the device from passing through the hole 80. An extension member 81 is slidably mounted in housing 75. A tower 82 with peg 83 is secured to housing 75 and passes through a slot 84 in extension member 81. Tower 82 and peg 83 may be integrally molded with housing 75. A tower 85 with peg 86 extends from extension members 81. Tower 85 and peg 86 may be integrally molded with extension member 81. Pegs 83 and 86 are substantially aligned and an electrical or similar tie 87 is looped around pegs 83 and 86. The operation of the device is similar to that for the device shown in Figures 1-9. However, housing 75 and extension member 81 are easier to produce by injection molding. Plate 77 may also be made by injection molding. If desired, pins 88 may be molded into plate 77 or otherwise provided in plate 77 to better secure the plate with respect to wall 79. Such pins ensure that plate 77, when installed, will not slide with respect to wall 79.

Figures 10-13 show an embodiment of the invention wherein the invention provides an electrical box to be installed in an opening in a hollow wall. Housing 100 takes the form of an electrical box which will accept for secure mounting a standard electrical wall switch or a structural electrical outlet. As shown in Figures 12 and 13, housing 100 includes a peg 101 secured therein. An extension member 102 with slots 103 therein is mounted in housing 100 to extend therefrom through opening 104 with slots 103 receiving peg 101. Extension member 102 includes a peg 105 secured therein and, in the unextended position shown in Figures 12 and 13, is spaced from peg 101. A tie 106, such as the previously described electrical tie, is looped around pegs 101 and 105. The pegs 101 and 105, in combination with tie 106, act to extend extension member 102 from housing 100 when the end of tie 106 is pulled.

Tabs 108 extend from housing 100 and are resiliently secured to housing 100 for movement into and out of housing 100. Tabs 108 may be molded integrally with housing 100 or otherwise secured thereto and extendable therefrom in any suitable manner. When in installed position as shown in Figures 10, 11, and 13, tabs 108 abut against the rear face 109 of wall 110 to prevent the device from passing through

14 receiving opening 111 in wall 110.

To install the device of Figures 10-13 in a receiving opening 111 in a wall 110, the back of housing 100 is inserted into the receiving opening as shown in Figure 12. The solid lines in Figure 12 show the tabs 108 on the front side 112 of wall 110. As housing 100 is pushed further into receiving opening 111, tabs 108 will be cammed by wall 110 toward one another into the interior of housing 100 as shown by broken lines in Figure 12. As the tabs pass through wall 110 they will move back outwardly to their normal positions as shown in Figure 13. When tabs 108 are inside wall 110 as shown in Figure 13, tie 106 is pulled to extend extension member 102 as shown in Figure 11 to contact spaced, confronting surface 113 formed by the rear face of wall 114. In this manner, tabs 108 are forced against rear face 109 of wall 110 and the device is held securely over receiving hole 111 and between the confronting surface 113 and wall 110. The front of housing 100 will be configured to extend through opening 111 to be flush with the front surface 112 of wall 110 in normal manner as shown in Figures 11 and 13.

While housing 100 is shown in the form of an electrical box, the housing could be made in various other forms to provide other items to be mounted in a hollow wall. Further, while the invention has been described in relation to walls, ceilings are generally constructed in similar fashion and "walls" are meant to include ceilings.

Whereas this invention is here illustrated and described with reference to embodiments thereof presently contemplated as the best mode of carrying out such invention in actual practice, it is to be understood that various changes may be made in adapting the invention to different embodiments without departing from the broader inventive concepts disclosed herein and comprehended by the claims that follow.