Tear-off device for a motor vehicle steering column

Abstract

An energy absorption device for a steering column assembly comprising an energy absorption plate, a gear plate, and a breakaway bracket. The energy absorption plate may have a first end and a second end with a curved portion therebetween. The gear plate may be engageable with and / or disengageable from a locking mechanism. The energy absorption plate may be attached to the gear plate at or near one end of the gear plate. The breakaway bracket may be attached to the gear plate at or near an opposite end of the gear plate.

Description

ASSERTING THE BENEFITS OF THE FILING DATE

[0001] This application claims the benefit of the filing date of US Provisional Application No. 63 / 430,787, filed December 7, 2022, the contents of which are hereby expressly incorporated by reference in their entirety for all purposes. AREA

[0002] Generally, the present teachings relate to an improved collapsible steering column assembly and associated methods. More particularly, the present teachings relate to an internally collapsible, tiltable, and / or telescopically adjustable steering column system having an energy absorption assembly configured to absorb energy in the event of an impact exceeding a threshold load. BACKGROUND

[0003] A vehicle collision typically involves two impacts. In the primary impact, the vehicle collides with another object. In the secondary impact, a vehicle occupant strikes a vehicle component. For example, a driver sometimes strikes the steering wheel due to inertia. To protect drivers from such secondary impacts, it has become common practice to use a shock-absorbing steering column. A folding steering column system is an example of a shock-absorbing steering column.

[0004] The structure of a shock-absorbing steering column device is designed so that, in the event of a secondary impact involving the driver, the impact energy acts on the steering column in the direction of travel of the vehicle. The steering column or parts of it may detach from one or more attachment points on the vehicle body and move forward (e.g., in a collapse stroke), so that the impact energy is absorbed during the collapse stroke. An external collapsing steering column assembly is an example of a system in which the entire column translates relative to its attachment points. An internal collapsing steering column assembly is typically attached to one or more attachment points near one of the ends of the assembly within the vehicle. During a collapse stroke due to a secondary impact, components of the assembly collapse longitudinally (e.g., generally within the volume they occupy during normal operation in the vehicle, i.e.,They generally fall within their footprint within the vehicle, but generally do not fall beyond a certain distance relative to a predetermined attachment point. An internal drop system thus has a stroke but can remain fixed to the one or more attachment points on the vehicle.

[0005] In many applications, steering column assemblies incorporate a tilt or a telescopic function, or both. For these applications, it is common to use levers for the manual execution of such functions by a vehicle user. For example, a so-called "manual tilt and telescopic" steering column assembly incorporates both a tilt ("rake") and a telescopic ("reach") function, with a lever that the vehicle user can manually release to adjust the tilt and telescopic adjustment to a selected position and then re-engage to lock the steering column in the selected position.

[0006] Some current assemblies incorporate an energy absorption plate or band within an energy absorption assembly. Some assemblies incorporate a breakaway element or device that requires the use of fasteners within the deformation area of ​​the energy absorption plate or band. Features in this area can affect the column's collapse load.

[0007] While existing designs serve their intended purpose, there remains a need for a different arrangement of the breakaway device relative to the energy absorption plate. There is a need for more space between the deformation area and the breakaway device. There is a need to add the necessary geometry to ensure that the breakaway devices fail in a controlled shear for better predictability. Predictability can be important because flexural failure, tensile failure, or a combination of shear, flexion, and tensile force can be difficult to predict and / or control. As an example, U.S. Patent No. 11,440,578 shows a rivet through the deformable portion of the energy absorption band. This positioning compromises the force-displacement profile of the steering column.Furthermore, the rivet lacks features that produce shear fracture, so it is likely to fail in a bending / tensile mode. Therefore, alternative designs are required. SUMMARY

[0008] The present teachings utilize a simple yet elegant design approach that allows relatively few components to be used to manufacture a steering column assembly, such as a collapsible steering column assembly. The steering column assembly may be an adjustable (e.g., in tilt and / or reach) steering column assembly. For example, while applicable to outward-folding assemblies (contemplated by the present teachings), the steering column assembly described herein may be an inward-folding assembly. It may be an assembly secured to one or more attachment points in a vehicle such that, upon a secondary impact, the steering column assembly resists forward movement substantially beyond the one or more attachment points (e.g., about 10 mm or more, or about 20 mm or more).It may be a collapsible steering column assembly that exhibits relatively good energy absorption characteristics, particularly in a secondary impact. It may be a collapsible steering column assembly that exhibits longitudinal displacement (e.g., forward movement) of one or more components of the assembly (e.g., a column tube) in a secondary impact.

[0009] Within the scope of the present teachings, a collapsible steering column assembly is provided having any combination of the following features in the following paragraphs. It may be an internally collapsible assembly or an externally collapsible assembly. However, an internally collapsible assembly is particularly attractive, wherein at least a portion of the assembly is secured against substantial forward movement (e.g., about 50 mm or less, about 20 mm or less, or about 10 mm or less) within a vehicle. The steering column assembly may include a steering wheel position adjustment portion (e.g., an assembly configured to adjust the tilt and / or reach of a steering wheel relative to a vehicle operator, such as a telescoping tubular assembly).It may include one or more brackets for at least partially supporting the steering wheel position adjustment portion and / or for securing the assembly within the vehicle. It may include a fastener (e.g., as described elsewhere herein, a rocker bolt or other elongated member, such as one configured to exert a fastening force to hold a steering column assembly in a desired position) for fixing the position of the steering wheel position adjustment portion (e.g., by actuating a lever configured to be actuated by an operator to apply or release a fastening force). During normal operation, the steering column assembly may be in a secure engagement position in which at least a portion of the steering shaft support structure (e.g., a column tube, a column housing, or both) is fixed in a fixed position within the steering column assembly.The safe engagement position may be the position selected by the user in an adjustable steering column arrangement.

[0010] The present teachings relate to an energy absorption device for a steering column assembly. The energy absorption device may comprise an energy absorption plate, a gear plate, a breakaway bracket, or any combination thereof.

[0011] The energy absorption assembly may include an energy absorption plate. The energy absorption plate may have a first end and a second end with a curved portion therebetween. The energy absorption plate may be operatively connected to a column tube of the steering column assembly. The energy absorption plate may be connected to a column tube via one or more fasteners, such as rivets. The rivets may be shear-resistant rivets.

[0012] The energy absorption device may include a gear plate. The gear plate may be configured to be engaged with and / or disengaged from a locking mechanism. A gear plate may be formed integrally with the energy absorption device (e.g., as a single piece). A gear plate may be separate from the energy absorption plate. The gear plate and the energy absorption plate may be formed from different materials, with different strengths (e.g., tensile strength), different thicknesses, or a combination thereof. The energy absorption plate may be attached to and / or extend from the gear plate (e.g., at or near an end of the gear plate). A fastener may connect the energy absorption plate and the gear plate at a joint.A slot may be provided at the junction between the gear plate and the energy absorption plate (e.g., in the energy absorption plate, in the gear plate, or in both). The gear plate may have a substantially flat surface. The gear plate may be configured to be positioned substantially parallel to the surface of a column tube of the steering column assembly. The gear plate may have a toothed surface configured to engage a locking pin to position the steering column assembly in a desired orientation (e.g., a desired telescopic position).

[0013] The energy absorption device may include a breakaway mount. The breakaway mount may include one or more features that engage or secure the breakaway mount to another part of the steering column device. The breakaway mount may be attached to a column tube (e.g., during normal operation or prior to an impact that exceeds a threshold load). The breakaway mount may engage one or more openings in a column tube (e.g., during normal operation or prior to an impact that exceeds a threshold load). The breakaway mount may include a column tube pin configured to be received in an opening in a column tube. The breakaway mount may be attached to the gear plate (e.g., at or near an end of the gear plate opposite the energy absorption plate).The breakaway bracket may include one or more gear plate anchors for engaging a portion of the gear plate. The gear plate may include an opening for receiving the gear plate anchor or a portion thereof. The gear plate anchor may engage the opening in the gear plate via one or more wings or tabs. The gear plate anchor may be connected to the gear plate, for example, via a snap fit. The breakaway bracket may include a slot for receiving and engaging a portion of a gear plate.

[0014] The breakaway mount may be configured to couple one end of the energy absorption plate to a column tube of the steering column assembly during normal operation. The breakaway mount may be configured to decouple the breakaway mount from the column tube when an input load exceeds a threshold load. The threshold load may be about 250 N or more, about 350 N or more, about 500 N or more, about 600 N or more, or about 800 N or more. The threshold load may be about 10,000 N or less, about 8,000 N or less, about 6,000 N or less, about 5,000 N or less, or about 1,000 N or less.

