Steering Wheel Skeleton Cover for Weight Reduction

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Solution Overview

Problem

Existing vehicle steering wheels require significant foam material for encapsulation, leading to increased weight and material usage, with challenges in protecting electrical lines and ensuring a secure connection between the foam and the steering wheel skeleton.

Innovation Solution

A steering wheel skeleton cover that closes the open profile of the steering wheel skeleton, using a plastic component with projections for guiding and fastening electrical lines and a one-piece plug connector, and a structured surface for enhanced bonding, reducing the need for foam material and weight while protecting electrical components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If foam encapsulation is applied to the steering wheel skeleton, then the steering wheel structure is stabilized and electrical lines are protected, but the steering wheel weight increases and material usage increases

Engineering Contradiction:

Improvestructural stabilityVSAvoidsteering wheel weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The skeleton cover is divided into multiple segments (front cover, rear cover, and optional side covers) that can be separately manufactured and assembled. This segmentation allows for optimized foam application in specific areas rather than complete encapsulation, reducing overall foam material usage and steering wheel weight while maintaining structural stability in critical regions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The skeleton cover provides localized protection and structural support where most needed, rather than requiring complete foam encapsulation throughout. The cover creates defined cavities that provide structural integrity, allowing foam to be used selectively for electrical line protection and cushioning only in areas where it adds value, thereby reducing total foam material and weight.

Inventive Principle:

Principle #3Local quality

2Object-affected harmful factors

If complete foam encapsulation is used, then electrical lines are protected, but manufacturing complexity increases due to the need for line channels

Engineering Contradiction:

Improveelectrical line protectionVSAvoidmanufacturing complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The skeleton cover is designed with pre-formed cavities and integrated mounting elements that accommodate electrical lines and components before foam application. This preliminary structuring eliminates the need to create line channels during or after foaming, simplifying the manufacturing process while ensuring electrical line protection is built into the design from the start.

Inventive Principle:

Principle #10Preliminary action

3Stability of the object's composition

If foam material is used for encapsulation, then the steering wheel skeleton is stabilized, but material consumption increases

Engineering Contradiction:

Improveskeleton stabilityVSAvoidfoam material quantity

Core Design Contradiction:

Stability of the object's compositionVSQuantity of substance

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Inventive Principle:

Principle #3Local quality

4Ease of manufacture

If the steering wheel skeleton has an open profile, then manufacturing is simplified, but structural integrity is reduced

Engineering Contradiction:

Improveskeleton manufacturingVSAvoidstructural integrity

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The skeleton cover merges with the open-profile skeleton to create a combined structure with closed cross-sections. The cover attaches to the skeleton's open profile, forming enclosed cavities that significantly enhance structural integrity, rigidity, and torsional resistance while preserving the manufacturing simplicity of the original open skeleton design.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The solution combines the metal or plastic skeleton with the skeleton cover to create a composite structure. This composite design leverages the ease of manufacturing the open skeleton while the added cover provides the structural integrity and closed-profile benefits, achieving both goals through material and structural combination.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentEP3551520B1Steering wheel skeleton cover, method for producing same, and steering wheel having such a steering wheel skeleton cover

Publication Date: 2021.06.02 DALPHI METAL ESPANA SA

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AI summary

The invention relates to a steering wheel skeleton cover (10) for mounting on a steering wheel skeleton (12) of a vehicle steering wheel (14), comprising a covering section (16) for closing a profile of the steering wheel skeleton (12), which profile is open in the cross-section thereof, and at least one fastening element (18, 20, 22) for fastening the steering wheel skeleton cover (10) to the steering wheel skeleton (12). The invention further relates to a method for producing a steering wheel skeleton cover (10) and a vehicle steering wheel (14) having such a steering wheel skeleton cover (10).