Single radial wedge for steering column tube for housing delashing

Abstract

A wedge assembly for a steering column assembly including a wedge body and a preload member. The wedge body has a generally curved column tube contact surface for contacting an outer surface of the column tube and a column housing contact surface configured to contact a column housing. The wedge assembly has a thick edge and a thin edge, the thickness of the wedge body decreasing from the thick edge to the thin edge. The preload member has an elongated body between a first end and a second end. The first end and the second end are secured to and / or disposed within the wedge body. A steering column assembly including the wedge assembly, the column tube, and the column housing is also envisioned.

Description

[Technical field]

[0001] (Priority) This application claims the benefit of U.S. Provisional Application No. 63 / 334,758, filed April 26, 2022, the entire disclosure of which is incorporated herein by reference for all purposes.

[0002] The present teachings relate generally to improved steering column assemblies and related methods (e.g., methods of assembling a steering column assembly). More particularly, the present teachings relate to a subassembly within a steering column assembly for reducing or eliminating lash. [Background technology]

[0003] In the automotive field, it has become common to use steering column assemblies that include tilt (rake) and / or telescoping ("reach") functions. Assemblies that use both tilt and telescoping functions are also known as "rake and reach steering column assemblies." The use of motors to translate the steering wheel relative to the vehicle operator is also becoming more common. It is common to use motors for either or both of the tilt and telescoping functions. For example, one motor may be operated to actuate the steering column assembly generally upwards or downwards in a vertical direction to adjust the height of the steering wheel relative to the vehicle operator, thereby performing the tilt function. Another motor may be operated to actuate the steering column assembly to adjust the fore-aft position of the steering wheel relative to the vehicle operator. The latter is typically achieved by translation of a telescoping tube arrangement, whereby at least one inner tube associated with the steering wheel translates relative to the steering shaft. In such a telescoping arrangement, the column tube is permitted to translate fore-aft within a fixed column tube and relative to a fixed column tube.

[0004] However, due to the steering column assembly being a relatively large assembly, even small differences in dimensional tolerances (e.g., between the column housing and the column tube) can result in a relatively large lash effect on the vehicle operator, i.e., differences in dimensional tolerances from vehicle to vehicle can lead to some vehicle operators being able to feel lateral movement of the steering column while adjusting the steering column, or even while steering.

[0005] One approach to reducing the lash between the column tube and the column housing is to use a grub screw that acts directly on a spring to preload a wear-resistant member against the column tube. However, this assembly requires many parts and may require additional adjustments.

[0006] As can be appreciated, different dimensional tolerances are expected for each assembly, which can result in complex assembly operations that are less efficient than desired. Summary of the Invention [Problem to be solved by the invention]

[0007] What is needed is an alternative assembly and method of manufacturing the assembly that can achieve de-lash of the steering column tube relative to the steering column housing, help reduce component count, provide improved stiffness, reduce sliding forces, improve ease of assembly, reduce or eliminate the need for adjustments, or combinations thereof. [Means for solving the problem]

[0008] The present teachings utilize a simple yet elegant construction approach that allows a relatively small number of components to be used to achieve an adjustable steering column assembly, which simplifies the manufacture of the adjustable steering column assembly and otherwise solves one or more of the problems discussed above.

[0009] The present teachings include a wedge assembly for a steering column assembly. The wedge assembly can include any of the following features in any combination:

[0010] The wedge assembly may be a radial wedge. The wedge assembly may include a wedge body. The wedge body may include a generally curved column tube contact surface configured to contact an outer surface of the column tube and a column housing contact surface configured to contact the column housing. The wedge body may have a pair of generally opposed long sides and a pair of generally opposed short sides. The edge (e.g., the long edge) may be a thick edge and the opposite edge (e.g., the opposite long edge) may be a thin edge. The thickness of the wedge body may decrease from the thick edge to the thin edge.

[0011] The wedge body may include one or more features for engaging a preload member, such as posts and / or cavities. The wedge assembly may include a preload member. The preload member may be, for example, a spring, an extension member from the wedge body, or both. The preload member may be a spring, such as a flat spring, leaf spring, wire spring, steel spring, or combinations thereof. The preload member may be a flexible extension member of the wedge body. The flexible extension member may be a molded feature of the wedge body that may deform to provide the preload. The preload member may be a resiliently compressible material (e.g., rubber).

[0012] The preload member may have an elongated body between a first end and a second end. The first end, the second end, or both of the preload member may be curved and / or coiled. The first end or the second end may be at least partially secured to and / or disposed about a feature of the wedge body, such as a post. The post may be defined by or created by a void in the material surrounding the post. The post may not extend beyond the column housing contact surface. The other of the second end or the first end may be contained within another portion of the wedge body, such as a cavity. The preload member may be captured by one or more cavities along the wedge body. The wedge body may not have a post. The load of the preload member may be approximately tangential to the column tube.

[0013] The wedge body can have a wedge angle of about 3 degrees or more, about 12 degrees or less, or both. The column tube contact surface, the column housing contact surface, a portion thereof, or a combination thereof can have a generally curved contact surface. The angle between the tangents along the generally curved contact surface can be about 3 degrees or more, about 12 degrees or less, or both. The angle between the tangents of each curved surface can vary continuously from the thin portion of the wedge to the thick portion of the wedge, allowing for a range of angles.

[0014] The wedge assembly may include one or more fastening features. For example, the wedge body may include a fastener groove for at least partially receiving the fastener. The fastener groove may extend through a portion of the thickness of the wedge body. The fastener groove may have a length greater than its width, allowing the fastener to remain within the groove while allowing the wedge body to move within the steering column assembly to provide delashing between the column housing and the column tube. The fastener groove may have a length that extends in a direction generally perpendicular to the longitudinal axis of the wedge body. The fastener groove may extend from the thick edge toward the thin edge. The fastening feature may be an extension member that is retained by a feature of the column housing. For example, the extension feature may be a snap-fit ​​feature molded into the wedge body.

[0015] The wedge cavity may include one or more surfaces for contacting the first end or the second end of the preload member to define the amount of travel of the preload member when compressed and / or to allow free movement of the preload member throughout its range of motion. The wedge assembly may have a controlled preload such that the wedge assembly creates a sliding force between the column tube and the column housing of about 5N to about 300N.

