Abstract:
A clamp assembly for securing a steering column shroud, comprising: a clamp pin which passes through an opening in the shroud and having a stopper towards one end, a toothed block carried by the clamp pin having a set of rake teeth, the teeth of the block being urged into engagement with a rack of teeth fixed to a support bracket by the stopper when the clamp assembly is in the clamped condition, thereby securing the relative positions of the fixed and moving portions of the steering assembly; and a biasing means that provides a biasing force that acts in an unclamped condition to bias the stopper of the clamp pin away from the moving part to permit the rack of teeth on the block to move clear of the rack of the support bracket, in which a substantial part of the biasing force provided by the biasing means acts upon the clamp pin without passing through the toothed block.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a national stage of International Application No. PCT/GB2014/050038 filed Jan. 7, 2014, the disclosures of which are incorporated herein by reference in entirety, and which claimed priority to Great Britain Patent Application No. 1300262.1 filed Jan. 8, 2013, the disclosures of which are incorporated herein by reference in entirety. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    This invention relates to improvements in clamp assemblies for steering column assemblies, especially but not exclusively to electric power assisted steering assemblies. In particular it relates to clamp assemblies for steering column assemblies adjusted for both rake and reach. 
         [0003]    It is known to provide a steering column assembly in which a steering wheel is connected to one or more road wheels through a collapsible or telescopic steering column shaft. The shaft is designed to collapse away from a driver of the vehicle if a load is applied to the steering wheel in the event of an accident. The shaft may comprise a single part shaft, which has a weakened central section that will concertina under an axial load. Alternatively it may comprise a two part telescopic shaft in which one part slides axially into the other under an axial load. 
         [0004]    To locate the steering shaft relative to the vehicle it is typically supported within one or more bearings carried by an adjustable support portion, often referred to as a steering column shroud. The shroud is in turn secured to a fixed portion bolted or otherwise fixed to a conveniently accessible part of the vehicle chassis or bulkhead. 
         [0005]    In many vehicles produced today the column shroud, which may for convenience be thought of as a non-adjustable portion and an adjustable portion, is releasably locked to the fixed portion of the vehicle in a way that permits the steering shaft to be adjusted for rake (up and down) and reach (in and out). In some applications it may be adjustable only for rake, or only for reach. Where it is adjustable for reach and rake the shroud typically comprises an inner and outer tube which telescope relative to each other, one of the tubes being fixed and the other moving to allow for the required adjustment. 
         [0006]    A lever—which must be located within easy reach of the driver—allows a clamping mechanism to be locked and unlocked for the position of the steering column shroud to be adjusted. This enables the driver of the vehicle to set the steering wheel at the most comfortable position. 
         [0007]    With the introduction of steering wheel mounted airbags there has recently been a demand that, once adjusted, the column must be held in place by a positive locking method. By this we mean that, when the clamp mechanism is moved into its locked position, there must be greater restraint against subsequent column movement for reach than would be created solely by friction. 
         [0008]    It is normal to increase the resistance to movement when clamped by providing for a toothed engagement between a rack of teeth on the fixed portion of the vehicle and a toothed block of the clamp assembly. The engagement between the teeth provides a positive locking of the shroud position. When unclamped the two racks of teeth are allowed to move apart so they can move relative to each other to permit rake adjustment. 
         [0009]    Similarly it is known to provide a toothed engagement between a further toothed block on the clamp assembly and a corresponding rack of teeth on the adjustable portion of the shroud. When the clamp assembly is in the unclamped condition the two racks of teeth are allowed to move apart so they can move relative to one another. This permits adjustment for reach. 
         [0010]    A basic problem with the use of teeth in this way is that on occasions the tips of the teeth on one rack may be exactly in line with the tips of the teeth of the other rack that should engage them when the driver attempts to move the clamp to the clamped condition. This so called tooth-on-tooth problem can either prevent the driver locking the clamp properly or in extreme cases damage the teeth or the locking mechanism. To resolve this it is known to allow one or more of the toothed blocks to be able to slide otherwise move by a small amount, perhaps up to one half of the tooth pitch of the racks, during clamping to permit the teeth of the racks to align correctly before reaching the clamped condition. 
