EP1660353A2

EP1660353A2 - Steering wheel

Info

Publication number: EP1660353A2
Application number: EP04783520A
Authority: EP
Inventors: Scott G. Warhover; Kurt P. Kastelic; Xiaoping Xu
Original assignee: Joyson Safety Systems Inc
Current assignee: Joyson Safety Systems Inc
Priority date: 2003-09-04
Filing date: 2004-09-01
Publication date: 2006-05-31
Also published as: EP1660353A4; WO2005023591A2; WO2005023591A3

Abstract

A steering wheel (20) has an annular rim (36). The rim includes a first section (37) and a second section (39), each of which is at least partially covered by a fill material (60). A plurality of first attachment components (40) are provided as an integral element on the second section of the rim (36). Each of the first attachment components (40) extends above a designated surface (45, 145) of the rim. The fill material (60) covers the second section of the rim (36). The fill material forms a cavity (72) about each first attachment component (40) thereby providing easy access to the first attachment component. A shell (102) has an arcuately shaped body (112) with a plurality of second attachment components (106) extending therefrom for snap engagement with corresponding first attachment components (40).

Description

STEERING WHEEL

The present invention relates to steering wheels for motor vehicles. The present invention provides a steering wheel in which each shell or other decorative material or layer is easily snapped onto a mating part of the steering wheel armature. Fig. 1 is an isometric view of a steering wheel armature according to the present invention. Fig. 1a is another isometric view of the steering wheel with a decorative shell aligned with, but positioned apart from the armature. Fig. 1b shows an alternate embodiment of the invention. Fig. 2 is a cross-sectional view through section line 2-2 of Fig. 1. Fig. 2a is a cross-sectional view of a first section of the steering wheel. Fig. 3 is an enlargement of a portion of Fig. 1. Fig. 3a shows an interlock mechanism secured to a post. Fig. 4 is a cross-sectional view through section 4-4 of Fig. 1. Fig. 5 is a cross-sectional view through section 5-5 of Fig. 1. Fig. 6 is an exploded view, in sectional form, illustrating the major components of the present invention. Fig. 7 illustrates the interrelationship of a number of major components of the invention including an interlock mechanism and a post. Fig. 8 is an enlarged view of an interlock mechanism. Fig. 9 is a partial exploded view of a steering wheel. Fig. 10 is a cross-sectional view of an assembled steering wheel. Fig. 11 illustrates an alternate embodiment of the invention. Fig. 12 shows another alternate embodiment. Figs. 1 and 1a show a steering wheel 20. The steering wheel armature 30 includes a plurality of first attachment components 40 that are each preferably formed as an integral, molded portion of the annular rim 36 of the steering wheel armature. Portions of the rim 36 are subsequently covered with a plastic fill material 60 as shown in Fig. 2a. One or more decorative pieces of fascia 100 are snapped upon a set of these first attachment components 40. In the preferred embodiment this fascia includes a wood laminate, however, other decorative materials such as carbon fiber, metal and plastic can be substituted. A leather wrap 130, shown in Fig. 1a, can cover the plastic fill material 60, as well as covering other portions of the armature 30, to give the steering wheel a more luxurious look and feel. The armature 30 includes a central hub 32 connectable to a steering shaft (not shown); a hub plate 33 and a plurality of spokes 34, which connect the hub plate 33 to the rim 36. The armature can be manufactured of cast aluminum or cast magnesium or from a steel stamping. Other materials and manufacturing techniques may find application in the present invention. The steering wheel rim 36 includes a first section 37 as well as an integrally formed second section 39. With the steering wheel in a null position on the steering shaft, the steering wheel will be positioned in front of the driver with the first section 37 closer to the driver's legs and the second section of the steering wheel oppositely oriented. The first section 37of the rim has a generally oval cross-section as illustrated in Fig. 2a. The second section 39 of the rim also has a somewhat oval cross-section and additionally includes a plurality of first attachment components 40 distributed along it. In the illustrated embodiment the first attachment components 40 extend upwardly from the second section 39 of the rim. The first attachment components 40 can be distributed uniformly along the second section 39 of the rim or the locking components can be concentrated in various regions forming groupings of first attachment components 40. One or more pieces of fascia 100 can be secured to the various first attachment components 40 shown in Fig. 1 b. Fig. 3 is an enlargement of a portion of the second section 39 of the rim 36 with a typical first attachment component 40. In a first embodiment of the invention, each first attachment component 40 includes a post 44 cast as an integral part of the rim 36. Alternatively the posts 44 can be formed as separate structures that can be screwed, riveted or otherwise connected to the rim. In the illustrated embodiment the post 44 is solid and has a circular- cylindrical configuration. However other post configurations are within the scope of the present invention; for example the post 44 can be configured as a hollow cylindrical member. The post 44 can have a rectangular or triangular hollow, cross-sectional shape. Preferably the post 44 extends perpendicular from a surface 45 of the rim 36. In other embodiments the posts can be positioned on the peripheral, radial surface, see numeral 145 in Fig. 1b, and extend radially outboard from the rim 36. Fig. 1 b schematically shows a piece of fascia 100 secured to the rim in this alternative configuration. A first attachment component 40 optionally includes an