# US 2017/0282954 A1 · Preimpregnated carbon fiber steering wheel > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2017/0282954 A1 - Document ID: US20170282954A1 - Status: Published application - Kind: A1 - Application number: 15/088,911 - Filed: 2016-04-01 - Published: 2017-10-05 - Earliest claimed: 2016-04-01 - Assignees: TK Holdings Inc. - Applicants: TK Holdings Inc. - Inventors: Makato Kawaguchi - Web page: https://patentgrep.com/patent/US20170282954A1 ## CPC - B62D 1/06: Rims, e.g. with heating means; Rim covers (B62D1/11 takes precedence) - B29C 65/02: by heating, with or without pressure - B29C 65/48: using adhesives {, i.e. using supplementary joining material; solvent bonding} - B29C 70/30: Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core - B29L 2031/3047: {Steering wheels} - B62D: MOTOR VEHICLES; TRAILERS (steering, or guiding on a desired track, of agricultural machines or implements A01B69/00; wheels, castors, axles, increasing wheel adhesion B60B; vehicle tyres, tyre inflation or tyre changing B60C; connections between vehicles of a train or the like B60D; vehicles for use on rail and road, amphibious or convertible vehicles B60F; suspension arrangements B60G; heating, cooling, ventilating or other air treating devices B60H; windows, windscreens, non-fixed roofs, doors or similar devices, protective coverings for vehicles not in use B60J; propulsion plant arrangements, auxiliary drives, transmissions, controls, instrumentation or dashboards B60K; electric equipment or propulsion of electrically-propelled vehicles B60L; power supply for electrically-propelled vehicles B60M; passenger accommodation not otherwise provided for B60N; adaptations for load transportation or to carry special loads or objects B60P; arrangement of signalling or lighting devices, the mounting or supporting thereof or circuits therefor, for vehicles in general B60Q; vehicles, vehicle fittings or vehicle parts not otherwise provided for B60R; servicing, cleaning, repairing, supporting, lifting, or manoeuvring, not otherwise provided for, B60S; brake arrangements, brake control systems or parts thereof B60T; air-cushion vehicles B60V; motor-cycles, accessories therefor B62J, B62K; testing of vehicles G01M) - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES ## Abstract Various implementations include an improved steering wheel and methods of making the same. The improved steering wheel includes a carbon fiber mat that is preimpregnated with an epoxy resin that is wrapped adjacent at least a portion of a steering wheel frame. The edges of the mat that overlap are coupled together directly via the epoxy resin by heat curing the mat. The preimpregnated mat does not crack when subjected to thermal cycle tests, which is an improvement over prior art steering wheels that include raw carbon fiber mats that are coupled to the frame using a separate adhesive. ## Claims ### Claim 1 A steering wheel for a vehicle comprising: a frame; and a preimpregnated carbon fiber mat comprising an epoxy resin, the preimpregnated carbon fiber mat having a first edge and a second edge that are opposite and spaced apart from each other and an inner surface and an outer surface, the inner surface comprises an overlap portion adjacent the first edge, wherein: the preimpregnated carbon fiber mat is disposed around the frame such that the inner surface faces the frame, and the overlap portion overlaps a portion of the outer surface adjacent the second edge and adheres directly to the outer surface via the epoxy resin in the preimpregnated carbon fiber mat during heat curing without a separate adhesive. ### Claim 2 (depends on 1) The steering wheel of claim 1, wherein the inner surface further comprises an adhesive portion, wherein an adhesive separate from the epoxy resin is disposed on the adhesive portion for coupling the adhesive portion adjacent the frame. ### Claim 3 (depends on 2) The steering wheel of claim 2, wherein the adhesive has a viscosity of at least 10,000 mPa·s. ### Claim 4 (depends on 1) The steering wheel of claim 1, further comprising a substrate disposed between the inner surface of the preimpregnated carbon fiber mat and the frame. ### Claim 5 (depends on 4) The steering wheel of claim 4, wherein the substrate is derived from a polycarbonate-acrylonitrile butadiene styrene copolymer. ### Claim 6 (depends on 4) The steering wheel of claim 4, wherein the inner surface further comprises an adhesive portion, wherein an adhesive separate from the epoxy resin is disposed on the adhesive portion for coupling the adhesive portion to the substrate. ### Claim 7 (depends on 1) The steering wheel of claim 1, wherein a width of the overlap portion is from about 8 to about 16 percent of a width of the preimpregnated carbon fiber mat, wherein the width is measured along a plane that extends orthogonal to the first edge and the second edge. ### Claim 8 (depends on 1) The steering wheel of claim 1, wherein a width of the overlap portion is from about 10 to about 20 millimeters, wherein the width is measured along a plane that extends orthogonal to the first edge and the second edge. ### Claim 9 (depends on 1) The steering wheel of claim 1, wherein the preimpregnated carbon fiber mat comprises from about 25 wt % to about 70 wt % epoxy resin, based on the total weight of the preimpregnated carbon fiber mat. ### Claim 10 (depends on 9) The steering wheel of claim 9, wherein the preimpregnated carbon fiber mat comprises from about 40 wt % to about 45 wt % epoxy resin, based on the total weight of the preimpregnated carbon fiber mat. ### Claim 11 (depends on 1) The steering wheel of claim 1, wherein the preimpregnated carbon fiber mat has a basis weight of from about 300 g/m2to about 400 g/m2. ### Claim 12 A method of wrapping a steering wheel for a vehicle comprising: wrapping a preimpregnated carbon fiber mat comprising an epoxy resin around a frame of a steering wheel, the preimpregnated carbon fiber mat having a first edge and a second edge that are opposite and spaced apart from each other, the mat having an inner surface that faces the frame and an outer surface, and the inner surface comprising an overlap portion adjacent the first edge; disposing the overlap portion over a portion of the outer surface adjacent the second edge in direct contact with the portion of the outer surface; and heat curing the preimpregnated carbon fiber mat, wherein during curing, the epoxy resin directly couples the overlap portion to the portion of the outer surface adjacent the second edge. ### Claim 13 (depends on 12) The method of claim 12, further comprising applying an adhesive that is separate from the epoxy resin between an adhesive portion of the inner surface and a substrate disposed between the frame and the inner surface of the preimpregnated carbon fiber mat, the adhesive portion being separate from the overlap portion, and wrapping the adhesive portion around the substrate. ### Claim 14 (depends on 13) The method of claim 13, wherein applying the adhesive comprises applying the adhesive to the adhesive portion of the inner surface. ### Claim 15 (depends on 14) The method of claim 14, wherein applying the adhesive further comprises applying the adhesive to the substrate. ### Claim 16 (depends on 13) The method of claim 13, wherein applying the adhesive comprises applying the adhesive to the substrate.