# US 11,027,767 B2 · Steering system rack with stepped portion > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,027,767 B2 - Document ID: US11027767B2 - Status: Granted - Kind: B2 - Application number: 16/206,343 - Filed: 2018-11-30 - Published: 2020-06-04 - Granted: 2021-06-08 - Earliest claimed: 2018-11-30 - Assignees: Steering Solutions IP Holding Corporation - Applicants: Steering Solutions IP Holding Corporation - Inventors: Michael J. Augustine; Kevin P. Douglas; Gary V. Weiss; William H. Georges - Web page: https://patentgrep.com/patent/US11027767B2 ## CPC - B62D 3/126: {characterised by the rack} - B21K 1/767: {Toothed racks} - B62D 5/0448: {Ball nuts} - B62D: MOTOR VEHICLES; TRAILERS (steering, or guiding on a desired track, of agricultural machines or implements A01B69/00; wheels, castors, axles, increasing wheel adhesion B60B; vehicle tyres, tyre inflation or tyre changing B60C; connections between vehicles of a train or the like B60D; vehicles for use on rail and road, amphibious or convertible vehicles B60F; suspension arrangements B60G; heating, cooling, ventilating or other air treating devices B60H; windows, windscreens, non-fixed roofs, doors or similar devices, protective coverings for vehicles not in use B60J; propulsion plant arrangements, auxiliary drives, transmissions, controls, instrumentation or dashboards B60K; electric equipment or propulsion of electrically-propelled vehicles B60L; power supply for electrically-propelled vehicles B60M; passenger accommodation not otherwise provided for B60N; adaptations for load transportation or to carry special loads or objects B60P; arrangement of signalling or lighting devices, the mounting or supporting thereof or circuits therefor, for vehicles in general B60Q; vehicles, vehicle fittings or vehicle parts not otherwise provided for B60R; servicing, cleaning, repairing, supporting, lifting, or manoeuvring, not otherwise provided for, B60S; brake arrangements, brake control systems or parts thereof B60T; air-cushion vehicles B60V; motor-cycles, accessories therefor B62J, B62K; testing of vehicles G01M) - B21K: MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS (making particular articles by working sheet metal without essentially removing material B21D; processing wire B21F; making pins, needles or nails B21G; making particular articles by rolling B21H; forging machines, pressing machines, hammering machines, in general B21J; making chains B21L; plating B23K) ## Abstract A rack bar blank for a steering system includes a first region having a first diameter. The rack bar blank also includes a second region having a second diameter that is greater than the first diameter prior to formation of teeth on the second region and a ball screw thread on the first region. ## Claims ### Claim 1 A rack bar blank for a steering system, the rack bar blank comprising: a first region having a first diameter; a second region having a second diameter that is greater than the first diameter prior to formation of teeth on the second region and a ball screw thread on the first region; and a transition region along an outer surface of the rack bar blank, the transition region extending radially outwardly in a direction from the first region to the second region, the transition region joining the first region and the second region. ### Claim 2 (depends on 1) The rack bar blank of claim 1, wherein the first region is a ball screw region engageable with a ball screw nut upon formation of a ball screw thread form thereon, the second region engageable with a pinion upon formation of teeth thereon. ### Claim 3 (depends on 1) The rack bar blank of claim 1, wherein the rack bar blank is a single, integrally formed component. ### Claim 4 (depends on 1) The rack bar blank of claim 1, wherein the rack bar blank comprises a plurality of components joined together. ### Claim 5 (depends on 1) The rack bar blank of claim 1, wherein the transition region is an angled ramp. ### Claim 6 (depends on 1) The rack bar blank of claim 1, wherein the transition region is a perpendicular step. ### Claim 7 (depends on 1) The rack bar blank of claim 1, wherein at least a portion of the transition region is curved. ### Claim 8 A method of forming a rack bar for a steering system comprising: modifying a single, integrally formed circular rack bar blank to provide a ball screw region having a first diameter along a first length of the rack bar blank and pinion mesh region having a second diameter along a second length of the rack bar blank, the second diameter being greater than the first diameter; cutting a plurality of teeth along and into the pinion mesh region after the first and second diameters have been formed; forming a ball screw thread into the ball screw region after the first and second diameters have been formed; and modifying the rack bar blank to include a transition region extending between the pinion mesh region and the ball screw region, the transition region extending radially outwardly in a direction from the first region to the second region. ### Claim 9 (depends on 8) The method of claim 8, wherein modifying the rack bar blank comprises a machining process. ### Claim 10 (depends on 8) The method of claim 8, wherein modifying the rack bar blank comprises a forming process.