Torque element retention system

1. A torque element retention system comprising:

a housing having an opening;

a torque assembly comprising a shaft and a torque element stacked along the shaft and configured substantially within the opening of the housing;

wherein the torque element comprises an arm portion and a foot portion;

wherein the opening comprises an arm opening section configured to receive the arm portion of the torque element in a clearance fit such that the torque element is not contacted by the housing in the arm portion, and a foot retention section configured to receive the foot portion of the torque element in a press fit such that the torque element is constrained by the housing in the foot portion;

wherein the torque element retention system has a system axis through the center of the shaft and extending through the foot retention section such that first and second foot end portions of the foot retention section extend in opposite directions normal to the system axis in approximately equal distance;

wherein the first and second foot end portions of the foot retention section each includes first and second non-parallel segments having no normal length to chord length ratio greater than 0.5 such that foot retention section is formable using die casting of metals with high-temperature melting points; and

wherein the chord length comprises a distance from a first point on the first segment to a second point on the second segment along a first line that is parallel to the system axis, wherein the normal length comprises a distance from the chord length to a point of intersection of the first and second segments along a second line perpendicular to the system axis, and wherein the normal length to chord length ratio is the normal length distance divided by the chord length distance.

2. The torque element retention system of claim 1 , wherein the first and second segments are substantially perpendicular to each other and approximately equal length such that each segment exerts a substantially balanced force on the torque element in the direction of the system axis and perpendicular thereto.

3. The torque element retention system of claim 1 , wherein the first and second segments are configured to constrain the torque element thereby preventing its relative movement to the housing and such that each segment exerts a bi-directional force on the torque element that is neither parallel nor perpendicular to the system axis.

4. The torque element retention system of claim 1 , wherein the first and second segments are configured to constrain the torque element thereby preventing its relative movement to the housing and such that each segment exerts a substantially symmetrical force on the torque element relative to an axis parallel to the system axis.

5. The torque element retention system of claim 1 , wherein each of the first and second segments have a radius such that the radius divided by a maximum chord length for each of the first and second segments is greater than 1.

6. The torque element retention system of claim 1 , wherein each of the first and second segments of each of the first and second foot end portions intersects at a point of the foot retention section that is furthest from the system axis.

7. The torque element retention system of claim 1 , wherein each of the first and second segments of each of the first foot end portion the first and each of the first and second segments of the second foot end portion are configured to constrain the torque element thereby preventing its relative movement to the housing and such that each segment exerts a substantially symmetrical force on the torque element both relative to the system axis and to an axis parallel to the system axis.

8. A torque element retention system comprising:

a housing having an opening;

a torque assembly comprising a shaft and a torque element stacked along the shaft and configured substantially within the opening of the housing;

wherein the torque element comprises an arm portion and a foot portion;

wherein the opening comprises an arm opening section configured to receive the arm portion of the torque element in a clearance fit such that the torque element is not contacted by the housing in the arm portion, and a foot retention section configured to receive the foot portion of the torque element in a press fit such that the torque element is constrained by the housing exclusively in the foot portion;

wherein the torque element retention system has a system axis through the center of the shaft and extending through the foot retention section such that the system axis divides the foot retention section approximately in half thereby forming first and second foot end portions each

with at least a first and second non-parallel segments that constrain the torque element thereby preventing its relative movement to the housing;

wherein the first and second non-parallel segments of the foot retention section have no normal length to chord length ratio greater than 0.5, such that the foot portion is self-broaching into the foot retention section of the housing; and

wherein the chord length comprises a distance from a first point on the first segment to a second point on the second segment along the first line that is parallel to the system axis, wherein a normal length comprises a distance from the chord length to a point of intersection of the first and second segments along a second line perpendicular to the system axis, and wherein the normal length to chord length ratio is the normal length distance divided by the chord length distance.

9. The torque element retention system of claim 8 , wherein a bi-directional force exerted by each of the first and second segments each prevent movement of the torque element in a direction of the system axis and in a direction perpendicular thereto.

10. The torque element retention system of claim 8 , wherein a bi-directional force exerted by the first segment on the torque element is symmetrical to the bi-directional force exerted by the second segment on the torque element relative to an axis perpendicular to the system axis.

11. The torque element retention system of claim 8 , wherein each of the first and second segments have a radius such that the radius divided by a maximum chord length for each of the first and second segments is greater than 1.