KR101896360B1 - Crimp connection for mesh shielding material used in steering wheel with capacitive sensing - Google Patents

Abstract

According to one aspect of the present invention, an assembly includes an electrically conductive member, an electrically conductive mesh, and a crimp connector. The electrically conductive mesh includes a first region and a second region. The first region is curved and extends from the second region. The electrically conductive member and one of the twisted first regions form a twisted, twisted connection about the electrically conductive member and the other of the twisted first regions. The crimp connector is crimped over the twisted connection to form a crimped connection.

Description

Technical Field [0001] The present invention relates to a crimp connection for a mesh shielding material used in a steering wheel for capacitive sensing.

This application claims priority to U.S. Provisional Application No. 62 / 250,659, filed November 4, 2015, incorporated herein by reference.

The present invention relates to electrical connections, and more particularly to crimp connections for connecting wires to electrically conductive mesh, for example in a steering wheel.

Soldering is a method used to achieve an electrical connection where the braze material melts and the two items are joined together. Soldering is used to connect the wires together, or to connect the wires to a circuit board, for example. However, soldering connections can be problematic for a number of reasons. This is one of the reasons why it may be difficult to utilize a certain amount of solder during the connection. Although it is desired to use the same amount of solder in multiple connections, different amounts may be used. This can be a problem with the steering wheel assembly where the electrical connection is located beneath the steering wheel cover. Some steering wheels may have moderate amounts of solder, but other steering wheels may include protruding lumps that the driver may feel with touch.

According to the invention, the crimp connection can, for example, connect the wire to an electrically conductive mesh in the steering wheel.

One exemplary embodiment of an assembly includes an electrically conductive member, an electrically conductive mesh, and a crimp connector. The electrically conductive mesh comprising: a second region; And a first region extending from the second region and twisted. One of the electrically conductive member and the twisted first region is twisted around the other of the electrically conductive member and the twisted first region to form a twisted connection. The crimp connector is crimped onto the twisted connection.

In another exemplary embodiment of the above-described assembly, a first region of the electrically conductive mesh includes a rectangular tab, and a second region of the electrically conductive mesh includes a first region of the electrically conductive mesh Lt; / RTI >

In another exemplary embodiment of the above-described assembly, the electrically conductive member is a wire, and the wire and the tapped first region are twisted around each other to form the twisted connection.

In another exemplary embodiment of the above-described assembly, a first region of the electrically conductive mesh comprising a crimped connection is folded over a second region of the electrically conductive mesh. In this embodiment, the cover covering the cover and the crimped connection between the second region of the electrically conductive mesh is bonded onto the second region of the electrically conductive mesh.

In another exemplary embodiment of the above-described assembly, the electrically conductive mesh includes a plurality of electrically conductive interlocking loops.

In another exemplary embodiment of the above-described assembly, the electrically conductive mesh comprises aluminum, copper or tungsten.

In another exemplary embodiment of the above-described assembly, the assembly includes a steering wheel core and an aesthetic cover surrounding the steering wheel core. A second region of the electrically conductive mesh surrounds the steering wheel core and is at least partially positioned between the steering wheel core and the outer cover.

In another exemplary embodiment of the above-described assembly, the assembly includes a capacitive sensor positioned between a second region of the electrically conductive mesh and the outer cover; And a heating element located between the second area of the electrically conductive mesh and the steering wheel core. A second region of the electrically conductive mesh is configured as EMI shielding to shield the capacitive sensor from electromagnetic interference (EMI) of the heating element.

One example of a method of electrically connecting an electrically conductive member to an electrically conductive mesh is to electrically connect the electrically conductive mesh, extending from a second region of the electrically conductive mesh, to form a twisted mesh region, Of the first region of the substrate. One of the electrically conductive member and the twisted mesh region is threaded around the other of the electrically conductive member and the twisted mesh region to form a twisted connection. The crimp connector is crimped onto the twisted connection to form a crimped connection.

In another exemplary embodiment of the above-described method, a first region of the electrically conductive mesh includes a rectangular tab, and a second region of the electrically conductive mesh includes a first region of the electrically conductive mesh Lt; / RTI >

In another exemplary embodiment of the above-described method, the electrically conductive member is a wire, and in order to form the twisted connection, one of the electrically conductive member and the twisted mesh region is electrically connected to the electrically conductive member And twisting around the other of the twisted mesh areas comprises twisting the wire and the twisted mesh area around each other.

