Shaft alignment component and method of aligning shaft assembly

Abstract

The invention relates to a shaft alignment component and a method of aligning a shaft assembly. A shaft assembly includes at least a first shaft section having a first shaft body defining a cavity and a first aperture extending through the first shaft body, and at least a second shaft section having a second shaft body and a second aperture extending through the second shaft body. The second shaft section is received within the cavity of the first shaft body such that the second shaft body translates axially within the cavity relative to the first shaft section. An alignment member is formed in at least the first shaft section, the alignment member being a non-piercing alignment member. The second shaft body contacts the alignment member when the first aperture of the first shaft body is aligned with the second aperture of the second shaft body.

Description

Technical Field

[0001] The embodiments described herein relate to vehicle steering systems, and more specifically to shaft alignment components for aligning the shafts of the steering column during assembly. Background Technology

[0002] Shaft assemblies are standard components in many mechanical systems, particularly in the automotive industry. These assemblies typically consist of two or more shaft segments connected via torque transmission geometry (e.g., splines) and fastened together with bolts and nuts. However, ensuring precise axial alignment between the shaft geometry and their corresponding bolt through-holes is challenging in typical shaft assemblies. Furthermore, visual alignment of the shaft geometry with their corresponding bolt through-holes can be difficult because the visibility of the shaft assembly can be limited when the shaft segments are installed within a vehicle. One example of a shaft alignment feature involves a portion of the outer shaft that projects radially inward to act as a stop feature when the inner shaft is inserted. However, this requires piercing the outer shaft to move the stop feature inward. This introduces the possibility of fluid intrusion and involves complex manufacturing processes.

[0003] Therefore, a shaft assembly is needed that includes an alignment component configured to ensure proper axial alignment of the various shaft segments during assembly. Summary of the Invention

[0004] In the embodiments described herein, a shaft assembly is disclosed. The shaft assembly includes at least a first shaft segment and at least a second shaft segment. The at least first shaft segment has a first shaft body defining a cavity and a first orifice extending through the first shaft body. The at least second shaft segment has a second shaft body and a second orifice extending through the second shaft body. The second shaft segment is received within the cavity of the first shaft body such that the second shaft body can be axially translated relative to the first shaft segment within the cavity. An alignment member is formed in at least the first shaft segment; the alignment member is a non-piercing alignment member. When the first orifice of the first shaft body is aligned with the second orifice of the second shaft body, the second shaft body contacts the alignment member.

[0005] In another embodiment, a steering column assembly is disclosed. The steering column assembly includes at least a first steering column segment and at least a second steering column segment, the at least first steering column segment having a first column body defining a cavity, and the at least second steering column segment having a second column body, the second steering column segment being configured to be received within the cavity of the first column body of the first steering column segment. A stop is formed in at least the first steering column segment, the stop being a non-puncture stop that does not form an opening in at least the first steering column segment. The steering column assembly is translatable between an extended position and a collapsed position, in which the second column body contacts the stop formed in the first column body.

[0006] In another embodiment, a method for aligning a shaft assembly is disclosed. The method includes: forming a non-piercing protrusion extending into a cavity defined by a first shaft segment of the shaft assembly; inserting a second shaft segment into the first shaft segment; translating the second shaft segment axially within the first shaft segment; and contacting the second shaft segment with the non-piercing protrusion such that a first orifice extending through the first shaft segment is aligned within a second orifice extending through the first shaft segment. Attached Figure Description

[0007] The embodiments illustrated in the accompanying drawings are illustrative and exemplary in nature and are not intended to limit the subject matter defined by the claims. The following detailed description of the illustrative embodiments can be understood when read in conjunction with the following drawings, in which similar structures are indicated by similar reference numerals, and wherein:

[0008] Figure 1 This is a cross-sectional view of a shaft assembly according to one or more embodiments shown and described herein, the shaft assembly including alignment members formed in a shaft segment;

[0009] Figure 2A It is in an misaligned position according to one or more embodiments shown and described herein. Figure 1 A sectional view of the shaft assembly;

[0010] Figure 2B It is located in the middle position according to one or more embodiments shown and described herein. Figure 1 A sectional view of the shaft assembly;