[0016] The wedge body can have a thinned portion, the thinned portion having a thickness that is less than a thickness at another point on a line along the length of the wedge body. The thinned portion can be located on a surface of the wedge body configured to face the column tube. The thinned portion can be located on a surface of the wedge body configured to face the column housing. The thinned portion can be free from contact with the column tube, the column housing, or both.

[0017] The present teachings also contemplate a steering column assembly for a motor vehicle. The steering column assembly may include a column housing, a column tube, and a wedge assembly disposed between the column tube and the column housing. The column housing may include a recess for receiving the wedge assembly. The recess may be generally wedge-shaped, such that the recess has a thicker portion and a thinner portion. The thicker portion is configured to receive a thicker edge of the wedge body, and the thinner portion is configured to receive a thinner edge of the wedge body. The recess may include a contact edge that contacts a preload member of the wedge assembly. The column housing may include a fastener opening generally aligned with the fastener groove of the wedge body. The fastener may pass through the opening and be at least partially received within the fastener groove of the wedge body. [Brief description of the drawings]

[0018] [Figure 1] 1 is an exemplary steering column in accordance with the present teachings. [Diagram 2] 1 is an exemplary column tube and wedge assembly in accordance with the present teachings. [Diagram 3] FIG. 3 is an enlarged view of the wedge assembly of FIG. 2. [Figure 4] 1 is an exemplary wedge body in accordance with the present teachings. [Diagram 5] 1 is an exemplary column housing in accordance with the present teachings. [Figure 6] FIG. 2 is a cross-sectional view of a column housing, column tube, and wedge assembly in accordance with the present teachings. [Figure 7] FIG. 2 is a free body diagram showing the interactions between the elements of a steering column assembly. [Figure 8] 4 illustrates contact areas within a steering column assembly due to forces exerted by a wedge assembly in accordance with the present teachings. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] Where necessary, detailed teachings are disclosed herein, but it should be understood that the disclosed teachings are merely exemplary and can be embodied in various and alternative forms. The figures are not necessarily to scale, and some features may be exaggerated or minimized to show the details of specific components. Therefore, specific structural and functional details disclosed herein should not be interpreted as limiting, but merely as a representative basis for teaching those skilled in the art to variously employ the present teachings. However, the relative positions and geometries of the elements shown in the figures are part of the generalized teachings, even if not explicitly described.

[0020] Turning now to further details of the assembly herein, generally, the assembly includes a column housing operatively coupled to a bracket structure. The column housing operatively supports a steering shaft that is driven by a steering wheel. To this end, the column housing may itself be a tube and / or may have a generally hollow structure adapted to receive another tube. It may also receive another tube that supports the steering shaft. One such tube, referred to herein as a column tube, typically has a hollow cavity along at least a portion (if not the entirety) of its length and may be sized and configured to receive and support a rotatable shaft, i.e., a steering shaft, and possibly one or more bearings. Both the shaft and any tube (column housing, column tube, or both) have a longitudinal axis. When mounted to a vehicle, the longitudinal axis of each of the shaft and any tubes is generally coaxially aligned, generally parallel aligned (e.g., within about 10°, or within about 5°) with the longitudinal axis of the vehicle, or each. The shaft, column housing, and any inner tube may be made of a suitable metal, such as steel or aluminum. Metallic components herein may also be made of other metals, such as magnesium. Such metals may be alloys, but generally pure metals are also possible.

[0021] One or more bracket structures (e.g., including an upper bracket) can be used to receive and / or support at least a portion of the steering shaft (e.g., while the shaft is at least partially received in the column tube, the column housing, or both) and to mount the steering column assembly in the automotive vehicle. The bracket structure can include a portion, such as an upper plate portion, adapted to mount to the vehicle structure (e.g., vehicle cross beam, instrument panel, etc.), or multiple portions adapted to mount to the vehicle structure. The bracket structure can include a portion adapted to support (e.g., pivotally support) the steering shaft (e.g., by a column tube telescopically disposed in the column housing). The bracket structure can be manufactured to include multiple structures, a single integral structure, or multiple components assembled together in an assembly to define the desired bracket structure. The bracket structure can be a cast structure (e.g., a structure made by casting an ingot), a forged structure (e.g., a structure made by forging a metal ingot), a machined structure, a solidified structure (e.g., a structure made by sintering and / or pressing a powdered metal ingot), or some combination thereof. One approach is to cast the bracket structure to form a metal casting (e.g., aluminum alloy, magnesium alloy, or ferrous metal casting). The bracket structure can then be configured to integrate features for mounting within the vehicle and to accommodate tilt features of the assembly relative to the vehicle operator. For example, these features can be integrated into a single upper bracket or distributed among separate bracket components.

[0022] The present teachings contemplate the use of at least one telescopic motor subassembly adapted to selectively drive (by a rod or other drive member) the steering shaft in a generally forward or rearward direction along the longitudinal axis of the steering shaft. The telescopic motor subassembly may include an electric motor having a motor shaft operatively driving a drive member (e.g., a rod threaded or having gear teeth over at least a portion of its length). The shaft may drive the drive member by using one or more gears or by using a threaded nut. The motor shaft may have a longitudinal axis oriented generally parallel to the longitudinal axis of the steering shaft and / or the inner tube. The motor shaft may have a longitudinal axis oriented generally transverse to the longitudinal axis of the steering shaft and / or the inner tube. The telescopic motor subassembly may be such that it includes a housing in which the motor is at least partially disposed. The housing may include one or more flat surfaces adapted for slidable abutment against another surface (e.g., a bracket, a flange of the column housing, or some other mounting structure) that may be part of or operatively connected to the column housing. Such flat surfaces may be part of a mounting structure for securing the telescopic motor subassembly to the overall assembly. A manually adjustable telescopic assembly may also be used.

[0023] The steering column assembly may include a telescopic motor subassembly mounting structure, which is coupled to the column housing, the telescopic motor subassembly, and the inner column tube during normal operation. The telescopic motor subassembly mounting structure may be adapted to disengage from the column housing upon impact exceeding a predetermined first impact load in accordance with the teachings of U.S. Publication No. 2013 / 0233117, incorporated by reference in its entirety for all purposes. The telescopic motor subassembly mounting structure and / or the motor may be located below the column housing. The telescopic motor subassembly mounting structure may translate along a lower surface of the column housing when disengaged from the column housing. Thus, the telescopic motor subassembly mounting structure may be adapted to connect with an energy absorber element and plastically deform the element after initial disengagement.

