Unitary Patch With Fastener Channel For Flush Wall Repair
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Solution Overview
Problem
Conventional wall patches and access panels require intrusive attachment methods, often necessitating the cutting of larger holes and can be unsightly if not properly matched in color or skillfully installed, especially when dealing with irregularly shaped damage or access openings.
Innovation Solution
A unitary patch with a channel for flush mounting using fasteners like hook and loop, magnetic, or screw fasteners, featuring aesthetic designs such as contoured surfaces, faux vents, or speaker mesh patterns that do not require cutting the surface to fit, allowing for easy installation and removal without compromising airflow or aesthetics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional attachment methods are used for wall patches and access panels, then secure mounting is achieved, but intrusive installation requiring larger cuts and additional materials is required
Solution Approach 1:
The patent replaces traditional mechanical attachment methods (screws, nails, adhesives) with a channel-based fastener system. The channel is defined in the inner face of the patch body, and fasteners are inserted into this channel to secure the patch to the surface. This substitution simplifies installation by eliminating the need for intrusive attachment means and large cuts, while maintaining secure mounting.
Solution Approach 2:
The patch is divided into distinct functional components: an outer face with aesthetic portion, an inner face with channel, and a body structure. The channel is specifically defined in the inner face to hold fasteners, separating the mounting function from the aesthetic covering function. This segmentation allows for non-intrusive installation while maintaining both security and appearance.
2Ease of manufacture
If conventional patches are used to cover wall damage, then coverage is achieved, but the patch requires cutting larger holes and additional materials making it unsightly
Solution Approach 1:
The patch is designed to serve multiple functions: it provides structural coverage for the opening, offers an aesthetic appearance through its outer face design, and enables non-intrusive installation via the channel system. The patch can be used for both damage concealment and equipment access, eliminating the need for separate repair and access solutions.
Solution Approach 2:
The outer face of the patch includes an aesthetic portion that can be designed to match surrounding wall surfaces. The patent specifically mentions that the outer face can include aesthetic portions to provide an aesthetic visual to cover the opening, allowing the patch to blend with the surrounding environment and appear less intrusive.
3Adaptability or versatility
If access panels require large cuts to be installed, then equipment access is enabled, but larger holes are created than the initial damage
Solution Approach 1:
The access panel is designed with removable fasteners that allow the panel to be easily detached and reattached. The channel system enables the panel to be removed for equipment access and then securely reinstalled, providing dynamic access functionality without requiring permanent large openings. The panel can be removed and repositioned as needed.
4Object-affected harmful factors
If traditional patching materials and compounds are used, then damage coverage is achieved, but repainting and color matching are required
Solution Approach 1:
The patent employs a pre-fabricated patch unit with a defined structure including outer face, inner face, and channel system. This disposable-like unit replaces the need for traditional patching materials (new material, compound, spackle) and eliminates the complex process of applying and repainting. The patch is installed as a complete unit that provides both structural and aesthetic coverage.
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
Enables easy, aesthetic, and non-intrusive covering of irregularly shaped openings or access points without cutting, providing a universal solution for both damage concealment and equipment access, with the ability to match surrounding finishes and materials, while maintaining functionality and appearance.
Implementation Method 1
The one or more fasteners can include one or more of: hook and loop fasteners, magnetic fasteners, dual lock fasteners, latches, and/or screws
Data Source
AI summary
In accordance with at least one aspect of this disclosure, a patch for covering an opening in a surface comprises, a unitary body having an inner face configured to abut the surface over the opening in the surface and an outer face opposite the inner face. The outer face can include an aesthetic portion to provide an aesthetic visual to cover the opening in the surface. The patch also comprises a channel defined in the inner face configured to hold one or more fasteners for mounting the unitary body to the surface such that the inner face sits flush on the surface.