Heat transfer aid for pipe mounting monoblock joint arrangement

Abstract

Joint arrangement comprising: a constant velocity joint having an outer race with a welded seat; a flange component having a weld seat projection on a first side, the weld seat projection configured to engage the weld seat of the outer ring; a conductive component interconnecting the outer ring and the flange component at an interface between the outer ring and a second side of the flange component opposite the first side; and a shaft component drivingly coupled to the constant velocity joint, wherein the constant velocity joint is received by the shaft component at the weld seat of the outer ring and drivingly coupled to it.

Description

TECHNICAL FIELD

[0001] The present description relates to a constant velocity joint assembly having a thermally conductive resin and / or a thermally conductive insert material leading from an interface between an outer ring and a flange component connected to the outer ring. BACKGROUND AND OVERVIEW

[0002] Vehicles may be equipped with a transmission that shifts a variety of different gears, where each of the different gears can output different torque and speeds for the same input torque. Likewise, vehicles may have a variety of axle assemblies with axles. Rotating elements, such as driveshafts, may couple a transmission and / or other component containing and / or drivingly connected to a transfer case to an axle so that torque from the transmission and / or other component can drive the axle. Rotating elements of the vehicle, including driveshafts, may be rotationally coupled via joints, such as one or more constant velocity joints (CVJs). CVJs may drivingly couple driveshafts to the outputs of the transmission and / or other transfer cases, and CVJs may drive driveshafts to the inputs of axle assemblies.

[0003] An interface between a CVJ assembly and the axle and / or transfer case may include a cup-shaped flange (e.g., a cup-shaped mating flange). The cup-shaped flange may be pivotally connected to the CVJ using fasteners, such as bolts. The interface and fasteners may have a desired contact area. The desired contact area may also be key to facilitating heat transfer during normal operating conditions to an extent that reduces damage to the CVJ and CVJ assembly, so that heat accumulated in the CVJ or flange is kept below a temperature threshold.However, a CVJ assembly may have suboptimal interfaces where the contact areas between the CVJ, flange, and / or fasteners are below the desired contact area due to factors such as low production volumes, packaging constraints, or customer requests. Furthermore, a CVJ and flange may be frictionally connected at the interface without fasteners and by welding for the reasons mentioned above, albeit with reduced heat transfer.

[0004] The inventors herein have recognized these and other problems with such systems and found a way to at least partially solve them. In one example, a joint assembly is developed that includes a constant velocity joint having an outer race with a weld seat; a flange component having a weld seat projection on a first side, the weld seat projection configured to mate with the weld seat of the outer race; a conductive component connecting the constant velocity joint and the flange component at an interface between the outer race and a second side of the flange component opposite the first side; and a shaft component drivingly connected to the constant velocity joint, the constant velocity joint being received by and drivingly connected to the shaft component at the weld seat of the outer race.

[0005] 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 CHARACTERS Fig. 1 shows an example schematic representation of a vehicle that may include one or more of the constant velocity joints (CVJs) of the present disclosure. Fig. 2 shows a sectional view of a joint assembly including a constant velocity joint (CVJ) of the present disclosure. Fig. 3 shows a cross-sectional view of the joint assembly including the CVJ of the present disclosure with a thermally conductive feature of the present disclosure. Fig. 4 shows a first method of assembling a joint assembly with the CVJ of the present disclosure. Fig. 5 shows a second method of assembling a joint assembly with the CVJ of the present disclosure. DETAILED DESCRIPTION

[0006] The following description relates to a constant velocity joint (CVJ) that is part of a larger joint assembly. The joint assembly includes: the CVJ having an outer ring with a weld seat; and a flange component having a weld seat projection on a first side, the weld seat projection configured to mate with the weld seat of the outer ring. A conductive component is located between and connects the outer ring to the flange component at an interface between the outer ring and a second side of the flange component. The joint assembly further includes a shaft component drivingly connected to the CVJ, the CVJ being received by and drivingly connected to the shaft component at the weld seat of the outer ring. The weld seat of the outer ring includes a grease cap to retain fluid (e.g.lubricant) in the outer ring and prevent the ingress of dust and other contaminants into the outer ring. The CVJ may be configured as a tube-mounted monoblock (TMMB). The flange component may include one or more additional projections configured to physically connect the flange component to another flange, e.g., a flange of an axle, a transfer case, a high-speed propeller shaft, and / or a transmission. The conductive component may be formed from a resin of a thermally conductive material, may be a low-melting-point metal, and / or may be a thermally conductive inert material such as graphite. The conductive component may be in surface contact with the flange component (e.g., with the weld seat projection) and with the outer ring of the CVJ. The CVJ may be further connected to the flange component by a variety of means, e.g.,by fastening, magnetic welding and / or friction welding.

[0007] Fig. 1 shows an example schematic representation of a vehicle that may include one or more of the CVJs of the present disclosure. Fig. 2 shows a sectional view of a CVJ and a joint assembly according to the present disclosure. Fig. 3 shows a cross-sectional view of the CVJ and joint assembly of the present disclosure with a thermally conductive feature of the present disclosure applied. Fig. 4 shows a method of assembling a joint assembly with the CVJ of the present disclosure. Fig. Figure 5 shows a second method for assembling a joint assembly with the CVJ of the present disclosure. The method according to Fig. 4 involves molding and bonding a conductive component, such as a component comprising a thermally conductive resin, to the surfaces of both an outer ring and a flange component and an intermediate bonding material using an additive manufacturing process. The method according to Fig. 5 includes inserting the conductive component as a prefabricated component and bonding the prefabricated component to the surfaces of the outer ring and the flange component and a bonding material therebetween. The additive manufacturing method and the bonding of the first method and the second method of Fig. 4-5 can be done by welding and / or soldering of heat-conducting material.

[0008] It should also be understood that the specific arrangements and systems illustrated in the accompanying drawings and described in the following description are exemplary embodiments of the inventive concepts defined herein. For purposes of explanation, the drawings are described together. Thus, like elements may be referred to by like reference numerals and need not be repeated.

[0009] Fig. 1 shows a schematic representation of an exemplary configuration with the relative arrangement of the various components. Fig. 2-3 show example configurations with approximate position. Fig. Figures 2-3 are drawn approximately to scale, but other relative dimensions may be used. The term "approximately" means plus or minus five percent of the range, unless otherwise noted.

[0010] Furthermore, Fig. 1-3 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 or outside another element may be referred to as such. Furthermore, the components may be described with respect to the reference axes included in the drawings.

[0011] Features described as axial may be approximately parallel to a datum axis unless otherwise specified. Features described as reverse may be approximately perpendicular to the datum axis unless otherwise specified. Features described as radial may circumferentially surround or extend outwardly from an axis, such as the datum axis, or a component or feature previously described as radial to a datum axis, unless otherwise specified.

[0012] Features described as longitudinal can be approximately parallel to a long axis. A lateral axis can be perpendicular to a long axis and a vertical axis. Features described as lateral can be approximately parallel to the lateral axis. A vertical axis can be perpendicular to a transverse axis and a long axis. Features described as vertical can be approximately parallel to a vertical axis.

