Snap-in retainer for regulator plug assembly

Abstract

The present disclosure relates to snap-in retainers for regulator plug assemblies. A rack and pinion steering system includes a rack housing defining a rack housing bore extending along an axis. The steering system also includes a regulator plug assembly. The regulator plug assembly includes a regulator plug disposed at least partially within the regulator bore. The regulator plug assembly also includes a lock ring disposed at least partially within the regulator bore, wherein the lock ring includes a plurality of radially outer teeth meshingly engaged with a plurality of housing teeth, wherein the lock ring includes a plurality of radially inner teeth meshingly engaged with a plurality of regulator plug teeth, wherein a number of teeth of the plurality of radially inner teeth and a number of teeth of the plurality of radially outer teeth differ by one.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority to U.S. Provisional Application No. 64 / 037,851, filed April 13, 2026; U.S. Provisional Application No. 63 / 978,825, filed February 9, 2026; and U.S. Provisional Application No. 63 / 863,074, filed August 13, 2025, the disclosures of which are incorporated herein by reference in their entirety. Technical Field

[0003] This disclosure relates to vehicle steering systems, and more specifically, to a retainer for an adjuster plug used in a rack and pinion steering assembly. Background Technology

[0004] The function of a rack and pinion steering system is to convert rotational motion into linear motion. A rack and pinion steering system may include an elongated steering rack (i.e., a toothed rod), a tie rod, a steering shaft, and a pinion. The tie rod may be attached to at least one steering wheel, which is attached to the steering rack. The pinion operatively engages with the teeth of the steering rack, thereby rotating in response to rotation of the steering shaft and causing the rack to move linearly. System components (such as a rack yoke or rack shoe) may contribute to the operative engagement of the pinion and rack. Axial or radial clearance between the rack yoke or rack shoe and the mating components can lead to undesirable noise, resulting in suboptimal steering feel performance, or increasing system complexity. Therefore, it is desirable to minimize system noise, improve steering feel performance, reduce system complexity, and improve the reliability of the pinion-rack engagement.

[0005] Attempts to address the aforementioned problems include utilizing a rack bearing housed within a cylindrical bore of a rack and pinion housing. An adjuster plug is screwed into the rack and pinion housing, compressing an adjuster spring between the rack bearing and the adjuster plug. The spring forces the rack bearing into contact with the rack, which is then compressed to engage with the pinion. The adjuster plug is rotated to set a precise clearance between the rack bearing and the adjuster plug. This clearance determines the degree to which the rack and pinion engagement can disengage during operation and is critical for the steering system's friction and NVH performance. Because the adjuster plug is positioned axially and is not tightened to achieve a clamping load like a typical threaded fastener, there is no friction in the threaded interface to prevent the plug from rotating after adjustment. This necessitates additional rotation-retaining mechanisms for the adjuster plug.

[0006] Existing regulator plug retention is achieved through two types of adhesives used for regulator plug retention. The first is a thread-locking adhesive applied to the regulator plug threads. This adhesive is activated when the regulator plug is screwed into the rack and pinion housing and cures over time. The second adhesive is a liquid adhesive applied to the interface between the regulator plug and the rack and pinion housing after the regulator plug has been assembled and adjusted. Once applied, this adhesive is cured with ultraviolet light. In some cases, the adhesive can present challenges related to assembly, performance, and steering system disassembly. Summary of the Invention

[0007] According to one aspect of this disclosure, a rack and pinion type adjuster assembly includes a housing having an adjuster boss having a hole and first engagement features circumferentially distributed around an adjusting axis. The adjuster assembly also includes an adjuster plug configured to be received by the hole and movable relative to the adjuster boss along the adjusting axis to position a rack support member, the adjuster plug including second engagement features circumferentially distributed around the adjusting axis. The adjuster assembly further includes a retainer separate from the housing and the adjuster plug, the retainer being configured to be positioned at one of a plurality of angular positions after the adjuster plug is positioned relative to the adjuster boss at a selected angular position, the retainer including: a first retainer engagement portion configured to engage with the first engagement feature; a second retainer engagement portion configured to engage with the second engagement feature; and an axial retaining portion configured to retain the retainer relative to the adjuster plug. The first retainer engagement portion and the first engagement feature are configured to restrict rotation of the retainer relative to the regulator boss, and the second retainer engagement portion and the second engagement feature are configured to restrict rotation of the regulator plug relative to the retainer, such that the retainer mechanically locks the regulator plug at a selected angular position relative to the regulator boss without requiring an adhesive bond between the regulator plug and the regulator boss.

