Split rear differential unit

Abstract

System, comprehensive: a split differential housing which is divided in two on an axis in a vertical plane, wherein the split differential housing comprises a first housing element which is coupled to a second housing element at an interface centered in the vertical plane, the axis being coaxial with a central axis of a drive axle.

Description

TECHNICAL AREA

[0001] A rear axle with independent suspension that can be split at the differential housing. The differential and differential housing can be compatible with both front-wheel drive and all-wheel drive systems. BACKGROUND AND SUMMARY

[0002] Vehicles such as sport utility vehicles (SUVs) or sedans may have front-wheel drive (FWD) to some extent to improve the vehicle's handling on the road. Such applications can include the use of FWD as part of a four-wheel drive (AWD) system with a rear drive unit (RDU). In an urban environment, for example, FWD can improve control on a road that is less navigable due to road damage, vehicle speed, or environmental conditions such as rain, snow, or ice.

[0003] In some cases, a vehicle, such as an SUV, may have a chassis with more limited space for a rear-mounted duplex unit (RDU). For example, an SUV chassis may have more material and supporting elements compared to a sedan, thus reducing the available installation space for a front-wheel-drive (FWD) RDU. A differential, such as a rear differential for an RDU, may utilize a variety of mounts, as well as a cap and cover, as part of a monolithic housing. Elements like the cap and cover, along with the mount flanges, can increase the packaging required for mounting the differential housing.

[0004] The inventors here have recognized these and other problems with such systems and found a way to solve them, at least partially. In one example, a system is developed that includes a split differential housing, divided in two along an axis on a vertical plane. The split differential housing comprises a first housing element coupled to a second housing element at an interface centered on the vertical plane, with the axis being coaxial with the center axis of a drive axle. In this way, the split housing design can be more compact compared to a one-piece differential housing formed from a single, complete shell, thus enabling the use of a rear differential unit in chassis with limited space, such as the chassis of an off-road vehicle.

[0005] It is understood that the above summary serves to present, in simplified form, a selection of concepts that are explained in more detail in the full description. It is not intended to identify the main or essential features of the claimed subject matter, the scope of which is clearly defined by the claims that follow the detailed description. Furthermore, the claimed subject matter is not limited to implementations that overcome the disadvantages mentioned above or elsewhere in this disclosure. BRIEF DESCRIPTION OF THE FIGURES Fig. Figure 1 shows an exemplary schematic representation of a vehicle which may contain a transmission of the present disclosure as part of the power transmission. Fig. Figure 2 shows an embodiment of a uniform housing for a rear differential of the prior art. Fig. Figure 3 shows a first example of a split housing of the differential of the present disclosure. Fig. Figure 4 shows a second example of a split housing of a differential of the present disclosure. DETAILED DESCRIPTION

[0006] The following description refers to a differential housing. The housing may be an axle carrier, such as a variant of the Salisbury axle, a solid axle design with a central differential housed within the axle carrier, which distributes torque between the wheels. A split differential housing is a housing divided into two parts on a vertical plane. The split differential housing comprises a first housing element coupled to a second housing element at an interface centered on the vertical plane, with the axle being coaxial with the center axis of a drive axle. The split differential housing may be mounted around the components of a differential, thereby enclosing or partially enclosing them. The differential may be a rear differential unit used for a rear axle.

[0007] The rear differential unit can provide rear-wheel drive (RWD) for a vehicle. A vehicle's steering wheel can generate rotational energy and transmit that energy as torque to the rear differential via at least one first driveshaft. The vehicle may also have a front differential. The front differential may be housed in a third casing, which is an axle carrier. This third casing is separate from the split differential casing. The front differential can, in a sense, provide front-wheel drive (FWD) to the vehicle. The front and rear differentials can also provide FWD and RWD modes as part of an all-wheel drive (AWD) system for the vehicle, which can be referred to here as the AWD mode.

[0008] Fig. Figure 1 shows an exemplary schematic representation of a vehicle which may contain a transmission of the present disclosure as part of the power transmission. Fig. Figure 2 shows an example of a uniform housing for a rear differential of the state of the art. Fig. Figure 3 shows a first example of a split housing of the differential of the present disclosure. Fig. Figure 4 shows a second example of a split housing of a differential of the present disclosure.

[0009] It is understood that the specific arrangements and systems shown in the accompanying drawings and described in the following description are exemplary embodiments of the inventive concepts defined herein. For the sake of clarity, the drawings are described together. Therefore, identical elements can be designated with the same reference numerals and need not be introduced again.

[0010] Fig. Figure 1 shows a schematic representation of an example configuration with the relative positioning of the different components. Fig. Figure 2 shows an example configuration of the state of the art with approximate positioning. Fig. Figures 3 to 4 show example configurations with approximate positioning. Fig. Figures 2 to 4 are shown approximately to scale; however, other relative dimensions may also be used. Unless otherwise stated, the term "approximately" means plus or minus five percent of the range.

[0011] Furthermore, Fig. 1-4 Examples of configurations with relative positioning of the various components. If it is shown that these elements are directly touching or directly coupled, they can be described as directly touching or directly coupled, respectively, in at least one example. Similarly, elements shown side by side or adjacent to each other can be described as being adjacent to each other or adjacent to each other, respectively, in at least one example. For instance, components that are in planar contact with each other can be described as being in planar contact. As another example, elements that are separated from each other, with only a gap between them and that have no other components, can be described as such in at least one case.In yet another example, elements that are displayed above / below each other, on opposite sides, or to the left / right of each other can be described as such, relative to one another. Furthermore, in at least one example, as shown in the figures, a topmost element or the highest point of an element can be referred to as the "top" of the component, and a bottommost element or the lowest point of the element can be referred to as the "bottom" of the component. The terms top / bottom, upper / lower, and above / below used here can refer to a vertical axis of the figures and be used to describe the positioning of elements within the figures relative to each other. Thus, in one example, elements displayed above other elements are arranged vertically above the other elements.As a further example, the shapes of the elements depicted in the figures can be described as such (e.g., circular, straight, planar, curved, rounded, beveled, angled, etc.). Furthermore, the depicted elements that intersect each other can be described as intersecting elements or mutually intersecting elements in at least one example. In addition, an element depicted inside or outside another element can be described as such. Finally, the components can be described with respect to the reference axes included in the drawings.