[0024] The present teachings further contemplate the use of at least one tilt subassembly adapted to selectively raise or lower the steering shaft. The tilt subassembly can be manually actuated, motorized, or both. The tilt subassembly can be mounted to the bracket structure (e.g., at a first mounting location along its length). The tilt subassembly can be incorporated into a housing structure defined within the bracket structure. The tilt subassembly can be mounted to a second location along its length (e.g., a second mounting location that is distal from a top surface of the bracket structure compared to the first mounting location).

[0025] The steering column assembly may include a column tube adapted to be received within the column housing. The column tube may be generally cylindrical. The column tube may have a generally circular cross-section. The column tube may have an elliptical cross-section. The column tube may have a non-circular cross-section. The column tube may have a cross-section that includes one or more straight, angled, non-curved sections, or combinations thereof. For example, the column tube may have a generally square or rectangular cross-section. The column tube may be at least partially hollow. The column tube may be entirely hollow. The column tube may support a steering shaft. The column tube may have an exterior surface adapted to support additional elements of the steering column assembly, such as a wedge assembly.

[0026] The column housing may have a shape or opening capable of receiving the column tube therein and / or allowing translational movement of the column tube relative to the column housing. The shape or opening of the column housing may be substantially complementary to the shape of the column tube. The shape or opening of the column housing may have one or more portions substantially complementary to portions of the column tube. The shape or opening of the column housing may have a shape that substantially matches the shape of the exterior dimensions of the column tube.

[0027] As shown, the column housing may be pivotally coupled to the bracket structure, for example, by a pivotal connection to the upper bracket (e.g., at or near a forward end of both the bracket structure (e.g., upper bracket) and the column housing), and may further be adapted to allow steering shaft adjustment (e.g., tilt adjustment, telescopic adjustment, or both), for example, by a tilt subassembly, a telescopic motor subassembly, or both. The column housing may have a generally cylindrical shape along at least a portion of its length, such as the aft portion. The column housing may have a generally cylindrical interior cavity configured to receive a generally cylindrical column tube. The column housing may be a cast structure (e.g., a structure made by casting an ingot), a forged structure (e.g., a structure made by forging a metal ingot), a machined structure, a solidified structure (e.g., a structure made by sintering and / or pressing a powdered metal ingot), or some combination thereof. The column housing may include one or more flats along a side opposite a side wall of the bracket structure. One preferred approach is to cast the column housing to form an aluminum alloy casting. The column housing may include one or more ribs. The column housing may include a structure onto which an energy absorbing device as taught in U.S. Publication No. 2013 / 0233117 (see, e.g., Figures 1a-5 and the associated discussion therein, which are incorporated by reference in their entirety for all purposes) may be secured or within which an energy absorbing device may be disposed (e.g., along a side of the housing so as to project generally radially outward relative to the longitudinal axis of the housing). A space will typically be defined between the column housing and the bracket structure (e.g., between the column housing and a downwardly projecting sidewall of the bracket structure), e.g., toward the aft end of the assembly.

[0028] For example, the column housing may be generally elongated. The column housing may have a substantially cylindrical configuration over at least a portion of its length (e.g., if the column tube has a generally cylindrical shape). The column housing may have a substantially cylindrical configuration that defines a hollow passage for receiving the column tube (e.g., if the column tube has a generally cylindrical shape). The column housing may have a shape generally similar to the outer dimensions of the column tube over at least a portion of its length. For example, if the column tube has a square cross section, the column housing may have a substantially square configuration over at least a portion of its length. The column housing may have a lower portion with a flange that projects laterally over at least a portion of the length of the column housing. The flange may project from both sides of the column housing. The flange may project laterally outward to a position that extends beyond the outermost reach of the wall from which it projects. The column housing may have one or more openings, e.g., slots, in a lower portion for exposing the inner column tube so that the column tube may be coupled (e.g., via a suitable bracket) with a drive member associated with the telescopic motor subassembly for longitudinal translation. The column housing is pivotally connected to a bracket structure (e.g., at or near the forward end of the assembly) so that in the event of a secondary collision, the column housing remains substantially fixed in its normal operating position. Implosion may occur when the column tube moves forward, causing one or more portions of the steering column assembly (e.g., telescoping motor subassembly) to break away and energy to be absorbed by an energy absorbing device connecting the column housing to another portion of the assembly (e.g., telescoping motor subassembly, column tube).

[0029] The steering column assembly may include a wedge assembly. The wedge assembly may function to achieve delashing of the column tube relative to the column housing. The wedge assembly may reduce component complexity compared to existing solutions for reducing or eliminating lash between the column housing and the column tube. The wedge assembly, or portions thereof, may increase the stiffness of the system. The wedge assembly may provide a combination of high stiffness while maintaining low sliding forces of the column tube within the housing.

[0030] The wedge assembly may include a wedge body and a preload member. A fastener or elongated member may be used to hold the wedge assembly in a particular position or to define the amount of travel of the wedge assembly within the steering column assembly. The wedge assembly may be a single spring-loaded radial wedge.

[0031] The wedge assembly may include a wedge body. The wedge body may have a generally rectangular perimeter with two generally opposed long sides and two generally opposed short sides. When viewed in cross section or from the side, one long side may have a thickness greater than the thickness of the opposite long side. The thickness decreases from one long side to the opposite long side, generally creating a wedge shape.

[0032] The wedge body may be made of any suitable material. The wedge body may be made of metal. For example, it may be plain carbon steel (e.g., SAE 1008 steel) with a relatively low carbon content. The wedge body may be made of plastic. The wedge body may be lubricated to allow sliding or movement of the wedge body relative to the column tube, the column housing, or both.

[0033] The wedge body can have one or more generally curved surfaces. The wedge body can have one or more surfaces adapted to contact the column tube (e.g., a column tube contacting surface). The one or more surfaces adapted to contact the column tube can have a generally curved shape that generally matches the curvature of the column tube onto which the wedge body can be disposed. The wedge body can be sized and / or positioned such that about 25% or more, about 50% or more, about 75% or more, or about 100% of the surface facing the column tube contacts the column tube.