[0008] According to another aspect of this disclosure, a rack and pinion steering system includes a rack housing defining a rack housing bore extending along an axis. The steering system also includes an adjuster plug assembly. The adjuster plug assembly includes an adjuster plug at least partially disposed within an adjuster bore. The adjuster plug assembly also includes a locking ring at least partially disposed within the adjuster bore, wherein the locking ring includes a plurality of radially external teeth engaging with a plurality of housing teeth, and wherein the locking ring includes a plurality of radially internal teeth engaging with a plurality of adjuster plug teeth, wherein the number of teeth of the plurality of radially internal teeth differs from the number of teeth of the plurality of radially external teeth by one.

[0009] According to another aspect of this disclosure, a rack and pinion type adjuster assembly includes a housing having an adjuster boss having a boss engagement feature arranged around an adjustment axis. The adjuster assembly also includes an adjuster plug configured to be received by the adjuster boss and positioned along the adjustment axis to set a rack support position, the adjuster plug including a plug engagement feature and an axial retaining feature. The adjuster assembly further includes a retainer separate from the housing and the adjuster plug, the retainer including: a retainer body; a first retainer engagement portion configured to engage with the boss engagement feature to limit rotation of the retainer relative to the adjuster boss; a second retainer engagement portion configured to engage with the plug engagement feature to limit rotation of the adjuster plug relative to the retainer; and a resilient axial retaining portion configured to radially deflect outward during installation of the retainer onto the adjuster plug and, after installation, radially deflect inward to engage with the axial retaining feature, thereby axially retaining the retainer relative to the adjuster plug. The resilient axial retaining portion includes a retaining clip or spring finger, the retaining clip extending along the arc length of the retaining body, and the spring finger configured to clamp below the lip of the adjuster plug. Attached Figure Description

[0010] The subject matter of this disclosure is specifically pointed out and clearly claimed in the claims at the end of the specification. The foregoing and other features and advantages of this disclosure will be apparent from the following detailed description taken in conjunction with the accompanying drawings.

[0011] Figure 1 This is a perspective view of an assembled regulator plug assembly according to one aspect of the present disclosure, the regulator plug assembly including a regulator plug, a regulator boss, and a retainer.

[0012] Figure 2 It is in a disassembled state. Figure 1 A three-dimensional view of the regulator plug assembly.

[0013] Figure 3 It is in the assembly state. Figure 1 End view of the regulator plug assembly.

[0014] Figure 4 This is a perspective view of a portion of the regulator plug and a portion of the retainer according to one aspect of this disclosure.

[0015] Figure 5 This is an end view of the regulator plug assembly according to another aspect of this disclosure.

[0016] Figure 6 yes Figure 5 End view of the retainer of the regulator plug assembly.

[0017] Figure 7This is a perspective view of the regulator plug assembly in an assembled state, according to another aspect of this disclosure.

[0018] Figure 8 This is an end view of the regulator plug assembly in an assembled state, according to another aspect of this disclosure.

[0019] Figure 9A It shows a relaxed state. Figure 8 A view of the retainer of the regulator plug assembly, wherein the retaining tab engages with the groove.

[0020] Figure 9B It shows the state of being in a stretched assembly. Figure 8 A view of the retainer of the regulator plug assembly, wherein the retaining tab is in the assembled position.

[0021] Figure 10 This is a view of the adjuster boss, showing a pattern of the adjuster boss slot.

[0022] Figure 11 This is a view of the regulator plug, showing the pattern of the regulator plug teeth.

[0023] Figure 12 This is a view of the retainer, showing the retainer inner groove, spring finger, and retainer outer teeth.

[0024] Figure 13 It is a cross-sectional view showing the engagement of the spring finger with the lip of the regulator plug.

[0025] Figures 14-16 This is a view of a component according to another aspect of this disclosure. Detailed Implementation

[0026] refer to Figures 1-4The figure shows an adjuster plug assembly for a rack and pinion steering system, generally indicated by reference numeral 10. The adjuster plug assembly 10 includes: an adjuster plug 12 received in an adjuster boss 14 of a rack and pinion housing; and a retainer 16 configured as a snap-in retainer that mechanically locks the adjuster plug 12 relative to the adjuster boss 14 after an adjustment operation is completed. In the steering system, a rack bearing is received in a cylindrical bore of the rack and pinion housing, and the adjuster plug 12 is screwed into the adjuster boss 14 to compress an adjuster spring between the rack bearing and the adjuster plug 12. The adjuster spring pushes the rack bearing into contact with the rack, thereby pressing the rack into engagement with the pinion. The adjuster plug 12 can be rotated to set the desired axial position and desired clearance associated with the rack bearing and the adjuster plug 12, thereby controlling the permissible disengagement of the rack and pinion engagement during operation and affecting the friction and noise, vibration, and ride comfort performance of the steering system. Because the adjuster plug 12 is set to the axial position, rather than being tightened to create a clamping load like conventional threaded fasteners, the threaded interface can provide little or no frictional resistance to subsequent rotation of the adjuster plug 12. Once the desired setting is achieved, the retainer 16 is inserted to hold the adjuster plug 12 in the selected angular position without relying on adhesive applied to the threaded interface.