[0012] Features described as axial can be approximately parallel to a datum axis unless otherwise specified. Features described as counter-rotating can be approximately perpendicular to the datum axis unless otherwise specified. Features described as radial can circumferentially surround or extend outward from an axis, such as the datum axis, or a component or feature previously described as radial to a datum axis, unless otherwise specified.

[0013] Features described as longitudinal can run approximately parallel to a longitudinal axis. A transverse axis can run perpendicular to the longitudinal axis. Features described as lateral can run approximately parallel to the transverse axis and perpendicular to the longitudinal axis.

[0014] In Fig. Figure 1 shows a vehicle 100 comprising a powertrain 101 and a transmission 103. The powertrain includes a drive motor 106 and a transmission 108. The drive motor 106 can be, for example, an internal combustion engine (ICE) or an electric motor and is operated to supply the transmission 108 with torque. The transmission 108 can be any type of transmission, such as a manual transmission, an automatic transmission, or a continuously variable transmission (CVT). The transmission 108 receives the torque generated by the drive motor 106 as input and transmits the torque to the transmission 103 according to a selected gear or setting. In addition to the drive motor 106, other persons may also be in the vehicle.In one example, the drive machine 106 is an internal combustion engine, and there is at least one second drive machine with an input to the transmission 108, where the second drive machine can be an electric machine such as an electric motor. The vehicle 100 can have a longitudinal axis 130. The drive train 101 and the drive train 103 can have a length parallel to the longitudinal axis 130. The vehicle 100 can also have a front 132 and a rear 134.

[0015] The drive motor 106 can be powered by energy from an energy storage device 105. In one example, the energy storage device 105 is a battery configured to store electrical energy. An inverter 107 can be arranged between the energy storage device 105 and the drive motor 106 and configured to convert direct current (DC) to alternating current (AC). The inverter 107 can include a variety of components and circuits with thermal requirements that affect the inverter's efficiency.

[0016] Vehicle 100 can be a commercial vehicle, a light, medium, or heavy commercial vehicle, a passenger vehicle, a vehicle not intended for road use, or an off-road vehicle. Additionally or alternatively, Vehicle 100 and / or one or more of its components can be used in industry, locomotives, the military, agriculture, and aerospace. In one example, Vehicle 100 is a fully electric vehicle or a vehicle with a fully electric operating mode, such as a plug-in hybrid vehicle. Thus, Drive Machine 106 is an electric machine. In one example, Drive Machine 106 is an electric motor / generator.

[0017] In some examples, such as in Fig. As shown in Figure 1, the drivetrain 103 includes a first axle assembly 102 and a second axle assembly 112. The first axle assembly 102 can be configured to drive a first set of wheels 104, and the second axle assembly 112 can be configured to drive a second set of wheels 114. In one example, the first axle assembly 102 is located near the front of the vehicle 100 and therefore comprises a front axle, and the second axle assembly 112 is located near the rear of the vehicle 100 and therefore comprises a rear axle. The first axle assembly 102 can be located closer to the front 132 than to the rear 134. The second axle assembly 112 can be located closer to the rear 134 than to the front 132. The drivetrain 103 is a front-wheel drive with all-wheel drive. The drive motors of the vehicle 100, e.g., the B.The rotational energy generated by the drive motor 106 can be transferred to the first axle arrangement 102 at the front of the vehicle 100. The transmission 103 is shown in an all-wheel-drive configuration, although other configurations are also possible. For example, the drive train 103 can have a rear-wheel drive or an all-wheel-drive configuration. Furthermore, the transmission 103 can include one or more tandem axle arrangements. Thus, the transmission 103 can also have other configurations without deviating from the scope of this disclosure, and those described in [reference to relevant section]. Fig. The configuration shown is for illustrative purposes only and does not represent a limitation. The vehicle can also include 100 additional wheels that are not connected to the transmission 103.

[0018] In some all-wheel drive configurations, such as in Fig. As shown in Figure 1, the transmission 103 includes a transfer case 110, which is configured to receive the torque output from the transmission 108. A first drive shaft 113 is connected to a first output 111 of the transfer case 110, while a second drive shaft 122 is connected to a second output 121 of the transfer case 110. The first drive shaft 113 (e.g., a front drive shaft) transmits the torque from the transfer case 110 to a first differential unit 116 of the first axle assembly 102 to drive the first wheelset 104, while the second drive shaft 122 (e.g., a rear drive shaft) transmits the torque from the transfer case 110 to a second differential unit 126 of the second axle assembly 112 to drive the second wheelset 114. For example, the first differential unit 116 is driven by a first axle half-shaft and a second axle half-shaft, e.g.The first set of axle shafts 118 is connected to the first set of wheels 104. The second differential unit 126 is drive-coupled to a first axle half-shaft and a second axle half-shaft, e.g., a second set of axle shafts 128, which are connected to the second set of wheels 114. The first set of axle shafts 118 and the second set of axle shafts 128 can each rotate about an axis of rotation. For example, the axis of rotation of the first axle assembly 102 can be a first axis of rotation 127, and the axis of rotation of the second axle assembly 112 can be a second axis of rotation 129. It is understood that the first set of axle shafts 118 and the second set of axle shafts 128 can be arranged in a housing. The first drive shaft 113 and the second drive shaft 122 can be arranged to extend parallel to the longitudinal axis 130.In one example configuration of vehicle 100, the second drive shaft 122 can be centered around the longitudinal axis 130. The second differential unit 126 can be part of a rear differential unit.

