PVD Steering Wheel Cover Coating With Reinforced Grounding

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Solution Overview

Problem

Physical vapor deposition (PVD) layers on injection-moulded components cause charge buildup, leading to interference with electrically sensitive sensors like driver's hand off detection systems, and existing grounding solutions like carbon fibre layers are structurally inadequate for PVD layers.

Innovation Solution

A coating system with a primer layer, a metal particle layer applied via PVD, and a structural reinforcement portion composed of an electrically-conductive material layer, including sublayers, supports rigid connections and ensures equipotential grounding, preventing charge interference.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If a PVD layer is applied on the injection-moulded component surface, then the appearance becomes attractive and the layer provides electrical conductivity, but charge buildup occurs that interferes with electrically sensitive sensors

Engineering Contradiction:

Improveappearance attractivenessVSAvoidcharge buildup interference

Core Design Contradiction:

Illumination intensityVSObject-affected harmful factors

Solution Approach 1:

A grounding connector is introduced as an intermediary element to provide a dedicated charge dissipation path. The connector includes a grounding portion that contacts the PVD layer and a connection portion that extends to a grounding point, acting as a mediator to transfer charges away from the sensor region without affecting the appearance function of the PVD layer.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The charge dissipation function is extracted from the PVD layer itself and separated into a dedicated grounding connector system. This allows the PVD layer to maintain its appearance and electrical conductivity functions while the separate grounding structure handles charge dissipation, preventing interference with sensors.

Inventive Principle:

Principle #2Taking out (Extraction)

2Ease of operation

If a carbon fibre layer is used as an alternative to PVD for grounding, then grounding is easily achieved through screw connections, but the layer is too thick and cannot structurally withstand connection stresses

Engineering Contradiction:

Improvegrounding achievement easeVSAvoidstress tolerance of grounding layer

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The structural reinforcement is applied locally only at the connection region where the grounding connector contacts the component. This localized reinforcement provides the necessary stress tolerance at the connection point without requiring the entire layer to be thick like carbon fibre, maintaining the thin profile needed for PVD compatibility while enabling robust mechanical connections.

Inventive Principle:

Principle #3Local quality

3Illumination intensity

If the PVD layer is made thinner to maintain appearance quality, then the appearance remains attractive, but the layer cannot structurally withstand screw or bolt connection stresses

Engineering Contradiction:

Improveappearance qualityVSAvoidconnection stress tolerance

Core Design Contradiction:

Illumination intensityVSStrength

Solution Approach 1:

The grounding connector combines multiple functions into a single integrated structure: it provides electrical contact with the thin PVD layer, establishes a mechanical connection through the connection portion, and creates a stress distribution path through the reinforcement structure. This merging allows the thin PVD layer to maintain its appearance quality while the integrated connector handles the mechanical stress requirements.

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The coating system enhances stress tolerance and eliminates charge interference by allowing secure connections and equal electrical potential, preventing layer breakage and sensor interference.

Implementation Method 1

a metal particle layer is applied on the primer layer by means of physical vapor deposition

Methodology Applied

Scientific EffectPhysical vapor deposition: Physical Vapour Deposition

Implementation Method 2

charges on the PVD layer can be conducted away by means of the grounding connector

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS20260061673A1Injection-moulded component, connection system, steering wheel cover plate, and vehicle

Publication Date: 2026.03.05 ZF ASIA PACIFIC AUTOMOTIVE SAFETY SYSTEMS (SHANGHAI) CO LTD

AI summary

The present invention relates to an injection-moulded component, a connection system, a steering wheel cover plate, a steering wheel and a vehicle. A surface of the injection-moulded component is provided with a coating that comprises a primer layer applied on the surface of the injection-moulded component, and a metal particle layer is applied on the primer layer by means of physical vapor deposition. It is provided according to the invention that the coating is provided with at least one structural reinforcement portion which is configured to enable the coating to be tolerant to rigid connection implemented by means of the structural reinforcement portion.