Rotary power transmission device comprising actuator holding feature

Abstract

To provide a rotary power transmission device comprising a device housing, a clutch, an actuator and a holding device.SOLUTION: A device housing has a rotating interior with a plurality of components. A clutch is provided in the device housing and has a clutch ring selectively engageable with one of the plurality of components. An actuator has a coil and a plunger that is driven to move along an axis relative to the clutch. A holding device has a first portion that engages the device housing, and a second portion that radially overlaps the coil and limits the axial movement of the coil relative to the device housing.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Application No. 63 / 320,863, filed March 17, 2022, the entire contents of which are incorporated herein by reference in their entirety.

[0002] The present disclosure generally relates to a rotary power transmission device having an actuator for a clutch and a retention feature for at least a portion of the actuator. [Background technology]

[0003] Electromagnetic actuators have a wire coil that generates an electromagnetic field to drive a plunger and actuate a device (e.g., move a clutch component). The coil is received within a housing that is mounted to the device's housing. The coil housing is often mounted by multiple individual fasteners and may be held in place by components that extend the axial length or size of the device's housing, which may be undesirable in many applications. The individual fasteners add complexity, time, and cost to construct and assemble the device. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] U.S. Provisional Application No. 63 / 320,863 [Patent Document 2] U.S. Patent No. 10,473,203 Summary of the Invention [Means for solving the problem]

[0005] In at least some implementations, a rotary power transmission device includes a device housing, a clutch, an actuator, and a retaining device. The device housing has an interior in which a plurality of components are received and rotate. The clutch is received within the device housing and has a clutch ring selectively engageable with one of the plurality of components. The actuator has a coil and a plunger driven to move along an axis and relative to the clutch. The retaining device has a first portion that engages the device housing and a second portion that radially overlaps the coil and limits axial movement of the coil relative to the device housing.

[0006] In at least some implementations, the coil includes a coil housing and a wire coil within the coil housing, wherein a first portion extends axially and is received over a portion of the device housing, and a second portion extends from the sidewall and overlaps a portion of the coil housing. In at least some implementations, the first portion of the retention device is press-fit onto an outer surface of the device housing. In at least some implementations, the first portion extends axially and the second portion extends radially from the sidewall. In at least some implementations, the coil housing has an inboard end adjacent to the device housing, the coil housing has an outboard end opposite and axially spaced from the inboard end, the retention device overlaps a portion of the coil housing between the inboard end and the outboard end, and the retention device does not extend axially beyond the outboard end. In at least some implementations, the coil housing includes a flange extending radially outward and positioned between an inboard end and an outboard end, the flange including a first surface received against the device housing, and the flange including a second surface engaged by a second portion of the retainer.

[0007] In at least some implementations, the coil includes a coil housing and a wire coil within the coil housing, a first portion of the retainer including a flange coupled to the device housing, and a second portion of the retainer including a sidewall extending from the flange and overlapping a portion of the coil housing. In at least some implementations, the device housing includes a groove, and the flange is press-fit into the groove using a friction fit between one surface of the flange and a surface defining the groove. In at least some implementations, when the plunger is driven to move, the plunger slides along an annular surface of the device housing, and the groove is spaced radially inward from the annular surface. In at least some implementations, the flange extends axially into the slot, and the flange has a radially inner surface and an opposing radially outer surface, at least one of the radially inner surface and the radially outer surface frictionally engaging the device housing within the slot.

[0008] In at least some implementations, the coil includes a coil housing and a wire coil within the coil housing, and the retention device includes multiple inwardly extending flanges defining a second portion of the retention device, where each flange radially overlaps the coil housing and captures a portion of the coil housing between the flange and the device housing. In at least some implementations, the first portion of the retention device is defined by a main body from which the flanges extend radially inward. In at least some implementations, the device housing includes a groove that opens to a radially outer surface of the device housing and extends radially into the device housing, and the main body is received in the groove. In at least some implementations, the coil housing is positioned within the device housing radially inward of the groove, and the flanges extend inward from the main body and radially overlap a portion of the coil housing. In at least some implementations, the device housing includes multiple circumferentially spaced skirts, where the grooves are formed in the multiple skirts, and the flanges are circumferentially received between adjacent skirts. In at least some implementations, the main body includes a first end and a second end circumferentially spaced from the first end, with a gap between the first end and the second end.

[0009] In at least some implementations, a rotary power transmission device includes a device housing having an interior within which a plurality of components are received and rotate, a clutch ring received within the device housing and selectively engageable with one of the plurality of components, an actuator, and a retaining device. The actuator has a coil housing, a coil within the coil housing, and a plunger driven to move along an axis and relative to the clutch ring to move the clutch ring relative to the device housing. The retaining device has a first portion that engages the device housing and a second portion that extends radially from the first portion toward the axis, the second portion radially overlapping the coil housing to limit axial movement of the coil housing relative to the device housing.

