Fiber Reinforced Plastic Steering Wheel Braided Rim Design
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Solution Overview
Problem
Existing vehicle steering wheels face challenges in achieving lightweight construction while maintaining structural integrity and safety, particularly in the connection between the fiber-reinforced plastic rim and the central steering wheel pot, and in absorbing impact energy during crashes.
Innovation Solution
A steering wheel design featuring a braided hose made of fiber composite material encasing a core structure, with a form-fitting connection via preformed spoke structures and strip material, allowing for adjustable grip and moment of inertia, and incorporating crash elements for energy absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a fiber-reinforced plastic steering wheel rim is constructed using traditional methods (continuous glass fibers coated with liquid plastic or short fibers pressed), then the rim achieves sufficient strength, but the manufacturing process becomes complex and weight reduction is limited
Solution Approach 1:
The patent employs fiber-reinforced plastic composite material (specifically carbon fiber-reinforced plastic) to construct the steering wheel rim, combining the high strength-to-weight ratio of carbon fibers with the structural integrity provided by the plastic matrix. This composite approach enables significant weight reduction while maintaining or enhancing structural strength compared to traditional materials.
Solution Approach 2:
The patent changes the material parameters by transitioning from traditional glass fiber composites to carbon fiber composites, and from solid plastic injection molding to a foam core with braided fiber overlay. This parameter change in material selection and structural configuration achieves both weight reduction and improved manufacturing efficiency.
2Weight of moving object
If the steering wheel rim is made entirely of fiber-reinforced plastic to reduce weight, then weight is reduced, but the connection strength between the rim and central steering wheel pot may be compromised
Solution Approach 1:
The connection structure utilizes fiber-reinforced plastic composite material that combines the lightweight properties of carbon fibers with the bonding capabilities of plastic resin. This composite material maintains connection strength while reducing overall weight compared to solid metal or solid plastic constructions.
Solution Approach 2:
The patent applies different material densities and structures to different regions of the steering wheel - a foam core for weight reduction in non-critical areas, and reinforced fiber composite structures at connection points and rim sections requiring higher strength. This local differentiation of material quality optimizes both weight and strength requirements.
3Weight of moving object
If a foam core structure is used to reduce weight and adjust moment of inertia, then weight and rotational characteristics are optimized, but the structural rigidity and crash energy absorption capability must be carefully managed
Solution Approach 1:
The patent uses a composite structure combining foam core material with an outer layer of fiber-reinforced plastic. The foam core provides lightweight mass with adjustable moment of inertia, while the fiber-reinforced plastic shell maintains structural rigidity and crash energy absorption capabilities. This composite approach resolves the contradiction between weight reduction and structural integrity.
Solution Approach 2:
The foam core is strategically positioned in the central and non-critical areas of the steering wheel where weight reduction is most beneficial, while the fiber-reinforced plastic provides localized strength at the rim, connection points, and crash zones. This spatial differentiation of material properties optimizes both weight and structural performance.
Data Source
Figure 1~2
AI summary
The invention relates to a method for producing a steering wheel of a vehicle, the rim (1) of which is composed at least in sections of fibre‑reinforced plastic and is pulled in the form of a braided tube onto a core structure of the rim, which core structure, when the plastic hardens in the die, ensures that the braided tube bears against the wall of the die cavity. A plastics rigid foam core or a tube filled with gas can be used as the core structure, and the rim can be formed by segments which are strung together and between which a crash element which plastically deforms in a suitable manner in the event of the driver impacting against the steering wheel is fitted. Furthermore, the connection between a steering wheel cup (2) and the steering wheel rim (1) and/or a spoke structure (2b) connecting said steering wheel components to each other can at least also be produced by said steering wheel components being wrapped with strip‑shaped fibre composite material (3) before being placed into a die. A correspondingly designed vehicle steering wheel is also claimed.