Automotive steering column detachment device

Abstract

An energy absorption assembly (50) for a steering column assembly includes an energy absorption plate (52), a gear plate (60), and a breakaway bracket (80). The energy absorption plate (52) may include a first end and a second end and may have a curved portion therebetween. The gear plate (60) may engage and / or disengage with a locking mechanism. The energy absorption plate (52) may be attached to the gear plate (60) at or near one end of the gear plate (60). The breakaway bracket (80) may be attached to the gear plate (60) at or near the opposite end of the gear plate (60).

Description

[Technical Field]

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

[0002] [Technical field] Generally, the present teachings relate to improved collapsible steering column assemblies and related methods. More specifically, the present teachings relate to tilt and / or telescopically adjustable internal collapsible steering column systems that include an energy absorption assembly configured to absorb energy upon the occurrence of an impact exceeding a threshold load. [Background technology]

[0003] During a vehicle collision, there are generally two impacts: a primary impact, in which the vehicle collides with another object; and a secondary impact, in which the vehicle occupant collides with a vehicle component. For example, a vehicle driver may collide with the steering wheel due to inertia. To help protect the driver from such a secondary impact, it has become common practice to use a crash-absorbing steering column. A collapsible steering column system is an example of a crash-absorbing steering column.

[0004] The structure of the crash-absorbing steering column device is such that, when a driver experiences a secondary impact, impact energy acts on the steering column in a forward direction of the vehicle. The steering column, or portions thereof, may break away from one or more fixed points to the vehicle body and move forward (e.g., through a collapse stroke), absorbing impact energy during the collapse stroke. An externally collapsing column assembly is an example of a system in which the entire column translates relative to its fixed points. An internally collapsing column assembly is typically fixed within the vehicle at one or more fixed points near one end of the assembly. During the collapse stroke from the secondary impact, the components of the assembly collapse longitudinally (e.g., generally within the volume they occupy within the vehicle during normal operation, i.e., generally within their "footprint" within the vehicle), but generally not beyond a certain distance relative to the predetermined fixed points. In this way, an internally collapsing system may have a stroke but remain fixed to the vehicle at one or more fixed points.

[0005] For many applications, steering column assemblies incorporate one or both of a tilt function and a telescopic function. In such applications, it is common to employ levers for manual activation of such functions by the vehicle user. As an example, in what are known as "manual rake and reach" steering column assemblies, the assembly has both a tilt ("rake") function and a telescopic ("reach") function, with levers provided for the vehicle user to manually release to allow rake and reach adjustment to a selected position and then reengage to lock the steering column in that selected position.

[0006] Some current assemblies include energy absorbing plates or straps within the energy absorbing assembly. Some assemblies include release features or devices that require the use of attachment features located within the deformation range of the energy absorbing plates or straps. Features in this area can affect the column collapse load.

[0007] While existing designs may work for their intended purposes, there is still a need for different packaging of the detachment device relative to the energy absorbing plate. There is a need to add more space between the deformation region and the detachment device. To increase predictability, there is a need to be able to add the required geometry to ensure the detachment feature detaches in controlled shear. Predictability can be important because bending failure, tension failure, or a combination of shear, bending, and tension can be difficult to predict and / or control. As an example, U.S. Pat. No. 11,440,578 shows a rivet that penetrates a deformable portion of an energy absorbing strap. Such positioning compromises the force-displacement profile of the steering column. Furthermore, because the rivet does not have features that cause shear failure, it is likely to fail in a bending / tension mode. Therefore, an alternative configuration is needed. Summary of the Invention

[0008] The present teachings utilize a simple yet elegant construction approach that allows for a relatively small number of components to be employed to achieve a steering column assembly, such as a collapsible steering column assembly. The steering column assembly may be an adjustable steering column assembly (e.g., for rake and / or reach). For example, although having applicability to externally collapsible assemblies (as contemplated within the present teachings), the steering column assembly herein may be an internally collapsible assembly. It may be an assembly mounted within a vehicle at one or more fixed points such that, during a secondary impact, the steering column assembly resists forward movement substantially beyond the one or more fixed points (e.g., more than about 10 mm or more, or more than about 20 mm or more). It may be a collapsible steering column assembly that exhibits relatively good energy absorption characteristics, particularly during a secondary impact. It may be a collapsible steering column assembly that exhibits longitudinal displacement (e.g., forward translation) of one or more components of the assembly (e.g., the column tube) during a secondary impact.

[0009] It is contemplated within the scope of the present teachings that a collapsing steering column assembly includes any combination of the following features in the following paragraphs. It may be an internal collapsing assembly or an external collapsing assembly, although internal collapsing assemblies in which at least a portion of the assembly is fixed against any substantial forward movement within the vehicle (e.g., less than about 50 mm, less than about 20 mm, or less than about 10 mm) are particularly attractive. The steering column assembly may include a steering wheel position adjustment portion (e.g., a mechanism adapted to adjust the rake and / or reach position of the steering wheel relative to the vehicle driver, such as a telescopic tubular mechanism). It may include one or more brackets for at least partially supporting the steering wheel position adjustment portion and / or for mounting the assembly within the vehicle. It may include a locking member (e.g., a tilt bolt or other elongated member, such as one adapted to apply a locking force that helps maintain the steering column assembly in a desired position, as described elsewhere herein) for locking the position of the steering wheel position adjustment portion (e.g., by operation of a lever adapted to be used by the driver to apply or remove a locking force). During normal operation, the steering column assembly may be in a fixed 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 secured in a fixed position within the steering column assembly. The fixed engagement position may be a user-selected adjustment position of the adjustable steering column assembly.

[0010] The present teachings contemplate an energy absorption assembly for a steering column assembly. The energy absorption assembly may include an energy absorption plate, a gear plate, a breakaway bracket, or a combination thereof.

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

[0012] The energy absorbing assembly may include a gear plate. The gear plate may be adapted to engage and / or disengage with the locking mechanism. The gear plate may be integrally formed with the energy absorbing assembly (e.g., as one piece). The gear plate may be separate from the energy absorbing plate. The gear plate and the energy absorbing plate may be formed of different materials, with different strengths (e.g., different tensile strengths), with different thicknesses, or combinations thereof. The energy absorbing plate may be attached to and / or extend from the gear plate (e.g., at or near one end of the gear plate). Fasteners may connect the energy absorbing plate and the gear plate at the joint. A slot may be disposed at the joint between the gear plate and the energy absorbing plate (e.g., in the energy absorbing plate, the gear plate, or both). The gear plate may have a generally planar surface. The gear plate may be configured to be positioned generally parallel to a surface of a column tube of the steering column assembly. The gear plate may include a toothed surface adapted 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 assembly may include a breakaway bracket. The breakaway bracket may include one or more features that engage with or secure another portion of the steering column assembly. The breakaway bracket may be attached to the column tube (e.g., during normal operation or before an impact exceeding a threshold load). The breakaway bracket may engage with one or more openings in the column tube (e.g., during normal operation or before an impact exceeding a threshold load). The breakaway bracket may include a column tube pin adapted to be received in the opening in the column tube. The breakaway bracket may be attached to the gear plate (e.g., at or near the end of the gear plate opposite the energy absorption plate). The breakaway bracket may include one or more gear plate anchors for engaging with 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 with the opening in the gear plate via one or more wings or tabs. The gear plate anchor may connect to the gear plate via, for example, a snap fit. The breakaway bracket may include a slot for receiving and engaging a portion of the gear plate.The breakaway bracket may include a slot for receiving and engaging a portion of the gear plate.

[0014] The release bracket 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 release bracket may be configured to decouple the release bracket from the column tube when an input load exceeds a threshold load. The threshold load may be approximately 250 N or more, approximately 350 N or more, approximately 500 N or more, approximately 600 N or more, or approximately 800 N or more. The threshold load may be approximately 10,000 N or less, approximately 8,000 N or less, approximately 6,000 N or less, approximately 5,000 N or less, or approximately 1,000 N or less.