[0010] In at least some implementations, the first portion extends axially and engages a portion of the device housing. In at least some implementations, the first portion is received within a groove in the device housing.

[0011] In at least some implementations, a first portion of the retainer may be conveniently press-fit into or onto a portion of the device housing, and a second portion may overlap a surface of the coil housing to facilitate holding the coil housing in a desired position or location relative to the device housing. In at least some implementations, the retainer may be installed without the need for fasteners, adhesives, bonding, welding, or the like.

[0012] The following detailed description of the preferred embodiments and best mode is set forth with reference to the accompanying drawings. [Brief explanation of the drawings]

[0013] [Figure 1] 1 is a schematic diagram of a vehicle driveline assembly. [Figure 2]FIG. 1 is a cross-sectional view of a differential with an electrically actuated clutch, the differential shown in an open position. [Figure 3] FIG. 1 is a perspective view of a differential including a retaining device for a solenoid coil. [Figure 4] FIG. 4 is a fragmentary cross-sectional view of a portion of FIG. [Figure 5] FIG. 1 is a perspective view of a differential including a retaining device for a solenoid coil. [Figure 6] FIG. 6 is a fragmentary cross-sectional view of a portion of FIG. 5. [Figure 7] FIG. 1 is a perspective view of a differential including a retaining device for a solenoid coil. [Figure 8] An exploded perspective view of the differential, as well as the retainer and solenoid coil. [Figure 9] FIG. 8 is a fragmentary cross-sectional view of a portion of FIG. [Figure 10] FIG. 8 is a fragmentary cross-sectional view of a portion of FIG. DETAILED DESCRIPTION OF THE INVENTION

[0014] Referring more particularly to the drawings, FIG. 1 shows a vehicle driveline 12 that delivers power from an engine 14 to a plurality of wheels, including front wheels 15 and rear wheels 16. The engine 14 delivers torque through a transmission 17 and a power transfer unit 18 that provides an output shaft 20. The output shaft 20 is coupled to a first propeller shaft 21, which is coupled to a rear drive unit 22, which may include a differential assembly 23. The power transfer unit 18 or other device may have an output shaft 24 that is coupled to a front drive unit 25 (which may include a differential assembly 26) via a second propeller shaft 27. A front left shaft 28 and a front right shaft 29 are coupled to the drive units / differentials 25, 26, which enable relative rotation between the side shafts 28, 29 and the front wheels 15. The rear left shaft 30 and rear right shaft 32 are coupled to rear drive units / differentials 22, 23, which allow relative rotation between the side shafts 30, 32 and the rear wheels 16. The power transfer unit 18 may include a decoupling assembly that, when in a coupled state, transfers torque to the second propeller shaft 27 to drive the front wheels 15. When coupled or decoupled, the power transfer unit 18 can provide torque to the first propeller shaft 21 to drive the rear wheels 16. Thus, depending on the state of the decoupling device, the power transfer train 12 can provide torque to only the rear wheels 16 or to all four wheels 15, 16.

[0015] Of course, other driveline configurations may be used if desired. For example, although shown with a rear-wheel-drive-based driveline, the lock-up differential could be used in a front-based all-wheel-drive system, or even in a two-wheel-drive front-engine / front-wheel-drive or front-engine / rear-wheel-drive drivetrain, and even in an e-axle (an e-motor-powered final drive unit).

[0016] 2, the first rear side shaft 30 is coupled to a first side gear 34 in the differential 23. Similarly, the second rear side shaft 32 is coupled to a second side gear 36 in the differential 23. The side gears 34, 36 are carried within a housing 37 (sometimes referred to as a differential housing or device housing) of the differential 23. The differential also includes pinion gears 38, 40 that are meshed with the side gears 34, 36, respectively, and mounted within the housing 37 on pinion shafts 42.

[0017] A clutch assembly 46 is provided for selectively locking and unlocking the differential 23. The clutch assembly 46 can have an actuated state and a disacted state, and in one state, the clutch assembly couples one of the side shafts (e.g., 32) to the differential housing 37 so that the coupled side shaft rotates with the housing. This causes the other side shaft 30 to rotate in unison with the housing 37 and the side shaft 32 coupled to the housing, so that both side shafts 30, 32 rotate at the same speed.

