Abstract:
A one-piece bracket is provided for mounting a tubular housing of a steering gear tube assembly to a vehicle member. At least one folded portion forming at least one receiving member is adapted for receiving a fastening member therethrough that couples the bracket to the vehicle member. A first leg portion is integral with and extends from the first folded portion. The first leg portion is contoured for being adapted to be coupled to the tubular housing. A second leg portion is integral with and extends from the first folded portion. The second leg portion is contoured for being adapted to be coupled to the tubular housing. The first and second leg portions are spaced apart a predetermined distance defining an opening therebetween for receiving the tubular housing.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]     Not Applicable.  
       STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH  
       [0002]     Not Applicable.  
       BACKGROUND OF THE INVENTION  
       [0003]     1. Field of the Invention  
         [0004]     This present invention relates to a support bracket for a steering gear tube assembly, and more specifically, to a one piece formed bracket of a steering gear tube assembly.  
         [0005]     2. Description of the Related Art  
         [0006]     Steering systems in motor vehicles typically comprise rack and pinion steering systems. The rack and pinion steering systems consist of a pinion shaft, pinion teeth, a rack including rack teeth, bearings, seals, and a housing. The housing has a hydraulic valve section and an extended rack section and houses the meshing of the pinion teeth and the rack teeth. The housing is commonly supported by one or more mounting brackets. The mounting brackets are coupled to the housing and are bolted to a vehicle frame or a unibody structure. Rubber grommets or bushings are used to dampen noise and vibrations from the road.  
         [0007]     The mounting brackets are typically spot welded to or strapped about the housing. The welded mounting brackets include two or more stamped metal parts that are welded together to form a unified bracket. The process for manufacturing a mounting bracket may include multiple manufacturing operations such as stamping, forming, and welding operations to form the unified bracket.  
       SUMMARY OF THE INVENTION  
       [0008]     The present invention has the advantage of utilizing a one piece bracket formed from a single piece of material for mounting a tube and bracket assembly of a rack and pinion steering system that requires no welding operation to form the mounting bracket. By employing a single piece of material to form the bracket, the number of components required for assembling the bracket assembly is reduced in addition to a reduced number of assembly steps.  
         [0009]     In one aspect of the present invention, a one-piece bracket is provided for mounting a tubular housing of a steering gear tube assembly to a vehicle member. At least one folded portion forming at least one receiving member is adapted for receiving a fastening member therethrough that couples the bracket to the vehicle member. A first leg portion is integral with and extends from the first folded portion. The first leg portion is contoured for being adapted to be coupled to the tubular housing. A second leg portion is integral with and extends from the first folded portion. The second leg portion is contoured for being adapted to be coupled to the tubular housing. The first and second leg portions are spaced apart a predetermined distance defining an opening therebetween for receiving the tubular housing.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]      FIG. 1  is a schematic illustration of a tube and bracket assembly for a rack and pinion steering system of a vehicle according to a preferred embodiment of the present invention.  
         [0011]      FIG. 2  is an elevation view of a portion of a prior art tube and bracket assembly.  
         [0012]      FIG. 3  is a perspective view of a mounting bracket according to the first preferred embodiment of the present invention.  
         [0013]      FIG. 4  is a plan view of a blank used for forming the mounting bracket of  FIG. 3  according to the first preferred embodiment of the present invention.  
         [0014]      FIG. 5  is a perspective view of a mounting bracket according to a second preferred embodiment of the present invention.  
         [0015]      FIG. 6  is a plan view of a blank used for forming the mounting bracket of  FIG. 5  according to the second preferred embodiment of the present invention.  
         [0016]      FIG. 7  is a perspective view of a mounting bracket according to a third preferred embodiment of the present invention.  
         [0017]      FIG. 8  is a plan view of a blank used for forming the mounting bracket of  FIG. 7  according to the third preferred embodiment of the present invention.  
         [0018]      FIG. 9  is a perspective view of a mounting bracket according to a fourth preferred embodiment of the present invention.  
         [0019]      FIG. 10  is a cross sectional view of a mounting bracket according to the fourth preferred embodiment of the present invention.  
         [0020]      FIG. 11  is a plan view of a blank used for forming the mounting bracket of  FIG. 9  according to the fourth preferred embodiment of the present invention.  
         [0021]      FIG. 12  is a perspective view of a mounting bracket according to a fifth preferred embodiment of the present invention.  
         [0022]      FIG. 13  is a plan view of a blank used for forming the mounting bracket of  FIG. 12  according to the fifth preferred embodiment of the present invention.  
