Ventilation box guide plate insert

Abstract

Axle arrangement for a vehicle, comprising: a guide plate comprising a first section parallel to a first plane, a second section parallel to a second plane and at an angle to the first section, and a third section parallel to a third plane and at an angle to the first and second sections; wherein The guide plate is a spring.

Description

Technical area

[0001] The present description generally relates to a baffle. More specifically, the present disclosure relates to a gear for housings of a drive axle assembly. BACKGROUND AND SUMMARY

[0002] Vehicle drive axle assemblies may include a differential system that allows a wheel at one end of a drive axle to rotate at a different speed than a wheel at the other end of the drive axle. Differentiation between the two wheels at opposite ends of a drive axle assembly is generally used to prevent wheel "slip" or "jump," for example, when the two wheels travel different distances through a corner or when two tires of different diameters are used.

[0003] The differential system is generally housed within a drive axle assembly housing and is bathed in a lubricant to reduce friction and increase the longevity of the various rotating internal differential components. During differential operation (e.g., when the differential gears rotate), lubricant can splash or be thrown out, and in some cases, it can escape (e.g., leak) from the drive axle assembly housing through a vent and / or breather. A lack of lubricant in the drive axle assembly housing can result in reduced longevity of the differential components and / or degraded performance. In addition, some of the lubricant that escapes from the drive axle housing is often retained on the housing and can cause discoloration.Furthermore, some of the lubricant leaking from the drive axle assembly housing may drip or fall beneath the vehicle onto the roadway and / or garage floor, causing customer dissatisfaction and / or creating the perception that a leak is present. Additionally or alternatively, lubricants may contribute to greenhouse gas emissions, and efforts to mitigate global warming may be desirable.

[0004] Attempts to prevent lubricant from leaking from the housing of a drive axle assembly include installing a baffle near the vent and / or a breather within the housing of the drive axle assembly. The housing may be molded and / or cast to include threaded holes and / or moldings for securing the baffle with a fastener, weld, or other additional element.

[0005] However, the inventors have recognized potential problems with such systems. Baffles with a single surface or multiple surfaces aligned in a single plane may not adequately prevent lubricant splashes and / or lubricant bubbles from escaping the housing of a drive axle assembly. Furthermore, the requirement for fasteners and / or drilling for mounting the baffle increases the manufacturing complexity, cost, and difficulty of installing the baffle. Often, space constraints make it difficult to maneuver a fastener tool into the drive axle assembly. Furthermore, the fastener is held to a tight tolerance to prevent the baffle from shifting position and potentially interfering with rotating differential components.

[0006] In one example, the problems described above may be solved by an axle assembly for a vehicle comprising a baffle including a first portion parallel to a first plane, a second portion parallel to a second plane and at an angle to the first portion, and a third portion parallel to a third plane and at an angle to the first portion and the second portion, wherein the baffle is a spring. In this way, the baffle includes a plurality of surfaces, each oriented in a different plane, to reduce leakage of lubricant from the housing of the drive axle assembly. Furthermore, the baffle may be incorporated into a housing of a drive axle assembly without the need for fasteners and / or mounting holes.For example, the deflector can exert a force on the drive axle assembly housing, holding the deflector in place within a cavity in the drive axle assembly housing. The force can be tailored to the vehicle's specific driving conditions, allowing it to maintain the deflector even under vibration, heavy loads, and other conditions. This allows the deflector to be installed without tools or special mounting points.

[0007] It should be understood that the above summary is intended to introduce, in simplified form, a selection of concepts that are further explained in the detailed description. It is not intended to identify the most important 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 address the disadvantages noted above or elsewhere in this disclosure. Short description of the drawings Fig. 1 shows an exemplary vehicle with a housing for a drive axle assembly; Fig. 2 shows an exemplary housing for a drive axle assembly; Fig. 3 shows a first schematic representation of a baffle according to one or more embodiments of the present disclosure; Fig. 4 shows a second schematic representation of the guide plate from Fig. 3; Fig. 5 shows a first view of an exemplary housing for a drive axle arrangement with the guide plate of Fig. 3; Fig. 6 shows a second view of the housing for a drive axle arrangement from Fig. 5; Fig. 7 shows a second exemplary housing for a drive axle arrangement with the guide plate of Fig. 3 in a first orientation; and Fig. 8 shows the housing for a drive axle arrangement made of Fig. 7 with the guide plate Fig. 3 in a second orientation. Detailed description

[0008] The following description refers to an axle housing with a baffle to reduce oil leakage from a vent in the axle housing. Fig. 1 shows a vehicle with a drive train that includes a housing for a drive axle assembly. Fig. 2 shows an exemplary housing for a drive axle assembly with a vent box. Fig. 3 and Fig. 4 show a guide plate which is inserted into the housing of the drive axle assembly of Fig. 2 can be used to prevent lubricant from flowing through the breather box of the drive axle assembly housing. Fig. 5 and Fig. 6 show a first example of a housing architecture for a drive axle assembly including a baffle disposed in a vent box. Fig. 7 and Fig. 8 show a second example of a housing architecture for a drive axle assembly in which the baffle is positioned in a first and a second orientation, respectively. Fig. 2, 5-8 are shown to scale, except for the baffle shown schematically, although other relative dimensions may be used.