[0015] The present teachings also contemplate an assembly for a steering column assembly including the energy absorption assembly and a column tube. The gear plate can be selectively attached to the column housing via an adjustment subassembly (e.g., a telescopic positive locking mechanism) of the steering column assembly. The energy absorption plate can be secured to the column tube by one or more fasteners. The fasteners can be rivets, such as non-shear rivets. The breakaway bracket can include a column tube pin extending from the breakaway bracket and received within the column tube (e.g., within 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 rivets. The breakaway bracket can include one or more fasteners, one or more column tube pins, or a combination thereof. When subjected to an impact exceeding a threshold load (e.g., a load of about 500 N or more, about 6000 N or less, or both), the release bracket may detach from the column tube while the energy absorption plate remains secured to the column tube. The column tube pin, shear rivet, or a combination thereof may shear to allow the release bracket to detach from the column tube. Alternatively or additionally, the release bracket may be secured to the column tube using one or more fasteners, such as non-shear rivets. The gear plate anchor may be positioned such that the release bracket detaches from the gear plate when the impact load exceeds the threshold load.

[0016] The present teachings also contemplate a steering column assembly including any combination of features, including, but not limited to, a column tube, a steering shaft supported for at least partial rotation by the column tube, a bracket for at least partial support of the column tube, an adjustment subassembly, and an energy absorption assembly as described herein. The adjustment subassembly may be adapted to selectively adjust the steering shaft, the column tube, or both, forward or rearward generally along the longitudinal axis. The adjustment subassembly may be adapted to selectively raise or lower the steering shaft, the column tube, or both.

[0017] As can be appreciated, it is possible to achieve unique assemblies (and associated methods) that allow the steering column assembly to be adjusted (e.g., tilt, telescopic, or both), facilitate assembly, reduce the number and / or size of required parts, provide energy absorption and / or release during a crash above a threshold load, or provide a combination thereof. [Brief explanation of the drawings]

[0018] [Figure 1] FIG. 1 is a side perspective view of an exemplary steering column assembly in accordance with the present teachings.

[0019] [Figure 2] FIG. 2 is a perspective view of an adjustment subassembly of a steering column assembly in accordance with the present teachings.

[0020] [Figure 3] FIG. 3 is an exemplary energy absorbing assembly in accordance with the present teachings.

[0021] [Figure 4] FIG. 4 is an exploded view of the energy absorption assembly of FIG.

[0022] [Figure 5A] 5A and 5B illustrate an exemplary breakaway bracket in accordance with the present teachings. [Figure 5B] 5A and 5B illustrate an exemplary breakaway bracket in accordance with the present teachings.

[0023] [Figure 6] FIG. 6 shows an exemplary energy absorption assembly secured to a partially transparent column tube.

[0024] [Figure 7] FIG. 7 illustrates an exemplary energy absorbing assembly in accordance with the present teachings.

[0025] [Figure 8] FIG. 8 illustrates an exemplary energy absorbing plate and telescopic stop bracket in accordance with the present teachings.

[0026] [Figure 9] FIG. 9 illustrates an exemplary breakaway bracket in accordance with the present teachings. DETAILED DESCRIPTION OF THE INVENTION

[0027] As required, details of the present teachings are disclosed herein. It should be understood that the disclosed teachings are merely examples and may be embodied in various and alternative forms. The drawings are not necessarily to scale, and some features may be exaggerated or minimized to show details of particular components. Some features may be omitted for clarity or the like. Therefore, specific structural and functional details disclosed herein should not be construed as limiting, but merely as a representative basis for teaching those skilled in the art that the present teachings can be variously employed.

[0028] The present teachings may include features of the steering column assembly (e.g., positive lock assembly) of U.S. Patent Application Publication No. 2021 / 0394816, the contents of which are expressly incorporated by reference herein in their entirety for all purposes.

[0029] In general, as will be understood from the following description, the present teachings relate to a steering column assembly. The steering column assembly may include a mounting portion for securing the steering column assembly to a vehicle in a fixed operating position. The assembly may have a collapsing and / or telescoping portion, at least a portion of which is adapted 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 controlled and / or limited to an amount of about 50 mm or less, about 20 mm or less, or about 10 mm or less). Within its basic concept, the present teachings are directed to a steering column assembly in which at least a portion of the collapsing portion may be adapted to move forward within the vehicle upon the occurrence of an impact, such as a secondary impact resulting in a threshold amount of load (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). The forward movement may be telescopic (e.g., at least one first structure (e.g., a column tube) operatively connected to the steering wheel may advance forward within the vehicle (e.g., along an axis generally parallel to the longitudinal axis of the vehicle (e.g., within about 10° of parallel to the longitudinal axis of the vehicle)) relative to at least one second structure (e.g., a column housing) that may at least partially surround the at least one first structure).

[0030] The present teachings contemplate that a steering column assembly may include tilt or rake adjustments adapted to allow a user to select a tilt angle of the steering wheel, reach adjustments adapted to allow a user to select a suitable fore-aft position of the steering wheel, or both. Generally, any such adjustments may be controlled by a suitable user-operated device (e.g., a lever, an electromechanical actuator, a motor, or the like). In a manually operated system, the lever or other user-operated device may be adapted to control the force applied to maintain the crush section in a user-selected position. For example, the lever or other user-operated device may be in operative engagement with one, two, or more mechanisms to releasably (and possibly adjustably) secure two or more components of the crush section together. In particular, with respect to tilt adjustment of the assembly, the securement may be achieved by a suitable securement member (e.g., an elongated force-applying member), such as a bolt (e.g., a tilt bolt), a rod, a strap, a bar, a band, a wedge, a cam, or other suitable member, or a combination thereof. For example, the fixing member may be adapted to rotate a cam or rotating member upon actuation of the user controlled device to engage with a wall of the tilt plate to fix the steering wheel at its desired angle. Upon actuation of the user controlled device, the pin may be forced out of engagement with or into engagement with one or more engagement features (e.g., a toothed portion, a shape complementary to the pin, or one or more openings) located on or attached to the column tube to allow telescopic adjustment.

[0031] In the illustrated embodiment, the present teachings describe an embodiment useful for an internal collapsing steering column assembly for an automotive vehicle. Generally, an assembly of the present teachings herein may include a steering shaft (e.g., that may be coupled to a steering wheel or other steering device) and / or a column tube supporting the steering shaft (e.g., via one or more bearings). A column housing may be employed. The column housing may be adapted to be telescopically coupled to the column tube (e.g., each may have longitudinal axes that are generally parallel or coaxial with each other). One or more brackets may be employed to at least partially secure either or both of the column tube and the column housing to the vehicle (e.g., to a cross-vehicle structure). The bracket or one or more tilt plates may include suitable portions (e.g., slots, such as generally vertically oriented slots) adapted to provide a guide structure for the tilt function. A user-operated device, such as a lever, may be employed to allow a user to manually operate and / or adjust the assembly. An electromechanical device may be employed that applies or releases force in response to a signal from an operating switch. The steering column assembly may be configured so that upon the occurrence of a threshold load realized 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 translate forward from its typical operating position. Thus, the column tube can be translatable forward relative to the column housing, taking the attached steering wheel with it. As a result, it can be seen that the steering wheel can be translated forward, e.g., away from the user.

[0032] The present teachings address an assembly that may typically include 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 (such as a lever as described above or some other user-operated device) adapted to actuate (e.g., manually actuate) the subassembly via tilt, 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 cause tilt, telescoping, or both. It is further contemplated that a lever may be used to effect the tilt or telescoping function, while a motor or other electromechanical actuator may be used to effect the other of the tilt and telescoping functions. At least one engagement means (e.g., a pin) may engage and disengage with the column tube or a structure secured thereto to selectively lock the steering shaft (e.g., via a lever) in a position desired by a user (e.g., a telescope position). One or more rotating members may engage and disengage (e.g., via interference) with walls of the tilt plate defining the vertical slot to adjust a tilt position desired by a user (e.g., via a lever). During an impact, such as a secondary impact, the column housing remains in a substantially fixed position relative to the forward pivot mounting position (e.g., any forward translation is limited to a relatively small amount (e.g., about 20 mm or less, or about 10 mm or less)).

[0033] The assemblies described herein generally include a tube operatively connected to a steering wheel (not shown), for example, via a steering shaft. One such tube, referred to herein as a column tube, typically has a hollow cavity along at least a portion (if not all) 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 the tube have a longitudinal axis. When installed in a vehicle, the longitudinal axes of the shaft and the tube (and the entire steering column assembly) may be substantially coaxially aligned, substantially parallel to the longitudinal axis of the vehicle, or otherwise aligned. The shaft and the column tube may be made of or include a suitable metal, such as one or more of iron (e.g., steel), magnesium, zinc, or aluminum.

[0034] 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. The column tube may have a forward end and an aft end and a longitudinal axis. Either or both of the forward end and the aft end may include suitable bearings that rotatably support the steering shaft.

