Steering Column Unit Resin Housing Metal Embedding
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Solution Overview
Problem
The existing column units for electric power steering apparatuses face challenges in achieving a balance between lightweight construction, maintaining sufficient strength and rigidity, and ensuring installation rigidity with respect to the vehicle body, particularly when combining synthetic resin and metal components, which often results in weak bonding and potential movement or vibration issues between the steering column and housing.
Innovation Solution
The column unit integrates a steering column with an outer and inner column, where the outer column and housing are made of synthetic resin, with the inner column collapsing during secondary collisions, and features a support bracket system that includes metal bolts for secure attachment to the vehicle body, enhancing bonding strength and rigidity through integral molding and strategic design features like shear pins and protrusions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the housing is made of synthetic resin to lighten weight and reduce cost, then weight is reduced and cost decreases, but bonding strength between the housing and steering column becomes weak
Solution Approach 1:
The patent uses composite materials by combining synthetic resin housing with metal reinforcement elements (embedding pieces) and adhesive materials. The housing main body is made of lightweight synthetic resin, while metal embedding pieces are embedded in the resin to provide reinforcement at critical bonding locations, creating a composite structure that achieves both weight reduction and sufficient bonding strength.
Solution Approach 2:
The patent applies local quality by concentrating reinforcement only where needed - metal embedding pieces are embedded in the synthetic resin housing at specific locations (front and rear ends) where bonding strength is critical. This localized reinforcement approach maintains the overall lightweight characteristic while providing sufficient strength at critical joints.
2Strength
If the steering column is made of metal to maintain strength and rigidity, then strength and rigidity are maintained, but weight increases
Solution Approach 1:
The patent applies local quality by using metal material only for the embedding pieces at critical locations rather than making the entire steering column from metal. The housing main body remains synthetic resin for weight reduction, while metal is strategically placed only where structural strength and bonding capability are required.
Solution Approach 2:
The patent uses composite materials by combining synthetic resin and metal in a hybrid structure. The housing consists of synthetic resin with embedded metal pieces, creating a composite structure that leverages the lightweight property of resin and the high strength property of metal at critical locations.
3Weight of moving object
If the housing is made of soft metal to reduce weight, then weight is reduced, but installation rigidity with respect to the vehicle body decreases
Solution Approach 1:
The patent uses composite materials by combining synthetic resin housing with metal reinforcement elements (embedding pieces). This composite structure provides both the weight reduction benefit of lightweight materials and the installation rigidity benefit of metal reinforcement at critical bonding locations.
Solution Approach 2:
The patent applies local quality by concentrating rigid metal embedding pieces at specific locations where installation rigidity is critical, while the rest of the housing remains lightweight synthetic resin. This localized reinforcement ensures stable installation to the vehicle body without requiring the entire housing to be made of heavy metal.
Data Source
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AI summary
Provided is an electric power steering apparatus that is both lightweight and rigid. A lightweight electric power steering apparatus is achieved wherein a gear housing 45 that houses an electric assist mechanism, a lower support bracket 54 for fastening the gear housing 45 to the vehicle body, a sensor housing 56 that houses a torque sensor 57, an outer column 30 of a steering column 6c, and an upper support bracket 59a for fastening the middle section of the outer column 3 to the vehicle body are all integrally formed of synthetic resin with glass fibers, improving the strength of the joined sections of these members.