         [0011]    To move the teeth apart when moving to the unclamped condition it is known to provide the teeth of the clamp assembly on toothed blocks which are threaded onto a clamp pin of the clamp assembly, and to use a biasing means such as a coil spring that acts via a spacer freely mounted on the pin directly upon the toothed block. When clamped this biasing force is overcome by a clamp mechanism to urge the toothed block onto the corresponding toothed rack. When unclamped the biasing means urges the toothed block and the clamp pin away from the racks of teeth. 
         [0012]    The applicant has found that the use of a high force of the biasing means acting on the toothed block can impair the free side to side movement of the block when clamped, leading to increased locking forces in instances where teeth are coincident. 
       BRIEF SUMMARY OF THE INVENTION 
       [0013]    According to a first aspect the invention provides a clamp assembly for securing a fixed portion of a vehicle, especially a support bracket, to a movable portion of a steering column, especially a steering column shroud, the clamp assembly comprising:
       a clamp pin which passes through an opening in the fixed portion and an opening in the moving portion, the clamp pin having a stopper located towards one end;   a toothed block carried by the clamp pin having a set of rake teeth, the teeth of the block being urged into engagement with a rack of teeth fixed to the support arm by the stopper when the clamp assembly is in the clamped condition, thereby securing the relative positions of the fixed and moving portions of the steering assembly;   and a biasing means that provides a biasing force that acts in an unclamped condition of the clamp assembly to bias the stopper of the clamp pin away from the moving part to permit the rack of teeth on the block to move clear of the rack of the support bracket, thereby permitting relative movement of the fixed and moving portion of the steering assembly;   characterised in that a substantial part of the biasing force provided by the biasing means acts upon the clamp pin without passing through the toothed block.       
 
         [0018]    By bypassing the toothed block the biasing force does not present a risk that the desirable free movement of the toothed block that helps reduce the risk of a tooth on tooth situation is restrained. 
         [0019]    In one arrangement none of the biasing force provided by the biasing means passes through the toothed block, the biasing means only acting upon the clamp pin. 
         [0020]    A clearance may be provided between the biasing means and the toothed block when the clamp assembly is in the unclamped condition. This permits a small amount of free movement of the toothed block either the axis of the pin or orthoganol to the pin (or both). This again helps reduce a tooth on tooth situation arising. By bypassing the toothed block we mean that the spring force does not impede this free movement of the block relative to the pin as it otherwise would if the force was to press the block against the clamp pin or any other part secured to the pin. 
         [0021]    The biasing means may comprise a spring and a spacer, the spring applying a biasing force to the spacer which in turn acts directly on a part of the clamp pin. The spring and spacer may both be threaded onto the clamp pin. The spring may be located in the space between the arms of the support bracket. 
         [0022]    The spacer may pass through a slot in the support bracket to engage the spring. It may comprise an anti-rotation spacer which acts to prevent the clamp pin from rotating. The spacer may co-operate with the slot in the fixed portion or moving portion to achieve the anti-rotation feature. 
         [0023]    The biasing force may be reacted by the support bracket of the steering assembly, perhaps by the biasing means acting on a further spacer which in turn acts on the support bracket. 
         [0024]    The clamp pin may be provided with a shoulder formed at a point along the length of the clamp pin distal from the stopper, the biasing means acting upon the shoulder. 
         [0025]    The shoulder may be defined by a transition from a portion of the clamp pin of a first diameter and a second diameter that is larger. The larger diameter portion may be closer to the stopper than the smaller diameter. 
         [0026]    In an alternative it may be a transition from a portion of clamp pin of round cross section and a portion of a non-round cross section, especially a square cross section, the non-round section being closer the stopper. 