integrally formed flange 46, which extends radially out of one or both oppositely located side surfaces 45 of the rim. One of the advantages provided by the flange 46 is that it provides additional surface or contact area about which the fill material 60 can be over-molded to provide for a more secure attachment. The flange 46 provides an optional seat for an interlock mechanism 90 that is part of the first attachment component 40. Fig. 3a shows an interlock mechanism 90 seated upon a corresponding post 44. The steering wheel 20, and more particularly the rim 36, is given an conventional annular shape by insert molding a fill material 60 about the first and second rim portions of 37, 39 respectively. The choice of fill material can be varied and is typically a plastic, and in some embodiments is chosen to provide the exterior surface of the rim of the steering wheel rather than a structure and surface that is covered by, for example, leather. The fill material 60 may be polyurethane TPEE, PVC, ABS, foam or other suitable fill material. In those steering wheels using a trim layer such as leather, the leather is selectively mounted, bonded and sewn, in a known manner, about the fill material 60. Fig. 2a shows a cross-sectional view of the first section 37 of the steering wheel 20, with fill material 60 molded about the first section 37 of the rim 36. The fill material 60 also covers the second section 39 of the rim. Figs. 4 -11 illustrate the construction of the second section of the steering wheel. Fig. 4 is a cross-sectional view of the completed second section of the steering wheel 200 taken at the location of section line 4-4 in Fig. 1. Fig. 4 shows the fill material 60 molded about the armature while the fill material is indicated by a phantom line in Fig. 1. Fig. 4shows the fill material 60 molded about the second section 39 of the rim. The bottom or lower section 62 of the fill material 60 is arcuately shaped and of conventional design. For the purpose of discussion the lower portions 62 of the fill material (that is, the section of the steering wheel distal from the driver) has a radius R. The lower portion or lower surface of this part of the fill material smoothly transitions into the corresponding lower surface of the fill material applied to the first section 37 of the rim. This component is generally shown in Fig. 1 where the fill material 60 is indicated by a phantom line extending about the periphery of the rim. The upper portion 64 of the fill material 60 (that is, the section of the steering wheel proximal to the driver) includes a contoured profile. For example, the center portion 66 of fill material is formed as a partial cylinder having a domed shape of radius R1. The fill material 60 adjacent each side of the center portion 66 is formed into parallel sloped side surfaces 68, 70, each of which is sloped inwardly. The fill material will take the profile or be formed to have the profile as illustrated in Fig. 4. For example, the fill material in those regions of the second section 39 of rim 36 is remote from any of the first attachment components 40. It is not desirable to envelop the posts 44 with fill material. Fig. 4 shows an optional leather layer 80 positioned about the lower portions 62 of the fill material 60 on both portions of the steering wheel rim and the upper portion 64 of the second section of the steering wheel. Fig. 4 also diagrammatically illustrates an exemplary fascia piece 100 (which supports a strip of leather or a strip of wood trim laminate or thin strip of natural wood 130). This fascia piece is snapped to the armature 30. Fig. 5 is another view of the steering wheel 20 showing the configuration of the fill material 60 in the vicinity of and about a representative one of the first attachment components 40 and more particularly one of the posts 44. The sloped surfaces 68, 70 of the fill material 60 extend in a generally parallel manner on opposing sides of each post 44 forming ledges. In Fig. 5 these sloped surfaces 68, 70 are covered by a leather layer 80, if used. The upper center portion of the fill material 60 in the vicinity of each post 44 is configured to form a chamber or cavity 72 so that, in the illustrated embodiment, a connecter 90, connected to the shell 102, can easily be placed about each post 44. The chamber 72 is formed by a plurality of walls formed in the fill material generally at the location of the post 44. In the present embodiment each first attachment component 40 comprises the post 44 as well as a separate interlock mechanism 90, which is illustrated in Figs. 6 and 7. The interlock mechanism 90 is a cylindrical, metal spring with a plurality of fastening components that engage each post to hold the interlock mechanism 90 in place upon a post 44 and to provide a snap- lock or friction lock with a mating component 106 of a fascia piece or shell 102. Each interlock mechanism 90 includes a cylindrical body 92 with a split wall 94 to permit the wall to flex as the shell 102 is installed. The cylindrical body 92 transitions into a flange 96. As shown in Fig. 7 a plurality of teeth 98, 99 are formed on the body 92. In Figs. 3, 3a, 6 and 7, some of the teeth 98 are inwardly directed to engage the wall of post 44 while other teeth 99 are outwardly directed to engage a mating part of the shell. While Fig. 6 has been designated as an exploded view, a portion of the fill material 60 is shown cast about the rim 36 while a part of the rim 36 with a post 44 is shown as a separate part. The rim is shown twice in this figure. Fig. 8 is an enlarged view of the interlock mechanism 90, showing more clearly the body 92, flange 96 and the inwardly and outwardly directed clamping or locking or snap-in teeth 98, 99 respectively. The locking or toothed components 98, 99 of the interlock mechanism 90 can be integrated into the post 44 thereby eliminating a separate interlock mechanism 90. Many less expensive steering wheels utilize the fill material 60 as the exterior surface of the steering wheel 20. Fig. 