[0015] The present teachings also relate to an assembly for a steering column assembly that includes the energy absorption assembly and a column tube. The gear plate can be selectively secured to the column housing via an adjustment assembly of the steering column assembly (e.g., a telescopic position locking mechanism). An energy absorption plate can be secured to the column tube with one or more fasteners. The fasteners can be rivets, such as shear-resistant rivets. The breakaway bracket can include a column tube pin extending from the breakaway bracket and received in the column tube (e.g., an opening in the column tube). The breakaway bracket can be secured to the column tube via one or more fasteners. The fasteners can be rivets, such as shear pins.The breakaway bracket may comprise one or more fasteners, one or more column tube pins, or a combination thereof. Upon an impact exceeding a threshold load (e.g., a load of approximately 500 N or more, approximately 6000 N or less, or both), the breakaway bracket may detach from the column tube while the energy absorption plate remains attached to the column tube. The column tube pin, the shear pins, or a combination thereof may shear to allow the breakaway bracket to detach from the column tube. Alternatively or additionally, it is contemplated that the breakaway bracket may be attached to the column tube using one or more fasteners, such as a shear-resistant rivet. The transmission plate anchorage may be arranged such that the breakaway bracket detaches from the transmission plate upon an impact load exceeding a threshold load.

[0016] The present teachings also relate to a steering column assembly comprising any combination of features, including, but not limited to, a column tube, a steering shaft at least partially rotatably supported by the column tube, a bracket for at least partially supporting the column tube, an adjustment subassembly, and the energy absorption assembly described herein. The adjustment subassembly may be configured to selectively adjust the steering shaft, the column tube, or both in a forward or rearward direction generally along the longitudinal axis. The adjustment subassembly may be configured to selectively raise or lower the steering shaft, the column tube, or both.

[0017] As can be seen, it is thus possible to realize a unique assembly (and associated methods) that can adjust (e.g., tilt, telescope, or both) a steering column assembly, facilitate assembly, reduce the number and / or size of required parts, enable energy absorption and / or breakaway upon impact above a threshold load, or a combination thereof. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a side perspective view of an illustrative steering column assembly according to the present teachings. Fig. 2 is a perspective view of an adjustment subassembly of a steering column assembly according to the present teachings. Fig. 3 is an exemplary energy absorption arrangement according to the present teachings. Fig. 4 is an exploded view of the energy absorption assembly of Fig. 3. Fig. 5A and Fig. 5B show an exemplary breakaway mount according to the present teachings. Fig. Figure 6 shows an exemplary energy absorption assembly attached to a partially transparent column tube. Fig. 7 shows an exemplary energy absorption arrangement according to the present teachings. Fig. 8 shows an exemplary energy absorption plate and telescopic stop holder according to the present teachings. Fig. 9 shows an exemplary breakaway mount according to the present teachings. DETAILED DESCRIPTION

[0018] The present teachings are disclosed herein in as much detail as necessary; however, it should be understood that the disclosed teachings are merely examples that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Some features may be omitted for clarity or other reasons. Therefore, the specific structural and functional details disclosed herein are not to be considered limiting, but merely as a representative basis for one skilled in the art to variously apply the present teachings.

[0019] The present teachings may incorporate features of the steering column assembly (e.g., a positive locking assembly) of U.S. Publication No. 2021 / 0394816, the contents of which are hereby expressly incorporated by reference in their entirety for all purposes herein.

[0020] In general, and as will be apparent from the following description, the present teachings relate to a steering column assembly. The steering column assembly may include a mounting portion for mounting the steering column assembly in a vehicle in a fixed operating position. The assembly may have a collapsible and / or telescopic portion, at least a portion of which is configured to move forward relative to the mounting portion while the mounting portion generally remains in its fixed operating position (e.g., any movement of the mounting portion may be limited and / or controlled to an amount of about 50 mm or less, about 20 mm or less, or about 10 mm or less). The basic concepts of the teachings include a steering column assembly that, in the event of an impact, for example, a secondary impact resulting in a load of a certain threshold (e.g.,a load of about 0.5 kN or more, or about 2 kN or more; a load of about 10 kN or less, or about 6 kN or less) occurs, can be configured such that at least a portion of the collapsible portion extends forward within the vehicle. The forward travel can be telescopic (e.g., at least one first structure operatively connected to a steering wheel (e.g., a column tube) can be translated forward (e.g., along an axis substantially parallel to a vehicle longitudinal axis (e.g., within about 10° of parallelism)) in a vehicle relative to at least one second structure that can at least partially surround the at least one first structure (e.g., a column housing).

[0021] The teaching contemplates that the steering column assembly include a tilt or reach adjustment configured to allow a user to select a tilt angle of a steering wheel, a reach adjustment configured to allow a user to select a suitable fore-and-aft position of the steering wheel, or both. Generally, each such adjustment may be controlled by a suitable user operating device (e.g., a lever, an electromechanical actuator, a motor, or otherwise). In a manually operated system, a lever or other user operating device may be configured to control a force exerted to maintain the collapsible portion in a user-selected position.For example, a lever or other user operating device may be operatively connected to one, two, or more mechanisms to releasably (and possibly also adjustably) connect two or more components of the collapsible portion. Particularly with respect to adjusting the tilt of the assembly, the securing may be implemented by a suitable securing element (e.g., an elongated force-applying element) such as a bolt (e.g., a tilt bolt), a rod, a strap, a bar, a band, a wedge, a cam, or other suitable element, or a combination thereof. For example, the securing element may be configured to rotate a cam or rotary member upon actuation of the user operating device and engage it with a wall of a tilt plate to secure the steering wheel at its desired angle.Upon actuation of the user control device, a pin can be pushed out of or engaged with one or more engagement elements (e.g., a toothed portion, a shape complementary to the pin, or one or more openings) arranged on or attached to a column tube, thereby enabling telescopic adjustment.

[0022] In the illustrated examples, aspects useful for an internally collapsible steering column assembly for a motor vehicle are described. In general, an assembly according to the present teachings may include a steering stem (e.g., one that can be coupled to a steering wheel or other steering device) and / or a column tube that supports the steering stem (e.g., via one or more bearings). A column housing may be used. It may be configured to be telescopically coupled to the column tube (e.g., each may have a longitudinal axis that is generally parallel or even coaxial with each other). One or more brackets may be used to at least partially attach either the column tube or the column housing, or both, to the vehicle (e.g., to a transverse structure). The bracket or one or more tilt plates may comprise a suitable portion (e.g.,a slot, such as a generally vertically oriented slot) configured to provide a guide structure for a tilt function. A user operating device, such as a lever, may be used to allow a user to manually actuate and / or adjust the assembly. An electromechanical device that applies or releases a force in response to a signal from an actuating switch may be used. The steering column assembly may be configured so that, in the event of a threshold load encountered during an impact, such as a secondary impact, at least a portion of the assembly (e.g., the column tube, the steering shaft, the steering wheel, or a combination thereof) can be translated forward from its typical operating position. This allows the column tube to be translated forward relative to the column housing, taking the steering wheel attached thereto with it.As a result, it is possible for the steering wheel to be moved forward, e.g. away from the user.

[0023] The teaching relates to an assembly typically comprising a column tube, a steering shaft, a bracket, a column housing, and a steering wheel adjustment subassembly (e.g., a manually operated steering wheel adjustment subassembly). The steering wheel adjustment subassembly may include a lever (as described or another user actuation device) configured to actuate (e.g., manually actuate) the subassembly by tilting, telescoping, or both. Instead of or in addition to manual actuation via a lever, one or more motors may be used. For example, one or more motors or other electromechanical actuators may effect tilting, telescoping, or both.It is envisaged that a lever may be used to effect one tilt or telescoping function, while a motor or other electromechanical actuator may be used to effect the other function, i.e., tilt or telescoping. At least one engagement element (e.g., a pin) may be engaged and disengaged from the column tube or a structure attached thereto to selectively lock the steering stem in a position (e.g., telescoping position) desired by the user (e.g., via the lever). One or more pivot members may be engaged (e.g., by interference fit) with a wall of a tilt plate defining a vertical slot for setting the tilt position desired by the user (e.g., via the lever).During an impact, such as a secondary impact, the column housing remains in a substantially fixed position relative to a forward pivot attachment location (e.g., any forward movement is limited to a relatively small amount (e.g., about 20 mm or less, or about 10 mm or less)).

[0024] The assemblies described herein generally comprise a tube operatively connected to a steering wheel (not shown), for example, via a steering shaft. Such a tube, referred to herein as a column tube, typically has a hollow cavity along at least part (if not all) of the length of the tube and may be sized and configured to receive and support a rotatable shaft, namely a steering shaft and possibly one or more bearings. Both the shaft and the tube have a longitudinal axis. When installed in a vehicle, the longitudinal axes of the shaft and the tube (and the steering column assembly in general) may be generally coaxial, generally parallel to a longitudinal axis of the vehicle, or each may be oriented parallel to one another.The shaft and column tube may consist of or contain a suitable metal, for example one or more of the metals iron (e.g. steel), magnesium, zinc or aluminum.