[0018] In at least some implementations, the clutch assembly 46 is electrically actuated and includes an actuator having a solenoid 48 with an annular coil of wire 49 and a drive member that may include an armature or plunger 54 received at least partially radially inside and axially overlapping the coil. In at least some implementations, the plunger 54 is also annular, and the plunger and coil 49 are coaxially arranged and carried by and rotate with the housing 37, with one side shaft (here, the second side shaft 32) extending coaxially through a portion of the housing 37 that extends through the coil and plunger. Power is supplied to the coil 49 via a power supply wire 50 to generate a magnetic field that displaces the plunger 54 relative to the coil and differential housing 37 from a first or retracted position to a second or advanced position. As described below, a biasing member such as a spring 55 may act on the plunger 54 or on a component engaged with the plunger to facilitate return of the plunger 54 from the second position to the first position when power is not applied to the coil 49. In at least some implementations, the clutch assembly 46 is activated when the plunger 54 is in the second position and deactivated when the plunger is in the first position. In the example shown, the plunger 54 is in its second position when power is applied to the coil 49 and moves to the first position when power is not applied to the coil, although the reverse may be true if desired (e.g., the clutch assembly 46 may be moved to the activated position by the biasing member 55 and deactivated by applying power to the coil).

[0019] In at least some implementations, as described below, the clutch assembly 46 may further include or be associated with a clutch member, referred to herein as a clutch ring 56, configured to be driven by the plunger 54 and engaged with the side gear 34. The clutch ring 56 may be annular, and a portion of the second side gear 36 and / or shaft 32 may extend through the clutch ring. The clutch ring 56 may include a rear surface 57 engageable by the plunger 54 and a front surface 59 having at least one engagement feature 58, such as a gear or clutch tooth 58 (e.g., a dog clutch tooth), configured to engage a corresponding engagement feature 60 (e.g., a gear or dog clutch tooth) formed on the rear surface of the first side gear 34. As mentioned above, when the coil 49 is not energized, the spring 55 may act on the clutch ring 56 to urge the clutch ring toward the plunger 54, moving the plunger to its first position. In the implementation shown, plunger 54 is positioned adjacent one side of housing wall 62 and clutch ring 56 is positioned adjacent the other side of wall 62. Wall 62 includes an aperture 64, and plunger 54 and clutch ring 56 include axially extending supports 66, 68, respectively, that extend into or through wall aperture 64, such that the plunger and clutch ring engage one another across or through the wall. Like coil 49 and plunger 54, clutch ring 56 is carried by and rotates with housing 37.

[0020] The differential 23 shown in FIG. 2 is shown in an open mode or position. In the implementation shown, in the open position of the differential, the coil 49 is not energized, the plunger 54 is in its first position, and the clutch ring 56 is not engaged with the side gear 34, allowing the side gear to rotate relative to the clutch ring 56 and the housing 37. In the open position, the side shafts 30, 32 can rotate at different speeds from one another. However, under certain driving conditions, it may be desirable for the side shafts 30, 32 to rotate in unison so that torque is applied to both wheels.

[0021] In the locked position, coil 49 is energized and plunger 54 is advanced to its second position driving clutch ring 56 into engagement with side gear 34 (i.e., teeth 58 engage and mesh with teeth 60). Side gear 34 is thus coupled to housing 37, so that it rotates with the housing, rather than against it. In effect, second side shaft 32 is locked to and rotates with housing 37, causing first side shaft 30 and second side shaft 32 to rotate in unison.

[0022] 2, 4, 6, 9, and 10, plunger 54 may be formed from multiple materials, including a material that is magnetically responsive to the magnetic field generated by coil 49 and at least one other material that may or may not be responsive to the magnetic field. Thus, when a magnetic field is generated by coil 49, plunger 54 may be driven from one position to another (e.g., from a retracted position to an advanced position). As used herein, a material is responsive to a magnetic field if a component formed from or including such a material can be displaced by a magnetic field of the magnitude generated by solenoid 48 of the type used in applications such as those described herein.

[0023] 2 and 3 , plunger 54 includes a main body having a central axis 73 that may be defined by a first body 74 and a second body 76 that are coupled to one another to move as a single unit or component and do not separate during use. First body 74 may be formed from a magnetically responsive material and may be received adjacent to and radially inward of coil 49 with a small air gap between first body 74 and coil 49. Second body 76 may have at least a portion that is radially inward of at least a portion of first body 74. Second body 76 may be annular and, at least in some implementations, may radially overlap a portion of first body 74. Advantageously, the second body 76 may be overmolded onto the first body 74 to form the second body and facilitate coupling the first and second bodies together, although other forming processes, such as, but not limited to, casting, stamping, or extrusion, may be used. The second body 76 may define part or all of the support portion 66 of the plunger 54, which may extend axially beyond the first body 74, if desired. The second body 76 may be formed from a magnetically unresponsive material (e.g., plastic, aluminum, stainless steel, etc.) and may provide a type of magnetic flux shield that enhances the magnetic field strength on or within the region of the first body 74 when the coil 49 is energized, ensuring proper response of the plunger 54. In this way, the magnetic field is more concentrated or stronger in the region of the first body 74, increasing the magnetic flux at or within the first body and improving the responsiveness of the plunger 54 to the generated magnetic field.

