Hole plugs

1 - 19 . (canceled)

20 . A process for plugging a hole of a component, comprising:

providing a plug, the plug comprising a base and a conical section extending from the base wherein the conical section is made from an expandable material;

locating the plug within the hole of the of the component; and

expanding the expandable material to assist in plugging the hole.

21 . A process according to claim 20 wherein the conical section is made from a material that is flexible and expandable.

22 . A process according to claim 20 wherein the conical section is hollow.

23 . A process according to claim 20 wherein the base is circular.

24 . A process according to claim 20 wherein the conical section and the base are integrally moulded from the expandable material.

25 . A process according to claim 20 wherein the maximum diameter of the conical section is 5 to 50 millimieters.

26 . A process according to claim 20 wherein the maximum diameter of the conical section is 5 to 10 millimeters.

27 . A process according to claim 20 wherein incisions are formed around the perimeter of the base.

28 . A process according to claim 20 wherein the conical section is provided with channels defined by vanes formed on the conical section.

29 . A process according to claim 20 wherein the plug is provided with an extension on the side of the base remote from the conical section.

30 . A process according to claim 20 wherein the expandable material is an expandable adhesive material, which can be activated to expand and foam and also act as an adhesive.

31 . A process according to claim 20 wherein the component is an automobile frame.

32 . A process according to claim 20 wherein the component is tubing and plug is located adjacent the end of the tubing.

33 . A process according to claim 20 wherein the component is an automotive vehicle sub frame and wherein the plug includes plural plugs and the step of locating the plug includes insertion of the plural plugs into unused or incompletely filled holes in the vehicle sub frame.

34 . A process for plugging a hole in a vehicle sub frame of an automotive vehicle, comprising:

providing a plug, the plug including a base and including a conical section extending from the base wherein the conical section is made from an expandable material and wherein the conical section has a diameter such that at least a portion of the conical section can pass through the hole while the base has a size that will not pass through the hole;

locating the plug within the hole of the of the vehicle sub frame;

subjecting the vehicle sub frame to an e-coat process, which encapsulates perimeter surfaces defining the hole with e-coat to facilitate corrosion protection; and

expanding the expandable material to assist in plugging the hole by baking the sub frame is a curing oven such that the expandable material expands in conditions in the curing oven, fills the hole and encapsulates the perimeter surfaces defining the hole.

35 . A process according to claim 34 wherein the plug is inserted prior to subjecting the automobile component to the e coat process.

36 . A process according to claim 35 wherein the conical section is made from a material that is hollow, flexible and expandable and includes channels formed by vanes in the conical section.

37 . A process according to claim 35 wherein the base is circular and wherein incisions are formed around the perimeter of the base.

38 . A process according to claim 35 wherein the conical section and the base are integrally moulded from the expandable material.

39 . A process according to claim 34 wherein the plug includes plural plugs and the step of locating the plug includes insertion of the plural plugs into unused or incompletely filled holes in the vehicle sub frame.

40 . A process for plugging a hole in vehicle sub frame of an automotive vehicle, comprising:

providing a plug, the plug comprising a base, a conical section extending from the base and an extension of the side of the base remote from the conical section, wherein:

i. the conical section is made from a flexible and expandable material;

ii. the conical section has a diameter such that at least a portion of the conical section can pass through the hole while the base has a size that will not pass through the hole;

iii. the conical section is hollow and the base is circular;

iv. the conical section and the base are integrally moulded from the expandable material;

v. the maximum diameter of the conical section is 5 to 10 millimeters;

vi. incisions are formed around the perimeter of the base;

vii. the conical section is provided with channels, which are defined by vanes formed on the conical section;

viii. the expandable material is an expandable adhesive material, which can be activated to expand and foam and also act as an adhesive;

locating the plug within the hole of the of the vehicle sub frame;

subjecting the vehicle sub frame to an e-coat process, which encapsulates perimeter surfaces defining the hole with e-coat to facilitate corrosion protection; and

expanding the expandable material to assist in plugging the hole by baking the sub frame is a curing oven such that the expandable material expands in conditions in the curing oven, fills the hole and encapsulates the perimeter surfaces defining the hole;

wherein the plug is inserted prior to subjecting the automobile component to the e coat process.

41 . A process according to claim 40 wherein the plug includes plural plugs and the step of locating the plug includes insertion of the plural plugs into unused or incompletely filled holes in the vehicle sub frame.