Expandable Mounting Plug for Reliable Hole Sealing Assembly
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Solution Overview
Problem
Existing mounting plugs for closing openings, particularly in vehicle bodies, face issues with assembly reliability due to resistance during insertion and the risk of incomplete sealing, leading to assembly errors and potential dislodgment under vehicle vibrations.
Innovation Solution
A two-part mounting plug with a radial collar and expansion element, where the radial collar expands outward upon insertion, ensuring complete engagement behind the hole edge, and a sealing ring for secure sealing and elastic retention, preventing rattling and accommodating tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rubber plug with a plate-like base body and circumferential shaft flange is used to close openings, then the plug can be inserted through the hole, but the flange offers considerable resistance during insertion and may cause the shaft to bend, leading to assembly errors and potential dislodgment under vibrations
Solution Approach 1:
The mounting plug is divided into two separate functional parts: a radial collar with hook elements for engagement and an expansion element for actuation. This segmentation allows the collar to be pre-assembled in a compact state for easy insertion, then expanded separately to achieve reliable engagement behind the opening edge, eliminating the bending issue of integrated shaft-flange designs
Solution Approach 2:
The radial collar transitions from a static pre-assembled state to a dynamic expanded state through the expansion element. The collar is designed to be elastically deformable, allowing it to spring outward upon actuation and engage behind the opening edge with positive mechanical action, ensuring reliable retention under vibration while maintaining ease of initial insertion
2Reliability
If excessive pressure is exerted on rubber plugs during assembly to ensure proper seating, then the plate-like base body may get into the hole completely, requiring manipulation or causing the plug to fall in, which prolongs assembly time
Solution Approach 1:
The radial collar is pre-assembled with the expansion element in a compact configuration that allows straightforward insertion through the opening without requiring excessive force. The preliminary arrangement of components prevents the base body from getting lost in the hole, as the pre-locked configuration provides immediate structural integrity during insertion
Solution Approach 2:
The expansion element provides tactile and visual feedback during actuation, allowing the installer to confirm proper engagement behind the opening edge. This feedback mechanism eliminates the need for excessive pressure or manipulation, as the installer can immediately verify correct installation through the expansion element's resistance and positioning
3Reliability
If the surrounding flange is made wider than the hole opening to ensure engagement, then the plug can lock behind the bore edge, but it offers considerable resistance during insertion and may bend the shaft
Solution Approach 1:
The radial collar with hook elements is nested within or integrated with the expansion element in a compact pre-assembled configuration. This nested structure allows the locking components to be stored in a space-efficient manner during insertion, then deployed outward when expanded, achieving reliable engagement without increasing overall plug complexity or insertion resistance
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 solution provides a simple, reliable, and error-free assembly process for closing openings, ensuring a secure seal and preventing dislodgment, even under vibrations, while allowing for detection of manipulation attempts.
Implementation Method 1
the expanding element (3) is designed such that, in cooperation with the radial collar, when the assembly plug is inserted and after a stop of the radial collar has been reached, the expanding part is pushed in further and in the process expands the radial collar outwards so that the flange-like elements engage behind the edge of the hole
Implementation Method 2
the sealing ring, which... exerts an elastic restoring force on the mounting plug in such a way that, for example, rattling is avoided and tolerances in the hole depth or the sheet thickness are reliably compensated
Data Source
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AI summary
The invention relates to a mounting plug (1) for closing openings, in particular openings in car bodies and the like, wherein the mounting plug has a first device (3) which has means (16) for locking behind an opening edge and also a second device (2) with which the means for locking behind the opening edge can be actuated radially outwards into a locking position, wherein the second device is axially displaceable in the first device and actuation can be carried out by the axial displacement.