[0034] The wedge body may have one or more opposing surfaces (e.g., from the column tube contact surface) adapted to contact the column housing (e.g., the column housing contact surface). The one or more surfaces adapted to contact the column housing may have a shape or configuration that matches one or more features of the column housing. For example, the column housing may include a recess that receives the wedge assembly or a portion thereof. The wedge body may be shaped such that it can be received within the recess. The column housing contact surface may be generally curved. The radius of curvature of the column housing contact surface may be the same as the radius of curvature of the column tube contact surface. The radius of curvature of the column housing contact surface may be different from the radius of curvature of the column tube contact surface. The wedge body may be sized and / or positioned such that about 25% or more, about 50% or more, about 75% or more, or about 100% of the surface facing the column housing contacts the column housing.

[0035] The wedge angle can be determined based on the dimensions or tolerances of the steering column assembly (e.g., column tube and column housing). The wedge angle can be measured at the tip of the thin long side of the wedge body. The wedge angle can be selected to allow the wedge assembly to preload the column tube. The wedge angle can be about 2 degrees or more, about 3 degrees or more, or about 5 degrees or more. The wedge angle can be about 15 degrees or less, about 12 degrees or less, about 10 degrees or less, or about 8 degrees or less.

[0036] In a wedge body having one or more generally curved contact surfaces, the angle of the tangents may vary from one portion of the wedge to another. For example, the angle of the tangents may vary continuously from the thick edge of the wedge to the thin edge. The angle (or range of angles) between the tangents of each surface may be about 2 degrees or more, about 3 degrees or more, or about 5 degrees or more. The angle (or range of angles) may be about 15 degrees or less, about 12 degrees or less, about 10 degrees or less, or about 8 degrees or less.

[0037] The wedge body may have a length (L), a width (W), a maximum thickness (Tmax) (e.g., toward the thicker edge at the long side of the wedge body), and a minimum thickness (Tmin) (e.g., toward the thinner edge at the long side of the wedge). The thickness at each long side may be substantially uniform. The thickness at each long side may vary. The thickness at a line extending along the length of the wedge body may be substantially uniform. The thickness at a line extending along the length of the wedge body may be non-uniform.

[0038] The wedge body may have a thinned portion, where the thickness of the thinned portion is less than the thickness at another point on a line extending along the length of the wedge body. The thinned portion may reduce the amount of material of the wedge body. The thinned portion may reduce the weight of the wedge body. The thinned portion may reduce the surface area that contacts the column housing, the column tube, or both. The thinned portion may allow the sliding force of the column tube in the housing to be kept low. The boundary of the thinned portion may be approximately parallel to the short side of the wedge body. The thinned portion may be approximately centrally located along the length of the wedge body. The thinned portion may be located on a surface facing the column tube, a surface facing the column housing, or both. When the wedge body is in a steering column assembly, it is envisioned that at least a portion of the thinned portion does not contact the column housing when facing the column housing, or does not contact the column tube when facing the column tube, or both. At the surface facing the column tube, the thinned portion is intended to separate that surface into two column tube contact surfaces adapted to contact the column tube.At the surface of the wedge body facing the column housing, the thinned portion is intended to separate that surface into two column housing contact surfaces adapted to contact the column tube.

[0039] The wedge body may include one or more features for securing the wedge to the column housing. The features may include snap-in features, hooks, or fastener grooves that allow a fastener (e.g., a bolt, pin, push nut, expansion member, or other method, any of which may be threaded) to attach the wedge body to the column housing. The fastener may be formed separately from the wedge body. The fastener may be formed integrally with the wedge body. The fastener may be part of the wedge body.

[0040] The wedge can have an extension member that is retained by a feature on the column housing. The extension member can be molded into the wedge body. The extension member can engage with the column housing (e.g., with a snap fit).

[0041] The column housing can have corresponding openings for receiving the fasteners, which can pass through the column housing and be received in the fastener grooves. The locking features can maintain the wedge body in a desired position relative to the column housing while the column tube moves telescopically or fore-aft within the steering column assembly. The locking features can allow approximately tangential (or lateral) movement of the wedge, while preventing or limiting axial movement of the wedge body, so that the wedge is free to move to remove clearances that may be caused by wear, thermal expansion, or other operating conditions between the wedge, housing, and column tube.

[0042] The fastener groove may pass through the entire wedge body (e.g., extend through the entire thickness of the wedge body). The fastener groove may extend partially through the thickness of the wedge body. The fastener groove may be circular. The fastener groove may be elongated such that the fastener groove has a length that is greater than its width. The width of the fastener groove may accommodate the fastener. The width of the fastener groove may prevent the fastener from moving across the width or from rattling. The length may be greater than the width to allow adjustment of the wedge assembly within the steering column assembly.

[0043] The fastener groove may be located at or near a long side of the wedge body (e.g., a thick edge of the wedge body). The fastener groove may be a notch or cutout formed in an edge of the wedge body. The fastener groove may be open on one side. The fastener groove may be closed at its opposite end. The closed end may function as a stop to define the allowable movement of the wedge body in one or more directions and / or to determine the appropriate amount of preload for the wedge body and / or preload member of the wedge assembly. The fastener groove may extend along the width of the groove body. The length of the fastener groove may be generally transverse to the longitudinal axis of the wedge body.

[0044] Due to the inclination of the wedge body and the use of an elongated slot in the wedge body to attach the wedge body to the column housing, simplified adjustments can be made to achieve a desired position of the wedge assembly relative to the column housing (e.g., relative to the opposing contact surface of the column housing) and / or relative to the column tube during assembly of the column housing and the column tube. For example, by moving the wedge located between the column housing and the column tube, the wedge body can reduce or increase any space between the column tube and the column housing. Furthermore, due to the single fastener installation made possible by the present teachings, a single fastening step can be performed by simply determining the appropriate desired position of the wedge body relative to the column tube and / or column housing of the steering column assembly and tightening the fastener to an appropriate load condition (e.g., to an appropriate or predetermined torque level). For example, the wedge assembly can be fixed at a desired preload condition to achieve an appropriate level of resistance against the column housing and / or column tube. One or more preload members can be used to help achieve the desired preload condition.

