(19)
(11)EP 3 193 044 B1

(12)EUROPEAN PATENT SPECIFICATION

(45)Mention of the grant of the patent:
26.06.2019 Bulletin 2019/26

(21)Application number: 16195368.2

(22)Date of filing:  24.10.2016
(51)International Patent Classification (IPC): 
F16H 48/40(2012.01)
F16H 48/08(2006.01)

(54)

DIFFERENTIAL ASSEMBLY WITH SPIDER SHAFT RETENTION

DIFFERENTIALANORDNUNG MIT STEGWELLENARRETIERUNG

ENSEMBLE DIFFÉRENTIEL AVEC RÉTENTION D'ARBRE D'ARAIGNÉE


(84)Designated Contracting States:
AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR

(30)Priority: 15.01.2016 US 201614996663

(43)Date of publication of application:
19.07.2017 Bulletin 2017/29

(73)Proprietor: ArvinMeritor Technology, LLC
Troy, MI 48084 (US)

(72)Inventors:
  • MARTIN, Robert
    Newark, OH Ohio 43055 (US)
  • KLEINHANS, Aaron
    Oakland, MI Michigan 48363 (US)

(74)Representative: Jones, John Bryn 
Withers & Rogers LLP 4 More London Riverside
London SE1 2AU
London SE1 2AU (GB)


(56)References cited: : 
DE-A1-102012 014 950
US-A1- 2015 059 180
US-A1- 2009 013 533
  
      
    Note: Within nine months from the publication of the mention of the grant of the European patent, any person may give notice to the European Patent Office of opposition to the European patent granted. Notice of opposition shall be filed in a written reasoned statement. It shall not be deemed to have been filed until the opposition fee has been paid. (Art. 99(1) European Patent Convention).


    Description

    TECHNICAL FIELD



    [0001] This disclosure relates to a differential assembly that has a case that is configured to retain shafts of a spider.

    BACKGROUND



    [0002] A bevel gear differential is disclosed in United States Patent Publication No. 2015/0059180. Another conventional differential gear is disclosed in DE102012014950A1. This document does not disclose the following features of claim 1: the recess is disposed between the outer surface and the first cavity; a primary spider shaft is mounted to the first case portion; and the secondary spider shaft has a retaining groove receiving the protrusion to retain the secondary spider shaft in the spider shaft hole.

    SUMMARY



    [0003] In at least one embodiment, a differential assembly is provided. The differential assembly includes a case and a spider. The case has a first case portion and a second case portion. The first case portion has a first cavity, an outer surface, a spider shaft hole, and a recess. The outer surface is disposed around the first cavity. The spider shaft hole extends from the outer surface to the first cavity. The recess is disposed between the outer surface and the first cavity and may extend from the spider shaft hole. The second case portion is disposed on the first case portion. The second case portion has a protrusion that extends through the recess into the spider shaft hole. The spider includes a primary spider shaft and a secondary spider shaft. The primary spider shaft is mounted to the first case portion. The secondary spider shaft is received in the spider shaft hole and extends between the spider shaft hole and the primary spider shaft. The secondary spider shaft has a retaining groove that receives the protrusion to retain the secondary spider shaft in the spider shaft hole.

    [0004] In at least one embodiment, a differential assembly is provided. The differential assembly may include a case and a spider. The case may rotate about an axis and may include a first case portion and a second case portion. The first case portion may have a first cavity, an outer surface, a set of spider shaft holes, and a recess. The first cavity may be disposed along the axis. The outer surface may extend around the first cavity. The set of spider shaft holes may be spaced apart from each other and may extend from the outer surface to the first cavity. The recess may be disposed between the outer surface and the first cavity and may extend from each member of the set of spider shaft holes. The second case portion may be disposed on the first case portion. The second case portion may have a second cavity and a protrusion. The second cavity may be disposed along the axis. The protrusion may extend through the recess into each member of the set of spider shaft holes. The spider may be at least partially disposed in the first cavity. The spider may include a primary spider shaft and a secondary spider shaft. The primary spider shaft may be received in first and second members of the set of spider shaft holes. The secondary spider shaft may be received in a third member of the set of spider shaft holes and may extend to the primary spider shaft. The secondary spider shaft may have a retaining groove that may receive the protrusion to retain the secondary spider shaft in the spider shaft hole.

    BRIEF DESCRIPTION OF THE DRAWINGS



    [0005] 

    Figure 1 is a perspective view of a differential assembly.

    Figures 2 and 3 are exploded views of the differential assembly.

    Figure 4 is a section view of the differential assembly along section line 4-4.


    DETAILED DESCRIPTION



    [0006] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.

    [0007] Referring to Figure 1, an exemplary differential assembly 10 is shown. The differential assembly 10 may be configured for use with a vehicle, such as a motor vehicle like a truck, bus, farm equipment, military transport or weaponry vehicle, or cargo loading equipment for land, air, or marine vessels.

    [0008] The differential assembly 10 may be provided with a vehicle drivetrain component, such as an axle assembly or transfer case, or wheel hub assembly. For example, the differential assembly 10 may be configured as an interaxle differential unit that may be provided with an axle assembly to compensate for speed differences between different axle assemblies that may be connected in series. The differential assembly 10 may also be provided with a wheel hub assembly that may rotatably support a vehicle wheel to provide gear reduction or gear ratio modification between a wheel axle and a traction wheel. The differential assembly 10 is described below primarily in the context of an axle assembly 12 and more specifically as a differential assembly 10 that may transmit torque to two wheel axles and their associated traction wheel assemblies and may permit the wheel axles and traction wheel assemblies to rotate at different velocities. As such, the differential assembly 10 may facilitate the transfer of torque between components and/or allow components to rotate at different velocities.