[0025] The column tube may be generally hollow. The column tube may be generally cylindrical. The column tube may have a generally rounded cross-section. For example, the cross-section may be generally circular. The column tube may have a non-circular cross-section. For example, the column tube may have one or more straight sections in its cross-section. The column tube may have one or more angled sections in its cross-section. For example, the column tube may have a square or rectangular cross-section. It may have a front end section and a rear end section and a longitudinal axis. The front or rear end section, or both, may include a suitable bearing that supports the steering stem for rotation.

[0026] The steering stem may have a rear end portion configured to receive a steering wheel (not shown). It may have a front end portion that extends through and can be retained by a bearing, a key lock ring, or both. As previously mentioned, the steering stem may be rotatably supported at least partially by the column tube and may have a longitudinal axis that may be substantially coaxial with the longitudinal axis of the column tube.

[0027] The column tube may have one or more openings along its length. Such openings may be configured to receive a fastener, such as a rivet or a pin extending from another element of the assembly (e.g., a column tube pin of a breakaway bracket).

[0028] One or more suitable brackets may be used. Each such bracket may include a portion for securing the steering column assembly within a vehicle (e.g., it may be secured to a vehicle structure such as a cross member, a dashboard, or the like). The bracket may have a portion that is at least partially adjacent to the steering stem support structure (e.g., the column tube, the column housing, or both). For example, a bracket may include or be connected to one or more downwardly depending (downwardly facing) walls (e.g., tilt plates) that define a tilt portion of the bracket. One or more of the downwardly depending walls (e.g., tilt plates) may be configured to form a structure having an elongated slot that provides a guide for the tilt function (e.g.,a guideway for a fastener such as a tilt bolt when it is moved during adjustment; this can limit upward and downward movement). The bracket can be an integrated structure such that the tilt section and the mounting section form a single structure (e.g., a casting, a stamping, or a combination thereof). The bracket can be made of separate structures that are assembled to define the mounting and tilt sections into a single structure. The mounting section can be omitted and / or located elsewhere within the steering column assembly. The tilt section can be omitted. A mounting bracket can be used separately from a structure that defines a tilt section.Examples of mounts that may be used in addition to those described herein include those set forth in U.S. Publication No. 2010 / 0300238 (which is incorporated by reference in its entirety for all purposes; see, for example, the description of mount 20); U.S. Patent No. 6,467,807, which is incorporated by reference in its entirety for all purposes (see, for example, the description of mounts 6 and 7 and the associated structure); and U.S. Patent No. 6,467,807, which is incorporated by reference in its entirety for all purposes (see, for example, the description of mounts 6 and 7 and the associated structure).

[0029] One or more brackets (e.g., tilt brackets), tilt plates, or a combination thereof may be used and configured to receive at least a portion of a steering shaft support structure (e.g., at least a portion of the column tube, the column housing, or both) and / or to secure the steering column assembly within the motor vehicle. For example, a tilt bracket of the present teachings may include an upper portion configured to be attached to a vehicle structure, such as a cross member, an instrument panel, or the like. The bracket (e.g., tilt bracket) may include a pair of generally opposing, downwardly directed or projecting walls (e.g., tilt plates). The bracket (e.g.,The tilt mount (e.g., tilt bracket) may comprise a structure or be directly or indirectly connected to one or more plates that at least partially flank at least a portion of the steering shaft support structure (e.g., the column tube). The mount (e.g., tilt bracket) may comprise, or be directly or indirectly connected to, a pair of opposing side walls, a top wall configured to be attached to the vehicle (e.g., to a cross member, an instrument panel, or other suitable structure), or a combination thereof. The side walls may project outwardly relative to the top wall (e.g., they may be generally orthogonal or oblique to the top wall). The mount (e.g., tilt bracket) may comprise a single downwardly projecting or aligned wall. The mount (e.g., tilt bracket) may be disposed laterally above and outwardly of an opposing portion of the column housing.

[0030] It is possible that the teachings contained herein could be used for steering column assemblies that are not adjustable but still require folding. In such cases, there is no hardware for tilt or reach adjustment. However, the concepts contained herein can still be implemented to achieve folding. A bracket may secure one or both elements of a column housing or a column tube to a vehicle. An energy absorption device may be used to limit the forward movement of one or more components of the steering column assembly, such as the column tube, the steering stem, or both.

[0031] However, the present teachings are particularly suitable for steering column assemblies that are adjustable (e.g., in tilt and / or reach). The assembly may include a manually operated steering wheel adjustment subassembly configured to selectively adjust the steering stem in a forward or rearward direction generally along the longitudinal axis, to selectively raise or lower the steering stem, or both. The steering wheel adjustment subassembly may include a lever or other feature configured to manually actuate the subassembly. The subassembly may include at least one engagement element (e.g., a pin, such as a locking pin) that is engaged and disengaged from the column tube or a structure attached thereto (e.g., a gear plate) to selectively lock the steering shaft in a user-desired position (e.g., a forward or rearward position).Other suitable hardware may be used in the subassembly, such as one or more thrust bearings, one or more nuts, one or more cam locating elements, and / or one or more cam moving elements (e.g., where the cam locating and cam moving elements are in an opposing operative relationship, such as through mutual contact). The subassembly may also include one or more spacers or dampers to cushion shocks between elements, allow for smoother adjustment, guide the deformation of one or more features in the assembly, or a combination thereof.

[0032] A column housing may be pivotally mounted at a pivot mounting location (e.g., a fixed mount) within the motor vehicle. The pivot mounting location may be located, for example, at or within about 20, about 30, about 40, or about 50 mm of a forward end of the column housing. The pivot mounting location may be located at a bottom of the column housing, at a top of the column housing, or at a location between the top and bottom of the column housing. The column housing may at least partially surround the column tube. The column housing may include one or more bosses or other structure to receive a biasing device (e.g., a spring) connecting the column housing to the tilt bracket. The column housing may be a cast structure (e.g., including a metal such as aluminum, magnesium, zinc, and / or iron (e.g., steel)).During a secondary impact, the column housing may remain in a substantially fixed position relative to the pivot mounting location. It may be mounted to move forward by a relatively small amount (e.g., about 50 mm or less, about 20 mm or less, or about 10 mm or less).

[0033] During an impact (e.g., a secondary impact), the structures of the present teachings may be configured to include any suitable combination of elements arranged to allow a column tube, a steering shaft, or both to translate longitudinally forward relative to the column housing.

[0034] The teachings also generally contemplate the possible use of one or more energy absorption devices or assemblies. The energy absorption devices or assemblies may be any suitable device configured to deform elastically, plastically, and / or elastically and plastically. During the course of deformation, the energy absorption devices are thus configured to absorb energy through the deformation. The energy absorption device may be operatively connected or arranged between two or more components. It may be configured to limit the relative movement between two or more components. The energy absorption devices may be wires, plates, strips, or the like. They may have a constant profile or a profile that varies along their length. They may be deployed to define one or more fixedly defined sections (e.g.,one end). They can have one or more free ends.

[0035] Energy absorption or control may be provided by one or more elements that detach from another element within the assembly upon an impact that exceeds a threshold load. For example, a bracket attached to the column tube may break or detach from the column tube upon an impact that exceeds a threshold load. The fasteners, such as rivets, or features extending from the bracket into an opening in the column tube that connect the components may shear, allowing the breakaway. Energy absorption or control may be provided by elements of the assembly that mesh with one another. For example, a gear plate may have one or more features that mesh with one or more features of an energy absorption plate.A gear plate may have one or more features that engage with a breakaway retainer.

[0036] The present assembly may utilize an energy absorption structure of the type or functioning as described in U.S. Publication No. 2013 / 0233117, which is incorporated herein by reference for all purposes. For example, the present arrangement may include at least one plastically deformable energy absorption device (e.g., a flexure plate, wire, or other structure configured to be at least partially supported by the column housing), wherein the energy absorption device, in use, absorbs energy through plastic deformation during the secondary impact after the steering shaft support structure (e.g., column tube and steering shaft) begins to translate along the column housing. Each plastically deformable energy absorption device may thus limit the amount of longitudinal movement of the column tube, the steering shaft, or both.

[0037] The present invention relates to an adjustment subassembly. The adjustment subassembly may comprise a tilt adjustment assembly, a telescopic adjustment assembly, or both. One or more components of the adjustment subassembly may effect or assist both tilt adjustment and telescopic adjustment. For example, by operating a user control device, such as a lever, both the telescopic adjustment assembly and the tilt adjustment assembly may be locked and / or unlocked.

