Steering Column Tape Interface for Wear and Debris Reduction
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Solution Overview
Problem
Existing steering column assemblies face wear issues and debris accumulation between the column jacket and box rocker, particularly when using dissimilar materials like steel and magnesium, where rigid sleeves do not provide an optimal solution.
Innovation Solution
Incorporating a section of tape between the box rocker inner surface and column jacket outer surface, which is compressible and adhered to the rocker body, allowing the column jacket to slide along the tape, reducing direct contact and mitigating wear and debris accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid sleeves are used between the column jacket and box rocker, then wear is reduced, but the solution is not optimal for dissimilar materials and creates debris accumulation issues
Solution Approach 1:
The patent introduces tape as an intermediary material between the column jacket and box rocker. This tape acts as a mediator that reduces direct contact and wear between the dissimilar materials (steel column jacket and magnesium box rocker), while also preventing debris accumulation by providing a smooth, continuous surface that doesn't trap particles like rigid sleeves do.
Solution Approach 2:
The patent changes the material parameter from rigid sleeves to flexible tape. This parameter change allows the tape to conform to the mating surfaces, provide better wear protection, and eliminate the gaps and crevices that cause debris accumulation in rigid sleeve configurations.
2Reliability
If tape is used between the column jacket and box rocker, then wear is reduced and debris is minimized, but the structural stiffness may be compromised
Solution Approach 1:
The patent employs flexible tape in the form of thin films between the column jacket and box rocker. This flexible film provides wear protection while maintaining structural integrity through proper adhesion to the mating surfaces, eliminating the need for thick rigid sleeves that would compromise the overall structure.
Solution Approach 2:
The patent creates a composite structure by combining the tape material with the existing steel column jacket and magnesium box rocker. This composite approach allows each material to perform its optimal function - the tape provides wear protection and debris prevention, while the rigid components maintain structural stiffness and load-bearing capacity.
3Reliability
If rigid sleeves are incorporated between the column jacket and box rocker, then wear protection is provided, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent replaces expensive, complex rigid sleeves with inexpensive tape that can be easily applied and replaced if needed. This disposable-like approach with the tape reduces manufacturing costs and assembly complexity while providing adequate wear protection for the application.
Solution Approach 2:
The patent uses tape with different material properties (including potential color coding for identification) to simplify assembly and maintenance. The tape's visual characteristics help in proper installation and inspection, reducing complexity compared to metallic sleeves that require precise fitting and alignment.
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 tape solution significantly reduces wear between the column jacket and box rocker, minimizes debris, and improves stiffness and axis alignment, while being easily adaptable and cost-effective compared to rigid sleeves.
Implementation Method 1
The first section of tape is at least partially adhered to the box rocker inner surface. The first section of tape is further adhered to a face surface of the box rocker body.
Implementation Method 2
The first section of tape is configured to compress between 20% and 25%.
Data Source
Figure 1
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AI summary
A steering column assembly for a motor vehicle, including a box rocker (12), a column jacket (16) and a first section of tape (20). The box rocker (12) has a rocker body (24) including a box rocker inner surface (40) that defines a box rocker bore (30). The box rocker (12) is configured to be fixed relative to the motor vehicle in an assembled position. The column jacket (16) is configured to be slidably received into the box rocker bore (30). The column jacket (16) has a column jacket outer diameter (70) including an outer surface (72) that opposes the box rocker inner surface (40). The first section of tape (20) is disposed between the box rocker inner surface (40) and the column jacket outer surface (72).