    [0009] Referring to Figure 4, the axle assembly 12 may include a housing 20, a first shaft 22, and a second shaft 24.

    [0010] The housing 20 may receive the differential assembly 10 and various components of the axle assembly 12. In addition, the housing 20 may facilitate mounting of the axle assembly 12 to the vehicle. In Figure 4, only a portion of the housing 20 is shown to more clearly illustrate the differential assembly 10.

    [0011] The first shaft 22 and the second shaft 24 may be at least partially disposed in the housing 20. In addition, the first shaft 22 and the second shaft 24 may be spaced apart from each other and may extend in opposite directions from the differential assembly 10. The first shaft 22 and the second shaft 24 may be configured to rotate about an axis 26. For instance, the first shaft 22 and the second shaft 24 may rotate independently or at different speeds about the axis 26 due to operation of the differential assembly 10. In at least one embodiment, the first shaft 22 and the second shaft 24 may be wheel axles or may be operatively connected to corresponding wheel axles that may be connected to corresponding wheel assemblies. As such, the first shaft 22 and/or the second shaft 24 may be rotated about the axis 26 by the differential assembly 10 to provide torque to a corresponding wheel assembly. In an interaxle differential unit configuration, the first shaft 22 may be an input shaft that may receive an input torque and the second shaft 24 may be an output shaft that may provide torque to another axle assembly. In a wheel hub assembly configuration, the first shaft 22 may be a wheel axle or may receive an input torque from a wheel axle and the second shaft 24 may provide torque to a wheel assembly.

    [0012] Referring to Figures 1-3, an example of a differential assembly 10 is shown in more detail. In at least one embodiment, the differential assembly 10 may include a case 30, a first gear 32, a second gear 34, a spider 36, and at least one pinion gear 38.

    [0013] The case 30 may be configured to receive components of the differential assembly 10. In addition, the case 30 may be configured to rotate about the axis 26. In at least one embodiment, the case 30 may include a first case portion 40 and a second case portion 42 that may cooperate to at least partially define a cavity. The cavity may at least partially receive the first gear 32, second gear 34, spider 36, and pinion gear(s) 38.

    [0014] Referring to Figures 2 and 3, an example of a first case portion 40 is shown. The first case portion 40 may include a first bearing portion 50, a flange portion 52, a first mounting portion 54, a first cavity 56, and a first hole 58.

    [0015] The first bearing portion 50 may extend around the axis 26 and may extend around and may at least partially define the first hole 58. As is best shown in Figure 4, the first bearing portion 50 may be disposed proximate and may engage a bearing 60 that may rotatably support the first case portion 40. The bearing 60 may be a roller bearing assembly that may include a plurality of rolling elements, such as balls or rollers, which may be disposed between an inner race and an outer race. The bearing 60 may be mounted on another component, such as the housing 20.

    [0016] The flange portion 52 may be disposed between the first bearing portion 50 and the first mounting portion 54. The flange portion 52 may extend away from the axis 26 and may extend further away from the axis 26 than the first bearing portion 50 and the first mounting portion 54. A ring gear 62 may be fixedly mounted to the flange portion 52 in some differential configurations, such as when the differential assembly 10 is provided in an axle assembly 12 and the first shaft 22 and second shaft 24 are wheel axles or transmit torque to wheel axles and traction wheel assemblies. The ring gear 62 may engage a pinion and receive torque from a pinion that may receive torque from a drivetrain component, such as an internal combustion engine, transmission, or transfer case. Torque provided to the pinion may be transmitted to the ring gear 62 and then to corresponding wheel end assemblies and traction wheels via the first shaft 22 and the second shaft 24. Alternatively, the ring gear may be omitted in various configurations, such as when the differential assembly is configured as an interaxle differential unit.

    [0017] The first mounting portion 54 may extend from the flange portion 52 toward the second case portion 42. As is best shown in Figure 2, the first mounting portion 54 may extend around and may at least partially define the first cavity 56. In at least one embodiment, the first mounting portion 54 may have an outer surface 70, a set of spider shaft holes 72, an inner wall 74, an outer wall 76, and a recess 78.

    [0018] The outer surface 70 may be an exterior of the first mounting portion 54. The outer surface may extend around the axis 26 and the first cavity 56 and may face away from the first cavity 56.

    [0019] The set of spider shaft holes 72 may be provided in the first mounting portion 54. A spider shaft hole 72 may receive a spider shaft of the spider 36 as will be discussed in more detail below. In the embodiment shown in Figure 2, four spider shaft holes 72 are shown; however, it is contemplated that a greater or lesser number of spider shaft holes 72 may be provided. The spider shaft holes 72 may be spaced apart from each other and may be arranged around the axis 26. For example, spider shaft holes 72 may be disposed along axes that may be disposed substantially perpendicular to the axis 26. The spider shaft holes 72 may be through holes that may be completely defined in the first case portion 40. For example, spider shaft holes 72 may extend from the first cavity 56 to the outer surface 70.

    [0020] The inner wall 74 may extend from an end of the first mounting portion 54 toward the second case portion 42. The inner wall 74 may at least partially define the first cavity 56. As such, the inner wall 74 may be disposed between the first cavity 56 and the recess 78. For example, the inner wall 74 may extend from the first cavity 56 to the recess 78. The inner wall 74 may be configured as a ring that may extend continuously around the axis 26 in one or more embodiments. In addition, the inner wall 74 may extend further from the flange portion 52 than the outer wall 76 in an axial direction or a direction parallel to the axis 26.

