Steering Column Held Bracket Strength via Resin Spacer
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Solution Overview
Problem
The existing steering column apparatus formed using hydroforming methods has a thin held bracket section, resulting in low strength and rigidity, which can lead to deformation under load and vibration issues due to metal edge contact during steering wheel adjustments.
Innovation Solution
A steering column apparatus with a cylindrical inner and outer column, where the held bracket section is integrally formed with the outer column using hydroforming, and a spacer made of a softer material is inserted between the held bracket sections to enhance strength and prevent metal edge contact, using notches and convex sections to maintain the adjusted position and reduce vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the held bracket section is integrally formed with the outer column using hydroforming, then manufacturing cost is reduced and integration is improved, but the thickness of the held bracket section becomes thin resulting in low strength and rigidity
Solution Approach 1:
The patent combines metal material (outer column) with resin material (held bracket section) to create a composite structure. The resin held bracket section is formed inside the metal outer column through injection molding, creating a composite component that leverages the strength of metal and the molding flexibility of resin, thereby maintaining both manufacturing efficiency and structural strength.
Solution Approach 2:
The patent applies different materials to different parts of the steering column assembly. The outer column uses metal for high strength requirements, while the held bracket section uses resin for cost-effective integration. This local differentiation of material properties optimizes both manufacturing cost and structural performance in specific regions.
2Device complexity
If the held bracket section is thin-walled from hydroforming, then manufacturing complexity is reduced, but deformation occurs under load due to insufficient strength
Solution Approach 1:
The resin held bracket section is injection-molded inside the metal outer column, creating a composite structure where the resin provides structural support and deformation resistance while the metal outer column provides additional strength. This composite approach maintains manufacturing simplicity while preventing deformation under load.
Solution Approach 2:
The steering column is divided into functional segments with different material properties: the metal outer column handles high-stress structural requirements, while the resin held bracket section handles positioning and low-stress support functions. This segmentation allows each part to be optimized for its specific role without compromising overall stability.
3Device complexity
If metal edges of the held bracket contact the rod during adjustment, then structural simplicity is maintained, but vibration and abnormal sound occur
Solution Approach 1:
The resin held bracket section acts as an intermediary between the metal rod and the adjustment mechanism. The resin material provides cushioning and vibration absorption during rod adjustment, eliminating metal-to-metal contact and the associated abnormal sounds while maintaining structural simplicity.
Solution Approach 2:
The patent changes the material parameter of the held bracket section from metal to resin, which fundamentally alters the contact characteristics during adjustment. The resin material's damping properties reduce vibration and noise generation while maintaining the structural simplicity of the overall design.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution significantly improves the strength and rigidity of the held bracket section, preventing deformation and vibration, while maintaining the adjusted position of the steering wheel, and stabilizing the outer column during impact loads.
Implementation Method 1
the outer circumferential surface of the rod and the inner peripheral edges of the through holes that are formed in the held bracket section do not come in contact with each other, it is possible to prevent an occurrence of vibrations or abnormal noise
Implementation Method 2
a held bracket section that is integrally formed with the outer column by causing metal to swell outward in the radial direction
Data Source
AI summary
Construction is achieved in which a held bracket section 30 is integrally formed with the end section of an outer column by a hydroforming method, so as to be able to substantially ensure the strength and rigidity of the held bracket section 30. A spacer 37 that is made of a material that is softer than the metal plate of the outer column 20a is assembled in the inside of the held bracket section 30 and between a pair of left and right held plate sections 31. Holes for inserting a rod for fastening the position of the steering wheel are provided in portions of the spacer 37 and held plate sections 31 that are aligned with each other.