[0045] The wedge assembly includes one or more preload members. The preload member may be a spring. The preload member may be coupled to the wedge body. The preload member may be configured to abut another portion of the steering column assembly. For example, a portion of the preload member may abut a portion of the column housing. The preload member may be an elongated member having a body and two opposing ends. The preload member may be a leaf spring, a flat spring, a wire, or a combination thereof. One or both ends of the preload member may be generally curved, curvilinear, or coiled. The curved or coiled end may act to secure the preload member to the wedge body. The curved or coiled end may act to prevent capture and / or to facilitate sliding or movement within the cavity. One or both ends of the preload member may be configured to engage the wedge body. For example, both ends of the preload member may engage the wedge body and the preload member body may extend away from the wedge body. The preload member body may abut a portion of the column housing.

[0046] The preload member may be formed separately from the wedge body. The preload member, or a portion thereof, may be integrally formed with the wedge body.

[0047] The preload member can extend from the wedge body. The preload member can be a flexible extension member of the wedge body. The flexible extension member of the wedge body can be a molded feature of the wedge body. The flexible extension member can be deformed to provide the preload.

[0048] The preload member may be made of a metallic material. For example, the preload member may be formed of or include steel. The preload member may be a resiliently compressible material. For example, the preload member may be formed of or include rubber.

[0049] One end of the preload member may be fixed to and / or in fixed relationship with the wedge body. The wedge body may include a post around which the preload member end is wrapped or otherwise secured. The post may be formed in the wedge body. The post may be formed at or near one or more ends of the wedge body. For example, the post may be located near a long side (e.g., a thick edge) and a short side. The post may be surrounded or defined by a void around the material forming the post. The post may be formed integrally with the wedge body. The post may be formed of a separate piece or may be otherwise attached to the wedge body. The height of the post may be equal to or less than the maximum thickness of the wedge body. The height of the post may be such that it does not extend beyond the thickness of the wedge body on the opposite side of the void surrounding the post. The height of the posts may be such that they do not extend beyond the plane of the surrounding wedge body so as to not catch on adjacent surfaces (e.g., column housing or column tube), interfere with their mating relationship, or prevent them from sliding relative to one another. For example, the posts may not extend beyond the column housing contact surface.

[0050] The opposite end of the preload member can be received within a cavity in the wedge body. The cavity can allow some movement of the end of the preload member. The cavity can act as a stop or define the amount of movement allowed. The cavity can determine the amount of preload on the preload member.

[0051] The cavity can be located on the same long side as the column (e.g., the thick edge), but adjacent to the opposite short side. The cavity can be a cavity that goes through the edge through its thickness. The cavity can be a notch that can receive the end of the preload member. The cavity can be a notch with an overhang that prevents the preload member from splaying out of the top of the cavity (e.g., to keep the end of the preload member within the wedge body and prevent movement in a direction toward the column tube).

[0052] When the preload member is pressed against the wedge body in the preload member body, with one end of the preload member fixed to the support and the opposite end of the preload member movable within the cavity, the end of the preload member in the cavity can move toward the outer edge of the cavity until it reaches a boundary (e.g., a wall defining the cavity). The boundary of the cavity allows the preload of the preload member to be controlled, and the wedge assembly is adapted to create a desired sliding force between the column housing and the column tube. For example, the desired sliding force is about 5N or more, about 10N or more, about 20N or more, about 40N or more, about 50N or more, or about 60N or more. The desired sliding force can be about 400N or less, about 300N or less, or about 200N or less.

[0053] The column housing may have one or more features for receiving the wedge assembly. The column housing may include a recess for receiving at least a portion of the wedge assembly. The recess may be located within the column housing in which the column tube is received. The recess may have a shape that generally matches the wedge shape of the wedge body. The recess may have a thick portion in which the thicker long side is received and a thin portion in which the thinner long side is disposed. The recess may have a wall that is adapted to contact a portion of a preload member (e.g., a preload member body) of the wedge assembly. The preload member may abut against this contact edge of the column housing, thereby allowing a load to be applied to the wedge in a tangential direction to the column tube.

[0054] The engagement between the preload member of the wedge assembly and the contact edge of the column housing creates a spring force that is approximately tangential to the column tube, which forces the wedge body further between the column housing and the column tube, thereby reducing or eliminating lash. This creates a vertical force, pushing the column tube toward the opposite housing. Three contact areas can be created: the contact area between the column housing, the wedge assembly, and the column tube, and two additional contact areas where the column tube contacts the column housing. Each contact area is approximately 120° apart from the adjacent contact area (e.g., three contact areas approximately equally spaced around a circle).

[0055] The objective of the design is also to achieve or maintain a low sliding force of the column tube within the housing. The sliding force may depend on the spring force, the wedge angle, the contact angle, the material used (and the lubrication of the material), or a combination thereof. The extension force can be about 5N or more, about 10N or more, about 25N or more, about 50N or more, about 75N or more, or about 90N or more. The extension force can be about 300N or less, about 250N or less, about 200N or less, about 150N or less, or about 110N or less. For example, the desired extension force can be about 100N±5N. Design choices such as wedge angle, spring force, preload of the preload member, etc. can be made to achieve the desired sliding force. For example, the wedge angle can be about 3 degrees to about 12 degrees. For example, the spring force can be about 20N to about 40N (e.g., about 27N to about 34N).

[0056] The present teachings also contemplate that the steering column assembly may include an energy absorbing structure adapted to help manage energy resulting from a secondary impact during a vehicle collision.

[0057] By way of example, and not limitation, a steering column assembly of the present teachings may include a structure such as that disclosed in U.S. Publication No. 2013 / 0233117 (U.S. Application No. 13 / 788,637, Read and Martinez), the entire disclosure of which is incorporated by reference for all purposes.

