Steering Wheel Horn Contact Structure for Compact Assembly
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Solution Overview
Problem
Existing steering wheel horn devices require complex assembly processes, additional components, and increased space due to the use of cages and screws, which are not suitable for newer steering wheel designs with smaller dimensions.
Innovation Solution
A horn device with contact elements fixed in a foam body of the steering wheel, eliminating the need for a cage and using anchoring pins and a bent spring section to close the horn circuit, allowing for compact integration and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cage and additional components are used to hold contact elements, then the horn device can be assembled, but the assembly complexity and production time increase
Solution Approach 1:
The contact elements are directly integrated into the foam body structure, eliminating the separate cage component. The foam body itself serves as the mounting structure, combining the support function and the contact element housing into a single integrated component, thereby reducing assembly complexity and production time
Solution Approach 2:
The cage and additional fastening components are completely removed from the horn device design. By extracting these unnecessary intermediate components, the patent achieves a simpler assembly process while maintaining the functional integrity of the horn device through direct integration into the foam body
2Reliability
If a cage and fastening components are used, then the contact elements can be positioned, but the space requirements increase
Solution Approach 1:
The positioning function previously performed by the cage is merged into the foam body structure. The foam body directly provides the geometric constraints and positioning features for the contact elements, eliminating the need for a separate cage and reducing the overall space required for the horn device
Solution Approach 2:
The cage and fastening components that occupied additional space are completely removed. The contact elements are positioned directly within the foam body using minimal structural features, significantly reducing the volume required for the horn device while maintaining accurate contact element positioning
3Reliability
If welding, riveting, or bolting methods are used to attach components, then the horn system can be assembled, but the production time and cost increase
Solution Approach 1:
The attachment function is merged into the foam body's inherent structural properties. The foam body provides natural anchoring and positioning features that eliminate the need for separate welding, riveting, or bolting operations, thereby reducing production time and cost while maintaining reliable component attachment
Solution Approach 2:
Traditional mechanical fastening methods (welding, riveting, bolting) are replaced by the foam body's material properties and structural design. The foam body provides friction-based holding and geometric constraint that achieves reliable attachment without requiring additional fastening operations, significantly improving productivity
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
This design minimizes space requirements, reduces assembly complexity, and enhances reliability by eliminating the need for additional components, enabling efficient production and maintenance while ensuring reliable horn signal activation.
Implementation Method 1
the contact elements are designed as contact plates and connected to the steering wheel by a frame... the contact flag and the support flag are designed and positioned to be complementary to each other such that the contact flag touches the support flag
Data Source
Figure 1a
Figure 1b~1c
Figure 2a~2b
AI summary
The invention relates to a horn (10) for a steering wheel (50), comprising a first contact element (20) and at least one second contact element (30), which are spaced apart from one another. According to the invention, the first contact element (20) has at least one contact lug (21) and the second contact element (30) has at least one base lug (31), the contact lug (21) and the base lug (31) being complementary to one other in such a way and being positioned in such a way that the contact lug (21) touches the base lug (31) in order to close a horn circuit.