Flexible Disc Wall Repair Device with Collapsible Perimeter
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Solution Overview
Problem
Existing methods for repairing holes in drywall plaster or plaster lathe walls are inadequate as they either merely cover the holes without restoring the wall's original strength or are cumbersome and inefficient.
Innovation Solution
A wall repair device comprising a thin, flexible disc with a collapsible perimeter and a removable wand, where the disc is inserted into the hole with adhesive, collapsing to attach to the backboard and then expanding, allowing for secure bonding and restoration of the wall's integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If existing methods are used to repair holes in drywall, then the holes are covered, but the wall's original strength is not restored
Solution Approach 1:
The repair device segments the wall repair function into distinct components: a collapsible disc for insertion, a wand for application and pulling, and adhesive for bonding. This segmentation allows the system to achieve both coverage and structural restoration by separating the functions of filling the hole and reinforcing the wall.
Solution Approach 2:
The disc is designed to collapse into a compact form that can be inserted into the hole, then expand to its full size on the backside of the wall. This nesting principle allows the repair material to be delivered through a small opening while achieving full coverage and structural reinforcement on the backside.
2Productivity
If a simple patching method is used, then the hole is covered, but the repair process is inefficient and cumbersome
Solution Approach 1:
The adhesive is pre-applied to the disc before insertion, and the disc is pre-collapsed into a compact form. This preliminary preparation eliminates steps during the repair process, allowing the user to simply insert, pull, and finish the repair without intermediate preparation steps, thereby improving efficiency while maintaining simplicity.
Solution Approach 2:
The disc automatically expands after insertion into the hole, eliminating the need for manual expansion steps. The adhesive self-bonds to the backboard when the disc is pulled back, reducing the need for additional fastening operations. These self-service features improve efficiency without complicating the operation.
3Strength
If the disc is made rigid for structural support, then it can provide strength, but it cannot be inserted through the hole
Solution Approach 1:
The disc transitions from a collapsed rigid or semi-rigid state during insertion to an expanded rigid state once positioned on the backside of the wall. This dynamic transformation allows the disc to be inserted through the hole in its compact form while providing structural support when expanded, resolving the contradiction between insertability and structural strength.
Solution Approach 2:
The disc is constructed with flexible materials that allow it to collapse into a thin, insertable form while maintaining the ability to expand to a rigid, structurally supportive configuration. This flexible shell approach enables the disc to adapt its physical properties during the repair process, achieving both insertability and structural strength.
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 effectively restores the structural integrity of the wall by securely attaching the disc to the backboard, enabling a seamless repair that matches the original wall surface, allowing for painting and ensuring durability.
Implementation Method 1
applying an adhesive to the inside portion of the surface area of the disc... allowing the adhesive on the inside portion of the surface area of the disc make contact with the wall
Data Source
AI summary
A wall repair device comprising a thin, flexible disc having an inside portion surface area, an outside portion surface area and an outside perimeter located around the outside edge of the disc and a center portion located in the center of the disc, wherein the center portion is an attachment means; a wand removeably attachable to the center portion of the disc; and wherein the outside perimeter of the disc is collapsible towards and in the direction of the length of the wand when the wand is attached to the center portion of the disc. A method to repair a hole in a wall, wherein the wall is made of drywall plaster or plaster lathe, is also disclosed herein.