[0024] 2 and 4, the second body 76 can have an inner surface 78 received adjacent to or about a surface 79 of the differential housing 37. The inner surface 78 can define a pilot diameter for receiving the plunger 54 on the annular surface 79 of the differential housing 37 for guiding linear axial movement of the plunger relative to the differential housing.

[0025] Referring to FIG. 2 , the clutch ring 56 has a main body 80 with a central axis that may be coaxial with the axis 73 of the plunger 54, a radially outer surface 84 extending axially between a rear face 57 and a front face 59, and a radially inner surface 86 that may have a smaller axial extent than the outer surface 84. The inner surface 86 of the clutch ring 56 may be received around the surface of the side gear 34. The support portion 68 of the clutch ring 56 defines a portion of the rear face 57 and is circumferentially spaced from and extends axially from the other portion of the rear face 57. The teeth 58 are located on the front face 59. The clutch ring 56 may be made of a metal such as alloy steel, chromium steel, chromium-molybdenum steel, nickel steel, nickel-chromium-molybdenum steel, medium / high carbon steel, etc.

[0026] In use, the differential 23 mounts a bearing 88 on the outer surface of the tubular portion 90 of the housing 37. In FIG. 2, the bearing 88 is shown in diagrammatic form as a dashed polygon and may include an inner race having an inner surface on the tubular outer surface of the tubular portion and an outer race received on the inner race. Suitable bearings are known in the art. As shown in FIG. 2, the bearing 88 extends radially beyond the surface 79 against which the plunger 54 slides during use. Engagement with the bearing 88 may prevent the plunger 54 from sliding off the housing 37. Additionally, an annular ring may be received on the housing surface 79, axially positioned between the plunger and the bearing. The ring may extend radially and overlap the coil 49 to prevent axial movement of the coil 49 relative to the housing 37.

[0027] In the implementation shown in FIG. 3 , the coil 49 is received within a housing 92, which may be made from any suitable material, such as various plastics. If desired, the housing 92 may be formed from two or more parts to facilitate assembly of the coil 49 to the housing 92; the housing may be molded over the coil; the housing may be annular, completely enclosing the coil. In implementations in which a ring is received on the housing surface 79 to retain the coil, the ring may be press-fit onto the surface 79 and abut against the adjacent side of the coil housing 92, such that the coil housing 92 is captured between the ring and the housing 37. When positioned in this manner, the ring consumes some axial portion of the surface 79, thus requiring a longer surface to accommodate the ring and accommodate the full axial movement of the plunger 54.

[0028] This additional axial length increases the overall size of the differential housing 37, creating challenges for drivetrains that must fit more components into a smaller area. Alternatively, if other portions of the housing 37 were made smaller to accommodate the additional space required for the ring, the strength and torque capacity of one or more portions of the housing 37, clutch ring 56, or other components would be reduced. In the example shown in U.S. Pat. No. 10,473,203, multiple separate clips are used to overlap the coil housing and hold the coil on the differential housing. Handling and installing smaller clips and fasteners can be time-consuming, and the fasteners used to secure the clips can be difficult to access. Additionally, the clips and fasteners in this example require radial space between the coil housing and the fasteners that mount the differential housing to the support via the mounting flange, which can increase the size of the housing.

[0029] 3 and 4, a retention device 100 is provided to restrain or prevent axial movement of the coil 49 relative to the differential housing 37. In at least some implementations, a first portion of the retention device 100 engages the differential housing 37 and a second portion of the retention device 100 engages the coil housing 92.

[0030] In the illustrated implementation, the retention device 100 is annular, including a cylindrical, radially thick, axially extending sidewall 102. The sidewall 102 extends from a first end 104 to a second end 106, and the retention device 100 includes a radially inwardly extending flange 108 at the second end 106 of the sidewall 102. A radially inner surface 110 of the sidewall 102 has a diameter sized to be closely received on an outer surface 112 of the differential housing 37 adjacent the coil 49. The retention device 100 may be coupled to the housing 37 by a press or friction fit, by one or more fasteners, adhesives, welding, crimping, staking, or the retention device may include an inwardly extending protrusion that is received in an opening or slot in the differential housing 37. In at least some implementations, the surface 112 upon which the sidewall 102 is received has a reduced diameter, so that the addition of the retention device 100 thereto does not increase the peripheral size of the housing 37. That is, the outer diameter of the retention device 100 can be equal to or smaller than the outer diameter of the portion of the housing 37 axially adjacent to the retention device 100. In at least some implementations, the portion of the differential housing 37 upon which the coil housing 92 is mounted is not under high stress, so reducing the thickness of the differential housing 37 in this region does not compromise the durability of the housing 37. Of course, other configurations may be used as desired.