[0019] The first differential unit 116 can provide the vehicle 100 with a certain degree of all-wheel drive as part of the torque transmitted via the first drive shaft 113. Likewise, the second differential unit 126 can provide the vehicle 100 with rear-wheel drive as part of the torque transmitted via the second drive shaft 122. The first differential unit 116 and the second differential unit 126 can provide the vehicle 100 with a front-wheel drive (FWD) or rear-wheel drive (RWD) mode, respectively, as part of an all-wheel drive (AWD) mode.

[0020] In some examples, the vehicle 100 may additionally or alternatively be a hybrid vehicle that includes both an internal combustion engine and an electric machine, each configured to supply power to one or more of the first axle assembly 102 and the second axle assembly 112. For example, one or both of the first axle assembly 102 and the second axle assembly 112 may, in a first operating mode where the electric machine is not operated to provide power (e.g., a combustion-only mode), be powered by power from the internal combustion engine; in a second operating mode where the internal combustion engine is not operated to provide power (e.g., a fully electric mode), be powered by power from the electric machine; and in a third operating mode (e.g.,in an electrically assisted mode) by means of power derived from both the internal combustion engine and the electric machine. In another example, one or both of the first axle arrangement 102 and the second axle arrangement 112 can be an electric axle arrangement configured to be driven by an integrated electric machine.

[0021] In some examples, the transmission 108 may additionally or alternatively be a first transmission that also includes a second transmission arranged on the second set of axle shafts 128. In this context, the transmission 108 can also be referred to as a gear transmission.

[0022] A set of reference axes 201 is used for comparing views that are in Fig. Figures 2-4 are provided. The reference axes 201 specify a y-axis, an x-axis, and a z-axis. In an example, the z-axis can be parallel to a direction of gravity, and the xy-plane can be parallel to a horizontal plane on which a differential housing assembly 202, a first differential housing assembly 302, and a second differential housing assembly 402 can rest. When specifying the direction, positive can refer to the arrow direction of the y-axis, x-axis, and z-axis, and negative to the opposite arrow direction of the y-axis, x-axis, and z-axis. A filled circle can represent an arrow and axis pointing toward or positive to a view. An unfilled circle can represent an arrow and axis pointing away from or negative to a view.

[0023] Fig. Figure 2 shows a first view 200 of an example of a differential housing arrangement 202 of the prior art. The differential housing arrangement 202 can be centered about an axis 212. The axis 212 can be a longitudinal axis for the differential housing arrangement 202. The axis 212 can run parallel or collinearly to a vehicle longitudinal axis, such as the longitudinal axis 130 of the vehicle 100 in Figure 2. Fig. 1. The differential housing assembly 202 can have a first side 204, a second side 206, a third side 208, and a fourth side 210. The third side 208 can serve as the front end of the differential housing assembly 202. The fourth side 210 can serve as the rear end of the differential housing assembly 202. The differential housing assembly 202 is a rear differential housing, such as a rear axle carrier, and can accommodate a rear differential of a vehicle.

[0024] The prior art differential housing assembly 202 has a housing 214 and a cap 216 that can enclose the components of the rear differential. The housing 214 can be a single unit that forms a shell around the components of the differential housing. The housing 214 can be connected to the cap 216 at an interface 221. A first flange 218 of the cap 216 and a second flange 220 of the housing 214 can be attached at the interface 221. The first flange 218 can be attached to the second flange 220 by means of a plurality of fasteners 244. A first bracket 222 and a second bracket 224 can be attached to the housing 214. The first bracket 222 can be attached to the first side 204 on a surface of a plurality of first extensions 226 of the housing 214.The second bracket 224 can be attached to the second side 206 on a surface of a plurality of second extensions 228 of the housing 214. The first bracket 222 and the second bracket 224 are connected to the housing 214 on opposite sides of the cap 216 relative to the axis 212, with the mounting surfaces of the brackets being substantially aligned with the cap 216. The first bracket 222 and the second bracket 224 can secure the differential housing assembly 202 to components of a vehicle, such as the vehicle 100. Fig. 1. Attach.

[0025] The differential housing assembly 202 can be an example of a support incorporated in a Salisbury axle. While conventional Salisbury axles, including the differential housing assembly 202, are suitable for some heavy-duty applications, they can be bulky and / or heavy, posing a packaging problem for vehicles with space and / or weight restrictions. Another challenge is that designs such as the differential housing assembly 202 may exhibit impaired sealing between the housing 214 and the cover 216 at the differential housing bearing bore (not shown, but see hole 318 in [reference missing]). Fig. 3 for a bearing bore of the differential housing of the described housing). The exposed split differential housing offers a durable and significantly more compact design, thereby resolving some of the problems associated with packaging, weight, and sealing capability.

[0026] Fig. Figure 3 shows an example 300 of a first differential housing assembly 302 according to the present disclosure. The first differential housing assembly 302 can be centered about the axis 212. The axis 212 can serve as the longitudinal axis for the first differential housing assembly 302. An axis 311 can extend perpendicular to the axis 212. The axis 311 can serve as the axis on which an axle shaft is centered, e.g., a central axis of a drive axle when it is drive-connected to the first differential housing assembly 302. The first differential housing assembly 302 can have a first side 304, a second side 306, a third side 308, and a fourth side 310. The third side 308 can be a front end of the first differential housing assembly 302. The fourth side 310 can be a rear end of the first differential housing assembly 302. For example, the first differential housing assembly 302 can support the second differential unit 126. Fig. 1. In one example, the first differential housing assembly 302 is a rear differential housing, such as a rear axle carrier, and may house a rear differential of a vehicle.

[0027] The first differential housing assembly 302 is a split differential housing divided in two along an axis in a vertical plane. The first differential housing assembly 302 has a first housing element 312 coupled to a second housing element 314 at an interface centered on the vertical plane, the axis being coaxial with a central axis of a drive shaft. For example, the first housing element 312 and the second housing element 314 can be connected to each other at an interface 316. The interface 316 can be centered on a plane 315 that is axially aligned with the axis 311 and formed by xz axes. In one example, the axis 311 can be the second rotation axis 129, which is defined by reference to Fig. 1 was described.