[0009] Fig. 1 schematically illustrates a vehicle 100 having a powertrain 102 according to the present disclosure. The vehicle 100 may take different forms in various embodiments, e.g., be a light, medium, or heavy-duty vehicle. To generate power, the powertrain 102 may include a power source 104. The power source 104 may be an internal combustion engine, an electric motor, combinations thereof, or other suitable devices for generating rotational energy. The internal combustion engine may include conventional components such as cylinders, pistons, valves, a fuel delivery system, an intake system, an exhaust system, and the like. Further, the electric motor may include conventional components such as a rotor, a stator, a housing, and the like, in some cases to generate both mechanical and electrical energy during a regenerative mode.For example, the powertrain 102 may be used in a hybrid or electric vehicle (e.g., a battery-powered electric vehicle). Therefore, in certain cases, the powertrain 102 may have a parallel, series, or series-parallel hybrid configuration. However, in other examples, the vehicle 100 may exclusively use an internal combustion engine to generate power. Additionally or alternatively, the vehicle 100 may also include only an electric motor.

[0010] The power source 104 may supply mechanical power to a differential 107 via a transmission 106. The power path may continue through the differential 107 to an axle 114, which includes a first axle shaft 115 and a second axle shaft 116. The mechanical power may be transmitted via the first axle shaft 115 and the second axle shaft 116 to a first drive gear 110 and a second drive gear 112, respectively. Thus, the differential 107 may distribute the rotational drive force received from the transmission 106 to the first drive gear 110 and the second drive gear 112 of the first axle shaft 115 and the second axle shaft 116, respectively, under certain operating conditions.

[0011] The transmission 106 may be equipped with a reduction gear that provides a speed-to-torque conversion function. That is, the transmission 106 may be a shiftable transmission, a continuously variable transmission, a continuously variable transmission, or the like. The transmission 106 may utilize mechanical components such as shafts, gears, bearings, and the like to perform the aforementioned reduction function.

[0012] The differential 107 may be configured to allow a speed variation between the axle shafts under certain conditions, e.g., when cornering. However, to increase the traction of the vehicle, the differential 107 may be a limited-slip differential designed to limit the speed variation between the first axle shaft 115 and the second axle shaft 116 under certain conditions. To achieve this speed-limiting function, the differential 107 may include a housing, sets of pinions, and side gears. The differential 107 may be disposed within a housing 108 of the drive axle assembly. Thus, a portion of the axle 114 (e.g., the first axle shaft 115 and the second axle shaft 116) may be disposed within the housing 108 of the drive axle assembly. The housing 108 of the drive axle assembly is described with reference to Fig. 2 further described.

[0013] Fig. 1 shows a lubrication system 118 configured to supply lubricant (e.g., natural and / or synthetic oil) to components of the transmission 106 and / or the drive axle assembly housing 108. In one example, the lubrication system 118 may include a reservoir (e.g., a sump), a pump for driving lubricant flow through the system, a plurality of conduits, and / or other suitable lubricant distribution components such as nozzles, valves, jets, and the like to perform lubricant distribution. Furthermore, the drive axle assembly housing 108 may include a closed splash lubrication arrangement. In such an example, upon rotation of the differential 107, lubricant may be picked up and distributed to various components within the drive axle assembly housing 108.Occasionally, lubricant may leak from the drive axle assembly housing 108 due to splashing and / or lubricant bubbles carried by air exiting the drive axle assembly housing. The drive axle assembly housing 108 may include a baffle to reduce or prevent lubricant leakage.

[0014] The vehicle 100 may include a control system 128 with a controller 130. The controller may include a processor 132 and a memory 134 storing instructions that, when executed by the processor 132, cause the controller 130 to perform various methods, control techniques, etc. described herein. The processor 132 may include a microprocessor unit and / or other types of circuitry. The memory 134 may include known data storage media such as random access memory, read-only memory, diagnostic memory, combinations thereof, etc. The memory 134 may further include non-volatile memory.

[0015] The control system 128 may receive various signals from sensors 136 located at various locations within the vehicle 100 and the powertrain 102. Conversely, the controller 130 may send control signals to a plurality of actuators 138 located at various locations within the vehicle 100 and the powertrain 102.

[0016] For example, the controller 130 may send signals to the power source 104. In response to receiving the command signal, an actuator in the power source 104 may adjust the output speed or torque. Other controllable components in the vehicle and the vehicle's transmission system may function similarly with respect to receiving command signals and adjusting the actuators. Furthermore, during a drive mode, the controller 130 may adjust the power source 104 to achieve, for example, a desired vehicle speed. Conversely, during idle operation, the power source 104 may be inactive, and power may be transferred from at least one of the first drive wheel 110 and the second drive wheel 112 to the differential 107, and so on.

[0017] Fig. 2 shows a housing 200 of a drive axle assembly according to the present disclosure. The housing 200 of the drive axle assembly is a non-limiting example of the housing 108 of the drive axle assembly of Fig. 1. The housing 200 of the drive axle assembly may contain a differential (e.g., the differential 107 of Fig. 1) that enables speed / torque conversion between a power source and the drive wheels of a vehicle.

[0018] The housing 200 of the drive axle assembly includes a shell 202 for receiving a differential, such as the differential 107 of Fig. 1. The housing 200 of the drive axle assembly further includes two axle housings 204 connected to the shell 202. The axle housings 204 each receive at least a portion of a rotatable axle (e.g., the first axle shaft 115 and the second axle shaft 116 of Fig. 1). The rotatable axles are each coupled to a wheel (e.g. the first drive wheel 110 and the second drive wheel 112 of Fig. 1) and supply the wheels with mechanical power (e.g. drive).

