Integrated Fastening Element for Vehicle Insulation Packages
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Solution Overview
Problem
Current insulation package fastening methods in vehicle cabins require additional process steps and a large number of components, leading to increased costs and installation time, as they necessitate separate application of fastening elements, which can prolong cabin unavailability for other processes.
Innovation Solution
Integration of fastening elements directly into the insulation package, such as discs or other types of fastening elements, within the foam rings or wrapping foils, allowing for snap-lock or non-positive connections with holding elements, thereby eliminating the need for external fastening elements and reducing installation complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate fastening elements (pins, discs, foam rings) are used to fasten insulation packages, then reliable fastening and sealing are achieved, but the number of components increases, installation time increases, and costs increase
Solution Approach 1:
The patent combines multiple separate fastening components (pin, disc, and foam ring) into a single integrated fastening element. The pin serves as the fastening means while simultaneously providing sealing and thermal bridge prevention functions that were previously handled by separate foam rings. This merging reduces the total number of components and simplifies the fastening system while maintaining reliable fastening quality.
Solution Approach 2:
The integrated fastening element performs multiple functions simultaneously: it provides mechanical fastening through the pin, prevents thermal bridges, and seals the insulation package against fluid ingress. This multi-functional design eliminates the need for separate specialized components for each function, thereby reducing component count while maintaining all necessary performance characteristics.
2Reliability
If separate fastening elements are applied in additional process steps, then proper fastening is achieved, but installation time increases and cabin availability decreases
Solution Approach 1:
The fastening element is pre-integrated into the insulation package during manufacturing, with the pin already positioned and configured. This preliminary preparation eliminates the need for separate installation steps during cabin assembly, as the insulation package arrives ready-to-install with all fastening components already in place, significantly reducing installation time.
Solution Approach 2:
By combining multiple fastening operations into a single integrated component, the patent reduces the number of discrete installation steps required. The insulation package with integrated fastening elements can be installed in one action rather than requiring sequential installation of pins, discs, and foam rings, thereby reducing cabin downtime.
3Reliability
If multiple separate fastening components are used, then adequate sealing and thermal bridge prevention are achieved, but personnel costs and installation effort increase
Solution Approach 1:
The patent merges the sealing function (previously requiring separate foam rings) with the fastening function into a single integrated element. The pin-based fastening element inherently provides both mechanical attachment and sealing/thermal break functions, reducing installation effort by eliminating the need to handle and install multiple separate components.
Data Source
AI summary
An insulation package is provided for insulating a cabin of a vehicle that includes, but is not limited to at least one wrapping foil and at least one core layer of an insulation material. The wrapping foil envelopes the core layer at least in some regions and includes, but is not limited to at least one opening for feeding-through a holding element. On the wrapping foil a fastening element is arranged that is designed to establish a mechanical connection with the holding element fed through the opening. This can be a positive-locking or a non-positive-locking connection. By integrating the fastening element in the insulation package, the expenditure for separate fasteners can be saved so that the installation time and the different components can be reduced.