[0028] The first housing element 312 can be a front housing section for the first differential housing assembly 302. The second housing element 314 can be a rear housing section for the first differential housing assembly 302. The first housing element 312 can be a front housing located closest to the third side 308 from the interface 316. The second housing element 314 can be a rear housing located closest to the fourth side 310 from the interface 316. The first housing element 312 can be longer in the longitudinal direction than the second housing element 314, with respect to the axis 212.

[0029] A support section is divided into two parts between the first housing element 312 and the second housing element 314. The first housing element 312 can include a first support section 321. Similarly, the second housing element 314 can include a second support section 323. The first support section 321 and the second support section 323 can be arranged around and enclose the gear components of the differential, such as the pinion, a ring gear, a first side differential gear, a second side differential gear, and a variety of ring gears. The design can be more durable and fatigue-resistant compared to conventional supports.

[0030] In one example, the interface 316 is a parting line seam centered on the plane 315. When coupled at the interface 316, the first housing element 312 and the second housing element 314 can form a variety of bearing bores or holes, such as at least two holes, that can accommodate and drive an axle shaft. For example, there is a first hole 318 on the first side 304 of the first differential housing assembly 302 and a second hole that is symmetrically opposite the first hole 318 with respect to the axis 212 (e.g., the second hole 418 in Fig. 4) The first hole 318 and the second hole can be centered on the axis 311 and arranged radially around it. A first bearing 319 can be arranged concentrically to the first hole 318. The first bearing 319 can be arranged around and support a first axle half-shaft. Likewise, the first hole 318 can receive and rotatably support the first axle half-shaft. The first hole 318 can be a first axle half-shaft support, and the second hole can be a second axle half-shaft support. The arrangement of the bearing bores with respect to the interface 316 of the first housing element 312 and the second housing element 314 can increase the sealing capability of the first differential housing assembly 302. For example, although the bearing bores are subject to strong separating forces, the opening travel of the interface 316 at the loaded bearing bores is reduced by incorporating a T-joint design 398.

[0031] A first bracket 326 can be attached to the second housing element 314. The first bracket 326 can be attached to the fourth side 310. The first bracket 326 can be located opposite the interface 316. In one example, the first differential housing assembly 302 can have a single bracket in the form of the first bracket 326. The first bracket 326 can have a first fastening element 328a and a second fastening element 328b, with which the second housing element 314 and the first differential housing assembly 302 can be attached to a component of a vehicle, such as the vehicle 100. Fig. 1. can be attached. One component of a vehicle to which the first bracket 326 can be attached can be the vehicle's chassis. Attaching it to the vehicle chassis using the first bracket 326 can significantly reduce the installation space required compared to the prior art.

[0032] The first housing element 312 can have a pinion nose 320. The pinion nose 320 can be arranged around a portion of the differential input shaft and a portion of a pinion gear. A cover 322 can be connected to the first side 304 of the pinion nose 320. The cover 322 can be attached to the pinion nose 320 via a flange 324. The cover 322 can be a housing. Components such as sensors, brakes, or other actuators and / or control components can be housed in the cover 322. The pinion nose 320 can have an opening 330 facing the third side 308. The opening 330 can be approximately circular and centered around the axis 212. The opening 330 can be centered about the axis 212, such that a center line of the pinion nose 320 and the mouth 330 can be approximately parallel and collinear with the axis 212. The opening 330 can be defined by an opening on an outer surface 335 of a first flange 332.The opening 330 can serve as an opening for a hole 331 for the pinion nose 320. The hole 331 can be defined by a substantially cylindrical inner surface 329 of the pinion nose 320 and the opening of the opening 330. The opening 330 and the hole 331 can accommodate an output, e.g., a shaft. The output, which can transmit rotational energy to the components of a differential via a torque generated by a vehicle driver, is housed in the first differential housing assembly 302.

[0033] The first flange 332 can be arranged around the opening 330. The first flange 332 can be attached to vehicle components to which the differential can be mounted. An inlet 334 can be approximately concentric with the opening 330. The pinion nose 320 and the first housing element 312 can be arranged around the inlet 334. The inlet 334 can be an inlet capable of transferring rotational energy into the differential, which is received by the first differential housing assembly 302. The inlet 334 can, for example, be a pinion shaft coupled to a pinion. In this example, the pinion can mesh with a ring gear of the differential, be driven by it, and transfer rotational energy to it via a torque. The aforementioned output (e.g., the shaft) can be driven by it to the inlet 334 in order to transfer rotational energy to it via a torque.

[0034] In one example, a mounting frame 336 can be arranged below and coupled to the pinion nose 320. The mounting frame 336 can attach the first housing element 312 to a component of a vehicle, such as the vehicle 100. For example, the mounting frame 336 can be connected to a component of the vehicle via a first mounting pin 338a and a second mounting pin 338b. For example, a plurality of fasteners can be complementary to the first mounting pin 338a and the second mounting pin 338b and pass through them. The fasteners can then be screwed into complementary holes in a vehicle part. Alternatively, the fasteners can be connected to or already mounted on a component of the vehicle.When the fasteners are passed through the first mounting pin 338a and the second mounting pin 338b and connected to a vehicle component, they can attach and mount the mounting frame 336 to a vehicle component, thereby securing the first housing element 312 to the vehicle component.

[0035] The first hole 318 can have a first diameter 342. The first diameter 342 can be an inner diameter for the first hole 318 and an outer diameter for the first bearing 319. A second diameter 344 can be an inner diameter of the first bearing 319. The second diameter 344 can also be larger than the outer diameter of the first axle shaft and surround it.