         [0023]      FIG. 14  is a perspective view of a mounting bracket according to a sixth preferred embodiment of the present invention.  
         [0024]      FIG. 15  is a plan view of a blank used for forming the mounting bracket of  FIG. 14  according to the sixth preferred embodiment of the present invention.  
         [0025]      FIG. 16  is a perspective view of a mounting bracket according to a seventh preferred embodiment of the present invention.  
         [0026]      FIG. 17  is a cross sectional view of a mounting bracket according to the seventh preferred embodiment of the present invention.  
         [0027]      FIG. 18  is a plan view of a blank used for forming the mounting bracket of  FIG. 16  according to the seventh preferred embodiment of the present invention.  
         [0028]      FIG. 19  is a perspective view of a mounting bracket according to an eighth preferred embodiment of the present invention.  
         [0029]      FIG. 20  is a plan view of a blank used for forming the mounting bracket of  FIG. 19  according to the eighth preferred embodiment of the present invention. 
     
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS  
       [0030]     There is shown in  FIG. 1 a  schematic illustration of a tube and bracket assembly, indicated generally at  10 , for a rack and pinion steering system of a vehicle (not shown) according to a first preferred embodiment of the present invention. The tube and bracket assembly  10  includes a pinion housing  12 , a tubular housing  16 , and an input shaft  26 . The tubular housing  16  includes a rack  19  having gear teeth (not shown). The pinion housing  12  houses the input shaft  26  and a pinion gear having gear teeth (not shown). The pinion housing  12  also houses the interconnection between the gear teeth of the rack  19  and the pinion gear teeth. As the input shaft  26  is rotationally displaced within the pinion housing  12 , the pinion gear teeth mesh with the rack gear teeth thereby causing the rack  19  within the tubular housing  16  to move laterally.  
         [0031]     The pinion housing  12  includes a set of hydraulic lines  29  for transferring hydraulic steering fluid between the tubular housing  16  and a power steering pump (not shown). The hydraulic steering fluid communicated between the tubular housing  16  and the power steering pump reduces the effort level of turning a steering wheel (not shown).  
         [0032]     The opposite ends of the rack  19  include sockets  21 ,  21 ′ for receiving balls  22 ,  22 ′. The sockets  21 ,  21 ′ and the balls  22 ,  22 ′ are coupled to form ball and socket joints for pivotably connecting tie rods  23 ,  23 ′ to the rack  19 . The tie rods  23 ,  23 ′ are connected to steerable vehicle wheels (not shown). A mounting bracket  30  is affixed to the tubular housing  16  for securing the tube and bracket assembly  10  to a frame of the vehicle  32 . The mounting bracket  30  rigidly secures the tube and bracket assembly  10  to the vehicle member  32  such as a vehicle frame or unibody via a fastening member  31  while internal components within the tubular housing  16  are allowed to move laterally for pivotably steering the vehicle wheels.  
         [0033]      FIG. 2  illustrates a portion of a typical prior art tube and bracket assembly  34 . A mounting bracket  35  is permanently affixed to tubular housing  16 . The mounting bracket  35  includes a semi-circular body portion  38  which abuts a substantial portion of the outer surface of the tubular member  36  (e.g. 180 degrees). The mounting bracket  35  is permanently affixed to the tubular member  36  by welding end portions  39  and  44  of the mounting bracket  35  to the substantial portion of the outer surface of the tubular member  36 .  
         [0034]     The mounting bracket  35  includes a first tab member  41  and a second tab member  42 . The first tab member  41  and the second tab member  42  each includes an aperture (not shown). The apertures of the first and second tab members  41  and  42  are axially aligned for receiving a fastening member  31  such as a bolt therethrough for securing the tube and bracket assembly  34  to a vehicle frame  32 .  
         [0035]     A tubular support member  37  is a separately formed cylindrical bore member that is affixed (i.e., welded) between the first and second tab members  41  and  42  with its bore axially aligned with each aperture of the first and second tab members  41  and  42 . The tubular support member  37  is permanently affixed to the first and second tab member  41  and  42  by welding the end portions  40  and  43  of the tubular support member  37  to the first and second tab members  41  and  42 , respectively. The tubular support member  37  provides structural support and prevents the first and second tab members  41  and  42  from collapsing as a respective fastener is inserted through each aperture and fastened to the frame of the vehicle  32  or unibody.  