[0058] Such a steering column assembly may include a bracket structure, such as an upper bracket (typically made of metal, such as aluminum, which may be cast) adapted to mount to a structure of the automotive vehicle (e.g., vehicle cross beam, instrument panel, or both). A displaceable inner tube (e.g., column tube) is configured to receive a steering shaft. A telescopic actuator device, such as an electric motor (which may be part of the telescopic motor assembly), is operatively attached to the column housing and column tube via one or more drive members (e.g., rods) to selectively actuate the inner tube in a forward or rearward direction by a vehicle operator. The assembly is also such that the telescopic motor assembly is capable of disengaging from its attachment to the housing in a controlled manner using one or more energy absorber elements, which may be selected based on a particular vehicle application and designed to vary or tune the desired response (e.g., timing of disengagement and / or plastic deformation during collapse stroke). During a secondary impact, the impact force by the vehicle operator is transmitted through the steering shaft to the column tube and drive members, causing an initial disengagement of the telescopic motor assembly. Additional energy from the impact is absorbed by one or more energy absorbing elements, which are positioned relative to (e.g., operatively relative to) the telescopic motor assembly and the inner tube, the housing, or both. The one or more energy absorbing element(s) can be configured (e.g., as a plastically deformable, relatively thin, generally folded, elongated metal strip or bent plate) and selected from materials (e.g., plain carbon steel, steel alloyed with one or more other metals, or other steels or metals) to plastically deform to absorb the impact energy. Such plastic deformation can be in a non-stretched state, so that the metal strip or bent plate can be folded on itself and pulled close to an edge of a structure (e.g., a flange associated with an inner column housing) or restrained against a wall to cause deformation.In this way, it is possible to achieve a load-displacement relationship that includes a first stage where the displacement increases as the load increases up to a peak displacement corresponding to the initial disengagement of the telescopic motor assembly, followed by a next stage where reliance on one or more energy absorber elements occurs as the energy from the load is absorbed primarily by deformation (including plastic deformation) of the energy absorber elements, after a possible energy absorption load delay (which delay can be selectively adjusted by the shape, size, or other characteristics of the energy absorber elements).

[0059] The teachings herein also contemplate a method of assembling a steering column assembly (e.g., the assembly described above). The method may include positioning a column tube adapted to hold or receive a steering shaft in a column housing having forward and aft ends, an outer wall and a longitudinal axis (e.g., the outer wall may be generally arcuate such that the column housing has a generally hollow cylindrical structure over a portion or all of its length). The wedge assembly may be attached from an open end of the column housing along the housing axis. It is also contemplated that there may be a radial pocket in the column housing into which the wedge assembly is inserted. The wedge assembly may be located between the column tube and the column housing, with the wedge body located in a recess in the column housing and the preload member adapted to contact a contact edge that defines a portion of the recess. An opening in the column housing for receiving a fastener is generally aligned with a fastener groove in the wedge body, and the fastener is inserted through the opening in the column housing and received within the groove body. The preload of the wedge assembly (e.g., the preload of the preload member) needs to be controlled so that the wedge and preload member system creates the desired sliding force between the column housing and the column tube (e.g., from about 5 N to about 300 N, or any range therebetween).

[0060] 1 illustrates an exemplary steering column assembly 10 having a forward end 12 and an aft end 14. The assembly includes a column housing 20 that at least partially receives and / or supports a column tube 30. The column tube is operatively coupled to a steering wheel (not shown), for example, via a steering shaft 34. Both the steering shaft 34 and the column tube 30 have a longitudinal axis LA. When installed in a vehicle, the respective longitudinal axes LA of the steering shaft and column tube may be substantially coaxially aligned, substantially aligned parallel, substantially aligned parallel to the longitudinal axis of the vehicle, or a combination thereof.

[0061] As shown, the steering column assembly 10 includes a bracket structure 16. One or more of the bracket structures may allow the steering column assembly to be mounted within a vehicle. One or more of the bracket structures may allow the steering column assembly to pivot to adjust the position of the steering wheel (e.g., to adjust the tilt of the steering column assembly). The bracket structure 16 as shown is pivotally coupled to a column housing 20 to accommodate tilt function of the assembly relative to the vehicle operator.

[0062] The steering column assembly 10 includes an adjustment subassembly 18 that allows for telescopic adjustment of the steering column assembly, tilt adjustment of the steering column assembly, or both. The illustrated steering column assembly 10 is an electric adjustment subassembly, which uses one or more motors to effect the adjustment. Manual adjustment subassemblies (e.g., through the use of a user-operated device such as a lever) are also contemplated.

[0063] 2 shows the column tube 30 upon which is disposed the wedge assembly 40. The wedge assembly 40 includes a wedge body 42 and a preload member 60.

[0064] Although the column tubes are shown as having a generally cylindrical or generally circular cross-section, other shapes of column tubes are contemplated. For example, the column tubes may have a square or rectangular cross-section. The wedge body may be configured to be generally complementary to the outer shape of the column tube. The wedge body may be configured to be attached to or positioned (e.g., without rocking) against the outer surface of the column tube.

[0065] Figure 3 is an enlarged view of the wedge assembly 40 of Figure 2. The wedge assembly includes a wedge body 42 having a column housing contact surface 44 (or two column housing contact surfaces separated by a thinned portion 58) adapted to contact the column housing 20 (see Figure 5) and a column tube contact surface 45 (or two column tube contact surfaces separated by a thinned portion 58) having a curved surface adapted to contact the outer surface of the column tube 30. The wedge body 42 has a thick edge 46 and a thin edge 48 on its long side, and the thickness of the wedge body decreases from the thick edge 46 to the thin edge 48 when viewed from the short side or cross section of the wedge body. A fastener 52 passes through an opening 24 in the column housing 20 (see Figure 5) and is received in a fastener groove 50 in the wedge body 42. The fastener groove has a width capable of accommodating a fastener 52 and a length to allow at least some movement of the fastener along its length such that when the wedge body is forced into the gap between the column tube and the column housing, the fastener remains positioned within the wedge body while allowing some movement of the wedge body. The fastener groove 50 is positioned approximately perpendicular to the longitudinal axis of the wedge body.

[0066] The wedge assembly 40 includes a preload member 60 having an elongated body 62 and two opposing ends 64 of the elongated body. The illustrated ends 64 are curved or coiled, although other configurations or shapes are contemplated. One end 64 wraps around the post 54 of the wedge body 42. The opposite end 64 of the preload member 60 is received within a cavity 56 of the wedge body 42. When a force is applied to the elongated body 62 of the preload member 60, the end 64 around the post 54 remains fixed, while the opposing end 64 within the cavity 56 is permitted to move within the confines of the cavity and engage or contact one or more surfaces that define the cavity. The engagement between the ends 64 and the cavity 56 can allow the wedge assembly 40 to be wedged between the column tube 30 and the column housing 20 as a delashing mechanism.