[0011] Figure 2C It is in the aligned position according to one or more embodiments shown and described herein. Figure 1 A sectional view of the shaft assembly;

[0012] Figure 3 Is Figure 1 A front view illustrating the process of forming alignment components in the shaft assembly;

[0013] Figure 4A This is a cross-sectional view of a steering column assembly in a first position according to one or more embodiments shown and described herein;

[0014] Figure 4B It is located in the second position according to one or more embodiments shown and described herein. Figure 4A A cross-sectional view of the steering column assembly;

[0015] Figure 5 This is an exemplary flowchart of a method for aligning a shaft assembly according to one or more embodiments shown and described herein; and

[0016] Figure 6 This is an exemplary flowchart of a method for limiting the movement of a steering column assembly according to one or more embodiments shown and described herein. Detailed Implementation

[0017] The embodiments disclosed herein relate to shaft assemblies, alignment members for shaft assemblies, and methods for aligning shaft assemblies. A shaft assembly includes at least a first shaft segment and at least a second shaft segment, the first shaft segment having a first shaft body defining a cavity and a first aperture extending through the first shaft body, and the second shaft segment having a second shaft body and a second aperture extending through the second shaft body. The second shaft segment is configured to be received within the cavity of the first shaft body such that the second shaft body is axially translated relative to the first shaft segment within the cavity. An alignment member is formed in at least the first shaft segment, and the second shaft body contacts the alignment member when the first aperture of the first shaft body aligns with the second aperture of the second shaft body. In the embodiments described herein, the shaft assembly can be used in conjunction with a steering assembly of a vehicle, such as a passenger car, truck, SUV, crossover, minivan, boat, aircraft, all-terrain vehicle, recreational vehicle, or other suitable vehicle including various steering system solutions.

[0018] As mentioned above, traditional shaft assemblies have several limitations and are difficult to axially align. For example, many shaft assemblies utilize stamped tabs to assist in aligning the shaft sections of the assembly. While these stamped tabs provide physical stops for alignment, they can be formed in the shaft sections via specific stamping presses, increasing production complexity and cost. Furthermore, the process of stamping the tabs through the shaft sections creates openings in the shaft assembly, increasing the risk of water intrusion and corrosion, and compromising the integrity and lifespan of the shaft assembly.

[0019] Other conventional shaft assemblies can utilize cold-formed flat sections or "raised sections" formed on the shaft as positioning features. However, the cold forming process is complex and expensive, making it difficult to achieve the desired tolerances for alignment of shaft segments. For example, irregularities introduced by the shaft segments of a cold-formed shaft assembly can lead to misalignment, which may impair the functionality of the assembly or require additional adjustments during assembly.

[0020] The disclosed shaft assembly aims to address these drawbacks by utilizing an alignment member configured to act as a locating feature for axial alignment of shaft segments used in the shaft assembly. In these embodiments, the alignment member can form a stop that does not pierce the surface of the shaft segment, thereby mitigating problems associated with water intrusion and corrosion. Furthermore, the alignment member can be formed in the shaft segment using existing drilling stations, eliminating the need for additional and / or separate equipment (e.g., stamping, cold forming, etc.).

[0021] As will be further described in detail herein, in some embodiments, the alignment member may also function as a travel restriction mechanism (such as a stop) configured to limit translation of at least one shaft segment of the shaft assembly. For example, in these embodiments, the alignment member may function as a stop for a segment of the shaft assembly, preventing the shaft segment from translating past the alignment member. In these embodiments, the alignment member may further enhance the versatility and reliability of the disclosed shaft assembly and ensure that the various components of the shaft assembly (e.g., the shafts) remain engaged and aligned during operation.

[0022] Embodiments of the shaft assemblies and methods for aligning the shaft assemblies will now be described in further detail herein. These shaft assemblies and methods will now be described in more detail below with reference to the accompanying drawings, wherein similar numbers denote similar structures.

