Steering column rotational fixer device

Abstract

The present teachings include a spacer adapted to engage with a portion of a steering column assembly to reduce or prevent rotation of a column tube, to limit telescoping adjustment of a steering wheel of the steering column assembly, or both. The spacer may include an outer face and a generally opposing column tube contact face. A projection may extend from the column tube contact face, which may be adapted to be received within an opening in the column tube. The spacer may include a forward face and a generally opposing rearward face. The spacer may include side walls that extend between the outer face and column tube contact face, forward face and rearward face, or both. The present teachings also include a steering column assembly including a column housing, column tube, and the spacer.

Description

STEERING COLUMN ROTATIONAL FIXER DEVICECLAIM OF BENEFIT OF FILING DATE

[0001] The present application claims the benefit of U.S. Provisional Application No. 63 / 654,230, filed on May 31, 2024, the content of which is hereby expressly incorporated by reference in its entirety for all purposes.FIELD

[0002] In general, the present teachings relate to an adjustable steering column assembly. More particularly, the present teachings are directed to a device adapted to reduce or prevent rotation of a steering column tube and / or limit telescoping adjustment of a steering wheel.BACKGROUND

[0003] In the field of automotive vehicles it has become popular to employ steering column assemblies that include the ability to adjust the assemblies, such as by performing tilt and / or telescoping functions, such assemblies being known also as “rake and reach steering column assemblies.” For many applications, steering column assemblies incorporate both tilt and telescopic functions. For these, it is possible to use a manual user operating device (e.g., a lever) or to employ motors to perform one or both of the functions. For example, one lever or motor may be operated to actuate the steering column assembly generally in an upward or downward vertical direction to adjust the height of a steering wheel relative to an operator of the vehicle, relative to the vehicle floor and / or vehicle ceiling, or both and thus perform the tilt function. Another lever or 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 typically achieves the adjustment by way of translation of a telescopic tubing arrangement by which at least one tube associated with the steering column assembly translates relative to a column housing. Industry is constantly seeking to improve these adjustment functions, such as by making the adjustment easier and / or smoother for the vehicle occupant. For example, it is desirable to have a smooth and controlled adjustment, such as by providing a guide or anti-rotational component while performing the telescoping in and / or telescoping out functions. Further, it is desirable for an anti-rotational component to be strong enough to withstand high torque loads.

[0004] In traditional steering column assemblies, there are multiple components forming an anti-rotation subassembly to prevent the column tube from undesirably rotatingduring different operating conditions. These multiple components may be difficult to install, due to the required position of the elements within the steering column assembly.

[0005] Existing designs may require a rivet or other fastener to affix the anti-rotational device to the column tube. This may complicate assembly and / or create another point of possible failure within the assembly, leading to a disengagement of the rotational fixer element from the column tube. In such designs, rotation of the column tube is prevented by tangential resistance load on the rotational fixer device. Reactions to this tangent load create undesirable reacting shear load on the fixer device.

[0006] Therefore, there is a need for an improved steering column assembly that provides adjustment (e.g., telescopic adjustment, tilt adjustment, or both); that simplifies assembly; that reduces or eliminates undesirable rotation of a column tube, particularly during adjustment or where resisting torque is desired; that reduces the number of components, especially with respect to an anti-rotational assembly; or a combination thereof. There is a need for an assembly that does not require separate fasteners. There is a need for a spacer that directs reaction loads in a way that reduces shearing loads.SUMMARY

[0007] The present teachings make use of a simple, yet elegant, construction approach by which relatively few components can be employed for achieving adjustment of a steering column assembly, especially telescoping adjustment. The telescoping adjustment may be generally smooth and / or may reduce or eliminate undesirable rotation of elements within the assembly (e.g., a column tube). The present teachings may make use of a simple, yet elegant approach for resisting torque. The present teachings meet the needs addressed above by providing a geometry of a spacer that directs reaction loads toward the center of a column tube, reducing the shearing load. The present teachings meet the needs addressed above by providing a geometry of a column housing that prevents the spacer from disengaging from the column tube (e.g., by trapping the spacer into the column tube or between the column tube and the column housing). The present teachings meet the needs addressed above by providing a spacer that can be received within and / or travel within a slot in the column housing, such that the telescope stroke in the telescope-out direction, telescope-in direction, or both, is limited by contact of the spacer within the housing.

[0008] The present teachings make use of a spacer. The spacer may be adapted to engage with a portion of the steering column assembly to reduce or prevent rotation of the columntube, to limit telescoping adjustment of a steering wheel of the steering column assembly; or both The spacer may include an outer face adapted to be situated away from an outer surface of a column tube. The outer face may be generally flat or planar. The spacer may include a generally opposing column tube contact face adapted to be situated adjacent and / or in contact with an outer surface of the column tube. The column tube contact face may have a surface having a generally complementary shape to the column tube or a shape similar to the column tube to allow for placement thereon. For example, the column tube may have a curvature that generally matches the curvature of the column tube (e.g., to prevent or reduce rocking of the spacer on the column tube). A projection may extend from the column tube contact face. The projection may be adapted to be received within an opening in the steering column assembly, such as an opening in the column tube. The projection may include a plurality of ribs, ridges, or other shapes that reduce or eliminate clearance between the boundaries defining the opening in the column tube and the projection. The spacer may include a forward face and a generally opposing rearward face. The spacer may include side walls extending between the outer face and the column tube contact face, between the forward face and rearward face, or both. The outer face may join the side walls, forward face, and rearward face. For example, the outer face may be a top surface having a generally square or rectangular shape. The forward face and rearward face may extend from opposing sides of the outer face. The side walls may extend from the other generally opposing sides of the outer face. The side walls (e.g., at the portion opposite where the side walls contact the outer face) may contact the column tube contact face, forming an edge. The edge may include an elongated notch. The elongated notch may be adapted to prevent or reduce rocking of the spacer on the column tube. The elongated notch may limit contact points of the spacer to the ends so the spacer sits flat on the column tube and does not rock.