In another exemplary embodiment of the above-described method, the method comprises the steps of folding a first region of the electrically conductive mesh including a crimped connection onto a second region of the electrically conductive mesh, And adhering a cover over the second region of the electrically conductive mesh to cover the crimped connection between the second regions of the electrically conductive mesh.

In another exemplary embodiment of the above-described method, before crimping, the crimp connector has a cylindrical shape.

In another exemplary embodiment of the above-described method, the electrically conductive mesh includes a plurality of electrically conductive interlocking loops.

In another exemplary embodiment of the above-described method, the electrically conductive mesh comprises aluminum, copper or tungsten.

In another exemplary embodiment of the above-described method, the method includes the steps of wrapping around the steering wheel core with the electrically conductive mesh; And surrounding the steering wheel core with the capacitive sensor layer such that the electrically conductive mesh is positioned between the steering wheel core and the capacitive sensor layer.

In another exemplary embodiment of the above-described method, the method includes wrapping around the steering wheel core with the heating element such that a heating element is positioned between the electrically conductive mesh and the steering wheel core.

One exemplary embodiment of a steering wheel assembly includes a steering wheel core, an electrically conductive shield layer; And a sensor layer. Each of the shield layer and the sensor layer at least partially surrounds the steering wheel core. The shield layer is positioned between the steering wheel core and the sensor layer. The shield layer comprises an electrically conductive mesh comprising a nickel-copper alloy.

In another exemplary embodiment of the steering wheel assembly described above, the electrically conductive mesh includes a plurality of knitted, electrically conductive interlocking loops.

The embodiments described herein can be taken independently or in combination. The features described in connection with one embodiment can be applied to all embodiments unless such features are incompatible. The features and other features described herein will become more apparent from the following drawings and description.

The invention can be better understood with reference to the following detailed description with reference to the accompanying drawings
Figure 1 schematically shows a vehicle with a steering wheel and an associated sensing circuit,
2 schematically shows an example of sensing and heating characteristics for a steering wheel,
Figures 3A-G schematically illustrate a method for electrically connecting a conductive member to a conductive mesh using a crimped connection,
Figure 4a schematically illustrates a crimp connector before crimping,
Figure 4b schematically illustrates the crimp connector of Figure 4a after crimping,
5 is a flow chart of a method for electrically connecting a conductive member to a conductive mesh using a crimped connection, and
6 illustrates an exemplary electrically conductive mesh.

According to one aspect of the invention, a method of electrically connecting a conductive member (e.g., a wire) to a conductive mesh using a crimped connection is described. The crimped connection can be used, for example, as part of electromagnetic interference (EMI) shielding for a steering wheel using capacitive sensing. Crimp connections can be omitted if required. In at least one embodiment, the first region of the conductive mesh extending from the second region of the conductive mesh is twisted to form a twisted mesh region. The twisted mesh region and the conductive member are twisted together to form a twisted connection and the crimp connector is crimped onto the twisted connection to form a crimped connection.

In one or more embodiments, the first region of the conductive mesh including the crimped connection is folded over the second region of the conductive mesh, and the cover is adhered onto the second region of the conductive mesh, Wrap the crimped connection between the two.

Figure 1 illustrates a vehicle 10 including a steering wheel 12, a sensor circuit 14 (e.g., a capacitive sensing circuit), and a shielding circuit 16 (e.g., EMI shielding). It will be appreciated that although the car 10 shown in Fig. 1 differs, the techniques described herein can be applied to other vehicles and can be applied to items other than the steering wheel. The driver 18 holds the steering wheel 12 by the hand 20. In one or more embodiments, the sensor circuit 14 is configured to sense when the driver's hand 20 touches the steering wheel 12 and the shielding circuit 16 is configured to sense when the driver's hand 20 touches the steering wheel 12, To provide electromagnetic interference shielding to the sensor circuitry 14 through the shielding layer.

Fig. 2 shows an example of the sensing and heating characteristics for the steering wheel 12 of Fig. In the example of FIG. 2, the steering wheel 12 includes a plurality of components between the steering wheel core 22 and the outer cover 24. The outer cover 24 may be, for example, a leather cover. The heating element wiring 27 is configured as an electric heating element to provide heat to the steering wheel 12. [ The heating element wiring 27 is connected to a power source 17 such as a car battery.

