Thermoplastic Polyurethane Steering Wheel Frame
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Solution Overview
Problem
Conventional steering wheel materials lack the necessary balance of impact resistance, flexibility, and durability, particularly in low-temperature conditions, which can lead to poor performance and safety concerns.
Innovation Solution
A steering wheel frame constructed from a thermoplastic polyurethane material with specific molecular weight and mechanical properties, combined with a flexible foam cover, is injection molded to provide enhanced impact resistance and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional steering wheel materials are used, then manufacturing cost and ease of manufacture are maintained, but impact resistance and durability deteriorate
Solution Approach 1:
The patent applies parameter changes by precisely controlling the molecular weight (50,000-350,000 Daltons) and dispersity (1.2-3.5) of the thermoplastic polyurethane material, along with adjusting hard segment content (20-60 wt%) and incorporating specific additives like antioxidants and UV stabilizers. These parameter optimizations enable the material to achieve superior impact resistance and durability while remaining compatible with standard injection molding processes, thus resolving the contradiction between improved strength and ease of manufacture
Solution Approach 2:
The patent employs composite materials by formulating a multi-component thermoplastic polyurethane system that combines polyol, diisocyanate, chain extender, and various additives (antioxidants, UV stabilizers, processing aids) into a unified composition. This composite approach allows the material to exhibit enhanced mechanical properties including impact resistance and durability while maintaining processability through injection molding, effectively balancing strength improvement with manufacturing ease
2Reliability
If thermoplastic polyurethane with specific molecular weight and properties is used, then impact resistance and durability are improved, but material cost increases
Solution Approach 1:
The patent optimizes material parameters by selecting a specific molecular weight range (50,000-350,000 Daltons) and dispersity (1.2-3.5) that achieves the desired durability and impact resistance at reasonable cost. The formulation includes 20-60 wt% hard segment content and specific additive packages, representing a balanced parameter set that delivers high reliability without excessive material cost
Solution Approach 2:
The patent applies local quality by incorporating specific additives (antioxidants, UV stabilizers, processing aids) at optimized concentrations within the thermoplastic polyurethane formulation. These localized functional enhancements improve overall durability and reliability while minimizing the cost increase, as only necessary additives are included at precise levels rather than uniformly throughout the entire material system
3Adaptability or versatility
If thermoplastic polyurethane material with specific properties is used, then flexibility and impact resistance are improved, but processing complexity increases
Solution Approach 1:
The patent achieves flexibility and adaptability through controlled parameter changes in the thermoplastic polyurethane formulation, including molecular weight (50,000-350,000 Daltons), dispersity (1.2-3.5), and hard segment content (20-60 wt%). These parameter optimizations provide the material with inherent flexibility and impact resistance while maintaining compatibility with standard injection molding processes, avoiding excessive processing complexity
Solution Approach 2:
The patent uses processing aids and lubricants as intermediary substances in the thermoplastic polyurethane formulation to facilitate manufacturing. These intermediaries improve flow characteristics and mold release properties, enabling easier processing of the flexible material without requiring complex equipment or processes, thus resolving the contradiction between flexibility and processing complexity
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
The solution achieves improved impact resistance, flexibility, and durability, ensuring better performance and safety, especially at low temperatures, through the use of thermoplastic polyurethane materials with tailored molecular weights and additives.
Implementation Method 1
a method of making the steering wheel frame by injection molding the first thermoplastic polyurethane composition to form the steering wheel frame
Implementation Method 2
a flexible injection molded thermoplastic polyurethane foam, wherein the flexible injection molded thermoplastic polyurethane foam is formed from the combination of (i) a second thermoplastic polyurethane material... and (ii) and a chemical blowing agent and/or a cell opening surfactant
Data Source
AI summary
A steering wheel for a vehicle is provided which comprises a steering wheel rim, a hub base and at least one spoke, wherein the hub base is arranged inside the steering wheel rim and the hub base is connected to the steering wheel rim by the at least one spoke. The steering wheel is formed from a rigid, injection molded thermoplastic polyurethane material.