[0013] In Fig. 1, a vehicle 100 is illustrated that includes a powertrain 101 and a transmission 103. The vehicle 100 may have a front end 102 and a rear end 104 located on opposite sides of the vehicle 100. Objects, components, and features of the vehicle 100 referred to as being near the front may be closest to the front end 102 compared to the rear end 104. Objects, components, and features of the vehicle 100 referred to as being near the rear may be closest to the rear end 104 compared to the front end 102. The powertrain 101 includes a prime mover 106 and a transmission 108. The prime mover 106 may be, for example, an internal combustion engine (ICE) or an electric motor and operates to provide rotational power to the transmission 108. The transmission 108 may be any type of transmission, such asa manual transmission, an automatic transmission, or a continuously variable transmission. Furthermore, the transmission 108 may be or include a manual transmission. The transmission 108 receives the torque generated by the prime mover 106 as input and outputs the torque to the drivetrain 103 according to a selected gear ratio or setting. Furthermore, in addition to the main drive 106, there may be additional drives in the vehicle, e.g., a secondary drive 120.

[0014] In some examples, the vehicle 100 may additionally or alternatively be a hybrid vehicle that includes both a motor and an electric machine, each configured to power one or more of the first axle assembly 112 and the second axle assembly 122. For example, one or both of the first axle assembly 112 and the second axle assembly 122 may be powered by power from the electric machine in a first operating mode in which the electric machine is not operating to provide power (e.g., a motor-only mode), by power from the electric machine in a second operating mode in which the motor is not operating to provide power (e.g., a pure electric mode), and by power from both the motor and the electric machine in a third operating mode (e.g., an electric-assist mode).In another example, one or both of the first axle assembly 112 and the second axle assembly 122 may be an electric axle assembly configured to be driven by an integrated electric machine.

[0015] For example, if the prime mover 106 is an internal combustion engine and the vehicle 100 is a hybrid vehicle, there may be at least one other prime mover in addition to the prime mover 106, which feeds into the transmission 108. The other drive may be an electric machine, e.g., an electric motor. In this example, the second mover 120 may be the other mover and an electric machine. In one example, the vehicle 100 may be a hybrid vehicle if, in addition to the prime mover 106, there are one or more second drives, with multiple torque inputs to the transmission 108. The vehicle 100 may have a longitudinal axis 130. The driveline 101 and the transmission line 103 may have a length parallel to the longitudinal axis 130.

[0016] The prime mover 106 may be powered by energy from an energy storage device 105. In one example, the energy storage device 105 is a battery, e.g., a traction battery, configured to store electrical energy. An inverter 107 may be disposed between the energy storage device 105 and the prime mover 106 and configured to convert direct current (DC) to alternating current (AC). The inverter 107 may include a variety of components and circuits with thermal requirements that affect the efficiency of the inverter.

[0017] The vehicle 100 may be a commercial vehicle, a light-duty, medium-duty, or heavy-duty vehicle, a passenger vehicle, an off-highway vehicle, a utility vehicle, an agricultural vehicle, and / or a sport utility vehicle. In one embodiment, the vehicle 100 may be a wheeled vehicle, such as an automobile. Additionally or alternatively, the vehicle 100 may be an aircraft, a boat, or other vehicle system. Additionally or alternatively, the vehicle 100 and / or one or more of its components, such as components of the powertrain 101 and / or the drivetrain 103, may be used in industrial, locomotive, military, agricultural, and / or aerospace applications. In one example, the vehicle 100 is an all-electric vehicle or a vehicle with an all-electric mode of operation, such as a plug-in hybrid vehicle.Thus, the prime mover 106 may be an electric machine. In one example, the prime mover 106 may be an electric motor / generator.

[0018] In some examples, such as Fig. 1, the geartrain 103 includes a first axle assembly 112 and a second axle assembly 122. The first axle assembly 112 may be configured to drive a first set of wheels 114, and the second axle assembly 122 may be configured to drive a second set of wheels 124. In one example, the first axle assembly 112 is located near a front of the vehicle 100 and therefore includes a front axle, and the second axle assembly 122 is located near a rear of the vehicle 100 and therefore includes a rear axle. The geartrain 103 is shown in an all-wheel drive configuration, although other configurations are possible. For example, the drivetrain 103 may be rear-wheel drive, front-wheel drive, or all-wheel drive. Additionally, the geartrain 103 may include one or more tandem axle assemblies.Thus, the transmission train 103 may have other configurations without departing from the scope of this disclosure, and the configurations shown in . Fig. 1 is for illustrative purposes and is not limiting. Additionally, the vehicle 100 may include additional wheels that are not coupled to the geartrain 103. The vehicle 100 may have a first drive shaft 113 and / or a second drive shaft 123. The transmission 108 may driveably couple the first drive shaft 113 and / or the second drive shaft 123. The transmission 108 may driveably couple the first drive shaft 113 and / or the second drive shaft 123 via the transfer case 110. The first drive shaft 113 may driveably couple the first axle assembly 112. The second drive shaft 123 may driveably couple the second axle assembly 122. The transmission 108 can drive-couple the first axle assembly 112 via the first drive shaft 113 so that the torque can be transmitted from the transmission 108 to the first axle assembly 112 via the first drive shaft 113.The transmission 108 can drive-couple the second axle assembly 122 via the second drive shaft 123 so that torque can be transmitted from the transmission 108 to the second axle assembly 122 via the second drive shaft 123.

[0019] The first axle assembly 112 may include a first differential 116 and a first set of axleshafts. The first differential 116 may driveably couple the first set of axleshafts to transmit torque to and drive the first set of axleshafts. The first set of axleshafts may include a first shaft 118a and a second shaft 118b. The second axle assembly 122 may include a second differential 126 and a second set of axleshafts. The second differential 126 may driveably couple the second set of axleshafts to transmit torque to and drive the second set of axleshafts. The second set of axleshafts may include a third shaft 128a and a fourth shaft 128b. The first set of axleshafts and the second set of axleshafts may be axle halfshafts for the first axle assembly 112 and the second axle assembly 122, respectively.The first shaft 118a and the second shaft 118b may be axle halfshafts for the first axle assembly 112. The third shaft 128a and the fourth shaft 128b may be axle halfshafts for the second axle assembly 122. The first and second differentials 116, 126 may distribute unequal torque to each of the first axle shaft groups and to each of the second axle shaft groups, respectively. For example, the first differential 116 may distribute unequal torque to the first shaft 118a and the second shaft 118b. Likewise, in this or another example, the second differential 126 may distribute unequal torque to the third shaft 128a and the fourth shaft 128b.