[0067] 4 shows a wedge body 42 having a column housing contact surface 44 (or a pair of column housing contact surfaces 44) adapted to contact a portion of the column housing when assembled in a steering column assembly. The opposite surface is a column tube contact surface 45 (or a pair of column tube contact surfaces) adapted to contact a portion of a column tube of the steering column assembly. The illustrated wedge body 42 also includes a thinned portion 58 located approximately centrally between the two column housing contact surfaces 44.

[0068] The wedge body 42 has a pair of long sides and a pair of short sides that form a generally rectangular body. The long sides can have one or more segments of greater thickness than an opposing segment on the opposite long side. One long side, or a portion thereof, is a generally thicker edge 46, and the opposite long side, or a portion thereof, is a generally thinner edge 48 compared to the thicker edge. The thickness of the wedge body 42 can generally decrease, at least in certain portions, from one long side to the opposite long side. This decrease in thickness can be visible from either the short sides or a cross section of the wedge body.

[0069] The thickness of the thinned portion 58 may be different from the thickness of one or more other segments of the thick edge 48, the thickness of one or more segments of the thin edge 48, or both. The thickness of the thinned portion 58 may still decrease from one long side to the opposite long side, even if the angle and / or slope is different. The thickness of the thinned portion 58 may be approximately uniform from long side to long side. The thinned portion may be formed on one or both sides of the wedge body 42. For example, the thinned portion 58 may be present and located between two column housing contact surfaces 44. The thinned portion 58 may be present between two column tube contact surfaces 45. The wedge body 42 may have a single continuous column housing contact surface, a single continuous column tube contact surface, or both (e.g., when a thinned portion is present on only one surface of the wedge body, or when a thinned portion is not present on the wedge body).

[0070] The wedge body 42 includes features for engaging or interacting with a preload member (see FIG. 3). The wedge body includes a post 54 around which a portion of the preload member may be wrapped or otherwise secured. The post 54 is surrounded by a void within the wedge body such that the post 54 is formed within the wedge body 42 and does not extend beyond the plane or tangent to the column housing contact surface 44.

[0071] The wedge body 42 includes a cavity 56 configured to receive an end of the preload member opposite the end that contacts the post 54. The cavity 56 is defined by one or more contact surfaces against which the end of the preload member contacts while a force is applied to the preload member. The end of the preload member is allowed to move within the confines of the cavity until it reaches a boundary of the cavity. At that point, the wedge body 42 is forced between a column tube and a column housing of the steering column assembly.

[0072] The wedge body includes a fastener groove 50. As shown, the fastener groove 50 is located in the thinned portion 58, although other configurations are contemplated. The fastener groove extends from one long side of the wedge body toward the center of the wedge body. The fastener groove 50 has a width sufficient to accommodate a fastener therein and a length sufficient to allow the wedge body to move a predetermined distance as the wedge body is forced between the column tube and the column housing.

[0073] FIG. 5 illustrates an exemplary column housing 20. The column housing 20 includes a generally cylindrical inner surface having a recess 22 configured to receive a wedge assembly 40 (see FIG. 3). An opening 24 through the column housing is disposed in the recess 22 to receive a fastener 52 that is also received in a fastener groove 50 in the wedge body 42 (see FIG. 3). The depth of the recess varies to correspond to the shape of the wedge body, and is shown here to correspond to a wedge body having thick and thin edges. The depth of the recess is greatest at or near the contact edge 26, where the elongated body 62 of the preload member 60 abuts the contact edge 26.

[0074] 6 is a cross-sectional view of the steering column assembly 10 having the column housing 20 and the column tube 30. The wedge assembly 40 is disposed within the recess 22 of the column housing 20 between the column housing 20 and the column tube 30.

[0075] 7 is a free body diagram illustrating the forces acting on the steering column assembly due to the wedge assembly 40. The wedge body has a thick edge 46 and a thin edge 48 and is spaced apart by an angle Φ 1 As shown, the preload member 60 abuts against the contact edge 26 of the column housing 20. The spring force Fs is indicated by the horizontal arrow. The wedge body 42 is forced in the direction of the spring force Fs, pushing against the column tube 30 to create a vertical force Fv.

[0076] 8 is a simplified diagram of the force due to the wedge assembly 40, which creates a contact area 70 where the column tube is forced towards the column housing. The spring force Fs is generally tangent to the outer surface of the column tube 30. A vertical force Fv pushes the column tube 30 towards the column housing 20 at the contact area 70, thereby reducing or eliminating lash.

[0077] The present teachings provide an example of the structure and operation of a "powered reach and rake" steering column assembly for a vehicle in accordance with the present teachings. Although the present teachings are shown as an internal collapse system, they are also applicable to other collapse modes (e.g., external collapse). The assembly can have tilt and telescopic adjustment functions. For each such function, there is an associated motor. However, it is possible to omit one of the motors (e.g., tilt adjustment can be done manually using a lever or other user-operated mechanism without a motor).

[0078] The elements described herein can be formed of multiple pieces (e.g., the wedge body can be formed of two or more pieces rather than a single piece). The elements described herein can be of unitary construction. For example, the preload member and wedge body can be integrally formed rather than having a separate preload member and a separate wedge body. For example, the preload member can include a flexible extension member of the wedge body. The flexible extension member can be a molded feature of the wedge body that can deform to provide the preload. The column housing can include a feature that functions as a preload member.

[0079] Although the column tube is shown as being generally cylindrical, it is contemplated that the column tube may have a non-circular cross section. For example, the column tube may have a square or rectangular cross section. The shape of the column housing or the portion that receives the column tube may have a shape that allows for translation of the column tube within the column housing. The portion of the column housing that receives the column tube may have a shape that is generally similar to the shape of the exterior surface of the column tube.

[0080] Although described herein as a wedge assembly pushing against the column housing, it is contemplated that the structure could be modified so that a preload member pushes against the column tube.

[0081] Although shown as having two contact surfaces between the wedge body and the column tube or between the wedge body and the column housing, a single contact surface is also contemplated, as are three or more contact surfaces.