[0009] The spacer may include curved side walls. A spacer with curved side walls may be an arc-type anti-rotational spacer. The curved side walls and outer face of the arc-type anti-rotational spacer may create a generally truncated arc shape (e.g., when viewing the forward face and / or rearward face).

[0010] The spacer may include angled side walls. A spacer with angled side walls may be a taper-type anti-rotational spacer. The angled side walls and outer face of the taper-type anti-rotational spacer may create a generally trapezoidal shape (e.g., when viewing the forward face and / or rearward face). An angle may be formed between the angled side walland the outer face. The angle may be about 90 degrees or more or about 110 degrees or more. The angle may be about 180 degrees or less or about 150 degrees or less.

[0011] The present teachings also contemplate a steering column assembly. The steering column assembly may include a column housing, a column tube, and the spacer. The column tube may have an opening adapted for receiving the projection of the spacer. The present teachings may be employed for a manually adjustable assembly, an electromechanically adjustable assembly, or both.

[0012] The column housing may include a spacer channel. The spacer channel may have a generally curved surface for receiving and / or retaining a spacer, such as an arc-type anti-rotational spacer between the column tube and the column housing. The generally curved surface may have a similar curvature as the curved side walls of the arc-type anti-rotational spacer.

[0013] The column housing may include an elongated slot. The elongated slot may have a widened portion that is wider than another portion of the elongated slot. The widened portion may allow for installation of the spacer into the column tube through the column housing. The spacer, such as a taper-type anti-rotational spacer, may be received within and / or travel between boundaries defining the elongated slot. The elongated slot may be at least partially defined by interior angled walls. An interior angled wall of the elongated slot and an adjacent angled side wall of a taper-type anti-rotational spacer may have planes that extend generally parallel to each other. The interior angled walls of the elongated slot may contact the angled side walls of the taper-type anti-rotational spacer at least during certain times (e.g., when the column tube is torqued).

[0014] As can be seen, it is believed that by employment of the teachings herein it is possible to achieve adjustment of a steering column assembly, a smooth telescoping adjustment, simplicity of assembly, reduction of components, reduction or elimination of undesirable rotation of the column tube, particularly during a telescoping adjustment or under torque loading, or a combination thereof.BRIEF DESCRIPTION OF THE DRAWINGS

[0015] FIG. 1 illustrates an exemplary steering column assembly having an electric adjustment subassembly in accordance with the present teachings.

[0016] FIG. 2 illustrates an exemplary steering column assembly having a manual adjustment subassembly in accordance with the present teachings.

[0017] FIG. 3 illustrates an existing anti-rotational design.

[0018] FIGs. 4A and 4B illustrate an arc-type anti-rotational spacer in accordance with the present teachings.

[0019] FIGs. 5A and 5B illustrate a taper-type anti-rotational spacer in accordance with the present teachings.

[0020] FIG.6 illustrates attachment of an anti-rotational spacer to a column tube in accordance with the present teachings.

[0021] FIGs. 7A and 7B illustrate a sectional view of the exemplary steering column assembly of FIG. 1.

[0022] FIGs. 8A and 8B illustrate a sectional view of the exemplary steering column assembly of FIG. 2.DETAILED DESCRIPTION

[0023] As required, details of the present teachings are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the teachings that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present teachings.

[0024] In general, the teachings herein are directed toward a unique combination of components for assisting in adjustment of a steering column assembly, and more particularly for providing elements such as those to provide for a smooth telescoping adjustment, simplicity of assembly of the steering column assembly, reduction or elimination of undesirable rotation of portions of the steering column assembly (e.g., a column tube, particularly during telescoping adjustment or under torque loading), or a combination thereof. By use of the teachings herein, it is possible to (but not limited to) limit undesirable rotation of a telescoping member during telescope adjustment of at least a portion of the steering column assembly (e.g., the column tube) when in an adjustment mode, center the column tube when the steering column assembly is in an unlocked position (e.g., not clamped, during an adjustment of the assembly), limit of rotational travel of the column tube when in an adjustment mode or when locked in position, retain the column tube longitudinally within the steering column (e.g., by resisting pull-out of the column tube from the assembly), or a combination thereof.

[0025] With more attention now to the details of the assemblies herein, they generally will include a column tube, a steering shaft, one or more brackets (e.g., a bracket structure for attachment of the steering column assembly in the vehicle, a tilt bracket, an interface bracket, or any combination thereof), a column housing, and a steering wheel adjustment subassembly (e.g., a manually or motor operated steering wheel adjustment subassembly). These elements may be discrete elements or two or more of the elements may be combined into a single unit. The column housing may be operatively connected with a bracket structure. The column housing operatively supports the steering shaft that is driven by a steering wheel. For this purpose, the column housing may itself be a tube or may have an opening for accommodating a tube-shaped structure. The column housing may provide a clamping feature, where it clamps around another portion of the steering column assembly (e.g., a column tube) when the assembly is not in an adjustment mode (e.g., tilt adjustment, telescoping adjustment, or both). The column housing may receive another tube that supports the steering shaft. One such tube, referred to herein as the column tube, may have a hollow cavity along at least a portion of (if not the entirety of) the length of the tube and may be sized and configured to receive and support a rotatable shaft, namely a steering shaft and possibly one or more bearings. Both the steering shaft and any tube (be it a column housing, a column tube, or both) will have a longitudinal axis. When installed in a vehicle, the longitudinal axis of each the shaft and any tube may be generally coaxially aligned, aligned generally parallel with a longitudinal axis of a vehicle (e.g., within about 10° or even about 5°), or each. The longitudinal axis of each of the shaft and any tube may form an angle with the longitudinal axis of a vehicle of about 45° or less, about 30° or less, or about 25° or less. The steering shaft, the column housing and any column tube may be made of a suitable metal, such as steel or aluminum. Metal components herein may also be made of other metals, such as magnesium. Such metals may be alloys. However, generally pure metals are also possible. The steering wheel adjustment subassembly may include a lever (or any other user operating device) adapted for actuating (e.g., manually actuating) the subassembly, and at least one engagement member that is brought into and out of engagement with the column tube for selectively locking the steering shaft into a position desired by a user. The steering wheel adjustment subassembly may include one or more electromechanical actuators for adjusting the assembly instead of or in addition to a lever and / or manual actuation.