         [0036]      FIG. 3  illustrates the first preferred embodiment of a mounting bracket  30  according to the present invention. The mounting bracket  30  includes a first leg portion  52  and a second leg portion  53  that are formed for attaching to the outer surface of the tubular housing  16  (shown in  FIG. 1 ). The mounting bracket  30  further includes a first tab member  54 , a second tab member  55 , and a tubular sleeve  56 . The first and second tab members  54  and  55  include apertures  57  (shown in  FIG. 4 ) and  58  that are axially aligned with the bore of the tubular sleeve  56  for receiving a fastening member  31  (shown in  FIG. 1 ) for securing the mounting bracket  30  and tubular housing  16  to a vehicle frame  32 . The tubular sleeve  56  provides structural support and prevents the first and second tab members  54  and  55  from collapsing when a fastening member  31  is inserted therethrough and fastened to the vehicle frame  32 . The mounting bracket  30  also includes a main body portion  61  that integrally interconnects the tubular sleeve  56 , the first and second leg portions  52  and  53 , and the first and second tab members  54  and  55 .  
         [0037]     A stamped one-piece integral metal blank  60  shown in  FIG. 4 , is used to form the mounting bracket  30 , shown in  FIG. 7 . The one-piece blank  60  includes the main body portion  61 , the first leg portion  52 , the second leg portion  53 , a third leg portion  63 , the first tab member  54 , and the second tab member  55 . Both the first leg portion  52  and the second leg portion  53  angularly extend from the main body portion  61 .  
         [0038]     The first tab member  54  and the second tab member  55  also angularly extend from the main body portion  61  and are symmetrical to one another. Both the first tab member  54  and the second tab member  55  include apertures  57  and  58 , respectively. The third leg portion  63  extends laterally from the main body portion  61  and is disposed an equal distance between the first tab member  54  and the second tab member  55 . Preferably, the one-piece blank  60  and the apertures  57  and  58  are formed during a one-step processing operation. Alternatively, the one-piece metal blank  60  may be formed initially and apertures  57  and  58  may be stamped thereafter.  
         [0039]      FIG. 3  illustrates the mounting bracket  30  formed from the one-piece integral blank  60 , shown in  FIG. 4 , into a final shape without utilizing any welding operations. The term one-piece and/or integral, as used herein and for all other embodiments, means the bracket, with all of its features is formed from a single piece of material. The forming operation preferably begins with the single flat piece of material prior to bending the material to create the features of the mounting bracket  30 . To form the mounting bracket  30 , the third leg portion  63  is folded to form the tubular sleeve  56  for receiving a fastener shaft (not shown) such as a bolt shaft for fastening to a vehicle frame  32  or unibody. The first leg portion  52  and first tab member  54  and the second leg portion  53  and second tab member  55  are folded along fold lines  64  and  65 , respectively, until the first tab member  54  and second tab member  55  each abut a respective end surface of the tubular sleeve  56 .  
         [0040]     When the first tab member  54  and the second tab member  55  abut the respective end surfaces of the tubular sleeve  56 , apertures  57  and  58  axially align with the bore of the tubular sleeve  56 . The tubular sleeve  56  prevents the first tab member  54  and the second tab member  55  from collapsing as a respective fastener is inserted through tubular sleeve  56  and apertures  57  and  58  for securing the bracket  30  and tubular housing  16  (as shown in  FIG. 1 ) to the vehicle frame  32  or unibody.  
         [0041]     A first end portion  66  of the second portion  53  is bent at fold lines  67  and  68  for contouring the second leg portion  53  to the outer surface of the tubular housing  16 . Alternatively, the first leg portion  52  may be bent at an end portion for contouring to the outer surface of the tubular housing  16 . The mounting bracket  30  is thereafter welded to the tubular housing  16  along the contacting locations of the first and second legs  52 ,  53 .  
         [0042]     Referring now to  FIG. 5  and using like reference numbers to indicate corresponding parts, there is illustrated a mounting bracket  70  according to a second preferred embodiment of the present invention. The mounting bracket  70  can be used in place of mounting bracket  30  in  FIG. 1 . The mounting bracket  70  includes a first support member  71  and a second support member  72 . The first support member  71  is integral and perpendicular to the first tab member  54 . The second support member  72  is integral and perpendicular to the second tab member  55 . The first support member  71  includes a top portion  73  that is curved and the second support member  72  includes a top portion  74  that is curved. The first support member  71  and the second support member  72  are substantially planar to one another.  
         [0043]     The mounting bracket  70  further includes a third support member  75  integrally formed and extending from the main body portion  61 . A top portion  76  of the third support member  75  is curved.  
