Method of making a horn pad

Claim 1

A method of manufacturing a horn pad assembly which includes a horn switch subassembly having an electrically conductive support plate adapted for mounting on a steering wheel and an electrically conductive switch plate which is spaced and insulated from the support plate by an insulation gasket and which has a pattern of slots rendering the switch plate sufficiently flexible to engage the support plate responsive to finger pressure, comprising the steps of: enclosing the horn switch subassembly in a sealed bag of heat shrinkable plastic film to mask the pattern of slots in the switch plate, heat shrinking the heat shrinkable plastic film to provide a relatively smooth and taut enclosure, and molding a decorative pad of resilient polymeric material onto the portions of the heat shrunk plastic film covering the switch plate and the sides and underside edges of the support plate.

Claim 2

A method of manufacturing a horn pad assembly which includes a horn switch subassembly having an electrically conductive support plate adapted for mounting on a steering wheel and an electrically conductive switch plate which is spaced and insulated from the support plate by an insulation gasket and which has a pattern of slots rendering the switch plate sufficiently flexible to engage the support plate responsive to finger pressure, comprising the steps of: enclosing the horn switch subassembly in a sealed bag of heat shrinkable plastic film to mask the pattern of slots in the switch plate, heat shrinking the heat shrinkable plastic film to provide a relatively smooth and taut enclosure, and molding a decorative pad of resilient polymeric material onto the portions of the heat shrunk plastic film covering the switch plate and the sides and underside edges of the support plate.

Claim 3

A method of manufacturing a horn pad assembly which includes a large, irregularly shaped horn switch subassembly having an electrically conductive support plate adapted for mounting on a steering wheel and an electrically conductive switch plate which is spaced and insulated from the support plate by an insulation gasket and which has a pattern of slots rendering the switch plate sufficiently flexible to engage the support plate responsive to finger pressure, comprising the steps of: enclosing the horn switch subassembly in a sealed bag of heat shrinkable plastic film to mask the pattern of slots in the switch plate, heat shrinking the heat shrinkable plastic film to provide a relatively smooth and taut enclosure, and molding a decorative pad of foamable self-skinning urethane onto the portions of the heat shrunk plastic film covering the switch plate and the sides and underside edges of the support plate.

Claim 4

A method of manufacturing a horn pad assembly which includes a large, irregularly shaped horn switch subassembly having an electrically conductive support plate adapted for mounting on a steering wheel and an electrically conductive switch plate which is spaced and insulated from the support plate by an insulation gasket and which has a pattern of slots rendering the switch plate sufficiently flexible to engage the support plate responsive to finger pressure, comprising the steps of: enclosing the horn switch subassembly in a sealed bag of heat shrinkable plastic film to mask the pattern of slots in the switch plate, heat shrinking the heat shrinkable plastic film to provide a relatively smooth and taut enclosure, and molding a decorative pad of foamable self-skinning urethane onto the portions of the heat shrunk plastic film covering the switch plate and the sides and underside edges of the support plate.

Claim 5

A method of manufacturing a horn pad assembly which includes a horn switch subassembly having an electrically conductive support plate having vertical skirts adapted for mounting on a steering wheel and an electrically conductive switch plate which is spaced and insulated from an upper surface of the support plate by an insulation gasket and which has a pattern of slots rendering the switch plate sufficiently flexible to engage the support plate responsive to finger pressure, comprising the steps of: enclosing the horn switch subassembly in a sealed bag of heat shrinkable plastic film to mask the pattern of slots in the switch plate, heat shrinking the heat shrinkable plastic film to provide a relatively smooth and taut enclosure, and molding a decorative pad of resilient polymeric material onto the portions of the heat shrunk plastic film covering the switch plate and the sides and underside edges of the support plate, said plastic film spanning the vertical skirts stretching during molding to permit the molded pad to wrap around the underside edges of the skirts for mechanically retaining the molded pad on the switch assembly.

Claim 6

A method of manufacturing a horn pad assembly which includes a horn switch subassembly having an electrically conductive support plate having vertical skirts adapted for mounting on a steering wheel and an electrically conductive switch plate which is spaced and insulated from an upper surface of the support plate by an insulation gasket and which has a pattern of slots rendering the switch plate sufficiently flexible to engage the support plate responsive to finger pressure, comprising the steps of: enclosing the horn switch subassembly in a sealed bag of heat shrinkable plastic film to mask the pattern of slots in the switch plate, heat shrinking the heat shrinkable plastic film to provide a relatively smooth and taut enclosure, and molding a decorative pad of resilient polymeric material onto the portions of the heat shrunk plastic film covering the switch plate and the sides and underside edges of the support plate, said plastic film spanning the vertical skirts stretching during molding to permit the molded pad to wrap around the underside edges of the skirts for mechanically retaining the molded pad on the switch assembly.

Claim 7

A method of manufacturing a horn pad assembly which includes a horn switch subassembly having an electrically conductive support plate having vertical skirts and protruding brackets at its underside for mounting on a steering wheel and an electrically conductive switch plate which is spaced and insulated from an upper surface of the support plate by an insulation gasket and which has a pattern of slots rendering the switch plate sufficiently flexible to engage the support plate responsive to finger pressure, and which has an integral terminal protruding through a central hole in the support plate into a protected area between the skirts, comprising the steps of: enclosing the horn switch subassembly in a sealed bag of heat shrinkable plastic film to mask the pattern of slots in the switch plate and the central hole in the support plate; heat shrinking the heat shrinkable plastic film to provide a relatively smooth and taut enclosure, and molding a decorative pad of resilient polymeric material onto the portions of the heat shrunk plastic film covering the switch plate and the sides and underside edges of the support plate, said plastic film being exposed at the central underside portion of the completed horn pad assembly to provide access to the brackets and integral terminal.

Claim 8

A method of manufacturing a horn pad assembly which includes a horn switch subassembly having an electrically conductive support plate having vertical skirts and protruding brackets at its underside for mounting on a steering wheel and an electrically conductive switch plate which is spaced and insulated from an upper surface of the support plate by an insulation gasket and which has a pattern of slots rendering the switch plate sufficiently flexible to engage the support plate responsive to finger pressure, and which has an integral terminal protruding through a central hole in the support plate into a protected area between the skirts, comprising the steps of: enclosing the horn switch subassembly in a sealed bag of heat shrinkable plastic film to mask the pattern of slots in the switch plate and the central hole in the support plate; heat shrinking the heat shrinkable plastic film to provide a relatively smooth and taut enclosure, and molding a decorative pad of resilient polymeric material onto the portions of the heat shrunk plastic film covering the switch plate and the sides and underside edges of the support plate, said plastic film being exposed at the central underside portion of the completed horn pad assembly to provide access to the brackets and integral terminal.