The heating element wiring 27 is located between the steering wheel core 22 and the insulating layer 28, which is configured as an electrical insulator. The adhesive layer (30) bonds the insulating layer (28) to the electrically conductive mesh (26). The conductive mesh is connected to the shielding circuit 16 via two crimped connections 52. The crimped connection 52 is described in more detail below with reference to Figures 3a-g below. In one or more embodiments, the shielding circuit 16 allows the conductive mesh 26 to function as EMI shielding shielding the sensor wiring 36 from the EMI of the heating element wiring 27.

The adhesive layer 32 bonds the conductive mesh 26 to an additional insulating layer 34, which is configured as an electrical insulator. In one or more embodiments, the insulating layers 28, 34 are foam layers comprising a foam material such as polyurethane foam or polymer rubber.

The sensor wiring 36 is connected to the sensor circuit 14. In embodiments where the sensor circuit 14 is a capacitive sensing circuit, the sensor wiring 36 is used to sense when the driver's hand is on the steering wheel 12, for example.

One of the heating element wire ring 27 and the sensor wire ring 36 may be a single wire or a plurality of sensor wires 36, Lt; RTI ID = 0.0 > wires. ≪ / RTI > In at least one embodiment, the heating element wiring 27 also includes an electrically conductive mesh.

In at least one embodiment, the conductive mesh 26 is electrically conductive and comprises a plurality of knitted interlocking loops. The conductive mesh 26 can be a metal and can include, for example, aluminum, copper or tungsten. The conductive mesh 26 may comprise such a metal (e. G., A nickel copper alloy) as the alloy and may use other alloys such as, for example, or stainless steel, galvanized steel, steel, or tinned steel have. Of course, it will be understood that other metals or other alloys may be used.

Figures 3A-G schematically illustrate a method of electrically connecting an electrically conductive member to an electrically conductive mesh 26 using a crimped connection 52. It should be understood that the electrically conductive member shown in Figures 3A-G is a wire 44, although other electrically conductive members may be used. 3A, the conductive mesh 26 includes a first region 40 extending from a second region 42. As shown in FIG. The second region 42 extends along a longitudinal axis L and the first region 40 extends along an axis T transverse to and orthogonal to the axis L. [ In some embodiments, the conductive mesh 26 is flat (e.g., not in the form of a braided tube). 3A, the second region 42 is larger than the first region 40 and the first region 40 of the conductive mesh 26 has a rectangular shape (e.g., a rectangular tab of the conductive mesh 26) ). In addition, in the embodiment of Fig. 3A, the first region 40 is in the same plane as the remainder of the second region 42. It will be appreciated that although only a portion of the second region is shown, the second region can be scaled to cover a designated area of the steering wheel core 22. [ In one particular example, the second region 42 is a thin, elongated strip having a length approximately equal to the circumference of the steering wheel 12.

The first region 40 is folded about the second region (Fig. 3B). In one example, the folding causes the first region 40 to be oriented at an angle of 90 [deg.] With respect to the second region 42. [ The first region 40 is twisted to form a twisted mesh region 40 '(FIG. 3C). The wire 44, including the shield 46, is positioned adjacent the warped mesh region 40 '(FIG. 3D). One of the wire 44 and the twisted mesh region 40 'is twisted around the other of the wire 44 and the twisted mesh region 40' to form a twisted connection 48 (FIG. 3E). In some embodiments, the wire 44 and the twisted mesh region 40 'are twisted around each other to form a twisted connection 48. In another embodiment, only one of the wire 44 and the twisted mesh region 40 'is twisted around the other of the wire 44 and the twisted mesh region 40'.

The crimp connector 50 slides into the twisted connection 48 in the direction shown in Figure 3E and is crimped onto the twisted connection 48 to form the crimped connection 52 (Figure 3F). The crimped connection 52 is folded back over the second area of the conductive mesh 26 and the cover 54 is adhered to the top of the crimped connection 52 to secure the cover 54 and the conductive mesh 26 (FIG. 3G) so as to enclose the crimped connection 52 between the first region 42 of the first electrode 42 and the second region 42 of the second electrode 42. The cover functions as a protective layer against the crimped connection (52). Attachment of the cover 54 may be accomplished using an adhesive such as a hot glue (e. G., From glue gun). The cover may face, for example, in a direction towards the steering wheel core 22, or vice versa, within the steering wheel 12.