         [0044]     A stamped one-piece integral metal blank  80  shown in  FIG. 6  is used to form the mounting bracket  70 , shown in  FIG. 5 . The one-piece blank  80  includes the main body portion  61 , the first leg portion  52 , the second leg portion  53 , the third leg portion  63 , the first tab member  54 , and the second tab member  55 . The first support member  71  is integrally formed with the first leg portion  52  and extends laterally from the first leg portion  52 . The second support member  72  is integrally formed with the second leg portion  53  and extends laterally from the first leg portion  53 . The third support member  75  is integrally formed with the main body portion  61 . The third support member  75  extends laterally from the main body portion  61  and is disposed an equal distance between the first leg portion  52  and the second leg portion  53 .  
         [0045]      FIG. 5  illustrates the mounting bracket  70  formed from the one-piece integral blank  80 , shown in  FIG. 6 , into a final shape without utilizing any welding operations. The formed mounting bracket  70  is the same as that described in the embodiment of  FIG. 3  with the following additions. The first and second support member  71  and  72  are folded along fold lines  77  and  78 , respectively, to substantially 90 degrees such that the first and second support member  71  and  72  are substantially planar to one another. The top portions  73  and  74  cooperatively form a continuous contoured edge surface for receiving and supporting the tubular member  16  (shown in  FIG. 1 ).  
         [0046]     The third support member  75  is folded along fold line  79  until a first side  81  and a second side  82  of the third support member  75  are perpendicular to the first leg portion  52  and the second leg portion  53 , respectively. The top portion  76  includes a contoured edge surface for receiving and supporting the tubular member  16 . The first leg portion  52  and the second leg portion  53  along with the first support member  71 , second support members  72 , and third support member  75  cooperatively box in a surface area of the tubular member  16  for providing added support strength to the mounting bracket  70 .  
         [0047]      FIG. 7  illustrates a third preferred embodiment of a mounting bracket  90  according to the present invention. The mounting bracket  90  can be used in place of mounting bracket  30  in  FIG. 1 . The mounting bracket  90  includes a first leg portion  91  and a second leg portion  92  that are contoured for attaching to the outer surface of the tubular housing  16  (shown in  FIG. 1 ). The mounting bracket  90  further includes a first tab member  93  and a second tab member  94  that have apertures  95  and  96 , respectively, for receiving a respective fastener for securing the mounting bracket  90  and tubular housing  16  to a vehicle frame  32 or unibody. The first tab member  93  extends along an outer surface the first leg portion  91  in spaced relation to the second tab member  94  which extends along the outer surface of the second leg portion  92 . The first tab member  93  and the second tab member  94  are substantially parallel to one another. A third leg portion  97  is disposed between the first and second tab members  93  and  94  for providing support and preventing the first and second tab members  93  and  94  from collapsing as a respective fastening member  31  is inserted therethrough and secured to the vehicle frame  32 . A main body portion  98  (shown in  FIG. 8 ) interconnects the first leg portion  91 , the second leg portion  92 , the third leg portion  97 , the first tab member  93 , and the second tab member  94 .  
         [0048]     A stamped one-piece integral metal blank  100 , shown in  FIG. 8 , is used to form the bracket  90 , shown in  FIG. 7 . The one-piece blank  100  includes the first leg portion  91 , the second leg portion  92 , the third leg portion  97 , the first tab member  93 , the second tab member  94 , and the main body portion  98 . The first tab member  93  and the second tab member  94  extend outwardly from the main body portion  98  and are substantially symmetrical to one another. The first leg portion  91  and the second leg portion  92  also extend laterally outward from one another and are substantially symmetrical to one another.  
         [0049]      FIG. 7  illustrates the mounting bracket  90  formed from the one-piece integral blank  100 , shown in  FIG. 8 , into the final shape without utilizing any welding operations. To form the mounting bracket  90 , the main body portion  85  is folded along a fold line  86  to substantially 90 degrees. The third leg portion  97  is folded along a fold line  87  to substantially 90 degrees. Both the first and second tab members  93  and  94  are folded along fold lines  102  and  103 , respectively, until a tab edge  104  and a tab edge  105  abut edges  106  and  107 , respectively, of the third end portion  97 . When the first tab member  93  and the second tab member  94  abut the third leg portion  97 , apertures  95  and  96  are axially aligned with one another for receiving a fastener (not shown) for attachment to a vehicle frame  32  or unibody. The third leg portion  97  disposed between the first and second tab members  93  and  94 , provides structural support for preventing the first and second tab members  93  and  94  from collapsing as the fastener is mounted through each aperture and fastened to the frame of the vehicle  32 .  