[0027] In one embodiment, the regulator boss 14 includes a plurality of pockets or grooves 18 for receiving corresponding lugs 20 of the retainer 16, and the regulator plug 12 includes a ring of teeth, splines, or other circumferential engagement features 22 that engage with segments of teeth, spline teeth, or other corresponding engagement features 24 of the retainer 16. The engagement between the lugs 20 of the retainer 16 and the pockets 18 of the regulator boss 14 restricts rotation of the retainer 16 relative to the regulator boss 14, while the engagement between the segments of teeth 24 of the retainer 16 and the ring of teeth 22 of the regulator plug 12 restricts rotation of the regulator plug 12 relative to the retainer 16. In some embodiments, four pockets of the regulator boss 14 receive four lugs of the retainer 16, and two segments of teeth of the retainer 16 engage with the ring of teeth of the regulator plug 12, although other numbers, shapes, and distributions of pockets, lugs, teeth, and segments of teeth may be used. The recess 18 can be formed as a die-cast feature of a rack and pinion housing and can roughly correspond to a recess available in an adhesive retainer design. During insertion of the retainer 16, the retaining rib 26 of the retainer 16 can expand radially beyond the outer diameter of the gear ring 22 of the adjuster plug 12 and then engage in the undercut 30 of the adjuster plug 12 to axially retain the retainer 16 relative to the adjuster plug 12. The outer diameter of the retainer 16 can fit tightly with the thread minor diameter of the adjuster boss 14 in the region adjacent to the meshing teeth, thereby preventing the tooth segment 24 of the retainer 16 and the gear ring 22 of the adjuster plug 12 from radially separating to a degree sufficient to disengage. In the region adjacent to the retaining rib 26, the outer diameter of the retainer 16 can define a gap 32 relative to the thread minor diameter of the adjuster boss 14 to allow the retainer 16 to expand radially as the retaining rib 26 passes the gear ring and then contract to engage with the undercut 30. The teeth 22 of the regulator plug 12 and / or the teeth 24 of the retainer 16 may be tapered, chamfered, inclined, or other lead-in shapes to facilitate the assembly of the retainer 16 to the regulator plug 12, such as... Figure 4 As shown.

[0028] The retainer disclosed herein provides a mechanical alternative to the adhesive-based rotational retention of the regulator plug 12. In some embodiments, the retainer 16 is a polymer retainer, such as an injection-molded plastic retainer, and in particular may be formed from an acetal copolymer, Delrin, nylon 6 / 6, polycarbonate, or another material selected to balance cost, strength, temperature resistance, chemical resistance, and manufacturability. In other embodiments, the retainer 16 may be metallic, or may include another material suitable for the operating environment. The regulator plug 12 may be a zinc die-cast component, and the toothed ring may have a tooth cross-section selected to be compatible with die casting, such as a tooth cross-section sized similarly to existing thread cross-sections, so that the tooth features are not too small to be cast. The undercut receiving the retaining rib may be located on the regulator plug 12 rather than in the housing, so that the undercut can be produced by a die-casting tool without machining into the housing. Mechanical retaining devices also avoid the disadvantages associated with riveting (which can damage the threads and impede rework or housing recycling) and the disadvantages associated with jam nuts (which may require clamping loads, may require changes in the material of the adjuster plug, and may increase costs or corrosion protection requirements).

[0029] The above text combined Figures 1-4 The benefits discussed in the embodiments are applicable to all embodiments disclosed herein.

[0030] Now for reference Figure 5 and Figure 6 Another embodiment of the regulator plug assembly is shown, and is generally designated by reference numeral 110. The regulator plug assembly 110 includes a regulator plug 112, a regulator boss 114, and a retainer 116. As disclosed herein, the retainer 116 is a locking ring.