[0031] When assembled to the housing 37, the flange 108 of the retention device 100 may radially overlap the coil housing 92 and axially abut a portion of the coil housing 92. When so assembled, the coil housing 92 is axially captured between the flange 108 and a surface of the differential housing 37. In the example shown, the coil housing 92 includes a radially outwardly extending flange 114 having a first face 116 that is received in the differential housing 37, a radially outer surface 118, and a second face 120 opposite the first face 116. During assembly, the retention device flange is received on the outer surface 118 and adjacent to or against the second face 120, such that the coil housing flange 114 is captured between the differential housing 37 and the retention device flange 108. In at least some implementations, the coil housing flange 114 is axially spaced from the outboard end 122 of the coil housing (where the inboard end 124 of the coil housing is received adjacent to or against the differential housing) by a distance at least as long as the axial thickness of the retainer flange 108. Thus, when assembled, the retainer flange 108 does not extend axially beyond the outboard end 122 of the coil housing 92 and therefore does not increase the axial dimension of the differential 23.

[0032] The retention device 100 may be made of any suitable material, including various metals and plastics, as well as composite materials. The retention device 100 can be lightweight and durable. Furthermore, the single-piece retention device 100 can engage a circumferentially continuous portion of the coil housing 92 or separate spaced-apart portions of the housing 92 to securely hold the coil housing 92 to the differential housing 37. The single-piece retention device 100 may be easier to handle and install than multiple clips with multiple fasteners. While described above as annular, the retention device 100 may also be C-shaped with a slot or opening defining the free end of the retention device. In at least some implementations, the retention device 100 spans more than 180 degrees circumferentially, and in some implementations, the retention device can span more than 300 degrees, such that the ends of the retention device 100 on either side of the gap are spaced apart by less than the outer diameter of the portion of the housing 37 in which the retention device is received.

[0033] 5 and 6 relate to a differential that may be configured and arranged similarly to differential 23 described above in connection with FIGS. 2-4, with the differences noted herein. To facilitate description of this embodiment, the same reference numerals are used for the same or similar components already described, and the above descriptions are incorporated herein. In FIGS. 5 and 6, a retention device 130 is provided to restrain or prevent axial movement of coil 49 relative to differential housing 37. In at least some implementations, a first portion of retention device 130 engages the differential housing and a second portion of retention device 130 engages the coil housing.

[0034] In the illustrated implementation, the retainer 130 is annular, having an axially thick cylindrical shape, and includes a radially extending sidewall 132. The sidewall 132 extends from a first end 134 to a second end 136, and the retainer 130 includes an axially extending flange 138 at the second end 136 of the sidewall 132. A radially inner surface 140 of the sidewall 132 extends radially such that the first end 134 overlaps the coil housing 92 and the inner surface 140 is positioned in contact with the outboard end 122 of the coil housing. The sidewall 132 also radially overlaps the plunger 54 and is axially outboard of the plunger 54.

[0035] In this implementation, the retention device is coupled to the differential housing 37 by a flange 138. In at least some implementations, the differential housing 37 includes a slot 142 into which the flange 138 is received. The flange 138 may be coupled to the housing 37 by a press fit or a friction fit, by one or more fasteners, adhesives, welding, crimping, staking, etc. In at least some implementations, a radially inner surface 144 or a radially outer surface 146 of the flange 138 is configured to frictionally engage an adjacent surface of the differential housing 37 within the slot 142. Configured in this manner, when the flange 138 is press fit into the slot 142, the inner surface 140 of the sidewall 132 engages the coil housing 92, capturing the coil housing 92 relative to the differential housing 37 and preventing axial movement of the coil housing 92 relative to the differential housing 37. In at least some implementations, a portion 148 of the differential housing 37 radially outward of the slot 142 may have a reduced axial extent, such that the outer surface 150 of the retention device 130 does not extend axially beyond the radially inner surface 152 of the slot 142, and the axial position of the bearing 88 is not affected by the retention device 130 when installed in the slot 142. Furthermore, the retention device 130 may be coupled to a bearing, such as bearing 88, or may be held in place by a bearing, such as bearing 88. For example, the retention device 130 may be captured between the bearing 88 and a surface of the housing 37, with or without any flanges received in the slots (e.g., the flanges 138 and slots 142 would be optional in such implementations).

[0036] In at least some implementations, slot 142 is formed in a surface positioned radially inward of housing surface 79 along which plunger 54 moves. In at least some implementations, when differential 23 is in use, the region of housing 37 in which slot 142 is formed is not under high stress, and therefore reducing the thickness of housing 37 in this region does not compromise the durability of housing 37. Of course, other configurations may be used if desired.