9 shows an elongated portion of the second section 39 of the rim 36, the corresponding fill material 60, with or without a corresponding layer of leather 80, and a strip of fascia 100 positioned about this part of the steering wheel. A plurality of interlock mechanisms 90 are shown spaced above this second section of the steering wheel 20 and below the fascia 100. Based on the above description, each interlock mechanism 90 is fitted about a corresponding post 44 in the manner illustrated in Fig. 5. Fig. 9 also illustrates a portion of the fascia 100 that is snapped or pressed upon the second section of the steering wheel. The fascia 100 comprises an injection-molded shell 102 having an arcuately shaped body 104 and a plurality of integrally formed hollow cylinders 106 serving as second attachment components, which extend downward from a lower or inner or under surface 108, which is concave in shape, of the body 104. These cylinders comprise other locking, press-on or snap-in components. The spacing between each of the cylinders 106 corresponds to the spacing between corresponding posts 44 to permit their interconnection. The inside diameter 110 of the cylinder 106 is generally sized to tightly grip the outside of the interlock mechanism 90 (or the post 44 if a separate interlock mechanism is not used). The top surface 112 of the shell 102 is arcuately (convex) shaped. The shell includes parallel sides 114, 116, which are sloped and are complementary to the shape of the sloped sides 68, 70 of the fill material 60, as well as conformal to the overlapped edges 82, 84 of the leather layer 80, if used to cover the sloped sides 68, 70. The shell 102 includes opposing ends 120, 122. When the shell 102 is snapped or pressed upon the second section of the steering wheel 20, the ends 120, 122 smoothly transition into sides 61 , 63 (see Fig. 1a) formed into the molded fill material (or of the fill material covered with leather) so the top surface of the completed steering wheel is smooth and uniform, that is, the fascia smoothly transitions to the adjacent portions of the steering wheel. In the preferred embodiment, one piece of fascia 100 is used; however, multiple pieces of fascia can be used across various sections of the steering wheel. The shell 102 can be manufactured of a PVC or ABS plastic. If a wood (solid wood, wood veneer) layer or leather wrap 80, 130 is not used, the exterior or outside surface of the shell 102 or the entire wheel can be painted. In Fig. 9 the upper surface 112 of shell 102 is covered with a thin strip of real or simulated wood 130. Techniques for forming the wood 130 and bonding or laminating wood to plastic are known in the industry. During assembly, the shell 102 is positioned relative to the posts 44; each hollow cylinder 106 is slipped about a corresponding interlock mechanism 90 (and post 44). Thereafter the shell 102 (that is the fascia 100) is seated upon the second section 39 of the rim, in which case the shell 102 becomes locked in place. Fig. 10 illustrates the completed construction of the second section 200 of steering wheel 20. The sloped sides 114, 16 of the shell 102 are closely mated to the leather 80, which covers the sloped sides 68, 70 of the fill or against these sides if not covered by a covering material such as leather. The sides 114, 116 of the shell positively load and compress the leather to provide for a functional and esthetically pleasing transition therebetween. In view of the various dimensional tolerances in the components comprising the steering wheel 20, it is preferable to leave the length of the hollow cylinder 106 slightly short so that it does not bottom upon the flange 96 or flange 46 so that the sloped surfaces will closely mate. The interconnection of the various teeth 98, 99 of interlock mechanism 90 can be seen in Fig. 10. Fig. 11 shows an alternate embodiment of the invention. Fig. 11 is substantially identical to Fig. 10. The fascia 100 shown in Fig. 10 generally provides for a pleasing decorative exterior to the steering wheel. In this embodiment of Fig. 11 the fascia 100', in addition to providing a decorative function, also provides an informational function. Both the shell 102 and wood layers 130 include provision for an informational device; such provision may include a cutout 150. The cutout 150 is closed at its top by a clear plastic lens or layer 152. Positioned below the lens or layer 152 is an informational device 154. As this informational device will generally be electronic in nature, a plurality of wires (not shown) extend from the informational device 154 to an electronic control module (not shown). For example, the device or display 154 may include one or more light emitting diodes that can individually and sequentially be lit to convey certain information to the driver of the vehicle. Alternatively, the light emitting diodes might only provide decorative function to illuminate the steering wheel in one or more luminescent colors. Alternatively, the informational device 154 may include one or more liquid crystal displays that can provide information to the driver, which might include information regarding the location of the vehicle, engine information, diagnostic information, news, or stock market reports. The post 44a is formed as a separate part received within a cavity or recess 144; the post 44a is secured to the rim by a fastener such as threaded fastener 146, which is received through bore 148 in the rim. Fig. 12 illustrates a further embodiment of the invention wherein the individual interlock mechanisms 90 have been eliminated and a recess 160, such as a groove, is formed on the walls of the post 44. A surface of the cylinder 106 is formed with an integral hook 107. When each cylinder 106, that is, the second attachment component, is mated to a corresponding post 44 (first attachment component) the integral hook 107 engages a corresponding groove 160 in a snap-together manner. The location of the recess can be in the cylinder and the hook in the post 44.