In at least one embodiment, the wire 44 is a 22 American wire size (AWG) wire. Of course, other dimensions may be used instead. The dimension of the wire 44 and the width of the first region 40 (measured in a direction parallel to the axis L, for example) may be achieved by obtaining a desired crimp size (i.e., the desired crimp cross-sectional area within the crimp connector 50) Lt; / RTI > In one or more embodiments, the width of the first region 40 (measured in a direction parallel to the axis L) may be 15 mm, or may be any value between 10 mm and 20 mm. In the same example, the length of the first region (e.g. along the axis T) may be 20 mm or 30 mm, or any value between 15 and 35 mm. Of course, it will be appreciated that these values are exemplary width and length values for the first region 40, and that other values may be used.

FIG. 4A schematically illustrates an exemplary crimp connector 50 before crimping, and FIG. 4B schematically illustrates an exemplary crimp connector 50 'after crimping. As shown in FIG. 4B, the crimping of the crimp connector 50 twists the creeping connector 50 to fix the twisted connection 48. 4B also shows an example of how the first region 40 and wire 44 are positioned after crimping. In the example of FIG. 4A, before crimping, the crimp connector 50 has a cylindrical shape. Of course, other crimp connectors may be used instead.

5 is a flow diagram of a method 100 for electrically connecting an electrically conductive member (e.g., wire 44) to an electrically conductive mesh 26 using a crimped connection 52. The first region 40 of the electrically conductive mesh 26 extending from the second region 42 of the electrically conductive mesh 26 is twisted to form a twisted mesh region 40 ' ). One of the electrically conductive member and the twisted mesh region 40 'is twisted around the other of the electrically conductive member and the twisted mesh region (block 104) to form a twisted connection 48. To form the crimped connection 52, the crimp connector is crimped onto the twisted connection 48 (block 106).

In one embodiment, the electrically conductive member is a wire, and the twisting step of the block 104 includes twisting the wire 44 and the twisted mesh region 40 'around each other. However, in other embodiments, only one of the wire 44 and the twisted mesh region 40 'is warped around the other of the wire 44 and the warped mesh region 40'.

In some embodiments of method 100, the first region 40 of the electrically conductive mesh 26, including the crimped connection 52, is bonded to the second region 42 of the electrically conductive mesh 26, Fold. In some such embodiments, the cover 54 covers the electrically conductive mesh 26 to cover the crimped connection 52 between the cover 54 and the second region 42 of the electrically conductive mesh 26, And adheres to the crimped first region 40 of the crimped connection 52 and acts as a protective layer against the crimped connection 52 (see FIG. 3G).

The second region 42 of conductive mesh 26 includes a steering wheel core 22 and an outer cover 24 wrapping around the steering wheel core 22, It can be a part. The second region 42 of the conductive mesh 26 is wrapped around the steering wheel core 922 and is at least partially positioned between the steering wheel core 22 and the outer cover 24. In some embodiments, In some embodiments, the second area 42 of conductive mesh is shaped to cover a designated area of the steering wheel core 22.

In some embodiments, a capacitive sensor (e.g., sensor wiring 36) is located between the outer cover 24 and the second region 42 of the conductive mesh 26, and a heating element (e.g., (27)) is located between the steering wheel core (22) and the second region (42) of the conductive mesh (26). In some embodiments, the second region 42 of the conductive mesh 26 is configured as an EMI shield for shielding the capacitive sensor from the EMI of the heating element. In some embodiments, the steering wheel 12 may omit the electric heating element, and the heating element wire ring 27 may not be included.

6 shows an exemplary electrically conductive mesh (not shown) that is a knitted mesh including an interlocking loop 62 in one row 64 wrapping around the legs 66 of the loop 67 of adjacent rows 68 26). The loops in the various rows of Fig. 6 can move relative to each other in the same plane without deforming the mesh 26, allowing the knitted mesh to extend in two directions. In one or more embodiments, each loop may function as a small spring when exposed to tension or compressive stress and return to its original shape when the stress is removed unless it is deformed beyond the yield point. In at least one embodiment, the conductive mesh 26 is knitted from wires within the range of .0035 "to .0200" or .0005 "to .0350" in diameter. Of course, it is understood that other meshes (e.g., woven meshes) may also be used.

By using the crimped connection 52 to electrically connect the wire 44 and the conductive mesh 26 instead of the solder connection, a more consistent result can be obtained, which may be beneficial for the steering wheel implementation have. For example, if the crimped connection 52 is located under the outer cover 240, the crimped connection 52 is connected to the hand 20 of the driver 18 rather than to the soldering connection using solder lumps Lt; RTI ID = 0.0 > less < / RTI >

While described in the exemplary embodiments, those of ordinary skill in the art will recognize that certain modifications may be made within the scope of the invention. For this reason, the following claims should be considered in determining the scope and content of the present invention.