[0036] The first housing element 312 can have a second flange 346, and the second housing element 314 can have a third flange 348. The second flange 346 extends around and from the first support section 321. The second flange 346 and the third flange 348 can extend outwards with respect to the axis 212. The second flange 346 can be attached to the third flange 348 at the interface 316. The second flange 346 can be attached to the third flange 348 by a plurality of fasteners. The plurality of fasteners can include a third fastener 350, a fourth fastener 352, a fifth fastener 354, a sixth fastener 356, a seventh fastener 358, and an eighth fastener 360. The fasteners can, for example, all have the same dimensions.Another example is that some or all of the fasteners can have different dimensions. Each of the fasteners can be complementary to a hole in the second flange 346 and a hole in the third flange 348. Each of the fasteners can be screwed through a complementary hole in the second flange 346 and a complementary hole in the third flange 348. The complementary holes for the fasteners in the second flange 346 and the third flange 348 can have centerlines that are approximately parallel to the axis 212 and extend through the material of the second flange 346 and the third flange 348. The complementary holes for the fasteners on the third flange 348 can be through holes. The second flange 346, for example, can have a first hole 362, a second hole 364, a third hole 366, a fourth hole 368, a fifth hole 370, and a sixth hole 372 for the fasteners.In this example, the first hole 362 can be complementary to the third fastener 350, the second hole 364 can be complementary to the fourth fastener 352, the third hole 366 can be complementary to the fifth fastener 354, the fourth hole 368 can be complementary to the sixth fastener 356, the fifth hole 370 can be complementary to the seventh fastener 358, and the sixth hole 372 can be complementary to the eighth fastener 360. The first hole 362, the second hole 364, the third hole 366, the fourth hole 368, the fifth hole 370, and the sixth hole 372 can be through holes extending through the material of the second flange 346 and visible when the second flange 346 is attached to the third flange 348.

[0037] The first housing element 312 can have a plurality of ribs that mechanically support the first housing element 312 and distribute the mechanical energy through it. For example, the first housing element 312 can have a first rib 374. The first rib 374 can extend from the first flange 332 to the first support section 321. Likewise, there can be a plurality of ribs, such as a second rib 376, a third rib 378, and a fourth rib 380, which can extend from the beginning of the pinion nose 320 to the material of the first support section 321. The second rib 376, the third rib 378, and the fourth rib 380 can be located closest to the first side 304.

[0038] In one example, several fasteners, such as a first ninth fastener 382a, a second ninth fastener 382b, a third ninth fastener 382c, and a fourth ninth fastener 382d, can be used to attach the cover 322 to the pinion nose 320. Each of the fasteners for attaching the cover 322 to the pinion nose 320, such as the first ninth fastener 382a, the second ninth fastener 382b, the third ninth fastener 382c, and the fourth ninth fastener 382d, can be complementary to a hole in the pinion nose and a hole in the flange 324.

[0039] The first fastening element 328a can have a first washer 386a and a second washer 388a. The first washer 386a and the second washer 388a can be arranged at opposite ends of a first shaft 390a of the first fastening element 328a. The first fastening element 328a can have a first head 392a at the end of the first shaft 390a, which can support the first washer 386a. Likewise, the second fastening element 328b can have a third washer 386b and a fourth washer 388b. The third washer 386b and the fourth washer 388b can be arranged at opposite ends of a second shaft 390b of the second fastening element 328b. The second fastening element 328b can have a second head 392b at the end of the second shaft 390b, which can support the third washer 386b.The first washer 386a and the second washer 388a can exert pressure on and bear against opposite sides of a bracket, e.g., a vehicle chassis, to which the first fastener 328a can be attached. The first shaft 390a can extend through a complementary hole in the bracket. When the bracket is attached to the first fastener 328a, the first shaft 390a can support the bracket. Likewise, the third washer 386b and the fourth washer 388b can exert pressure on and bear against the opposite side of a bracket to which the second fastener 328b can be attached. The second shaft 390b can extend through a complementary hole in the bracket. When the bracket is attached to the second fastener 328b, the second shaft 390b can support the bracket.

[0040] Fig. Figure 4 shows an example 400 of a second differential housing arrangement 402. The second differential housing arrangement 402 can be an embodiment of a differential housing as defined in the present disclosure. The second differential housing arrangement 402 can have features common to the first differential housing arrangement 302, which are not listed again here for the sake of brevity. The second differential housing arrangement 402 can be centered about the axis 212. The axis 212 can serve as the longitudinal axis for the second differential housing arrangement 402. Likewise, the axis 311 can serve as the axis about which an axle shaft is centered, e.g., a central axis of a drive axle when it is drive-coupled to the second differential housing arrangement 402.

[0041] In one example, the second differential housing assembly 402 is a rear differential housing, e.g., a rear axle carrier, in which a rear differential of a vehicle can be accommodated. The second differential housing assembly 402 can, for example, house the second differential unit 126 of Fig. 1. The second differential housing assembly 402 is also a split housing assembly. The second differential housing assembly 402 can include a third housing element 412 and the second housing element 314. The third housing element 412 can be a second example of a front housing element similar to the first housing element 312 in Fig. The third housing element 412 can be a second example of a front housing section for the second differential housing assembly 402. The second housing element 314 can be an example of a rear housing section for the second differential housing assembly 402. The third housing element 412 has elements of the first housing element 312, such as the pinion nose 320, the first support section 321, and the first flange 332. However, the third housing element 412 can have a variety of other elements that differ from those of the first housing element 312, such as a mounting bracket 414. The third housing element 412 is longer in the longitudinal direction than the second housing element 314, with respect to the axis 212.

