Steering Wheel Sheath Composite Structure for Rapid Mounting
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Solution Overview
Problem
Conventional steering wheel sheath manufacturing methods result in a product that requires complex and time-consuming mounting processes, increasing production costs and complexity.
Innovation Solution
A steering wheel sheath comprising a carbon fiber-comprising composite element and an arcuate leather element, with specifically designed connection and engaging portions for easy assembly and enhanced user customization, utilizing an adhesive for secure coupling and a customized manufacturing process that includes baking and surface treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the steering wheel sheath is integrally formed by coupling thermo foam, prepreg, and exterior decoration material, then high mechanical strength and toughness are achieved, but the mounting process becomes time-consuming and complicated
Solution Approach 1:
The steering wheel sheath is divided into multiple independent components: a composite element (containing thermo foam and carbon fiber), an exterior decoration material layer, and a mounting structure with positioning features. This segmentation allows each component to be manufactured separately and assembled quickly through snap-fit or adhesive mounting, eliminating the time-consuming integral forming process while maintaining structural integrity.
Solution Approach 2:
The composite element and exterior decoration material are pre-assembled into a complete sheath structure before mounting. Positioning features such as clips, tabs, or adhesive layers are pre-installed on the mounting structure. This preliminary preparation enables rapid installation by simply engaging the pre-assembled sheath with the steering wheel, significantly reducing mounting time while preserving mechanical strength.
2Stability of the object's composition
If the steering wheel sheath is integrally formed by coupling thermo foam, prepreg, and exterior decoration material, then high toughness is achieved, but manufacturing complexity and costs increase
Solution Approach 1:
The sheath is segmented into a composite element providing structural toughness and an exterior decoration material layer providing aesthetic function. Each segment can be manufactured using optimized processes for its specific requirements, then assembled through simple mounting structures. This reduces manufacturing complexity compared to integral forming while maintaining the toughness provided by the composite materials.
Solution Approach 2:
The mounting structure integrates multiple functions: it provides mechanical attachment, positioning alignment, and structural support. By merging these functions into a single integrated mounting component rather than requiring separate operations for each function, the overall manufacturing complexity is reduced while maintaining the toughness of the composite structure.
3Strength
If the steering wheel sheath is integrally formed, then high mechanical strength is achieved, but production costs increase due to post-manufacturing processing
Solution Approach 1:
The composite element with mounting features is pre-manufactured as a complete assembly ready for installation. This preliminary action eliminates the need for post-manufacturing processing such as drilling, fastening, or sealing operations that would increase production costs. The pre-integrated mounting structure allows for simple snap-fit or adhesive attachment, reducing both labor and material costs while maintaining mechanical strength.
Solution Approach 2:
The mounting structure incorporates self-aligning features such as positioning ribs, guide slots, or self-adhering surfaces that enable the sheath to mount itself without requiring additional processing equipment or operations. This self-service mounting capability eliminates post-manufacturing processing steps, reducing production costs while maintaining the mechanical strength provided by the composite construction.
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
Facilitates simplified user-mounted installation and enhances the overall feel and mechanical properties of the steering wheel sheath, reducing production complexity and costs while maintaining high mechanical strength and toughness.
Implementation Method 1
An adhesive is applied to outer walls of the two connection portions of the composite element or inner walls of the two engaging portions of the leather element such that the two engaging portions of the leather element are connected to the two connection portions of the composite element, respectively, and thus coupled and fixed together.
Implementation Method 2
placing the molds (50, 51) on a hot-pressing platform to perform a pressing-heating process until temperature rises to around 130° C. ̃150° C. and stays at this temperature range for 15 minutes, thereby allowing the thermo foam (10), the prepreg (20) and the exterior decoration material (30) to be coupled together to form an integrally-formed element.
Data Source
AI summary
A steering wheel sheath includes a carbon fiber-comprising composite element and a leather element. The composite element forms a notch and a receiving space axially. Two ends of the composite element extend to form two connection portions bending by a predetermined angle. Inner walls of openings at two ends of the leather element form two engaging portions corresponding in position to the two connection portions of the composite element. An adhesive is applied to outer walls of the two connection portions of the composite element or inner walls of the two engaging portions of the leather element; hence, the composite element and the leather element are connected, coupled and fixed together. The customized manufacturing process allows the steering wheel sheath to be mounted by users and enhances overall feel.