[0019] The housing 200 of the drive axle assembly includes an upper portion 206, a lower portion 208 and a substantially hollow inner portion, a portion of which is Fig. 5-8. The hollow inner portion may contain a predetermined amount of lubricant to lubricate and cool various moving parts, including the differential, within the drive axle assembly housing 200.

[0020] The housing 200 of the drive axle assembly may include an opening 212 in the upper portion 206. Although Fig. 2 shows that the opening 212 is located in a cover 210 of the shell 202, in other examples the opening 212 may be located anywhere in the shell 202 or the axle housings 204.

[0021] Regardless of the position, the opening 212 extends to the hollow inner portion of the drive axle assembly housing 200. The opening 212 may be circular and is defined by a circular wall in the upper portion 206. In some examples, the circular wall may include a substantially smooth bore, but in other examples, the circular wall may be threaded.

[0022] Fig. 2 further shows a device for venting the drive axle assembly housing 200, also referred to as a breather 214. The breather 214 may extend through the drive axle assembly housing 200 and form a passage for the entry and / or exit of air into the drive axle assembly housing. In the illustrated example, a portion of the breather 214 disposed outside the drive axle assembly housing 200 may be L-shaped. At least a portion of the breather 214 may be disposed within the opening 212 of the upper portion 206. Furthermore, the breather 214 may be disposed at any location within the drive axle assembly housing 200 that is above the lubricant level (not shown).

[0023] Fig. 3 and Fig. 4 show a first schematic representation and a second schematic representation of a guide plate 300, which will be described together. Fig. 3 and Fig. 4 each include a Cartesian coordinate system 399 for orienting the views. In one example, the y-axis may be a vertical axis (e.g., parallel to a gravitational axis), the x-axis may be a longitudinal axis (e.g., a horizontal axis), and / or the z-axis may be a lateral axis. However, in other examples, the axes may have other orientations.

[0024] The baffle 300 includes a first section 302, a second section 304, and a third section 306. The second section 304 is located between the first section 302 and the third section 306. Furthermore, the second section 304 is connected to the first section 302 and the third section 306 along a first bend 308 and a second bend 310, respectively. The first section 302 may be angled relative to the second section 304 at an angle A1, as shown in Fig. 4. For example, the first portion 302 may be oriented such that a front surface 312 of the first portion lies within a first plane 392, and the second portion 304 may be oriented such that a front surface 314 of the second portion lies within a second plane 394, wherein the second plane 394 is angled relative to the first plane 392. The first plane 392 and the second plane 394 may intersect at the first bend 308. Accordingly, the second portion 304 may be angled relative to the third portion 306 at an angle A2, as shown in Fig. 4. For example, the third portion 306 may be oriented such that a front surface 316 of the third portion lies within a third plane 396, where the third plane 396 is angled relative to the second plane 394 and / or the first plane 392. In one example, the third plane 396 is angled only relative to the second plane 394 and parallel to the first plane 392. The second plane 394 and the third plane 396 may intersect at the second bend 310. In some examples, the first portion 302, the second portion 304, and the third portion 306 may be oriented such that the baffle 300 has a Z-shape.

[0025] The baffle 300 may be configured to contract and expand in directions parallel to the double-headed arrow 398, similar to a spring. The compression and expansion of the baffle 300 may occur by bending the baffle at the first bend 308 and the second bend 310. This allows the baffle 300 to be compressed such that the angle A1 and / or the angle A2 can be reduced from approximately 90 degrees to a range of 0-80 degrees. In this way, the first section 302 can be moved closer to the second section 304 and / or the third section 306 can be moved closer to the second section 304 when a compressive force is applied to the baffle 300 in a direction parallel to the double-headed arrow 398. Compressing the baffle 300 may allow the baffle to be installed in a smaller space than would be possible if the baffle were not compressed.When no compressive force is applied to the baffle 300, the baffle may extend in directions parallel to the double-headed arrow 398 because the angle A1 and the angle A2 increase again to an angle of approximately 90 degrees. The baffle 300 may be configured to bend only at the first bend 308 and the second bend 310. For example, the baffle 300 may not bend at a point in the second section 304 when a compressive force is applied. In one example, the baffle 300 is an elastic element, such as a spring, and expands when no compressive force is applied to it.

[0026] In some examples, the baffle 300 may also include high-strength, low-alloy steel sheet, aluminum, and / or high-temperature polymer materials. Additionally or alternatively, the baffle 300 may include one or more of the following elements: magnesium, titanium, carbon fiber, steel, stainless steel, silicon, polymers, and the like. The baffle 300 may, in some examples, be manufactured by a mold. Additionally or alternatively, the baffle 300 may be manufactured using additive manufacturing.

[0027] The guide plate 300 can, for example, be installed in a ventilation box of a housing of a drive axle assembly, such as the housing 200 of the drive axle assembly of Fig. 2. Furthermore, the baffle 300 can exert an outward force in directions parallel to the double-headed arrow 398, similar to a spring, on one or more components within the housing of the drive axle assembly that are located near the first portion 302 and / or the third portion 306. The expansive force (e.g., spring force) exerted by the baffle 300 can securely hold the baffle in place without the need for fasteners, adhesives, attachment devices, combinations thereof, or the like. The positioning of the baffle 300 in a housing of a drive axle assembly is described with reference to Fig. 5-8 further described.

