Steering column with foamed in-place structure

Abstract

A composite steering column jacket including a pair of composite sections joined along a flange area. The composite sections include outer and inner walls spaced coaxially from each other, that mate at first and second flanges. A cavity is defined by the space between the inner and outer walls and is filled with a foam material that is disposed within. The composite steering column jacket has an increased stiffness and reduced weight when compared to conventional metal steering column jackets.

1 . A composite steering column jacket assembly comprising: 
 a longitudinally extending outer tubular wall member;    a longitudinally extending inner tubular wall member disposed in said outer tubular wall member and defining a space between said inner and outer tubular wall members;    said inner and outer tubular wall members joined immovably to one another by at least one longitudinally extending side flange, wherein said at least one longitudinally extending side flange includes first and second longitudinally extending side flanges;    including foam material disposed in said space, wherein said foam material is polyurethane foam; and    at least one mounting bracket fabricated separately from said inner and outer tubular wall members and coupled to said first and second flanges, wherein there are three of said mounting brackets including an adapter bracket, a shear bracket and a lower bracket, and including a cable extending between said adapter bracket and said lower bracket.