Disconnect clutch for differential

Abstract

A differential for a vehicle includes a final drive gear having a final drive gear spline, a differential carrier having a differential carrier spline, and an axially slidable clutch. The axially slidable clutch includes a first clutch spline drivingly engaged with one of the final drive gear spline or the differential carrier spline, and a second clutch spline drivingly engaged with the other of the final drive gear spline or the differential carrier spline. And the second clutch spline is configured to selectively drivingly engage with the other of the final drive gear spline or the differential carrier spline. In an example embodiment, the differential further includes a pair of side gears, each including an internal spline for drivingly engaging with a respective axle shaft; a pair of radially offset star gears, each of which is drivingly engaged with two of the side gears; and a shaft extending through the pair of radially offset spider gears into the differential carrier.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 417,314 filed on October 18, 2022 and U.S. Non-Provisional Patent Application No. 18 / 102,347 filed on January 27, 2023, the entire disclosures of both U.S. patent applications are incorporated herein by reference. Technical Field

[0003] The present disclosure relates generally to differentials for vehicles and, more particularly, to disconnect clutches for differentials. Background Art

[0004] Disconnect clutches for differentials are known. Examples are shown in U.S. Patent No. 11,186,168 to Kim et al., entitled "POWER TRAIN FOR VEHICLE" and U.S. Patent No. 9,649,931 to Zhao, entitled "VEHICLE DIFFERRENTIAL ASSEMBLY." Summary of the invention

[0005] A differential for a vehicle, the differential comprising: a final drive gear having a final drive gear spline, a differential carrier having a differential carrier spline, and an axially slidable clutch. The axially slidable clutch comprises a first clutch spline and a second clutch spline, the first clutch spline drivingly engaging with one of the final drive gear spline or the differential carrier spline, and the second clutch spline is for selectively drivingly engaging with the other of the final drive gear spline or the differential carrier spline. In an example embodiment, the differential further comprises: a pair of side gears, each of the side gears comprising an internal spline for drivingly engaging with a corresponding axle shaft; a pair of radially offset spider gears, each of the radially offset spider gears drivingly engaging with two of the side gears; and a shaft extending through the pair of radially offset spider gears into the differential carrier.

[0006] In some example embodiments, the axially slidable clutch further comprises an annular portion having a circumferential recess arranged to receive a shift fork. In some example embodiments, the differential further comprises a shift fork engaged in the circumferential recess for axially displacing the axially slidable clutch to engage and disengage the second clutch spline with the other of the final drive gear spline or the differential carrier spline. In example embodiments, the differential further comprises a threaded shaft. The shift fork has a threaded portion, the threaded shaft is mounted in the threaded portion, and rotation of the threaded shaft in the threaded portion causes the shift fork to pivot.

[0007] In some example embodiments, the first clutch spline faces radially inward and the second clutch spline faces radially outward. In some example embodiments, the first clutch spline is drivingly engaged with the differential carrier spline, and the second clutch spline is selectively drivingly engaged with the final drive gear spline. In example embodiments, the final drive gear has a drive gear portion and a spline portion, the spline portion having a cylindrical portion fixed to the drive gear portion, and a radially inwardly extending protrusion including the final drive gear spline. In some example embodiments, the differential further includes a bearing. The final drive gear is rotatably supported on the differential carrier by the bearing. In example embodiments, the bearing is a double row ball bearing.

[0008] In some example embodiments, the first clutch spline is selectively drivingly engaged with the differential carrier spline, and the second clutch spline is drivingly engaged with the final drive gear spline. In some example embodiments, the final drive gear includes a drive gear portion and a differential housing fixed to the drive gear portion. The differential housing includes the final drive gear spline. In example embodiments, the differential housing surrounds the differential carrier.

[0009] In some example embodiments, the differential housing includes a first differential housing half having a first radial wall, and a second differential housing half having a second radial wall in contact with the first radial wall. In example embodiments, the first radial wall and the second radial wall extend radially outward, and the drive gear portion has a radially inwardly extending protrusion that is radially aligned with the first radial wall and the second radial wall. In example embodiments, the differential also includes a bushing, and the differential housing is rotatably supported on the differential carrier by the bushing. In example embodiments, the differential housing has a plurality of openings, and the axially slidable clutch has a plurality of axial protrusions extending through corresponding openings of the plurality of openings. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 A cross-sectional view of a first embodiment of a differential according to an example aspect of the present disclosure is illustrated.

[0011] Figure 2 A perspective cross-sectional view of a second embodiment of a differential according to an example aspect of the present disclosure is illustrated.