    [0021] The outer wall 76 may also extend from an end of the first mounting portion 54 toward the second case portion 42. The outer wall 76 may at least partially define the outer surface 70 in one or more embodiments. The outer wall 76 may cooperate with the inner wall 74 to at least partially define the recess 78. As such, the outer wall 76 may be disposed between the outer surface 70 and the recess 78. For example, the outer wall 76 may extend from the outer surface 70 to the recess 78. The outer wall 76 may be configured as a ring that may extend continuously around the axis 26.

    [0022] The recess 78 may be disposed between the first cavity 56 and the outer surface 70. For instance, the recess 78 may be disposed between the inner wall 74 and the outer wall 76 and may be spaced apart from or separated from the first cavity 56 and the outer surface 70. The recess 78 may extend to one or more spider shaft holes 72. As such, the recess 78 may intersect and may not be separated from a spider shaft hole 72. In the embodiment shown in Figure 2, the recess 78 is configured as a ring that may be radially disposed about the axis 26 and that may extend continuously around the axis 26 and may extend from an end of the first mounting portion 54 to the spider shaft holes 72. Alternatively, the recess 78 may not extend continuously around the axis 26. For example, a plurality of recesses 78 may be provided that may each extend from a corresponding spider shaft hole 72 to an end of the first mounting portion 54 such that one or more recesses may be spaced apart from each other.

    [0023] The first cavity 56 may be disposed in the first case portion 40. The first cavity 56 may receive the first gear 32, spider 36, and at least a portion of a pinion gear 38. In addition, the first cavity 56 may extend from an end of the first mounting portion 54 to the first hole 58.

    [0024] The first hole 58 may be disposed along the axis 26. The first hole 58 may be configured to receive the first shaft 22 and/or the first gear 32. For example, the first hole 58 may be provided with a stepped configuration that may help position and inhibit axial movement of the first gear 32 away from the second gear 34. The first hole 58 may also receive a bearing 60 that may rotatably support the case 30 as is best shown in Figure 4.

    [0025] Referring to Figures 2 and 3, the second case portion 42 may be mounted to and may not rotate with respect to the first case portion 40. For instance, the second case portion 42 may be welded to the first case portion 40 with a weld that may extend from the outer surface 70 toward the axis 26 and may extend continuously around the axis 26. Alternatively, the first case portion 40 and the second case portion 42 may be assembled using one or more fasteners, such as bolts. In at least one embodiment, the second case portion 42 may include a second bearing portion 80, a second mounting portion 82, a second cavity 84, and a second hole 86.

    [0026] The second bearing portion 80 may extend around the axis 26 and may extend around the second hole 86. As is best shown in Figure 4, a bearing 60 that rotatably supports the second case portion 42 may be disposed on the second bearing portion 80. The bearing 60 may be mounted on another component, such as the housing 20. Gear teeth 90 may be provided with the second bearing portion 80 to facilitate locking of the differential assembly 10. For instance, a clutch collar may selectively engage the gear teeth 90 to lock the differential assembly 10 and inhibit the second shaft 24 from rotating with respect to the case 30 and the first shaft 22 in a manner known by those skilled in the art.

    [0027] The second mounting portion 82 may extend outwardly from the second bearing portion 80 toward the first case portion 40. As is best shown in Figure 3, the second mounting portion 82 may extend around and may at least partially define the second cavity 84. In at least one embodiment, the second mounting portion 82 may have a protrusion 100.

    [0028] The protrusion 100 may be disposed between the second cavity 84 and an outer surface 102 of the second case portion 42. The protrusion 100 may be configured as a ring that may extend continuously around the axis 26 and the inner wall 74 of the first case portion 40. The protrusion 100 may also be radially disposed about the axis 26. In addition the protrusion 100 may extend from an end of the second mounting portion 82 through the recess 78 and into one or more spider shaft holes 72 when the case 30 is assembled. Alternately, the protrusion 100 may not extend continuously around the axis 26. For example a plurality of protrusions 100 may be provided that may be spaced apart from each other and that may extend through a recess 78 and into a corresponding spider shaft hole 72. As is best shown in Figure 4, a gap 104 may be provided between an exterior surface 106 of the protrusion 100 and the outer wall 76. The gap 104 may provide clearance that may allow a weld that joins the first case portion 40 to the second case portion 42 to fully penetrate to the gap 104 but not penetrate the protrusion 100. The exterior surface 106 may be an outside circumference of the protrusion 100.

    [0029] Referring again to Figures 2 and 3, the second cavity 84 may be disposed in the second case portion 42. The second cavity 84 may receive the second gear 34 and may receive a portion of a pinion gear 38. For instance, the inner wall 74 may extend into and may be received in the second cavity 84. The second cavity 84 may extend from an end of the second mounting portion 82 to the second hole 86.

    [0030] The second hole 86, which is best shown in Figure 3, may be disposed along the axis 26. The second hole 86 may be configured to receive the second shaft 24 and/or the second gear 34. For example, the second hole 86 may be provided with a stepped configuration that may help position and inhibit axial movement of the second gear 34 away from the first gear 32.

    [0031] The first gear 32 may be disposed in the first case portion 40. For example, the first gear 32 may be at least partially disposed in the first hole 58 and may be configured to rotate about the axis 26. In at least one embodiment, the first gear 32 may include a first gear hole 110 and a gear portion 112.