[0026] The teachings, in general, also envision the possible use of one or more energy absorption devices. The energy absorption devices may be a suitable device adapted todeform elastically and / or elastically and plastically. In the course of deforming, the energy absorption devices are thus adapted to absorb energy by way of the deformation. The energy absorption device may be operatively connected or located between or among two or more components. It may be configured so that it limits relative movement as between or among two or more components. The energy absorption devices may be wires, plates or the like. They may have a constant profile or a varying profile along their length. They may be employed to have one or more fixedly constrained portions (e.g., an end). They may have one or more free ends.

[0027] The assembly herein may further employ an energy absorption structure of the type described in U.S. Publication Nos. 2013 / 0233117 and 2017 / 0247047, or International Application Nos. PCT / US2017 / 053583 and PCT / US2017 / 053711 , the entirety of which are incorporated by reference herein for all purposes. For instance the assembly herein may include at least one plastically deformable energy absorption device (e.g., a bend plate, a wire, or some other structure adapted to be carried at least partially by the column housing, column tube, or both), wherein the energy absorption device, when employed, absorbs energy by plastic deformation during the secondary impact after the steering shaft support structure (e.g., column tube and steering shaft) starts to translate along the column housing. Any plastically deformable energy absorption device may thus limit the extent of longitudinal travel of the column tube, steering shaft, or both.

[0028] One or more suitable brackets may be employed. Any such bracket may include a portion for mounting the steering column assembly within a vehicle (e.g., it can be secured to a vehicle structure, such as a cross vehicle beam, instrument panel, or otherwise). The bracket may have a portion that at least partially adjoins the steering shaft support structure (e.g., the column tube, the column housing or both). For example, a bracket may include one or a plurality of downward depending (downwardly oriented) walls (e.g., tilt plates) that define a tilt portion of the bracket. One or more of the downward depending walls (e.g., tilt plates) may be adapted to provide a structure that has an elongated slot that provides guidance for the tilt function (e.g., it provides a guide path for a securing member such as a tilt bolt as it travels during adjustment; it may thus limit upward and downward travel). The bracket may be an integrated structure so that the tilt portion and the mounting portion are a single structure (e.g., a casting, a stamping, or a combination thereof). The bracket may be made of separate structures that are assembled together to define the mounting and tilt portions in a single structure. The mounting portion may be omitted and / or may be located elsewhere within thesteering column assembly. The tilt portion may be omitted. A mounting bracket may be employed separately from a structure defining a tilt portion. Examples of brackets that may be employed, in addition to the examples described herein, include those of United States Published Application No. 20100300238 (the entirety of which is incorporated by reference for all purposes; see, e.g., description of bracket 20); United States Patent No. 6,467,807, the entirety of which is incorporated by reference for all purposes (see, e.g., description of brackets 6 and 7 and associated structure).

[0029] One or more brackets (e.g., tilt brackets) may be employed and adapted for receiving at least a portion of a steering shaft support structure (e.g., at least a portion of the column tube, the column housing, or both), and / or for mounting the steering column assembly within the automotive vehicle. By way of example, a tilt bracket of the present teachings may include an upper portion that is adapted to be secured to a vehicle structure, such as a cross vehicle beam, instrument panel, or otherwise. The bracket (e.g., tilt bracket) may have a pair of generally opposing downwardly oriented or projecting walls (e.g., tilt plates). The bracket (e.g., tilt bracket) may have a structure that at least partially flanks at least a portion of the steering shaft support structure (e.g., the column tube). The bracket (e.g., tilt bracket) may include a pair of opposing side walls, and an upper wall that is configured to attach to the vehicle (e.g., to a cross vehicle beam, an instrument panel, or other suitable structure). The side walls may project outward relative to the upper wall (e.g., they may be generally orthogonally or obliquely disposed relative to the upper wall). The bracket (e.g., tilt bracket) may have a single downwardly projecting or oriented wall. The bracket (e.g., tilt bracket) may be disposed laterally above and outward relative to an opposing portion of the column housing.

[0030] One or more bracket structures may be a cast structure (e.g., structure made by casting a mass), a forged structure (e.g., a structure made by forging a metal mass), a machined structure, a consolidated structure (e.g., a structure made by a step of sintering and / or pressing a powder metal mass), or any combination thereof. One approach is to cast the bracket structure to form a metal casting (e.g., an aluminum alloy, magnesium alloy, or a ferrous metal casting). The bracket structure thus may be configured for integrating functions of mounting within a vehicle and accommodating a tilt function of the assembly relative to a vehicle operator. For instance, the functions may be integrated into a single bracket, or spread among separate bracket components.

