Hole Plug Flange Structure to Prevent Bending in Overlapping Holes
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Solution Overview
Problem
Hole plugs tend to bend backward when inserted into overlapping attachment holes, causing attachment issues due to the flange abutting the edge of larger diameter holes.
Innovation Solution
A hole plug attachment structure with a tube-shaped outer peripheral wall, a blocking portion, a ring-shaped flange, and a hook portion, where the flange location abutting the larger diameter hole is thicker than the smaller one, preventing backward bending by distributing the reaction force effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the hole plug is pressed further during insertion into overlapping attachment holes, then the attachment is secured, but the flange bends backward causing attachment failure
Solution Approach 1:
The flange is designed with non-uniform thickness: a first thickness in the region abutting the larger diameter attachment hole and a second thickness (greater than the first) in the region abutting the smaller diameter attachment hole. This local quality differentiation reinforces the flange at the critical thinner section to prevent backward bending while maintaining adequate coverage at both attachment hole sizes.
2Strength
If the flange is made thicker to prevent bending, then the flange strength increases, but the insertion force required increases
Solution Approach 1:
Instead of uniformly thickening the entire flange, the invention applies increased thickness only at the specific location (second thickness region) where the flange abuts the smaller diameter attachment hole during insertion. This localized reinforcement provides the necessary strength to prevent backward bending while minimizing the overall insertion force required, as other regions of the flange maintain their original, thinner dimensions.
Data Source
AI summary
A hole plug attachment structure includes: a first attachment-target member is formed with a first attachment hole; a second attachment-target member is formed with a second attachment hole; and a hole plug that includes a tube-shaped outer peripheral wall, a blocking portion, a ring shaped flange jutting out toward a radial direction outer side of the outer peripheral wall from an end portion of the outer peripheral wall on an opposite side from an insertion direction so as to cover a location surrounding the second attachment hole, and a hook portion, a location of the flange that abuts an edge of the second attachment hole being thicker than a location of the flange that abuts the edge of the first attachment hole, in a state in which a back face of the flange abuts both the edge of the first attachment hole and the edge of the second attachment hole.