[0028] The first portion 302 of the baffle 300 includes an opening 318 and a tab 320. The tab 320 may be a portion of the first portion 302 that has been cut (e.g., severed) from a remainder of the first portion along an edge 322. Further, the tab 320 may be connected to the front surface 312 of the first portion 302 along a second edge 324 and angled from the front surface 312 at an angle A3. For example, the tab 320 may be oriented to lie within a fourth plane 393, where the fourth plane 393 is inclined relative to the first plane 392 of the first portion 302 at an angle A3. The opening 318 may be located directly above the second edge 324 and may be framed by the second edge and a third edge 326, the third edge being complementary to the edge 322. Thus, the opening 318 and the tab 320 may have the same shape.Additionally or alternatively, the opening 318 and the tab 320 may have complementary shapes, with the opening 318 and the tab 320 being formed via a punch through a corresponding portion of the baffle 300. In the illustrated example, the opening 318 and the tab 320 may both be parts of an ellipse; however, in other examples, the tab and the opening may also have rectangles, triangles, semicircles, or any other suitable shape.

[0029] In one example, the opening 318 is formed by a punch in a body of the first portion 302. The opening 318 may be disposed in the first plane 392 of the first portion 302 and configured to direct gases in a direction perpendicular to the first plane 392. The tab 320, which is continuous with the first portion 302 and formed by punching the opening 318, may extend in a first direction away from the front surface 312 of the first portion 302. In one example, the front surface 312 and the tab 320 each face in the first direction.

[0030] The second portion 304 of the baffle 300 may include a second opening 328 and a second tab 330. In some examples, the second opening 328 and the second tab 330 may have the same shape and size as the opening 318 and the tab 320, respectively. The second tab 330 may be aligned in a fifth plane 395, where the fifth plane 395 is inclined at an angle A4 relative to the second plane 394 of the second portion 304. In one example, the second opening 328 is formed by a punch in a body of the second portion 304. The second opening 328 may be disposed in the second plane 394 of the second portion 304 and configured to direct gases in a direction perpendicular to the second plane 394.The second tab 330, which is continuous with the second portion 304 and formed by punching the second opening 328, may extend in a second direction away from the rear surface opposite the front surface 314 of the second portion 304. In one example, the rear surface (e.g., opposite the front surface 314) and the second tab 330 each face in the second direction.

[0031] The third portion 306 of the baffle 300 may include a third opening 332 and a third tab 334. In some examples, the third opening 332 and the third tab 334 may have the same shape and size as the opening 318 and the tab 320, respectively. The third tab 334 may be aligned in a sixth plane 397, where the sixth plane 397 is inclined at an angle A5 relative to the third plane 396 of the third portion 306. In one example, the third opening 332 is formed by a punch in a body of the third portion 306. The third opening 332 may be disposed in the third plane 396 of the third portion 306 and configured to direct gases in a direction perpendicular to the third plane 396. The third tab 334, which is continuous with the third portion 306 and is formed by punching the third opening 332, may extend in a third direction away from the front surface 316 of the third portion 306.In one example, the front surface 316 and the third tab 334 each face in the third direction.

[0032] The lubricant may exit through one or more openings (e.g., opening 318) of the baffle 300 through splashing and / or airborne bubbles. The relative angles between the tab 320 and the first portion 302, the second tab 330 and the second portion 304, and the third tab 334 and the third portion 306 cause the lubricant flowing through the baffle 300 to change direction multiple times. In addition, the lubricant may come into contact with multiple flat surfaces and edges. Thus, lubricant bubbles may condense on the baffle 300 and the lubricant may be prevented from flowing directly through one or more openings of the baffle. By positioning the baffle 300 near a vent of a housing, a drive axle assembly (e.g.,the breather 214 of the drive axle assembly housing 200), the lubricant can be separated from the vented air by the tabs and / or angled sections of the baffle, allowing the lubricant to flow back into a sump by gravity.

[0033] Fig. 5 shows a cross-sectional view of an exemplary housing 500 of a drive axle assembly in which the baffle 300 is arranged in the housing of the drive axle assembly. Fig. 6 shows a second illustration of the housing 500 for a drive axle assembly and the baffle 300. A portion of the housing 500 of the drive axle assembly has been omitted from the illustration to facilitate visualization of the baffle 300 within the housing of the drive axle assembly. Fig. 5 and Fig. 6 are described together. They also include Fig. 5 and Fig. 6 each depicts a Cartesian coordinate system 599 for orienting the views. In one example, the y-axis may be a vertical axis (e.g., parallel to a gravity axis), the x-axis may be a longitudinal axis (e.g., a horizontal axis), and / or the z-axis may be a lateral axis. However, in other examples, the axes may have other orientations. In one example, gravity is parallel to a direction opposite the y-axis.

[0034] The drive axle assembly housing 500 may be a non-limiting example of the drive axle assembly housing 200 of Fig. 2. Thus, the housing of the drive axle assembly 500 may include a central portion (e.g., a shell) for receiving a differential and two side portions (e.g., axle housings) connected to the central portion. The side portions may each receive at least one portion of a rotatable axle (e.g., the first axle shaft 115 and the second axle shaft 116 of Fig. 1).

[0035] The drive axle assembly housing 500 may include a top portion 502, a side portion 504, and a hollow inner portion 506. The top portion 502, the side portion 504, a bottom portion (not shown), and a second side portion (not shown) may surround and define the outer perimeter of the hollow inner portion 506. The hollow inner portion 506 may contain a predetermined amount of lubricant that lubricates and cools various moving parts, including the differential, within the hollow inner portion 506.