[0031] As mentioned, the steering column assembly of the present teachings may include one or more steering wheel or steering column adjustment subassemblies. For example, an adjustment subassembly may provide a user with the ability to adjust the steering wheel (and thereby the steering shaft) in a fore and / or aft direction (e.g., telescopic adjustment). An adjustment subassembly may provide a user with the ability to adjust the position by raising and lowering the steering wheel, and thereby the steering shaft (e.g., tilt adjustment), relative to the user. The steering column assembly may provide the ability to perform either or both of these functions (e.g., telescopic adjustment and / or tilt adjustment). These functions may be accomplished by one adjustment subassembly or more than one adjustment subassembly (e.g., one adjustment subassembly for providing telescopic adjustment and one adjustment subassembly for providing tilt adjustment).

[0032] An adjustable telescoping subassembly may be employed for selectively driving the steering shaft in a fore and / or aft direction generally along the longitudinal axis of the steering shaft. In general, the adjustment of the telescoping subassembly may be controlled by a suitable user operating device (e.g., a lever, an electromechanical actuator, or otherwise). For a manually operated system, a lever or other user operating device may be adapted to control a force applied to maintain the collapsing portion in a user selected position. For example, a lever or other user operating device may be in operative engagement with one, two, or more clamping portions or other suitable mechanism to releasably (and possibly adjustably as well) secure two or more components of the collapsing portion together. Clamping or other securing may be realized by a suitable securing member (e.g., an elongated force applying member), such as an elongated member, bolt (e.g., a tilt bolt), pin, rod, strap, bar, band, wedge, or other suitable member. For instance, the securing member may be adapted, upon actuation of the user operating device to cause generally opposing portions (e.g., clamping portions) to separate or come closer together such as, respectively, for releasing the components relative to each other or for securing the components relative to each other.

[0033] The teachings may include employing at least one telescoping motor subassembly adapted for selectively driving the steering shaft (by way of a rod or other drive member) in a fore or aft direction generally along the longitudinal axis of the steering shaft. The telescoping motor subassembly may include an electric motor. The telescoping motor subassembly may include a motor shaft that operatively drives a drive member (e.g., a rod that is threaded or has gear teeth over at least a portion of its length). The shaft may drive thedrive member by use of one or more gears. It may drive the drive member by way of a threaded nut. The motor shaft may have a longitudinal axis that is oriented generally parallel with the longitudinal axis of the steering shaft and / or inner tube. The motor shaft may have a longitudinal axis that is oriented generally transverse with the longitudinal axis of the steering shaft and / or inner tube. The telescoping motor subassembly may be such that it includes a housing within which the motor is at least partially located.

[0034] The teachings may further contemplate employing at least one tilt subassembly that is adapted for selectively raising or lowering the steering shaft. The optional tilt subassembly may be manually actuated, motorized, or both. It may be attached (e.g., at a first mount location along its length) to the bracket structure. For example, as discussed, it may be incorporated within a housing structure (e.g., a column housing) defined in the bracket structure. It may be attached at a second location along its length (e.g., at a second mount location that is distal from the upper surface of the bracket structure as compared with the first mount location).

[0035] As indicated, a column housing may be pivotally coupled with the bracket structure (e.g., at a forward end of both the bracket structure and the column housing) and is adapted to permit steering shaft adjustment (e.g., tilt adjustment, telescopic adjustment or both, such as by way of the tilt subassembly, telescoping subassembly, or both). The column housing may be a cast structure (e.g., a structure made by casting a mass), a forged structure (e.g., a structure made by forging a metal mass), a machined structure, a consolidated structure (e.g., a structure made by a step of sintering and / or pressing a powder metal mass) or any combination thereof. One 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 be generally elongated. It may have a substantially cylindrical configuration. The column housing may have a portion that is capable of receiving a substantially cylindrical part, such as a column tube. The column housing may include an opening of a similar shape as the shape of the outer dimension of the column tube. The column housing may have a lower portion that has laterally projecting flanges over at least a portion of the column housing length. The flanges may project from both sides of the column housing. The flanges may project laterally outward to a location 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 or a gap, for exposing the column tube so that the column tube can be connected with and translate longitudinally (e.g., associated with the telescoping subassembly). The one or more openings,such as slots or a gap, may be adapted to receive another portion of the steering column assembly, such as a portion of the column tube.

[0036] The column housing of the steering column assembly may include one or more features for accommodating the spacer secured to the column tube. The column housing may include an elongated slot. The walls defining the elongated slot may be adapted to contact a portion of the spacer, such as during a telescoping adjustment or during torque loading. The elongated slot may be enclosed or partially enclosed. The elongated slot may enclose or partially enclose a spacer. The slot may assist in guiding translation fore and aft of the column tube during a telescoping adjustment. For example, during a telescoping adjustment, the spacer may contact one or more walls defining the elongated slot, thereby guiding the direction of travel in a longitudinal direction. The slot, through contact with the spacer, may prohibit rotational movement of the column tube about the longitudinal axis of the column tube. The walls defining the height of the slot may act as a telescope stop for the steering column assembly to stop further telescoping in or out. The elongated slot may be configured in such a way that the spacer may be installed on the column tube while the column tube is at least partially situated within the column housing. For example, the elongated slot may have a widened portion outside of the of normal telescoping operation area that is capable of allowing the spacer to pass through the widened opening to be secured to the column tube.

[0037] The column housing may include a spacer channel. The spacer channel may be free of a slot. The spacer channel may have a dimension that allows a spacer to travel therein. The spacer channel may have an interior curved surface. The curved surface may allow for an arc-type anti-rotational spacer to travel within the confines of the channel.

[0038] 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 cross-section may have an oval shape The column tube may have a non-circular cross-section. For example, the column tube may have one or more straight portions in its cross-sectional shape. The column tube may have one or more angled portions in its cross-sectional shape. For example, the column tube may have a square or rectangular cross-section.