         [0050]     The first leg portion  91  and the second leg portion  92  include end portions that are bent to form a substantially semi-circular mounting surface. The combined shape of the first leg portion  91  and the second leg portion  92  form the substantially semi-circular mounting surface that conforms to the outer surface of the tubular housing  16 . The mounting bracket  90  is thereafter welded to the tubular housing  16  along edges  108  and  109  of the substantially semi-circular mounting surface.  
         [0051]     Referring now to  FIG. 9  and  FIG. 10  there is illustrated a mounting bracket  110  according to a fourth preferred embodiment of the present invention. The mounting bracket  110  can be used in place of mounting bracket  30  in  FIG. 1 . The mounting bracket  110  includes a first leg portion  111  and a second leg portion  112  that are contoured for attaching to the outer surface of the tubular housing  16  (shown in  FIG. 1 ). The mounting bracket  110  further includes a main body portion  113  having a first flared support region  114 and a second flared support region  115 . The main body portion  113  is integral to the first and second leg portions  111  and  112 . A rear tab member  116  is formed integral to the main body portion  113 . A top tab member  117  is integrally formed to the rear tab member  116 . A first tab member  118  and a second tab member  120  are integrally formed to respective sides of the top tab member  117 . The first tab member  118  and the second tab member  120  are preferably trapezoidal shaped and are substantially parallel to one another. The first tab member  118  includes an aperture  119  and the second tab member  120  includes an aperture  121  for receiving a fastener (not shown) therethrough. A third leg member  122  is disposed between the first and second tab members  118  and  120  and forms a sleeve  126  therebetween. The first tab member  118  includes tab support members  123   a  and  123   b.  The second tab member  120  includes tab support members  124   a  and  124   b.    
         [0052]     A stamped one-piece integral metal blank  125 , shown in  FIG. 11 , is used to form the bracket  110 , shown in  FIGS. 9 and 10 . The one-piece blank  125  includes the main body portion  113 , the first leg portion  111 , the second leg portion  112 , the third leg portion  122 , the first tab member  118 , the second tab member  120 , the rear tab member  116  and the top tab member  117 . The first leg portion  111  and the second leg portion  112  extend outwardly from the main body portion  113 . The main body portion  113  includes the flared support regions  114  and  115  in opposing directions from one another.  
         [0053]     The rear tab member  116  extends laterally from the second flared support region  115  of the main body portion  113 . A top portion extends laterally outward from rear tab member  116 . The first tab member  118  and the second tab member  120  extend laterally outward from the top tab member  117  in opposing directions. The first tab member  118  and the second tab member  120  are substantially symmetrical to one another. The first tab member  118  includes the aperture  119  and the second tab member  120  includes the aperture  121 . Preferably, the one-piece blank  125 , including the apertures  119  and  121 , is formed during a one-step processing operation. Alternatively, the one-piece blank  125  may be initially formed and apertures  119  and  121  may be stamped thereafter.  
         [0054]      FIG. 9  and  FIG. 10  illustrates the mounting bracket  110  formed from the one-piece integral blank  125 , shown in  FIG. 11 , into the final shape without utilizing any welding operations. To form the mounting bracket  110 , the third leg  122  is folded to form the tubular sleeve  126  for receiving a fastener shaft (not shown) such as a bolt shaft for attaching to a vehicle frame  32  or unibody. The first and second tab members  118  and  120  are folded along fold line  127  and fold line  128  until the first and second tab member  118  and  120  each abut a respective end of the sleeve. The top tab member  117  is folded along fold line  136  until an edge surface  129  of the first tab member  118  and an edge surface  135  of the second tab member  120  abut the rear tab member  116 . The rear tab member  116  is bent along fold line  130  until a bottom edge surface  131  of the first tab member  118  and a bottom edge surface  132  of the second tab member  120  abuts the main body portion  113 . A trapezoidal shaped open-ended box is thereafter formed about the sleeve member  126 .  
         [0055]     The first leg portion  111  and the second leg portion  112  include end portions that are bent to form a substantially semi-circular mounting surface. The combined shape of the first leg portion  111  and the second leg portion  112  in cooperation with the main body portion  113  form the substantially semi-circular mounting surface that conforms to the outer surface of the tubular housing  16 .  
