Multilayer Hole-Closing Diecut for Fire-Resistant Sealing
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Solution Overview
Problem
Current methods for closing holes in metal sheets or plastics parts, particularly in vehicle bodies, fail to provide airtight, watertight, and fire-resistant sealing while also meeting soundproofing and repaintability requirements, leading to issues with corrosion, noise transmission, and fire safety.
Innovation Solution
A diecut with a specific layer sequence comprising a metallic layer, woven glass fabric, pressure-sensitive adhesive, flame-retardant foam, and additional adhesive layers, optimized for heat resistance and mechanical strength, is used to permanently close holes, ensuring moisture and soundproofing while maintaining compatibility with paint and fire protection standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plastic plugs are used to close holes, then hole closure is achieved, but airtight and watertight sealing is not reliably provided
Solution Approach 1:
The diecut comprises a multi-layer composite structure including a carrier (10), adhesive layers (20, 30), and a foam layer (40). This composite structure combines the strengths of different materials: the carrier provides structural integrity and paintability, the adhesive layers ensure secure bonding, and the foam layer provides airtight and watertight sealing. This resolves the contradiction by achieving reliable sealing that single-material plugs cannot provide.
2Reliability
If adhesive tapes are used to close holes, then some sealing is achieved, but fire resistance and soundproofing requirements are not met
Solution Approach 1:
The diecut incorporates a foam layer (40) with flame-retardant properties as part of its composite structure. This foam layer specifically addresses fire safety requirements while simultaneously providing soundproofing capabilities. The multi-layer composite design allows the diecut to meet multiple safety standards (fire resistance, airtightness, watertightness) that single-material solutions cannot achieve.
3Adaptability or versatility
If multiple different sized plugs are used for different hole sizes, then hole closure is achieved, but logistical and administrative complexity increases
Solution Approach 1:
The diecut is designed as a universal closing element that can be adapted to different hole sizes through its customizable dimensions and layer configurations. The multi-layer composite structure (carrier, adhesive layers, foam layer) maintains its functional integrity across different sizes, allowing a single design family to serve multiple hole closure applications. This reduces logistical complexity compared to maintaining separate specialized plugs for each hole size.
4Object-affected harmful factors
If thick sealing materials are used to ensure airtight closure, then moisture protection is improved, but soundproofing effectiveness decreases
Solution Approach 1:
The diecut's foam layer (40) is optimized to provide both airtight sealing and soundproofing functions within an appropriate thickness range. The composite structure allows the foam layer to work in conjunction with the carrier and adhesive layers to achieve moisture protection and sound attenuation without requiring excessive material thickness. The multi-material composition enables simultaneous optimization of sealing and acoustic properties.
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 prevents moisture penetration, enhances soundproofing, and provides reliable fire resistance, addressing the limitations of existing solutions by ensuring holes are securely and safely closed in vehicle bodies.
Implementation Method 1
a first pressure-sensitive adhesive layer (20) arranged between the carrier (10) and the substrate (50), a second pressure-sensitive adhesive layer (30) arranged between the foam layer (40) and the substrate (50)
Data Source
AI summary
The present invention relates to a diecut especially for the permanent closing of holes especially in metal sheets or in plastics parts, having a carrier composed of an assembly, more particularly laminate in the specified layer sequence, of optionally at least one first layer, which is formed by a metallic layer having a thickness of 10 to 40 μm, optionally at least one second layer, which is formed by a woven glass fabric or laid glass fabric having a basis weight of 30 to 200 g/m2, optionally at least one third layer, which is formed by a first pressure-sensitive adhesive having a basis weight of 70 to 200 g/m2, at least one fourth layer, which is formed by a flame-retardant foam having a thickness of at least 0.5 to 2.5 mm, and at least one fifth layer, which is formed by a second, acrylate-based pressure-sensitive adhesive having a basis weight of 300 to 1800 g/m2, preferably 360 to 1500 g/m2 and/or a thickness of 400 to 1800 μm, preferably 800 to 1500 μm.