[0039] The column tube may include one or more openings. The opening of the column tube may be adapted to receive a portion of a spacer (e.g., a projection of a spacer). The shape of the opening may be a shape that allows the projection to be retained therein. Forexample, where the projection is generally an oval or racetrack shape, the opening may be generally an oval or racetrack shape having the same or similar dimensions such that the projection is held securely within the opening (e.g., via press fit or interference fit).

[0040] Telescoping of the column tube, steering shaft, steering wheel, or a combination thereof may be eased or further eased by the use of a spacer secured to a portion of the steering column assembly. For example, a spacer may be secured to the column tube and may be permitted to translate fore and aft along a portion of the column housing as the column tube is translated fore and aft. The spacer may act as a stop during telescoping. The spacer may act to reduce or prevent rotation of the column tube within the assembly during normal operation, during adjustment, during applied torque, or a combination thereof. The spacer may act to prevent separation of elements within the assembly. For example, the spacer may act to join and / or prevent separation of or between the column tube and the column housing.

[0041] The spacer may provide for a smooth telescope feeling (e.g., through interactions with other elements of the steering column assembly, such as an elongated slot of a column housing). The spacer may serve as an anti-rotational feature for the column tube, such as during telescoping adjustment. The spacer may constrain undesirable looseness, such as during telescoping adjustment. The anti-rotational feature may be useful during torque loading. The anti-rotational feature may be strong enough to withstand high torque loads. The spacer may be a single, unitary piece. The spacer may eliminate the need for additional members or anti-rotational features, thereby simplifying the anti-rotational features, assembly, the like, or a combination thereof. The spacer may be formed of any material capable of withstanding forces to which it would be subjected during a telescoping adjustment, during torque loading, or both. The spacer, for example, may be formed of a polymeric material, a plastic material, polyoxymethylene, nylon, glass-filled, nylon, the like, or a combination thereof.

[0042] The spacer may be generally symmetrical in one or more directions (e.g., along a longitudinal axis, along a transverse axis, or both). The spacer may be generally reversible. For example, the forward face of the spacer may be positioned in a forward direction within the steering column assembly or could be positioned in a rearward direction within the assembly. The spacer may have a length dimension (e.g., along an axis extending from the forward face to the rearward face). The spacer may have a width dimension (e.g., along an axis extending between side walls). The length and width dimensions may be generally equal.The length dimension may be greater than the width dimension. The width dimension may be greater than the length dimension.

[0043] The present teachings contemplate spacers having generally curved side walls to form an arc-type anti-rotational spacer. The present teachings contemplate having generally angled side walls to form a taper-type anti-rotational spacer.

[0044] The spacer may include an outer face. The outer face may be adapted to be positioned away from the column tube when installed. The outer face may be generally planar. The outer face may be generally flat. The outer face may act to join other portions of the spacer and / or be situated between other portions of the spacer (e.g., side walls, a forward face, rearward face, or a combination thereof. The outer face (e.g., having a flat or planar surface) may be present to ensure contact between the spacer and column housing occurs in a particular area. For example, the contact between the spacer and the column housing may be in an area where the tangent line is on the order of about 30 degrees or more, about 45 degrees or less, or both. If contact is at too shallow of an angle, it is possible the spacer could become wedged in the housing when a torque is applied, may stick the column tube within the assembly, may create an undesirable increase in telescope force, or a combination thereof.

[0045] The outer face may have a shape having one or more straight edges. The straight edges may define the boundary between the outer face and another face (e.g., forward and / or rearward face) or side wall. For example, the outer face may have a generally square or generally rectangular shape such that the forward face extends from one edge, the rearward face extends from an opposing edge, and the side walls extend from the remaining edges. In one example where the outer face is generally rectangular, the long edges of the outer face may be generally parallel to the longitudinal axis of the column tube, column housing, steering column assembly, or a combination hereof. Thus, the side walls may extend from the long edges, while the forward face and rearward face extend from shorter edges.

[0046] The spacer may include a column tube contact face. The column tube contact face may be adapted to contact the outer surface of the column tube when installed. The column tube contact surface may have a generally similar shape and / or generally complementary shape to the shape of the outer surface of the column tube to which it is attached. For example, if a column tube is generally cylindrical and / or has a curved outer surface, the column tube contact face may have generally the same curvature as the curvedouter surface of the column tube. This may reduce or prevent rocking of the spacer on the column tube.

[0047] The spacer may include a projection extending therefrom. The projection may be adapted to be received within the opening in the column housing. The projection may extend from the column tube contact face. The projection may be capable of withstanding forces of about 10 N or more, about 20 N or more, or about 30 N or more. The projection may be capable of withstanding forces of about 100 N or less, about 250 N or less, or about 350 N or less. The projection may be capable of withstanding torque of about 10 Nm or more, about 20 Nm or more, or about 30 Nm or more. The projection may be capable of withstanding torque of about 100 Nm or less, about 250 Nm or less, or about 350 Nm or less.

[0048] The projection may have a shape that generally matches the shape of the opening of the column tube into which it will be received. As shown, the projection has a generally oval or racetrack shape, though other shapes are possible. The projection may have a shape (e.g., when looking at the projection from the bottom of the spacer) that has one or more generally straight portions, one or more generally curved portions, one or more angled portions, one or more corners, one or more rounded edges, or a combination thereof.

[0049] The projection may include one or more ribs, extensions, textures, or the like. These features may act to eliminate clearance between the spacer and the column tube. The features may provide a press-fit or interference fit between the projection and the column tube. The press-in and / or pull-off force to install and / or remove the spacer may be about 5N or more, about 20 N or less, or both, or any value or range of values therebetween. The projection may be integrally formed with the spacer so that additional fasteners are not required.

[0050] The spacer may include a forward face. The forward face may be adapted to be positioned in a forward direction within the steering column assembly. The spacer may include a generally opposing rearward face. The rearward face may be adapted to be positioned in a rearward direction within the steering column assembly. The forward face, rearward face, or both may extend between the outer face and the column tube contact face.