    [0032] The first gear hole 110 may be disposed along the axis 26. The first gear hole 110 may be configured to receive the first shaft 22. The first gear 32 may rotate with the first shaft 22. For example, the first gear hole 110 may have a spline that may mate with a corresponding spline on the first shaft 22 such that the first gear 32 may not rotate with respect to the first shaft 22.

    [0033] The gear portion 112 may face toward and may be spaced apart from the spider 36. The gear portion 112 may have a set of teeth that may be arranged around the axis 26 and that may mate with teeth on one or more pinion gears 38. A thrust washer 114 or bearing may be disposed between the gear portion 112 and the first case portion 40.

    [0034] The second gear 34 may be disposed in the second case portion 42. For example, the second gear 34 may be at least partially disposed in the second hole 86 and may be configured to rotate about the axis 26. The second gear 34 may be spaced apart from the first gear 32 and may have a similar or identical configuration as the first gear 32. In at least one embodiment, the second gear 34 may include a second gear hole 120 and a gear portion 122.

    [0035] The second gear hole 120 may be disposed along the axis 26. The second gear hole 120 may be configured to receive the second shaft 24. In at least one embodiment, the second gear 34 may rotate with the first shaft 22. For example, the second gear hole 120 may have a spline that may mate with a corresponding spline on the second shaft 24 such that the second gear 34 may not rotate with respect to the second shaft 24.

    [0036] The gear portion 122 may face toward and may be spaced apart from the spider 36. The gear portion 122 may have a set of teeth that may be arranged around the axis 26 and that may mate with teeth on one or more pinion gears 38. A thrust washer 114 or bearing may be disposed between the gear portion 122 and the second case portion 42.

    [0037] The spider 36 may rotate about the axis 26 with the case 30. In at least one embodiment, the spider 36 may include a primary spider shaft 130 and at least one secondary spider shaft 132.

    [0038] The primary spider shaft 130 may be mounted to the first case portion 40. For example, the primary spider shaft 130 may have opposing ends that may be received in corresponding spider shaft holes 72 of the first case portion 40. As such, the primary spider shaft 130 may extend across the first cavity 56 and may extend through the axis 26. The primary spider shaft 130 may be disposed along a primary spider shaft axis 140. The primary spider shaft axis 140 may intersect and may be disposed substantially perpendicular to the axis 26. The primary spider shaft 130 may have a generally cylindrical configuration and may include a notch 142, a lubricant groove 144, and a retaining groove 146.

    [0039] One or more notches 142 may be disposed proximate the center of the primary spider shaft 130. In the embodiment shown in Figures 2 and 3, two notches 142 are provided that are disposed opposite each other and extend inwardly toward the axis 26. A notch 142 may receive and facilitate positioning of a secondary spider shaft 132 with respect to the primary spider shaft 130.

    [0040] One or more lubricant grooves 144 may be disposed between the axis 26 and an end of the primary spider shaft 130. For instance, a lubricant groove 144 may be disposed between the axis 26 and a retaining groove 146. In the embodiment shown in Figures 2 and 3, a pair of lubricant grooves 144 is disposed proximate opposite ends of the primary spider shaft 130. Each pair of lubricant grooves 144 may have two grooves that may be disposed opposite each other and extend toward the primary spider shaft axis 140. The lubricant groove 144 may be disposed adjacent to a pinion gear 38 and may allow lubricant, such as oil, to flow between the hole of the pinion gear 38 and the outside of the primary spider shaft 130 to help reduce friction between the pinion gear 38 and the primary spider shaft 130. The lubricant grooves 144 may have a greater axial length or length in a direction that extends along the primary spider shaft axis 140 than the retaining grooves 146.

    [0041] One or more retaining grooves 146 may be disposed between the axis 26 and an end of the primary spider shaft 130. For instance, a retaining groove 146 may be disposed between the lubricant groove 144 and an end of the primary spider shaft 130. In addition, the retaining groove 146 may be spaced apart or separated from the lubricant groove 144. In the embodiment shown in Figures 2 and 3, two retaining grooves 146 are provided that are disposed directly opposite each other and extend toward the primary spider shaft axis 140. At least one retaining groove 146 may face toward the second case portion 42 and may receive and may engage the protrusion 100 of the second case portion 42. As such, the protrusion 100 may help inhibit movement of the primary spider shaft 130 along the primary spider shaft axis 140 and rotation of the primary spider shaft 130 about the primary spider shaft axis 140.

    [0042] One or more secondary spider shafts 132 may be mounted to the first case portion 40. The secondary spider shaft 132 may extend between a spider shaft hole 72 and the primary spider shaft 130. For example, the secondary spider shaft 132 may have a first end that may be received in the notch 142 of the primary spider shaft 130 and a second end that may be disposed opposite the first end and may be received in a corresponding spider shaft hole 72. The secondary spider shaft 132 may be disposed along a secondary spider shaft axis 150. The secondary spider shaft axis 150 may intersect and may be disposed substantially perpendicular to the axis 26 and the primary spider shaft axis 140. In addition, the primary spider shaft axis 140 and secondary spider shaft axis 150 may be substantially coplanar or disposed in a common plane. In the embodiment shown in Figures 2 and 3, two secondary spider shafts 132 are provided that are disposed on opposite sides of the primary spider shaft 130 and are coaxially disposed along the secondary spider shaft axis 150. The secondary spider shafts 132 may have common or substantially identical configurations that may include a tapered end 152, a lubricant groove 154, and a retaining groove 156.