[0023] See now Figures 1 to 2C The image depicts a shaft assembly 10. In these embodiments, the shaft assembly 10 may include a plurality of shaft segments 12, each of which defines a body 14 extending between a distal end 16 and a proximal end 18. For example, as... Figures 2A to 2C As most clearly shown, the plurality of axis segments 12 may include a first axis segment 22 and a second axis segment 24, wherein at least one of the plurality of axis segments 12 is configured to be received by at least another of the plurality of axis segments 12.

[0024] In these embodiments, the first shaft segment 22 may be defined as a first shaft body 32 extending between a distal end 36 and a proximal end 38 of the first shaft, and the second shaft segment 24 may be defined as a second shaft body 42 extending between a distal end 46 and a proximal end 48 of the second shaft. The first shaft body 32 may also define a cavity 34 configured to receive the second shaft body 42 of the second shaft segment 24, such that the second shaft body 42 can be axially translated within the cavity 34 of the first shaft body 32 (e.g., along such a path). Figures 2A to 2C (The coordinate axes depicted along the longitudinal direction of the + / -x axis).

[0025] although Figure 1 and Figures 2A to 2C The shaft assembly 10 is depicted as including a first shaft segment 22 and a second shaft segment 24; however, it should be understood that the shaft assembly 10 may include any number of multiple shaft segments 12 without departing from the scope of this disclosure. For example, in some embodiments, the shaft assembly 10 may include three shaft segments, four shaft segments, or any other number of shaft segments. In embodiments where the shaft assembly 10 includes not only the first and second shaft segments (e.g., three or more shaft segments), the multiple shaft segments 12 may be arranged in a scalable manner.

[0026] See still Figure 1 and Figures 2A to 2C Each of the plurality of shaft segments 12 may also include an aperture 50, which can be aligned to secure (e.g., fasten or otherwise couple) each of the plurality of shaft segments 12 together. In these embodiments, it should be understood that the aperture 50 may extend entirely through the body 14 of each of the plurality of shaft segments 12, such that fasteners or other similar coupling mechanisms can be inserted through the aperture 50 formed in the body 14. For example, as Figures 2A to 2C As most clearly depicted, the first shaft segment 22 may include a first aperture 52, and the second shaft segment 24 may include a second aperture 54. In these embodiments, when the first aperture 52 of the first shaft segment 22 is aligned with the second aperture 54 of the second shaft segment 24, a bolt or other similar fastener may be inserted through the first aperture 52 and the second aperture 54 to secure the first shaft segment 22 to the second shaft segment 24.

[0027] To ensure proper alignment of the first aperture 52 of the first shaft section 22 and the second aperture 54 of the second shaft section 24, at least one shaft section of the plurality of shaft sections 12 (e.g., such as...) Figure 1 and Figures 2A to 2C The first axis segment 22 depicted may also include alignment components 60, such as stops or any other similar mechanisms configured to limit translation of the second axis segment 24 relative to the first axis segment 22, as will be described in detail herein.

[0028] exist Figure 1 The alignment component 60 is depicted most clearly in this section. For example... Figure 1 As shown, the alignment member 60 may be a protrusion extending inward from the outer surface of the first shaft body 32 and into the cavity 34 defined by the first shaft body 32. In these embodiments, the alignment member 60 may also include a stop surface 62 that engages the second shaft body 42 when the first aperture 52 of the first shaft segment 22 is aligned with the second aperture 54 of the second shaft segment 24. Therefore, it should be understood that, in operation, the contact between the stop surface 62 of the alignment member 60 and the second shaft body 42 can indicate to the user that the first aperture 52 and the second aperture 54 are aligned. It should also be understood that, in embodiments where the first aperture 52 and the second aperture 54 are not visible to the user during operation, aligning the first aperture 52 and the second aperture 54 using the contact between the stop surface 62 of the alignment member 60 and the second shaft body 42 may be particularly advantageous.

[0029] like Figure 1Further depicted, the alignment member 60 may be formed as a curved or semi-circular protrusion that extends at least partially into the cavity 34 defined by the first shaft body 32. However, it should be understood that the alignment member 60 may take any shape without departing from the scope of this disclosure. For example, although not depicted, the alignment member 60 may be a square, rectangular, triangular, or any other similar shape that extends into the cavity 34 of the first shaft body 32 and is configured to facilitate the alignment of the first aperture 52 and the second aperture 54, as described herein.