[0038] The present assembly comprises a tilt adjustment device. The assembly may include two or more tilt plates extending downwardly on opposite sides of the column tube, the column housing, or both. The tilt plates may have one or more slots. The slots may be generally straight. The slots may have a curve. The slots may be generally vertical. The slots may be at an angle to the longitudinal axis of the steering column assembly. A tilt bolt or other elongated fastener may extend between the two tilt plates, and the tilt bolt may be received in the slots. Height adjustment of the assembly may be accomplished by upward or downward movement of the tilt bolt within the slots when the user's control device, such as a lever, is in an unlocked position.The assembly can be held at the desired angle or height when the user's control device, such as a lever, is moved to the locked position.

[0039] To lock the assembly at a desired height or angle relative to the driver, the user actuating device, such as a lever, may actuate a locking system, such as a cam locking system. A pivot may be disposed in one or both slots of the opposing tilt plates in the tilt adjustment assembly. The pivot may, for example, be generally elongated or teardrop-shaped. The pivot may engage (e.g., via teeth) a wall defining the slot of the tilt plate when the lever or other user actuating device is in a locked position. A spring may be keyed to the tilt bolt and attached to the pivot so that when the lever is in a locked position, the spring pushes or rotates the pivot so that the teeth contact the tilt plate (e.g., a wall defining the slot).Due to the shape of the pivot, when the lever is in an unlocked position, the pivot can detach from the wall that defines the slot of the tilt plate (and the teeth can be free from the surface), and the pivot and tilt pin can move freely up or down within the slot to adjust the height and angle of the steering wheel for the driver or user.

[0040] The present disclosure also relates to a telescopic adjustment device. Features of the telescopic adjustment device may also serve to absorb energy and / or break off upon impact, for example, a secondary impact. Certain features of the telescopic adjustment device may be part of the energy absorption device. Features of the telescopic adjustment device, particularly those that serve to absorb energy or break off upon impact, are also useful in other form-fitting devices or non-form-fitting devices. Such use is also within the scope of the present disclosure. Although these features are advantageous in the exemplary form-fitting device described herein, the present disclosure is not limited to use in the form-fitting device described herein.

[0041] The telescopic adjustment unit and / or the energy absorption unit may include a gear plate. The gear plate may be configured to be operably attached to another part of the steering column assembly, such as the column tube, the column housing, or both. The gear plate may serve to provide an engagement area to lock the telescopic adjustment unit. The gear plate may include one or more features for attaching the gear plate to another part of the steering column assembly. The gear plate may include one or more openings for receiving a fastener (such as a rivet, pin, screw, bolt, or the like), one or more projections or fasteners (e.g., integrated fasteners) for receiving an opening elsewhere in the assembly (e.g., an opening in a column tube), or both.

[0042] The gear plate may be generally planar. The gear plate may have one or more segments or surfaces that are generally planar (e.g., a surface facing away from the member to which it is attached, such as the surface facing away from the column tube).

[0043] The gear plate may include one or more sidewalls. The sidewalls may extend generally transversely to the surface with the engagement region. The sidewalls may be configured to extend toward an outer surface of the column tube. The sidewalls may provide stability to the gear plate, ensure a desired alignment of the gear plate relative to the column tube, prevent the gear plate from rocking on the column tube, or a combination thereof.

[0044] The portion of the gear plate facing away from the column tube (or other member to which it is attached) is engageable with a fastener or pin, such as a spring-loaded locking pin. This locking pin can be actuated by the user's actuating device, such as a lever, of the steering column assembly. To engage the locking pin, the gear plate may have a friction surface, such as a toothed or textured surface. The gear plate may have a stepped surface. The gear plate may have a surface generally complementary to the portion of the locking pin with which it engages to enable locking engagement between the structures. The gear plate may have one or more openings for receiving a portion of the locking pin.

[0045] The adjustment subassembly may include a locking pin or other element configured to engage the gear plate to effect a locking engagement (e.g., locking after a telescopic adjustment). The locking pin may be pushed into and out of engagement with the gear plate depending on whether the assembly is in a locking or unlocking position. For example, the locking pin may be pushed toward the gear plate when locking the lever, and the locking pin may be lifted away from the gear plate when unlocking the lever to enable smooth telescopic adjustment. The locking pin may be in a substantially orthogonal relationship to the longitudinal axis of the column tube, substantially orthogonal to the longitudinal axis of the gear plate, or both.

[0046] The locking pin may include one or more features that allow it to engage and / or contact one or more other elements of the assembly. A plurality of teeth or other engagement features may be provided at or near one end of the locking pin for engagement with the gear plate. Other engagement features may include a textured surface, a stepped surface, a complementary surface to the surface of the gear plate with which it contacts, an extension for receipt in an opening, or the like, or a combination thereof.

[0047] A head may be located at an opposite end of the locking pin. The head may be housed in another part of the assembly, such as a preload plate. Within the assembly, the head of the locking pin may extend toward the lever of the adjustment subassembly, away from the column tube, or in both directions.

[0048] The locking pin may include a body portion. The body portion may serve to provide an area around which a spring (e.g., a return spring) may be disposed. The body portion may add length to the locking pin (e.g., to make the pin the required length for its intended purpose). The body portion may serve to connect the engaging element (e.g., teeth) to another portion of the locking pin (e.g., a lip).

[0049] The locking pin may have a lip. The lip may have a diameter or maximum width that is greater than that of the head, the body portion, or both. The lip may have one or more surfaces upon which pressure is exerted in a locked position, an unlocked position, or both. This may enable the locking pin to be engaged or disengaged from the gear plate. The bias plate may rest on the lip of the locking pin when the head of the locking pin is received therein. The bias plate may compress or bias the locking pin toward the gear plate via contact with the lip. In an unlocked position, a spring (e.g.a return spring) arranged around the body of the locking pin, come into contact with the lip on the opposite side to lift the locking pin from the gear plate and enable smooth telescopic operation.

[0050] The locking pin may have a generally circular cross-section. The locking pin may have a generally rounded cross-section. The locking pin may have one or more sections in which the cross-section includes one or more flat areas (e.g., D-shaped). The locking pin may have one or more generally flat surfaces extending along at least a portion of the length of the locking pin. The generally flat surface may extend along the length of the body of the locking pin, along the entire length of the locking pin, or both.The generally flat surface can reduce or prevent rotation of the locking pin within the assembly to ensure proper alignment between the locking pin and the gear plate, for example, between the teeth of the locking pin and the toothed surface of the gear plate.

[0051] The adjustment subassembly may include a bias plate. The bias plate may act as a spring and bias the locking pin into the gear plate (e.g., in the case of tooth-to-tooth engagement). The bias plate may have a portion that receives a portion of the locking pin. For example, the bias plate may have a pin opening for receiving the head of the locking pin. The bias plate may have a portion that contacts a contact portion of the user actuating device, e.g., a lever.

[0052] The preload plate may include an outer section. The preload plate may include an inner section. The preload plate may include an arcuate section connecting the inner section and the outer section. The arcuate section may provide some flexibility to the preload plate to allow it to flex or act like a spring. The inner and outer sections may be generally parallel to each other when at rest or when no forces are applied to them. The inner and outer sections may be forced towards each other by the flexibility of the arcuate section upon the application of a certain force or pressure (e.g., to form an angular relationship instead of a parallel relationship). The preload plate may have a generally C-shaped configuration.

[0053] The outer portion may comprise one or more contact elements for contacting the contact portion of the user operating device, such as a lever. For example, the outer portion may comprise one or more ribs, projections, or the like for contacting the contact portion in a locked position, an unlocked position, or both.

[0054] The inner segment may include a pin opening for receiving the head of the locking pin. The pin opening may have a shape substantially conforming to the shape of the head to reduce rotation or movement of the locking pin within the opening. This may be further achieved by the presence of one or more tabs on the opening. The tabs may extend toward the outer segment and contact the head of the locking pin to further retain the locking pin in position (e.g., by friction, preventing pivoting or rotation, or both).

