Expandable Hole Plug Assembly for Fluid-Tight Sealing
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Solution Overview
Problem
Existing methods for plugging holes in components, particularly in automotive applications, are time-consuming and costly due to the difficulty in accessing and positioning separate foam blocks or seals, which are bulky and inefficient in forming a fluid-tight barrier.
Innovation Solution
An expandable hole plug assembly with a main body and an expandable layer that secures within a panel hole, expanding to form a fluid-tight barrier upon temperature or pressure change, allowing for efficient sealing without the need for additional sealing materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate and distinct foam blocks or seals are used to plug holes, then fluid-tight barrier is provided, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the hole plug body and the expandable sealing layer into a single integrated assembly. The expandable layer is directly connected to the plug body, eliminating the need for separate foam blocks or seals. This merging reduces device complexity while maintaining the fluid-tight barrier function through the expandable layer that expands to fill the hole and prevent fluid passage.
2Object-affected harmful factors
If all holes are plugged with hole plugs, then moisture and sound infiltration is prevented, but manufacturing time and cost increase
Solution Approach 1:
The patent utilizes parameter changes (temperature and/or pressure) to trigger the expansion of the sealing layer. The expandable layer is configured to expand in response to changes in temperature and/or pressure, transforming from a compact state during assembly to an expanded sealing state after installation. This allows for efficient sealing without requiring manual intervention for each hole, thereby improving manufacturing productivity while effectively preventing moisture and sound infiltration.
3Reliability
If separate foam blocks are positioned between panels, then fluid-tight barrier is achieved, but ease of operation deteriorates due to difficulty in positioning
Solution Approach 1:
The expandable layer performs self-service by automatically expanding to the correct position and shape within the hole after the plug assembly is installed. The expansion mechanism eliminates the need for precise manual positioning of separate foam blocks. The layer expands in situ to fill the hole and create the fluid-tight barrier, making the operation easier while maintaining reliability.
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 expandable hole plug assembly reduces manufacturing time and cost by providing a reliable, fluid-tight seal with minimal components, effectively preventing moisture and sound infiltration.
Implementation Method 1
The expandable layer is configured to expand in response to a change in temperature and/or pressure
Implementation Method 2
The expandable layer is configured to expand in response to a change in temperature and/or pressure
Data Source
AI summary
A hole plug assembly is configured to be secured within a hole of a panel, and may include a main body having at least a portion that is configured to be secured in the hole of the panel, and an expandable layer connected to the main body. The expandable layer is configured to expand into the hole to form a fluid-tight barrier.