[0035] The steering shaft may have a rearward end adapted to receive a steering wheel (not shown). It may have a forward end that extends therethrough and may be supported by a bearing, a key-lock collar, or both. As previously mentioned, the steering shaft may be rotatably supported at least in part by the column tube and may have a longitudinal axis that may be generally coaxially aligned with the longitudinal axis of the column tube.

[0036] The column tube may include one or more openings along its length, which may be adapted to receive fasteners such as rivets or pins (e.g., column tube pins of a breakaway bracket) extending from another element of the assembly.

[0037] One or more suitable brackets may be employed. Any such bracket may include a portion for mounting the steering column assembly within the vehicle (e.g., it may be secured to a vehicle structure such as a vehicle cross beam, instrument panel, or the like). The bracket may have a portion that at least partially abuts the steering shaft support structure (e.g., a column tube, a column housing, or both). For example, the bracket may include or be coupled to one or more downwardly depending (downwardly facing) walls (e.g., tilt plates) that define the tilt portion of the bracket. One or more of the downwardly depending walls (e.g., tilt plates) may be adapted to provide a structure with elongated slots that provide guidance for the tilt function (e.g., it may provide a guide path for a fastener such as a tilt bolt as it moves during adjustment, thereby limiting upward and downward movement). The bracket may be an integrated structure (e.g., cast, pressed, or a combination thereof) such that the tilt portion and the mounting portion are a single structure. The bracket may also be made from multiple separate structures assembled together to define the mounting portion and tilt portion within a single structure. The mounting portion may be omitted and / or located elsewhere in the steering column assembly. The tilt portion may be omitted. A mounting bracket may be employed separate from the structure defining the tilt portion. In addition to the examples described herein, examples of brackets that may be employed include those in U.S. Patent Application Publication No. 2010 / 0300238, which is incorporated by reference in its entirety for all purposes (see, e.g., the description of bracket 20) and U.S. Patent No. 6,467,807, which is incorporated by reference in its entirety for all purposes (see, e.g., the description of brackets 6 and 7 and related structures).

[0038] One or more brackets (e.g., tilt brackets), tilt plates, or combinations thereof may be employed and adapted to receive at least a portion of the steering shaft support structure (e.g., at least a portion of the column tube, the column housing, or both) and / or to mount the steering column assembly within the automotive vehicle. As an example, a tilt bracket of the present teachings may include an upper portion adapted to be secured to a vehicle structure such as a vehicle cross beam, an instrument panel, or the like. The bracket (e.g., tilt bracket) may have a pair of generally opposing downward-facing or downward-projecting walls (e.g., tilt plates). The bracket (e.g., tilt bracket) may have a structure at least partially adjacent to a side of at least a portion of the steering shaft support structure (e.g., the column tube) or may be directly or indirectly coupled to such one or more plates. The bracket (e.g., tilt bracket) may include, or be directly or indirectly coupled to, a pair of opposing side walls, an upper wall configured for attachment to a vehicle (e.g., a vehicle cross beam, an instrument panel, or other suitable structure), or a combination thereof. The side walls may project outwardly relative to the upper wall (e.g., the side walls may be disposed generally perpendicular or diagonally relative to the upper wall). The bracket (e.g., tilt bracket) may have a single downwardly projecting or downwardly oriented wall. The bracket (e.g., tilt bracket) may be disposed laterally above and outwardly relative to opposing portions of the column housing.

[0039] The teachings herein can be employed in steering column assemblies that are not adjustable but still require the ability to collapse. In such cases, there would be no rake or reach adjustment hardware. However, the concepts herein can still be adapted to achieve the collapse formula. A mounting bracket may secure one or both of the column housing and column tube to the vehicle. An energy absorption device may be employed to limit forward movement of one or more components of the steering column assembly, such as the column tube, the steering shaft, or both.

[0040] However, the present teachings are particularly applicable to an adjustable steering column assembly (e.g., for rake and / or reach). The assembly may include a manually operated steering wheel adjustment subassembly adapted to selectively adjust the steering shaft generally along a longitudinal axis in a fore-aft direction, selectively raise or lower the steering shaft, or both. The steering wheel adjustment subassembly may include a lever or other feature adapted to manually actuate the subassembly. The subassembly may include at least one engagement member (e.g., a pin such as a locking pin) that engages and disengages with the column tube or a structure secured 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, such as one or more thrust bearings, one or more nuts, one or more cam retaining elements, and / or one or more cam moving elements, may also be employed in the subassembly (e.g., the cam retaining element and the cam moving element are in opposing operating relationship, such as by contacting each other). The subassembly may also include one or more spacers or dampers to cushion shocks between elements, allow for smoother adjustment, guide deformation of one or more features within the assembly, or a combination thereof.

[0041] The column housing may be pivotally mounted at a pivot mounting location (e.g., a permanently fixed mounting location) within the automotive vehicle. The pivot mounting location may be at or within a range of approximately 20 mm, approximately 30 mm, approximately 40 mm, or approximately 50 mm from the forward end of the column housing. The pivot mounting location may be below the column housing, above the column housing, or somewhere between the upper and lower sides of the column housing. The column housing may at least partially surround the column tube. The column housing may have one or more protrusions or other structures for receiving a biasing device (e.g., a spring) connecting the column housing with the tilt bracket. The column housing may be of cast construction (e.g., including metals such as aluminum, magnesium, zinc, and / or iron (e.g., steel)). During a secondary impact, the column housing may remain in a generally fixed position relative to the pivot mounting location. It may be fixed to translate forward only a relatively small amount (e.g., approximately 50 mm or less, approximately 20 mm or less, or approximately 10 mm or less).

[0042] During an impact (e.g., a secondary impact), the structure of the present teachings can be configured to include a combination of suitable elements arranged in such a manner that the column tube, the steering shaft, or both, are longitudinally translatable forward relative to the column housing.

[0043] The present teachings also generally contemplate the use of one or more energy absorbing devices or assemblies. The energy absorbing device or assembly may be any suitable device adapted to deform elastically, plastically, and / or elastically and plastically. Thus, during the deformation process, the energy absorbing device is adapted to absorb energy through the deformation. The energy absorbing device may optionally be operatively connected or disposed between two or more components. The energy absorbing device may be configured to limit relative movement between two or more components. The energy absorbing devices may be wires, plates, strips, etc. They may have a constant or varying profile along their length. They may be adapted to have one or more fixed restraints (e.g., end portions). They may have one or more free ends.

[0044] Upon the occurrence of an impact exceeding a threshold load, energy absorption or control may be provided by one or more elements breaking away (separating) from another element within the assembly. For example, a bracket secured to a column tube may break away (separate) from or disengage from the column tube when subjected to an impact exceeding the threshold load. Fasteners such as rivets or features extending from the bracket into the opening in the column tube connecting the components may shear, causing separation. Energy absorption or control may also be provided by elements of the assembly engaging with each other. For example, a gear plate may have one or more features that engage with one or more features of an energy absorption plate. Or, the gear plate may have one or more features that engage with a breakaway bracket.

[0045] The assemblies herein may employ energy absorbing structures of the structural type or operational manner described in U.S. Patent Application Publication No. 2013 / 0233117, the entirety of which is incorporated by reference herein for all purposes. For example, the assemblies herein may include at least one plastically deformable energy absorbing device (e.g., a bent plate, wire, or other structure adapted to be at least partially supported by the column housing) that, when employed, absorbs energy during a secondary impact by plastic deformation after the steering shaft support structure (e.g., the column tube and steering shaft) begins translational movement along the column housing. Any plastically deformable energy absorbing device may limit the range of longitudinal movement of the column tube, the steering shaft, or both.

[0046] The present teachings contemplate an adjustment subassembly. The adjustment subassembly may include a tilt adjustment assembly, a telescopic adjustment assembly, or both. One or more components of the adjustment subassembly may operate to cause or facilitate both tilt and telescopic adjustment. For example, activation of a user-operated device, such as a lever, may lock and / or unlock both the telescopic and tilt adjustment assemblies.

[0047] The assembly herein includes a tilt adjustment assembly. The assembly may include two or more tilt plates extending downward from opposite sides of the column tube, the column housing, or both. The tilt plates may include one or more slots. The slots may be generally straight. The slots may have a curved portion. The slots may be generally vertical. The slots may be angled relative to the longitudinal axis of the steering column assembly. A tilt bolt or other elongated fastener may extend between the two tilt plates and be received in the slot. Height adjustment of the assembly may be possible by moving the tilt bolt up or down within the slot when a user-operated device, such as a lever, is in an unlocked position. The assembly may be held at a desired angle or height when the user-operated device, such as a lever, is moved to a locked position.

