Stretchable Sensing Steering Wheel Circuit for Wrinkle-Free Assembly
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Solution Overview
Problem
Existing capacitive sensing steering wheels face challenges due to the lack of elasticity in sensor fabrics, leading to increased complexity in assembly processes, formation of wrinkles, and higher manufacturing costs, especially when incorporating heating features.
Innovation Solution
A sensing steering wheel design featuring an elastic base layer with a stretchable conductive sensing pattern layer and insulating protective layers, allowing for a sleeve-like assembly onto a steering wheel grip without wrinkles, and optionally including an elastic conductive layer for heating functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensor fabric is attached to steering wheel pre-coated with adhesive, then sensing capability is achieved, but wrinkles are formed and assembly complexity increases
Solution Approach 1:
The patent uses a flexible elastic base layer as a substrate for the sensor fabric, allowing the entire assembly to be stretched and sleeved onto the steering wheel grip without forming wrinkles. This elastic base layer acts as a flexible shell that conforms to the curved surface of the steering wheel while maintaining the integrity of the sensor fabric.
Solution Approach 2:
The patent implements a dynamic assembly process where the sensing circuit layer is stretched to a predetermined size before being sleeved onto the steering wheel grip. This dynamic stretching process allows the rigid sensor fabric to be accommodated on the curved surface without wrinkles, reducing assembly complexity.
2Reliability
If sensor fabric is attached to steering wheel pre-coated with adhesive, then sensing capability is achieved, but manufacturing cost increases due to extra trimming processes
Solution Approach 1:
The flexible elastic base layer eliminates the need for extra trimming processes by providing a wrinkle-free surface that conforms to the steering wheel grip. This reduces manufacturing steps and associated costs while maintaining sensing capability.
Solution Approach 2:
The sensing circuit layer is pre-stretched to a predetermined size before assembly onto the steering wheel grip. This preliminary action ensures proper fit and eliminates the need for post-assembly trimming, reducing manufacturing complexity and cost.
3Adaptability or versatility
If heating pads are incorporated into sensing steering wheel, then heating functionality is achieved, but assembly process complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the heating function with the existing sensing circuit layer by integrating heating elements directly into the elastic base layer or sensing pattern layer. This consolidation eliminates the need for separate heating pad assembly steps, reducing overall assembly complexity while maintaining heating functionality.
Solution Approach 2:
The elastic base layer serves multiple functions: it provides structural support for the sensor fabric, enables stretching for assembly, and can incorporate heating elements. This multi-functionality reduces the need for separate components and assembly steps, simplifying the overall manufacturing process.
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
Reduces assembly complexity and manufacturing costs while providing improved coverage and sensitivity, along with the ability to incorporate heating functions without additional assembly steps.
Implementation Method 1
The elastic sensing pattern layer is formed of a stretchable conductive material and includes at least one sensor unit and at least one sensing line corresponding to the at least one sensor unit
Implementation Method 2
The elastic base layer has a first surface and a second surface opposite to each other... the sensing circuit layer is stretched to sleeve onto the steering wheel grip
Data Source
AI summary
A sensing steering wheel and a method for fabricating the same are provided. The sensing steering wheel includes a steering wheel grip and a sensing circuit layer. The sensing circuit layer includes an elastic base layer, an elastic sensing pattern layer and a first insulating protective layer. The elastic base layer has a first surface and a second surface opposite to each other. The elastic sensing pattern layer is disposed on the first surface, the elastic sensing pattern layer is formed of a stretchable conductive material and includes at least one sensor unit and at least one sensing line corresponding to the at least one sensor unit. The first insulating protective layer is disposed on the elastic sensing pattern layer. The sensing circuit layer has an enclosed belt structure and is stretched to sleeve onto the steering wheel grip.