[0020] In some configurations, such as Fig. 1, the powertrain 103 includes a transfer case 110 configured to receive the rotary power output from the transmission 108. The first input shaft 113 is drivingly connected to a first output 132 of the transfer case 110, while the second input shaft 123 is drivingly connected to a second output 142 of the transfer case 110. The first input shaft 113 may driveably couple the first differential 116 via a first input 134. The first drive shaft 113 (e.g., a front drive shaft) transmits the rotational power from the transfer case 110 to a first differential 116 of the first axle assembly 112 to drive the first set of wheels 114, while the second drive shaft 123 (e.g., a rear drive shaft) transmits the rotational power from the transfer case 110 to a second differential 126 of the second axle assembly 122 to drive the second set of wheels 124.For example, the first differential 116 is drivingly connected to a first set of axleshafts coupled to the first set of wheels 114, and the second differential 126 is drivingly connected to a second set of axleshafts coupled to the second set of wheels 124. The first differential 116 may driveably couple the first shaft 118a and the second shaft 118b. The second differential 126 may driveably couple the third shaft 128a and the fourth shaft 128b. The first set of axleshafts and the second set of axleshafts may each be housed in a housing. The first drive shaft 113 and the second drive shaft 123 may be arranged to extend parallel to the longitudinal axis 130. In one example configuration of the vehicle 100, the second drive shaft 123 may be centered about the longitudinal axis 130.

[0021] The first input shaft 113 may driveably couple the first differential 116 via a first input 134. Likewise, the second input shaft 123 may driveably couple the second differential 126 via a second input 144. The first input shaft 113 and the second input shaft 123 may be driveably connected to other rotating elements, such as their respective inputs and outputs, via a plurality of joints. For example, the first input shaft 113 may be driveably connected to the first output 132 via a first joint 136. Furthermore, the first input shaft 113 may be driveably connected to the first input 134 via a second joint 138. Likewise, the second input shaft 123 may be driveably connected to the second output 142 via a third joint 146. In addition, the second drive shaft 123 can be drivingly connected to the second input 144 via a fourth joint 148.

[0022] The first differential 116 may driveably couple the first shaft 118a via a third output 172. The first differential 116 may driveably couple the second shaft 118b via a fourth output 174. The second differential 126 may driveably couple the third shaft 128a via a fifth output 176. The second differential 126 may driveably couple the fourth shaft 128b via a sixth output 178. The first shaft 118a and the second shaft 118b may be driveably connected to other rotating elements, such as the third output 172 and the fourth output 174, respectively, and the first gear set 114, via a plurality of joints. For example, the first shaft 118a may be driveably connected to the third output 172 via a fifth joint 182. Additionally or alternatively, the first shaft 118a can drive-couple a wheel of the first wheel set 114 via a sixth joint 184.The second shaft 118b may be drivingly connected to the fourth output 174 via a seventh joint 186. Additionally or alternatively, the second shaft 118b may driveably couple a wheel of the first gear set 114 via an eighth joint 188. In this or another example, the third shaft 128a may be driveably connected to the fifth output 176 via a ninth joint 190. Additionally or alternatively, the third shaft 128a may driveably couple a wheel of the second gear set 124 via a tenth joint 192. The fourth shaft 128b may be driveably connected to the sixth output 178 via an eleventh joint 194. Additionally or alternatively, the fourth shaft 128b may driveably couple a wheel of the second gear set 124 via a twelfth joint 196.

[0023] The vehicle 100 and drivetrain 103 may include a plurality of CVJs. A CVJ may driveably couple at least a first rotating member and a second rotating member, e.g., a first shaft and a second shaft, such that the first rotating member and the second rotating member can freely rotate and / or pivot, and the first rotating member can drive the second rotating member, and vice versa, at an angle between the first rotating member and the second rotating member. The CVJ may compensate for the angle between the first rotating member and the second rotating member when the angle is between a threshold range of angles. The angle between the first rotating member and the second rotating member may change during rotation, e.g., during operation of the suspension, where the position of the first axle or the second axle may change.The first joint 136, the second joint 138, the third joint 146, and / or the fourth joint 148 may be CVJs. Additionally or alternatively, the fifth joint 182, the sixth joint 184, the seventh joint 186, the eighth joint 188, the ninth joint 190, the tenth joint 192, the eleventh joint 194, and / or the twelfth joint 196 may also be CVJs. Furthermore, additional CVJs may be drivingly coupled to other shafts and rotating elements of the vehicle 100.

[0024] The first differential 116 may provide some front-wheel drive to the vehicle 100 as part of the rotational power transmitted via the first drive shaft 113. Similarly, the second differential 126 may provide rear-wheel drive to the vehicle 100 as part of the rotational power transmitted via the second drive shaft 123. The first differential 116 and the second differential 126 may provide front-wheel drive and rear-wheel drive, respectively, as part of an all-wheel drive mode for the vehicle 100.

[0025] The adjustment of the transmission 103 between the various modes, as well as the control of operation within each mode, may be based on a vehicle control system 154, including a controller 156. The controller 156 may be a microcomputer, including components such as a microprocessor unit, input / output ports, an electronic storage medium for executable programs and calibration values, e.g., a read-only memory chip, random access memory, diagnostic memory, and a data bus. The storage medium may be programmed with computer-readable data representing instructions executable by a processor to perform the methods described below, as well as other variations that are expected but not explicitly listed. In one example, the controller 156 may be a powertrain control module (PCM).

[0026] The controller 156 may receive various signals from sensors 158 coupled to various areas of the vehicle 100. The sensors 158 may include, for example, sensors on the prime mover 106 or another prime mover for measuring the speed and temperature of the prime mover, a pedal position sensor for detecting the actuation of a pedal actuated by the driver, e.g., an accelerator or brake pedal, a lever position sensor for detecting the adjustment of a lever, e.g., a brake lever, speed sensors on the first and second wheel sets 114, 124, etc. After receiving the signals from the various sensors 158 Fig. 1, the controller 156 processes the received signals and deploys various actuators 160 of the vehicle 100 to adjust the operation of the transmission based on the received signals and the instructions stored in the memory of the controller 156. For example, the controller 156 may receive an indication of brake pedal application, signaling a desire for a lower vehicle speed. Vehicle braking may be directly proportional to the position of the accelerator pedal, e.g., the degree of application. Another example is that the controller 156 may receive an indication of accelerator pedal application, signaling a desire for a higher vehicle speed. Vehicle acceleration may be directly proportional to the accelerator pedal position, e.g., the degree of application. In response, the controller 156 may command actions such as shifting gears of the transmission 108.Alternatively, the gears of the transmission 108 can also be shifted manually, e.g., if the transmission 108 is a manual transmission.

[0027] In some embodiments, transmission 108 may additionally or alternatively be a first transmission, and vehicle 100 may have a second transmission disposed on the second set of axle shafts, the third shaft 128a and the fourth shaft 128b. Transmission 108 may be a gear box. Alternatively, transmission 108 may also be an axle transmission or a transaxle transmission.

[0028] A set of reference axes 201 is provided for comparison between the views in Fig. 2-3. The reference axes 201 indicate a y-axis, an x-axis, and a z-axis. In one example, the z-axis may be parallel to a direction of gravity and the xy-plane may be parallel to a horizontal plane on which a joint assembly 202 of Fig. 2. A circle can represent an axis of the reference axes 201 that is perpendicular to a view. A filled circle can represent an arrow and an axis that is directed toward or positively toward a view. An open circle can represent an arrow and an axis that is directed away from or negative toward a view.