    [0043] The tapered end 152 may be disposed proximate the primary spider shaft 130. For example the tapered end 152 may be received in a notch 142 of the primary spider shaft 130. The secondary spider shaft 132 and its tapered end 152 may not be fixedly attached to the primary spider shaft 130 in one or more embodiments.

    [0044] One or more lubricant grooves 154 may be disposed between the axis 26 and an end of the secondary spider shaft 132. For instance, a lubricant groove 154 may be disposed between the axis 26 and a retaining groove 156 of the secondary spider shaft 132. In the embodiment shown in Figures 2 and 3, two lubricant grooves 154 are provided that are disposed opposite each other and extend toward the secondary spider shaft axis 150. The lubricant groove 154 may be disposed adjacent to a pinion gear 38 and may allow lubricant, such as oil, to flow between the hole of the pinion gear 38 and the outside of the secondary spider shaft 132 to help reduce friction between the pinion gear 38 and the secondary spider shaft 132. The lubricant grooves 154 may have a greater axial length or length in a direction that extends along the secondary spider shaft axis 150 than the retaining grooves 156.

    [0045] One or more retaining grooves 156 may be disposed between the axis 26 and an end of the secondary spider shaft 132. For instance, a retaining groove 156 may be disposed between the lubricant groove 154 and an end of the secondary spider shaft 132. In addition, the retaining groove 156 may be spaced apart from the lubricant groove 154. In the embodiment shown in Figures 2 and 3, two retaining grooves 156 are provided that are disposed directly opposite each other and extend toward the secondary spider shaft axis 150. At least one retaining groove 156 may face toward the second case portion 42 and may receive and may engage the protrusion 100 of the second case portion 42. As such, the protrusion 100 may help inhibit movement of the secondary spider shaft 132 along the secondary spider shaft axis 150 and rotation of the secondary spider shaft 132 about the secondary spider shaft axis 150.

    [0046] A pinion gear 38 may be rotatably disposed on the primary spider shaft 130 and the secondary spider shafts 132. For instance, two pinion gears 38 may be disposed on the primary spider shaft 130 proximate corresponding lubricant grooves 144 while a single pinion gear 38 may be disposed on each secondary spider shaft 132 proximate a corresponding lubricant groove 154. Each pinion gear 38 may be disposed in the cavity of the case 30 and may be retained on a corresponding spider shaft with one or more fasteners 160, such as a washer and/or a thrust bearing. The fastener 160 may engage the inner wall 74 of the first case portion 40. The pinion gears 38 on the primary spider shaft 130 may rotate about the primary spider shaft axis 140. The pinion gear 38 on the secondary spider shaft 132 may rotate about the secondary spider shaft axis 150. Each pinion gear 38 may include a set of teeth that mate with teeth on the first gear 32 and teeth on the second gear 34.

    [0047] The differential assembly described above may allow a multi-piece spider having one or more spider shafts to be retained in a case of a differential prior to joining the first and second case portions together, thereby facilitating assembly. In addition, the differential assembly described above may allow the positioning of spider shafts to be readily inspected and checked prior to welding the first and second case portions. The differential assembly described above may also allow one or more spider shafts to be retained without the use of additional fasteners or separate fasteners, such as a screw or roll pin, thereby reducing the number of parts, assembly time, and associated costs.

    [0048] While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the scope of the inventions defined by the claims. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention, as far as they are covered by the claims.


    Claims

    1. A differential assembly (10) comprising:

    a case (30) and a spider (36), the case (30) including:

    a first case portion (40) that has a first cavity (56), an outer surface (70) that is disposed around the first cavity (56), a spider shaft hole (72) that extends from the outer surface (70) to the first cavity (56), and a recess (78) that is disposed between the outer surface (70) and the first cavity (56) and that extends from the spider shaft hole (72); and

    a second case portion (42) that is disposed on the first case portion (40), wherein the second case portion (42) has a protrusion (100) that extends through the recess (78) into the spider shaft hole (72); and

    the spider (36) including:

    a primary spider shaft (130) that is mounted to the first case portion (40); and

    a secondary spider shaft (132) that is received in the spider shaft hole (72) and that extends between the spider shaft hole (72) and the primary spider shaft (130), wherein the secondary spider shaft (132) has a retaining groove (156) that receives the protrusion (100) to retain the secondary spider shaft (132) in the spider shaft hole (72).


     
    2. The differential assembly (10) of claim 1 wherein the case (30) is configured to rotate about an axis (26) and the recess (78) extends continuously around the axis (26).
     
    3. The differential assembly (10) of claim 2 wherein the protrusion (100) extends continuously around the axis (26) and preferably engages the secondary spider shaft (132).
     
    4. The differential assembly (10) of claim 1 wherein the recess (78) is spaced apart from the outer surface (70) and the first cavity (56).
     
    5. The differential assembly (10) of claim 4 wherein the first case portion (40) further comprises an inner wall (74) and an outer wall (76) that cooperate to at least partially define the recess (78), wherein the inner wall (74) extends from the first cavity (56) to the recess (78) and the outer wall (76) extends from the outer surface (70) to the recess (78).
     
    6. The differential assembly (10) of claim 5 wherein the second case portion (42) has a second cavity (84) that extends from the first cavity (56), wherein the inner wall (74) is received in the second cavity (84).
     