[0030] See now Figures 2A to 2C The alignment of the shaft assembly 10 will be described in further detail. For example, as Figure 2A As depicted, the shaft assembly 10 can be positioned such that the first proximal end 38 of the first shaft body 32 is positioned adjacent to the second distal end 46 of the second shaft body 42. With the first shaft body 32 and the second shaft body 42 positioned adjacent to each other, a user can insert the second shaft body 42 into a cavity 34 formed in the first shaft body 32, such that the second shaft body 42 is axially translated within the first shaft body 32 toward the first distal end 36 (e.g., in a cavity 34 formed in the first shaft body 32). Figures 2A to 2C (in the -x direction depicted on the coordinate axes). In these embodiments, when the second shaft body 42 traverses the cavity 34 of the first shaft body 32, the first aperture 52 and the second aperture 54 can begin to at least partially overlap, as... Figure 2B The description.

[0031] like Figure 2C As depicted, the second shaft body 42 can continue to translate within the cavity 34 of the first shaft body 32 (e.g., toward the distal end 36 of the first shaft, as described herein) until the second shaft body 42 contacts the stop surface 62 of the alignment member 60 formed in the first shaft body 32. In these embodiments, the contact between the stop surface 62 of the alignment member 60 and the second shaft body 42 (e.g., the distal end 46 of the second shaft) can indicate to the user that the first aperture 52 and the second aperture 54 are aligned. Furthermore, the stop surface 62 of the alignment member 60 can prevent further translation of the second shaft body 42 toward the distal end 36 of the first shaft, thereby maintaining the alignment between the first aperture 52 and the second aperture 54.

[0032] See now Figure 3The exemplary process of forming the alignment member 60 is described. In these embodiments, the alignment member 60 may be formed in at least one of the plurality of shaft segments 12 (e.g., the first shaft segment 22) via a flow drill process or other similar processes (e.g., friction drilling, etc.) that do not pierce the body 14 of the shaft segment 12. As described herein, a flow drill process can be defined as any process capable of forming a protrusion in the body 14 of the plurality of shaft segments 12 (e.g., utilizing heat from friction or other similar means) without forming a perforation in the body. For example, as Figure 3 As shown, the flow drill 70 can be moved to contact the body 14 of at least one of the plurality of shaft segments 12, such that the frictional force generated by the flow drill is directed inward (e.g., in the case of...). Figure 3 At least a portion of the body 14 is pressed down in the -y direction depicted on the coordinate axis to form an alignment member 60. For example, in these embodiments, when the flow drill 70 is moved to contact the body 14, the flow drill 70 can rotate (e.g., spin), such that the rotation of the flow drill 70 and the contact between the flow drill 70 and the body 14 generate frictional forces for forming the alignment member 60.

[0033] It should be understood that, in the embodiments described herein, the flow drilling process for forming the alignment member 60 can be used to mitigate problems related to water intrusion, corrosion, and any other similar problems typically associated with stamping operations used to form perforations and / or openings. Furthermore, it should be noted that the flow drilling process described herein can be implemented in a drilling station used for manufacturing the shaft assembly 10, which can help minimize the amount of equipment required to manufacture the shaft assembly 10.

[0034] Now go to Figure 4A and Figure 4B Another embodiment of the axle assembly 10 is depicted. In these embodiments, the axle assembly 10 may be a steering column assembly 100, which includes a plurality of steering column segments 102, such as a first steering column segment 110 and a second steering column segment 120. The first steering column segment 110 and the second steering column segment 120 may be (e.g., releasably or inseparably) coupled together such that the first steering column segment 110 may translate axially relative to and about the second steering column segment 120.

[0035] See still Figure 4A and Figure 4BIn these embodiments, the first steering column section 110 may include a first column body 112 extending between a distal end 114 and a proximal end 116 of the first column, and the second steering column section 120 similarly includes a second column body 122 extending between a distal end 124 and a proximal end 126 of the second column. In these embodiments, the first column body 112 may further define a cavity 118 configured to receive the second column body 122 such that the first column body 112 can translate about the second column body 122, as will be described in detail herein.