[0012] Figure 3 yes Figure 2 An end view of the embodiment shown in , showing an axially slidable clutch disposed between the final drive gear splines and the differential carrier splines. DETAILED DESCRIPTION

[0013] Embodiments of the present disclosure are described herein. It should be understood that similar reference numerals appearing in different figures indicate identical or functionally similar structural elements. In addition, it should be understood that the disclosed embodiments are examples only, and other embodiments may take various forms and alternative forms. The drawings are not necessarily drawn to scale; some features may be exaggerated or minimized to show the details of specific components. Therefore, the specific structural and functional details disclosed herein should not be interpreted as restrictive, but only as a representative basis for teaching those skilled in the art to adopt embodiments in various ways. As will be understood by those of ordinary skill in the art, the various features illustrated and described with reference to any of the drawings in the drawings may be combined with the features illustrated in one or more other drawings to produce embodiments that are not explicitly illustrated or described. The combination of the illustrated features provides representative embodiments for typical applications. However, for specific applications or implementations, various combinations and modifications of features consistent with the teachings of the present disclosure may be desired.

[0014] The terms used herein are only for the purpose of describing specific aspects and are not intended to limit the scope of the present disclosure. Unless otherwise specified, all technical terms and scientific terms used herein have the same meaning as those generally understood by those of ordinary skill in the art to which the present disclosure belongs. Although any method, device or material similar or equivalent to those described herein can be used in the practice or testing of the present disclosure, the following example methods, devices and materials will now be described.

[0015] Reference Figure 1 The following description is given. Figure 1A cross-sectional view of a differential 100 is illustrated. The differential 100 for a vehicle (not shown) includes a final drive gear 102 having a final drive gear spline 104, a differential carrier 106 having a differential carrier spline 108, and an axially slidable clutch 110. The axially slidable clutch includes a first clutch spline 112 drivingly engaged with the spline 108, and a second clutch spline 114 for selectively drivingly engaging with the spline 104, as described in more detail below. The differential 100 also includes side gears 116, each of which has an internal spline 118 for drivingly engaging with a corresponding axle shaft (not shown); and radially offset spider gears 120, each of which is drivingly engaged with two of the side gears; and a shaft 122, which extends through the radially offset spider gears into the differential carrier. For example, the shaft 122 can be fixed in the differential carrier by a pin installed in a hole 123.

[0016] The axially slidable clutch comprises an annular portion 124 having a circumferential recess 126 arranged to receive a shift fork 128. The shift fork engages in the circumferential recess for axially displacing the axially slidable clutch when pivoting on a pivot shaft 130, thereby engaging and disengaging the second clutch spline 114 with the spline 104. That is, the axially slidable clutch is axially displaced when the shift fork pivots. The differential 100 also includes a threaded shaft 132. The shift fork comprises a threaded portion 134, for example, which is arranged as a nut that can pivot in the shift fork. The threaded shaft is mounted in the threaded portion, and the rotation of the threaded shaft in the threaded portion causes the shift fork to pivot. For example, the threaded shaft 132 is supported by a bearing 133 and driven by an electric motor 135.

[0017] like Figure 1 As shown in , the first clutch splines 112 face radially inwardly, and the second clutch splines 114 face radially outwardly. The first clutch splines 112 are drivingly engaged with the differential carrier splines 108, and the second clutch splines 114 are selectively drivingly engaged with the final drive gear splines 104. The final drive gear 102 includes a drive gear portion 136 and a spline portion 138. The spline portion includes a cylindrical portion 140 fixed to the drive gear portion (for example, by welding), and a radially inwardly extending protrusion 142 having a final drive gear spline. The differential 100 also includes a bearing 144, and the final drive gear is rotatably supported on the differential carrier by the bearing. As shown in FIG. Figure 1Bearing 144 is shown as a double row angular contact ball bearing, but other bearing types (such as tapered roller bearings) may be used. Bearing 146, shown as a ball bearing, and bearing 148, shown as a cylindrical roller bearing, support the differential carrier in the axle housing (not shown).

[0018] Reference Figure 2 The following description is given. Figure 2 A perspective cross-sectional view of a differential 200 is illustrated. The differential 200 for a vehicle (not shown) includes a final drive gear 202 having a final drive gear spline 204, a differential carrier 206 having a differential carrier spline 208, and an axially slidable clutch 210. The axially slidable clutch includes a first clutch spline 212 drivingly engaged with the spline 204, and a second clutch spline 214 for selectively drivingly engaging with the spline 208, as described in more detail below. The differential 200 also includes side gears 216, each having an internal spline 218 for drivingly engaging with a corresponding axle shaft (not shown); and radially offset spider gears 220, each drivingly engaged with two of the side gears; and a shaft 222 extending through the radially offset spider gears into the differential carrier.