[0048] To lock the assembly at a desired height or angle for the driver, a user-operated device such as a lever may operate a locking system, such as a cam lock system. A rotating member may be disposed within one or both of the opposing tilt plate slots in the tilt adjustment assembly. The rotating member may be, for example, generally oval or teardrop-shaped. The rotating member may engage with walls defining the tilt plate slot (e.g., via teeth) when the lever or other user-operated device is in the locked position. A spring may be keyed to the tilt bolt and attached to the rotating member so that when the lever is in the locked position, the spring pushes or rotates the rotating member so that the teeth contact the tilt plate (e.g., the walls defining the slot). Due to the shape of the rotating member, when the lever is in the unlocked position, the rotating member disengages from the walls defining the tilt plate slot (the teeth may move away from the surface), allowing the rotating member and tilt bolt to move freely up or down within the slot to adjust the height and angle of the steering wheel for the driver or user.

[0049] The present teachings also contemplate telescopic adjustment assemblies. Features of a telescopic adjustment assembly may act to absorb and / or release energy upon impact, such as a secondary impact. Certain features of a telescopic adjustment assembly may be part of an energy-absorbing assembly. Features of a telescopic adjustment assembly, particularly features that act to absorb and / or release energy upon impact, may also be useful in other positive lock assemblies or non-positive lock assemblies. Such uses are also within the scope of the present teachings. While these features are beneficial in the exemplary positive lock structures described herein, the present teachings are not limited to use with positive lock structures such as those described herein.

[0050] The telescopic adjustment assembly and / or the energy absorption assembly may include a gear plate. The gear plate may be adapted to be operably secured to another portion of the steering column assembly, such as the column tube, the column housing, or both. The gear plate may function to provide an engagement area to allow locking of the telescopic adjustment assembly. The gear plate may include one or more features for securing the gear plate to another portion of the steering column assembly. The gear plate may include one or more openings for receiving fasteners (such as rivets, pins, screws, bolts), one or more protrusions or fasteners (e.g., integral fasteners) for reception in openings elsewhere in the assembly (e.g., openings in the column tube), or both.

[0051] The gear plate may be generally planar. The gear plate may have one or more segments or surfaces (e.g., a surface away from an element to which the gear plate is secured, such as a surface away from a column tube) that are generally planar.

[0052] The gear plate may include one or more side walls. The side walls may be generally transverse to the surface having the engagement region. The side walls may be adapted to extend toward the outer surface of the column tube. The side walls may provide stability to the gear plate, provide a desired orientation of the gear plate relative to the column tube, prevent rocking of the gear plate on the column tube, or a combination thereof.

[0053] The portion of the gear plate away from the column tube (or other element to which the column tube is attached) may engage a fastener or pin, such as a spring-biased locking pin. The locking pin may be actuated by a user-operated device, such as a lever on the steering column assembly. For engagement with the locking pin, the gear plate may include a friction surface, such as a toothed or textured surface. The gear plate may include a stepped surface. The gear plate may include a surface that is generally complementary in shape to a portion of the locking pin that engages to enable locking engagement between the structures. The gear plate may include one or more openings to receive a portion of the locking pin.

[0054] The adjustment subassembly may include a locking pin or other member adapted to engage with the gear plate to provide a locking engagement (e.g., locking after telescopic adjustment). Depending on whether the assembly is in a locked or unlocked position, the locking pin may be pushed into engagement with the gear plate or released from engagement with the gear plate. For example, when the lever is locked, the locking pin may be pushed toward the gear plate, and when the lever is unlocked, the locking pin may be lifted from the gear plate to allow smooth telescopic adjustment. The locking pin may be generally perpendicular to the longitudinal axis of the column tube, generally perpendicular to the longitudinal axis of the gear plate, or both.

[0055] The locking pin may have one or more features that allow it to engage and / or contact one or more other elements of the assembly. The locking pin may have a plurality of teeth or other engagement features at or near one end for engaging with the gear plate. Other engagement features may include textured surfaces, stepped surfaces, surfaces that are complementary to the contacting gear plate surface, extensions for being received within an opening, or combinations thereof.

[0056] The opposite end of the locking pin may be provided with a head that may be received within another portion of the assembly, such as a preload plate, where the head of the locking pin may extend toward the lever of the adjustment subassembly, away from the column tube, or both.

[0057] The locking pin can include a body portion. The body portion can function to provide an area around which a spring (e.g., a return spring) can be disposed. The body portion can provide length to the locking pin (e.g., make the pin as long as necessary to serve its intended purpose). The body portion can function to couple an engagement feature (e.g., a tooth) to another portion of the locking pin (e.g., a lip).

[0058] The locking pin may include a lip. The lip may have a larger diameter or maximum width than the head, the body portion, or both. The lip may provide one or more surfaces against which pressure is applied when in the locked position, the unlocked position, or both, allowing the locking pin to engage or disengage from the gear plate. A preload plate may rest on the lip of the locking pin when the head of the locking pin is received within the lip. The preload plate may urge or preload the locking pin toward the gear plate through contact with the lip. When in the unlocked position, a spring (e.g., a return spring) located around the body portion of the locking pin may contact the lip on the opposite side, lifting the locking pin from the gear plate and allowing smooth telescopic operation.

[0059] 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 portions whose cross-section includes one or more flat regions (e.g., shaped like the letter "D"). The locking pin may include one or more generally flat surfaces extending along at least a portion of the length of the locking pin. The generally flat surfaces may extend along the length of a body portion of the locking pin, along the entire length of the locking pin, or both. The generally flat surfaces may reduce or eliminate rotation of the locking pin within the assembly and may ensure proper alignment between the locking pin and the gear plate (e.g., between the teeth of the locking pin and the toothed surface of the gear plate).

[0060] The adjustment subassembly may include a preload plate. The preload plate may act as a spring to preload the locking pin into the gear plate (e.g., for tooth-to-tooth engagement). The preload plate may include a portion that receives a portion of the locking pin. For example, the preload plate may include a pin opening for receiving the head of the locking pin. The preload plate may include a portion that contacts a contact portion of a user-operated device, such as a lever.

[0061] The preload plate may include an outer segment. The preload plate may include an inner segment. The preload plate may include an arcuate portion connecting the inner and outer segments. The arcuate portion may provide a degree of flexibility to the preload plate, allowing it to bend or act as a spring. The inner and outer segments may be generally parallel to one another when at rest or when no force is acting thereon. Through the flexibility of the arcuate portion, the inner and outer segments may be biased toward one another (e.g., form an angular relationship rather than a parallel relationship) upon application of a certain force or pressure. The preload plate may have a generally C-shape.

[0062] The outer segment may include one or more contact features for contacting a contact portion of a user-operated device, such as a lever. For example, the outer segment may include one or more ridges, protrusions, or the like for contacting the contact portion while in the locked position, the unlocked position, or both.

[0063] The inner segment may include a pin opening for receiving the head of the locking pin. The pin opening may have a shape that is generally identical to the shape of the head of the locking pin 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 in the opening. The tabs may extend toward the outer segment and contact the head of the locking pin to further hold the locking pin in place (e.g., through friction, by preventing rocking or rotation, or both).

[0064] For telescopic adjustment, the portion of the gear plate facing away from the column tube may engage a fastener, such as a spring-loaded fastener, such as a locking pin (which may be actuated by a lever on the steering column assembly). The fastener may be inserted through an opening in the column housing, the tilt plate, or both. The fastener may be positioned generally perpendicular to the column tube. When a fastener, such as a spring-loaded fastener, is pressed or pressure is applied (i.e., when the spring is compressed), a tip of the fastener may be engaged with the gear plate. For example, if the gear plate includes a toothed surface, these teeth may engage the toothed end of the locking pin to provide a locking engagement and prevent further forward or rearward movement of the column tube. The pressure or compression of the spring-loaded fastener may be provided by a portion of a lever or other user-operated device. Pressure may be applied to a preload plate, which is distributed to the locking pin. Thus, a lever or other user-operated device may allow a user or driver to control the fore-aft telescopic adjustment of the steering column assembly. The lever may include a ramp portion or angled segment that faces the column tube and / or column housing. When the lever is in the locked position, the ramp portion may contact the head of a fastener (e.g., a locking pin), such as a preload plate (e.g., a contact feature) or a spring-loaded fastener, thereby pushing the pin toward the column tube. When the lever is in the unlocked position, the spring-loaded fastener may be released, and as the spring returns to its uncompressed state, the tip or end of the fastener disengages from the gear plate (e.g., a toothed surface), allowing the user to freely pull or push the steering wheel to telescopically adjust its position. Similarly, if the portion of the gear plate facing away from the column tube includes a series of holes or openings, the fasteners may have a corresponding shape that fits snugly within the holes or openings. Alternatively, the telescopic adjustment assembly may include a slot or gap through which the fastener may be received.The fastener may have an oval cross-section, and in one position the fastener may move freely within a slot or gap, and when rotated may prevent further movement (e.g., similar to the rotating members and slots described herein with respect to tilt adjustment).