[0036] like Figure 4A and Figure 4B Further depicted, the steering column assembly 100 can be in an extended position (e.g., as shown in the image). Figure 4A (as depicted) and the location of the collapse (e.g., as shown) Figure 4B Translation between (as depicted). In these embodiments, the translation of the first steering column section 110 relative to the second steering column section 120 (e.g., in...) Figure 4A and Figure 4B The steering column assembly 100 can be moved between a collapsed position and an extended position in the + / -x direction depicted on the coordinate axes. Although not depicted, in the embodiments described herein, a steering mechanism (such as a steering wheel or other steering input) can be mounted to the first steering column section 110 such that translation of the steering column assembly 100 adjusts the position of the steering mechanism within the vehicle.

[0037] See still Figure 4A and Figure 4B The first steering column section 110 may also include a stop 130 or any other similar mechanism configured to restrict axial translation of the first steering column section 110. In these embodiments, the stop 130 may be formed in the first column body 112 of the first steering column section 110 such that the stop 130 protrudes inward (e.g., into a cavity 118 formed within the first column body 112). It should be understood that the stop 130 may be formed in the first steering column section 110 via a flow drilling process or other similar processes that do not pierce the first column body 112 of the first steering column section (e.g., friction drilling, etc.).

[0038] See still Figure 4A and Figure 4B The operation of the steering column assembly 100 will be described in further detail. For example, as described herein, by causing the first column body 112 of the first steering column section 110 along a first direction (e.g., along such a direction as...) Figure 4A and Figure 4B The coordinate axes depict the -x direction) and the second direction opposite to the first direction (e.g., along such a direction). Figure 4A and Figure 4BThe steering column assembly 100 can be translated in the +x direction depicted on the coordinate axes, and can be extended to an extended position (e.g., Figure 4A ) and the location of the collapse (e.g., Figure 4B Translate between ).

[0039] More specifically, by translating the first pillar body 112 along a first direction, causing the proximal end 116 of the first pillar to move toward the distal end 124 of the second pillar, the steering column assembly 100 can move from a collapsed position to an extended position. In these embodiments, as the first pillar body 112 translates along the first direction, the length of the steering column assembly 100 can increase, causing a steering mechanism (not depicted) mounted on the distal end 114 of the first pillar to move away from the control console of the vehicle in which the steering column assembly 100 is fixed.

[0040] Conversely, by translating the first column body 112 along the second direction, causing the distal end 114 of the first column to move toward the distal end 124 of the second column, the steering column assembly 100 can move from an extended position to a collapsed position. In these embodiments, the first column body 112 can be moved along the second direction (e.g., along such a direction as...). Figure 4A and Figure 4B The first steering column section 110 is translated in the +x direction (as depicted on the coordinate axis) until the distal end 124 of the second column contacts the stop 130 formed in the body 112 of the first column. Once the distal end 124 of the second column contacts the stop 130, the stop 130 can prevent the first steering column section 110 from further translating in the second direction, which can prevent the steering column assembly 100 from collapsing beyond the stop 130.

[0041] In these embodiments, it should be understood that the stop 130 may be formed in a position of the first steering column section 110 corresponding to the maximum collapse position. For example, in some embodiments, if the first steering column section 110 translates beyond the maximum collapse position, the first steering column section 110 may become radially misaligned and wedged around the second steering column section 120, which may prevent the steering column assembly 100 from translating to the extended position. Therefore, the stop 130 may be positioned such that the maximum collapse position corresponds to the position of the stop 130.

[0042] Now go to Figure 5 An exemplary flowchart of a method 500 for aligning a shaft assembly is depicted. In these embodiments, the method may initially involve forming a protrusion extending into a cavity defined by a first shaft segment of the shaft assembly, as depicted at block 510. With the protrusion formed in the first shaft segment, the method may proceed to block 520, which may involve inserting a second shaft segment into the cavity of the first shaft segment.

[0043] In the embodiments described herein, a second shaft segment may be inserted into a first shaft segment such that the second shaft segment can be translated within a cavity of the first shaft segment. As depicted at box 530, the method may also involve translating the second shaft segment axially within the first shaft segment and may further involve contacting the second shaft segment with a protrusion formed in a cavity of the first shaft segment, as shown at box 540. In these embodiments, when the second shaft segment contacts the protrusion, a first orifice extending through the first shaft segment may be positioned to align with a second orifice extending through the second shaft segment.

