DIRECT APPLICATION AUTOMOTIVE STEERING WHEEL HEATER

1 . A heated steering wheel assembly, comprising:

a primary support member defining a general shape of the steering wheel;

a rigid over-molding layer generally encasing said primary support member;

an electrically resistive layer disposed on said over-molding layer for being energized to create a heat source on the steering wheel;

a first electrically conductive strip applied to said electrically resistive layer defining a positive electrical connection to said electrically resistive layer;

a second electrically conductive strip applied to said electrically resistive layer defining a negative electrical connection to said electrically resistive layer;

a dielectric layer encasing said electrically resistive layer and said first and second electrically conductive strips for insulation; and,

a finishing cover layer applied over said dielectric layer generally encasing said dielectric layer.

2 . The steering wheel assembly of claim 1 wherein said primary support member is a magnesium armature.

3 . The steering wheel assembly of claim 1 wherein said rigid over-molding layer consists of a urethane foam.

4 . The steering wheel assembly of claim 1 wherein said electrically resistive layer includes a paste selected from the group consisting of carbon, graphite, or a blend thereof, which is cured to said rigid over-molding layer.

5 . The steering wheel assembly of claim 4 wherein said paste includes a plasticized base allowing for flexing.

6 . The steering wheel assembly of claim 1 wherein said electrically resistive layer has a conductivity in the range of 60-100 ohms for a given square surface area.

7 . The steering wheel assembly of claim 1 including a ridge line extending around the length of said rigid over-molding layer.

8 . The steering wheel assembly of claim 7 wherein said ridge line defines a gap in said electrically resistive layer applied around the length of said rigid over-molding layer.

9 . The steering wheel assembly of claim 7 wherein said first and second electrically conductive strips are disposed adjacent to and on opposite sides of said ridge line.

10 . The steering wheel assembly of claim 9 wherein said first and second electrically conductive strips are spaced apart approximately in the range of 2-6 mm with said ridge line disposed generally at a midpoint between said first electrically conductive strip and said second electrically conductive strip.

11 . The steering wheel assembly of claim 1 wherein said first and second electrically conductive strips extend generally parallel to each other along the length of said electrically resistive layer around the steering wheel.

12 . The steering wheel assembly of claim 1 wherein said first and second electrically conductive strips consist of a silver based coating.

13 . The steering wheel assembly of claim 1 wherein said primary support member includes a groove running the length of said support member for receiving said rigid over-molding layer to resist rotation of said over-molding layer around said support member.

14 . The steering wheel assembly of claim 1 including a stitching channel extending around at least a portion of a circumference of said over-molding layer.

15 . The steering wheel assembly of claim 14 wherein said first and second electrically conductive strips extend into said stitching channel, and a plurality of electrical wire connectors disposed in said stitching channel engaging each of said electrically conductive strips.

16 . The steering wheel assembly of claim 15 wherein said electrical wire connectors include at least one prong extending into said rigid over-molding layer and a base running across at least a portion of one of said first and second electrically conductive strips.

17 . The steering wheel assembly of claim 1 including a third electrically conductive strip applied to said electrically resistive layer defining a positive electrical connection to said electrically resistive layer.

18 . A method for forming a heated steering wheel assembly, comprising the steps of:

providing a primary support member defining a general shape of the steering wheel;

applying a rigid over-molding layer generally encasing said primary support member;

applying an electrically resistive layer disposed on said over-molding layer for being energized to create a heat source on the steering wheel;

applying a first electrically conductive strip to said electrically resistive layer defining a positive electrical connection to said electrically resistive layer;

applying a second electrically conductive strip to said electrically resistive layer defining a negative electrical connection to said electrically resistive layer;

applying a dielectric layer encasing said electrically resistive layer and said first and second electrically conductive strips for insulation; and,

applying a finishing cover layer over said dielectric layer generally encasing said dielectric layer.

19 . The method of claim 18 including the step of forming a ridge line extending around the length of said rigid over-molding layer which defines a gap in said electrically resistive layer applied around the length of said rigid over-molding layer.

20 . The method of claim 19 including the step of applying said first and second electrically conductive strips adjacent to and on opposite sides of said ridge line, and spacing said electrically conductive strips apart approximately in the range of 2-6 mm with said ridge line disposed generally at a midpoint between said first electrically conductive strip and said second electrically conductive strip.