Optimized double washer pull plug for minimizing coating error

1. An optimized dual washer pull plug apparatus for masking a mechanical part, the mechanical part having a first side, a second side, and an aperture that extends from the first side to the second side, the optimized dual washer pull plug comprised of:

a plug body having a first end and a second end;

a first centering component between the first end of the plug body and the second end of the plug body, the first centering component having a first end and a second end and the first centering component having a length between the first and second ends of the first centering component, a diameter between the first and second ends of the first centering component, and being generally cylindrical between the first and second ends of the first centering component;

a second centering component between the first centering component and the second end of the plug body, the second centering component having a first end and a second end and the second centering having a length between the first and second ends of the second centering component, a diameter between the first and second ends of the second centering component, and being generally cylindrical between the first and second ends of the second centering component, the length of the second centering component greater than the length of the first centering component;

a first masking flange at the first end of the first centering component, the first masking flange having a first major diameter, a first flexibility coefficient, and an angle θ 1 , said first flexibility coefficient directly proportional to the amount of force necessary to pull said first masking flange through the aperture of the mechanical part; and

a second masking flange at the first end of the second centering component, the second masking flange having a second major diameter, a second flexibility coefficient, and an angle θ 2 ,

wherein said plug body, said first centering component, said second centering component, said first masking flange, and said second masking flange withstanding temperatures of up to 600° F.,

wherein the first centering component is configured to center the first masking flange relative to the aperture of the mechanical part on the first side of the mechanical part,

wherein the second centering component is configured to center the second masking flange relative to the aperture of the mechanical part on the second side of the mechanical part,

wherein the plug body has a diameter between the first and second centering components that is less than the diameter the first centering component and less than the diameter of the second centering component,

and wherein the first masking flange has a thickness less than the second masking flange such that the first masking flange is more flexible than the second masking flange.

2. The apparatus of claim 1 wherein said first and said second centering components are adapted to fit securely against an interior surface of an entrance thread of the mechanical part forming a barrier that is impenetrable by coating particles.

3. The apparatus of claim 1 , wherein said first masking flange has a thickness of 20/1000 inch to ¼ inch.

4. The apparatus of claim 1 wherein said first masking flange has a major diameter 105 to 200% greater than a diameter of the aperture of the mechanical part.

5. The apparatus of claim 1 wherein said angle θ 1 ranges from 10 to 170 degrees.

6. The apparatus of claim 1 wherein said angle θ 2 ranges from 10 to 170 degrees.

7. The apparatus of claim 1 wherein said first end of the plug body further includes a first gripping ridge and said second end of the plug body further includes a second gripping ridge.

8. The apparatus of claim 1 wherein said apparatus is adapted for use with a weld nut.

9. The apparatus of claim 1 wherein said apparatus is adapted for use with a press nut.

10. The apparatus of claim 1 wherein at least one of said first end and said second end further includes an aperture for hanging a part that is to be coated on a coating line.

11. The apparatus of claim 1 , wherein the first and the second centering components are between the first and the second masking flanges.

12. The apparatus of claim 1 , wherein the diameter of the first centering component is equal to the diameter of the second centering component.

13. The apparatus of claim 1 , wherein a portion of the plug body between the first centering component and the second centering component is concave.

14. An optimized dual washer pull plug apparatus comprised of:

a mechanical part, the mechanical part including a first side, a second side, an aperture that extends from the first side to the second side;

a plug body having a first end and a second end;

a first centering component between the first end of the plug body and the second end of the plug body, the first centering component having a first end and a second end and the first centering component having a length between the first and second ends of the first centering component and being generally cylindrical between the first and second ends of the first centering component;

a second centering component between the first centering component and the second end of the plug body, the second centering component having a first end and a second end and the second centering having a length between the first and second ends of the second centering component and being generally frusto-conical between the first and second ends of the second centering component, the length of the second centering component greater than the length of the first centering component;

an angular shaped first masking flange at the first end of the first centering component, the first masking flange having a first major diameter, a first flexibility coefficient, and an angle θ 1 , said first flexibility coefficient directly proportional to the amount of force necessary to pull said first masking flange through the aperture of the mechanical part;

a triangular shaped second masking flange at the first end of the second centering component, the second masking flange having a second major diameter, a second flexibility coefficient, and an angle θ 2 ; and

wherein said plug body, said first centering component, said second centering component, said first masking flange, and said second masking flange withstanding temperatures of up to 600° F.,

wherein the first centering component is received in the aperture of the mechanical part to center the first masking flange relative to the aperture of the mechanical part on the first side of the mechanical part to mask the aperture, and

wherein the second centering component is received in the aperture of the mechanical part to center the second masking flange relative to the aperture of the mechanical part on the second side of the mechanical part mask the aperture,

and wherein the first masking flange has a thickness less than the second masking flange such that the first masking flange is more flexible than the second masking flange.

15. The apparatus of claim 14 , wherein the mechanical part includes threads located within the aperture, and wherein the first and second centering components engage the threads when the first and second centering components are located within the aperture of the mechanical part.

16. The apparatus of claim 14 , wherein the first major diameter of the first masking flange is 105 to 200% greater than a diameter of the aperture of the mechanical part.

17. The apparatus of claim 14 , wherein the mechanical part includes a weld nut.

18. The apparatus of claim 14 , wherein the mechanical part includes a press nut.

19. The apparatus of claim 14 , wherein the first centering component has a diameter between the first and second ends of the first centering component, wherein the second centering component has a diameter between the first and second ends of the second centering component, wherein the plug body has a diameter between the first and second centering components that is less than the diameters of the first and second centering components.

20. The apparatus of claim 19 , wherein a portion of the plug body between the first centering component and the second centering component is concave.