[0065] The steering column assembly may include an energy absorption assembly. The energy absorption assembly may function to absorb energy, particularly during an impact above a threshold load. The energy may be absorbed by plastic deformation of a portion of the assembly, by elastic deformation of a portion of the assembly, by detachment (separation) of one or more portions of the assembly from another portion of the assembly, or by a combination thereof.

[0066] The energy absorption assembly may include any of a gear plate, an energy absorption plate, a breakaway bracket, or a combination thereof.

[0067] The gear plate may be as described above. The gear plate may be generally planar. The gear plate may include one or more features for engaging with other elements in the steering column assembly. The gear plate may include features for engaging with a portion of the adjustment subassembly. A portion of the gear plate may engage with the locking pin. For example, a toothed or textured surface may engage with a complementary toothed or textured surface on one end of the locking pin.

[0068] The gear plate may be fabricated from a material having sufficient strength to not bend, break, or deform when subjected to an impact exceeding a threshold load (e.g., greater than about 500 N, less than about 6000 N, or any range therebetween). The gear plate may be formed from any suitable metal or metal alloy. Suitable materials may include aluminum, magnesium, zinc, and / or iron (e.g., steel).

[0069] 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 may be provided an area adapted to contact and / or connect to the energy absorption plate.

[0070] For example, an opening may be provided at or near one end of the gear plate to receive a fastener for connecting the gear plate to the energy absorbing plate. The opening may include a collar or extension that surrounds the fastener. This may provide stability, maintain the distance between the gear plate and the second segment of the energy absorbing plate, reduce or prevent rocking of the gear plate, maintain the position or orientation of the fastener, or a combination thereof. The collar or extension may act as a nut. The opening may be free of a collar or extension.

[0071] The gear plate may include one or more features for supporting a damper. The damper may be utilized as a stop within the telescopic adjustment assembly to prevent excessive forward or rearward movement of the column tube. The damper may operate to maintain the position of the gear plate, provide stability to the gear plate, maintain the distance between the gear plate and the second segment of the energy absorption plate, reduce or prevent rocking of the gear plate, or a combination thereof. The damper may operate to protect the gear plate. The damper may operate to absorb energy within the energy absorption assembly. The damper may operate to maintain the position of the gear plate and / or prevent movement of the gear plate upon contact with the locking pin.

[0072] The damper may be located on one or more sides of the gear plate. For example, the damper may be located on one or both long edges of the gear plate. The damper may have one or more portions that are wider than other portions of the damper (e.g., may form a T-shape). This may help provide a soft stop during movement of one or more components of the steering column assembly.

[0073] The damper may be made of a polymer. The damper may be made of a resilient, elastic, and / or elastomeric material. The damper may be made of a plastic.

[0074] The damper may be one or more components. The damper may include two separate components located on opposite sides of the gear plate. The damper may be a single component. The damper may have a portion located on opposite sides of the gear plate and an adjacent portion located between the gear plate and the second surface of the energy absorbing plate.

[0075] An energy absorbing assembly may include a component that provides energy absorption. Such a component may be a wire, plate, strip, etc. For convenience, the component is referred to herein as an energy absorbing plate. The energy absorbing plate may be deformable when subjected to an impact exceeding a threshold load. The energy absorbing plate may have sufficient strength to deform without fracture. The energy absorbing plate may be formed from, for example, plastic, metal, metal alloy, or combinations thereof. Suitable materials may include aluminum, magnesium, zinc, and / or iron (e.g., steel).

[0076] The energy-absorbing plate may have a first end and an opposite second end. The energy-absorbing plate may be configured (arranged) to be bent, curved, or otherwise formed to have a nonlinear and / or non-planar configuration (e.g., the first end and second end are not coplanar). A curved portion may be provided between the first end and the second end. A segment (e.g., a first segment) of the energy-absorbing plate may be between the first end and the curved portion. The segment may be generally planar. A segment (e.g., a second segment) of the energy-absorbing plate may also be between the second end and the curved portion. The segment may also be generally planar.

[0077] The first and second segments can be generally parallel to one another. The first and second segments can be angled relative to one another. The angle formed between the first and second segments can be about 45 degrees or less, about 30 degrees or less, or about 15 degrees or less.

[0078] The first segment of the energy-absorbing plate can have a length. The second segment of the energy-absorbing plate can also have a length. The first segment can be shorter than the second segment. The ratio of the length of the second segment to the length of the first segment can be about 2:1 or more, about 3:1 or more, about 4:1 or more, or about 5:1 or more. The ratio of the length of the second segment to the length of the first segment can be about 15:1 or less, about 10:1 or less, or about 8:1 or less.

[0079] The energy absorbing plate may be adapted to be secured to a portion of the gear plate at a joint. The energy absorbing plate may include one or more features for attachment to the gear plate (e.g., integrated fasteners or openings for receiving fasteners). The gear plate may include one or more features for attachment to the energy absorbing plate (e.g., integrated fasteners or openings for receiving fasteners). For example, a first segment of the energy absorbing plate may be attached to a portion of the gear plate, both of which have aligned openings for fasteners to be positioned therebetween. It is envisioned that the fasteners may pass only through the first segment of the energy absorbing plate and not through the second segment of the energy absorbing plate.

[0080] One or more of the openings (e.g., the opening in the first segment of the energy absorbing plate, the opening in the gear plate, or both) may be slots rather than circular openings. Slots may be incorporated into the joint to allow the gear plate to slide relative to the energy absorbing plate. This may allow disengagement (e.g., of the breakaway bracket) to occur before the energy absorbing plate is engaged. The disengagement may be completely decoupled from the energy absorbing portion and / or the energy absorbing plate.

[0081] The gear plate and the energy absorbing plate may be formed of different materials. The gear plate may be formed of a stronger material than the energy absorbing plate. This may be advantageous in situations where the energy absorbing plate is configured to deform upon impact above a threshold load. It is envisioned that there may be situations where it is not desirable for the gear plate to deform in the same or similar manner.

[0082] The gear plate and the energy absorbing plate can be made of the same material. The energy absorbing plate can be integrally formed with the gear plate. The first end of the energy absorbing plate can be, for example, at or near the start of the toothed portion, or at or near the position where the damper is located on the gear plate, or at or near the position where the gear plate (and / or the gear plate with the damper) becomes wider than the energy absorbing portion.

[0083] The energy absorbing plate may include one or more features to allow the energy absorbing plate to be secured to a column tube of a steering column assembly. A second segment of the energy absorbing plate may be adapted to be positioned on an outer surface of the column tube. For example, the energy absorbing plate (e.g., the second segment) may include one or more openings for receiving fasteners. The openings may be aligned with one or more openings in the column tube such that the fasteners can be received in both openings. The fasteners may include pins, clips, screws, rivets, etc. For example, one or more rivets may be used to secure the energy absorbing plate to the column tube. The rivets may be shear rivets. Alternatively, the rivets may be non-shear rivets.

[0084] It is contemplated that one or more slots may be located in the opening in the second segment of the energy absorbing plate, the opening in the column tube, or both. The slots may allow a detachment to occur before the energy absorbing plate is engaged. This may decouple the detachment from the energy absorber and / or the energy absorbing plate.

[0085] The energy absorption assembly may include a portion adapted to detach from another portion of the steering column assembly. Detachment may occur upon an impact exceeding a threshold load (e.g., greater than about 500 N, less than about 6000 N, or any range or value therebetween). The portion adapted to detach may be a break-away bracket. The break-away bracket may be adapted to engage with the gear plate, the column tube of the steering column assembly, or both. The break-away bracket may be formed of a material capable of breaking, shearing, or deforming in a desired manner so that the break-away bracket can detach from another portion of the assembly, such as the column tube or gear plate, upon an impact exceeding the threshold load. The break-away bracket, or at least a portion thereof, may be made of a polymeric material. The break-away bracket, or at least a portion thereof, may be made of a plastic material.