    7. The differential assembly (10) of claim 6 wherein the case (30) is configured to rotate about an axis (26) and the inner wall (74) and the outer wall (76) extend continuously around the axis (26) and preferably the protrusion (100) extends continuously around the inner wall (74) of the first case portion (40).
     
    8. The differential assembly (10) of claim 1 wherein the spider shaft hole (72) is a through hole that is completely defined in the first case portion (40).
     
    9. The differential assembly (10) of claim 1 further comprising a pinion gear (38) that is rotatably disposed on the secondary spider shaft (132), wherein the secondary spider shaft (132) has a lubricant groove (144) that is disposed between the pinion gear (38) and the secondary spider shaft (132) and is separated from the retaining groove (156).
     
    10. The differential assembly (10) of claim 1 wherein the primary spider shaft (130) has a notch (142) that receives a tapered end (152) of the secondary spider shaft (132).
     
    11. The differential assembly (10) of claim 1 wherein the first case portion (40) includes a set of spider shaft holes (72) that are spaced apart from each other and extend from the outer surface (70) to the first cavity (56), and the recess (78) extends from each member of the set of spider shaft holes (72), the protrusion (100) extends into each member of the set of spider shaft holes (72), the primary spider shaft (130) is received in first and second members of the set of spider shaft holes (72), and the secondary spider shaft (132) is received in a third member of the set of spider shaft holes (72) and extends from the third member to the primary spider shaft (130).
     
    12. The differential assembly (10) of claim 11 wherein the spider (36) further comprises a second secondary spider shaft (132) that is received in a fourth member of the set of spider shaft holes (72) and that extends from the fourth member to the primary spider shaft (130), preferably wherein the second secondary spider shaft (132) has a retaining groove (156) that receives and engages the protrusion (100) to retain the second secondary spider shaft (132) in the spider shaft hole (72).
     
    13. The differential assembly (10) of claim 12 wherein the primary spider shaft (130) is disposed along a primary spider shaft axis (140) and the secondary spider shaft (132) and the second secondary spider shaft (132) are disposed along a secndary spider shaft axis (150), preferably wherein the primary spider shaft (130) and the primary spider shaft axis (140) both intersect an axis (26) about which the case (30) is rotatable.
     
    14. The differential assembly (10) of claim 1 wherein the primary spider shaft (130) has a pair of retaining grooves (146) disposed proximate opposite ends of the primary spider shaft (130), wherein the protrusion (100) is received in the pair of retaining grooves (146).
     
    15. The differential assembly (10) of claim 1 further comprising a first gear (32) disposed in the first cavity (56), a second gear (34) disposed in a second cavity (84) of the second case portion (42), and at least one pinion gear (38) that engages the first gear (32) and the second gear (34).
     


    Ansprüche

    1. Differentialanordnung (10), Folgendes umfassend:
    ein Gehäuse (30) und einen Steg (36), wobei das Gehäuse (30) Folgendes aufweist:

    einen ersten Gehäuseabschnitt (40), der einen ersten Hohlraum (56), eine Außenfläche (70), die um den ersten Hohlraum (56) herum angeordnet ist, eine Stegwellenbohrung (72), die sich von der Außenfläche (70) zum ersten Hohlraum (56) erstreckt, und eine Aussparung (78), die zwischen der Außenfläche (70) und dem ersten Hohlraum (56) angeordnet ist und sich von der Stegwellenbohrung (72) erstreckt, aufweist; und

    einen zweiten Gehäuseabschnitt (42), der auf dem ersten Gehäuseabschnitt (40) angeordnet ist, wobei der zweite Gehäuseabschnitt (42) einen Vorsprung (100) aufweist, der sich durch die Aussparung (78) in die Stegwellenbohrung (72) erstreckt; und

    wobei der Steg (36) Folgendes aufweist:

    eine primäre Stegwelle (130), die auf dem ersten Gehäuseabschnitt (40) montiert ist; und

    eine sekundäre Stegwelle (132), die in der Stegwellenbohrung (72) aufgenommen wird und die sich zwischen der Stegwellenbohrung (72) und der primären Stegwelle (130) erstreckt, wobei die sekundäre Stegwelle (132) eine Haltenut (156) aufweist, die den Vorsprung (100) aufnimmt, um die sekundäre Stegwelle (132) in der Stegwellenbohrung (72) zu halten.


     
    2. Differentialanordnung (10) nach Anspruch 1, wobei das Gehäuse (30) dazu ausgelegt ist, sich um eine Achse (26) zu drehen, und wobei sich die Aussparung (78) kontinuierlich um die Achse (26) erstreckt.
     
    3. Differentialanordnung (10) nach Anspruch 2, wobei sich der Vorsprung (100) kontinuierlich um die Achse (26) erstreckt und bevorzugt in die sekundäre Stegwelle (132) eingreift.
     
    4. Differentialanordnung (10) nach Anspruch 1, wobei die Aussparung (78) von der Außenfläche (70) und dem ersten Hohlraum (56) beabstandet ist.
     
    5. Differentialanordnung (10) nach Anspruch 4, wobei der erste Gehäuseabschnitt (40) ferner eine Innenwand (74) und eine Außenwand (76) umfasst, die zusammenwirken, um die Aussparung (78) zumindest teilweise zu definieren, wobei sich die Innenwand (74) vom ersten Hohlraum (56) zur Aussparung (78) erstreckt und sich die Außenwand (76) von der Außenfläche (70) zur Aussparung (78) erstreckt.
     