[0042] When coupled at interface 316, the third housing element 412 and the second housing element 314 can form a variety of holes, e.g., at least two holes, that can accommodate an axle shaft and drive it to that shaft. For example, on the second side 306 of the second differential housing assembly 402, there is a second hole 418. The second hole 418 can be centered on the axle 311 and arranged radially around it. A second bearing 419 can be arranged concentrically to the second hole 418. The second hole 418 can have some of the same dimensions, such as the same inner diameter, as the first hole 318. Fig. 3. Likewise, the first hole 318 can be located on the opposite side of the axle 212 and mirror the second hole 418. The second bearing 419 can be arranged around a second axle half-shaft and rotatably support it. Likewise, the second hole 418 can receive the second axle half-shaft and rotatably support it. When received by the second hole 418, the second axle half-shaft can extend in the opposite direction to a first axle half-shaft received by the first hole 318. The second axle half-shaft and the first axle half-shaft can be driven by a wheel of a variety of wheels, such as the second wheels 114 of Fig. 1, be connected on opposite sides of axis 212.

[0043] The third housing element 412 of the second differential housing assembly 402 can have a mounting bracket 414. The mounting bracket 414 can be arranged around the pinion nose 320. The mounting bracket 414 can be located between the flange and the interface 316 along and with respect to the axis 212. The mounting bracket 414 can have a first web 422, which is closest to the first side 304, and a second web 424, which is closest to the second side 306. The first web 422 and the second web 424 can be formed between a first support 426 and a second support 427. The first support 426 can be located on the top of the third housing element 412. The second support 427 can be located on the bottom of the third housing element 412. The first support 426 can include a first projection 420 and a second projection 421. The second support 427 can include a third projection 423 and a fourth projection 425.The first bridge 422 can be located between the first projection 420 and the third projection 423. The second bridge 424 can be located between the second projection 421 and the fourth projection 425. The first bridge 422 and the second bridge 424 can be connected to or formed from the material of the first housing element 312.

[0044] The third housing element 412 of the second differential housing assembly 402 can be attached to a vehicle, e.g., vehicle 100, by means of a second bracket 428 and a third bracket 430. The second bracket 428 and the third bracket 430 can be the first and second lateral supports, respectively, for the third housing element 412. The second bracket 428 can be attached to a component or element of the vehicle by means of a third fastener 432. The third bracket 430 can be attached to a component or element of the vehicle by means of a fourth fastener 434. A variety of fasteners can secure the second bracket 428 to the mounting bracket 414. Each of these fasteners can be screwed or inserted through a complementary hole extending through the material of the second bracket 428 and a complementary hole extending through the material of the mounting bracket 414.Similarly, a variety of fasteners can secure the third bracket 430 to the mounting support 414. Each of these fasteners can be screwed or inserted through a complementary hole extending through the material of the third bracket 430 and a complementary hole extending through the material of the mounting support 414. In one example, the second bracket 428 can be a first wing and the third bracket 430 a second wing symmetrically opposite the first wing, with the first and second wings configured to be mounted to a vehicle chassis.

[0045] In one example, the second bracket 428 can be attached to the first web 422 by at least one fifth fastening element 436. The third bracket 430 can be attached to the second web 424 by at least one sixth fastening element 438. The fifth fastening element 436 can extend through a complementary hole in the second bracket 428 and a first complementary hole 437 in the mounting bracket 414 and be screwed through. The sixth fastening element 438 can extend through a complementary hole in the third bracket 430 and a second complementary hole 439 in the mounting bracket 414 and be screwed through. The first complementary hole 437 can be a through hole extending through the material of the first projection 420. The second complementary hole 439 can be a through hole extending through the material of the second projection 421.The first complementary hole 437 and the second complementary hole 439 may each have centerlines that run approximately parallel to the axis 212. Additionally, a third complementary hole 441 may be present, extending through the material of the fourth projection 425. The third complementary hole 441 may be a through hole. The third complementary hole 441 may be complementary to an additional fastening element for the third bracket 430. The additional fastening element of the third bracket 430 may extend through a complementary hole of the third bracket 430 and the third complementary hole 441 to fasten the third bracket 430 to the mounting support 414. The third complementary hole 441 may have a centerline that runs approximately parallel to the second complementary hole 439. An additional complementary hole may be present, extending through the third projection 423.This additional complementary hole can be a through hole that fits an additional fastener for the second bracket 428. The additional fastener of the second bracket 428 can extend through a complementary hole of the second bracket 428 and the additional complementary hole of the third projection 423.

[0046] However, the number of fasteners, complementary holes of the second bracket 428, and complementary holes of the mounting bracket 414 for attaching the second bracket 428 to the mounting bracket 414 is not limited. There may be a greater or lesser number of fasteners, complementary holes of the second bracket 428, and complementary holes of the mounting bracket 414 for attaching the second bracket 428 to the mounting bracket 414 than in the [reference to be added]. Fig. 3. The embodiment of the second differential housing arrangement 402 shown. The number of fasteners, complementary holes of the third bracket 430, and complementary holes of the mounting carrier 414 for attaching the third bracket 430 to the mounting carrier 414 is also not limited. There may be a greater or lesser number of fasteners, complementary holes of the third bracket 430, and complementary holes of the mounting carrier 414 for attaching the third bracket 430 to the mounting carrier 414 than in the embodiment shown in Figure 3. Fig. 3 embodiment of the second differential housing arrangement 402.

[0047] Additionally, the third housing element 412 can have a variety of ribs and other structures that can mechanically absorb and distribute the mechanical energy through the third housing element 412. For example, the third housing element 412 can have a sixth rib 440, a seventh rib 442, an eighth rib 444, and a ninth rib 446 arranged around the axis 212. The sixth rib 440, the seventh rib 442, the eighth rib 444, and the ninth rib 446 can have lengths that extend approximately parallel to the axis 212. The sixth rib 440, the seventh rib 442, the eighth rib 444, and the ninth rib 446 can extend between the first support section 321 and the mounting bracket 414, connecting them or encompassing their material. The sixth rib 440 and the seventh rib 442 can be connected to a surface of the first support 426.Likewise, the eighth rib 444 and the ninth rib 446 can be connected to the second web 424. A partial ring 448 can arch around the axis 212 and the third housing element 412 between the eighth rib 444 and the ninth rib 446. The partial ring 448 can be connected to or comprise the material of the third housing element 412. The partial ring 448 can mechanically support the eighth rib 444, the ninth rib 446, the second web 424, the pinion nose 320, and the first support section 321.