[0037] The retention device 130 may be made of any suitable material, including various metals and plastics, as well as composite materials. The retention device 130 can be lightweight and durable. Furthermore, the single-piece retention device 130 can engage a circumferentially continuous portion of the coil housing 92 or separate, spaced-apart portions of the housing to securely hold the coil housing to the differential housing 37. A single-piece retention device 130 may be easier to handle and install than multiple clips with multiple fasteners. While described above as annular, the retention device 130 may also be C-shaped with a slot or opening defining the free end of the retention device. In at least some implementations, the retention device spans more than 180 degrees circumferentially, and in some implementations, the retention device can span more than 300 degrees between its ends.

[0038] Additionally, the retaining device 130 can provide a stop surface that limits the movement of the plunger 54 (e.g., can define a first position for the plunger 54). In some implementations, an unfinished differential assembly that does not include the bearings 88 may be transported from one location to another, and the plunger 54 may become separated from the differential housing 37 because the bearings are not in place. Thus, in addition to or instead of defining a first position for the plunger 54, the retaining device 130 can hold the plunger 54 in the housing 37 until the bearings 88 or other plunger stop surface are provided.

[0039] 7-10 relate to a differential that may be configured and arranged similarly to differential 23 described above in connection with FIGS. 2-4, with the differences noted here. To facilitate description of this embodiment, like reference numerals are used for like components already described, and the above descriptions are incorporated herein. In FIGS. 7-10, a retention device 160 is provided to restrain or prevent axial movement of coil 49 relative to differential housing 37. In at least some implementations, a first portion of retention device 160 engages the differential housing, and a second portion of retention device 160 engages coil housing 92.

[0040] In the implementation shown, the retainer 160 is generally annular with a gap 162 between circumferentially spaced apart first and second ends 164, 166 of the retainer. Thus, the retainer has a so-called "C-shape." In at least some implementations, the retainer 160 circumferentially spans more than 180 degrees, and in some implementations, the retainer can span more than 300 degrees, such that the ends 164, 166 of the retainer 160 are spaced apart by less than the outer diameter of the portion of the housing 37 in which the retainer 160 is received.

[0041] The retention device 160 has an axial dimension between the inwardly facing surface 168 and the outwardly facing surface 170 and a radial dimension between the outer surface 172 and the inner surface 174. As shown in FIGS. 8-10 , the outer surface 172 may have the same radius along the entire circumferential extent of the retention device, or may be otherwise configured as desired. The inner surface 174 has a varying radius along the circumferential extent of the retention device 160, along which a plurality of spaced apart, radially inwardly extending flanges 176 are provided. Thus configured, the main body 178 of the retention device 160 has a first radial dimension, and in the region of the flanges 176, the retention device 160 has a second, larger radial dimension. The cross-sectional view of FIG. 9 is taken through the flanges 176, and the cross-sectional view of FIG. 10 is taken through a portion of the main body 178 of the retention device.

[0042] As shown in FIG. 8 , the differential housing 37 has one or more axially extending skirts 180 that are radially outward of and axially overlap at least a portion of the coil housing 92. Multiple skirts 180 are shown in FIG. 8 , and the housing 37 will be described herein with reference to the multiple skirts. The skirts 180 each include a groove 182 in their radially outer surface, and upon assembly, the retainer 160 is received in the groove 182. As shown in FIG. 8 , gaps 184 may be formed between adjacent skirts 180 to receive the retainer flanges 176. If one or more gaps 184 are not formed, appropriately spaced openings that align with the grooves 182 and extend through the skirts may be formed. In such a configuration, the retainer 160 may need to be further opened to allow the retainer flanges to pass through the outer surface of the skirt. In at least some implementations, the inner surface 174 of the main body 178 is radially smaller than the outer surface 186 of the skirt, and therefore the retainer 160 must be bent and opened to allow the inner surface 174 to pass through and past the outer surface 186 of the skirt. Then, when the retainer 160 is aligned with the groove 182, the material of the retainer 160 can resiliently return to its unbent state with the inner surface 174 received by and radially overlapping the skirt 180 within the groove 182. The groove 182 can have an axial dimension sized to receive the retainer 160 therein and limit axial movement of the retainer 160 relative to the differential housing 37.

[0043] To maintain the axial position of the coil housing 92 using the skirt-mounted retainer 160, the coil housing 92 includes a radially extending, axially facing stop surface 188. As shown in FIG. 9 , the retainer flange 176 radially overlaps and axially abuts the stop surface 188. A portion of the coil housing 92 between the inboard end 124 and the stop surface 188 is captured between the differential housing 37 and the inboard surface 168 of the retainer 160, specifically the inboard surface 168 of the retainer flange 176. In this manner, axial movement of the coil housing 92 relative to the differential housing 37 is limited or prevented. In the illustrated example, the stop surface 188 is a sidewall of a groove 190 formed in the radially outer surface 192 of the coil housing 92, which is wider than the axial dimension of the retainer 160 (e.g., the axial dimension of the retainer flange 176).