[0086] The release bracket may have one or more features to allow the release bracket to be attached to the gear plate. The release bracket may be positioned at or near an end of the gear plate opposite the end connected to or integrally formed with the energy absorption plate. The release bracket may be positioned at least partially between the gear plate and the column tube. The release bracket may operate to connect the gear plate and the column tube. The release bracket may operate to provide sufficient distance between the gear plate and the column tube. The release bracket may hold the end of the gear plate opposite the energy absorption plate at a desired distance from the column tube (e.g., the gear plate is held generally parallel to the longitudinal axis of the column tube).

[0087] The break-away bracket may be positioned between the column tube and the underside of the gear plate (e.g., the surface opposite the tooth flank). The gear plate may have an opening adapted to receive a portion of the break-away bracket to secure the break-away bracket to the gear plate. The gear plate and break-away bracket may be attached, for example, via a snap fit. The break-away bracket may have anchors (e.g., including wings or tabs) that are received in the openings, allowing the break-away bracket to snap into the opening in the gear plate. Other attachment methods are also contemplated, such as using a friction fit, fasteners, adhesives, or a combination thereof.

[0088] The breakaway bracket may include a structure having a slot adapted to receive one end of the gear plate therein or therethrough. The breakaway bracket may have a body extending generally perpendicular to the gear plate, the column tube, or both. To resist withdrawal of the gear plate from the breakaway bracket, the walls defining the slot may include one or more features or anchors, such as barbs, tabs, or other protrusions.

[0089] The release bracket may include one or more features for attachment to the column tube. The release bracket may include one or more features adapted to shear or break when the column tube moves forward upon impact. Thus, the release bracket may remain in place while the column tube continues to move forward due to the release bracket detaching from the column tube. Thus, the features and / or the release bracket may be made of a material that is capable of securing the release bracket to the column tube during normal operation, but that detaches or shears upon an impact above a threshold load.

[0090] The release bracket may have a length dimension. The release bracket may have a height dimension. The height dimension may vary over the length of the release bracket. The length dimension may be greater than the maximum height dimension of the release bracket. The length dimension may be sufficiently greater than the height dimension to promote and / or ensure that decoupling of the energy absorption plate from the column tube is due at least partially (or at least primarily) to shear failure in the release bracket or one or more release bracket attachment portions.

[0091] The release bracket may include a column tube pin extending from the release bracket into the opening in the column tube. The column tube pin may be integrally formed with the release bracket and may extend 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 matches the opening in the column tube into which it is received. The column tube pin may include one or more features for securing the pin within the opening (e.g., one or more features for snap-fitting the release bracket onto the column tube, into the opening, or both). The column tube pin may be adapted to shear or break when subjected to an impact exceeding a threshold load, such that the release bracket may separate from the column tube as the column tube moves forward. The size of the column tube pin (e.g., diameter, length, shape, or a combination thereof) may be selected based on a predetermined threshold load that will cause release.

[0092] The breakaway bracket may include one or more openings for receiving fasteners. The openings may be generally aligned with openings in the column tube such that fasteners may be received in both openings to secure the breakaway bracket to the column tube. The fasteners may be, for example, rivets. The rivets may be shear rivets. Shear rivets may shear when subjected to an impact exceeding a threshold load, resulting in the breakaway bracket separating from the column tube as the column tube moves forward. Shear rivets may allow for a controlled breakaway load.

[0093] The release bracket may not have a column tube pin. The release bracket may not have one or more openings or one or more fasteners. The release bracket may have only one or more column tube pins, only one or more openings, or only one or more fasteners. The column tube may include any combination of one or more column tube pins, one or more openings, and one or more fasteners.

[0094] When subjected to an impact exceeding the threshold load, the column tube of the steering column may move generally forward. During an impact exceeding the threshold load, the release bracket may detach from the column tube. During an impact exceeding the threshold load, the release bracket may detach from the gear plate. The detachment may occur by shearing a shear rivet, breaking or shearing a column tube pin, breaking a gear plate anchor, or a combination thereof. During a secondary impact where the load exceeds the threshold load, the release bracket may remain stationary as the column tube continues to move forward.

[0095] It is also envisioned that the breakaway bracket may be secured to the column tube using one or more fasteners, such as non-shear rivets. The gear plate anchor may be positioned such that the breakaway bracket separates from the gear plate upon impact loads exceeding a threshold load.

[0096] The breakaway bracket may be packaged (mounted) at a location separate from the energy absorbing plate. For example, the breakaway bracket may be located at or near one end of the gear plate, and the energy absorbing plate may be located at the opposite end of the gear plate. This may allow the breakaway bracket to be partially or completely decoupled from the energy absorption of the energy absorbing plate. This may be due to the positional relationship of the breakaway bracket to the energy absorbing plate. This may be due to the presence of one or more slots (e.g., at the joint between the gear plate and the energy absorbing plate, where the energy absorbing plate is coupled to the column tube, or both) to allow slippage of the energy absorbing plate relative to the gear plate, the column tube, or both.

[0097] During or after disengagement, the energy absorbing plate may be engaged. As the column tube continues to move forward, the energy absorbing plate remains attached to the column tube and gear plate. The gear plate remains stationary. When the energy absorbing plate is engaged, it may unwrap or unwind. During unwrapping or unwinding, the position of the curved portion of the energy absorbing plate may change, the length of the second segment may shorten, or both may occur.

[0098] Referring now to the drawings, FIG. 1 shows a steering column assembly 10 having a forward end 12 and a rearward end 14. A column housing 18 is pivotally mounted to a vehicle via one or more bracket structures 16, although other mounting configurations and brackets are contemplated. The steering column assembly 10 includes a steering shaft 22 at the rearward end 14, which is adapted 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 vehicle operator.

[0099] FIG. 2 shows an exemplary adjustment subassembly 30, which includes a lever 32 that allows a user or driver to control the telescopic adjustment of the steering column assembly. The column tube 20 is movable, particularly fore-aft and aft, relative to the column housing 18 (see FIG. 1) for telescopic adjustment. The steering shaft 22 (see FIG. 2) and column tube 20 are adapted to be adjusted upwardly or downwardly relative to the driver via a tilt assembly. The tilt assembly includes two parallel, downwardly depending tilt plates or side walls 38 that support and engage tilt bolts 34. Adjustment of the tilt and / or telescopic aspects of the steering shaft 22 and column tube 20 can be initiated by manipulating the lever 32, which can engage and / or disengage an adjustment mechanism or lock and / or unlock the adjustment mechanism to allow the driver to position the steering wheel as desired.

[0100] In FIG. 2 , the column housing is not shown for clarity of illustration of the adjustment subassembly 30. The position of the column tube 20 can be adjusted up or down by the vehicle driver or user via a tilt assembly. The tilt assembly includes a tilt bolt 34 supported at both ends by opposing side walls 38. Each side wall 38 has a slot 36 for receiving the tilt bolt 34 and, optionally, one or more locking members (e.g., cams or rotating members). 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 is allowed to move along the slot 36 during tilt adjustment and can lock in place when the lever 32 is locked.

[0101] When the lever 32 is locked and unlocked, this causes a contact portion 40 of the lever to contact a preload plate 42. The contact portion 40 may have a ramped or angled surface that applies pressure to the preload plate 42 in the locked position and releases or reduces pressure on the preload plate 42 in the unlocked position. The preload plate 42 is engaged with a locking pin 44. When the lever 32 is in the locked position, the locking pin 44 is forced toward a portion of the energy absorption assembly 50 that includes a gear plate 60 (see FIG. 3). The gear plate 60 is selectively attached to the column housing 20 via a telescopic positive locking mechanism. The locking pin 44 engages with the gear plate 60, for example, at a toothed surface 62 of the gear plate. When the lever 32 is in the unlocked position, a return spring 46 pushes the locking pin 44 away from the gear plate 60, causing disengagement between the locking pin 44 and the gear plate 60.

[0102] Figure 3 shows an energy absorption assembly 50 including an energy absorption plate 52, a gear plate 60, and a breakaway bracket 80. Figure 4 is an exploded view of the energy absorption assembly 50 of Figure 3.