[0029] In Fig. 2 shows a first view 200 of the joint assembly 202. The first view 200 may be a sectional view of the joint assembly 202, showing a section through the joint assembly 202 in a sectional plane that includes an axis 210 and is parallel to a plane formed by the y-axis and the z-axis. The axis 210 may be a central axis on which the joint assembly 202 may be centered, e.g., positioned radially around the axis 210. The joint assembly 202 may have a first side 204 and a second side 206, with the first side 204 opposite the second side 206. The joint assembly 202 may have an outer side 208, with the outer side 208 being a volume, e.g., a packaging space, that surrounds the joint assembly 202. The joint assembly 202 may be an example of the first joint 136, the second joint 138, the third joint 146 and / or the fourth joint 148 of Fig. 1.

[0030] The joint assembly 202 includes a CVJ 214, a flange component 216, a conductive component (in Fig. 3) and a shaft component 212. The CVJ 214 may be configured, for example, as a TMMB joint. The CVJ 214 includes an outer ring 220 having a weld seat 244. The flange component 216 includes a weld seat projection 234 on a first side 204, the weld seat projection 234 being configured to mate with the weld seat 244 of the outer ring 220. The conductive component connects the outer ring 220 and the flange component 216 at an interface 250 between a second side of the flange component 216, opposite the first side, and the outer ring 220. The shaft component 212 is drivingly connected to the CVJ 214 at the weld seat 244 of the outer ring 220. The CVJ 214 further includes an inner ring 286 and a cage 282 located between the outer ring 220 and the inner ring 286. A plurality of bearings, such as balls, are located in an outer ring raceway 264 of the outer ring 220 and an inner ring raceway 284 of the inner ring 286.A lubricant fills an internal cavity of a sealing system, such as a boot 228, which is configured to retain the lubricant and prevent contaminants from entering the CVJ 214. The CVJ 214 is mounted on a drive shaft tube, for example, by magnetic arc and / or friction welding.

[0031] The shaft component 212 may be a rotating element through which torque can be transferred to or from the CVJ 214. The shaft component 212 may be physically and rotatably connected to the CVJ 214. The shaft component 212 may drive and rotatably couple an input or an output, such as the first drive shaft 113, the second drive shaft 123, the first output 132, the second output 142, the first input 134, or the second input 144 of the vehicle 100 of Fig. 1. Likewise, torque may be transmitted to and from the joint assembly 202 via the flange component 216. The flange component 216 may be coupled to an input or an output, such as the first drive shaft 113, the second drive shaft 123, the first output 132, the second output 142, the first input 134, or the second input 144 of the vehicle 100 of Fig. 1. When the flange component 216 and the outer ring 220 are physically coupled, they may form a head assembly. As a head assembly, the flange component 216 and the outer ring 220 may be physically and drivingly coupled to a rotating element, such as an input or output of the joint assembly 202.

[0032] The shaft component 212 may be centered on a centerline 218 such that the shaft component 212 may be arranged radially about the centerline 218. The centerline 218 may be aligned with the axis 210 such that it is coaxial with the axis 210. However, the centerline 218 may be out of alignment with the centerline 218. The shaft component 212 may include or be physically connected to a weld seat 222. The weld seat 222 of the shaft may be arranged on the opposite side of the joint assembly 202 from the flange component 216. The weld seat 222 may be coupled to an input or an output, for example, to the first drive shaft 113, the second drive shaft 123, the first output 132, the second output 142, the first input 134, or the second input 144 of the vehicle 100 of Fig. 1. When coupled to a component, the shaft weld seat 222 may be drivingly coupled so that it is driven by or drives the coupled component. The shaft component 212 may include a sleeve seat 224 extending between the shaft weld seat 222 and a tube-shaft keyway 230. The tube-shaft spline 230 may be attached to the CVJ 214 via a keyway in the inner race 286. When received over the CVJ 214, the tube-shaft spline 230 may drivingly couple the CVJ 214 so that the CVJ 214 may be driven via the shaft component 212. The shaft component 212 and the CVJ 214 may be centered on the axis 210.

[0033] A cover component may be positioned around the shaft component 212, covering portions thereof, sharing a common surface with it, forming a fluid seal against it, and coupling it. In particular, the cover component may be flexibly coupled to the shaft component 212 such that the shaft component can be rotated and / or spun while the cover component remains stationary relative to it. The cover component may be rigidly connected to the outer ring 220 via a fastening component, wherein the fastening component may be rigidly connected to the outer ring 220 and create a fluid seal against it. The fluid seals between the cover component and the shaft component 212, the cover component and the fastening component, and the fastening component and the outer ring 220 may be at least fluid-tight and in particular watertight.In other words, the fluid seals between the cover component and the shaft component 212, the cover component and the fastening component, and the fastening component and the outer ring 220 can block and reduce the ingress of liquids and at least water and aqueous fluid from outside 208 into the volume between the shaft component and the cover component, the shaft component and the fastening component, the cover component and the fastening component, the cover component and the outer ring, and the fastening component and the outer ring.

[0034] For example, a first portion of the sleeve seat 224 may be covered by a sleeve 226, with the sleeve being the cover component. The sleeve 226 may have a common surface that contacts and physically couples a second portion of the stud that is smaller than and enclosed by the first portion of the sleeve seat 224. The sleeve 226 may be physically connected to the sleeve socket 228, with the sleeve socket 228 being the attachment component for the cover component. The sleeve socket 228 may be physically connected to the outer ring 220. More specifically, the sleeve socket 228 may be rigidly connected to the outer ring 220. The sleeve socket 228 may be physically and rigidly coupled to the outer ring 220 via a snap connection. The sleeve socket 228 may have an extension that wraps around one or more outer surfaces of the outer ring 220, such asa first surface 242, can be positioned around, presses against it and snaps into place thereon.

[0035] In addition, the sleeve, when coupled, can form at least a fluid-tight seal. In other words, the sleeve 226 and the sleeve can 228 can seal a first cavity 252 of the outer ring 220 from the outer surface 208. The sleeve 226 and the sleeve can 228 can prevent water and dust from entering the cavity and coming into contact with the CVJ 214. The sleeve 226 and the sleeve can 228 can prevent damage to the CVJ 214 therein from contact with water and dust. The sleeve 226 and the sleeve can 228 can also prevent the first cavity 252 and portions of the sleeve seat 224 from being damaged by contact with components, features, or surfaces in the outer surface 208. The sleeve 226, the sleeve can 228, and the first cavity 252 can form a first chamber 246, e.g. B. when the sleeve 226 is connected to the sleeve box 228 and the seal is connected to the outer ring 220.The first chamber 246 may be fluid-tight and at least watertight, e.g., if the sleeve 226 and the sleeve can 228, or another cover component and fastening component, form seals with the shaft component 212 and the outer race 220 around it. A lubricant, such as grease, for the 214 and its bearings may be housed in the first chamber 246.

