Steering Wheel Outer Skin Ultrasonic Welding Fixing Groove
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional steering wheel manufacturing is complex and expensive due to the manual stitching of leather or artificial leather outer skins, which requires significant manual labor and time.
Innovation Solution
A steering wheel design featuring a resilient material cover with a fixing groove and an outer skin made from flexible material, where the outer skin's edges are ultrasonically welded within the groove, and a decorative element is used to cover the seams, reducing manual labor and enhancing manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional manual stitching is used to secure the outer skin, then the steering wheel can be properly manufactured, but the manufacturing process becomes complex and expensive requiring significant manual labor
Solution Approach 1:
The patent replaces the manual mechanical stitching process with an automated adhesive application system. The adhesive is applied in a continuous bead along the seam line, and the outer skin panels are bonded together using this adhesive instead of being manually stitched, thereby eliminating the need for complex manual stitching operations while maintaining secure bonding of the outer skin
Solution Approach 2:
The adhesive application system is designed to automatically apply adhesive along the seam line without requiring manual intervention for each stitch. The system uses a continuous adhesive bead that self-aligns with the panel edges, allowing the bonding process to proceed with minimal manual guidance and significantly reduced labor requirements
2Reliability
If manual stitching is used to secure the outer skin, then the outer skin can be properly fixed, but the manufacturing time and labor requirements increase significantly
Solution Approach 1:
The patent replaces the time-consuming manual stitching operation with a rapid adhesive bonding process. The continuous adhesive bead is applied quickly along the entire seam line, and the panels are pressed together to bond, eliminating the need for time-consuming needle and thread operations while ensuring reliable fixation of the outer skin
Solution Approach 2:
The adhesive is pre-applied in a continuous bead along the seam line before the outer skin panels are assembled. This preliminary adhesive application ensures that when the panels are brought together, the bonding occurs immediately and uniformly along the entire seam, providing reliable fixation without requiring subsequent manual stitching operations
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 simplifies the manufacturing process by reducing manual stitching and enhances the aesthetic appeal of the steering wheel while maintaining grip and durability.
Implementation Method 1
the opposed edges of the outer skin are fixed within the fixing groove or recess by ultrasonic welding
Data Source
AI summary
A steering wheel has a rim having an armature encapsulated by a cover of resilient material. The cover has a fixing groove or recess formed therein so as to extend around the rim generally circumferentially with respect to the steering wheel. An outer skin is formed from flexible material and is provided over and around the cover such that two opposed edges of the outer skin are both positioned within the fixing groove or recess and fixed therein. The outer skin includes at least one seam terminating in a seam-end located along one of the opposed edges of the outer skin such that each edge of the outer skin positioned within the fixing groove or recess has at least one seam-end, and wherein each seam-end formed along one of the edges is circumferentially offset around the rim from each seam-end formed along the other edge.