[0019] The axially slidable clutch includes an annular portion 224 having a circumferential recess 226 arranged to receive a shift fork (not shown). The shift fork engages in the circumferential recess for axially displacing the axially slidable clutch to engage and disengage the splines 214 with the splines 208. The differential also includes a threaded shaft (not shown). The shift fork has a threaded portion (not shown) in which the threaded shaft is mounted and rotation of the threaded shaft in the threaded portion pivots the shift fork. The shift fork of the differential 200 is generally of the same configuration as the shift fork 128 of the differential 100 described above.

[0020] Reference Figures 2 to 3 The following description is given. Figure 3 is an end view showing an axially slidable clutch disposed between the final drive gear splines and the differential carrier splines. Figure 2 As shown in , clutch splines 212 are drivingly engaged with the final drive gear splines, and clutch splines 214 are selectively drivingly engaged with the differential carrier splines. Figure 3As shown in , splines 204 and 208 have a generally wavy profile with a nearly constant thickness therebetween. It should be noted that the inner diameter of the final drive gear splines is greater than the outer diameter of the differential carrier splines. In other words, if the axially slidable clutch is removed, the final drive gear splines will rotate relative to the differential carrier splines even if they overlap axially. The configuration of the axially slidable clutch is similar to the sleeve 52 shown and described in U.S. Patent No. 10,883,548 to Lee, entitled "ELECTRIC AXLE WITH DIFFERENTIAL SUN GEAR DISCONNECT CLUTCH", which U.S. patent disclosure is incorporated herein by reference as if fully set forth.

[0021] The final drive gear 202 includes a drive gear portion 228 and a differential housing 230 secured to the drive gear portion (eg, by bolts, which are not shown). The differential housing includes a final drive gear spline. Figure 2 As shown in , the differential housing 230 surrounds the differential carrier 206. The differential housing 230 includes a first differential housing half 232 having a first radial wall 234, and a second differential housing half 236 having a second radial wall 238 in contact with the first radial wall 234. The first radial wall and the second radial wall extend radially outward, and the drive gear portion has a radially inwardly extending protrusion 240, which is radially aligned with the first radial wall and the second radial wall. By radially aligned, it is meant that a line drawn orthogonal to the radial direction passes through the protrusion 240 and the radial walls 234 and 238.

[0022] The differential 200 also includes bushings 242 and 244 located on opposite axial sides of the differential carrier. The differential carrier is axially and rotatably supported in the differential housing by the bushings. Bearings 246, shown as ball bearings, and bearings 248, shown as cylindrical roller bearings, support the differential housing in the axle housing (not shown).

[0023] The differential case 230 includes an opening 250, and the axially slidable clutch includes an axial protrusion 252 extending through the corresponding opening 250. The annular portion 224 includes a recess 254 for receiving the axial protrusion. A snap ring 256 is installed in the corresponding grooves of the axial protrusion and the annular portion to axially position the axial protrusion in the annular portion. The protrusion connects the spline portion 258 of the axially slidable clutch to the annular portion 224.

[0024] Although exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms covered by the claims. The words used in the specification are descriptive rather than restrictive, and it should be understood that various changes can be made without departing from the spirit and scope of the present disclosure. As previously described, the features of various embodiments can be combined to form other embodiments of the present disclosure that may not be explicitly described or illustrated. Although various embodiments may have been described as providing advantages or being superior to other embodiments or prior art implementations in terms of one or more desired characteristics, it is recognized by those of ordinary skill in the art that one or more features or characteristics can be compromised to achieve the desired overall system properties, depending on the specific application and implementation. These properties may include, but are not limited to, cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, maintainability, weight, manufacturability, ease of assembly, etc. Therefore, to the extent that any embodiment is described as being less desirable than other embodiments or prior art implementations in terms of one or more characteristics, these embodiments do not exceed the scope of the present disclosure and may be desirable for specific applications.