[0031] To provide reliable rotational retention of the regulator plug 112 at any angular orientation satisfying the clearance requirements, a retainer 116 is mounted between the regulator plug 112 and the rack housing 114. The retainer 116 is annular about the axis of the regulator bore and is at least partially disposed within the regulator bore. The retainer 116 carries a plurality of radially external teeth 120 and a plurality of radially internal teeth 122, the radially external teeth 120 being configured to engage with a plurality of housing teeth 118 on the rack housing 114, and the radially internal teeth 122 being configured to engage with a plurality of regulator plug teeth 119 on the regulator plug 112. The external teeth 120 and internal teeth 122 are formed as splines, sawtooth, zigzag, knurled, or other discrete tooth features capable of transmitting torque. For example, the tooth profile can be straight-edged, involute, or trapezoidal. Introduced chamfers and root fillets may be provided to facilitate assembly and reduce stress concentration.

[0032] The retainer 116 is characterized in that the number of teeth of the plurality of radially external teeth 120 differs from the number of teeth of the plurality of radially internal teeth 122 by one. If This indicates the number of external teeth 120. To indicate the number of internal teeth 122, then... A difference of one tooth creates a vernier relationship between the two meshes, allowing the retainer 116 to be rotatably indexed to simultaneously achieve line-to-line engagement with both the housing tooth 118 and the adjuster plug tooth 119 at fine incremental angular intervals around the entire circumference. The vernier relationship enables angular indexing resolution. It is given by the following formula:

[0033] For example, for and The resolution is:

[0034] This means that for any target orientation of the regulator plug 112, there is a rotational position of the retainer 116 within 0.6 degrees, which produces simultaneous engagement with both sets of teeth, allowing the plug to be locked without interfering with the established axial position.

[0035] When the regulator plug 112 includes a pitch of When threading, the vernier angle resolution corresponds to the linear axial adjustment increment expressed by the following relationship. :

[0036] For 1.0 With a typical pitch and a vernier step size of 0.6 degrees, the linear increment is approximately Or approximately 0.6 micrometers. This resolution allows the adjuster plug 112 to be locked in the orientation required to maintain the precise axial setting of the rack clearance.

[0037] Figure 5 An adjuster plug 112 assembled in the adjuster hole of the rack housing 114 is shown, with housing teeth 118 and adjuster plug teeth 119 visible in the top view. In this case, the plug has been rotated to achieve the desired axial setting. Figure 6 A retainer 116 is shown, concentrically positioned between the housing teeth 118 and the regulator plug teeth 119. The outer radial teeth 120 of the ring are sized and pitched to mesh with the housing teeth 118, while the inner radial teeth 122 are sized and pitched to mesh with the regulator plug teeth 119. Due to and With a one-tooth difference between them, retainer 116 rotates about the axis until an external tooth 120 aligns with the tooth space of the mating housing and an internal tooth 122 aligns with the tooth space of the mating adjuster plug. Then retainer 116 is axially positioned such that the two sets of teeth are fully engaged around their respective circumferences.

[0038] The housing teeth 118 can be formed directly in the regulator hole of a cast or machined aluminum housing, broached in a steel housing, machined in a steel insert press-fitted into the housing, or formed in a separate retaining collar secured to the housing 114 by threads, riveting, or bayonet joints. The regulator plug teeth 119 can be integrally formed with the outer circumference of the regulator plug 112 and can be formed by, for example, hobbing, casting, broaching, rolling, or powder metal molding. In one embodiment, the regulator plug teeth 119 are radially outwardly projecting serrations provided on the flange of the regulator plug 112. In another embodiment, the regulator plug teeth 119 are provided on a removable collar that is crimped or welded to the regulator plug 112, enabling maintenance and replacement.

[0039] The retainer 116 can be made of polymer or metallic materials. Suitable polymers include nylon 6 / 6, glass-filled nylon, PEEK (polyetheretherketone), and acetal. Suitable metals include spring steel, stainless steel, and precipitation-hardened stainless steel. In polymer embodiments, the retainer 116 can be injection molded to have net-shape teeth and localized reinforcing ribs to limit elastic deformation under torque. In metallic embodiments, the retainer 116 can be stamped and embossed, powder metal sintered to a net shape, or machined. If corrosion resistance is required, the ring can be electroplated, anodized, nitrided, or coated with a dry film lubricant. The tooth flank angles and surface finishes are selected to transmit the target locking torque while allowing for field maintenance removal if necessary.

