Profiled Wood Patch for Groove Repair
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Solution Overview
Problem
Existing methods for repairing wood panels with defects, such as knotholes and cracks, using wood patches are inefficient due to issues like unsuitable patch shapes, low bond strength, and high production costs, as well as the risk of damaging the patch's edges during insertion.
Innovation Solution
A wood patch design with a slightly wider central area and narrower ends, allowing easy insertion into a rectangular groove without resistance, and featuring small indentations and bulges that prevent edge contact, ensuring secure adhesion and automatic centering within the groove.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a cylindrical drill is used to create a conical depression for wood patches, then the patch insertion is simplified, but the patches become circular in shape which is visually unappealing and unsuitable for cracks
Solution Approach 1:
The wood patch is divided into multiple segments (typically three rectangular pieces) that are joined together to form an elongated patch suitable for filling cracks and linear defects, rather than using a single circular patch
Solution Approach 2:
Instead of shaping the patch to fit a pre-formed conical hole, the invention creates a rectangular groove and inserts a rectangular patch that fits within it, inverting the traditional approach of using cylindrical drills and circular patches
2Adaptability or versatility
If a V-shaped groove is created and multiple wood pieces are hammered in, then elongated defects can be filled, but the patches are not form-fitting and bond strength is low
Solution Approach 1:
The rectangular groove is pre-formed with precise dimensions before patch insertion, ensuring that the patch will fit snugly and provide maximum bond strength upon insertion
Solution Approach 2:
Adhesive is applied to the groove surfaces to create a strong bonding interface between the patch and the wood, replacing the mechanical hammering method with a chemical bonding approach
3Ease of manufacture
If wood patches are inserted into grooves with rectangular openings, then the patches can be easily manufactured, but the edges of the patch are at risk of breaking during insertion
Solution Approach 1:
Rounding fillets are created at the corners of the rectangular groove to eliminate sharp edges, providing a cushioning effect that prevents patch corner breakage during insertion while maintaining easy manufacturability
4Ease of manufacture
If the groove walls are made parallel to each other, then the groove is easy to manufacture, but the patch cannot be securely retained without additional fixation devices
Solution Approach 1:
The groove design combines parallel walls for easy manufacturing with rounded corner fillets that provide mechanical interlocking and adhesive bonding surfaces, creating a composite geometric structure that achieves both manufacturability and retention strength
Data Source
Figure 1
Figure 2
AI summary
The wooden plate (P) has a groove that is provided with a rectangle opening (N1) and two opposite walls (N2), which are provided flat and parallel to each other. Two connected front walls (N3) are provided with cylindrical segments. Two front surfaces (F3) are provided as wood patch (F) of the cylindrical segments. The radius of the front surfaces is same as the radius of the front walls of the groove. Front width of the front surfaces is smaller than groove width (N5). Independent claims are also included for the following: (1) a milling tool for manufacturing a wood patch; (2) a method for manufacturing wood patches; and (3) a method for patching a defect in a wooden plate.