[0025] Reference numerals list

[0026] 100 Differential

[0027] 102 Final drive gear

[0028] 104 Final drive gear spline

[0029] 106 Differential carrier

[0030] 108 Differential carrier spline

[0031] 110 Axially slidable clutch

[0032] 112 First clutch spline

[0033] 114 Second clutch spline

[0034] 116 Side gear

[0035] 118 Internal spline

[0036] 120 Radially offset star gear

[0037] 122 Axis

[0038] 123 holes

[0039] 124 Ring part

[0040] 126 Circumferential notch

[0041] 128 Shift fork

[0042] 130 Pivot shaft

[0043] 132 with threaded shaft

[0044] 133 Bearing

[0045] 134 Threaded part

[0046] 135 Electric Motor

[0047] 136 driving gear part

[0048] 138 Spline part

[0049] 140 cylindrical part

[0050] 142 radially inwardly extending protrusion

[0051] 144 Bearings

[0052] 146 Bearings

[0053] 148 Bearings

[0054] 200 Differential

[0055] 202 Final drive gear

[0056] 204 Final drive gear spline

[0057] 206 Differential carrier

[0058] 208 Differential carrier spline

[0059] 210 Axially slidable clutch

[0060] 212 First clutch spline

[0061] 214 Second clutch spline

[0062] 216 Side gear

[0063] 218 Internal spline

[0064] 220 Radially offset star gear

[0065] 222 Axis

[0066] 224 Ring part

[0067] 226 Circumferential notch

[0068] 228 driving gear part

[0069] 230 Differential housing

[0070] 232 First differential case half

[0071] 234 First radial wall

[0072] 236 Second differential case half

[0073] 238 Second radial wall

[0074] 240 radially inwardly extending protrusion

[0075] 242 Bushing

[0076] 244 Bushing

[0077] 246 Bearings

[0078] 248 Bearings

[0079] 250 Opening

[0080] 252 Axial protrusion

[0081] 254 recess

[0082] 256 Snap ring

[0083] 258 Spline part

Claims

1. A differential for a vehicle, the differential comprising: a final drive gear, the final drive gear comprising a final drive gear spline; a differential carrier, the differential carrier comprising differential carrier splines; as well as An axially slidable clutch, the axially slidable clutch comprising: a first clutch spline drivingly engaged with one of the final drive gear splines or the differential carrier splines; as well as A second clutch spline for selective driving engagement with the other of the final drive gear splines or the differential carrier splines.

2. The differential according to claim 1, further comprising: a pair of side gears, each of the side gears including internal splines for drivingly engaging a corresponding axle shaft; a pair of radially offset spider gears, each of the radially offset spider gears drivingly engaging two of the side gears; as well as A shaft extends through a pair of the radially offset spider gears and into the differential carrier.

3. The differential according to claim 1, wherein: The axially slidable clutch further includes an annular portion having a circumferential recess arranged to receive a shift fork.

4. The differential of claim 3 further comprising the shift fork engaged in the circumferential recess for axially displacing the axially slidable clutch to engage and disengage the second clutch splines with the other of the final drive gear splines or the differential carrier splines.

5. The differential of claim 4 further comprising a threaded shaft, wherein: The shift fork includes a threaded portion; The threaded shaft is mounted in the threaded portion; and Rotation of the threaded shaft in the threaded portion causes the shift fork to pivot.

6. The differential according to claim 1, wherein: The first clutch splines face radially inwardly, and the second clutch splines face radially outwardly.

7. The differential according to claim 6, wherein: The first clutch splines are drivingly engaged with the differential carrier splines, and the second clutch splines are selectively drivingly engaged with the final drive gear splines.

8. The differential according to claim 7, wherein: The final drive gear comprises: a drive gear portion; and A spline portion includes a cylindrical portion fixed to the drive gear portion and a radially inwardly extending projection having the final drive gear splines.

9. The differential according to claim 7, further comprising a bearing, wherein: The final drive gear is rotatably supported on the differential carrier via the bearing.

10. The differential according to claim 9, wherein: The bearing is a double row ball bearing.

11. The differential according to claim 6, wherein: The first clutch splines are selectively drivingly engaged with the differential carrier splines, and the second clutch splines are drivingly engaged with the final drive gear splines.

12. The differential according to claim 11, wherein: The final drive gear comprises: a driving gear portion; and A differential housing is secured to the drive gear portion and includes the final drive gear splines.

13. The differential according to claim 12, wherein: The differential housing surrounds the differential carrier.

14. The differential according to claim 12, wherein: The differential housing comprises: a first differential housing half, the first differential housing half comprising a first radial wall; and A second differential housing half includes a second radial wall in contact with the first radial wall.

15. The differential of claim 14, wherein: The first radial wall and the second radial wall extend radially outward; and The drive gear portion includes a radially inwardly extending protrusion that is radially aligned with the first radial wall and the second radial wall.

16. The differential of claim 12, further comprising a bushing, wherein the differential housing is rotatably supported on the differential carrier via the bushing.

17. The differential of claim 12, wherein: The differential housing includes a plurality of openings; and The axially slidable clutch includes a plurality of axial protrusions extending through corresponding ones of the plurality of apertures.

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