Rack and pinion units

Claim 2

A rack and pinion steering gear comprising: a rack bar carrying a rack; pinion means including a shaft, a pinion on said shaft, and bearing means for mounting said shaft for rotation; and a unitary housing including at least two mating housing shells enclosing said rack bar, said pinion and said bearing means, each of said shells including first support means slidably mounting said rack bar, second support means fixedly mounting said pinion assembly with said pinion operatively engaging said rack, and securing means permanently securing said shells together in a fixed, mated relationship.

Claim 3

A rack and pinion steering gear according to claim 1 wherein said first support means comprises: a bearing bushing receiving said rack bar in sliding engagement; and a bearing seat molded in said housing shells for mounting said bearing bushing at a point remote from the engagement of said rack with said pinion.

Claim 4

A rack and pinion steering gear according to claim 1, comprising: a yoke mounted in one of said shells opposite the engagement of said rack and said pinion for holding said rack against said pinion, said yoke including a surface shaped complemental to the adjacent surface of said rack bar and receiving said rack bar in sliding engagement.

Claim 5

A rack and pinion steering gear according to claim 1, wherein said rack bar has a generally circular cross section.

Claim 6

A rack and pinion steering gear according to claim 1, wherein said securing means includes a bonding material.

Claim 7

A rack and pinion steering gear according to claim 1, wherein said shells include a plastic material.

Claim 8

A rack and pinion steering gear according to claim 6, wherein said shells include an acetal co-polymer.

Claim 9

A rack and pinion steering gear according to claim 1, wherein said shells include a thermoplastic material and said securing means includes heat welded adjacent portions of said shells.

Claim 10

A rack and pinion steering gear according to claim 1, wherein said shells include a thermosetting plastic material and said securing means includes a bonding agent.

Claim 11

A rack and pinion steering gear according to claim 1, comprising means defining integrally formed channels in each of said shells which direct the flow of a lubricant along said rack bar.

Claim 12

A rack and pinion steering gear according to claim 10, wherein said channel defining means includes longitudinally and transversely extending ribs projecting inwardly within said shells to define said channels and strengthen said shells.

Claim 13

A rack and pinion steering gear according to claim 10, comprising: means articulately coupled to each end of said rack bar for connecting said rack bar to steerable wheels of a vehicle; and flexible sealing means at each end of said housing connecting the respective articulately coupled means and said housing in a fluid sealed relationship.

Claim 14

A rack and pinion steering gear comprising: a rack bar carrying a rack and having a circular cross section; a pinion assembly including, a shaft; bearing means mounting said shaft for rotation, and a pinion mounted on said shaft for rotation therewith; a unitary housing including at least two mating plastic housing shells together enclosing said rack bar, said bearing means and said pinion, each of said housing shells including first support means mounting said rack bar for longitudinal movement including a rack bar bearing, and a rack bar bearing seat integrally molded in said housing shells, second support means fixedly mounting said pinion assembly with said pinion operatively engaging said rack; a yoke also supporting said rack bar opposite its engagement with said pinion, said yoke having an arcuate surface conforming to the circular cross section of said rack bar and receiving said rack bar in sliding engagement; means biasing said yoke toward said rack bar, and means permanently securing said shells together in a fixed mated relationship.

Claim 15

A rack and pinion steering gear comprising: a rack bar carrying a rack and having a circular cross section; a pinion assembly including, a shaft; bearing means mounting said shaft for rotation, and a pinion mounted on said shaft for rotation therewith; a unitary housing including at least two mating plastic housing shells together enclosing said rack bar, said bearing means and said pinion, each of said housing shells including first support means mounting said rack bar for longitudinal movement including a rack bar bearing, and a rack bar bearing seat integrally molded in said housing shells, second support means fixedly mounting said pinion assembly with said pinion operatively engaging said rack; a yoke also supporting said rack bar opposite its engagement with said pinion, said yoke having an arcuate surface conforming to the circular cross section of said rack bar and receiving said rack bar in sliding engagement; means biasing said yoke toward said rack bar, and means permanently securing said shells together in a fixed mated relationship.

Claim 16

A rack and pinion unit for a vehicle steering gear which comprises a rack bar carrying a rack, a pinion having teeth meshed with said rack and a shaft extending from the teeth, bearings rotatably supporting said pinion, bearings slidably supporting said rack bar, a longitudinally split housing composed of at least two preformed shell-like components embracing said rack bar and pinion and each providing recesses and seats locating and retaining said pinion bearings and said rack bar bearings, and said shell-like components being secured together along the length thereof to form a unitary housing for the rack bar and pinion.

Claim 17

A rack and pinion unit for a vehicle steering gear which comprises a rack bar carrying a rack, a pinion having teeth meshed with said rack and a shaft extending from the teeth, bearings rotatably supporting said pinion, bearings slidably supporting said rack bar, a longitudinally split housing composed of at least two preformed shell-like components embracing said rack bar and pinion and each providing recesses and seats locating and retaining said pinion bearings and said rack bar bearings, and said shell-like components being secured together along the length thereof to form a unitary housing for the rack bar and pinion.

Claim 18

The rack and pinion unit of claim 14 wherein the unitary housing has a pinion casing portion and a tubular rack bar casing portion extending from the pinion casing portion to enclose the major part of the length of the rack bar and wherein each of said shell-like components integrally incorporate a part of the pinion casing portion and a part of the rack bar casing portion.

Claim 19

The rack and pinion unit of claim 15 in which the separation line is shaped to receive the pinion shaft and the pinion shaft extends from the housing.

Claim 20

The rack and pinion unit of claim 14 wherein the unitary housing comprises two shell-like components having a separation line which extends throughout the length of the housing in the longitudinal direction of the rack bar.

Claim 21

The rack and pinion unit of claim 14 wherein the preformed shell-like components of the unitary housing are made from engineering plastics material having a Young's modulus of about 3 × 10 5 to 2 × 10 6 pounds per square inch, a tensile strength of not less than about 6,000 pounds per square inch, and an elongation at break of not less than about 5 percent.

Claim 22

The rack and pinion unit of claim 18 wherein the engineering plastics material is substantially stable over a temperature range of at least -5° C. to at least 35° C.