         [0027]    Where a square cross section portion is provided the toothed block may be provided with a hole of corresponding cross section through which the clamp pin is threaded, the non-round cross section preventing rotation of the toothed block relative to the clamp pin. 
         [0028]    The stopper may comprise a head formed integral with a shaft of the clamp pin. 
         [0029]    At least one secondary biasing means may be located between the spring means and the toothed block which maintains a clearance between the block and spring means when unclamped. The provision of the secondary biasing means helps to move the toothed block along the clamp pin maintaining the clearance between the spring means and the toothed block. 
         [0030]    The secondary biasing means should be capable of transferring only a small fraction of the biasing force onto the toothed block. For instance, no more than 20 percent, or 10 percent, or 5 percent of the biasing force may pass through the toothed block and back to the clamp pin. 
         [0031]    The secondary biasing means may comprise at least one resilient block, such as rubber block or soft plastic block. The block may be integral with the spacer of the spring means. 
         [0032]    The clamp assembly may include two toothed blocks, a first toothed block carrying a first rack of teeth and the second block carrying a second rack of teeth. 
         [0033]    The first toothed block may include teeth that engage corresponding teeth located on the support bracket. The second block of teeth may engage corresponding teeth located on the shroud, perhaps on a rail attached to the shroud. 
         [0034]    The two toothed blocks may be supported on the clamp pin between the biasing means and the stopper. 
         [0035]    Each of the blocks may include an opening through which the clamp pin passes allowing the blocks to move along the clamp pin. 
         [0036]    The clamp assembly may include a releasable clamp mechanism which in the clamped condition pulls the clamp pin and hence the stopper in a direction that causes the toothed block to engage the fixed rack. This may therefore provide a clamp force that acts in an opposite direction to the biasing force of the biasing means. It must be a sufficient force to overcome the biasing force. 
         [0037]    The clamp mechanism may include a clamp lever, and may include a cam assembly rotatable by the clamp lever. 
         [0038]    The fixed portion may comprise a bracket having two spaced arms, the clamp pin passing through an opening in each of the arms. The or each opening may be elongated permitting the clamp pin to be moved along the opening to adjust for rake. The rake rack of teeth, where provided, may extend along the side of the opening. 
         [0039]    The moving portion may comprise a part of a steering column shroud, the clamp pin passing through an opening in the shroud. A rail may be secured to the shroud that includes the opening. The or each opening may be elongated permitting movement of the clamp pin along the opening for reach adjustment. The reach rack of teeth where provided by extend along the side of the opening. 
         [0040]    Where it is adjustable for reach, the shroud may be telescopic comprising inner and outer portions, the inner portion sliding in the outer portion. The moving portion may comprise the outer portion or it may comprise the inner portion. The inner and outer portions may comprise tubes. The shroud may be fabricated or cast or a mix of fabricated and cast parts. 
         [0041]    According to a second aspect the invention provides a steering column assembly including an adjustable steering column shroud and a support bracket and a clamp assembly according to the first aspect. 
         [0042]    The steering column assembly may be adjustable for rake or for reach or for both rake and reach. 