[0040] To retain the retainer 116 axially after engagement, any suitable retaining feature and / or technique can be used. In addition to engagement, a slight interference fit between the retainer 116 and the housing 114 can be used to suppress clicking. The retaining force is designed such that once the retainer 116 is in place and engaged, the torque applied to the regulator plug 112 is reacted by both internal and external engagement, thereby preventing the regulator plug 112 from rotating under operating loads.

[0041] The size range was selected to balance indexing resolution with tooth strength and manufacturability. In a representative embodiment, the number of external teeth... The number of internal teeth can range from 18 to 60. Chosen as with They differ by exactly one. For example, hour , .

[0042] During assembly, the steering rack, rack bearing, and adjuster spring are positioned within the rack housing 114. The adjuster plug 112 is screwed into the adjuster bore until a specified torque-to-turn or axial displacement is achieved, thus setting the rack clearance. Without disturbing the set position, a retainer 116 is concentrically arranged around the adjuster plug 112 and positioned within the adjuster bore. The retainer 116 rotates about the axis while the assembler applies slight axial pressure. As the ring rotates, the paired teeth on the inner and outer circumferences gradually approach alignment. Upon the next simultaneous alignment, the retainer 116 falls into full engagement with the housing teeth 118 and the adjuster plug teeth 119. Then any snap-fit ​​or retaining features, if present, engage, capturing the retainer 116. Because the vernier resolution is very fine, the rotation required to achieve the next alignment is small, preventing disturbance to the axial setting of the adjuster plug.

[0043] Vernier engagement provides a self-centering effect because, in any given ring orientation, only one pair of internal and external teeth will be precisely tip-to-tip aligned. As the ring approaches this orientation, the tooth chamfer guides the ring into the mating backlash. The full 360-degree tooth distribution produces high torque capacity. For a system with 24 internal teeth and 25 external teeth, the static torque capacity is... It can be approximated as:

[0044] in It is the coefficient of friction on the tooth flank. It is the normal force of each mating tooth pair. It is the average radius of the mating teeth. It refers to the number of teeth that simultaneously share the load. This is achieved by selecting the tooth geometry and material. And through control to generate The axial interference or snap-fit ​​engagement allows for adjustment of the holding torque.

[0045] Environmental reliability is achieved by selecting tooth profiles and materials capable of withstanding grease, oil, and debris in the steering gear assembly. The vernier locking mechanism is insensitive to the variability of the thread adhesive, eliminating curing time limitations and facilitating disassembly and maintenance without the need for thread cleaning. During durability loads, the torque reversal at adjuster plug 112 is directly borne by the meshing teeth rather than by the adhesive bonding line, reducing retention force loss over time.

[0046] The geometry of the internal and external teeth can be made asymmetrical to offset unidirectional mounting, thereby providing greater anti-loosening properties in the direction of the torque generated by the rack load, or facilitating easier maintenance removal in the opposite direction. The tooth height can be slightly tapered in the axial direction to create a wedging effect that increases the holding torque when an axial load is applied. The tooth flanks can be crowning to accommodate slight misalignment between the adjuster plug 112 and the housing 114.

[0047] The retainer 116 may be integrally formed with additional features. An annular sealing lip may be integrally molded with the polymer ring to form a splash barrier that mates with a groove in the regulator plug 112. Identification features, such as notches or laser markings, may be provided on the retainer 116 to indicate its rotational position during assembly. A stop feature may be included to limit rotation of the ring relative to the housing 114 within a range to ensure at least one simultaneous alignment of the inner and outer teeth within a defined assembly window.

[0048] During operation, once the adjuster plug 112 is set to the precise axial position required for optimal rack and pinion engagement, the retainer 116 is indexed to the nearest simultaneous alignment position and pushed into place. This is due to the vernier step size. The size is small, thus preserving the adjustment accuracy set by the plug thread. The locking assembly prevents the adjuster plug 112 from rotating under normal vehicle operating loads and environmental conditions. If servicing adjustment is required, the retaining feature is released, the retainer 116 is retracted, the adjuster plug 112 is rotated to a new axial position, and the retainer 116 is reinstalled in a new vernier indexing position without the need for adhesive removal or curing.

[0049] Although the embodiments described herein focus on a difference of one tooth between the internal and external tooth counts, the principle of vernier indexing can be applied to other combinations of tooth counts. However, a difference of one tooth provides the finest resolution for a given total tooth count and facilitates uniform tooth engagement around the circumference. The dimensions of the retainer 116, housing teeth 118, and adjuster plug teeth 119 can be designed for different steering gear mechanisms (including electric power steering and hydraulic power steering systems) and can be adapted to housings made of aluminum, magnesium, or steel.