[0044] See still Figure 5 In these embodiments, the method may also involve inserting a fastener through a first orifice in the first shaft section and a second orifice in the second shaft section to connect the first shaft section to the second shaft section. Furthermore, it should be understood that, in the embodiments described herein, the method steps for forming a protrusion in the first shaft section may involve using a flow drilling process or any other similar friction drilling process to form the protrusion. In these embodiments, using a flow drilling process or other similar friction drilling process ensures that the protrusion is formed as a non-piercing protrusion (e.g., a protrusion that does not include a hole extending into a cavity).

[0045] Now go to Figure 6 An exemplary flowchart of a method 600 for restricting movement of a steering column assembly is depicted. In these embodiments, the method may initially involve forming a stop extending into a cavity defined by a first column segment of the steering column assembly, as depicted at block 610. With the stop formed in the first steering column segment, the method may proceed to block 620, which may involve inserting a second steering column into the cavity of the first steering column segment.

[0046] In the embodiments described herein, a second steering column segment may be inserted into a first steering column segment such that the second steering column segment can translate within the cavity of the first steering column segment between an extended position and a collapsed position. As depicted at box 630, the method may also involve axially translating the second steering column segment within the first steering column segment from an extended position to a collapsed position, and may further involve contacting the second steering column segment with a stop formed within the cavity of the first steering column segment, as shown at box 640. In these embodiments, the contact between the second steering column segment and the stop prevents further axial translation of the second steering column segment relative to the first steering column segment, thereby ensuring that the second steering column segment does not translate beyond the maximum collapsed position within the first steering column segment.

[0047] In light of the foregoing, it should be understood that the embodiments described herein relate to shaft assemblies and steering column assemblies. The shaft assembly includes at least a first shaft segment and at least a second shaft segment, the first shaft segment having a first shaft body defining a cavity and a first orifice extending through the first shaft body, and the second shaft segment having a second shaft body and a second orifice extending through the second shaft body. The second shaft segment is configured to be received within the cavity of the first shaft body such that the second shaft body can be axially translated relative to the first shaft segment within the cavity. An alignment member is formed in at least the first shaft segment, and the second shaft body contacts the alignment member when the first orifice of the first shaft body aligns with the second orifice of the second shaft body. Because the alignment member forms a stop that does not pierce the surface of the shaft segment, problems related to water intrusion and corrosion can be mitigated. Furthermore, the alignment member can be formed in the shaft segment using existing drilling positions, eliminating the need for additional and / or separate equipment (e.g., stamping, cold forming, etc.).

[0048] The embodiments disclosed herein can be further described with reference to the following aspects:

[0049] According to one aspect of this disclosure, and potentially in combination with other aspects of this disclosure, a shaft assembly includes: at least a first shaft segment, a first shaft body having a defined cavity and a first orifice extending through the first shaft body; at least a second shaft segment having a second shaft body and a second orifice extending through the second shaft body, the second shaft segment being configured to be received within the cavity of the first shaft body such that the second shaft body is axially translated relative to the first shaft segment within the cavity; and an alignment member formed in at least the first shaft segment, the alignment member being a non-piercing alignment member; wherein, when the first orifice of the first shaft body is aligned with the second orifice of the second shaft body, the second shaft body contacts the alignment member.

[0050] According to one aspect of this disclosure, and potentially in combination with other aspects of this disclosure, the alignment component further includes a stop surface that contacts the second shaft body when the first orifice is aligned with the second orifice.

[0051] According to one aspect of this disclosure, and potentially in combination with other aspects of this disclosure, the alignment member is a protrusion extending into a cavity of the first shaft body.

[0052] According to one aspect of this disclosure, and potentially in combination with other aspects of this disclosure, the alignment component is a non-piercing alignment component that does not form an opening in the first axis body.

[0053] According to one aspect of this disclosure, and potentially in combination with other aspects of this disclosure, the alignment component is a protrusion formed by the flow drill bit.

