Steering Wheel Rim Projections for Control Element Mounting

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Solution Overview

Problem

Existing steering wheel designs, particularly 1-spoke steering wheels, face challenges in ergonomically attaching control elements due to limited space and stability issues, leading to inadequate accessibility and haptic sensations during operation.

Innovation Solution

A steering wheel skeleton with projections on the rim, extending between specific clock positions, provides a stable mounting position for control elements, enhancing accessibility and stability by integrating these projections as part of the one-piece injection molded part, preferably made from magnesium or aluminum alloys, with reinforcement inserts for added strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If control elements are integrated directly into the foam covering of the steering wheel rim, then the steering wheel can be manufactured with a simple structure, but the number of controllable functions is limited and the tactile sensation is poor due to low stability and yielding of the foam

Engineering Contradiction:

Improvestructure complexityVSAvoidnumber of controllable functions

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The steering wheel rim is segmented by adding protrusions that extend from the rim toward the hub, creating distinct mounting zones for control elements. These protrusions divide the rim structure into functional segments, allowing multiple controls to be positioned at optimal locations without increasing overall structural complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Protrusions serve as intermediary structures between the foam covering and control elements. They provide a stable mounting platform that transfers forces between the controls and the steering wheel rim, eliminating the yielding problem of direct foam mounting while maintaining manufacturing simplicity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If removable control units are installed on the steering wheel, then more functions can be controlled, but the control units may detach under significant external force

Engineering Contradiction:

Improvenumber of controllable functionsVSAvoidattachment stability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The protrusions are integrated directly into the steering wheel rim structure, merging the mounting mechanism with the rim itself. This creates a permanent, reliable attachment system that cannot detach under external force, while still allowing multiple control elements to be mounted on the protrusions.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of operation

If spokes are positioned at the 3 o'clock and 9 o'clock positions to place controls, then controls are easily accessible in driver's normal grip position, but this arrangement is not ergonomically feasible for all steering wheel shapes particularly single-spoke steering wheels

Engineering Contradiction:

Improveaccessibility of controlsVSAvoidergonomic feasibility for different steering wheel shapes

Core Design Contradiction:

Ease of operationVSAdaptability or versatility

Solution Approach 1:

The protrusion-based mounting system provides a universal solution that works with any steering wheel configuration (single-spoke, two-spoke, multi-spoke). The protrusions can be positioned at optimal ergonomic locations regardless of spoke arrangement, allowing controls to be placed at 3 o'clock, 9 o'clock, or other positions as needed for different steering wheel designs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 allows for a higher number of controls to be securely attached, improving ergonomics and stability, ensuring easy access and enhanced haptic feedback, while maintaining cost-effectiveness and crash safety through foam encapsulation.

Implementation Method 1

an injection molding material is injected under pressure into the (optionally closed) negative mold

Methodology Applied

Scientific EffectInjection molding:

Implementation Method 2

The hub and rim are connected by at least one spoke. The frame is then covered with a foam covering that essentially encases the metal structure in the area of the spokes and rim.

Methodology Applied

Scientific EffectFoam encapsulation: Foam

Data Source

PatentEP3356201B1Steering wheel skeleton and steering wheel comprising operator elements, and manufacturing method

Publication Date: 2021.01.06 PSA AUTOMOBILES SA

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AI summary

The invention relates to a steering wheel skeleton (10) comprising a hub (11) and a steering wheel rim (12) which are connected to each other by at least one spoke (13); at least one projection (14) for accommodating an operator element, in particular a multifunctional switch unit, is located on an inner face of the steering wheel rim (12). The invention further relates to a steering wheel comprising a steering wheel skeleton (10) of this type and to a manufacturing method.