[0050] Now for reference Figures 7-13 Another embodiment of the regulator plug assembly is shown, and is generally designated by reference numeral 210. The regulator plug assembly 210 includes a regulator plug 212, a regulator boss 214, and a retainer 216. The retainer 216 is a snap-fit ​​polymer retainer having a ring-shaped body configured to expand radially during installation and then return to its free-state shape after installation. Reference Figure 8 The retainer 216 may include a large retaining clip, a bent ring, and vernier teeth. Compared to smaller rib or tab arrangements, the large retaining clip extends along a relatively large arc length of the ring and provides greater radial engagement with the groove of the adjuster plug 212 after assembly. The bent ring introduces additional effective length into the annular body, allowing the ring to elastically deform during installation, rather than forcing the perfectly circular ring to stretch beyond its desired limits.

[0051] The bent ring structure facilitates the assembly of the retainer 216 onto the external features of the regulator plug 212. During installation, the retaining clip is pushed radially outward as it passes over the outer diameter region of the regulator plug 212 (e.g., the toothed or splined region axially adjacent to the retaining groove). Because the ring is bent rather than circular in its free state, it can bend and open as the retaining clip passes over the outer diameter of the regulator plug 212. After the retaining clip passes over the outer diameter region and reaches the groove, the ring relaxes, and the retaining clip engages radially inward into the groove to establish axial retention of the retainer 216 on the regulator plug 212.

[0052] This operation is by Figure 9A and Figure 9B As shown. Figure 9B The retainer 216 is shown in a stretched state during assembly. Figure 9A The image shows the ring in a relaxed state after assembly. In this way, the curved ring geometry allows feature 226 to expand radially during installation, while reducing the likelihood of excessive stress, yielding deformation, or fracture that could occur in a ring lacking sufficient flexibility.

[0053] Figure 8 The polymer embodiment shown can also employ vernier teeth to improve indexing between the retainer 216 and the regulator plug 212. Compared to a finer spline arrangement, vernier teeth allow for angular alignment in smaller rotational increments, thus allowing the retainer 216 to be installed with less interference with the previously established adjustment position of the regulator plug 212. The relatively large tooth geometry is also advantageous for manufacturing processes such as injection molding of the retainer 216 and die casting of the regulator plug 212.

[0054] In other embodiments, the retainer 216 is formed as a metallic retainer, such as a stamped steel retainer, for applications requiring high-temperature resistance, chemical resistance, or increased structural stability. In metallic embodiments, rotational retention is provided by a first interface between the retainer 216 and the adjuster boss 214, and a second interface between the retainer 216 and the adjuster plug 212, while axial retention is provided by a spring finger engaging the adjuster plug 212.

[0055] Reference Figure 10The regulator boss 214 includes a circularly patterned regulator boss groove 218 formed at one end of the regulator boss 214. The regulator boss groove 218 is configured to receive a corresponding external tooth 220 of the retainer 216. The circular pattern of the regulator boss groove 218 can be formed as part of a die-cast rack and pinion housing. (Reference) Figure 11 The regulator plug 212 includes regulator plug teeth 222 with a circular pattern. The regulator plug teeth 222 are arranged to engage with corresponding inner grooves 224 of the retainer 216.

[0056] refer to Figure 12 The metal retainer 216 can be formed as an annular member having a retainer inner groove 224, a spring finger 226, and a retainer outer tooth 220. The retainer outer tooth 220 is positioned to... Figure 10 The adjusting boss groove 218 engages with the retaining part inner groove 224 to be positioned with Figure 11 The regulator plug teeth 222 engage. When the retainer 216 is installed, these engaging interfaces restrict the relative rotation between the retainer 216 and the regulator boss 214, and between the retainer 216 and the regulator plug 212, thereby restricting the rotation of the regulator plug 212 relative to the regulator boss 214.

[0057] refer to Figure 13 The axial retention of the metal retainer 216 is achieved by the engagement of the spring finger 226 with the lip 228 of the adjuster plug 212. When the retainer 216 is axially inserted, the spring finger 226 deflects outward as it passes the lip 228 and then springs back inward, thereby clamping under the lip 228. Once clamped under the lip 228, the spring finger 226 prevents the retainer 216 from retracting and keeps the retainer 216 engaged with the adjuster plug 212 and the adjuster boss 214. Figure 13 Shoulder 230 adjacent to spring finger 226 is also shown. In some embodiments, the geometry of spring finger 226 may be selected relative to adjuster plug 212 such that spring finger 226 is slightly embedded in adjuster plug 212, thereby supplementing the holding force provided by lip 228.