         [0043]    Other advantages of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiments, when read in light of the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0044]      FIG. 1  is a first perspective view of a first embodiment of a steering column assembly which incorporates a clamp assembly according to a first aspect of the invention; 
           [0045]      FIG. 2  is a cross section through a portion of the embodiment of  FIG. 1 ; 
           [0046]      FIG. 3  is an enlarged cross section corresponding to a part of the view of  FIG. 2  showing in detail the arrangement of the spring means and toothed block; 
           [0047]      FIG. 4  is a view (a) from one side and (b) from the opposite side of a spacer part of the spring means shown in  FIG. 3 ; 
           [0048]      FIG. 5  is a view (a) from one side and (b) from the opposite side of an anti-rotation spacer shown in  FIG. 4 ; 
           [0049]      FIG. 6  is a perspective view of a section of the clamp pin of  FIG. 2  showing the shoulder present where the clamp pin changes from a square to a round cross section which earths out the spring force; 
           [0050]      FIG. 7  is a cross section of a second embodiment of steering column assembly showing in detail the arrangement of the spring means and toothed block 
           [0051]      FIG. 8  is an enlarged cross section corresponding to a part of the view of  FIG. 7  showing in detail the arrangement of the spring means and toothed block; 
           [0052]      FIG. 9  shows a part of the clamp pin of the second embodiment that differs from the clamp pin of the first embodiment only in the relative location of the shoulder and the stopper; 
           [0053]      FIG. 10  is a cross section of a modification of the second embodiment of steering column assembly which provides third embodiment of the present invention showing in detail the arrangement of the spring means and toothed block and additional resilient spacers between the spring means and the toothed racks; and 
           [0054]      FIG. 11  is (a) a perspective view and (b) a view in cross section of the spacer part of the spring means of the third embodiment. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0055]    A first embodiment 1 of a steering column assembly for a vehicle which incorporates a clamp assembly according to a first aspect of the invention is shown in  FIGS. 2 to 6  of the accompanying drawings. It comprises a steering column shroud having a tubular shroud portion  2  that fits around a collapsible steering shaft  3  as shown in  FIG. 1 . 
         [0056]    The tubular shroud portion  2  may be fixed to a gearbox (not shown) at an end distant from the steering wheel and is able to pivot around a horizontal axis that extends orthogonal to the axis of the steering shaft. The axis is located within the gearbox so that pivoting about this axis allows the shroud to be adjusted for rake. If a gearbox is not provided it may pivot about some other part of the steering assembly. The inner portion, notably, is not able to move along its axis, only to pivot. This steering assembly can therefore only be adjusted for rake, not reach. 
         [0057]    The pivoting movement of the shroud  2  is restrained by securing the tubular shroud portion to a support bracket  4  using a clamp assembly as will be described. The clamp assembly is releasable so that the position of the moving portion of the steering column shroud, and hence steering wheel, can be adjusted. When locked the assembly locks the moving portion to the bracket  4  to prevent any relative movement between them although in some cases this could be overcome, for example in the event of an accident. 
         [0058]    The support bracket  4  comprises two downwardly extending arms  4   a,    4   b.  The bracket  4  will be referred to herein after as the fixed portion of the steering assembly, being considered fixed in that it is fixed relative to the vehicle body (not shown). The tubular portion  2  of the shroud is reinforced by a box section rail  5  which fits snugly between the two arms  4   a,    4   b  of the bracket  4 . 
         [0059]    The clamp assembly of the first embodiment is shown in detail in  FIG. 2  of the drawings. 
         [0060]    The clamp assembly comprises a clamp pin  101  that extends through an elongate opening  102 ,  103  in each of the support bracket arms  4   a , 4   b  and an opening on opposing sides of the rail  5  on the tubular shroud  2 . The slots in the bracket  4  are roughly orthogonal to the axis of the shroud, generally extending along a vertical axis as can be seen in  FIG. 1  and the clamp pin can move up and down along those slots to make rake adjustments when the clamp assembly is unlocked. 
         [0061]    To positively lock the shroud  2  in place, a toothed rack  7  is provided alongside a slot on an outer face of one arm  4   b  of the support bracket  4 . This is provided by a stamped member  7  which carries two racks of teeth  7   a,    7   b,  each located on a respective side of the slot  103 . Of course, it may be possible to make the racks an integral part of the support bracket arm, perhaps by stamping or pressing them into the arm 
         [0062]    The clamp pin  101  has a stopper  104  at one end and carries a toothed block  105  that is slidingly mounted on the pin so that it can move to and fro across the pin. The block  105  is located between the stopper  104  and the support arm  103  that is provided with the toothed racks. The block  105  carries two racks of teeth  105   a,    105   b  which oppose the racks of teeth  103 , 104  on the support bracket  102 . 