[0048] The third housing element 412 can be attached to the second housing element 314 at interface 316 to form the second differential housing assembly 402 via a plurality of fasteners. In one embodiment, the second housing element 314 can be attached to the third housing element 412 at interface 316 via a seventh fastener 452, an eighth fastener 454, a ninth fastener 456, a tenth fastener 458, an eleventh fastener 460, and a twelfth fastener 462. The seventh fastener 452, the eighth fastener 454, the ninth fastener 456, the tenth fastener 458, the eleventh fastener 460, and the twelfth fastener 462 can be positioned about the axis 212 and extend through complementary holes in the second housing element 314 and the third housing element 412.The complementary holes can be located on the third flange 348 of the second housing element 314 and on the second flange 346 of the third housing element 412. Likewise, in one embodiment, the second housing element 314 can be attached to the first housing element 312 via the seventh fastening element 452, the eighth fastening element 454, the ninth fastening element 456, the tenth fastening element 458, the eleventh fastening element 460, and the twelfth fastening element 462.

[0049] In one embodiment, the first bracket 326 can be attached to the second housing element 314 by means of a thirteenth fastening element 472, a fourteenth fastening element 474, and a fifteenth fastening element 476. The thirteenth fastening element 472, the fourteenth fastening element 474, and the fifteenth fastening element 476 can each extend through a complementary hole in the first bracket 326 and a complementary hole in the second housing element 314. For example, the thirteenth fastening element 472, the fourteenth fastening element 474, and the fifteenth fastening element 476 can be screwed through their respective complementary holes in the first bracket 326 and the second housing element 314. If the thirteenth fastening element 472, the fourteenth fastening element 474 and the fifteenth fastening element 476 are threaded, the first bracket 326 can be attached to the second housing element 314.

[0050] Returning to the mounting bracket 414: The first support 426 of the mounting bracket 414 can have a first cavity 482a and a second cavity 482b. The first cavity 482a and the second cavity 482b can have an opening on the top of the first support 426 and extend downwards through it. A fifth rib 484 can separate the first cavity 482a from the second cavity 482b. The first cavity 482a can be located closest to the first side 304 of the fifth rib 484. The second cavity 482b can be located closest to the second side 306 of the fifth rib 484.

[0051] The third fastening element 432 can have a third head 486. The fourth fastening element 434 can have a fourth head 488. The third head 486 and the second bracket 428 can abut elements of a bracket to which the third fastening element 432 can be attached. The second bracket 428 can have a first recess 490 in which elements of the bracket can be accommodated. The fourth head 488 and the third bracket 430 can abut elements of a bracket to which the fourth fastening element 434 can be attached. The third bracket 430 can have a second recess 492 in which elements of the bracket can be accommodated. The fourth fastening element 434 can be fastened to the third bracket 430 by means of a nut 494. Likewise, the third fastening element 432 can be fastened to the second bracket 428 by means of a nut.

[0052] This system provides a rear axle differential carrier with a split housing, comprising a first housing element and a second housing element. The rear axle differential carrier can be housed and mounted within a vehicle. The first housing can be a front housing, located closest to the front of the vehicle compared to the second housing. The second housing can be a rear housing, located closest to the rear of the vehicle compared to the first housing. The rear axle differential carrier can accommodate a rear axle differential on the rear axle of a vehicle. The first and second housings can be joined at an interface to enclose components of a rear differential.The first and second housings can be attached using a variety of fasteners that can be bolted through complementary holes in a first flange of the first housing and a second flange of the second housing. The first and second flanges can share a common surface at their interface. The rear differential carrier can have two holes, each supporting an axle half-shaft. In one example, the rear differential carrier can be attached to a vehicle component by means of a mounting frame attached to the first housing and a single bracket attached to the second housing. In another example, the rear differential carrier can be attached to a vehicle component by means of a first and second lateral bracket attached to the first housing and a single bracket attached to the second housing.

[0053] The first housing may contain a pinion nose configured to receive an output from a drive motor to couple the rear differential for drive and to transmit rotational energy via a torque.

[0054] The vehicle housing the rear differential carrier can, in a sense, have both rear-wheel drive (RWD) and front-wheel drive (FWD). Rear-wheel drive is provided by a rear differential housed within the rear differential carrier. All-wheel drive is provided by a front differential housed within a front differential carrier. The front and rear differentials can provide the vehicle with both FWD and RWD modes, as well as an all-wheel drive (AWD) mode.

[0055] The technical effect of the revealed systems is a durable and compact design with fewer mounting brackets.

[0056] The disclosure also provides support for a system comprising a split differential housing divided in two along an axis on a vertical plane, the split differential housing comprising a first housing element coupled to a second housing element at an interface centered on the vertical plane, the axis being coaxial with a central axis of a drive axle. In a first example of the system, the first housing element comprises a pinion nose and a mounting bracket arranged around the pinion nose, the mounting bracket being connected to a first wing and a second wing symmetrically opposite the first wing. In a second example of the system, which optionally includes the first example, the first wing and the second wing are configured to be mounted on a vehicle chassis.In a third example of the system, optionally comprising one or both of the first and second examples, the first housing element includes a pinion nose configured to couple with a mounting frame. In a fourth example of the system, optionally comprising one or more or each of the first through third examples, the second housing element includes a bracket positioned opposite the interface, the bracket being configured to be attached to a vehicle chassis via a first mounting element and a second mounting element.In a fifth example of the system, which optionally includes one or more or each of the first through fourth examples, the first housing element comprises a first support section and the second housing element comprises a second support section, wherein the first support section and the second support section are configured to enclose gear components of a differential. In a sixth example of the system, which optionally includes one or more or each of the first through fifth examples, the split differential housing further comprises a support section configured to enclose gear components of a differential, wherein the support section is split in two between the first housing element and the second housing element.In a seventh example of the system, which optionally includes one or more or each of the first through sixth examples, the interface is a parting line seam centered on a plane parallel to the center axis of a first axle half-shaft mount and a second axle half-shaft mount. In an eighth example of the system, which optionally includes one or more or each of the first through seventh examples, the first housing element is longitudinally longer than the second housing element. In a ninth example of the system, which optionally includes one or more or each of the first through eighth examples, the split differential housing is a rear axle carrier.

