Layered Wall Patch With Gradient Structure
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Solution Overview
Problem
Repairing damaged structures like wall boards is challenging due to the difficulty in creating a structurally sound and visually appealing patch that is not easily detectable after application.
Innovation Solution
A layered wall patch structure with a base layer and stacked layers, where each stacked layer has an exposed lower surface region that extends laterally beyond the underlying layer, providing a gradient in thickness and adhesive area to adhere to the wall surface, offering structural support while minimizing visual detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a simple patch is applied to cover damaged areas, then the repair process is simple and quick, but the patch is easily detectable and visually appealing
Solution Approach 1:
The patch is divided into multiple stacked layers with progressively smaller exposed lower surface regions. Each layer is stacked on the previous layer, creating a stepped configuration where the exposed regions form a gradient that blends the patch into the surrounding surface, making it visually undetectable after painting.
2Strength
If the patch thickness is increased to provide structural support, then impact resistance improves, but the visual detection of the patch increases
Solution Approach 1:
Instead of increasing thickness uniformly in one dimension, the patent uses multiple stacked layers where each layer extends laterally beyond the layer below it. This creates a gradient in the lateral dimension while maintaining controlled thickness, allowing structural support without visual prominence.
3Reliability
If the adhesive area is increased to improve bonding, then the patch adheres more securely to the wall surface, but the visual contrast between patch and surrounding surface increases
Solution Approach 1:
The adhesive is applied to the exposed lower surface regions of each stacked layer, which are progressively smaller in area. This creates a gradient adhesive configuration where sufficient adhesion is maintained for secure bonding, while the reducing adhesive area on upper layers minimizes visual contrast with the surrounding wall surface.
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 layered structure provides significant impact resistance and blends seamlessly with the surrounding surface, making the patch nearly undetectable after application and coating, such as painting.
Implementation Method 1
Adhesive may operate to adhere the exposed lower surface regions
Data Source
AI summary
Aspects of the disclosure are directed to apparatuses and/or methods involving a wall patch. As may be implemented in accordance with one or more aspects characterized herein, a wall patch has a plurality of layers including a base layer having an upper surface and a lower surface, and stacked layers stacked over the upper surface of the base layer. Each stacked layer is stacked on one of the other layers and has an exposed lower surface region that extends laterally beyond the layer upon which it is stacked. Adhesive may operate to adhere the exposed lower surface regions and the lower surface of the base layer may be adhered to a wall surface. The stacked layers, base layer and adhesive to provide a gradient defined by the thicknesses of the layers and adhesive, and defined by the area of the exposed lower surface regions of the stacked layers.