         [0056]     The mounting bracket  110  is thereafter welded to the tubular housing  16  (shown in  FIG. 1 ) along edges  133  and  134  of the substantially semi-circular mounting surface.  
         [0057]      FIG. 12  illustrates a fifth preferred embodiment of a mounting bracket  140 . The mounting bracket  140  can be used in place of mounting bracket  30  in  FIG. 1 . The mounting bracket  140  includes a main body portion  151  having a first leg portion  158  and a second leg portion  159  that forms a substantially circular sleeve  141  for receiving the tubular member  16  (shown in  FIG. 1 ). The mounting bracket  140  includes a first tab member  142  extending from the first leg portion  158  that is in spaced relation to a second tab member  143  extending from the second leg portion  159 . The first and second tab members  142  and  143  are substantially parallel to one another. A third leg portion  178  extends from the second tab member  143  for forming a tubular sleeve  179 . The tubular sleeve  179  is disposed between the first and second tab members  142  and  143 .  
         [0058]     The first and second tab members  142  and  143  include apertures  144  and  145  (shown in  FIG. 13 ). The apertures  144  and  145  are axially aligned with the tubular sleeve  179  for receiving a respective fastening member  31  for fastening the mounting bracket  140  and tubular housing  16  to a vehicle frame  32  or unibody. The mounting bracket  140  includes a first extended portion  146  and a second extended portion  147  (shown in  FIG. 13 ) that are each respectively disposed between the first and second tab members  142  and  143 . The first and second extended portions  146  and  147  in cooperation with the tubular sleeve  179  provide structural support as the respective fastener is inserted through the apertures  144  and  145  and secured to the vehicle frame  32 .  
         [0059]     A stamped one-piece integral metal blank  150 , shown in  FIG. 13 , is used to form the mounting bracket  140 , shown in  FIG. 12 . The one-piece blank  150  includes a main body portion  151  that has the first leg portion  158  and the second leg portion  159  integrally formed to the main body portion  151  and extending in opposite directions therefrom. The first tab member  142  extends from the first leg portion  158  and the second tab member  143  extends from the second leg portion  159 . Both the first tab member  142  and the second tab member  143  include apertures  144  and  145 , respectively. The first extended portion  146  extends laterally from the first leg portion  158  and the second extended portion  147  extends laterally from the second leg portion  159 . A third leg portion  178  extends laterally from the second extended portion  147 .  
         [0060]     To form the mounting bracket  140  shown in  FIG. 12 , the third leg portion  178  is bent to form the tubular sleeve  179 . The first tab member  142  and second tab member  143  are folded along fold lines  152  and  153 , respectively, to substantially 90 degrees with respect to the first and second leg portions  158  and  159 , respectively. The first and second leg portions  158  and  159  are circularly bent until apertures  144  and  145  are axially aligned. The substantially circular sleeve  141  is formed for receiving and conforming to an outer surface of the tubular housing  16 .  
         [0061]     The first extended portion  146  is folded along fold line  154  until the first extended portion  146  is substantially 90 degrees to the first tab member  142 . Similarly, the second extended portion  147  is folded along fold line  157  until the second extended portion  147  is substantially 90 degrees to the first tab member  143 . The first and second extended portions  146  and  147  in cooperation with the tubular sleeve  179  are support members that add structural support for preventing the first and second tab members  142  and  143  from collapsing as the fastener is mounted through each aperture and fastened to the frame of the vehicle  32 . The mounting bracket  140  may be welded to the outer surface of the tubular member (not shown) along edge surfaces  155  and  156  of the substantially circular sleeve  141  for preventing rotation of the tubular member  16  relative to the mounting bracket  140 .  
         [0062]      FIG. 14  illustrates a sixth preferred embodiment of the mounting bracket  160  according to the present invention. The mounting bracket  160  can be used in place of mounting bracket  30  in  FIG. 1 . The mounting bracket  160  includes a tubular sleeve  161  that is integrally formed between a first leg portion  162  and a second leg portion  163 . The first and second leg portion  162  and  163  include apertures  164  and  165  (shown in  FIG. 15 ), respectively, that are axially aligned with the centerline of the tubular sleeve  161 . The first and second leg portions  162  and  163  extend radially outward from the centerline of the tubular sleeve  161  for attachment to the tubular member  16  (shown in  FIG. 1 ). A first end portion  166  of the first leg portion  162  and a second end portion  167  of the second leg portion  163  are angled to accommodate the contour of an outer surface (i.e., profile) of the tubular member  16  (shown in  FIG. 1 ).  