[0057] The disclosure also provides a mounting for a drive axle, comprising: a differential unit coupled to a first axle half-shaft and a second axle half-shaft, the first axle half-shaft and the second axle half-shaft rotating about an axis of rotation; and a split differential housing that encloses and rotatably supports the differential unit, the split differential housing being divided in two on a vertical plane axially aligned with the axis of rotation. In a first example of the system, the split differential housing comprises a first housing element connected to a second housing element at an interface centered in the vertical plane. In a second example of the system, which optionally includes the first example, the drive axle is a rear drive axle.In a third example of the system, which optionally includes one or both of the first and second examples, the drive axle is a rear drive axle in an all-wheel-drive configuration. In a fourth example of the system, which optionally includes one or more or each of the first through third examples, the first housing element comprises a pinion nose with a first wing and a second wing attached thereto, the first wing and the second wing being configured to be coupled to a vehicle chassis.

[0058] The disclosure also provides a mounting for a system comprising: a drive shaft including a differential unit, and a split differential housing comprising a first housing element coupled to a second housing element, and a first axle half-shaft mount and a second axle half-shaft mount configured to rotatably support the drive shaft, the first axle half-shaft mount and the second axle half-shaft mount being split in two between the first and second housing elements. In a first example of the system, the split differential housing is coupled at an interface centered on a vertical plane parallel to a central axis of the drive shaft.In a second example of the system, which optionally includes the first example, the system further comprises: a first bearing concentric to the first axle half-shaft mount and a second bearing concentric to the second axle half-shaft mount. In a third example of the system, which optionally includes one or both of the first and second examples, the first housing element is longitudinally longer than the second housing element. In a fourth example of the system, which optionally includes one or more or each of the first through third examples, the split differential housing is configured to accommodate a vehicle's rear differential.

[0059] In another representation, a system for a front-wheel drive train is housed with a rear differential unit to provide all-wheel drive, wherein the rear differential unit is housed in a split housing arrangement comprising a first housing section attached to a second housing section at an interface centered on a central axis of a rear drive axle, wherein a first lateral mounting element and a second lateral mounting element are coupled to the first housing section, and a central support is coupled to the second housing section.

[0060] It is understood that the configurations and processes disclosed here are exemplary and that these specific examples should not be considered restrictive, as numerous variations are possible. The subject matter of this disclosure includes all novel and non-obvious combinations and sub-combinations of the various systems and configurations, as well as other features, functions, and / or properties disclosed herein.

[0061] The following claims highlight in particular certain combinations and subcombinations that are to be considered novel and not obvious. These claims may refer to "one" element or "a first" element, or the equivalent thereof. Such claims are to be understood as including one or more such elements, with two or more such elements neither required nor excluded. Other combinations and subcombinations of the disclosed features, functions, elements, and / or properties may be claimed by amending the present claims or by filing new claims in this or a related application. Such claims, whether they have a broader, narrower, the same, or different scope than the original claims, are also to be considered as included in the subject matter of the present disclosure.

Claims

[1] System comprising: a split differential case split in two at an axle in a vertical plane, the split differential case comprising a first case member coupled to a second case member at an interface centered in the vertical plane, the axle being coaxial with a central axis of a drive axle. [2] System in which the first housing element comprises a pinion nose and a mounting bracket arranged around the pinion nose, the mounting bracket being connected to a first wing and a second wing symmetrically opposite the first wing. [3] The system of claim 2, wherein the first wing and the second wing are adapted to be attached to a vehicle chassis. [4] A system according to any one of the preceding claims, wherein the first housing member comprises a pinion nose configured to be connected to a mounting frame. [5] A system according to any one of the preceding claims, wherein the second housing member comprises a bracket arranged opposite the interface, the bracket being adapted to be secured to a vehicle chassis via a first fastening member and a second fastening member. [6] A system according to any one of the preceding claims, wherein the first housing member comprises a first support portion and the second housing member comprises a second support portion, the first support portion and the second support portion being adapted to enclose transmission components of a differential. [7] The system of any preceding claim, wherein the split differential case further comprises a support portion configured to enclose transmission components of a differential, the support portion being split in two between the first case member and the second case member. [8] A system according to any preceding claim, wherein the interface is a parting line weld centered on a plane parallel to the center axis of a first axle half-shaft support and a second axle half-shaft support. [9] A system according to any preceding claim, wherein the first housing member is longer in the longitudinal direction than the second housing member. [10] A system according to any preceding claim, wherein the split differential housing is a rear axle carrier. [11] Drive axle comprising: a differential unit coupled to a first axle half-shaft and a second axle half-shaft, the first axle half-shaft and the second axle half-shaft rotating on a rotational axis; and a split differential case enclosing and rotatably supporting the differential unit, the split differential case being split in two in a vertical plane axially aligned with the axis of rotation. [12] The drive axle of claim 11, wherein the split differential case comprises a first case member connected to a second case member at an interface centered in the vertical plane. [13] Drive axle according to claim 11 or 12, wherein the drive axle is a rear drive axle. [14] A drive axle according to any one of claims 11 to 13, wherein the drive axle is a rear drive axle in an all-wheel drive configuration. [15] The drive axle of claim 12, wherein the first housing member comprises a pinion nose having a first wing and a second wing mounted thereon, the first wing and the second wing being adapted to be coupled to a vehicle chassis.

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