Diecut Carrier for Permanent Hole Sealing
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Solution Overview
Problem
Current methods for closing holes in metal sheets or plastics parts, particularly in vehicle bodies, are inadequate as they do not securely seal holes, are complex and expensive to produce, and fail to effectively prevent moisture and noise penetration, especially under mechanical stress and in the underfloor region.
Innovation Solution
A diecut with a carrier composed of a laminate of two polymeric films, including a heavy-duty film and a functional layer with a self-adhesive composition, which provides enhanced mechanical strength, barrier properties, and soundproofing, ensuring airtight and watertight closure of holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional plastics plugs are used to close holes, then hole closure is achieved, but the closure is not secure and allows moisture and air passage
Solution Approach 1:
The diecut combines multiple materials with different functions: a heavy-duty polymeric film (≥1.0 kg/m²) provides mechanical strength and puncture resistance, while a lower film with adhesive composition provides bonding to the substrate. This composite structure achieves secure, airtight, and watertight closure that conventional single-material plugs cannot provide.
Solution Approach 2:
The invention uses a flexible heavy-duty polymeric film as the carrier that can conform to the hole opening while providing sufficient mechanical strength. The film's flexibility allows it to adapt to various hole sizes and shapes while maintaining its barrier properties against moisture and air passage.
2Adaptability or versatility
If multiple sizes of plugs are used to cover different hole sizes, then all hole sizes can be closed, but logistical and administrative effort increases significantly
Solution Approach 1:
The diecut is designed as a universal closure system where a single product type with adjustable dimensions can close holes of various sizes (5-50 mm). The heavy-duty film carrier can be manufactured in different sizes but maintains the same functional structure, eliminating the need for multiple specialized plug types and their associated storage and handling requirements.
Solution Approach 2:
The invention changes the dimensional parameters of the diecut (area, diameter) while maintaining the same structural design and material composition. This allows a single design family to cover multiple hole sizes without increasing complexity in manufacturing, storage, or application procedures.
3Strength
If heavy-duty film with basis weight ≥1.0 kg/m² is used, then mechanical strength and puncture resistance improve, but material consumption and cost increase
Solution Approach 1:
The heavy-duty polymeric film is applied locally only where mechanical strength is needed - specifically at the hole opening and surrounding area. The film extends beyond the hole opening by a defined margin (1-20 mm) to provide adequate coverage and strength, but does not require excessive material beyond what is necessary for the reinforcement function.
Solution Approach 2:
The composite structure distributes material requirements efficiently: the heavy-duty film (≥1.0 kg/m²) provides localized reinforcement at the hole opening where mechanical stress concentrates, while the overall quantity of material is controlled by the defined extension margin beyond the hole perimeter, optimizing the balance between strength and material consumption.
4Reliability
If adhesive composition is applied to the lower film, then bond strength to substrate improves, but risk of adhesive migration into the heavy-duty film increases
Solution Approach 1:
The lower film acts as an intermediary layer between the adhesive composition and the heavy-duty film carrier. It provides a barrier that prevents direct contact between the adhesive and the heavy-duty film, thereby preventing adhesive migration while still allowing the adhesive to bond effectively to the lower film and the substrate beneath it.
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 diecut effectively seals holes against moisture, noise, and mechanical stress, maintaining bond strength over time and allowing for easy removal, while covering a range of hole sizes with improved tear resistance and puncture resistance.
Implementation Method 1
The lower film, on the side facing away from the upper film, bearing an applied adhesive, more particularly self-adhesive, composition
Data Source
AI summary
Diecuts are configured for permanent closing of holes and have a carrier comprising an assembly of at least two polymeric films. An upper film of the at least two polymeric films has a basis weight of at least 1.0 kg/m2 and a lower film of the at least two polymeric films consisting of at least two layers, wherein a first layer is in the form of a polymeric film and faces the upper film, and a second layer is in the form of a functional layer with a side of the lower film, facing away from the upper film, bears an applied adhesive composition.