Wall Repair Patch With Irregular Protrusions for Seamless Edges
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Solution Overview
Problem
Traditional wall repair methods are labor-intensive and fail to create seamless edges between repaired and undamaged sections, often resulting in visible patches and inadequate support.
Innovation Solution
A wall repair apparatus with a perimeter of irregularly spaced protrusions of variable length and depth, allowing for a seamless edge when painted, customizable to fit specific wall damage, and made from materials like fibrous materials, synthetic polymers, or metals, which can be applied directly to the wall and painted over to blend with the surrounding area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional wall repair methods are used, then the repair can be performed with simple materials, but the edge between repaired and undamaged sections is visible and the repair is not seamless
Solution Approach 1:
The perimeter of the wall repair apparatus includes irregularly spaced protrusions of variable length and variable depth that overlap to form pockets and holes. This asymmetric, irregular structure creates a rag edge or deckled edge that breaks up the outline of the patch, allowing paint to penetrate and create a seamless transition between the repaired and undamaged wall sections.
Solution Approach 2:
The apparatus features localized variations in the perimeter structure with protrusions of different lengths and depths at different locations. This local quality variation allows different regions of the perimeter to interact with paint and wall surface differently, creating optimal seamless edges in each local area while maintaining overall structural integrity.
2Strength
If a planar wall patch is used, then the apparatus is simple to manufacture, but it fails to provide support for the repair and does not conform to damaged surfaces
Solution Approach 1:
The bottom surface of the apparatus is configured to substantially conform to the contour of the damaged wall, replacing the traditional planar structure with a curved, adaptive surface. This curvature allows the apparatus to match the three-dimensional topology of damaged areas, providing structural support while maintaining ease of manufacture through formable materials.
3Manufacturing precision
If an uneven perimeter is used to break up the outline, then the patch outline is disrupted, but the finished repair still shows variation between repaired and unrepaired wall
Solution Approach 1:
The perimeter structure includes pockets and holes formed by overlapping protrusions, creating a porous configuration that allows paint to penetrate through and into the edge regions. This porosity enables paint to fill voids and crevices, creating a seamless appearance that is difficult to differentiate from the undamaged wall, while the irregular structure naturally breaks up the outline.
Data Source
AI summary
A wall repair apparatus comprising a body, a top surface, a bottom surface, and an edge or a perimeter comprising a plurality of irregularly spaced protrusions of variable length and variable depth. The plurality of irregularly spaced protrusions or variable length and variable depth may form a rag edge or a deckled edge that allows for a seamless transition between the repaired wall and the undamaged wall when painted.