Steering Wheel Heating Mat Crease-Free Attachment
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Solution Overview
Problem
Existing steering wheel heating technologies face challenges in applying heating elements without creases, as they require mechanical stretching which can lead to material instability and surface damage due to limited material strength and embedding issues.
Innovation Solution
The use of knob-shaped, hooked, and mushroom-shaped elements on the steering wheel rim to securely attach a heating mat with a knitted carrier material, allowing for easy alignment and fixation without creases, and subsequent adhesion or foaming for permanent attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the heating element is tensioned and mechanically stretched to apply it to the steering wheel rim without creases, then the surface smoothness and crease-free appearance is improved, but the material stability and surface integrity deteriorate due to limited material strength
Solution Approach 1:
The heating element is segmented into a modular assembly comprising a heating mat with carrier material, an intermediate foam layer, and an outer foam encapsulation. This segmentation allows each layer to be optimized independently - the carrier material provides structural support during application, the intermediate foam allows controlled expansion without excessive tension, and the outer foam provides final surface smoothing - thereby resolving the contradiction between achieving crease-free surface and maintaining material strength
Solution Approach 2:
The heating mat is pre-assembled with the carrier material and heating conductors before application to the steering wheel rim. The carrier material is prepared in advance to provide the necessary mechanical support, and the heating conductors are pre-positioned in a wavy or meandering pattern that anticipates the stretching requirements during application, allowing the final assembly to be applied without excessive tension that would damage the materials
2Shape
If the heating conductors are embedded in a thin elastomer layer with high thread tension to achieve improved feel and surface, then the surface quality is improved, but the elastomer layer stability deteriorates and may tear during sewing or embedding
Solution Approach 1:
The carrier material is designed with locally optimized properties - it has sufficient thickness and structural integrity at the locations where heating conductors are attached to provide anchoring support, while allowing the outer foam encapsulation to provide the final thin, smooth surface quality. This local differentiation of material properties allows the heating conductors to be securely embedded without requiring the entire elastomer layer to have high tensile strength throughout
Solution Approach 2:
The heating element uses a composite structure with the carrier material (textile fabric, fleece, film, woven or knitted fabric) combined with foam layers. The carrier material provides mechanical support and stability during the embedding process, while the foam layers provide the final smooth surface. This composite approach allows the heating conductors to be securely attached without tearing the delicate outer surface layer
3Strength
If adhesive is applied to fix the heating mat to the steering wheel rim, then the attachment strength is improved, but the ability to detach and realign during assembly is lost
Solution Approach 1:
The heating mat is pre-assembled as a complete unit with the carrier material and heating conductors attached before application to the steering wheel rim. This preliminary assembly allows the entire heating element to be positioned and aligned as one piece, and adhesive is only applied in the final installation step. This sequence allows for easy detachment and realignment during positioning, while still achieving strong attachment once the final position is confirmed
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
Enables quick, secure, and crease-free installation of the heating element, improving stability and surface integrity by allowing for detachment and realignment during assembly and providing a uniform, comfortable feel similar to non-heatable steering wheels.
Implementation Method 1
heating conductors (7) which run in a wavy or meandering manner and are fastened to the carrier material (6)... Fusing occurs after a voltage has been applied to the grid line
Implementation Method 2
the heating mat (5) is fixed by means of knob-shaped, hooked and/or mushroom-shaped elements (12), which penetrate the heating mat (5) and hook into the carrier material (6)
Implementation Method 3
adhesive and at least partially filled with foam
Data Source
Figure 1~2
Figure 3~4
Figure 5A~5D
AI summary
The steering wheel (1) has a heating mat (5) composed of a thin three-dimensional and flexible textile carrier for an undulating or serpentine heating wire (7). The heating mat is held in place at the steering wheel by projections (12) around it, penetrating into the mat to anchor the carrier material (6).