[0036] It goes without saying that there can be other configurations of cover components besides a cuff. Another example is the cover component in the form of a jacket.

[0037] In addition to the sleeve 226 or other cover component, a fluid seal may be formed between the sleeve can 228 and the outer ring 220 via a sealing element 245. The sealing component 245 may be annular (e.g., an annular seal), such as an O-ring. The sealing component 245 may be disposed between, e.g., radially between, pressing against the outer ring 220 and establishing a fluid-tight seal between and against the sleeve can 228 and the outer ring 220. More specifically, the sealing component 245 may be disposed within a groove 247 and pressing against a plurality of groove surfaces (e.g., surfaces surrounding and defining the volumetric shape of the groove 247).When the sealing component 245 is pressed over the sleeve can 228 and in particular the extension of the sleeve can 228 around it, it can create a fluid-tight and at least watertight seal against one or more of the groove surfaces of the groove 247.

[0038] The outer ring 220 may be physically connected to the weld seat boss 234 of the flange component 216. The weld seat boss 234 may be connected to an interface 238 of the flange component. The interface 238 of the flange component may be part of a head for the flange component 216, e.g., when the flange component 216 and the outer ring 220 are part of a head unit. Torque may be transmitted from the CVJ 214 to the outer ring 220 and to and through the flange component 216, similar to the transmission of torque via a disk-shaped joint assembly.

[0039] The weld seat of the flange component may be a projection, referred to herein as weld seat projection 234, extending from the flange component 216. The flange component 216 may also include a passageway 236 and the interface 238 for fastening the flange component. The passageway 236 may be concentric with the weld seat projection 234 and the interface 238 of the flange component. The weld seat projection 234 may be connected to the interface 238 of the flange component of the fastener. The interface 238 of the flange component may extend outwardly from the weld seat projection 234 and the passageway 236, where outward means relative to and away from the axis 210. In other words, the interface 238 of the flange component may extend radially beyond the weld seat projection 234 and the passageway 236. The interface 238 of the flange component may include a plurality of holes 240.The holes 240 may be through-holes, such as through holes, or they may be threaded. For example, a plurality of fasteners may be passed through and received by the holes 240 to secure the interface 238 of the flange component to a rotating member, such as an input or output connection flange. In this or another example, a plurality of dowels may be passed through and received by the holes 240. The outer ring 220 may be physically connected to the flange component 216, where the outer ring 220 may be physically connected to the weld seat boss 234. The outer ring 220 and the flange component 216 may be centered on the axis 210. For example, the outer ring 220 and the flange component 216 may be radially disposed about the axis 210.When the shaft component 212 is no longer aligned with the axis 210, the outer ring 220 and the flange component 216 can remain centered on the axis 210.

[0040] The outer ring 220 may include a variety of features that form the "cup" shape of the outer ring, including surfaces 242, 266, 268, 270, the outer ring weld seat 244, and the region of the outer ring 220 containing the tracks 264. The inner portions of the outer ring are defined by surfaces 242, 266, 268, 270, and the track region may form the first cavity 252. The outer ring weld seat 244 may be physically coupled to the weld seat boss 234, forming a common surface. The sleeve can 228 may physically couple the raceway region of the outer ring 220, for example, by crimping.

[0041] The outer ring weld seat 244 and the weld seat projection 234 may be connected at an interface 250, for example, by a weld. The interface 250 may be a conductive surface (e.g., a thermally conductive surface) between the outer ring 220 and the weld seat projection 234, across which heat transfer may occur. The CVJ 214 may be drivingly connected to the weld seat projection 234 so that torque from the CVJ 214 can drive the weld seat projection 234 and vice versa.

[0042] The outer ring 220 may have a second cavity 254, and the flange component 216 may have a third cavity 256. An inner surface of a second flange may form the second cavity 254. An inner surface of the flange component 216 may form the third cavity 256. The second cavity 254 and the third cavity 256 may form a second chamber 248, e.g., when the second flange is connected to the flange component 216. The first cavity 252 may have a vent opening 260. The vent opening 260 may communicate between the second cavity 254 and the second chamber 248 and the CVJ interior and supply fluid thereto. The opening 260 may extend through the wall 262.

[0043] The first cavity 252 may include the outer ring raceway 264, a bore surface 266, a third surface 268, and a fourth surface 270. The outer ring raceway 264, the surface 266, the third surface 268, and the fourth surface 270 may be inner surfaces of the outer ring 220 and extend radially to the axis 210. The outer ring raceway 264 and the fourth surface 270 may be curved and concave in shape. The second surface 266 and the third surface 268 may be curved and cylindrical in shape. The fourth surface 270 may be connected to and adjacent to the opening 260.

[0044] The weld seat 244 of the outer ring may have a fifth surface 272, wherein the fifth surface 272 may be an inner surface of the weld seat 244 of the outer ring. Likewise, the flange component 216 may have a sixth surface 274, wherein the sixth surface 274 may be an inner surface of the weld seat projection 234. The fifth surface 272 and the sixth surface 274 may curve about the axis 210, for example, radially about the axis 210. The fifth surface 272 may curve inwardly toward the wall 262 with respect to the axis 210. The fifth surface 272 may be connected to the wall 262 and may be adjacent to surfaces of the wall 262 that are surrounded by the third cavity 256. Likewise, the sixth surface 274 may curve inwardly relative to the axis 210 toward the passage 236. The sixth surface 274 may be adjacent to a seventh surface 276 of the passage 236. The seventh surface 276 may curve radially around the axis 210.The passage 236 may also include a mounting boss 278 that radially curves around the axis 210. A first portion of the passage 236, including the seventh surface 276, may have a smaller diameter than a second portion of the passage 236, including the mounting pilot 278.

[0045] The CVJ 214 may include a plurality of joint parts, including a cage 282, an outer ring 220, and an inner ring 286. The cage 282 may be a support for a plurality of bearings. The cage 282 may be physically surrounded by the outer ring 220 and the inner ring via the spherical bearing surfaces. The cage 282 may be pivotally mounted therein relative to the outer ring 220 and the flange component 216. The inner ring 286 may be physically connected to the shaft component 212, e.g., via the tube-shaft keyway 230. The inner ring 286 may be rotatably mounted therein with the shaft component 212. The shaft component 212 and the inner ring 286 may be pivoted such that the centerline 218 is not coaxial with the axis 210. The bearings (not shown) are clamped by the inner ring raceway 284, the outer ring raceways 264, and the cage windows. The CVJ bearings can be ball bearings.

[0046] The inner ring 286 and the shaft component 212 can be pivoted at an angle 292 to the axis 210. The angle 292 is an angle by which the centerline 218 can deviate from coaxiality with the axis 210. The angle of the cage and the balls contained therein moves by half of the angle 292 because the design shown is a Rzeppa joint. The position of the balls is controlled by the rail geometry and the cage windows. The efficiency of the joint decreases and losses increase with increasing angle. As the angle increases, the importance of heat transfer from the joint increases.