[0036] The housing of the drive axle assembly 500 includes a vent box 508. The vent box 508 may be a hollow portion of the drive axle assembly housing 500 defined by the top portion 502, the side portion 504, and an inner wall 510. The inner wall 510 may be integrated into the drive axle assembly housing to hold the baffle 300 in position. Further, the inner wall 510 may extend from the top portion 502 in a direction parallel to gravity 597 such that a bottom 512 of the inner wall is positioned near an inner corner 514 of the side portion 504. A passage 516 is provided between the bottom 512 and the inner corner 514 so that air can pass from the hollow inner portion 506 into the vent box 508.

[0037] The drive axle assembly housing 500 may include an opening 518 extending through the upper portion 502. Thus, the opening 518 may fluidly connect the vent box 508 to an ambient atmosphere or a region external to the hollow interior portion 506, allowing air to enter and / or exit the vent box of the drive axle assembly housing 500. In some examples, the opening 518 may be circular (e.g., cylindrical) and may be defined by a circular wall 520 in the upper portion 502. In other examples, the opening 518 may be rectangular, triangular, elliptical, or another suitable shape. In some examples, the circular wall 520 includes a substantially smooth bore; however, in other examples, the circular wall may be threaded and / or textured.

[0038] Although in Fig. 5 and Fig. 6, the drive axle assembly housing 500 may include a vent for venting air from the drive axle assembly housing. A portion of the vent may be disposed within the opening 518 of the upper portion 502. The vent may allow air to flow from the hollow interior portion 506 through the passage 516, through the vent box 508, into the opening 518, and out of the drive axle assembly housing 500.

[0039] As in Fig. 5 and Fig. 6, the baffle 300 is disposed within the vent box 508. The baffle 300 may be oriented such that at least a portion (e.g., an end) of the first section 302 is proximate to and in surface contact with the inner wall 510. Furthermore, at least a portion (e.g., an end) of the third section 306 may be proximate to and in surface contact with a surface 522 of the vent box 508, wherein the surface 522 is disposed opposite the inner wall 510. Furthermore, the first bend 308 and / or the second bend 310 of the baffle 300 may be proximate to and in surface contact with an inner surface of the vent box 508.

[0040] The baffle 300 can be held between the inner wall 510 and the surface 522 because the first portion 302 exerts a force on the inner wall 510 and the third portion 306 exerts a force on the surface 522. The force exerted by the baffle 300 on the inner wall 510 and the surface 522 can be adjusted by adjusting the shape, thickness, and / or material of the baffle 300. The force can be adjusted depending on the flow dynamics of the air to the air box, the installation size, the vehicle configuration, and the intended vehicle use. Thus, the baffle 300 can be installed in the vent box 508 and held therein without fasteners, tools, or similar devices. This can reduce the manufacturing costs and complexity of installing the baffle 300.In addition, the baffle 300 may be compressed during installation so that the baffle can slide through the passage 516 in a more compressed state than when the baffle 300 is in the expanded state in the vent box 508. In this way, the installation of the baffle 300 in the housing 500 of the drive axle assembly may be less complex and faster than with a baffle that is not compressed and / or uses a fastener.

[0041] The baffle 300 may impede air and / or lubricant flowing through the vent box 508. For example, air, represented by solid arrows 550, and lubricant, represented by dashed arrows 552, may initially pass from the hollow inner section 506 through the passage 516 and into the vent box 508. Air (e.g., solid arrows 550) and lubricant (e.g., dashed arrows 552) may flow through the opening 318 of the first section 302. The tab 320 may block the direct flow of air and lubricant to the opening 328 of the second section 304. Collisions with the baffle 300, combined with the swirl and indirect flow pattern through the baffle 300, may promote the separation of the lubricant from the air. This prevents some of the lubricant from flowing through the second opening.The lubricant deposits on the surfaces of the vent box 508 and flows back into a lubricant sump in the housing. The air and lubricant can then be forced past the second tab 330 and through the second portion 304 (e.g., through the second opening 328 of FIG. Fig. 3) of the baffle 300. The second tab 330 can direct the air and lubricant away from the third opening of the third section 306. The turbulence of the air mixed with the lubricant increases, which further promotes the separation of the lubricant from the air. The air and lubricant can then flow past the third tab 334 and through the third section 306 (e.g., through the third opening 332 of Fig. 3) of the baffle 300. The third tab 334 can direct the air and lubricant away from the opening 518. As can be seen from the size of the dashed arrows 552, a relatively small amount of lubricant flows through the third opening. The turbulence and misdirected flow after the third section can separate any remaining lubricant mixed with the air, allowing only air, or essentially only air (e.g., <1% lubricant), to flow through the opening 518. Thus, all of the air entering the vent box 508 from the hollow inner section 506 can flow through the baffle 300 and exit the vent box via the opening 518. The amount of lubricant can be represented by the size of the dashes in each of the dashed arrows 552.

[0042] In this way, it may be difficult for the lubricant (e.g., oil) to reach the breather due to the angled sections and tabs of the baffle 300. The angled sections and tabs force the air and / or lubricant to follow multiple turns while providing a large surface area for the lubricant to adhere to. Additionally, any lubricant splashes that reach the breather box 508 cannot easily pass through the baffle 300 and are instead deflected back toward the hollow inner section 506. In this way, positioning the baffle 300 within the breather box 508 of the drive axle assembly housing 500 can reduce or prevent lubricant from entering the breather (e.g., opening 518) and / or exiting the drive axle assembly housing via the breather box.

