Conical Repair Insert for Structural and Cosmetic Material Restoration
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Solution Overview
Problem
Existing repair methods for construction materials, such as adhesive, tape, and patches, fail to provide both structural and cosmetic restoration, often requiring skilled labor and result in visible defects, thermal discontinuities, and repeated repairs due to shrinkage and mismatched thermal expansion coefficients.
Innovation Solution
A conical-shaped repair device with a recess and tab, designed to fit into defects, allowing for structural adhesion and easy installation, featuring a conical surface with a helical cut and a planar proximal surface, which can be rotated to engage with the material and form an interference fit, using adhesives to secure the repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If adhesive, tape, patches, and screens are used for repair, then cosmetic repair is provided, but structural restoration is not achieved and structural defects remain
Solution Approach 1:
The patent combines cosmetic repair and structural restoration into a single integrated repair device. The conical repair device includes both a cosmetic surface layer and an internal structural core that works together to simultaneously restore appearance and structural integrity, eliminating the need for separate cosmetic and structural repair components.
Solution Approach 2:
The repair device utilizes composite material construction with different layers serving different functions - an outer cosmetic layer for appearance restoration and an inner structural layer for strength restoration. This composite structure allows simultaneous achievement of both cosmetic and structural repair goals.
2Ease of manufacture
If existing defect area is expanded to accommodate patches, then patch installation is enabled, but structural qualities are further compromised
Solution Approach 1:
The conical repair device is self-installing and self-positioning. The conical shape allows the device to be inserted into the defect and automatically find its optimal position through rotation and engagement with the defect walls, eliminating the need for skilled workers to carefully measure and fit patches, and avoiding the need to expand the defect area.
Solution Approach 2:
Instead of expanding the defect area to fit a patch (traditional approach), the invention inverts the approach by having the repair device conform to the existing defect area. The conical shape adapts to the hole or crack dimensions, eliminating the need to enlarge the defect for installation.
3Reliability
If repair materials with mismatched thermal expansion coefficients are used, then repair is achieved, but thermal discontinuities are created under thermal cycling
Solution Approach 1:
The patent selects repair materials with thermal expansion coefficients matched to the base construction material. By changing the material parameter (thermal expansion coefficient) to match the substrate, the invention eliminates thermal discontinuities and prevents cracking or detachment during thermal cycling, while maintaining reliable repair function.
4Manufacturing precision
If skilled individuals are used for repair, then acceptable structural and cosmetic results are achieved, but time and cost increase
Solution Approach 1:
The conical repair device is designed for self-installation by users with rudimentary skills. The device includes self-positioning features, rotation engagement mechanisms, and intuitive installation steps that eliminate the need for skilled workers, thereby reducing installation time and cost while maintaining consistent repair quality through design-guided precision.
Solution Approach 2:
The repair device is pre-formed with the optimal conical shape and integrated structural-cosmetic layers during manufacturing. This preliminary preparation of the repair geometry and material configuration eliminates the need for skilled workers to perform complex fitting, cutting, and shaping operations during installation, reducing both time and skill requirements.
5Reliability
If adhesive and tape are used for repair, then initial repair is achieved, but shrinkage occurs over time requiring repeated repairs
Solution Approach 1:
The patent uses composite material construction with materials selected for dimensional stability and resistance to shrinkage. The structural core and cosmetic layer are both made from materials that maintain their dimensions over time, preventing the shrinkage problems associated with adhesive and tape repairs, and eliminating the need for repeated repairs.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The device provides structural integrity and cosmetic restoration with ease of installation, minimizing visible defects and thermal discontinuities, ensuring long-lasting repairs without the need for repeated applications.
Implementation Method 1
the device can be rotated to engage with the material and form an interference fit
Implementation Method 2
using adhesives to secure the repair
Data Source
AI summary
A construction material repair device designed for filling, repairing, and restoring defects in construction materials comprising right-handed female tapered helical thread to aid insertion and adhesively secured into the construction material to cosmetically repair and structurally restore the defect in minimal steps, time, and cost. The device is manufactured in a variety of materials to match or complement the construction material requiring repair.