[0058] The disclosed mechanical retaining device allows the adjuster plug 212 to be set to the desired position and then locked in place without a curing step. Thus, the retainer 216 can reduce sensitivity to contaminants present on the threaded interface, reduce variations related to adhesive application and curing conditions, and facilitate readjustment or disassembly because the retaining function is provided by a removable mechanical component rather than by the engaged threaded interface. Depending on the embodiment, the disclosed arrangement also allows the rotational locking features on the adjuster boss 214 and the adjuster plug 212 to be incorporated into components that can be manufactured by die casting, stamping, or molding.

[0059] although Figure 8 , Figure 9A and Figure 9B An example of a polymer bent ring is shown, while Figures 10-13 An embodiment of stamped metal is shown, but the disclosed features can be used independently or in combination, provided they are compatible with the intended design. For example, the retainer can use a radially expandable ring body with an enlarged retaining feature for axial retention, or it can be used together with a toothed rotary locking feature and an elastic finger element for axial retention. The material selection, number of teeth, tooth profile, groove geometry, finger geometry, and interference fit between the retaining feature and the adjuster plug 212 can be selected based on the required mounting force, retaining torque capacity, environmental exposure, and manufacturing process of a particular steering system.

[0060] refer to Figure 14 Another embodiment of this disclosure is shown, and is generally indicated by reference numeral 300. An adjuster plug 312 is screwed into an adjuster boss 314 of a rack and pinion housing (not shown). After the clearance between the rack bearing and the adjuster plug is adjusted, a retainer 316 is inserted to lock the adjuster plug 312 into the adjuster boss 314.

[0061] Now for reference Figures 14-16 The end of the regulator boss 314 includes a circularly patterned groove 320 that engages with external teeth 322 on the retainer 316. The circular pattern of the groove is intended to be a die-cast feature in the rack and pinion housing. Circularly patterned teeth 324 on the regulator plug 312 engage with an inner groove 326 on the retainer 316. The engagement of the groove and teeth restricts the rotation of the regulator plug 312.

[0062] When the retainer 316 is inserted, the retaining clip 328 expands beyond the major diameter of the adjuster plug teeth and then engages in the adjuster plug recess 330. This provides reliable axial retention of the retainer 316 on the adjuster plug 312 and prevents the groove and teeth from disengaging. The expansion of the retaining clip 328 during assembly and mating into the adjuster plug recess is intended to be similar to that of a common external retainer ring fitted into a recess on a shaft. The retainer 316 can expand beyond the tapered mandrel and be axially pressed into place, or it can be expanded using ordinary retainer pliers for assembly. If the adjuster plug must be removed, the retainer can be easily removed using retainer pliers. This is an advantage over the other embodiments discussed.

[0063] Compared to thread-bonded adhesives and competing designs, the steel external snap ring regulator plug retainer retains the advantages of other retainer embodiments. Like other embodiments, the steel external snap ring retainer is designed so that the interface between the regulator plug and the rack housing can be produced using a die-casting process.

[0064] Although this disclosure has been described in detail with reference to only a limited number of embodiments, it should be readily understood that this disclosure is not limited to these disclosed embodiments. Rather, modifications may be made to this disclosure to include any number of variations, alterations, substitutions, or equivalent arrangements not previously described, but such variations, alterations, substitutions, or equivalent arrangements are consistent with the spirit and scope of this disclosure. Furthermore, while various embodiments of this disclosure have been described, it should be understood that aspects of this disclosure may include only some of the described embodiments. Therefore, this disclosure should not be considered as limited to the foregoing description.

Claims

1. A rack and pinion type adjuster assembly, comprising: A housing including an adjuster boss having a hole and first engagement features circumferentially distributed around an adjustment axis; An adjuster plug, configured to be received by the hole and movable relative to the adjuster boss along the adjuster axis to set the position of the rack support member, the adjuster plug including a second engagement feature circumferentially distributed around the adjuster axis; as well as A retainer, separate from the housing and the adjuster plug, is configured to be positioned in one of a plurality of angular positions after the adjuster plug is positioned relative to the adjuster boss at a selected angular position. The retainer includes: a first retainer engagement portion configured to engage with a first engagement feature; a second retainer engagement portion configured to engage with a second engagement feature; and an axial retaining portion configured to retain the retainer relative to the adjuster plug. The first retainer engagement portion and the first engagement feature are configured to restrict rotation of the retainer relative to the regulator boss, and the second retainer engagement portion and the second engagement feature are configured to restrict rotation of the regulator plug relative to the retainer, such that the retainer mechanically locks the regulator plug at a selected angular position relative to the regulator boss without requiring an adhesive bond between the regulator plug and the regulator boss.