[0051] The spacer may include side walls. A side wall may extend between the forward face and the rearward face. The side walls may extend between the outer face and the column tube contact face. An edge may be formed between the side wall and the column tube contact face. The edge may include an elongated notch, thinned portion, cutout, groove, or otherfeature. The feature may act to limit the contact points of the spacer to the ends so the spacer sits flat on the column tube and / or does not rock on the column tube.

[0052] One or more side walls of the spacer may be a generally curved side wall. Curvature may be visible, for example, when viewing the spacer from the forward face, rearward face, or both. The spacer may have two generally curved side walls. In a spacer with curved side walls, this may be an arc-type anti-rotational spacer. Where both side walls of the spacer are curved, the spacer may have a generally truncated arc shape, where the outer face is generally flat, and the curved side walls extend outwardly between the column tube contact face and the outer face.

[0053] One or more side walls of the spacer may be generally free of curves. One or more side walls may be generally flat. One or more side walls may be positioned generally at an angle relative to other portions of the spacer (e.g., the outer face, the column tube contact face, the forward face, the rearward face, an opposing side wall, or a combination thereof). One or more side walls of the spacer may be positioned such that the planes of the side walls extend toward each other as they approach the outer face of the column tube. This may be a taper-type anti-rotational spacer. For example, an angle may be formed between the angled side wall and the outer face. The angle may be about 90 degrees or more, about 100 degrees or more, or about 110 degrees or more. The angle may be less than 180 degrees, about 160 degrees or less, or about 150 degrees or less. When viewing the spacer from the forward face and / or rearward face, the shape of the spacer may be generally trapezoidal with a flat outer face and the angled side walls.

[0054] The side walls may act to contact the column housing (e.g., a spacer channel or a wall defining a longitudinal slot) during adjustment of the steering column assembly (e.g., telescoping adjustment), during an applied torque to the column tube, or both. The side walls may be shaped to fit within the confines of the column housing such that the spacer may travel within the column housing (e.g., the spacer channel and / or longitudinal slot) during adjustment without binding, wedging, or sticking. The column housing may act to retain the spacer and / or trap the spacer within the column tube and / or between the column tube and column housing. The dimensions or geometry of the area of the column housing adapted to receive the spacer and the dimensions or geometry of the spacer may prevent the spacer from disengaging from the column tube.

[0055] The angle of contact between the spacer and the column housing may be about 30 degrees or more. The angle of contact between the spacer and the column housing maybe about 75 degrees or less. The angle may be selected to generate torque-resisting friction. At too small of an angle, the spacer may become stuck or wedged into the column housing and column tube and bind.

[0056] With an arc-type anti-rotational spacer, it may be received within a spacer channel of the column housing. The spacer channel may have a generally curved inner surface. The generally curved inner surface may have a similar curvature as the curved side walls of the arc-type anti-rotational spacer.

[0057] With a taper-type anti-rotational spacer, the spacer may be received within the elongated slot of the column housing. The walls defining the slot of the column housing may be generally angled. A plane extending along a wall defining the slot and a plane extending along the side wall of the spacer may be generally parallel.

[0058] The spacer may act to direct reaction loads to reduce shearing loads. The reaction loads may be directed toward the center of the column tube. The contact between the column housing and the spacer may be such that when the column tube is torqued, the resulting reaction load generates friction between the column tube and the spacer and between the column tube and the column housing. The friction acts to help resist the input torque.

[0059] T urning now to the figures, Figures 1 and 2 illustrate exemplary steering column assemblies 10. Each assembly has a forward end 12 and a rearward end 14. One or more bracket structures 16 allow for securing or mounting the steering column assembly 10 within an automotive vehicle. The steering column assembly 10 includes a steering shaft 18 at the rearward end 14, which is adapted for supporting a steering wheel (not shown). The steering shaft 18 is supported by a column tube 30, which is supported by a column housing 20.

[0060] The steering column assembly 10 of Figure 1 includes an adjustment subassembly 40 illustrated as an electromechanical assembly and / or an assembly including one or more motors for actuating tilt adjustment, telescoping adjustment, or both.

[0061] The steering column assembly of Figure 2 includes an adjustment subassembly 40 illustrated as a manual adjustment assembly including a lever for actuating locking and unlocking functions of the assembly.

[0062] In Figure 2, the column housing 20 includes a slot 22 through which the column tube 30 is visible. Within the slot 22 and secured to the column tube 30 is an anti-rotational spacer 50 in accordance with the present teachings. As shown, the slot 22 is wider toward theforward end 12, which may allow for the anti-rotational spacer 50 to be installed on the column tube 30 when the column tube 30 is already in the column housing 20.

[0063] Figure 3 illustrates an existing design where a rivet 46 secures a rotational fixer device 48 to a column tube 30. In these designs, the column housing (not shown) is fully open, so the rotational fixer device 48 must be secured to the column tube 30 with a fastener, such as the rivet 46 as shown. Constraint to the rotation of the column tube is achieved by tangential resistance load on the rotational fixer device 48, illustrated by the straight arrow. Reactions to this tangent load will create a reacting shear load on the rotational fixer device 48. Should the fastener 46 shear or become otherwise disengaged from the column tube 30, the rotational fixer device 48 may become disconnected from the column tube as well.

[0064] Figures 4A and 4B illustrate an exemplary anti-rotational spacer 50, shown as an arc-type anti-rotational spacer 52. The arc-type anti-rotational spacer 52 includes an outer face 56 and a generally opposing column tube contact face 58. The column tube contact face 58 as shown has a generally curved surface. The generally curved surface generally matches the curvature of the outer surface of the column tube 30 with which it is in contact (see Fig. 6). Extending from the column tube contact face 58 is a projection 74. The projection 74 includes a plurality of ribs 76 which create a press-fit or friction fit connection between the arctype anti-rotational spacer 52 and the walls defining an opening 32 in the column tube 30 (see Fig. 6).