[0043] Fig. 7 shows a 700 of the drive axle assembly in which the guide plate 300 is in a first position. Fig. Figure 8 shows a drive axle assembly housing 700 with the guide vane 300 oriented in a second position. A portion of the drive axle assembly housing 700 has been omitted from the illustration to facilitate visualization of the guide vane 300 within the drive axle assembly housing. Also included are Fig. 7 and Fig. 8 each use a Cartesian coordinate system 799 for orienting the views. In one example, the y-axis may be a vertical axis (e.g., parallel to a gravity axis), the x-axis may be a longitudinal axis (e.g., a horizontal axis), and / or the z-axis may be a lateral axis. However, in other examples, the axes may have other orientations. In one example, gravity is parallel to a direction opposite the y-axis.

[0044] The drive axle assembly housing 700 may include a hollow inner portion 702, a vent box 704, an opening 706, and a breather (not shown), similar to the drive axle assembly housing 500 of Fig. 5 and Fig. 6. The vent box 704 may be positioned near a cover of the drive axle assembly housing. Additionally, the vent box 704 may be defined by an inner surface 708, an extension 710, and a plate 712. The inner surface 708 may include a bottom surface 714, a side surface 716, and a top surface 718, where the top surface is longer than the bottom surface. The top surface 718 may extend from the side surface 716 to the extension 710, and the extension may extend in the direction of gravity 797 from the top surface. The plate 712 may include a first portion 720 and a second portion 722, where the first portion is longer than the second portion. Additionally, the plate 712 may include a corner 724 disposed between the first portion 720 and the second portion 722, connecting the first portion and the second portion.The first portion 720 may be angled relative to the second portion 722 such that the plate 712 has an L-shape. In one example, the angle of the corner 724 may be greater than 90°.

[0045] A fastener 726 may extend through the second portion 722 of the plate 712 and connect the plate to the extension 710 of the drive axle assembly housing 700. The fastener 726 may be a bolt, a screw, or another type of fastener. In some examples, at least a portion of the fastener 726 may extend entirely through the extension 710 and thus be positioned within the vent box 704. In some examples, the plate 712 may additionally or alternatively be physically connected to the drive axle assembly housing 700 by gluing, welding, fusing, or a similar method.

[0046] The opening 706 may extend through the top surface 718 of the inner surface 708. Thus, the opening 706 may fluidly connect the vent box 704 to the outside environment, allowing air to enter and / or exit the vent box of the drive axle assembly housing 700. In some examples, the opening 706 may be circular (e.g., cylindrical). In other examples, the opening 706 may be rectangular, triangular, elliptical, or another suitable shape. In some examples, an inner surface of the opening 706 includes a substantially smooth bore; however, in other examples, the inner surface of the opening may be threaded and / or textured. Air may escape from the hollow inner portion 702 through the vent box 704, through the opening 706 (e.g., through the breather), and out of the drive axle assembly housing 700.

[0047] The baffle 300 may be positioned in the vent box 704 of the drive axle assembly housing 700. As shown in Fig. 7, a portion (e.g., an end) of the first portion 302 of the baffle 300 may be disposed proximate to the extension 710 and in surface contact therewith. Further, a portion (e.g., an end) of the third portion 306 may be disposed proximate to the side surface 716 of the inner surface 708 and in surface contact therewith. The baffle 300 may be compressed between the side surface 716 and the extension 710. Thus, the first portion 302 may exert a force on the extension 710 and the third portion may exert a force on the side surface 716. The force exerted by the baffle 300 may securely hold the baffle in place without the need for a fastener and / or drilling for mounting. For example, the baffle 300 may exert a threshold force (e.g., a predetermined force) on one or more portions of the inner surface 708.The threshold force may be based on the expected operation of the vehicle including the baffle 300 and may be greater than the forces acting on the baffle due to vibration, harshness, forces due to road irregularities, combinations thereof, and the like. Furthermore, the first bend 308 of the baffle 300 may be located near and in surface contact with the first portion 720 of the plate 712. Similarly, the second bend 310 may be located near and in surface contact with the upper surface 718 of the inner surface 708. Thus, air and oil may be forced to pass through the openings (e.g., opening 318) of the baffle 300 to reach the opening 706 (e.g., the breather).

[0048] The baffle 300 may be compressed and pressed into the vent box 704 during installation. For example, the fastener 726 and plate 712 may be removed, the baffle 300 compressed and inserted into the vent box 704, and the plate and fastener reattached. In this way, the installation of the baffle 300 into the drive axle assembly housing 700 may be less complex and faster than a baffle that is not compressed and / or requires a fastener. In another example, the plate 712 may remain installed (e.g., secured to the drive axle assembly housing 700 by the fastener 726) while the baffle 300 is installed into the vent box 704.This allows the baffle 300 to be compressed and forced past the plate 712 so that the baffle is positioned between the plate and the inner surface 708 of the vent box 704 and oriented to reduce the leakage of lubricant from the drive axle assembly housing 700.

[0049] In some examples, the inner surface of plate 712 and / or the inner surface 708 of vent box 704 may be textured in one or more areas. If present, the textured areas may be in surface contact with the baffle 300, for example, at the first bend 308, the second bend 310, an end of the first section 302 opposite the first bend, and / or an end of the third section 306 opposite the third bend, and may help hold the baffle in a desired position. The textured areas may, in some examples, be reinforcing ribs and / or rough (e.g., like a sandpaper texture).

[0050] Fig. Figure 8 shows a drive axle assembly housing 700 and the baffle 300 with the baffle oriented in a second position. A portion of the drive axle assembly housing 700 has been omitted from the illustration to facilitate visualization of the baffle 300 within the drive axle assembly housing.