[0047] In Fig. 3, the first view 200 of the joint arrangement 202 is shown, wherein the joint arrangement 202 of Fig. 3 comprises a plurality of thermal conductors, such as a conductive component 322, housed above the second chamber 248. The conductive component 322 may be a cylindrical body of revolution. The conductive component 322 may physically connect the second cavity 254 and the third cavity 256. The conductive component 322 may physically couple the fifth surface 272, the sixth surface 274, and the interface 250, for example, by bonding. The conductive component 322 may radially curve about the axis 210 with the curvature of the fifth surface 272 and the sixth surface 274. The conductive component 322 may have a first inner surface 342. The first inner surface 342 may be flush with the radius of the seventh surface 276 and curve accordingly.

[0048] The conductive component 322 can increase the surface area for conductive heat transfer between the outer race 220 and the flange component 216 beyond the interface 250. The conductive component 322 can act as a heat sink and conductor by conducting thermal energy from the outer race 220 and transferring it to the flange component 216. The thermal energy is then passed to the axle, high-speed propeller shaft, transfer case, and / or transmission for dissipation. The thermal energy absorbed via the component 322 can also be dissipated by convection via a fluid, such as air, coolant, and / or lubricant, housed in the second chamber 248.

[0049] The conductive component 322 may, for example, comprise a thermally conductive resin (e.g., made of a thermally conductive resin). As a resin, the conductive component 322 may be applied to the fifth surface 272, the sixth surface 274, and the interface 250 and cured. Alternatively, the conductive component 322 may also comprise a low-melting-point metal. For example, the conductive component 322 may be a low-melting-point metal soldered to the fifth surface 272, the sixth surface 274, and the interface 250. As another example, the conductive component 322 may be a low-melting-point metal insert welded or soldered to the fifth surface 272, the sixth surface 274, and the interface 250. As another example, the component 322 may comprise a thermally conductive and inert material such as graphite.The conductive component 322 may be a thermally conductive and inert material bonded to the fifth surface 272, the sixth surface 274, and the interface 250 as an insert.

[0050] The disclosure also provides support for a joint assembly comprising: a constant velocity joint having an outer race with a weld seat, a flange component having a weld seat protrusion on a first side, the weld seat protrusion configured to mate with the weld seat of the outer race, a conductive component connecting the outer race and the flange component at an interface between the outer race and a second side of the flange component opposite the first side, and a shaft component drivingly coupled to the constant velocity joint, the constant velocity joint being received by and drivingly coupled to the shaft component at the weld seat of the outer race. In a first example of the system, a chamber is formed between the outer race and the flange component, and the conductive component is removably positioned in the chamber.In a second example of the system, optionally including the first example, the system further comprises: a second conductive component disposed within the chamber. In a third example of the system, optionally including one or both of the first and second examples, the flange component comprises a passageway in fluid communication with the chamber, and wherein the passageway is coaxial with a central axis of the outer ring and the flange component. In a fourth example of the system, optionally including one or more or each of the first to third examples, the conductive component has a third surface, and the third surface is flush with and curves with a fourth surface of the passageway. In a fifth example of the system, optionally including one or more or each of the first to fourth examples, the conductive component comprises a thermally conductive resin.In a sixth example of the system, optionally comprising one or more or each of the first to fifth examples, the conductive component comprises a low melting point metal. In a seventh example of the system, optionally comprising one or more or each of the first to sixth examples, the conductive component comprises a conductive inert material. In an eighth example of the system, optionally comprising one or more or each of the first to seventh examples, the shaft component is coupled to the constant velocity joint via a containment shell coupled to the outer race on a side of the outer race opposite the flange component, and wherein the coupling of the boot can and the outer race creates a fluid-tight cavity therebetween.In a ninth example of the system, optionally comprising one or more or each of the first to eighth examples, the constant velocity joint is configured as a tube mount monoblock (TMMB) joint including the outer race with the weld seat. In a tenth example of the system, optionally comprising one or more or each of the first to ninth examples, the shaft component is rotatably connected to a rotational input and / or output. In an eleventh example of the system, optionally comprising one or more or each of the first to tenth examples, the flange component is rotatably coupled to a rotational input and / or output.

[0051] The disclosure also provides a constant velocity joint support comprising: a tube-mounted monoblock joint having a weld seat on a back surface, a flange component having a weld seat protrusion on a front surface, the weld seat protrusion configured to mate with the weld seat, and a conductive component disposed at an interface between the weld seat protrusion and the weld seat. In a first example of the system, the tube-mounted monoblock joint has an outer ring, an inner ring, and a cage disposed between the outer ring and the inner ring. In a second example of the system, optionally including the first example, the system further comprises: a plurality of balls disposed in an inner ring raceway of the inner ring and an outer ring raceway of the outer ring.In a third example of the system, optionally including one or both of the first and second examples, the outer race is connected to the weld seat projection of the flange component at the weld seat of the tube-mounted monoblock joint. In a fourth example of the system, optionally including one or more or each of the first to third examples, the system further comprises: a sealing system. In a fifth example of the system, optionally including one or more or each of the first to fourth examples, the tube-mounted monoblock joint couples the constant velocity joint to a driveshaft tube.

[0052] Fig. 4 shows a first example of a first method 400 for constructing and assembling a constant velocity joint assembly in accordance with the present disclosure, such as a constant velocity joint assembly 202.

[0053] The method 400 begins at 402 with the assembly of an outer ring, a cage, bearings, and an inner ring, forming a CVJ. For example, the outer ring 220, the cage 282, the ball bearings, and the inner ring 286 are assembled via 402 to form the CVJ 214. 402 includes installing bearings into an outer ring retaining feature, such as the outer ring raceway 264. 402 includes inserting the cage with the bearings into a volume of the outer ring while the outer ring is positioned around the cage and the bearings between the outer ring and cage retaining features. Further construction of the CVJ includes inserting other bearings into other inner ring retaining devices, such as the inner ring raceway 284. Further, the method 400 includes inserting the inner ring with the bearings into a space surrounded by the cage, with the other bearings disposed between the cage and the inner ring.

[0054] The method 400 continues to 404, where the outer ring and a flange portion are secured to reduce unwanted movement thereof.

[0055] Method 400 continues to 406, where the outer ring and the flange portion are aligned. Alignment includes positioning an outer protrusion of the outer ring to oppose a flange of the flange component. Alignment also includes overlapping a first portion of the outer protrusion with a second portion of a flange. The first portion and the second portion overlap within a certain range. The outer protrusion may be a weld surface.

[0056] Method 400 proceeds to 408 and includes applying bonding material to one or more surfaces of the outer ring and / or the flange portion. The bonding material may be applied, for example, by welding. In particular, the bonding material may be applied by brazing. The thermally conductive bonding material may be, for example, a resin (e.g., a thermally conductive resin), and 408 includes converting the resin to the liquid or plastic state and applying the resin to one or more surfaces of the outer ring and / or the flange portion, for example, by melting or brazing.As another example, the joining material may be a low melting point metal, metalloid, or alloy, and 408 comprises converting the low melting point metal, metalloid, or alloy into a liquid state and applying the low melting point metal to one or more surfaces of the outer ring and / or the flange portion, for example by melting or brazing.