Claims

1. A steering wheel (20) comprising: an armature (30) including an annular rim (36), the rim including a first section (37) and a second section (39), each of the first and second sections (37, 39) of the rim at least partially covered by a fill or covering material (60); a plurality of first attachment components (40) provided on at least the second section (39) of the rim (36), each of the first attachment components (40) extending above a designated surface (45, 145) of the rim, the fill or covering material (60) covering designated portions of the second section of the rim (36), the fill or covering material (60) configured to form a cavity (72) about each first attachment component (40) thereby providing easy access to the first attachment components (40); a shell (102) having a plurality of second attachment components (106) extending therefrom for interlocking engagement with corresponding first attachment components (40).

2. A steering wheel as defined in Claim 1 where the shell includes an arcuately shaped body (112).

3. A steering wheel as defined in Claim 1 or 2 wherein the first attachment components (40) comprises posts (44).

4. A steering wheel as defined in Claim 3 wherein the posts (44) are secured to the rim (36) as a separate part.

5. A steering wheel as defined in Claim 3 wherein the posts (44) are integral with the rim (36).

6. A steering wheel as defined in Claim 1 or 2 wherein the second attachment components comprise a hollow cylindrical parts (106) and wherein the first attachment components comprise posts (44) that fits within the cylindrical part (106).

7. A steering wheel as defined in Claim 1 or 2 wherein the second attachment components comprise hollow cylindrical parts (106) and the first attachment components (40) comprise posts (44) extending from a surface of the rim (36)and further comprise at least one outwardly extending flange (46) positioned at a base of each post (44).

6. A steering wheel as defined in Claim 4 or 5 wherein the first attachment components (40) each comprise an interlock mechanism (90) positioned about the post (44) that interlocks with the hollow cylindrical part (106).

7. A steering wheel as defined in Claim 10 wherein the at least one lock tooth (98, 99) is provided by each of the interlock mechanisms (90).

8. A steering wheel as defined in Claim 4 or 5 wherein the first attachment components (40) each have either a recess (160) or a hook (107) formed on a wall of the post that mates with either a recess (160) or a hook (107) formed on the interior of the hollow cylindrical part (106) to interlock the post (44) with the hollow cylindrical part (106).