[0051] A portion (e.g., an end) of the first portion 302 of the baffle 300 may be disposed proximate to the side surface 716 of the inner surface 708 and in surface contact therewith. Furthermore, a portion of the third portion 306 may be disposed proximate to the plate 712 and in surface contact therewith. The baffle 300 may be compressed between the side surface 716 and the plate 712. Thus, the first portion 302 may exert a force on the side surface 716 and the third portion may exert a force on the plate 712. The force exerted by the baffle 300 may securely hold the baffle in place without the need for a fastener and / or drilling for mounting. Furthermore, the first bend 308 of the baffle 300 may be disposed proximate to the first portion 720 of the plate 712 and in surface contact therewith.Accordingly, the second bend 310 may be disposed near and in surface contact with the upper surface 718 of the inner surface 708. Thus, air and oil may be forced to pass through the openings (e.g., opening 318) of the baffle 300 to reach the opening 706 (e.g., the breather).

[0052] The baffle 300 may be compressed during installation so that the baffle can fit into the vent box 704. For example, the fastener 726 and plate 712 may be removed, the baffle 300 compressed and inserted into the vent box 704, and the plate and fastener reattached so that the baffle is compressed by the plate and the inner surface 708. In this way, the installation of the baffle 300 into the drive axle assembly housing 700 may be less complex and faster than with a baffle that is not compressed and / or requires a fastener.

[0053] In each of the orientations Fig. 7 and Fig. 8, the baffle 300 may impede airflow through the vent box 704. For example, air flowing from the hollow inner section 702 to the opening 706 (e.g., the breather) flows through the openings (e.g., opening 318 in the first section 302) in the baffle. Thus, due to the angled sections and tabs of the baffle 300, it may be difficult for lubricant bubbles (e.g., oil) to reach the breather. The angled sections and tabs force the air and / or lubricant to follow multiple turns while providing a large surface area for the lubricant to adhere to. Additionally, lubricant splashes that reach the vent box 704 cannot easily pass through the baffle 300 and are instead redirected toward the hollow inner section 702.In this way, positioning the baffle 300 within the vent box 704 of the drive axle assembly housing 700 may reduce or prevent lubricant from entering the vent and / or exiting the drive axle assembly housing via the vent box.

[0054] Current axle breathers, mounted in close proximity to oil spray from rotating gears, require the installation of a baffle. A baffle prevents lubricant from splashing directly onto the axle breather outlet / inlet. Baffles are typically stamped and held to a close tolerance after assembly to ensure all parts fit together as intended and the baffle does not fall out of position and potentially interfere with rotating gears. The proposed baffle is a roughly stamped part with open-cut holes that can be hand-installed into a cavity and held in place by the further assembly of other components. The baffle ensures lubricant drainage while providing simple assembly, saving components and manufacturing costs.

[0055] The purpose of the baffle is to reduce or prevent the leakage of lubricant through the breather device of a drive axle housing. The baffle can be a simple stamped part with kinks and air channels partially punched into it. The punched passages in the baffle force air and oil to flow around multiple corners. It can be difficult for oil bubbles to maintain adhesion when passing through multiple levels, and the oil may not adhere to the baffle and / or remain a bubble. The airflow through the baffle prevents oil bubbles from reaching the breather outlet. The baffle can be designed with multiple bends / kinks that allow the baffle to act like a spring. This allows the baffle to be installed before final assembly and to be locked in place during assembly, preventing it from moving out of position.This eliminates the need for a precision mounting hole in the baffle or a corresponding threaded hole in a support. Therefore, the baffle can lead to easier installation and eliminate the need for machining, assembly, and fastener costs.

[0056] The technical effect of a spring-like deflector, which includes multiple sections, tabs, and openings, is that the deflector can be installed into a drive axle assembly housing without the need for fasteners or holes for mounting the deflector. Furthermore, the deflector can reduce or prevent lubricant leakage from the drive axle housing by directing airflow through the openings and around the corners of the deflector.

[0057] Fig.2-8 show example configurations with the relative arrangement of the various components. When these elements are in direct contact with each other or are directly coupled, they may be referred to as being in direct contact or directly coupled, respectively, at least in one example. Similarly, elements shown side by side or adjacent to each other may be adjacent to each other or adjacent to each other, at least in one example. For example, components that are in surface-to-surface contact with each other may be referred to as being in surface-to-surface contact. As another example, in at least one instance, elements that are separated from each other with only a space between them and that do not have any other components may be referred to as such.In yet another example, elements depicted above / below, on opposite sides, or to the left / right of each other may be referred to as such, relative to each other. Further, in at least one example, as depicted in the figures, a topmost element or point of an element may be referred to as a "top" of the component, and a bottommost element or point of the element may be referred to as a "bottom" of the component. As used herein, the terms top / bottom, upper / lower, above / below may refer to a vertical axis of the figures and may be used to describe the positioning of elements of the figures relative to each other. Thus, in one example, elements displayed above other elements are arranged vertically above the other elements.As another example, the shapes of the elements depicted in the figures may be referred to as such (e.g., circular, straight, flat, curved, rounded, beveled, angled, or the like). Furthermore, in at least one example, depicted elements that intersect each other may be referred to as intersecting elements or as intersecting elements. Furthermore, an element depicted inside another element or outside another element may be referred to as such.