[0055] For telescopic adjustment, the portion of the gear plate facing away from the column tube can engage a fastener, for example a spring-loaded fastener such as a locking pin, which can be actuated by the lever of the steering column assembly. The fastener can be passed through an opening in the column housing, the tilt plate, or both. The fastener can be positioned substantially perpendicular to the column tube. When the fastener, for example a spring-loaded fastener, is pushed or when pressure is applied (i.e., the spring is compressed), the tip of the fastener can be brought into engagement with the gear plate.For example, if the gear plate has a toothed surface, those teeth can engage a toothed end of a locking pin to form a locking engagement that prevents further movement of the column tube in a forward or rearward direction. The pressure or compression of the spring-loaded fastener can be provided by a portion of the lever or other user-operated device. The pressure can be applied to a bias plate that is distributed to the locking pin. In this way, the lever or other user-operated device can also allow the user or driver to control the telescopic adjustment of the steering column assembly in a forward and rearward direction. The lever can have a ramp portion or angled segment facing the column tube and / or column housing.When the lever is in a locked position, the ramp portion can contact the bias plate (e.g., at the contact point) or the head of the fastener, for example, a spring-loaded fastener such as a locking pin, thereby pushing the pin toward the column tube. When the lever is in an unlocked position, the spring-loaded fastener can be released, and when the spring returns to an uncompressed state, the tip or end of the fastener is released from engagement with the gear plate (e.g., the toothed surface), allowing a user to freely pull or push the steering wheel to telescopically adjust the position. Similarly, if the part of the gear plate facing away from the column tube has a series of holes or openings, the fastener can have a corresponding shape to fit precisely into the hole or opening.The telescopic assembly may instead include a slot or gap into which a fastener can be received. The fastener may have an elongated cross-section so that it can be freely slid into a position within the slot or gap and, when rotated, can prevent further movement (e.g., similar to the pivot and slot described herein with respect to tilt adjustment).

[0056] The steering column assembly may include an energy absorption assembly. The energy absorption assembly may be designed to absorb energy, particularly during an impact that exceeds a threshold load. Energy may be absorbed by plastic deformation of a portion of the assembly. Energy may be absorbed by elastic deformation of a portion of the assembly. Energy may be absorbed by one or more portions of the assembly breaking away from another portion of the assembly. Energy may be absorbed by a combination of these.

[0057] The energy absorption assembly may comprise a gear plate, an energy absorption plate, a breakaway bracket, or a combination thereof.

[0058] The gear plate may be as previously described. The gear plate may be generally planar. The gear plate may include one or more features for engaging other elements within the steering column assembly. The gear plate may include features for engaging a portion of an adjustment subassembly. A portion of the gear plate may engage a locking pin. For example, a toothed or textured surface may engage a complementary toothed or textured surface of one end of the locking pin.

[0059] The gear plate may be made of a material with sufficient strength so that it will not bend, break, or deform upon impact exceeding a threshold load (e.g., approximately 500 N or more, approximately 6000 N or less, or any range in between). The gear plate may be made of any suitable metal or metal alloy. Suitable materials may include aluminum, magnesium, zinc, and / or iron (e.g., steel).

[0060] The gear plate may include one or more features for engaging other parts of the energy absorption assembly. At or near one end of the gear plate, there may be an area configured for contacting and / or connecting to an energy absorption plate.

[0061] For example, an opening may be provided at or near one end of the gear plate for receiving a fastener to connect the gear plate to an energy absorption plate. A collar or extended portion may be provided at the opening to surround the fastener. This may provide stability, maintain the distance between the gear plate and a second segment of the energy absorption plate, reduce or prevent sway of the gear plate, maintain the position or orientation of the fastener, or a combination thereof. The collar or extended portion may function as a nut. The opening may be free of a collar or extended portion.

[0062] The gear plate may include one or more features for retaining a damper. A damper may be used as a stop within a telescoping assembly to prevent the column tube from translating excessively in a forward or reverse direction. The damper may serve to maintain the position of the gear plate, provide stability to the gear plate, maintain the distance between the gear plate and a second segment of the energy absorption plate, reduce or prevent sway of the gear plate, or a combination thereof. The damper may serve to protect the gear plate. The damper may serve to absorb energy within the energy absorption assembly. The damper may serve to maintain the position of the gear plate and / or prevent movement of the gear plate upon contact between the gear plate and a locking pin.

[0063] A damper can be located on one or more sides of the gear plate. For example, a damper can be located on one or both longitudinal edges of the gear plate. The damper can have one or more sections that are wider than other sections of the damper (e.g., in a T-shape). This can help ensure a smooth stop during movement of one or more components of the steering column assembly.

[0064] The damper can be made of polymer. The damper can be made of an elastic, springy, and / or elastomeric material. The damper can be made of plastic.

[0065] The damper may consist of one or more parts. The damper may comprise two separate parts located on opposite sides of the gear plate. The damper may be a single piece. The damper may have parts located on opposite sides of the gear plate, with an adjacent part disposed between the gear plate and the second surface of the energy absorption plate.

[0066] The energy absorption assembly may include a component for energy absorption. Such a component may be a wire, a plate, a strip, or the like. For simplicity, the component is referred to herein as an energy absorption plate. The energy absorption plate may deform upon impact exceeding a threshold load. The energy absorption plate may have sufficient strength so that it deforms without breaking. The energy absorption plate may be made of, for example, plastic, metal, a metal alloy, or a combination thereof. Suitable materials may include aluminum, magnesium, zinc, and / or iron (e.g., steel).

[0067] The energy absorption plate may have a first end and an opposite second end. The energy absorption plate may be arranged such that the plate is bent, curved, or otherwise shaped such that the plate has a non-linear and / or non-planar configuration (e.g., where the first end and the second end are not in the same plane). A curved portion may be located between the first end and the second end. A segment (e.g., a first segment) of the energy absorption plate may be located between the first end and the curved portion. The segment may be generally planar. A segment (e.g., a second segment) of the energy absorption plate may be located between the second end and the curved portion. The segment may be generally planar.

[0068] The first segment and the second segment may be generally parallel to each other. The first segment and the second segment may be at an angle to each other. The angle between the first segment and the second segment may be about 45 degrees or less, about 30 degrees or less, or about 15 degrees or less.

[0069] The first segment of the energy absorption plate may have a length. The second segment of the energy absorption plate may have a length. The first segment may be shorter than the second segment. The ratio of the length of the second segment to the length of the first segment may be about 2:1 or greater, about 3:1 or greater, about 4:1 or greater, or about 5:1 or greater. The ratio of the length of the second segment to the length of the first segment may be about 15:1 or less, about 10:1 or less, or about 8:1 or less.

[0070] The energy absorption plate may be configured to be attached to a portion of a gear plate at a joint. The energy absorption plate may include one or more features for attachment to the gear plate, such as an integral fastener or an opening for receiving a fastener. The gear plate may include one or more features for attachment to the energy absorption plate, such as an integral fastener or an opening for receiving a fastener. For example, the first segment of the energy absorption plate may be attached to a portion of the gear plate, both having aligned openings for a fastener to be mounted therebetween. It is contemplated that the fastener may only penetrate the first segment of the energy absorption plate and not the second segment of the energy absorption plate.

[0071] At one or more of the openings (e.g., an opening in the first segment of the energy absorption plate, an opening in the gear plate, or both), the opening may be a slot instead of a circular opening. A slot may be incorporated at the joint to allow the gear plate to slide relative to the energy absorption plate. This allows for breakaway (e.g., a breakaway mount) to occur before the energy absorption plate engages. The breakaway may be completely decoupled from the energy absorption and / or the energy absorption plate.

[0072] The gear plate and the energy absorption plate can be made of different materials. The gear plate can be made of a material that is stronger than the energy absorption plate. This can be advantageous in situations where the energy absorption plate is designed to deform upon impact that exceeds a threshold load. It is conceivable that there are situations where deformation of the gear plate in the same or similar manner is undesirable.

[0073] The gear plate and the energy absorption plate can be made of the same material. The energy absorption plate can be formed integrally with the gear plate. For example, the first end of the energy absorption plate can be located at or near the point where a toothed section begins, at or near the point where a damper is located on the gear plate, or at or near the point where the gear plate (and / or the gear plate with a damper) becomes wider than the energy absorption section.

[0074] The energy absorption plate may include one or more features to enable the energy absorption plate to be secured to a column tube of the steering column assembly. The second segment of the energy absorption plate may be configured to be positioned on the outer surface of the column tube. For example, the energy absorption plate (e.g., on the second segment) may include one or more openings for receiving a fastener. The openings may be aligned with one or more openings in the column tube so that a fastener may be received in both openings. Fasteners may include pins, staples, screws, rivets, or the like. For example, one or more rivets may be used to secure the energy absorption plate to the column tube. The rivets may be shear pins. The rivets may be shear-resistant rivets.

[0075] It is contemplated that one or more slots may be located at an opening in the second segment of the energy absorption plate, at an opening in the column tube, or at both locations. Slots may allow for tearing before the energy absorption plate engages. This may decouple the tearing from the energy absorption and / or the energy absorption plate.