[0103] The energy-absorbing plate 52 includes a first end 53 and a second end 58 with a curved portion 57 therebetween. The curved portion is shown with the first segment 55 (between the first end 53 and the curved portion 57) and the second segment 59 (between the curved portion 57 and the second end 58) of the energy-absorbing plate 52 generally parallel to one another, although other angles are contemplated. The energy-absorbing plate includes fasteners 56 extending through at least a portion of the plate (e.g., the first segment 55). The fasteners may be integrally formed with the energy-absorbing plate 52 or may be separate. A portion of the energy-absorbing plate 52 adapted to contact a column tube of a steering column assembly includes one or more fastener openings 68. The fasteners 56 are received within the fastener openings. As shown, the fasteners 56 are non-shear rivets 72 for attaching the energy-absorbing plate 52 to the column tube 20.

[0104] The gear plate 60 is joined to the energy absorbing plate 52 at a joint 54. The gear plate includes a fastener opening 68. The fastener opening 68 can receive the fastener 56 located at one end of the energy absorbing plate 52. As shown, the fastener opening 68 has a wall or collar 70 defining the fastener opening 68. While it is shown as a downwardly extending tubular section, it is contemplated that other shapes are possible, and that the wall may be omitted. The gear plate 60 includes a toothed portion 62 that engages with the locking pin 44 to lock the steering column assembly in a particular telescopic orientation. The gear plate includes dampers 64 located on opposite sides of the gear plate along a portion of its length. The illustrated gear plate 60 includes an anchor opening 63 located at the end opposite the fastener opening 68. The anchor opening 63 receives a gear plate anchor 84 of the breakaway bracket 80.

[0105] Although the gear plate and the energy absorbing plate are shown as two separate pieces joined together, it is envisioned that these elements may be integrally formed as a single piece.

[0106] The breakaway bracket 80 is adapted to be secured to the gear plate 60 (via gear plate anchors 84 that engage anchor openings 63 in the gear plate) and the column tube 20. The breakaway bracket includes fastener openings 68 (shown as shear rivet openings 86). The fastener openings 68 are adapted to receive fasteners such as shear rivets. On the opposite side of the breakaway bracket 80 from the gear plate anchors 84 is a column tube pin 82 that is adapted to engage with an opening in the column tube 20. In the event of an impact exceeding a threshold load, the column tube pin 82 may break, thereby allowing the breakaway bracket 80 to break away from the column tube.

[0107] 5A and 5B show top and bottom views of an exemplary breakaway bracket 80. The breakaway bracket 80 includes fastener openings 68 that extend through the thickness of the breakaway bracket and are capable of receiving fasteners to secure the breakaway bracket. The fasteners may be, for example, shear rivets. Thus, the fastener openings 68 may be shear rivet openings 86.

[0108] As shown in FIG. 5A , the gear plate anchor 84 is positioned on the top surface of the breakaway bracket 80. The gear plate anchor 84 is adapted to engage with the 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. Depending on the shape of the gear plate anchor, it may resist pull-out during engagement or assembly. For example, as shown, the gear plate anchor 84 includes two curved or rounded portions that generally match the shape of the end boundaries of the slot in the anchor opening. Two generally opposing tabs or wings 85 engage the side walls of the anchor opening. The coupling or connection between the gear plate anchor 84 and the gear plate 60 may be achieved by, for example, a friction fit or a snap fit.

[0109] 5B, a column tube pin 82 extends from the underside of the release bracket 80. The column tube pin 82 is adapted to pass through an opening in the column tube of the steering column assembly.

[0110] FIG. 6 shows the energy absorption assembly 50 secured to the column tube 20. The column tube is shown largely transparent to show the fasteners securing the energy absorption assembly to the column tube. The energy absorption plate 52 is secured to the column tube 20 via fasteners 56, shown as non-shear rivets 72. On the side of the energy absorption plate opposite the curved portion is a joint 54 between the energy absorption plate 52 and a gear plate 60. The energy absorption plate and gear plate 60 are joined by the fasteners 56. The gear plate includes a damper 64 located on the visible side of the illustration. A breakaway bracket 80 connects the gear plate to the column tube 20 on one end of the gear plate opposite the energy absorption plate. The breakaway bracket 80 includes a column tube pin 82 that passes through an opening in the column tube. The fasteners 56, shown as shear rivets 88, connect the breakaway bracket 80 to the column tube 20.

[0111] The direction of the arrows (located below the column tube) indicates the direction of movement of the column tube 20 during an impact above the threshold load. Such an impact may shear the shear rivet 88. During a collision, the column tube pin 82 may also shear. If the shear rivet 88 and column tube pin 82 shear, the breakaway bracket remains stationary and the column tube 20 continues to slide below the breakaway bracket 80, unwinding, or shifting the position of the curved portion of the energy absorbing plate 52. The energy absorbing plate 52 remains secured to the column tube 20 by the non-shear rivets 72.

[0112] One or more fastener openings in the energy absorption assembly may incorporate slots. For example, the fastener openings in the energy absorption plate 52 may incorporate slots. The slots may ensure that disengagement of the bracket occurs before the energy absorption plate is engaged. This allows disengagement to be completely decoupled from energy absorption via the energy absorption plate. In another example, a slot may be provided at the joint between the gear plate and the energy absorption plate. Such a slot may allow the gear plate to slip relative to the energy absorption plate, thereby decoupling disengagement from energy absorption via the energy absorption plate.

[0113] FIG. 7 shows an energy absorption assembly 50 in which an energy absorption plate 52 is coupled to a gear plate 60 via one or more fasteners 56. A breakaway bracket 80 is provided at one end opposite the gear plate 60. A telescopic stop bracket 90 is secured to the energy absorption plate 52 and supports a telescopic stop damper 92. The telescopic stop bracket 90 and telescopic stop damper 92 are adapted to be disposed outside the column housing. The telescopic stop bracket operates within a slot in the column housing to define and limit the range of telescopic adjustment. The telescopic stop damper reduces noise and / or impact force spikes resulting from impacts when the end stops during telescopic adjustment. While the telescopic stop bracket is shown separately, it is contemplated that the telescopic stop bracket may be integrated into the gear plate or the energy absorption plate.

[0114] Figure 8 shows the energy absorption plate 52 of Figure 7. Fasteners 56 (which may be non-shear rivets 72) are located in one location, allowing the energy absorption plate 52 to be secured to the column tube of the steering column assembly. A telescopic stop bracket 90 is secured to the energy absorption plate at a portion opposite the curved portion of the energy absorption plate. On opposite sides (both sides) of the telescopic stop bracket 90, (two) fasteners 56 secure the telescopic stop bracket (via strips extending above the telescopic stop bracket and secured on both sides) while securing the energy absorption plate 52 to the gear plate 60 (see Figure 7).

[0115] Figure 9 shows the breakaway bracket 80 of Figure 7. The breakaway bracket 80 has a slot 83 for receiving a portion of the gear plate 60 (see Figure 7). One or more gear plate anchor 84 features may engage with the gear plate to secure the gear plate within the breakaway bracket. The breakaway bracket 80 includes a column tube pin 82 adapted to be received within an opening in the column tube. The column tube pin 82 may, for example, frictionally engage or snap fit with the opening in the column tube to secure the breakaway bracket during normal operation. Upon the occurrence of an impact exceeding a threshold load, the column tube pin 82 may shear, allowing the breakaway bracket 80 to break away from the column tube.

[0116] While exemplary embodiments have been described above, these embodiments are not intended to describe all possible forms of the invention. Rather, the terms used herein are terms of description rather than limitation, and it will be understood that various changes may be made without departing from the spirit and scope of the invention. Furthermore, features of various embodiments may be combined to form further embodiments of the invention.

[0117] As can be appreciated, variations on the foregoing teachings can be employed. For example, the release bracket can be secured to the column tube. The release bracket can be detached from the gear plate instead of or in addition to being detached from the column tube. As another example, although the release bracket is shown in the drawings as having a column tube pin, either alone or in combination with a rivet, it is also contemplated that the column tube pin can be omitted. One or more shear rivets can be used, either alone or in combination with one or more column tube pins. It is also contemplated that one or more rivets can be omitted. One or more column tube pins can be used, either alone or in combination with one or more rivets.