[0082] Any numerical value recited herein includes all values ​​from the lower value to the higher value in increments of one unit, provided that there is at least a two unit separation between the lower and higher values. As an example, where the amount of a component or value of a process variable, such as temperature, pressure, time, is described as being, for example, 1-90, preferably 20-80, more preferably 30-70, it is intended herein to explicitly recite values ​​such as 15-85, 22-68, 43-51, 30-32, etc. In the case of values ​​less than one, one unit is considered to be 0.0001, 0.001, 0.01, or 0.1, as appropriate. These are merely examples of what is specifically intended, and all possible combinations of numerical values ​​between the lowest and highest recited values ​​are considered to be explicitly set forth in this application in a similar manner.

[0083] Unless otherwise stated, all ranges include the endpoints and all numbers between the endpoints. The use of "about" or "approximately" in connection with a range applies to both ends of the range. Thus, "about 20 to 30" is intended to encompass "about 20 to about 30," inclusive of at least the specified endpoints.

[0084] Relative dimensions and / or ratios disclosed herein are part of the teachings (eg, in the text and in the drawings) even if not explicitly stated.

[0085] The disclosures of all articles and references, including patent applications and literature, are incorporated by reference for all purposes. The term "consisting essentially of" to describe a combination is intended to include the specified elements, components, ingredients, or steps, as well as other elements, components, ingredients, or steps that do not materially affect the basic and novel characteristics of the combination. The use of the terms "comprising" or "including" herein to describe a combination of elements, components, ingredients, or steps also contemplates embodiments that consist essentially of or even consist only of the elements, components, ingredients, or steps.

[0086] A plurality of elements, components, components, or steps may be provided by a single integrated element, component, component, or step. Alternatively, a single element, component, component, or step may be divided into a plurality of elements, components, components, or steps. The disclosure of "a" or "one" to describe an element, component, component, or step is not intended to exclude additional elements, components, components, or steps.

[0087] The relative positions of elements depicted in the drawings are part of the teaching of this specification even if not described verbally. [Explanation of symbols]

[0088] 10 Steering column assembly 12 Front end 14 Rear end 16 Bracket structure 18 Adjustment subassembly 20 Column housing 22 Recess 24 Opening 26 Contact Edge 30 Column Tube 34 Steering shaft 40 Wedge Assembly 42 Wedge body 44 Column housing contact surface 45 Column tube contact surface 46 Thick Edge 48 Thin Edge 50 Fastener groove 52 Fastener 54 Post 56 Cavity 58 Thin Section 60 Preload member 62 Long and thin body 64 Curved or coiled ends 70 Contact part Fs Spring force Φ1 angle Fv Vertical force

Claims

1. a. A preload member having an elongated body, b. The wedge body and A wedge assembly for a steering column assembly comprising, The wedge body is, i. A column tube contact surface configured to contact the outer surface of the column tube, ii. A column housing contact surface configured to contact the column housing, iii. Generally, a pair of opposite long sides, where one long side is a thick edge and the other long side is a thin edge, and the thickness of the wedge body decreases from the thick edge to the thin edge, iv. Generally, the opposite pair of short sides, v. A support column, one or more cavities, or both, A wedge assembly equipped with a wedge.

2. The wedge assembly according to claim 1, wherein the wedge body has a wedge angle of about 3 degrees to about 12 degrees.

3. The wedge assembly according to claim 1, wherein the column tube contact surface, the column housing contact surface, or both thereof have substantially curved contact surfaces, and the angle between tangents along the substantially curved contact surfaces is about 3 degrees or more, about 12 degrees or less, or both.

4. The wedge assembly according to claim 1, wherein the preloading member is a spring, and the preloading member is a leaf spring, a wire spring, a steel spring, or a combination thereof.

5. The wedge assembly according to claim 1, wherein the preload member has a first end and a second end, and the first end, the second end, or both are curved and / or coiled.

6. The wedge assembly according to claim 1, wherein the wedge body includes the support column, and the preloading member has a first end and a second end, the first end or the second end being fixed to the support column of the wedge body and / or at least partially positioned around the support column of the wedge body.

7. The wedge assembly according to claim 1, wherein the wedge body includes one or more cavities, and the preload member has a first end and a second end, and the first end, the second end, or both are housed in the one or more cavities of the wedge body.

8. The wedge assembly according to claim 1, wherein the preloading member is a flexible expansion member of the wedge body.

9. The wedge assembly according to claim 1, wherein the preloading member is made of an elastically compressible material.

10. The wedge assembly according to claim 9, wherein the preloading member is made of rubber.

11. The wedge assembly according to claim 1, wherein the wedge body includes one or more fixing features for fixing the wedge assembly inside the column housing, between the column housing and the column tube, or both.

12. The wedge assembly according to claim 11, wherein the one or more fixing features enable the wedge body to move generally in the lateral and / or tangential direction.

13. The wedge assembly according to claim 11, wherein the fixing feature portion of the wedge body includes a fastener groove for housing a fastener, and the fastener groove penetrates a portion of the thickness of the wedge body.

14. The wedge assembly according to claim 1, wherein the wedge body includes one or more cavities, each of which has one or more surfaces for contacting a first end or a second end of the preload member in order to define the amount of movement of the preload member when compressed, and / or to allow free movement of the preload member over the entire range of motion.

15. The wedge assembly according to claim 1, wherein the load of the preload member is substantially tangential to the column tube.

16. The wedge assembly according to claim 1, wherein the wedge body includes the support column, and the support column is created by the voids in the material surrounding the support column.

17. The wedge assembly according to claim 1, wherein the wedge body includes the support column, and the support column does not extend beyond the contact surface of the column housing.

18. The wedge assembly according to claim 1, wherein the wedge body has a thin-walled portion, and the thin-walled portion has a thickness less than the thickness at another point along the length of the wedge body.

19. The wedge assembly according to claim 1, wherein the wedge assembly has a preload controlled to create a sliding force between the column housing and the column tube of approximately 5 N to approximately 300 N.

20. a. Column housing and, b. The column tube received within the column housing, c. The wedge assembly according to claim 1, disposed between the column tube and the column housing, Equipped with, The column housing is provided with a recess for receiving the wedge assembly, The steering column assembly for an automobile, wherein the recess includes a preload member contact edge that contacts the preload member of the wedge assembly.

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