[0076] The energy absorption assembly may include a portion configured to detach from another portion of the steering column assembly. The detachment may occur upon an impact that exceeds a threshold load (e.g., approximately 500 N or more, approximately 6000 N or less, or any range or value therebetween). The portion configured to break away may be a breakaway mount. The breakaway mount may be configured to engage the gear plate, the column tube of the steering column assembly, or both. The breakaway mount may be formed from a material capable of breaking, shearing, or deforming in a desired manner such that the breakaway mount may break away from another portion of the assembly, such as the column tube or the gear plate, upon an impact that exceeds a threshold load.The breakaway bracket, or at least a portion thereof, may be made of a polymer material. The breakaway bracket, or at least a portion thereof, may be made of a plastic material.

[0077] The breakaway mount may include one or more features that allow the breakaway mount to be attached to the gear plate. The breakaway mount may be positioned at or near the end of the gear plate opposite the end connected to or integral with the energy absorption plate. The breakaway mount may be positioned at least partially between the gear plate and the column tube. The breakaway mount may serve to connect the gear plate and the column tube. The breakaway mount may serve to ensure sufficient spacing between the gear plate and the column tube. The breakaway mount may hold the opposite end of the gear plate from the energy absorption plate at a desired distance from the column tube (e.g., such that the gear plate is held generally parallel to the longitudinal axis of the column tube).

[0078] The breakaway bracket may be positioned between the column tube and the underside of the gear plate (e.g., the surface opposite the tooth surface). The gear plate may have an opening configured to receive a portion of the breakaway bracket to secure the breakaway bracket to the gear plate. The gear plate and breakaway bracket may be secured, for example, by snapping into place. The breakaway bracket may have an anchor (e.g., with wings or tabs) received in the opening and allowing the breakaway bracket to snap into place in the opening of the gear plate. Other attachment methods are also conceivable, such as friction fit or the use of fasteners, adhesives, or a combination thereof.

[0079] The breakaway bracket may include a structure with a slot configured to receive one end of the gear plate therein or therethrough. The breakaway bracket may include a body extending generally perpendicular to the gear plate, the column tube, or both. The walls defining the slot may include one or more features or anchors, such as a barb, tab, or other projection, to resist pulling the gear plate out of the breakaway bracket.

[0080] The breakaway bracket may include one or more features for attachment to the column tube. The breakaway bracket may include one or more features configured to shear or break upon forward movement of the column tube upon impact. Therefore, the breakaway bracket may remain in position while the column tube continues to move forward due to the breakaway bracket breaking away from the column tube. Therefore, the features and / or the breakaway bracket may be constructed of a material that secures the breakaway bracket to the column tube during normal operation, but breaks or breaks away upon impact exceeding a threshold load.

[0081] The breakaway bracket may have a length dimension. The breakaway bracket may have a height dimension. The height dimension may vary along the length of the breakaway bracket. The length dimension may be greater than the highest height dimension of the breakaway bracket. The length dimension may be sufficiently large relative to the height dimension to promote and / or ensure the decoupling of the energy absorption panel from the column tube, at least partially or at least primarily, through a shear fracture in the breakaway bracket or one or more of the breakaway bracket attachments.

[0082] The breakaway bracket may include a column tube pin extending from the breakaway bracket into an opening in the column tube. The column tube pin may be integrally formed with the breakaway bracket and extend in a direction generally transverse to the longitudinal axis of the column tube. The column tube pin may be generally cylindrical. The column tube pin may have a shape that generally conforms to the opening in the column tube into which it is received. The column tube pin may include one or more features to secure the pin in the opening (e.g., one or more features to snap the breakaway bracket onto the column tube, into the opening, or both). The column tube pin may be configured to shear or fracture upon an impact that exceeds a threshold load, such that the breakaway bracket separates from the column tube as the column tube translates forward. The size of the column tube pin (e.g.,The material (e.g., diameter, length, shape, or a combination thereof) may be selected based on a predetermined threshold load that causes tearing.

[0083] The breakaway bracket may have one or more openings for receiving a fastener. The opening may be generally aligned with an opening in the column tube so that a fastener may be received in either opening to secure the breakaway bracket to the column tube. The fastener may be, for example, a rivet. The rivet may be a shear pin. The shear pin may shear upon impact exceeding a threshold load, causing the breakaway bracket to separate from the column tube as the column tube shifts forward. The shear pin may allow for controlled breakaway loads.

[0084] The breakaway bracket may be free of a column tube pin. The breakaway bracket may be free of one or more openings or one or more fasteners. The breakaway bracket may have only one or more column tube pins, or only one or more openings, or one or more fasteners. The column tube may have any combination of one or more column tube pins, one or more openings, and one or more fasteners.

[0085] In an impact that exceeds a threshold load, the steering column tube may translate in a generally forward direction. During the impact that exceeds a threshold load, the breakaway mount may separate from the column tube. During the impact that exceeds a threshold load, the breakaway mount may separate from the gear plate. The breakaway may occur due to the shearing of a shear pin, the breaking or shearing of a column tube pin, the breaking of a gear plate anchorage, or a combination thereof. The breakaway mount may remain stationary while the column tube continues to translate forward during a secondary impact where the load exceeds a threshold load.

[0086] It is intended that the breakaway bracket can be attached to the column tube with one or more fasteners, such as a shear-resistant rivet. The gear plate anchorage can be arranged so that the breakaway bracket detaches from the gear plate upon impact load exceeding a threshold load.

[0087] The breakaway bracket may be packaged separately from the energy absorption plate. For example, the breakaway bracket may be located at or near one end of the gear plate, and the energy absorption plate may be located at the opposite end of the gear plate. This may partially or completely decouple the breakaway bracket from the energy absorption of the energy absorption plate. This may be due to the positional relationship of the breakaway bracket relative to the energy absorption plate. This may be due to the presence of one or more slots (e.g., at the junction between the gear plate and the energy absorption plate, where the energy absorption plate connects to the column tube, or at both locations) that allow the energy absorption plate to slide relative to the gear plate, the column tube, or both.

[0088] During or after the breakaway, the energy absorption plate may engage. As the column tube continues to move forward, the energy absorption plate remains attached to the column tube and the gear plate. The gear plate remains stationary. As the energy absorption plate engages, the plate may unwind or unravel. During unwinding or unravel, the position of the curved section of the energy absorption plate may change, the length of the second segment may shorten, or both may occur.

[0089] In the Fig. 1, a steering column assembly 10 is shown having a front end 12 and a rear end 14. A column housing 18 is pivotally mounted to the vehicle via one or more support structures 16, although other configurations and mounting brackets are also conceivable. The steering column assembly 10 includes a steering shaft 22 at the rear end 14, which is configured to support a steering wheel (not shown). The steering shaft 22 is supported by a column tube 20, both of which are supported by the column housing 18. The steering column assembly includes an adjustment subassembly 30 that allows movement of the column tube, the column housing, or both relative to each other and / or relative to the driver of the vehicle.

[0090] Fig. Figure 2 shows an exemplary adjustment subassembly 30 that includes a lever 32 that allows the user or driver to control the telescopic adjustment of the steering column assembly. The column tube 20 is movable relative to the column housing 18 (see Fig. 1), especially in a forward and backward direction for telescopic adjustment. The steering shaft 22 (see Fig. 2) and the column tube 20 are configured to be adjusted upwardly or downwardly relative to a driver via a tilt assembly comprising two parallel and downwardly depending tilt plates or sidewalls 38 that support and engage a tilt bolt 34. Adjustment of the steering shaft 22 and the column tube 20 in the tilt and / or telescopic directions can be initiated by actuating the lever 32, which engages and / or disengages adjustment mechanisms and / or locks and / or unlocks the mechanisms, allowing a driver to position the steering wheel in a desired position.

[0091] To clarify the adjustment subassembly 30 in Fig. 2, the column housing is not shown. The position of the column tube 20 can be adjusted up and down relative to a driver or user of the vehicle via the tilt assembly, which includes the tilt bolt 34 supported on either end of opposing sidewalls 38, each having a slot 36 for receiving the tilt bolt 34 and optionally one or more locking elements (e.g., a cam or pivot). The angle of the column tube 20 can be manually adjusted by unlocking the lever 32 and moving the steering wheel (not shown) to the desired height or tilt. The tilt bolt 34 can move along the slot 36 during tilt adjustment and lock into place when the lever 32 is locked.

[0092] When locking and unlocking the lever 32, a contact portion 40 of the lever comes into contact with a biasing plate 42. The contact portion 40 may include a ramp or an angled surface that applies pressure to the biasing plate 42 when locked and releases or reduces the pressure on the biasing plate when unlocked. The biasing plate 42 engages a locking pin 44. When the lever 32 is in a locked position, the locking pin 44 is urged toward a portion of an energy absorption assembly 50 that includes a gear plate 60 (see Fig. 3) which is selectively attached to the column housing 20 via the telescopic position locking mechanism. The locking pin 44 engages the gear plate 60, for example, on a toothed surface 62 of the gear plate. When the lever 32 is in an unlocked position, a return spring 46 urges the locking pin 44 away from the gear plate 60, thereby releasing the lock between the locking pin 44 and the gear plate 60.