[0118] As can be appreciated, variations on the foregoing teachings may be employed. For example, it may be possible to create a steering wheel adjustment subassembly from multiple subassemblies. Instead of the toothed end of the pin engaging a toothed portion of the gear plate, it is contemplated that the pin (which may not have teeth) is inserted into one of a series of openings along the length of the gear plate. It is also contemplated that the toothed slot may be located elsewhere in the assembly. For example, instead of, or in addition to, a cam or rotating member being located within a slot in the tilt plate, the slot may be defined by a toothed opening that engages with a spring or toothed cam or rotating member. The teachings herein refer to secondary impact events that result in certain functional aspects of the teachings, but are not limited to only secondary impact events. Rather, where reference is made to a secondary impact, unless otherwise limited, the present teachings should be considered to contemplate other impacts or situations in which a threshold load substantially exceeding normal driving loads (e.g., in a forward-facing direction of the vehicle) is encountered and translation of the column tube is desirable to substantially reduce the load that would be transmitted to the vehicle driver.

[0119] Any numerical value recited herein includes all values ​​from any lower limit to any upper limit in increments of one unit, provided that there is a separation of at least two units between any lower limit and any upper limit. As an example, if the amount of a component or the value of a process variable, such as temperature, pressure, or time, is recited as being, for example, 1 to 90, preferably 20 to 80, and more preferably 30 to 70, then values ​​such as 15 to 85, 22 to 68, 43 to 51, 30 to 32, etc., are intended to be expressly recited herein. For 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 recited lower and upper limits are similarly considered to be expressly set forth herein.

[0120] Unless otherwise specified, all ranges include their endpoints and all values ​​between them. The use of the terms "about" or "approximately" in connection with a range applies to both ends of the range. Thus, "about 20 to 30" is intended to cover "about 20 to about 30," inclusive of at least the specified endpoints.

[0121] The disclosures of all literature and references, including patent applications and patent publications, are incorporated by reference in their entirety for all purposes. The term "consisting essentially of" when describing a combination may include, in addition to the specified elements, components, ingredients, or steps, other elements, components, ingredients, or steps that do not materially affect the basic and novel characteristics of the combination. As used herein, the use of the terms "comprising" or "including" to describe a combination of elements, components, ingredients, or steps also contemplates embodiments that consist essentially of or consist only of those elements, components, ingredients, or steps.

[0122] A plurality of elements, components, ingredients, or steps may be provided by a single integrated element, component, ingredient, or step. Alternatively, a single integrated element, component, ingredient, ingredient, or step may be divided into separate elements, components, ingredients, or steps. The disclosure of the term "a" or "one" to describe an element, component, ingredient, or step is not intended to exclude additional elements, components, ingredients, or steps.

[0123] The relative positions of elements depicted in the drawings, even if not described in words, are part of the teachings herein, and the geometries shown in the drawings, even if not described in words (and are not intended to be limiting), are also within the scope of the present teachings. [Explanation of symbols]

[0124] 10 Steering column assembly 12 Front end 14 Rear end 16 Bracket structure 18 Column housing 20 column tube 22 Steering shaft 30 Adjustment Subassembly 32 Lever 34 Tilt bolt 36 slots 38 Side wall 40 Contact area 42 Preload plate 44 Lock pin 46 Return spring 50 Energy Absorption Assembly 52 Energy absorption plate 53 First end 54 Joint (between energy absorption plate and gear plate) 55 First Segment 56 Fasteners 57 Curved section 58 Second end 59 Second Segment 60 gear plate 62 Toothed surface 63 Anchor opening 64 Damper 66 Bracket opening 68 Fastener opening 70 Collar or wall defining fastener opening 72 Non-shear rivets 80 Detachment bracket 82 Column tube pin 83 Slots 84 Gear Plate Anchor 85 tabs 86 Shear rivet opening 88 Shear rivet 90 Telescopic stopper bracket 92 Telescopic stopper damper

Claims

1. 1. An energy absorption assembly for a steering column assembly, comprising: a. an energy absorbing plate having a first end and a second end with a curved portion therebetween; b. a gear plate adapted to engage and / or disengage the locking mechanism; c. a breakaway bracket; Equipped with the energy absorbing plate is attached to and / or extends from the gear plate at or near one end of the gear plate; The breakaway bracket is attached to the gear plate at or near the opposite end of the gear plate.

1. An energy absorption assembly comprising:

2. The energy absorbing plate is adapted to be operably coupled to a column tube of the steering column assembly.

10. The energy absorption assembly of claim 1.

3. The energy absorbing plate is adapted to be coupled to a column tube of the steering column assembly via one or more fasteners.

3. An energy absorption assembly according to claim 1 or 2.

4. The one or more fasteners are non-shear rivets 4. The energy absorption assembly of claim 3.

5. The energy absorption plate and the gear plate are separate elements.

5. An energy absorption assembly according to any one of claims 1 to 4.

6. A fastener connects the energy absorption plate and the gear plate at a joint.

6. An energy absorption assembly according to any one of claims 1 to 5.

7. A slot is disposed at the junction between the gear plate and the energy absorbing plate (e.g., in the energy absorbing plate, in the gear plate, or in both).

7. The energy absorbing assembly of claim 6.

8. The gear plate has a toothed surface for engaging a locking pin of an adjustment subassembly of the steering column assembly.

8. An energy absorbing assembly according to any one of claims 1 to 7.

9. The energy absorption plate and the gear plate are made of different materials.

9. An energy absorption assembly according to any one of claims 1 to 8.

10. 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 is configured to disengage from one or both of the column tube or the energy absorption plate when an input load exceeds a threshold load.

10. An energy absorption assembly according to any one of claims 1 to 9.

11. The threshold load is greater than or equal to about 500 N, less than or equal to about 6000 N, or both.

11. The energy absorbing assembly of claim 10.

12. The breakaway bracket includes one or more gear plate anchors for engaging a portion of the gear plate.

12. An energy absorption assembly according to any preceding claim.

13. The gear plate includes an opening for receiving a gear plate anchor of the breakaway bracket.

13. The energy absorbing assembly of claim 12.

14. The gear plate anchor engages the opening in the gear plate via one or more wings or tabs.

14. The energy absorbing assembly of claim 13.

15. The release bracket includes a column tube pin adapted to be received within an opening in a column tube of the steering column assembly.

15. An energy absorbing assembly according to any preceding claim.

16. The breakaway bracket includes a slot for receiving and engaging a portion of the gear plate.

16. An energy absorption assembly according to any preceding claim.

17. The energy absorption plate and the gear plate are integrally formed (e.g., as one component).

17. An energy absorbing assembly according to any preceding claim.

18. the release bracket has a length to height dimension large enough to facilitate disengagement of the energy absorption plate from the column tube primarily due to shear failure of the release bracket or one or more release bracket attachment portions.

18. An energy absorbing assembly according to any preceding claim.

19. 1. An assembly for a steering column assembly, comprising: a. an energy absorbing assembly according to any one of claims 1 to 18; b. a column tube; An assembly comprising:

20. The gear plate is selectively attached to the column housing via an adjustment subassembly (e.g., a telescopic positive locking mechanism) of the steering column assembly.

20. The assembly of claim 19.

21. The energy absorption plate is secured to the column tube by one or more non-shear rivets. Assembly according to claim 19 or 20.

22. The release bracket includes a column tube pin extending from the release bracket and received within the column tube.

22. An assembly according to any one of claims 19 to 21.

23. The release bracket is secured to the column tube via one or more shear rivets.

23. An assembly according to any one of claims 19 to 22.

24. When subjected to an impact exceeding a threshold load, the release bracket is adapted to release from the column tube while the energy absorbing plate remains fixed to the column tube.

24. An assembly according to any one of claims 19 to 23.

25. The threshold load is greater than or equal to about 500 N, less than or equal to about 6000 N, or both.

25. The assembly of claim 24.

26. The column tube pin and / or the shear rivet shear to allow the release bracket to release from the column tube.

26. An assembly according to any one of claims 22 to 25.

27. 1. A steering column assembly comprising: a. a column tube; b) a steering shaft supported for at least partial rotation by the column tube; c) a bracket for at least partially supporting the column tube; d. an adjustment subassembly; e. an energy absorption assembly according to any one of claims 1 to 18; A steering column assembly comprising:

28. The adjustment subassembly includes: a. selectively adjusting the steering shaft, the column tube, or both, forward or rearward generally along the longitudinal axis; b. Selectively raising or lowering the steering shaft, the column tube, or both; or c. Execute both a. and b. It is adapted to 28. The steering column assembly of claim 27.

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