[0054] According to one aspect of this disclosure, and potentially in combination with other aspects of this disclosure, the alignment member prevents the second axis body from translating beyond the alignment member in at least one direction.

[0055] According to one aspect of this disclosure, and potentially in combination with other aspects of this disclosure, a fastener extends through a first aperture and a second aperture to connect a first shaft segment to a second shaft segment.

[0056] According to one aspect of this disclosure, and potentially in combination with other aspects of this disclosure, the alignment component is fluid-sealed relative to the cavity of the first shaft body.

[0057] According to one aspect of this disclosure, and potentially in combination with other aspects of this disclosure, a steering column assembly includes: at least a first steering column segment having a first column body with a defined cavity; at least a second steering column segment having a second column body, the second steering column segment being configured to be received within the cavity of the first column body of the first steering column segment; and a stop formed in at least the first steering column segment, the stop being a non-puncture stop that does not form an opening in at least the first steering column; wherein the steering column assembly is translatable between an extended position and a collapsed position, in which the second column body contacts the stop formed in the first column body.

[0058] According to one aspect of this disclosure, and potentially in combination with other aspects of this disclosure, the first steering column section is axially translated about the second steering column section to move the steering column between an extended position and a collapsed position.

[0059] According to one aspect of this disclosure, and potentially in combination with other aspects of this disclosure, the stop also includes a stop surface that contacts the second column body when the steering column assembly is in the collapsed position.

[0060] According to one aspect of this disclosure, and potentially in combination with other aspects of this disclosure, the stop is a protrusion extending into a cavity of the first column body.

[0061] According to one aspect of this disclosure, and potentially in combination with other aspects of this disclosure, the stop is a protrusion formed by the flowing drill bit.

[0062] According to one aspect of this disclosure, and potentially in combination with other aspects of this disclosure, when the steering column assembly translates from an extended position to a collapsed position, a stop prevents the first column body from translating beyond the stop.

[0063] According to one aspect of this disclosure, and potentially in combination with other aspects of this disclosure, the stop is formed in the first column body at a position corresponding to the maximum collapse position of the steering column assembly.

[0064] According to one aspect of this disclosure, and potentially in combination with other aspects of this disclosure, a method of aligning a shaft assembly includes: forming a non-piercing protrusion extending into a cavity defined by a first shaft segment of the shaft assembly; inserting a second shaft segment into the first shaft segment; translating the second shaft segment axially within the first shaft segment; and contacting the second shaft segment with the non-piercing protrusion such that a first orifice extending through the first shaft segment is aligned within a second orifice extending through the first shaft segment.

[0065] According to one aspect of this disclosure, and potentially in combination with other aspects of this disclosure, the method further includes inserting a fastener through a first aperture of a first shaft section and a second aperture of a second shaft section to engage the first shaft section to the second shaft section.

[0066] According to one aspect of this disclosure, and potentially in combination with other aspects of this disclosure, the non-piercing protrusion in the cavity defined by the first axis segment further includes the non-piercing protrusion being formed using a flow drilling process.

[0067] According to one aspect of this disclosure, and potentially in combination with other aspects of this disclosure, the non-piercing protrusion in the cavity defined by the first shaft segment also includes the non-piercing protrusion being formed using a friction drilling process.

[0068] According to one aspect of this disclosure, and potentially in combination with other aspects of this disclosure, the method steps of contacting the second shaft segment with the non-piercing protrusion further include preventing additional axial translation of the second shaft segment in at least one direction.

[0069] The terminology used herein is for descriptive purposes only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms, including “at least one,” unless explicitly indicated otherwise. “Or” means “and / or.” As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items. It will also be understood that, when used in this specification, the terms “comprising” or “including” specify the presence of the stated features, areas, integrals, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, areas, integrals, steps, operations, elements, components, and / or groups thereof. The term “or combinations thereof” means a combination including at least one of the foregoing elements.

[0070] It should be noted that the terms “approximately” and “about” are used herein to indicate the degree of uncertainty that may be attributable to any quantitative comparison, value, measurement, or other representation. These terms are also used herein to indicate the extent to which a quantitative representation may differ from the stated reference without altering the fundamental function of the subject matter under discussion.