         [0063]    The clamp assembly includes a cam/follower mechanism  106  for moving the stopper  104  of the clamp pin  101  towards and away from the support bracket arm  103  during locking and unlocking. This is achieved by a clamp means mounted on the pin  101  at the other end of the clamp pin to the stopper which pulls the stopper towards the support bracket to clamp. When released a biasing means  109 , 110 , 111  pushes the stopper away from the support bracket arm, in turn allowing the toothed block to move away to an unclamped condition. 
         [0064]    The cam/follower mechanism is located between a stiff nut  107  at the end of the clamp pin and the arm of the support bracket that does not carry the toothed rack, i.e. on the opposite side of the bracket to the toothed block. The cam/follower mechanism working with the stopper and stiff nut forms a clamp mechanism which can squeeze the bracket arms  4   a,    4   b  together onto the rail  5 , and also press the block  105  towards the bracket  4 . 
         [0065]    The cam mechanism comprises a cam portion that is mounted on the clamp pin  101 . Attached to this is an adjustment handle  108  that can be seen in  FIGS. 1 and 2 . The cam portion is rotatably mounted to the clamp pin  101  so that it can be rotated by moving the handle  108 , and carries a ramped cam face which abuts a corresponding ramped cam face provided on a fixed cam portion. The fixed cam portion fits partially within the rake slot of the bracket in such a manner that it cannot rotate but can move to and fro along the shaft. The overall length of the combination of fixed and moving cams on the shaft varies as the handle turns. 
         [0066]    The biasing means comprises a coil spring  109  that is wound around the centre of the clamp pin  101 . One end acts upon an inner face of the arm  4   a  of the support bracket  4  nearest the cam mechanism through a reaction member  110 . The other end of the spring is terminated at a point along the clamp pin  101  close to the opening in the arm  4   b  that is closest to the toothed block  105 . A shaped spacer  111  is threaded onto the clamp pin  101  and has a first part that passes through the slot  103  in the bracket arm  4   b  to engage the spring  109  and a second, enlarged part that is located between the arm  4   b  and the toothed block  105 . This is shown in more detail in  FIGS. 4(   a ) and  4 ( b ). The enlarged part acts upon a shoulder  112  formed along the clamp pin. This can be seen most clearly in  FIGS. 3 and 6  of the drawings. The shoulder  112  is positioned so that it holds the spacer  111  slightly away from the toothed block  105 , creating a small clearance between the toothed block and spacer. 
         [0067]    When the clamp assembly is in the clamped or locked condition, the stopper  104  is pulled towards the support bracket  4   b  by the cam mechanism. This presses the teeth of the toothed block  105  into engagement with the teeth on the support bracket  4 . At the same time, the shoulder  112  on the clamp pin  101  presses against the spacer  111  which compresses the spring  109 . 
         [0068]    When the cam mechanism is moved to unclamp the clamp assembly, the stopper  104  moves away from the support bracket arm  4   b  under the biasing force of the spring  109  acting on the spacer  111  which in turn acts on the shoulder  112 . The spring force does not act on the toothed block  105  and so does not apply an undesirable load to the toothed block. 
         [0069]    A second embodiment is shown in  FIGS. 7 to 9 . The most significant difference between the second embodiment and the first embodiment is that the steering assembly can be adjusted for rake as well as reach. Where appropriate like parts have been marked using the same reference numerals as the first embodiment for clarity. 
         [0070]    Reach adjustment is provided by a two part telescopic tubular shroud. The shroud comprises an outer tubular portion  3  that can slide telescopically over an inner tubular shroud portion. The outer portion  3  can slide up and down the inner portion to enable the length of the shroud to be adjusted. This permits the reach of the steering to be adjusted. The movable outer portion carries the rail  5  of the first embodiment. 
