Steering Wheel Foam Conductor Insertion Tool
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Solution Overview
Problem
Existing methods for introducing electrical conductors, such as heating wires, into the foam covering of a steering wheel skeleton are time-consuming and labor-intensive, requiring additional steps for insertion and securing the wires, which affects the uniformity and efficiency of heating.
Innovation Solution
A method and tool combination that simultaneously cuts into the foam and inserts the electrical conductor, using a cutting tool with an integrated insertion tool, allowing for a single work step and secure fixation through elastic closure of the cut edges or thermoplastic adhesive activation, ensuring quick and even placement of the conductor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrical conductor is inserted using previously known methods, then the conductor can be reliably held in the foam, but the introduction process is very time-consuming and labor-intensive
Solution Approach 1:
The patent combines the cutting operation and conductor insertion operation into a single integrated tool and process step. The cutting tool creates an incision in the foam while simultaneously guiding the conductor into the incision, eliminating the need for separate insertion and securing steps. This merging of operations directly resolves the contradiction by maintaining reliable conductor holding through the foam's elastic closure while dramatically improving introduction efficiency.
Solution Approach 2:
The cutting tool creates the incision and begins the insertion process simultaneously, preparing the path for conductor placement before the conductor fully enters the foam. The cut edges are elastically pushed apart in advance by the cutting action, creating an open pathway that guides the conductor into position before the edges return to close and secure it.
2Power
If the heating wires are arranged at the smallest possible depth in the foam covering, then good and efficient heat output is achieved, but the wires must be reliably held to prevent slipping
Solution Approach 1:
The foam material's elastic properties enable it to self-close the incision after the conductor is inserted, automatically securing the conductor in place without requiring additional fastening mechanisms. The foam's natural elasticity provides the holding force that prevents wire slipping while allowing the wire to be positioned at the optimal shallow depth for heat output efficiency.
3Manufacturing precision
If the heating wires are arranged at a constant depth in the foam covering, then uniform heating is ensured, but the introduction process becomes more complex
Solution Approach 1:
The cutting tool is designed to perform multiple functions simultaneously: cutting the foam, guiding the conductor, and controlling the insertion depth. This multi-functional tool design achieves constant conductor depth (ensuring uniform heating) without significantly increasing process complexity, as the same tool that creates the incision also controls the conductor placement depth through its structural design.
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 approach significantly reduces the time and effort required for conductor placement, ensures secure and uniform heating, and allows for precise control of the conductor's depth and orientation, enhancing the efficiency and reliability of the heating process.
Implementation Method 1
the cut edges, which have been pressed apart, rest against one another again. The edges of the cut are elastically pushed apart when the incision is made by the cutting tool and, after the cutting tool is advanced or removed, they return elastically to their starting position
Implementation Method 2
the conductor/wire has a thin thermoplastic adhesive coating. This can be activated by energizing / heating, which additionally fixes the wire
Implementation Method 3
the conductor is bonded to the encapsulation in another way, for example by a Smartbond process. According to a further preferred embodiment it is provided that the conductor is fixed in the encapsulation by brief heating and subsequent cooling. In this method, the heating is preferably carried out to a temperature in the range of the melting temperature of the surrounding foam
Data Source
Figure 1
Figure 2a~2b
Figure 3a~3b
AI summary
The invention relates to a method for introducing an electrical conductor (22), in particular a heating wire, into a foam cladding (20) of a steering wheel frame (18), comprising the following steps: making at least one cut (26) into the foam cladding (20) by means of a cutting tool (34), and simultaneously introducing the conductor into the produced cut (26). The invention further relates to a tool and a tool assembly for performing said method and to a vehicle steering wheel.