Claims (20)

An electrically conductive member;
As an electrically conductive mesh,
A second region extending along the second axis; And
A first region extending from the second region along a first axis intersecting the second axis and twisted,
Wherein the electrically conductive member and one of the twisted first regions form a twisted twisted connection about the electrically conductive member and the other of the twisted first regions
The electrically conductive mesh; And
And a crimp connector forming a crimped crimped connection on the twisted connection,
Wherein a first region of the electrically conductive mesh comprising the crimped connection is folded over a second region of the electrically conductive mesh, the assembly comprising:
And a cover adhered onto a second region of the electrically conductive mesh, the cover covering a crimped connection between the cover and a second region of the electrically conductive mesh. The method according to claim 1,
Wherein the first region of the electrically conductive mesh includes a rectangular tab and the second region of the electrically conductive mesh is larger than the first region of the electrically conductive mesh. The method according to claim 1,
Wherein the electrically conductive member is a wire and the wire and the twisted first region are twisted about each other to form a twisted connection. delete The method according to claim 1,
≪ / RTI > wherein the electrically conductive mesh comprises a plurality of electrically conductive interlocking loops. The method according to claim 1,
≪ / RTI > wherein the electrically conductive mesh comprises aluminum, copper or tungsten. The method according to claim 6,
RTI ID = 0.0 > 1, < / RTI > wherein the electrically conductive mesh comprises a nickel-copper alloy. The method according to claim 1,
Steering wheel core; And
An outer cover covering the periphery of the steering wheel core;
Lt; / RTI >
Wherein a second region of the electrically conductive mesh surrounds the steering wheel core and is at least partially positioned between the steering wheel core and the outer cover. 9. The method of claim 8,
A capacitive sensor positioned between a second region of the electrically conductive mesh and the outer cover; And
A heating element located between a second region of the electrically conductive mesh and the steering wheel core;
Lt; / RTI >
Wherein the second region of the electrically conductive mesh is configured as EMI shielding to shield the capacitive sensor from electromagnetic interference (EMI) of the heating element. A method of electrically connecting an electrically conductive member to an electrically conductive mesh, the method comprising:
A first region of the electrically conductive mesh extending along a first axis intersecting the second axis from a second region extending along a second axis of the electrically conductive mesh to form a twisted mesh region, A twisting step;
Twisting one of the electrically conductive member and the twisted mesh region around the other of the electrically conductive member and the twisted mesh region to form a twisted connection; And
Crimping the crimp connector over the twisted connection to form a crimped connection;
Folding a first region of the electrically conductive mesh including the crimped connection onto a second region of the electrically conductive mesh; And
And adhering the cover covering the cover and the crimped connection between the second region of the electrically conductive mesh onto a second region of the electrically conductive mesh. To the electrically conductive mesh. 11. The method of claim 10,
Wherein the first region of the electrically conductive mesh comprises a rectangular tab and the second region of the electrically conductive mesh is larger than the first region of the electrically conductive mesh. A method for electrically connecting to an electrically conductive mesh. 11. The method of claim 10,
Wherein the electrically conductive member is a wire and wherein one of the electrically conductive member and the twisted mesh region is twisted about the other of the electrically conductive member and the twisted mesh region to form the twisted connection Wherein the step comprises twisting the wire and the twisted mesh region around each other. ≪ RTI ID = 0.0 >< / RTI > delete 11. The method of claim 10,
Characterized in that before crimping, the crimp connector is cylindrical. ≪ RTI ID = 0.0 >< / RTI > 11. The method of claim 10,
Characterized in that the electrically conductive mesh comprises a plurality of electrically conductive interlocking loops. ≪ Desc / Clms Page number 13 > 11. The method of claim 10,
Characterized in that the electrically conductive mesh comprises aluminum, copper or tungsten. ≪ Desc / Clms Page number 13 > 11. The method of claim 10,
Wrapping around the steering wheel core with the electrically conductive mesh; And
Wrapping around the steering wheel core with the capacitive sensor layer such that the electrically conductive mesh is positioned between the steering wheel core and the capacitive sensor layer;
And electrically connecting the electrically conductive member to the electrically conductive mesh. 18. The method of claim 17,
And wrapping around the steering wheel core with the heating element so that a heating element is positioned between the electrically conductive mesh and the steering wheel core. The method of claim 1, . delete delete

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