         [0063]     A stamped one-piece integral metal blank  170 , as shown in  FIG. 15 , is used to form the mounting bracket  160  as shown in  FIG. 14 . The one-piece blank  170  includes a main body portion  171  having the first leg portion  162  and the second leg portion  163  extending outwardly from opposing sides of the main body portion  171 . The first leg portion  162  is asymmetrical to the second leg portion  163 . The first leg portion  162  and the second leg portion  163  include apertures  164  and  165 , respectively. The main body portion  171  includes opposed ends  172   a  and  172   b  that are symmetrical to one another. Preferably, the one-piece blank  170 , including the apertures  164  and  165  is formed during a one-step processing operation. Alternatively, the one-piece blank  170  may be initially formed and apertures  164  and  165  may be stamped thereafter.  
         [0064]     Referring now to  FIG. 14  with reference to  FIG. 15 , the mounting bracket  160  is formed from the one-piece integral blank  170  shown in  FIG. 15 . To form the mounting bracket  160 , opposed ends  172   a  and  172   b  of the main body portion  171  are folded in a generally circular manner and adjoined at edges  173  and  174  to form the tubular sleeve  161 . Alternatively, a single end having a respective length could be used to form a tubular sleeve. The first leg portion  162  and the second leg portion  163  include abutment surfaces  177   a  and  177   b,  respectively, for abutting tubular sleeve ends  175  and  176 . The first and second leg portions  162  and  163  are folded at substantially right angles to the main body portion  171  until abutment surfaces  177   a  and  177   b  abut tubular ends  175  and  176 , respectively. When the abutment surfaces  177   a  and  177   b  are in contact with tubular ends  175  and  176 , respectively, apertures  164  and  165  are axially aligned with the bore of the tubular sleeve  161 .  
         [0065]     The first leg portion  162  includes the first end portion  166  that is offset for contouring the first leg portion  162  to the outer surface of the tubular housing  16 . Similarly, second leg portion  163  includes the second end portion  167  that is offset for contouring the second leg portion  163  to the outer surface of the tubular housing  16 . In addition, both the first leg portion  162  and the second leg portion  163  may each be offset at more than one location along each respective leg for contouring or fitting each leg to the outer surface of the tubular housing  16 . To secure the bracket  160  to the tubular member  16 , the first and second end portions  166  and  167  are welded to the tubular member.  
         [0066]      FIGS. 16 and 17  illustrate a seventh preferred embodiment of the mounting bracket  200  according to the present invention. The mounting bracket  200  can be used in place of mounting bracket  30  in  FIG. 1 . The mounting bracket  200  includes a tubular sleeve  201  that is integrally formed between a first tab member  202  and a second tab member  203 . The first and second tab members  202  and  203  include apertures  204  and  205  that are axially aligned with the centerline of the tubular sleeve  201 . A first leg portion  206  is integrally connected to the first tab member  202 . A second leg portion  207  is integrally connected to the second tab member  203 . A first tab support member  208   a  and a second tab member  208   b  (shown in  FIG. 18 ) are integrally formed to the first tab member  202 . A third tab member  209   a  and a fourth tab member  209   b  (shown in  FIG. 18 ) are integrally formed to the second tab member  203 . The first leg member  206  and the second leg member  207  are contoured for receiving the outer surface (i.e., profile) of the tubular member  16  (shown in  FIG. 1 ). The tab support members  208   a,    208   b,    209   a,  and  209   b  also receive the tubular support member and provide structural support for the mounting bracket  200 .  
         [0067]     A stamped one-piece integral metal blank  210 , as shown in  FIG. 18 , is used to form the mounting bracket  200  as shown in  FIGS. 16 and 17 . The one-piece blank  210  includes a main body portion  212  having the first tab member  202  and the second tab member  203  extending outwardly from opposing sides of the main body portion  212 . The first tab member  202  is symmetrical to the second tab member  203 . The main body portion  212  includes opposing ends  214  and  216  that are symmetrical to one another. The first leg portion  206  is integrally formed to the first tab member  202 . The first and second support members  208   a  and  208   b  are integral to the first tab member  202  and extend laterally from opposing sides. The second leg member  207  is integrally formed to the second tab member  203 . The third and fourth tab support members  209   a  and  209   b  are integral to the second tab member  203  and extend laterally from opposing sides.  