[0057] 408 includes a plurality of substeps, including 412 and 414. At 412, the first method 400 includes applying bonding material to at least the first portion of the outer boss. At 414, the method 400 includes applying bonding material to at least the second portion of the flange. Either 412 or 414 may be completed as part of the bonding material application at 408. Stated another way, if 412 is completed as part of 408, 414 may be optional, and vice versa. It should be understood that 408 may include both 412 and 414.

[0058] The method 400 continues 422 and includes joining the outer ring and the flange portion, more specifically, joining the outer boss and the flange via the conductive joining material. Joining includes joining the outer ring and the flange portion into a unitary structure. Joining the outer ring and the flange includes forming a cavity through the outer ring and the flange, with the outer ring and the flange component disposed around the cavity, and the cavity disposed between the outer ring and the flange component. The outer ring and the flange component may enclose the cavity.

[0059] Method 400 proceeds to 424 and includes inserting a conductive component into the cavity formed between and within the surfaces of the outer ring and the flange component. Further steps 424 may include forming the conductive component into a desired shape during the insertion and application of conductive component material into the cavity. The conductive component comprises a thermally conductive material and may include the conductive component 322 made of Fig. 3. Inserting and forming the conductive component into the cavity may include arranging the conductive component in a cylindrical body of revolution within the cavity. The conductive component is insertable into the cavity and can be applied to the surfaces surrounding the cavity via an outwardly open passage of the flange component that is volumetrically connected to the cavity. For example, the conductive component can be inserted into the cavity and applied via the passage 236 in Fig. 2-3 be applied to the surfaces around the cavity and bonded.

[0060] The conductive component comprises, for example, thermally conductive resin. Another example: The conductive component comprises a low-melting-point metal, metalloid, or alloy. In these examples, the conductive component may be applied as a conductive resin, low-melting-point metal, low-melting-point metalloid, and / or low-melting-point alloy in a liquid, plastic, or other liquid state in contact with the internal surfaces surrounding the cavity. The thermally conductive material of the conductive component may be the same material as the bonding material. In other words, the thermally conductive material and the bonding material may be a common material having approximately the same chemical composition.

[0061] During insertion into the cavity and application to the outer ring and flange component, 424 may include applying and solidifying the conductive material of the conductive component while rotating the outer ring and flange component about an axis. Spinning, depositing, and cooling the conductive material includes forming the conductive material into a shape, such as a cylindrical solid of revolution. Spinning, depositing, and cooling the conductive material also includes forming the conductive component through an additive manufacturing process. Spinning and deposition may continue until the conductive material of the conductive component reaches a desired thickness equal to or greater than a thickness threshold. In one of these examples, applying and additively forming the conductive material into the conductive component may be accomplished by welding and / or soldering the conductive material.

[0062] Method 400 proceeds to 426 and includes joining the conductive component to the outer ring, the flange, and the conductive connecting material. The conductive connecting material to the outer ring, the flange component, and the conductive connecting material may be joined by welding.

[0063] The method 400 continues to 428 and includes rigidly connecting a shaft component to the inner ring. The shaft component may be the shaft component 212 of Fig. 2-3. For example, method 400 may include inserting and rigidly connecting the shaft component to the inner ring via such a hole, where the hole may be a bushing. The shaft component may include at least a first attachment feature and the inner ring may include at least a second attachment feature, the second attachment feature positioned around the hole and engageable with the first attachment feature. Therefore, at 428, method 400 may include connecting the first attachment feature to the second attachment feature by inserting the shaft component into the hole. For example, the bore may be a keyway having one or more keyways, and the keyway(s) of the shaft component, e.g., the keyway(s) of tubular shaft 230, may fit within the one or more keyways or the one or more grooves of the inner ring around the keyway bore.

[0064] Method 400 proceeds to 430 and includes attaching and rigidly connecting a fastening component to the outer ring, wherein the fastening component serves to connect a cover to the CVJ. 430 includes establishing a fluid-tight and, in particular, at least watertight seal between the fastening component and one or more outer surfaces of the outer ring. Coupling the fastening part may, for example, comprise a snap-on connection of the fastening part to the outer ring. The fastening component may be for a collar, e.g., a collar socket, such as the collar socket 228.

[0065] The method 400 continues at 432 and includes encasing a shaft component with a cover component (e.g., a cover). Further, at 432, the method 400 includes coupling the cover component to the shaft component and the fastening component, which is rigidly connected to the outer ring. At 432, the method 400 includes flexibly connecting the cover component to the shaft such that the shaft is rotatable separately from the cover component. 432 includes creating a fluid-tight, and in particular at least watertight, seal between the sleeve and one or more outer surfaces of the shaft component. Likewise, at 432, the method 400 includes rigidly connecting the cover component to the fastening component. The cover is, for example, a sleeve, such as sleeve 226.The method 400 at 432 includes firmly connecting the sleeve to the sleeve can and therein firmly connecting the sleeve to the outer ring.

[0066] After 432, the procedure ends 400.

[0067] It should be understood that in another example, 432 and 430 may be reversed, with 432 occurring before 432. In this example, method 400 ends after 430.

[0068] Another example is that 430 and / or 432 may occur before the shaft component is rigidly connected to the inner ring at 428. In this example, method 400 ends after 428.

[0069] Fig. 5 shows a first example of a second method 500 for designing and assembling a constant velocity joint assembly in accordance with the present disclosure, for example, a constant velocity joint assembly 202. The method 500 includes many of the steps of the method 400 of Fig. 4 and cannot be repeated for the sake of brevity.

[0070] Method 500 differs from method 400 after 406. After 406, method 500 proceeds to 512, wherein a conductive component and a first housing component are connected via a thermally conductive bonding material. The first housing component may be either the outer ring or the flange component (see method 400). The bonding material may be the same material used in method 400 and / or used to bond the outer ring and the flange at 408. The conductive component is bonded to the outer ring or the flange portion via the bonding material. The bonding material may be converted into a fluid or a deformable plastic, for example, by melting, and the bonding material may be bonded to the surface of the first housing part by welding and soldering.

[0071] The conductive component of the method 500 is a thermally conductive insert or a plurality of inserts formed from a material in the solid phase or in the plastic phase. The conductive component of the method 500 may be the conductive component 322 made of Fig. 2-3. For example, the conductive component of method 500 comprises a resin (e.g., a thermally conductive resin), where the resin is in a solid phase or a plastic phase. Another example: The conductive component comprises a metal, metalloid, or low-melting point alloy in a solid or plastic phase. Another example: The conductive component comprises another solid, thermally conductive material, e.g., graphite. In these examples, the conductive component may comprise a plurality of smaller components arranged and / or bonded together to form the conductive component. For example, the subcomponents of the conductive component are assembled into a final shape for the conductive component, e.g., a cylindrical body of revolution, by assembling and rigidly bonding them to the first housing.