[0044] In at least some implementations, the differential includes an annular plate 194 having inwardly extending tabs 196 received in gaps 184 between skirts 180. The tabs 196 may be bolted to the clutch ring 56 to enable detection of the position of the clutch ring 56 by a position sensing device responsive to movement of the plate 194. In such a configuration, the retainer flange 176 may be configured and arranged to be received in the same gaps 184 between the skirts 180 already formed for the plate 194. Furthermore, the plate 194 and / or a portion of the housing 37 may have a larger outer diameter than the retainer 160, and the retainer 160 may be received between opposite axial ends of the differential housing 37 such that the retainer 160 does not increase the axial dimension of the differential 23.

[0045] The retention device 160 may be made of any suitable material, including various metals and plastics, as well as composite materials. The retention device 160 may be lightweight and durable. Furthermore, the single-piece retention device 160 may engage a circumferentially continuous portion of the coil housing 92 or separate spaced-apart portions of the housing 92 to securely hold the coil housing to the differential housing 37. The single-piece retention device 160 may be easier to handle and install than multiple clips with multiple fasteners.

[0046] The retention devices 100, 130, 160 avoid the need to accommodate components on the surface 79 along which the plunger 54 moves. This allows the surface 79 to be shorter axially, if desired, and that distance / dimension can be added to one or both of the clutch ring 56 and the surface 198 (labeled in FIG. 6 ) of the differential housing 37 that overlaps the side gear 34. Providing a thicker clutch ring 56 strengthens the clutch ring, allowing it to handle greater loads. Providing a longer interface between the differential housing surface 198 and the side gear 34 strengthens the housing 37, allowing it to handle greater loads. Additionally, the coil 49 may be larger, allowing for a stronger driving force for the plunger 54. For example, in this case, the coil 49 could extend the entire length of the surface 79 or beyond, and the components that hold the coil would not be positioned on the surface 79 and would not interfere with this extension or expansion of the coil.

[0047] The additional strength of the housing 37 and / or clutch ring 56, and the ability to increase the size of the coil 49, are commercially relevant in at least some applications where a smaller size differential assembly is required when applying relatively high torque. Simply making the housing larger to handle higher loads is not acceptable, and making the housing smaller while still being functional can be difficult to achieve. Thus, the retention devices described herein are a significant advancement over previous components used to retain solenoid coils in differential housings.

[0048] While the above description relates to a locking differential device, other rotary power transmission devices, such as power take-off units or axle disconnects, may utilize a clutch with an actuator as described herein. In this regard, a power transmission device may include multiple rotating components, such as gears and / or shafts, with the clutch and actuator used to selectively couple at least two of the components to one another, e.g., to alter the torque flow path through the device. Accordingly, the present disclosure is not limited to a particular application but more generally relates to an actuator with a retention device as described. While the forms of the invention disclosed herein constitute presently preferred embodiments, many other forms and embodiments are possible. It is not intended herein to mention all possible equivalent forms or derivatives of the invention. It is understood that the terms used herein are merely descriptive rather than limiting, and that various modifications may be made without departing from the spirit or scope of the invention.

[0049] All terms used in the claims are intended to be given their broadest reasonable construction and their ordinary meaning as understood by one of ordinary skill in the art, unless expressly indicated to the contrary herein. In particular, the use of singular articles such as "a," "the," "said," etc. should be read as describing one or more of the indicated elements, unless the claims are expressly limited to the contrary. [Explanation of symbols]

[0050] 14 Engine 15 front wheels 16 rear wheels 17 Transmission 18 Power Transmission Unit 20 Output shaft 21 First propeller shaft 22 Rear drive unit 23 Differential, differential assembly 24 output shaft 25 Front drive unit, drive unit 26 Differential, differential assembly 27 Second propeller shaft 28 Front left shaft, side shaft 29 Front right shaft, side shaft 30 Rear left shaft, side shaft, first rear side shaft 32 Rear right shaft, side shaft, second rear side shaft 34 First Side Gear, Side Gear 36 Second side gear, side gear 37 Housing, differential housing 38 Pinion Gear 40 Pinion Gear 42 Pinion shaft 46 Clutch assembly 48 Solenoid 49 Wire coils, coils 50 Power supply wire 54 Plunger 55 Springs, biasing members 56 Clutch ring 57 Rear 58 Teeth, Engaging Feature 59 Front 60 Engagement feature, teeth 62 Wall 64 aperture 66 Support part 68 Support part 73 Central axis, axis 74 First Body 76 Second Body 78 Inner surface 79 Surface, Housing Surface 80 Main body 84 radially outer surface, outer surface 86 Radial inner surface, inner surface 88 Bearings 90 Tubular section 92 Housing, coil housing 100 Holding device 102 Side wall 104 first end 106 Second end 108 Flange, retaining device flange 110 Radial inner surface 112 outer surface, surface 114 Flanges, Coil Housing Flanges 116 First Side 118 radially outer surface, outer surface 120 Second Side 122 outer end 124 Inner end 130 Holding device 132 Side wall 134 first end 136 Second End 138 flange 140 Radial inner surface, inner surface 142 slots 144 Radial inner surface 146 Radial outer surface 148 part 150 outer surface 152 Radial inner surface 160 Holding device 162 Gap 164 first end, end 166 second end, end 168 Inward-facing surface 170 Outward Facing 172 Outer surface 174 Inner surface 176 Flanges, retaining device flanges 178 Main body 180 skirt 182 Groove 184 Gap 186 Outer surface 188 Stop Surface 190 Groove 192 Radial outer surface 194 plates 196 tabs 198 Surface