         [0068]     The first leg portion  206  is asymmetrical to the second leg portion  207 . Preferably, the one-piece blank  210 , including the apertures  204  and  205 , is formed during a one-step processing operation. Alternatively, the one-piece blank  210  may be initially formed and apertures  204  and  205  may be stamped thereafter.  
         [0069]     Referring now to  FIGS. 16 and 17  with reference to  FIG. 18 , the mounting bracket  200  is formed from the one-piece integral blank  210  shown in  FIG. 18 . To form the mounting bracket  200 , opposed ends  214  and  216  of the main body portion  212  are folded in a generally circular manner and adjoined at edges  218  and  220  to form the tubular sleeve  201 . The first tab member  202  and the second tab member  203  include abutment surfaces  222  and  224 , respectively, for abutting tubular sleeve ends  226  and  228 . The first and second tab members  202  and  203  are folded along fold lines  230  and  232 , respectively, at substantially right angles until abutment surfaces  222  and  224  abut tubular ends  226  and  228 , respectively. When the abutment surfaces  222  and  224  are in contact with tubular ends  226  and  228 , respectively, apertures  204  and  205  are axially aligned with the bore of the tubular sleeve  201 .  
         [0070]     The first and third support members  208   a  and  209   a  are folded along fold lines  234  and  238 , respectively, to substantially 90 degrees so that the first and third support member  208   a  and  209   a  are substantially planar to one another. Similarly, the second and fourth support members  208   b  and  209   b  are folded along fold lines  236  and  240 , respectively, to substantially 90 degrees so that the second and fourth support member  208   b  and  209   b  are substantially planar to one another.  
         [0071]     The first leg portion  206  and the second leg portion  207  are bent to form a substantially semi-circular mounting surface. The combined shape of the first leg portion  206  and the second leg portion  207  form the substantially semi circular mounting surface that conforms to the outer surface of a tubular housing  16  (shown in  FIG. 1 ). The support members  208   a - b  and  209   a - b  in cooperation with the contoured leg portions  206  and  207  box in a portion of the attaching surface region of the tubular member  16  for structural support.  
         [0072]     As described earlier, the first leg portion  206  and second leg portion  207  are asymmetrical to one another. This allows the mounting bracket  200  to be attached to a vehicle frame or unibody in those locations in which a centered mounted bracket would have difficulties attaching thereto. Alternatively, the leg portions may be symmetrical.  
         [0073]      FIG. 19  illustrates an eighth preferred embodiment of a mounting bracket  250  according to the present invention. The mounting bracket  250  can be used in place of mounting bracket  30  in  FIG. 1 . The mounting bracket  250  includes a first leg portion  251  and a second leg portion  252  that are contoured for attaching to an outer surface of the tubular housing  16  (shown in  FIG. 1 ). The mounting bracket  250  further includes a tubular sleeve  253  that is integrally formed by a third leg portion  254 .  
         [0074]     A stamped one-piece integral blank  260 , as shown in  FIG. 20 , is used to form the bracket  250  of  FIG. 19 . The one-piece blank  260  is T-shaped and includes the first leg portion  251 , the second leg portion  252 , and the third leg portion  254 . The first leg portion  251  and the second leg portion  252  are preferably symmetrical to one another. The third leg portion  254  is formed at an equal distance between the first leg portion  251  and the second leg portion  252  and extends substantially at a right angle from both the first leg portion  251  and second leg portion  252 . Alternatively the third leg portion  254  may be formed offset between the first leg portion  251  and the second leg portion  252 .  
         [0075]     Referring now to  FIG. 19  with reference to  FIG. 20 , the mounting bracket  250  is formed from the one-piece integral blank  260  shown in  FIG. 20 . To form the mounting bracket  250  from the one-piece integral blank  260 , the first leg portion  251  and the second leg portion  252  are bent to form a substantially semi-circular mounting surface. The combined shape of the first leg portion  251  and the second leg portion  252  form the substantially semi-circular mounting surface that conforms to the outer surface of a tubular housing  16  (shown in  FIG. 1 ). The third leg portion  254  is folded to form a tubular sleeve  253  for receiving a fastener shaft (not shown) such as a bolt shaft. The substantially semi-circular mounting surface is affixed to the tubular housing  16  preferably by a welding process along mounting bracket edges  261  and  262 .  
         [0076]     From the foregoing description, one of ordinary skill in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications to the invention to adapt it to various usages and conditions. For example, each of the above referenced embodiments are stamped, formed, and folded to produce the a respective mounting bracket; alternatively, portions of the bracket such as legs, tab members, support members, or sleeve ends may be welded to one another for added stiffness and support.