Steering Column Attachment Features Using Composite Injection Molding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional steering columns for motor vehicles are heavy due to metallic materials and require complex welding processes for assembly, which increases weight and reduces efficiency in manufacturing.
Innovation Solution
A steering column assembly using injection moldable materials like nylon or polypropylene with a load glass fiber component, which are molded to form high-strength attachment features that surround the main steering column shaft, reducing weight and eliminating the need for metalworking processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic materials and welding processes are used for steering column assembly, then structural strength is ensured, but weight increases and manufacturing complexity increases
Solution Approach 1:
The patent applies composite materials by combining a metal steering column shaft with injection-molded polymer attachment features containing glass fiber reinforcement. This composite structure allows the metal shaft to provide core structural strength while the polymer attachment features reduce overall weight compared to traditional all-metal construction with welds.
Solution Approach 2:
The patent replaces the mechanical welding process with an injection molding process. Instead of joining metal parts through welding, the attachment features are directly molded onto the shaft, eliminating the need for separate welding operations and reducing assembly complexity while maintaining structural integrity.
2Strength
If metallic materials and welding processes are used for steering column assembly, then structural strength is ensured, but manufacturing complexity increases
Solution Approach 1:
The patent merges the attachment feature formation and shaft construction into a single injection molding operation. The attachment features are molded directly onto the steering column shaft in one process step, combining what would traditionally be separate manufacturing and assembly operations into a unified process.
Solution Approach 2:
The patent substitutes the welding mechanical system with an injection molding process. This replacement eliminates the need for welding equipment, skilled welders, and complex welding procedures, thereby reducing manufacturing complexity while still achieving strong structural connections.
3Weight of moving object
If injection moldable materials with glass fiber component are used, then weight is reduced and manufacturing efficiency is improved, but material strength requirements increase
Solution Approach 1:
The patent uses composite materials consisting of injection-moldable polymer matrices reinforced with glass fibers. The glass fiber reinforcement provides the necessary tensile and structural strength to the polymer attachment features, allowing them to meet strength requirements while maintaining the weight reduction benefits of using polymer instead of metal.
Data Source
AI summary
A steering column assembly for a motor vehicle is provided. The steering column assembly may include a main steering column shaft; a first tubular member; a first attachment feature; and a second attachment feature. The first attachment feature and the second attachment feature may be formed of an injection moldable material such as nylon or polypropylene, having a load glass fiber component. The first and second attachment features are injection molded about the main steering column shaft. A method of constructing a steering column assembly for a motor vehicle is also provided, wherein the first attachment feature and the second attachment feature are injection molded and positioned about the main steering column shaft.