Crimp Connection for Mesh Shielding in Capacitive Steering Wheels

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Solution Overview

Problem

Soldered connections in steering wheel assemblies can be inconsistent, leading to undesirable lumps that are detectable by the driver, making it difficult to achieve uniform electrical connections.

Innovation Solution

A crimped connection method using a twisted electrically conductive mesh and a crimp connector, where a first area of the mesh is twisted from a second area and wrapped around a conductive member, with a crimp connector secured over the twisted connection, eliminating the need for solder and providing a consistent and compact electrical link.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If soldering is used to make electrical connections, then electrical connections can be established, but inconsistent amounts of solder lead to prominent lumps detectable by driver touch

Engineering Contradiction:

Improveconsistency of electrical connectionVSAvoidprofile of connection beneath cover

Core Design Contradiction:

ReliabilityVSShape

Solution Approach 1:

The patent replaces the thermal/mechanical soldering process with a purely mechanical crimping system. The crimp connector mechanically deforms the conductive mesh and wire together to create an electrical connection, eliminating the need for solder and the associated consistency problems with solder application.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the connection method from thermal bonding (soldering) to mechanical bonding (crimping). This parameter change in the connection mechanism fundamentally alters how the electrical connection is formed, providing consistent results without the variability inherent in manual solder application.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If solder is used to connect wires to circuit boards, then electrical connections are made, but varying amounts of solder create detectable lumps under the steering wheel cover

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoiddriver detection of connection lumps

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the soldering process with a mechanical crimping system that forms connections through controlled deformation. This eliminates the variable solder application that creates detectable lumps, as the crimping process provides consistent mechanical bonding without excess material.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent extracts and eliminates the solder material from the connection process entirely. By removing solder and replacing it with a direct mechanical crimping system, the source of the problematic lumps is completely removed from the assembly.

Inventive Principle:

Principle #2Taking out (Extraction)

3Manufacturing precision

If manual soldering is performed, then electrical connections can be made, but achieving uniform solder application is difficult and time-consuming

Engineering Contradiction:

Improveuniformity of solder applicationVSAvoidconnection assembly speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces the manual soldering operation with an automated crimping process. The crimp connector is simply positioned and crimped onto the conductive mesh and wire, a much faster and more consistent process than manual soldering, thereby improving both precision and productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The conductive mesh is pre-formed with a specific geometry that facilitates easy insertion and crimping. This preliminary preparation of the mesh structure enables rapid assembly through crimping, eliminating the time-consuming nature of manual soldering while ensuring uniform connections.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS10355376B2Crimp connection for mesh shielding material used in steering wheel with capacitive sensing

Publication Date: 2019.07.16 GENTHERM INC

AI summary

An example assembly includes an electrically conductive member, an electrically conductive mesh, and a crimp connector. The electrically conductive mesh includes a first area and a second area. The second area extends along a second longitudinal axis and is larger than the first area. The first area is twisted and extends from the second area along a first longitudinal axis that is transverse to the second longitudinal axis. One of the electrically conductive member and the twisted first area is twisted around the other of the electrically conductive member and the twisted first area to form a twisted connection. The crimp connector is crimped onto the twisted connection to form a crimped connection. The first area of the electrically conductive mesh, including the crimped connection, is folded onto the second area of the electrically conductive mesh.