2. The rack and pinion type adjuster assembly of claim 1, wherein the first engagement feature includes a recess or groove of the adjuster boss, and wherein the first retainer engagement portion includes a lug received by the recess or groove.

3. The rack and pinion type adjuster assembly according to claim 2, wherein the recess or groove is formed as a die-cast feature of the housing.

4. The rack and pinion type adjuster assembly of claim 1, wherein the second engagement feature includes a gear ring disposed on the adjuster plug, and wherein the second retainer engagement portion includes a tooth segment configured to engage with the gear ring.

5. The rack and pinion adjuster assembly of claim 4, wherein the tooth segment comprises two circumferentially spaced tooth segments.

6. The rack and pinion adjuster assembly of claim 4, wherein the gear ring and gear segments include tapered, chamfered, or inclined lead-in surfaces configured to facilitate assembly of the retainer to the adjuster plug.

7. The rack and pinion adjuster assembly of claim 1, wherein the axial retaining portion includes a retaining rib configured to expand radially across the outer diameter region of the adjuster plug and engage with the undercut of the adjuster plug.

8. The rack and pinion adjuster assembly of claim 7, wherein the retainer defines a clearance relative to the threaded small diameter of the adjuster boss adjacent to the retaining rib to allow the retaining rib to expand radially during assembly.

9. The rack and pinion type adjuster assembly of claim 8, wherein the undercut portion is formed on the adjuster plug.

10. The rack and pinion adjuster assembly of claim 1, wherein the retainer comprises an injection-molded polymer retainer.

11. The rack and pinion type adjuster assembly of claim 1, wherein the adjuster plug comprises a zinc die-cast component.

12. The rack and pinion adjuster assembly of claim 11, wherein the second engagement feature has a toothed section whose dimensions are adapted to be formed by die casting.

13. The rack and pinion adjuster assembly of claim 1, wherein the retainer comprises a curved ring body configured to expand radially during installation and return to its free-state shape after installation.

14. The rack and pinion adjuster assembly of claim 13, wherein the axial retaining portion includes an enlarged retaining snap that extends along the arc length of the curved ring body and is configured to engage with a groove of the adjuster plug.

15. The rack and pinion adjuster assembly of claim 1, wherein the retainer comprises a stamped steel retainer.

16. The rack and pinion adjuster assembly of claim 15, wherein the axial retaining portion includes a spring finger configured to clamp below the lip of the adjuster plug.

17. The rack and pinion adjuster assembly of claim 16, wherein the spring finger is configured to be embedded in the adjuster plug.

18. A rack and pinion steering system, comprising: A rack housing that defines a rack housing bore extending along its axis; as well as Regulator plug assembly, including: A regulator plug is disposed at least partially within the regulator hole; as well as A locking ring, at least partially disposed within the regulator hole, wherein the locking ring includes a plurality of radially external teeth that engage with a plurality of housing teeth, and wherein the locking ring includes a plurality of radially internal teeth that engage with a plurality of regulator plug teeth, wherein the number of teeth of the plurality of radially internal teeth differs from the number of teeth of the plurality of radially external teeth by one.

19. The rack and pinion adjuster assembly of claim 18, wherein the number of radially outer teeth differs from the number of radially inner teeth by one to define a vernier relationship, the vernier relationship being configured to allow the retainer to engage with the housing teeth and the adjuster plug teeth at incremental angular positions around the adjustment axis.

20. A rack and pinion type adjuster assembly, comprising: A housing, comprising an adjuster boss having a boss engagement feature arranged around an adjustment axis; An adjuster plug, configured to be received by an adjuster boss and positioned along the adjusting axis to set a rack support position, the adjuster plug including a plug engagement feature and an axial retention feature; as well as A retainer, separate from the housing and the regulator plug, includes: a retainer body; a first retainer engagement portion configured to engage with the boss engagement feature to restrict rotation of the retainer relative to the regulator boss; a second retainer engagement portion configured to engage with the plug engagement feature to restrict rotation of the regulator plug relative to the retainer; and a resilient axial retaining portion configured to radially deflect outward during installation of the retainer onto the regulator plug, and radially inward after installation to engage with the axial retaining feature, thereby axially retaining the retainer relative to the regulator plug. The resilient axial retaining portion includes a retaining clip or a spring finger, the retaining clip extending along the arc length of the retaining body, and the spring finger configured to clamp below the lip of the adjuster plug.

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