Claims

1. a device housing having an interior within which a plurality of components are received and rotate; a clutch having a clutch ring received within the device housing and selectively engageable with one of the plurality of components; an actuator having a coil and a plunger driven to move along an axis and relative to the clutch; a retainer having a first portion that engages the device housing and a second portion that radially overlaps the coil and limits axial movement of the coil relative to the device housing; A rotary power transmission device comprising:

2. 2. The device of claim 1, wherein the coil includes a coil housing and a wire coil within the coil housing, the first portion extending axially and received to overlap a portion of the device housing, and the second portion extending from a sidewall and overlapping a portion of the coil housing.

3. The device of claim 2 , wherein the first portion of the retainer is press-fit onto an outer surface of the device housing.

4. The device of claim 2 , wherein the first portion extends axially and the second portion extends radially from the sidewall.

5. 3. The device of claim 2, wherein the coil housing has an inboard end adjacent the device housing, the coil housing has an outboard end opposite the inboard end and axially spaced from the inboard end, the retention device overlapping a portion of the coil housing between the inboard end and the outboard end, and the retention device not extending axially beyond the outboard end.

6. 6. The device of claim 5, wherein the coil housing includes a flange extending radially outward and positioned between the inboard end and the outboard end, the flange including a first surface that is received against the device housing, and the flange including a second surface that is engaged by the second portion of the retention device.

7. 2. The device of claim 1, wherein the coil has a coil housing and a wire coil within the coil housing, the first portion of the retainer includes a flange coupled to the device housing, and the second portion of the retainer includes a sidewall extending from the flange and overlapping a portion of the coil housing.

8. 8. The device of claim 7, wherein the device housing includes a groove, and the flange is press-fit into the groove using a friction fit between one surface of the flange and a surface defining the groove.

9. 9. The device of claim 8, wherein when the plunger is driven to move, the plunger slides along an annular surface of the device housing, and the groove is spaced radially inward from the annular surface.

10. 9. The device of claim 8, wherein the flange extends axially into the slot, the flange having a radially inner surface and an opposing radially outer surface, at least one of the radially inner surface and the radially outer surface frictionally engaging the device housing within the slot.

11. 2. The device of claim 1, wherein the coil has a coil housing and a wire coil within the coil housing, and the retainer includes a plurality of inwardly extending flanges that define the second portion of the retainer, each of the plurality of flanges radially overlapping the coil housing and sandwiching a portion of the coil housing between the flange and the device housing.

12. The device of claim 11 , wherein the first portion of the retainer is defined by a main body from which the flange extends radially inward.

13. 13. The device of claim 12, wherein the device housing includes a groove that opens to a radially outer surface of the device housing and extends radially into the device housing, the main body being received in the groove.

14. 14. The device of claim 13, wherein the coil housing is located within the device housing radially inward of the groove, and the flange extends inward from the main body and radially overlaps a portion of the coil housing.

15. 15. The device of claim 14, wherein the device housing includes a plurality of circumferentially spaced skirts, the grooves being formed in the plurality of skirts, and the flanges being circumferentially received between adjacent skirts.

16. 14. The device of claim 13, wherein the main body includes a first end and a second end circumferentially spaced from the first end, with a gap between the first end and the second end.

17. a device housing having an interior within which a plurality of components are received and rotate; a clutch ring received within the device housing and selectively engageable with one of the plurality of components; an actuator having a coil housing, a coil within the coil housing, and a plunger driven to move along an axis and relative to the clutch ring to move the clutch ring relative to the device housing; a retainer having a first portion that engages the device housing and a second portion that extends radially from the first portion toward the axis, the second portion radially overlapping the coil housing and limiting axial movement of the coil housing relative to the device housing; A rotary power transmission device comprising:

18. 18. The device of claim 17, wherein the first portion extends axially and engages a portion of the device housing.

19. 18. The device of claim 17, wherein the first portion is received in a groove in the device housing.

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