Polymer Drive Fingers for Steering Wheel Rotary Switch
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Solution Overview
Problem
The existing designs for electrical switch contactors in vehicle steering columns are complex to manufacture and can cause noise pollution and discomfort due to functional clearances when the steering wheel is operated.
Innovation Solution
The use of polymer materials for drive fingers and locking fins, which are easy to manufacture and provide a strong, silent, and comfortable connection, reducing functional play and noise, with the drive fingers and fins being distributed symmetrically or asymmetrically for effective rotational drive.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional metal drive elements and cutouts are used, then the connection is mechanically strong, but the design complexity and manufacturing complexity increase
Solution Approach 1:
The patent merges the drive elements and locking fins into a single integrated polymer component. The rotary contactor and steering wheel are connected through integrated drive fingers and locking fins that form a unified structure, eliminating the need for separate metal drive elements and reducing assembly steps while maintaining mechanical strength through the polymer material's inherent properties.
Solution Approach 2:
The patent employs polymer composite materials that combine the advantages of metal strength with manufacturing simplicity. The polymer material used for drive fingers and locking fins provides sufficient mechanical strength while enabling easier manufacturing processes such as injection molding, thereby reducing both design and manufacturing complexity compared to traditional metal components.
2Ease of operation
If multiple drive elements and cutouts are used, then rotational drive is achieved, but functional clearances cause noise and discomfort
Solution Approach 1:
The patent utilizes the flexible and damping properties of polymer materials in the drive fingers and locking fins. The polymer material absorbs vibrations and reduces functional clearances between components, thereby minimizing noise generation during rotational operation while maintaining smooth ease of operation.
Solution Approach 2:
The polymer composite material provides both the mechanical strength needed for effective rotational drive and the damping characteristics that reduce noise. The material's inherent elasticity and vibration absorption capabilities eliminate the noise issues associated with traditional metal components that create functional clearances during operation.
3Manufacturing precision
If traditional metal components are used, then manufacturing precision can be achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent combines multiple metal components into a single polymer part that can be manufactured in one process. The integrated drive fingers and locking fins are produced through injection molding, which achieves precise dimensional tolerances and consistent geometric features without the complex machining and assembly required for traditional metal components.
Solution Approach 2:
The patent replaces traditional mechanical machining processes for metal components with polymer injection molding. This substitution maintains manufacturing precision through the molding process's inherent accuracy while dramatically simplifying manufacturing operations, reducing tooling requirements, and lowering production complexity.
Data Source
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AI summary
The invention relates to an assembly comprising an electric switch (1) and a steering wheel (20) of a vehicle, in particular a motor vehicle, said electric switch (1) comprising a rotary contactor (3) on which said steering wheel (20) is mounted, said assembly being characterised in that either the rotary contactor (3) or the steering wheel (20) comprises at least one catch (10) for rotating the other one of the steering wheel (20) or the rotary contactor (3), said catch (10) being at least partially covered with a polymer material, and in that the other one of the steering wheel (20) or the rotary contactor (3) comprises means (24) for engaging with said catch (10).