[0093] Fig. 3 shows an energy absorption assembly 50 comprising an energy absorption plate 52, a gear plate 60 and a breakaway bracket 80. Fig. 4 is an exploded view of the energy absorption assembly 50 of Fig. 3.

[0094] The energy absorption plate 52 includes a first end 53 and a second end 58, between which a curved portion 57 is located. The curved portion, as shown, comprises a first portion 55 (between the first end 53 and the curved portion 57) and a second portion 59 (between the curved portion 57 and the second end 58) of the energy absorption plate 52, which are generally parallel to each other, although other angles are also contemplated. The energy absorption plate includes a fastener 56 penetrating at least a portion of the plate (e.g., at the first segment 55). The fastener may be integrally formed with the energy absorption plate 52 or separate. The portion of the energy absorption plate 52 configured for contact with a column tube of a steering column assembly includes one or more fastener openings 68.A fastener 56 is received in the mounting openings. As shown, the fastener 56 is a shear-resistant rivet 72 for securing the energy absorption plate 52 to the column tube 20.

[0095] The gear plate 60 is connected to the energy absorption plate 52 at a connection point 54. The gear plate includes a mounting opening 68. The mounting opening is adapted to receive the fastener 56 disposed at one end of the energy absorption plate 52. As illustrated, the mounting opening includes a wall or collar 70 defining the mounting opening and is depicted as a downwardly extending tubular portion, although other shapes are possible, or the wall may be omitted. The gear plate 60 includes a toothed portion 62 that engages the locking pin 44 to lock the steering column assembly in a particular telescopic orientation. The gear plate includes dampers 64 disposed on opposite sides of the gear plate along a portion of its length.As shown, the gear plate 60 includes an anchoring opening 63 located at an opposite end of the mounting opening 68. The anchoring opening 63 receives a gear plate anchor 84 of a breakaway bracket 80.

[0096] While the gear plate and the energy absorption plate are shown as two separate parts that are connected together, it is also contemplated that these elements may be integrally molded from a single part.

[0097] The breakaway bracket 80 is configured to be secured to the gear plate 60 (via the gear plate anchor 84 engaging the gear plate anchor opening 63) and the column tube 20. The breakaway bracket includes a mounting opening 68 (shown as a shear pin opening 86) configured to receive a fastener, such as a shear pin. On a side of the breakaway bracket 80 opposite the gear plate anchor 84 is a column tube pin 82 configured to engage an opening in a column tube 20. Upon an impact exceeding a threshold load, the column tube pin 82 may fracture, causing the breakaway bracket 80 to detach from the column tube.

[0098] The Fig. 5A and Fig. 5B show a top view and a bottom view of an exemplary breakaway bracket 80. The breakaway bracket 80 includes a mounting opening 68 that penetrates the thickness of the breakaway bracket and can receive a fastener for securing the breakaway bracket. The fastener can be, for example, a shear pin. The mounting opening 68 would therefore be a shear pin opening 86.

[0099] As in Fig. 5A, a gear plate anchor 84 is positioned on top of the breakaway bracket 80. The gear plate anchor 84 is configured to engage an anchor opening 63 of the gear plate 60 (see Fig. 4). The gear plate anchor 84 is generally shaped to fit within the anchor opening 63. The shape of the gear plate anchor can resist withdrawal when engaged or installed. For example, as shown, the gear plate anchor 84 includes two curved or rounded sections that generally conform to the shape of the end limits of the slot of the anchor opening. Two generally opposed tabs or wings 85 engage the side walls of the anchor opening. The coupling or locking between the gear plate anchor 84 and the gear plate 60 can be achieved by friction or snap-fit, for example.

[0100] As in Fig. As shown in Figure 5B, a column tube pin 82 protrudes from the underside of the breakaway bracket 80. The column tube pin 82 is configured to penetrate an opening in a column tube of a steering column assembly.

[0101] Fig. 6 shows an energy absorption assembly 50 attached to a column tube 20. The column tube is shown generally transparent to show the fasteners securing the energy absorption assembly to the column tube. An energy absorption plate 52 is attached to the column tube 20 via fasteners 56, shown as shear-resistant rivets 72. On the opposite side of the curved portion of the energy absorption plate is a junction 54 between the energy absorption plate 52 and a gear plate 60. The energy absorption plate and the gear plate 60 are connected together by a fastener 56. The gear plate includes a damper 64 disposed on the side visible in the illustration. A breakaway bracket 80 connects the gear plate to the column tube 20 at the end of the gear plate opposite the energy absorption plate.The breakaway bracket 80 includes a column tube pin 82 that penetrates an opening in the column tube. A fastener 56, depicted as a shear pin 88, connects the breakaway bracket 80 to the column tube 20.

[0102] The direction of the arrow (below the column tube) indicates the direction of movement of the column tube 20 upon an impact exceeding a threshold load. During such an impact, the shear pin 88 may shear. The column tube pin 82 also shears upon impact. Once the shear pin 88 and the column tube pin 82 shear, the breakaway mount 80 remains stationary while the column tube 20 continues to slide underneath, unwinding, rolling, or translating the curved portion of the energy absorption plate 52. The energy absorption plate 52 remains attached to the column tube 20 due to the shear-resistant rivets 72.

[0103] Slots may be included at one or more mounting openings of the energy absorption assembly. For example, it is contemplated that slots may be included in the energy absorption plate 52 at the mounting openings. Slots may ensure that the tear-off of the bracket occurs before the energy absorption plate engages. This could completely decouple the tear-off device from the energy absorber via the energy absorber plate. In another example, a slot may be arranged at the junction between the gear plate and the energy absorber plate. Such a slot would allow the gear plate to slide relative to the energy absorber plate, thereby decoupled the tear-off device from the energy absorber via the energy absorber plate.

[0104] Fig. Figure 7 shows an energy absorption assembly 50 including an energy absorption plate 52 connected to a gear plate 60 via one or more fasteners 56. A breakaway bracket 80 is located at the opposite end of the gear plate 60. A telescopic stop bracket 90 is attached to the energy absorption plate 52 and supports a telescopic stop damper 92. The telescopic stop bracket 90 and telescopic stop damper 92 are configured to be located externally of a column housing. The telescopic stop bracket acts within a slot in the column housing to define and limit the range of telescopic adjustment. The telescopic stop damper reduces noise and / or shock force peaks caused by impacts upon impacting the end stop during telescopic adjustment.Although the telescopic stop bracket is shown separately, it is also conceivable that the telescopic stop bracket is integrated into the gear plate or the energy absorption plate.

[0105] Fig. 8 shows the energy absorption plate 52 of Fig. 7. A fastener 56, which may be a shear-resistant rivet 72, is arranged at a portion so that the energy absorption plate 52 can be attached to a column tube of a steering column assembly. The telescopic stop bracket 90 is attached to the energy absorption plate at a portion on the opposite side of the curved portion of the energy absorption plate. The fasteners 56 on opposite sides of the telescopic stop bracket 90 attach the telescopic stop bracket (via a strip that extends across the telescopic stop bracket and is anchored on both sides) and simultaneously attach the energy absorption plate 52 to the transmission plate 60 (see Fig. 7).

[0106] Fig. 9 shows the breakaway bracket 80 from Fig. 7. The breakaway bracket 80 has a slot 83 for receiving a portion of the gear plate 60 (see Fig.7). One or more gear plate anchors 84 can engage the gear plate to secure the gear plate in the breakaway bracket. The breakaway bracket 80 includes a column tube pin 82 configured to be received within an opening in a column tube. The column tube pin 82 can, for example, frictionally or positively engage the opening in the column tube to secure the breakaway bracket during normal operation. Upon an impact exceeding a threshold load, the column tube pin 82 can shear, causing the breakaway bracket 80 to separate from the column tube.

[0107] Although exemplary embodiments are described above, these embodiments are not intended to describe all possible forms of the invention. Rather, the terms used in the description are descriptive rather than limiting, and it is understood that various changes may be made without departing from the spirit and scope of the invention. In addition, the features of different embodiments may be combined to form further embodiments of the invention.

[0108] As can be seen, variations of the above disclosures can be used. For example, the breakaway bracket can be attached to the column tube. Instead of or in addition to breaking away from the column tube, the breakaway bracket can break away from the gear plate. As a further example, a breakaway bracket with a column tube pin is shown in the figures, alone or in combination with a rivet, but it is also conceivable that a column tube pin is omitted. One or more shear pins can be used alone or in combination with one or more column tube pins. It is also conceivable that one or more rivets can be omitted. One or more column tube pins can be used alone or in combination with one or more rivets.

