Single-Piece Expansion Plug for Tapered Hole Sealing
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Solution Overview
Problem
Existing multi-piece expansion plugs are costly, complex, and may not effectively seal tapered holes or withstand elevated pressures, and simple plugs can scratch holes during installation, leading to leakage pathways.
Innovation Solution
A single-piece expansion plug with an inner recess and external tapered wall, expanded using a tool with a spring-loaded pin that contacts the plug to seat and expand it within a tapered hole, ensuring reliable and repeatable installation without excessive force, which reduces scratching and enhances sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multi-piece expansion plugs are used, then sealing effectiveness is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent merges the cylindrical body and the expansion mechanism into a single integrated piece. The plug consists of a unitary body with an internal cavity that receives an expansion tool, eliminating the need for separate cylindrical and conical components that would require assembly. This single-piece construction reduces manufacturing complexity while maintaining the expansion sealing function.
2Ease of manufacture
If simple non-expanding plugs are used, then manufacturing simplicity is improved, but sealing reliability deteriorates due to hole scratching
Solution Approach 1:
The patent implements a dynamic expansion mechanism where the plug transitions from a compact inserted state to an expanded sealed state. The internal cavity receives an expansion tool that forces the plug material outward against the hole walls, creating a seal without scratching. This dynamic transformation allows the same simple single-piece structure to achieve both ease of manufacture and sealing reliability.
3Reliability
If elevated pressure resistance is improved, then sealing reliability is enhanced, but device complexity increases
Solution Approach 1:
The patent changes the physical state and geometry of the plug through expansion. The plug material is forced to deform and expand outward, changing its volume and contact pressure parameters. This parameter change allows the simple single-piece structure to withstand elevated pressures by creating a tight seal against the hole walls without requiring complex reinforcement structures.
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 cost-effective, simple, and reliable method to seal tapered holes while withstanding elevated pressures, minimizing hole damage and ensuring effective sealing without leakage pathways.
Implementation Method 1
A pin is located in a channel extending into the tool from the distal end. The pin is configured to move along a central axis of the tool such that in an extended position, the pin extends beyond the distal end
Implementation Method 2
The end section is configured to contact the plug to expand the plug outwardly towards the hole
Data Source
AI summary
A single piece expansion plug and method of using the same in connection with a tool is provided. The plug has an inner recess extending partially into a top of the plug, the inner recess defining a tapered inner wall. The plug is installed with a tool having a tapered end at a greater angle with respect to the taper inner wall. The tool presses against the tapered inner wall to expand the plug against a hole. The tool includes a pin that retracts against a spring to seat the plug in the hole to be sealed such that the pin contacts the plug prior to the tapered inner wall and tapered end coming into contact.