Adaptable Sealing Hole Plug With Slotted Lip Segments
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Solution Overview
Problem
Conventional hole plugs are not adaptable to varying hole sizes and require an additional sealing step, as they are either too large for smaller holes or too small for larger holes, and often rely on adhesive sealing which is inefficient.
Innovation Solution
A hole plug design featuring slotted lips that can deflect and rotate to fit different hole sizes, combined with an expandable sealing core that secures the plug in place without the need for external sealing, using materials like polyurethane foam or expandable resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a hole plug is sized for a particular hole size, then it provides effective sealing for that specific size, but it cannot be used with holes of different sizes
Solution Approach 1:
The hole plug is divided into multiple lip segments (first lip segment, second lip segment) that can move independently relative to each other. These segments are connected through gaps that allow relative deflection and rotation, enabling the plug to adapt to different hole diameters while maintaining sealing effectiveness through the sealing core.
Solution Approach 2:
The hole plug transitions from a static, fixed-size design to a dynamic structure where the lips can deflect and rotate during insertion. This dynamic behavior allows the plug to automatically adjust its configuration to match the target hole size, providing both adaptability and reliable sealing.
2Reliability
If adhesive sealing is used on both sides of the component, then sealing is achieved, but an additional sealing step and extra materials are required
Solution Approach 1:
The hole plug performs its own sealing function through the expandable sealing core that expands to contact and seal against the component surfaces directly. This self-sealing mechanism eliminates the need for external adhesive sealing steps, reducing complexity while maintaining reliable sealing.
Solution Approach 2:
The sealing function is merged with the hole plug structure itself through the integrated sealing core. Instead of using separate adhesive layers on both sides, the sealing core provides unified sealing action, combining the plug and seal into a single component system.
3Adaptability or versatility
If a hole plug is made from resilient material, then it provides flexibility and sealing, but it cannot adapt to varying hole sizes
Solution Approach 1:
By segmenting the lip structure into movable parts connected by gaps, the plug can deflect and rotate during insertion to navigate different hole sizes. This segmentation maintains ease of insertion while enabling size adaptability that solid structures cannot achieve.
Solution Approach 2:
The plug utilizes changes in physical parameters (deflection, rotation, expansion) to adapt to different hole sizes. The resilient material properties are combined with geometric changes in the segmented structure, allowing the plug to modify its effective dimensions to match various hole sizes while maintaining low insertion forces.
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 secure sealing of holes across a range of sizes with low insertion force and eliminates the need for additional sealing steps, providing a fluid-tight barrier without the limitations of traditional hole plugs.
Implementation Method 1
The sealing core may be formed of a polyurethane foam, a urethane foam, a two part closed cell foam, an expandable resin, and/or the like
Data Source
AI summary
A hole plug is configured to plug a hole of a component, and includes a first lip that is configured to be positioned on a first surface of the component, and second lip that is configured to be positioned on a second surface of the component. The second surface is opposite from the first surface. At least one of the first lip or the second lip includes a first lip segment, a second lip segment, and at least one gap formed between the first lip segment and the second lip segment. The gap(s) is configured to allow the first lip segment and second lip segment to deflect and rotate relative to one another to adapt a size of the first lip and/or the second lip to the hole of the component.