[0065] The arc-type anti-rotational spacer 52 includes curved side walls 62 that connect the outer face 56 and the column tube contact face 58 on opposing sides of the arctype anti-rotational spacer 52. An edge 66 is formed where the curved side walls 62 meet the column tube contact face 58. The edge 66 may be a long edge of the arc-type anti-rotational spacer 52. Optionally, the edge 66 may include an elongated notch 68 that extends over at least a portion of the edge. The elongated notch may limit the contact points of the spacer to the ends so the spacer sits flat on the column tube and does not rock. When viewing the arctype anti-rotational spacer 52 from a forward face 70 or a rearward face 72, the curved side walls 62 and the outer face 56 may create a generally truncated arc shape.

[0066] Figures 5A and 5B illustrate an exemplary anti-rotational spacer 50, shown as a taper-type anti-rotational spacer 54. The taper-type anti-rotational spacer 54 includes an outer face 56 and a generally opposing column tube contact face 58. The column tube contact face 58 as shown has a generally curved surface. The generally curved surface generally matches the curvature of the outer surface of the column tube 30 with which it is in contact(see Fig. 6). Extending from the column tube contact face 58 is a projection 74. The projection 74 includes a plurality of ribs 76 which create a press-fit or friction fit connection between the arc-type anti-rotational spacer 52 and the walls defining an opening 32 in the column tube 30 (see Fig. 6).

[0067] The taper-type anti-rotational spacer 54 includes angled side walls 64 that are generally flat. The angled side walls 64 extend between the column tube contact face 58 and the outer face 56. An edge 66 is formed where the angled side walls 64 meet the column tube contact face 58. An angle is formed between the angled side wall 64 and the outer face 56, where the angle a is greater than 90 degrees and less than 180 degrees (e.g., about 110 degrees or more, about 150 degrees or less, or both). When viewing the taper-type anti- rotational spacer 54 from a forward face 70 or rearward face 72, the angled side walls 64, and outer face 56 create a generally trapezoidal shape.

[0068] Figure 6 illustrates an attachment between an anti-rotational spacer 50 (e.g., of either the arc-type or the taper-type) where the projection 74 of the anti-rotational spacer 50 is received within an opening 32 of a column tube 30. Ribs 76 (see Figs. 4A-5B) may create a friction fit or press-fit, such that the anti-rotational spacer 50 is held in place on the outer surface of the column tube 30 during ordinary use. The ribs may act to eliminate clearance between the spacer and the column tube.

[0069] Figures 7A and 7B are section views of the steering column assembly of Fig. 1 taken along line A-A. A column housing 20 supports a column tube 30 located therein. As seen in Figure 7B, an arc-type anti-rotational spacer 52 is connected to the column tube 30 via a projection 74 of the arc-type anti-rotational spacer 52 extending through and engaging with an opening in the column tube. The column housing 20 includes a spacer channel 26 of sufficient size and dimension that the arc-type anti-rotational spacer 52 is permitted to fit within and travel along the spacer channel 26. The curved side walls 62 of the arc-type anti-rotational spacer have a generally similar curvature to an interior curved surface 28 of the spacer channel 26. The curved side walls 62 may contact the interior curved surface 28 during normal use, during telescoping adjustment, during rotation of the column tube, when the column tube is torqued, or a combination thereof. The engagement between the curved side walls and the interior curved surface may provide friction for controlling adjustment, for directing reaction loads to the center of the column tube, or both. The spacer channel 26 may assist in retaining the arc-type anti-rotational spacer within the steering column assembly. The geometry of the housing may prevent the arc-type anti-rotational spacer 52 from disengaging from the columntube 30 by trapping the arc-type anti-rotational spacer 52 between the column housing 20 and the column tube 30.

[0070] Figures 8A and 8B are section views of the steering column assembly of Fig. 2 taken along line B-B. A column housing 20 supports a column tube 30 located therein. A tapertype anti-rotational spacer 54 is connected to the column tube 30 via a projection 74 of the taper-type anti-rotational spacer 54 extending through and engaging with an opening in the column tube. The column housing 20 includes a slot 22 that is at least in part defined by interior angled walls 24. The slot 22 may have a widened portion (e.g., at a forward end of the steering column assembly) outside of the normal telescope operation area where the anti- rotational spacer can be passed through the column housing 20 and assembled into the column tube 30.

[0071] Angled side walls 64 of the taper-type anti-rotational spacer 54 are adapted to be received between the interior angled walls 24 of the column housing 20. The angle of the angled side walls 64 and the angle of the interior angled wall 24 may be generally complementary or may have planes that extend generally parallel to each other. The geometry of the interior angled walls 24 may prevent the taper-type anti-rotational spacer 54 from disengaging from the column tube 30 by trapping the taper-type anti-rotational spacer 54 between the column tube 30 and the column housing 20.

[0072] The angled side walls 64 and interior angled walls 24 may contact each other at least during certain times. Contact between the column housing 20 and the taper-type anti- rotational spacer 54 may be such that when the column tube 30 is torqued (shown as T), the resulting reaction load R generates friction F between the taper-type anti-rotational spacer 54 and the column tube 30 and friction F between the column tube 30 and the column housing 20. The friction F may act to resist the input torque T.

[0073] While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the teachings. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. It is contemplated that rather than or in addition to a projection from the spacer into the column tube, the column tube may have a feature that engages with the spacer (e.g., an opening in the spacer).

