Deformable TPU Surface Patch for Curved Repairs
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Solution Overview
Problem
Conventional drywall repair patches with metal plates are inflexible, cannot repair curved surfaces, have different thermal expansion rates, and are not customizable, leading to cracking and limited utility.
Innovation Solution
A flexible patch unit made of deformable Thermoplastic Polyurethane (TPU) sheets and adhesive mesh, customizable in shape and dimension, with low thermal expansion, allowing adherence to various surfaces and preventing cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal plate is used in a repair patch, then strength and structural integrity are improved, but flexibility is lost and the patch cannot be used on curved surfaces
Solution Approach 1:
The patent replaces the rigid metal plate with a flexible fiberglass mesh embedded in a polymer matrix. This mesh structure provides reinforcement similar to metal plates while maintaining flexibility, allowing the repair patch to conform to curved surfaces and various geometries without cracking or breaking.
Solution Approach 2:
The patent uses a composite material consisting of a polymer matrix (such as acrylic or polyethylene) combined with a fiberglass mesh. This composite provides both the structural integrity needed for strength and the flexibility required for adaptability, resolving the contradiction between these two properties.
2Strength
If a metal plate is used in a repair patch, then structural support is improved, but thermal expansion mismatch causes cracking over time
Solution Approach 1:
The patent uses a polymer-based composite material that has a coefficient of thermal expansion similar to drywall and plaster. This homogeneity in thermal properties ensures that the repair patch expands and contracts at the same rate as the surrounding material during temperature fluctuations, preventing stress buildup and cracking.
Solution Approach 2:
The fiberglass mesh embedded in the polymer matrix creates a composite material with thermal expansion properties matched to building materials. This composite structure maintains structural support while avoiding the thermal expansion mismatch problems associated with metal plates.
3Ease of manufacture
If standard dimensions are used for repair patches, then manufacturing is simplified, but customization for different damaged portions is limited
Solution Approach 1:
The patent designs the repair patch with flexible dimensions and shapes that can be easily adjusted during installation. The patch can be cut, shaped, and sized to match various damaged portions, transforming from a static standard product to a dynamic customizable solution that adapts to different repair needs.
Solution Approach 2:
The patent allows for variation in patch parameters such as size, shape, and thickness to accommodate different damaged areas. This flexibility in parameters enables customization for various applications while maintaining ease of manufacture through simple material composition and construction methods.
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 flexible patch unit effectively repairs damaged surfaces, including curved areas, maintains integrity over temperature fluctuations, and can be customized to fit various dimensions without cracking.
Implementation Method 1
A user may apply the drywall compound over the patch unit after adhering the patch unit to the drywall surface
Data Source
AI summary
A surface repair patch unit is disclosed. The patch unit may include a deformable Thermoplastic Polyurethane (TPU) sheet and a deformable adhesive mesh sheet. The deformable adhesive mesh sheet may be attached or fused to the TPU sheet such that the TPU sheet may be disposed on a mesh sheet interior surface. The patch unit may be configured to be adhered to a damaged surface via the deformable adhesive mesh sheet, and the TPU sheet may substantially cover the damaged surface. The patch unit may further include a first protective film and a second protective film that may be removably attached to patch unit opposing surfaces, and may protect the opposing surfaces from ambient environment.