         [0071]    Similar to the first embodiment, the inner portion is fixed to a gearbox or other fixed part and is able to pivot around a horizontal axis that extends orthogonal to the axis of the steering shaft. The axis is located within the gearbox so that pivoting about this axis allows the shroud to be adjusted for rake. The inner portion, notably, is not able to move along it axis, only to pivot. 
         [0072]    The pivoting and telescoping movement of the shroud  3  is restrained by securing the moving portion (the outer tubular portion) to the support bracket  4  using a clamp assembly similar to that of the first embodiment. Rake adjustment is accommodated by passing a clamp pin  201  through a pair of elongate slots in the support arm bracket  4 . Reach adjustment is accommodated by making the opening in the rail  5  through which the clamp pin passes elongated slots, the axis of the slots running parallel to the axis of the shroud. The clamp pin can therefore move along these slots when unclamped. 
         [0073]    The clamp assembly is releasable so that the position of the moving portion of the steering column shroud, and hence steering wheel, can be adjusted independently for reach and rake. When locked the assembly locks the moving portion to the bracket to prevent any relative movement between them although in some cases this could be overcome, for example in the event of an accident. 
         [0074]    Where the first embodiment included a single toothed block that had teeth that cooperate with teeth on the support bracket to provide positive locking of the rake position, this embodiment includes two toothed blocks  205 ,  206 . The blocks  205 ,  206  are threaded onto the end of the clamp pin between the stopper and the arm of the support bracket that carries the rake adjustment teeth. These can best be seen in  FIG. 8  of the drawings. 
         [0075]    A first toothed block  205  carries a rack of teeth  205   a  and is shaped so that it passes through the elongate slot in the support bracket arm  4   b.  This rack carries teeth which in the clamped condition of the clamp assembly engage teeth provided alongside the slot in the rail and so controls the reach of the steering assembly. 
         [0076]    A second toothed block  206  also carries a rack of teeth  206   a  and is shaped so that it engages a corresponding rack of teeth that are carried by arm  4   b  of the support bracket. This second block therefore function in a similar way to the block  105  of the first embodiment. At least a part of this second block must therefore pass through the slot in the support bracket arm. The block  206  is located nearer the stopper than the block  205 . 
         [0077]    As with the first embodiment, a cam mechanism is provided and a biasing means  109 ,  110 , and  211  that biases the clamp pin  201  in a direction that releases the toothed blocks when unclamped. This biasing means comprises a coil spring  109  wrapped around the clamp pin and a spacer  211 . The spacer  211  acts on a shoulder  202  formed in the pin that ensures that the biasing force (shown by the arrows in  FIG. 8 ) is applied to the pin  201  but not the toothed blocks. The clamp pin  201  is generally the same as the first embodiment and is shown in more detail in  FIG. 9 . 
         [0078]    Also present is a spacer block  113  that is located on an inner face of the arm  4   b.  This has an opening through which the clamp pin and the smaller end of the spacer  112  is passed. It is shown in detail in  FIGS. 5(   a ) and  5 ( b ). 
         [0079]    A third embodiment is illustrated in  FIGS. 10 and 11  of the drawings. This is very similar to the second embodiment, allowing reach and rake adjustment. Where parts are the same in the third embodiment as they are in the second embodiment the same reference numerals have been used for clarity. 
         [0080]    The third embodiment differs from the second only by the provision of a modified spacer  211   a  that replaces spacer  211 . The spacer  211   a  of the spring means includes two resilient elements or pads  212  that fit in the clearance between the main body of the spacer  211   a  and the first toothed block  205 . These pads do not transfer any spring force to the toothed block but control the movement of the blocks relative to the spacer preventing rattle due to the clearance. In the unclamped condition the elements bias the toothed blocks towards the stopper independent of the biasing force applied by the biasing means. 
         [0081]    In accordance with the provisions of the patent statutes, the principle and mode of operation of this invention have been explained and illustrated in its preferred embodiments. However, it must be understood that this invention may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope.