Steering Wheel Polymer Branch Conductor Positioning
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Solution Overview
Problem
Existing vehicle steering wheels with energy consumers in the rim face challenges in positioning energy conductors without increasing metal costs or compromising appearance quality, as they require complex internal structures and limited space for conductor passage.
Innovation Solution
A steering wheel design featuring a metal hub and rim with a polymer branch containing energy conductors, positioned using non-mechanical means before polymer injection, allowing for embedded conductor placement without mechanical connecting pieces, thus maintaining aesthetic quality and increasing conductor passage possibilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mechanical connecting piece is added to position the energy conductor, then the conductor positioning is guaranteed, but the metal structure complexity and cost increase
Solution Approach 1:
The patent replaces the mechanical connecting piece (metal support) with a positioning means made of non-metallic material that is integrated into the polymer injection molding process. This substitution eliminates the need for separate metal positioning components while achieving the same conductor positioning function through the molding process itself, thereby reducing metal structure complexity and cost.
Solution Approach 2:
The patent merges the positioning function with the polymer branch structure by integrating the positioning means directly into the injected polymer. Instead of having a separate metal support component, the positioning feature is combined with the polymer material that already serves as the structural element, reducing the number of discrete metal parts and simplifying the overall metal structure.
2Manufacturing precision
If a mechanical connecting piece is added to position the energy conductor, then the conductor positioning is guaranteed, but the number of conductors that can pass from hub to rim is limited
Solution Approach 1:
By replacing the metal support structure with a polymer-integrated positioning means, the patent removes the spatial constraints imposed by rigid metal components. This allows for more flexible routing and positioning of multiple conductors within the branch structure, enabling increased conductor passage capacity from hub to rim without the geometric limitations of metal support geometry.
Solution Approach 2:
The patent changes the material parameter from rigid metal to flexible polymer, which allows the positioning structure to accommodate multiple conductors of varying sizes and configurations. The polymer material can be molded to create positioning features that adapt to different conductor arrangements, thereby increasing the number of conductors that can be accommodated.
3Ease of operation
If the energy conductor is placed close to the polymer surface, then the conductor is easily accessible, but the appearance quality of the steering wheel is compromised
Solution Approach 1:
The patent incorporates the positioning means into the polymer injection molding process itself, positioning the conductor at the correct depth relative to the polymer surface before the final surface finish is achieved. This preliminary positioning ensures that the conductor is embedded at the appropriate depth to maintain appearance quality while still allowing for necessary accessibility, as the positioning is established during the forming process rather than requiring post-processing adjustments.
Data Source
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Figure 3
AI summary
The invention relates to a vehicle steering wheel comprising: - a metal hub, - a rim, - at least one branch comprising a mechanical connecting piece securing the rim to the hub, characterized in that it comprises at least one other branch made from injected polymer between the hub and the rim, with no mechanical connecting piece securing the rim to the hub, and containing at least one energy conductor, the steering wheel comprising positioning means arranged to position said at least one energy conductor before the polymer of said branch is injected so as to guarantee a minimum distance between said at least one energy conductor and a surface of the polymer once injected.