[0058] The disclosure provides support for an axle assembly for a vehicle including a deflector comprising a first portion parallel to a first plane, a second portion parallel to a second plane and at an angle to the first portion, and a third portion parallel to a third plane and at an angle to the first portion and the second portion, wherein the deflector is a spring. A first example of the axle assembly includes the deflector applying a force to the components of the axle assembly. A second example of the axle assembly, optionally including the first example, further includes the deflector being held in the axle assembly solely by the force.A third example of the axle assembly, optionally including one or more of the preceding examples, further includes where the first section, the second section, and the third section each include at least one opening and a tab. A fourth example of the axle assembly, optionally including one or more of the preceding examples, further includes where a first bend is located between the first section and the second section and a second bend is located between the second section and the third section, wherein the first bend and the second bend are flexible and the first section, the second section, and the third section are rigid. A fifth example of the axle assembly, optionally including one or more of the preceding examples, further includes where the first section, the second section, and the third section are each square.A sixth example of the axle assembly, optionally including one or more of the preceding examples, further includes that the guide plate comprises a Z-shape. A seventh example of the axle assembly, optionally including one or more of the preceding examples, further includes that the guide plate is free of a mounting hole and is not held in the axle assembly by a physical connecting element.

[0059] The disclosure also provides support for an axle assembly of a vehicle including a vent box comprising a plate adjacent an opening and a baffle configured to expand within a cavity formed by the plate, the baffle being retained within the cavity only by a force exerted by the baffle on the plate. A first example of the axle assembly further includes the baffle comprising a first portion, a second portion, and a third portion arranged in three different planes. A second example of the axle assembly, optionally including the first example, further includes the baffle being flexible between the first portion and the second portion, and between the second portion and the third portion.A third example of the axis arrangement, optionally including one or more of the preceding examples, further includes the first portion, the second portion, and the third portion each comprising a tab and an opening. A fourth example of the axis arrangement, optionally including one or more of the preceding examples, further includes the tab being angled to a corresponding portion. A fifth example of the axis arrangement, optionally including one or more of the preceding examples, further includes the baffle being compressible. A sixth example of the axis arrangement, optionally including one or more of the preceding examples, further includes the air flowing through multiple planes as it flows through the baffle to the opening.

[0060] The disclosure further provides support for a vane of an axle assembly including a first portion disposed along a first plane and comprising a first tab and a first opening, a second portion disposed along a second plane and comprising a second tab and a second opening, a third portion disposed along a third plane and comprising a third tab and a third opening, a first bend disposed between the first portion and the second portion, and a second bend disposed between the second portion and the third portion, wherein the first bend and the second bend are flexible.A first example of the baffle further includes the first opening allowing air to flow in a first direction, the second opening allowing air to flow in a second direction that is at an angle to the first direction, and the third opening allowing air to flow in a third direction that is at an angle to the second direction. A second example of the baffle, optionally including the first example, further includes the third direction being parallel to the first direction. A third example of the baffle, optionally including one or more of the preceding examples, further includes the first tab being arranged along a fourth plane, the second tab being arranged along a fifth plane that forms an angle with the fourth plane, and the third tab being arranged along a sixth plane that forms an angle with each of the fourth and fifth planes.A fourth example of the axis arrangement, optionally including one or more of the preceding examples, further includes that the fourth plane is parallel to the second plane.

[0061] The term “approximately” means plus or minus five percent of the range, unless otherwise stated.

[0062] The following claims particularly point out certain combinations and subcombinations that are considered novel and non-obvious. These claims may refer to "a" element or "a first" element, or the equivalent thereof. Such claims are to be construed as including the inclusion of one or more such elements, neither requiring nor excluding two or more such elements. 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 broader, narrower, equal, or different in scope than the original claims, are also to be considered included within the subject matter of the present disclosure.

Claims

[1] Axle arrangement for a vehicle, comprising: a baffle comprising a first section parallel to a first plane, a second section parallel to a second plane and at an angle to the first section, and a third section parallel to a third plane and at an angle to the first section and the second section; wherein the baffle is a spring. [2] Axle assembly according to one of the preceding claims, wherein the guide plate exerts a force on components of the axle assembly. [3] Axle assembly according to claim 2, wherein the guide plate is held in the axle assembly only by the force. [4] An axle assembly according to any preceding claim, wherein the first portion, the second portion and the third portion each comprise at least one opening and one tab. [5] An axle assembly according to any preceding claim, wherein a first bend is located between the first portion and the second portion and a second bend is located between the second portion and the third portion, wherein the first bend and the second bend are flexible and the first portion, the second portion and the third portion are rigid. [6] An axle assembly according to any preceding claim, wherein the first section, the second section and the third section are each square. [7] Axle arrangement according to one of the preceding claims, wherein the guide plate comprises a Z-shape. [8] An axle assembly according to any preceding claim, wherein the guide plate is free of a mounting hole and is not held in the axle assembly by a physical connecting element. [9] Axle arrangement of a vehicle, comprising: a vent box comprising a plate adjacent to an opening; and a baffle adapted to expand within a cavity formed by the plate, the baffle being held within the cavity only by a force exerted by the baffle on the plate. [10] Axle assembly according to claim 9, wherein the guide plate comprises a first section, a second section and a third section arranged in three different planes. [11] The axle assembly of claim 10, wherein the baffle is flexible between the first portion and the second portion and between the second portion and the third portion. [12] An axle assembly according to claim 10 or 11, wherein the first portion, the second portion and the third portion each comprise a tab and an opening. [13] Axle assembly according to claim 12, wherein the tab is angled to a corresponding portion. [14] Axle arrangement according to one of claims 9 to 13, wherein the guide plate is compressible. [15] An axle assembly according to any one of claims 9 to 14, wherein the air flows through multiple planes as it flows through the baffle to the opening.

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