    6. Differentialanordnung (10) nach Anspruch 5, wobei der zweite Gehäuseabschnitt (42) einen zweiten Hohlraum (84) aufweist, der sich vom ersten Hohlraum (56) erstreckt, wobei die Innenwand (74) im zweiten Hohlraum (84) aufgenommen wird.
     
    7. Differentialanordnung (10) nach Anspruch 6, wobei das Gehäuse (30) dazu ausgelegt ist, sich um eine Achse (26) zu drehen, und wobei sich die Innenwand (74) und die Außenwand (76) kontinuierlich um die Achse (26) erstrecken und wobei sich der Vorsprung (100) bevorzugt kontinuierlich um die Innenwand (74) des ersten Gehäuseabschnitts (40) erstreckt.
     
    8. Differentialanordnung (10) nach Anspruch 1, wobei die Stegwellenbohrung (72) eine Durchgangsbohrung ist, die vollständig durch den ersten Gehäuseabschnitt (40) definiert wird.
     
    9. Differentialanordnung (10) nach Anspruch 1, ferner ein Ritzel (38) umfassend, das drehbar auf der sekundären Stegwelle (132) angeordnet ist, wobei die sekundäre Stegwelle (132) eine Schmiernut (144) aufweist, die zwischen dem Ritzel (38) und der sekundären Stegwelle (132) angeordnet ist und von der Haltenut (156) getrennt ist.
     
    10. Differentialanordnung (10) nach Anspruch 1, wobei die primäre Stegwelle (130) eine Kerbe (142) aufweist, die ein verjüngtes Ende (152) der sekundären Stegwelle (132) aufnimmt.
     
    11. Differentialanordnung (10) nach Anspruch 1, wobei der erste Gehäuseabschnitt (40) einen Satz Stegwellenbohrungen (72) aufweist, die voneinander beabstandet sind und sich von der Außenfläche (70) zum ersten Hohlraum (56) erstrecken, und wobei sich die Aussparung (78) von jedem Element des Satzes Stegwellenbohrungen (72) erstreckt, wobei sich der Vorsprung (100) in jedes Element des Satzes Stegwellenbohrungen (72) erstreckt, wobei die primäre Stegwelle (130) im ersten und zweiten Element des Satzes Stegwellenbohrungen (72) aufgenommen wird, und wobei die sekundäre Stegwelle (132) in einem dritten Element des Satzes Stegwellenbohrungen (72) aufgenommen wird und sich vom dritten Element zur primären Stegwelle (130) erstreckt.
     
    12. Differentialanordnung (10) nach Anspruch 11, wobei der Steg (36) ferner eine zweite sekundäre Stegwelle (132) umfasst, die in einem vierten Element des Satzes Stegwellenbohrungen (72) aufgenommen wird und sich vom vierten Element zur primären Stegwelle (130) erstreckt, bevorzugt wobei die zweite sekundäre Stegwelle (132) eine Haltenut (156) aufweist, die den Vorsprung (100) aufnimmt und in diesen eingreift, um die zweite sekundäre Stegwelle (132) in der Stegwellenbohrung (72) zu halten.
     
    13. Differentialanordnung (10) nach Anspruch 12, wobei die primäre Stegwelle (130) entlang einer primären Stegwellenachse (140) angeordnet ist und wobei die sekundäre Stegwelle (132) und die zweite sekundäre Stegwelle (132) entlang einer sekundären Stegwellenachse (150) angeordnet sind, bevorzugt wobei die primäre Stegwelle (130) und die primäre Stegwellenachse (140) eine Achse (26) schneiden, um die das Gehäuse (30) drehbar ist.
     
    14. Differentialanordnung (10) nach Anspruch 1, wobei die primäre Stegwelle (130) ein Paar Haltenuten (146) aufweist, die an gegenüberliegende Enden der primären Stegwelle (130) angrenzend angeordnet sind, wobei der Vorsprung (100) in dem Paar Haltenuten (146) aufgenommen wird.
     
    15. Differentialanordnung (10) nach Anspruch 1, ferner ein erstes Zahnrad (32), das im ersten Hohlraum (56) angeordnet ist, ein zweites Zahnrad (34), das in einem zweiten Hohlraum (84) des zweiten Gehäuseabschnitts (42) angeordnet ist und mindestens ein Ritzel (38), das in das erste Zahnrad (32) und das zweite Zahnrad (34) eingreift, umfassend.
     


    Revendications

    1. Ensemble différentiel (10), comprenant :

    un boîtier (30) et un croisillon (36), le boîtier (30) comportant :

    une première partie de boîtier (40) qui présente une première cavité (56), une surface extérieure (70) qui est disposée autour de la première cavité (56), un trou d'arbre à croisillon (72) qui s'étend depuis la surface extérieure (70) jusqu'à la première cavité (56), et un renfoncement (78) disposé entre la surface extérieure (70) et la première cavité (56) et qui s'étend depuis le trou d'arbre à croisillon (72) ; et

    une deuxième partie de boîtier (42) qui est disposée sur la première partie de boîtier (40), la deuxième partie de boîtier (42) présentant une saillie (100) qui s'étend à travers le renfoncement (78) jusque dans le trou d'arbre à croisillon (72) ; et

    le croisillon (36) comportant :

    un arbre à croisillon primaire (130) monté sur la première partie de boîtier (40) ; et

    un arbre à croisillon secondaire (132) reçu dans le trou d'arbre à croisillon (12) et qui s'étend entre le trou d'arbre à croisillon (72) et l'arbre à croisillon primaire (130), l'arbre à croisillon secondaire (132) présentant une rainure de retenue (156) qui reçoit la saillie (100) pour retenir l'arbre à croisillon secondaire (132) dans le trou d'arbre à croisillon (72).