[0109] As can be appreciated, variations of the above disclosures may be used. For example, the steering wheel adjustment subassembly may be manufactured from multiple subassemblies. Instead of a toothed end of a pin engaging a toothed portion of a gear plate, it is contemplated that a pin (which may not have teeth) may be inserted into one of a series of openings along the length of the gear plate. It is also contemplated that toothed slots may be disposed elsewhere within the assembly. For example, instead of or in addition to a cam or rotary member located in a slot of the tilt plate, the slot may be defined by a toothed opening engaged by a spring or a toothed cam or rotary member.Although the present disclosure references secondary impact events as the cause of certain functional aspects of the disclosure, the disclosure is not limited exclusively to secondary impact events. Rather, unless otherwise noted, disclosures that refer to a secondary impact should be understood to also contemplate other impacts or conditions where a threshold load (e.g., in a forward direction in a vehicle) occurs that significantly exceeds a normal operating load and where displacement of the column tube may be desirable to significantly reduce the load that would otherwise be transferred to a vehicle operator.

[0110] All numerical values ​​mentioned herein include all values ​​from the lower value to the upper value in increments of one unit, provided that there is a distance of at least 2 units between each lower value and each higher value. For example, if the amount of a component or the value of a process variable such as temperature, pressure, time, and the like is stated to be, for example, 1 to 90, preferably 20 to 80, more preferably 30 to 70, values ​​such as 15 to 85, 22 to 68, 43 to 51, 30 to 32, etc., are expressly stated in this description. For values ​​less than one, one unit is considered to be 0.0001, 0.001, 0.01, or 0.1, as appropriate. These are only examples of what is specifically intended, and all possible combinations of numerical values ​​between the lowest and highest listed values ​​are to be considered expressly stated in this application in a similar manner.

[0111] Unless otherwise noted, all ranges include both the endpoints and all numbers between the endpoints. The use of "about" or "approximately" in conjunction with a range applies to both ends of the range. Thus, "about 20 to 30" includes "about 20 to about 30," including at least the specified endpoints.

[0112] The disclosures of all articles and references, including patent applications and publications, are incorporated by reference in their entirety for all purposes. The term "consisting essentially of" to describe a combination includes the identified elements, ingredients, components, or steps as well as any other elements, ingredients, components, or steps that do not substantially affect the basic and novel characteristics of the combination. The use of the terms "comprising" or "including" to describe combinations of elements, ingredients, components, or steps in this specification also includes embodiments that consist essentially of, or even consist of, the elements, ingredients, components, or steps.

[0113] Multiple elements, constituents, components, or steps may be provided by a single integrated element, constituent, component, or step. Alternatively, a single integrated element, constituent, component, or step may be divided into multiple separate elements, constituents, components, or steps. The use of "a" or "an" to describe an element, constituent, component, or step is not intended to exclude additional elements, constituents, components, or steps.

[0114] The relative positional relationships of the elements illustrated in the drawings are part of the present disclosure, even if they are not described literally. Furthermore, the geometries illustrated in the drawings (which are not limiting, however) are also within the scope of the disclosure, even if they are not described literally. PARTS LIST 10 Steering column assembly 12 Front end 14 Rear end 16 support structures 18 column housings 20 column tube 22 Steering shaft 30 Adjustment subassembly 32 levers 34 tilt bolts 36 slot 38 side wall 40 Contact area 42 prestressing plate 44 locking pin 46 Return spring 50 Energy absorption assembly 52 Energy absorption plate 53 First End 54 Connection (between energy absorption plate and gear plate) 55 First Segment 56 Fastening element 57 Curved area 58 Second End 59 Second Segment 60 gear plate 62 Gearing 63 Anchor opening 64 dampers 66 bracket opening 68 Mounting hole 70 Sleeve or wall that limits the mounting opening 72 shear-resistant rivets 80 Tear-off bracket 82 Column tube pin 83 slot 84 gear plate anchors 85 tabs 86 Shear pin opening 88 Shear pin 90 Telescopic stop bracket 92 Telescopic stop damper QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] US 63 / 430,787

[0001] US 11,440,578

[0007] US 6,467,807

[0028]

Claims

[1] Energy absorption device for a steering column assembly, comprising: a. an energy absorption plate having a first end and a second end with a curved portion therebetween; and b. a gear plate adapted to be engaged with and / or disengaged from a locking mechanism; c. a tear-off bracket; wherein the energy absorption plate is attached to and / or extends from the transmission plate at or near one end of the transmission plate; and wherein the breakaway bracket is secured to the gear plate at or near an opposite end of the gear plate. [2] The energy absorption device according to claim 1, wherein the energy absorption plate is configured to be operatively coupled to a column tube of the steering column device. [3] Energy absorption device according to claim 1 or 2, wherein the energy absorption plate is adapted to be coupled to a column tube of the steering column assembly via one or more fastening elements. [4] The energy absorption device of claim 3, wherein the one or more fasteners are shear-stable rivets. [5] Energy absorption device according to one of the preceding claims, wherein the energy absorption plate and the gear plate are separate elements. [6] Energy absorption device according to one of the preceding claims, wherein a fastening element connects the energy absorption plate and the gear plate at a connection point. [7] Energy absorption device according to claim 6, wherein a slot is located at the junction between the gear plate and the energy absorption plate (e.g. in the energy absorption plate, in the gear plate or in both). [8] An energy absorption device according to any preceding claim, wherein the gear plate has a toothed surface for engagement with a locking pin of an adjustment subassembly of the steering column assembly. [9] Energy absorption device according to one of the preceding claims, wherein the energy absorption plate and the gear plate are formed from different materials. [10] Energy absorption device according to one of the preceding claims, wherein the breakaway bracket is configured to couple the second end of the energy absorption plate to a column tube of the steering column assembly during normal operation and to decouple the breakaway bracket from one of the column tube or energy absorption plate when an input load exceeds a threshold load, or both. [11] The energy absorption device of claim 10, wherein the threshold load is about 500 N or more, about 6000 N or less, or both. [12] An energy absorption device according to any preceding claim, wherein the breakaway mount comprises one or more gear plate anchors for engaging a portion of the gear plate. [13] The energy absorption device of claim 12, wherein the gear plate has an opening for receiving a gear plate anchor of the breakaway bracket. [14] The energy absorption device of claim 13, wherein the gear plate anchor engages the opening in the gear plate via one or more wings or tabs. [15] An energy absorption device according to any preceding claim, wherein the breakaway bracket comprises a column tube pin adapted to be received in an opening in a column tube of the steering column device. [16] An energy absorption device according to any preceding claim, wherein the breakaway bracket includes a slot for receiving and engaging a portion of a gear plate. [17] Energy absorption device according to one of claims 1 to 4 or 8 to 16, wherein the energy absorption plate and the gear plate are integrally formed (e.g. in one piece). [18] An energy absorption assembly according to any preceding claim, wherein the breakaway bracket has a longitudinal dimension sufficiently large relative to a height dimension to promote decoupling of the energy absorption panel from the column tube primarily due to shear failure in the breakaway bracket or one or more breakaway bracket attachments. [19] Assembly for a steering column assembly, comprising: a. the energy absorption assembly according to any one of the preceding claims; and b. a column tube. [20] The assembly of claim 19, wherein the gear plate is selectively secured to the column housing by an adjustment subassembly of the steering column assembly (e.g., a telescopic positive locking mechanism). [21] The assembly of claim 19 or 20, wherein the energy absorption plate is attached to the column tube by one or more shear-resistant rivets. [22] The assembly of any one of claims 19 to 21, wherein the breakaway bracket comprises a column tube pin extending from the breakaway bracket and received in the column tube. [23] The assembly of any one of claims 19 to 22, wherein the breakaway bracket is attached to the column tube via one or more shear pins. [24] The assembly of any one of claims 19 to 23, wherein upon an impact exceeding a threshold load, the breakaway bracket is arranged to detach from the column tube while the energy absorption plate remains attached to the column tube. [25] The assembly of claim 24, wherein the threshold load is about 500 N or more, about 6000 N or less, or both. [26] The assembly of any one of claims 22 to 25, wherein the column tube pin and / or the shear pins shear to enable the breakaway bracket to be torn away from the column. [27] A steering column assembly comprising: a. a column tube; b. a steering shaft which is at least partially rotatably supported by the column; c. a bracket for at least partially supporting the column tube; d. an adjustment subassembly; and e. the energy absorption assembly according to any one of the preceding claims. [28] Steering column assembly according to claim 27, wherein the adjustment subassembly is arranged to: a. selectively adjusting the steering shaft, the column tube, or both in a forward or rearward direction substantially along the longitudinal axis; b. selectively raising or lowering the steering shaft, the column tube, or both; or c. both a. and b.

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