Steering Wheel Rim Heating Element Integration
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Solution Overview
Problem
Existing steering wheels with heat generating members to warm the rim portion in cold weather are costly to manufacture due to the need for multiple molds in the molding process, which increases production costs.
Innovation Solution
A steering wheel design featuring a rim metal core with integrated heating elements, including a heat generating member, a heat transfer sheet, and a flexible heat insulating sheet, where the heating element is affixed to the rim metal core with an adherent layer, eliminating the need for a separate heat insulating portion mold and reducing manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate heat insulating portion is formed by molding plastic using a mold, then heat insulation performance is improved, but manufacturing complexity and cost increase due to requiring multiple molds
Solution Approach 1:
The patent combines the heat insulating portion with the base material into a single integrated component formed by one mold. The one-mold integrally formed structure includes both the base material and heat insulating portion as unified parts, eliminating the need for separate molding processes and multiple molds while maintaining effective heat insulation between the heating element and rim metal core
Solution Approach 2:
The base material serves dual functions: it provides structural support as the foundation of the rim portion and simultaneously acts as the heat insulating portion when formed with an insulating material layer. This multi-functional design eliminates the need for a separate heat insulating component while maintaining insulation performance
2Loss of energy
If heat insulating material is placed between the heating element and rim metal core, then heat transfer to the core is reduced, but manufacturing complexity increases due to additional components
Solution Approach 1:
The heat insulating material is merged with the base material to form an integrated one-mold structure. The base material with insulating material layer creates a unified component that simultaneously provides structural support and heat insulation, reducing the number of separate parts while preventing heat loss to the rim metal core
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 efficiently heats the rim portion surface while reducing production costs by simplifying the manufacturing process and maintaining effective heat distribution without degrading the heat generating performance.
Implementation Method 1
heat generating member that generates heat when electrified
Implementation Method 2
heat transfer sheet that transfers heat of the heat generating member to the coating portion
Implementation Method 3
heat insulating sheet that hinders heat of the heat generating member from being transferred to the rim metal core
Data Source
AI summary
A steering wheel having a rim portion is provided. The rim portion includes a rim metal core, at least one heating element, which extends around the core, and a coating portion, which coats the heating element. The heating element includes a heat generating member for generating heat when electrified, a heat transfer sheet, and a flexible heat insulating sheet. The heat transfer sheet transfers heat of the heat generating member to the coating portion. The heat insulating sheet hinders heat of the heat generating member from being transferred to the core. The heat insulating sheet has first and second surfaces. The heat transfer sheet is laid on the first surface. The heat generating member is located between the first surface and the heat transfer sheet. The heating element is affixed to the core at the second surface, while being flexed to conform to the surface of the core.