[0071] While specific embodiments have been shown and described herein, it should be understood that various other changes and modifications may be made without departing from the spirit and scope of the claimed subject matter. Furthermore, although various aspects of the claimed subject matter have been described herein, these aspects need not be used in combination. Therefore, the appended claims are intended to cover all such changes and modifications within the scope of the claimed subject matter.

Claims

1. A shaft assembly, comprising: At least a first shaft section, having a first shaft body defining a cavity and a first orifice extending through the first shaft body; At least a second shaft segment having a second shaft body and a second orifice extending through the second shaft body, the second shaft segment being configured to be received within the cavity of the first shaft body such that the second shaft body can be axially translated relative to the first shaft segment within the cavity; as well as An alignment component is formed in the at least first axial section, the alignment component being a non-piercing alignment component; Specifically, when the first opening of the first shaft body is aligned with the second opening of the second shaft body, the second shaft body contacts the alignment component.

2. The shaft assembly of claim 1, wherein, The alignment component also includes a stop surface, which contacts the second shaft body when the first orifice is aligned with the second orifice.

3. The shaft assembly of claim 1, wherein, The alignment component is a protrusion extending into the cavity of the first shaft body.

4. The shaft assembly of claim 1, wherein, The alignment component does not form an opening in the first shaft body.

5. The shaft assembly of claim 1, wherein, The alignment component is a protrusion formed by the flowing drill bit.

6. The shaft assembly of claim 1, wherein, The alignment component prevents the second shaft body from translating beyond the alignment component in at least one direction.

7. The shaft assembly of claim 1 further includes a fastener extending through the first aperture and the second aperture to connect the first shaft segment to the second shaft segment.

8. The shaft assembly of claim 1, wherein, The alignment component is fluid-sealed relative to the cavity of the first shaft body.

9. A steering column assembly, comprising: At least the first steering column section, having a first column body with a defined cavity; At least a second steering column section having a second column body, the second steering column section being configured to be received within the cavity of the first column body of the first steering column section; as well as A stop is formed in the at least first steering column section, the stop being a non-puncture stop that does not form an opening in the at least first steering column section; The steering column assembly is capable of translating between an extended position and a collapsed position, wherein in the collapsed position, the second column body contacts the stop formed in the first column body.

10. The steering column assembly of claim 9, wherein, The first steering column section is axially translated about the second steering column section to move the steering column between the extended position and the collapsed position.

11. The steering column assembly of claim 9, wherein, The stop also includes a stop surface, which contacts the second column body when the steering column assembly is in the collapsed position.

12. The column assembly of claim 9, wherein, The stop is a protrusion that extends into the cavity of the first column body.

13. The steering column assembly of claim 9, wherein, The stop is a protrusion formed by the flowing drill bit.

14. The column assembly of claim 9, wherein, When the steering column assembly translates from the extended position to the collapsed position, the stop prevents the first column body from translating beyond the stop.

15. The steering column assembly according to claim 9, wherein, The stop is formed in the first column body at a position corresponding to the maximum collapse position of the steering column assembly.

16. A method for aligning a shaft assembly, comprising: Forming a non-piercing protrusion extending into the cavity defined by the first shaft segment of the shaft assembly; Insert the second axis segment into the first axis segment; The second axis segment is translated axially within the first axis segment; and The second shaft segment is brought into contact with the non-piercing protrusion, such that the first orifice extending through the first shaft segment is aligned within the second orifice extending through the first shaft segment.

17. The method of claim 16, further comprising: Fasteners are inserted through the first hole of the first shaft section and the second hole of the second shaft section to connect the first shaft section to the second shaft section.

18. The method according to claim 16, wherein, Forming the non-piercing protrusion in the cavity defined by the first axial section further includes forming the non-piercing protrusion using a flow drilling process.

19. The method of claim 16, wherein, Forming the non-piercing protrusion in the cavity defined by the first axial section further includes forming the non-piercing protrusion using a friction drilling process.

20. The method of claim 16, wherein, The method steps for bringing the second shaft section into contact with the non-piercing protrusion further include: preventing the second shaft section from undergoing additional axial translation in at least one direction.

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