[0074] Any numerical values recited herein include all values from the lower value to the upper value in increments of one unit provided that there is a separation of at least 2 unitsbetween any lower value and any higher value. As an example, if it is stated that the amount of a component or a value of a process variable such as, for example, temperature, pressure, time and the like is, for example, from 1 to 90, preferably from 20 to 80, more preferably from 30 to 70, it is intended that values such as 15 to 85, 22 to 68, 43 to 51, 30 to 32 etc. are expressly enumerated in this specification. For values which are less than one, one unit is considered to be 0.0001, 0.001 , 0.01 or 0.1 as appropriate. These are only examples of what is specifically intended and all possible combinations of numerical values between the lowest value and the highest value enumerated are to be considered to be expressly stated in this application in a similar manner.

[0075] Unless otherwise stated, all ranges include both 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 cover “about 20 to about 30”, inclusive of at least the specified endpoints.

[0076] The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. The term “consisting essentially of” to describe a combination shall include the elements, ingredients, components or steps identified, and such other elements ingredients, components or steps that do not materially affect the basic and novel characteristics of the combination. The use of the terms “comprising” or “including” to describe combinations of elements, ingredients, components or steps herein also contemplates embodiments that consist essentially of, or even consisting of, the elements, ingredients, components or steps.

[0077] Plural elements, ingredients, components or steps can be provided by a single integrated element, ingredient, component or step. Alternatively, a single integrated element, ingredient, component or step might be divided into separate plural elements, ingredients, components or steps. The disclosure of “a” or “one” to describe an element, ingredient, component or step is not intended to foreclose additional elements, ingredients, components or steps.

[0078] Relative positional relationships of elements depicted in the drawings are part of the teachings herein, even if not verbally described.Element List

Claims

CLAIMSWhat is claimed is:

1. A spacer comprising: a) an outer face; b) a generally opposing column tube contact face; c) a projection extending from the column tube contact face and adapted to be received within an opening of an element of a steering column assembly (e.g., a column tube); d) a forward face; e) a generally opposing rearward face; and f) one or more side walls extending between the outer face and column tube contact face, between the forward face and rearward face, or both; wherein the spacer is adapted to engage with a portion of the steering column assembly to reduce or prevent rotation of the column tube, to limit telescoping adjustment of a steering wheel of the steering column assembly, to prevent column separation, or a combination thereof.

2. The spacer of claim 1, wherein the side walls are curved side walls such that the spacer is an arc-type anti-rotational spacer.

3. The spacer of claim 2, wherein the curved side walls and outer face of the arc-type anti- rotational spacer create a generally truncated arc shape (e.g., when viewing the forward face and / or rearward face).

4. The spacer of claim 1, wherein the side walls are generally angled such that the spacer is a taper-type anti-rotational spacer.

5. The spacer of claim 4, wherein the angled side walls and the outer face of the taper-type anti-rotational spacer create a generally trapezoidal shape (e.g., when viewing the forward face and / or rearward face).

6. The spacer of claim 4 or 5, wherein an angle is formed between the angled side wall and the outer face, wherein the angle is about 90 degrees or more, about 180 degrees or less, or both (e.g., about 110 degrees or more, about 150 degrees or less, or both).

7. The spacer of any of the preceding claims, wherein the outer face is generally planar.

8. The spacer of any of the preceding claims, wherein the column tube contact face is generally curved (e.g., to generally match the curvature of the column tube).

9. The spacer of any of the preceding claims, wherein the outer face joins the side walls, forward face, and rearward face.

10. The spacer of any of the preceding claims, wherein an edge is formed between a side wall and the column tube contact face.

11. The spacer of claim 10, wherein the edge includes an elongated notch (e.g., adapted to prevent or reduce rocking of the spacer on the column tube).

12. The spacer of any of the preceding claims, wherein the projection has a plurality of ribs configured for eliminating clearance between the spacer and the column tube.

13. A steering column assembly comprising: a. a column housing; b. a column tube at least partially received within the column housing, the column tube having an opening; c. the spacer of any of the preceding claims, wherein the projection of the spacer is received within the opening of the column tube.

14. The steering column assembly of claim 13, wherein the spacer is an arc-type anti- rotational spacer.

15. The steering column assembly of claim 13 or 14, wherein the column housing includes a spacer channel having a generally curved surface for receiving and / or retaining the arctype anti-rotational spacer between the column tube and the column housing.

16. The steering column assembly of claim 15, wherein the generally curved surface of thespacer channel has a generally similar curvature as the curved side walls of the arc-type anti-rotational spacer.

17. The steering column assembly of claim 13, wherein the spacer is a taper-type anti- rotational spacer.

18. The steering column assembly of any of claims 13 to 17, wherein the column housing includes an elongated slot.

19. The steering column assembly of claim 18, wherein the elongated slot has a widened portion that is wider than another portion of the elongated slot to allow for installation of the spacer onto the column tube through the column housing.

20. The steering column assembly of any of claims 13 to 19, wherein the spacer is received within and / or travels between boundaries defining the elongated slot.

21. The steering column assembly of any of claims 18 to 20, wherein the elongated slot is at least partially defined by interior angled walls.

22. The steering column assembly of claim 21 , wherein one of the interior angled walls of the elongated slot and the adjacent angled side wall of a taper-type anti-rotational spacer are generally complementary or have planes that extend generally parallel to each other.

23. The steering column assembly of claim 21 or 22, wherein the interior angled walls of the elongated slot contact the angled side walls of a taper-type anti-rotational spacer at least during certain times (e.g., when the column tube is torqued).

24. The steering column assembly of any of claims 13 to 23, wherein the steering column assembly is a manually adjustable steering column assembly.

25. The steering column assembly of any of claims 13 to 23, wherein the steering column assembly is an electromechanically adjustable steering column assembly.

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