Integrated Electrode Structure for Steering Wheel Manufacturing
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Solution Overview
Problem
Conventional methods for manufacturing steering wheels with integrated sensors and heating functions are costly and require additional components, increasing man-hours and complexity.
Innovation Solution
An electrode structure is integrated onto the steering wheel's core metal, featuring an insulator with engagement portions and dual electrodes that function as both sensor and heater, eliminating the need for notches and separate components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a cutting tool is used to make notches in the foam and separate conductors are inserted into the first layer and second layer, then the sensor and heating functions can be implemented, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The patent combines the sensor electrode and heater electrode into a single integrated electrode structure that is disposed on the outer circumference of the core metal. This eliminates the need for separate notches and separate conductor insertions into different foam layers, thereby reducing manufacturing complexity while maintaining both sensor and heating functions.
Solution Approach 2:
The integrated electrode structure serves dual functions: it acts as both a sensor electrode for detecting grip force and as a heater electrode for providing heating functionality. This multi-functional design reduces the number of components and simplifies the manufacturing process compared to using separate conductors for each function.
2Adaptability or versatility
If separate conductors are inserted into the first layer and second layer of the foam, then the sensor and heating functions are achieved, but the number of manufacturing steps and man-hours increase
Solution Approach 1:
The patent merges the sensor and heating functions into a single integrated electrode structure attached to the core metal, eliminating the need for separate conductor insertions into the foam layers. This reduces the number of manufacturing steps and improves production efficiency.
Solution Approach 2:
The electrode structure is pre-integrated onto the core metal before the foam is formed or attached, rather than requiring post-assembly insertion of separate conductors. This preliminary integration reduces manufacturing steps and improves productivity.
3Adaptability or versatility
If notches are made in the foam for inserting conductors, then the sensor and heating functions are implemented, but the appearance of the steering wheel is compromised
Solution Approach 1:
The patent combines both the sensor electrode and heater electrode into a single integrated structure attached to the outer circumference of the core metal, eliminating the need for notches in the foam. This preserves the smooth, continuous appearance of the steering wheel while maintaining dual functionality.
Solution Approach 2:
Instead of inserting conductors radially into the foam layers (requiring notches), the patent positions the integrated electrode structure on the outer circumference of the core metal, utilizing the circumferential dimension. This alternative positioning eliminates the need for notches and preserves the steering wheel's appearance.
Data Source
AI summary
An electrode structure includes an insulator and a first electrode that is in the shape of a line, where the first electrode is disposed on a first surface of the insulator, and the first surface is on an opposite side of the insulator relative to a surface of the insulator that faces a core metal of a steering wheel. The insulator includes an engagement portion that engages an engagement-target portion included in the core metal. After the electrode structure is engaged with the core metal, a foam is shaped into a mold to form the steering wheel.