     
    2. Ensemble différentiel (10) selon la revendication 1, dans lequel le boîtier (30) est configuré pour tourner autour d'un axe (26) et le renfoncement (78) s'étend en continu autour de l'axe (26).
     
    3. Ensemble différentiel (10) selon la revendication 2, dans lequel la saillie (100) s'étend en continu autour de l'axe (26) et de préférence vient en prise avec l'arbre à croisillon secondaire (132).
     
    4. Ensemble différentiel (10) selon la revendication 1, dans lequel le renfoncement (78) est espacé de la surface extérieure (70) et de la première cavité (56).
     
    5. Ensemble différentiel (10) selon la revendication 4, dans lequel la première partie de boîtier (40) comprend en outre une paroi intérieure (74) et une paroi extérieure (76) qui coopèrent pour définir au moins en partie le renfoncement (78), la paroi intérieure (74) s'étendant depuis la première cavité (56) jusqu'au renfoncement (78) et la paroi extérieure (76) s'étendant depuis la surface extérieure (70) jusqu'au renfoncement (78).
     
    6. Ensemble différentiel (10) selon la revendication 5, dans lequel la deuxième partie de boîtier (42) présente une deuxième cavité (84) qui s'étend depuis la première cavité (56), la paroi intérieure (74) étant reçue dans la deuxième cavité (84).
     
    7. Ensemble différentiel (10) selon la revendication 6, dans lequel le boîtier (30) est configuré pour tourner autour d'un axe (26) et la paroi intérieure (74) et la paroi extérieure (76) s'étendent en continu autour de l'axe (26) et de préférence la saillie (100) s'étend en continu autour de la paroi intérieure (74) de la première partie de boîtier (40).
     
    8. Ensemble différentiel (10) selon la revendication 1, dans lequel le trou d'arbre à croisillon (72) est un trou traversant qui est complètement défini dans la première partie de boîtier (40).
     
    9. Ensemble différentiel (10) selon la revendication 1, comprenant en outre un engrenage à pignon (38) qui est disposé de manière rotative sur l'arbre à croisillon secondaire (132), l'arbre à croisillon secondaire (132) présentant une rainure de lubrifiant (144) qui est disposée entre l'engrenage à pignon (38) et l'arbre à croisillon secondaire (132) et qui est séparée de la rainure de retenue (156).
     
    10. Ensemble différentiel (10) selon la revendication 1, dans lequel l'arbre à croisillon primaire (130) présente une encoche (142) qui reçoit une extrémité effilée (152) de l'arbre à croisillon secondaire (132).
     
    11. Ensemble différentiel (10) selon la revendication 1, dans lequel la première partie de boîtier (40) comporte un ensemble de trous d'arbre à croisillon (72) qui sont espacés les uns des autres et qui s'étendent depuis la surface extérieure (70) jusqu'à la première cavité (56), et le renfoncement (78) s'étend depuis chaque élément de l'ensemble de trous d'arbre à croisillon (72), la saillie (100) s'étend dans chaque élément de l'ensemble de trous d'arbre à croisillon (72), l'arbre à croisillon primaire (130) est reçu dans des premier et deuxième éléments de l'ensemble de trous d'arbre à croisillon (72), et l'arbre à croisillon secondaire (132) est reçu dans un troisième élément de l'ensemble de trous d'arbre à croisillon (72) et s'étend depuis le troisième élément jusqu'à l'arbre à croisillon primaire (130).
     
    12. Ensemble différentiel (10) selon la revendication 11, dans lequel le croisillon (36) comprend en outre un deuxième arbre à croisillon secondaire (132) qui est reçu dans un quatrième élément de l'ensemble de trous d'arbre à croisillon (72) et qui s'étend depuis le quatrième élément jusqu'à l'arbre à croisillon primaire (130), de préférence dans lequel le deuxième arbre à croisillon secondaire (132) présente une rainure de retenue (156) qui reçoit et vient en prise avec la saillie (100) pour retenir le deuxième arbre à croisillon secondaire (132) dans le trou d'arbre à croisillon (72).
     
    13. Ensemble différentiel (10) selon la revendication 12, dans lequel l'arbre à croisillon primaire (130) est disposé le long d'un axe d'arbre à croisillon primaire (140) et l'arbre à croisillon secondaire (132) et le deuxième arbre à croisillon secondaire (132) sont disposés le long d'un axe d'arbre à croisillon secondaire (150), de préférence dans lequel l'arbre à croisillon primaire (130) et l'axe d'arbre à croisillon primaire (140) coupent tous les deux un axe (32) autour duquel peut tourner le boîtier (30).
     
    14. Ensemble différentiel (10) selon la revendication 1, dans lequel l'arbre à croisillon primaire (130) présente une paire de rainures de retenue (146) disposées à proximité d'extrémités opposées de l'arbre à croisillon primaire (130), la saillie (100) étant reçue dans la paire de rainures de retenue (146).
     
    15. Ensemble différentiel (10) selon la revendication 1, comprenant en outre un premier engrenage (32) disposé dans la première cavité (56), un deuxième engrenage (34) disposée dans une deuxième cavité (84) de la deuxième partie de boîtier (42) et au moins un engrenage à pignon (38) qui vient en prise avec le premier engrenage (32) et le deuxième engrenage (34).
     




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    Cited references

    REFERENCES CITED IN THE DESCRIPTION



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    Patent documents cited in the description