[0072] After 512, the method 500 continues to 408, wherein the joining material is applied to the mating surfaces of the outer ring and the flange component.

[0073] After 408, method 500 deviates from method 400. After 408, method 500 proceeds to 524 and includes covering the conductive component with a second housing. For example, if the first housing is the outer ring, the second housing is the flange component. As another example, if the first housing is the flange component, the second housing is the outer ring.

[0074] After 524, the method 500 continues with 422, wherein the outer ring and the flange are joined into a unitary structure.

[0075] After 422, method 500 differs from method 400. After 422, method 500 proceeds to 528, where the thermally conductive component is bonded to the second housing and the bonding material between the outer projection of the outer ring and the flange of the flange portion. Joining at 528 may include melting and applying additional bonding material to one or more surfaces of the second housing and a bonding portion connecting the outer ring and the flange component. The bonding portion includes the bonding material applied at 408, which bonds the flange and the outer ring into a unitary component at 422. After application, 528 includes placing the additional bonding material in common surface contact with the thermally conductive component and cooling the additional bonding material to a solid.The additional connecting material can be applied and connected by welding. In particular, the connecting material can be applied and connected by soldering. The additional connecting material is also a thermally conductive connecting material. Furthermore, the additional connecting material and the connecting material of the connecting portion can be the same material. In other words, the additional connecting material and the connecting material can be a common material. For example, the thermally conductive connecting material is a resin (e.g., a thermally conductive resin), and 528 includes converting the resin into the liquid or plastic state and applying the resin to one or more surfaces of the outer ring and / or the flange portion, e.g., by melting or soldering, respectively.As another example, the additional joining material may be a low melting point metal, metalloid, or alloy, and 528 includes converting the low melting point metal, metalloid, or alloy into a liquid state and applying the low melting point metal to one or more surfaces of the outer ring and / or the flange portion, for example, by melting or brazing.

[0076] After 528, the method 500 continues with 428, wherein a fastener for a cover is fixedly connected to the outer ring.

[0077] As with procedure 400, procedure 500 ends after 432.

[0078] Also, in another example, in method 500, 432 and 430 may be reversed, with 430 occurring before 432. In this example, method 500 ends after 430.

[0079] As another example, 430 and / or 432 may occur before the shaft component is securely connected to the inner ring at 428. In this other example, method 500 ends after 428.

[0080] Procedures 400 and 500 of Fig.4-5 of the disclosure also provide support for a method of manufacturing a constant velocity joint assembly comprising: disposing an outer protrusion of an outer ring to oppose a flange of a larger flange component, overlapping a first portion of the outer protrusion with a second portion of the flange, bonding the outer protrusion of the outer ring to the flange via a conductive bonding material, forming a cavity over the outer ring and the flange component, applying a conductive component to a plurality of surfaces of the outer ring and the flange component around the cavity, and bonding the conductive component to the conductive bonding material.In a first example of the method, the conductive connecting material is applied and joined to the outer ring, the flange component, and the conductive connecting material by welding, wherein the outer projection is a weld surface. In a second example of the method, optionally including the first example, the conductive connecting material and the conductive component comprise a common material. In a third example of the method, optionally including one or both of the first and second examples, the conductive component is arranged to form a body of revolution with a cylindrical nature within the cavity.

[0081] Although various embodiments have been described above, they are to be considered as examples and not as limitations. Those skilled in the art will appreciate that the disclosed subject matter may be embodied in other specific forms without departing from the spirit of the subject matter. The embodiments described above are, therefore, to be considered in all respects as illustrative and not restrictive. Thus, the configurations and routines disclosed herein are exemplary, and the specific examples are not to be considered as limiting, as numerous variations are possible. For example, the technology described above may be applied to powertrains that include various types of power sources, including various types of prime movers, internal combustion engines, and / or transmissions.The subject matter of the present 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.

[0082] It should be understood that the configurations and routines disclosed herein are exemplary in nature, and that these specific embodiments are not intended to be limiting, as numerous variations are possible. Unless expressly stated otherwise, the terms "first," "second," "third," etc., are not intended to denote any order, position, quantity, or importance, but are used merely to distinguish the individual elements. The subject matter of the present 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 characteristics disclosed herein.

[0083] 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] Joint arrangement comprising: a constant velocity joint having an outer race with a welded seat; a flange component having a weld seat projection on a first side, the weld seat projection configured to engage the weld seat of the outer ring; a conductive component interconnecting the outer ring and the flange component at an interface between the outer ring and a second side of the flange component opposite the first side; and a shaft component drivingly coupled to the constant velocity joint, wherein the constant velocity joint is received by the shaft component at the weld seat of the outer ring and drivingly coupled to it. [2] The joint assembly of claim 1, wherein a chamber is formed between the outer ring and the flange component and the conductive component is removably positioned in the chamber, and / or further comprising a second conductive component positioned in the chamber. [3] The joint assembly of claim 2, wherein the flange component includes a passageway in fluid communication with the chamber, and wherein the passageway is coaxial with a central axis of the outer ring and the flange component, and / or the conductive component has a third surface, and the third surface is flush with and curves with a fourth surface of the passageway. [4] The joint assembly of claim 1, wherein the conductive component comprises a thermally conductive resin. [5] The joint assembly of claim 1, wherein the conductive component comprises a low melting point metal. [6] The joint assembly of claim 1, wherein the conductive component is formed from a conductive inert material. [7] A joint assembly according to claim 1, wherein the shaft component is coupled to the constant velocity joint via a containment shell coupled to the outer ring on a side of the outer ring opposite the flange component, and wherein the coupling of the containment shell and the outer ring creates a fluid-tight cavity therebetween. [8] Joint assembly according to claim 1, wherein the constant velocity joint is configured as a tube-mounted monoblock joint (TMMB) enclosing the outer ring with the weld seat. [9] Joint assembly according to claim 1, wherein the shaft component is arranged to be rotationally coupled to a rotary input and / or output. [10] The joint assembly of claim 1, wherein the flange component is configured to be rotationally coupled to a rotary input and / or output. [11] Constant velocity joint, comprising: a pipe-mounted monoblock joint with a welded seat on a back side; a flange component having a weld seat projection on an end face, the weld seat projection being configured to engage the weld seat; and a conductive component disposed at an interface between the weld seat projection and the weld seat. [12] Constant velocity joint according to claim 11, wherein the tube-mounted monoblock joint comprises an outer ring, an inner ring and a cage arranged between the outer ring and the inner ring and / or comprising a plurality of balls arranged in an inner ring raceway of the inner ring and an outer ring raceway of the outer ring. [13] Constant velocity joint according to claim 12, wherein the outer ring is coupled to the weld seat projection of the flange component at the weld seat of the tube mount monoblock joint. [14] Constant velocity joint according to claim 11, further comprising a sealing system. [15] Constant velocity joint according to claim 11, wherein the tube-mounted monoblock joint is arranged to couple the constant velocity joint to a drive shaft tube.

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