Abstract: A telescoping steering column assembly and method of manufacturing the assembly are disclosed. The assembly includes an outer jacket defining at least one hole and a central axis. An inner jacket is disposed in the outer jacket and slides relative to the outer jacket along the central axis. A plug having a body portion and a flange extending radially outwardly from the body portion is disposed in the hole of the outer jacket. The plug defines at least one channel and the plug is heated to create a molten material that flows into the channel of the plug for securing the plug within the hole to prevent movement of the plug along the central axis and for aligning the inner jacket within the outer jacket to allow the inner jacket to slide within the outer jacket.

Abstract: A variable road feedback device (20) for a steer-by-wire system (50) comprises a housing (31) that contains a magnetorheological fluid (32), a magnetic field generator (34) for generating a variable magnetic field within the housing (31) in order to vary the viscous resistance of the magnetorheological fluid (32) therein, and a rotor (24) rotatably mounted within the housing (31) that rotates through the magnetorheological fluid (32) and is responsive to the variable viscous resistance thereof.

Abstract: A variable road feedback device (20) for a steer-by-wire system (50) comprises a housing (31) that contains a magnetorheological fluid (32), a magnetic field generator (34) for generating a variable magnetic field within the housing (31) in order to vary the viscous resistance of the magnetorheological fluid (32) therein, and a rotor (24) rotatably mounted within the housing (31) that rotates through the magnetorheological fluid (32) and is responsive to the variable viscous resistance thereof.

Abstract: A connection between a collapsible mast jacket of an energy absorbing steering column and a motor vehicle body including a mounting bracket on the mast jacket having a planar flange, a capsule slot in the planar flange, and a snap-in capsule. The snap-in capsule includes a retaining channel, an integral cantilever spring, and a detent lug on the end of the cantilever spring which overlaps the retaining channel. When the snap-in capsule is pushed into the capsule slot, the retaining channel cooperates with a peripheral edge of the capsule slot in guiding the snap-in capsule and in retaining the snap-in capsule perpendicular to the planar flange. Concurrently, the detent lug is ejected from the retaining channel against a restoring force attributable to resilient flexure of the cantilever spring. When the snap-in capsule attains a seated position in the capsule slot, the cantilever spring snaps the detent lug into a detent notch in the planar flange.

Abstract: An energy-absorbing motor vehicle steering column including a structural housing, a pair of wedge blocks supported in guide channels on the structural housing for linear translation parallel to a longitudinal centerline of the steering column, a retainer plate on the structural housing over the guide channels, a lateral shoulder on each wedge block, and springs between each of the wedge blocks and the structural housing. When the wedge blocks are pushed backward in their guide channels, the springs are compressed and tip the wedge blocks upward to seat the lateral shoulders on the wedge blocks against the retainer plate and thereby retain the wedge blocks in retracted positions. The retainer plate is hooked over a lateral rod on a body of the motor vehicle to support an aft end of the structural housing vertically on the vehicle body.

Abstract: An energy-absorbing steering column for a motor vehicle including a housing, an energy absorber between the housing and a body structure of the motor vehicle, a box-shaped bracket on the body structure surrounding a first end of the housing for vertical support, and a horizontal rod on the housing near a second end thereof, the lateral ends of which are seated on horizontal shoulders of a pair of vertical hangers on the body structure for vertical support of the second end of the housing. A cam is rotatably supported on the horizontal rod and locked in a retracted position by a retainer until the housing achieves vertical support on the body structure by the box-shaped bracket and the horizontal shoulders of the vertical hangers. When the retainer is withdrawn from the cam, a torsion spring rotates the cam to a position wedged between the body structure and the housing to eliminate vertical lash.

Abstract: An energy-absorbing motor vehicle steering column including a structural housing, a releasable attachment between a body of the motor vehicle and a forward end of the structural housing, and a releasable attachment between an aft end of the structural housing and the vehicle body which restrains the aft end vertically and in the direction of a longitudinal centerline of the structural housing. The aft attachment includes a lateral rod on the vehicle body, a retainer on the structural housing which hooks over the lateral rod, a pair of blocks on the structural housing slidable in the direction of the longitudinal centerline of the latter, each having a ramp facing the lateral rod, and a pair of springs biasing the blocks toward the aft end of the structural housing. The springs wedge the ramps on the blocks under the lateral rod.

Abstract: A rotary telescopeable shaft particularly suited for use as an intermediate steering shaft of a motor vehicle including a cylindrical tubular shaft having a flat side, a cylindrical solid shaft slidably telescoped inside of the tubular shaft having a flat side facing the flat side on the tubular shaft and coupling the shafts for unitary rotation, and a unitized resilient insert concealed in a notch in the solid shaft. The notch has a pair of lateral ramps which converge with the flat side of the tubular shaft and a longitudinal ramp which converges with a cylindrical segment of the tubular shaft. The unitized resilient insert consists of a slider on each lateral ramp, a slider on the longitudinal ramp, and a spring wedging the sliders between the lateral ramps and the flat side of the tubular shaft to eliminate runnning clearance perpendicular to the flat side and between the longitudinal ramp and the cylindrical segment of the tubular shaft to eliminate running clearance parallel to the flat side.