A differential assembly

Abstract

A differential assembly includes an axle shaft retainer configured to mount within the retainer passage of the differential case. An example axle shaft retainer includes: a spacer disposed at a first end of a stem and a mounting arm disposed at a second end of the stem. The axle shaft retainer attaches to the differential case using the mounting arm. In an example, the axle shaft retainer is cantilevered off the differential case using the mounting arm.

Description

A DIFFERENTIAL ASSEMBLYCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 557, 153, filed February 23, 2024, the disclosure of which is incorporated by reference in its entirety.BACKGROUND

[0002] Traction modifying locking differentials typically include a gear case defining a gear chamber, and disposed therein, a differential gear set. The gear set manages the transfer of torque between first and second axle shafts. Such differentials may be found in various types of vehicles (e.g., combustion engines, electric engines, hybrid vehicles, etc.).SUMMARY

[0003] In accordance with some aspects of the disclosure, a differential assembly includes an axle shaft retainer configured to mount within the retainer passage of the differential case. In certain examples, the differential case defines aligned first and second axle passages leading to a cavity and a retainer passage leading to the cavity. In certain examples, the axle shaft retainer includes: a stem extending between opposite first and second ends, a spacer disposed at the first end of the stem, and an arm extending from the second end of the stem towards a distal end, the arm being configured to attach to the differential case.

[0004] In certain implementations, the differential assembly also includes a first axle shaft disposed in the first axle passage; and a second axle shaft disposed in the second axle passage. In certain examples, the spacer is axially disposed between the first and second axle shafts.

[0005] In accordance with some aspects of the disclosure, a differential case includes a body defining a peripheral sidewall extending between first and second ends of the body. The body defines a first axle passage leading along the length from the first end of the body to an internal cavity. The body also defines a second axle passage leading along the length from the second end of the body to the internal cavity. The body also defines a retainer passage extending between the internal cavity and an exterior of the peripheral sidewall. The body also defines a slot extending outwardly from the retainer passage. The body also defines a fastener support surface partially bounding the slot. The fastener support surface is recessed inwardly from an exterior of the peripheral sidewall.

[0006] A variety of additional inventive aspects will be set forth in the description that follows. The inventive aspects can relate to individual features and to combinations of features. It is to be understood that both the forgoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the broad inventive concepts upon which the embodiments disclosed herein are based.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The accompanying drawings, which are incorporated in and constitute a part of the description, illustrate several aspects of the present disclosure. A brief description of the drawings is as follows:

[0008] FIG. 1 is a perspective view of an example differential arrangement configured in accordance with the principles of the present disclosure;

[0009] FIG. 2 is a cross-sectional view of the differential arrangement of FIG. 1 ;

[0010] FIG. 3 is a perspective view of an example axle shaft retainer configured in accordance with the principles of the present disclosure;

[0011] FIG. 4 is another perspective view of the axle shaft retainer of FIG. 3;

[0012] FIG. 5 shows the axle shaft retainer of FIG. 3 exploded outwardly from the retainer passage of the differential arrangement of FIG. 1 ;

[0013] FIG. 6 is a perspective view of the cross-section of FIG. 2 with the axle shaft retainer and respective fastener removed for ease in viewing the body of the differential arrangement; and

[0014] FIG. 7 is a perspective view of the differential arrangement of FIG. 1 with the fastener for mounting the axle shaft retainer exploded outwardly from the body of the differential arrangement.DETAILED DESCRIPTION

[0015] Reference will now be made in detail to exemplary aspects of the present disclosure that are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

[0016] This disclosure is directed to a differential assembly having an axle shaft retainer enhanced for easy insertion and removal. In certain implementations, the axle shaft retainer is an integral piece that is inserted and removed as a unit. In certain examples, the axle shaft retainer is monolithically formed. In certain implementations, the axle shaft retainer ismounted to the differential case at one end by one or more fasteners. In certain examples, the axle shaft retainer is mounted using a single fastener.

[0017] Referring to FIGS. 1 and 2, an example differential assembly 100 configured in accordance with the principles of the present disclosure is illustrated. The differential case 102 includes a differential case 102 extending along a length L between opposite first and second ends 104, 106. A differential gear set 105 is disposed within the case 102. The differential case 102 defines a first axle shaft passage 108 extending inwardly from the first end 104 to a central cavity 110. The differential case 102 also defines a second axle shaft passage 112 extending inwardly from the second end 106 to the central cavity 110. The axle shaft passages 108, 112 are configured to receive and align respective axle shafts Al, A2 so that ends El, E2 of the axle shafts Al, A2 oppose each other. The axle shafts Al, A2 are operably connected to each other through the differential gear set 105.

[0018] When the axle shafts Al, A2 are being installed at the differential case 102, each axle shaft Al, A2 is pushed along the length L of the respective axle shaft passage 108, 112 so that the respective end El, E2 are disposed within the cavity 110. A clip or other retention structure is mounted to the end El, E2 within the cavity 110 and the axle shaft Al, A2 is pulled back until the clip or other retention structure enters a respective pocket Pl, P2. In certain examples, the pocket Pl, P2 is defined within a respective side gear of the differential gear set 105. When both axles shafts Al, A2 are mounted within the respective axle shaft passages 108, 112, an axle shaft retainer 150 is mounted to the differential case 102 to limit or inhibit axial movement of the axle shafts Al, A2 along the length L of the differential case 102.

[0019] The shaft retainer 150 extends between a first end 152 and a second end 154. A puck or other spacer 156 is disposed at the first end 152. In the example shown, the spacer 156 is cylindrical. In other examples, the spacer 156 can have any desired shape. An arm 160 is disposed at the second end 154. A stem 158 connects the spacer 156 and the arm 160. In certain examples, the arm 160 extends outwardly from the stem 158 at an orthogonal angle to the stem 158. In certain examples, a fastener aperture 162 is disposed at a distal end of the arm 160. In certain examples, the spacer 156, the stem 158, and the arm 160 are integral with each other. In an example, the spacer 156, the stem 158, and the arm 160 are monolithically formed.

[0020] In certain implementations, the differential case 102 defines a retainer passage 120 leading to the cavity 110. In certain examples, the retainer passage 120 extends between the cavity 110 and an exterior of a peripheral sidewall 122 of the differential case 102. In certain examples, the retainer passage 120 extends orthogonal to the axle shaft passages 108, 112. When the shaft retainer 150 is disposed in the retainer passage 120, the spacer 156 of the shaftretainer 150 is positioned between the ends El, E2 of the axle shafts Al, A2. In certain examples, the spacer 156 is positioned between the ends El, E2 along an axis of rotation R of the axle shafts Al, A2 (e.g., see FIG. 2).

[0021] In certain implementations, the shaft retainer 150 is removably connected to the differential case 102. In certain examples, the shaft retainer 150 is removably connected to the differential case 102 using one or more fasteners 164. In an example, the shaft retainer 150 is connected to the differential case 102 using a single fastener, which facilitates installation and removal. In certain implementations, the shaft retainer 150 is cantilevered within the retainer passage 120 when connected to the differential case 102. For example, the fastener 164 can be installed at a distal end 166 of the arm 160. In certain examples, the stem 158 and spacer 156 hang down from the arm 160 into the cavity 110.

[0022] In certain implementations, the differential case 102 defines a slot 170 extending outwardly from the retainer passage 120. In certain examples, the slot 170 extends parallel to the axis of rotation R of the axle shafts Al, A2. In some examples, the slot 170 extends outwardly from the retainer passage 120 in one direction. In other examples, the slot 170 extends outwardly from the retainer passage 120 in multiple directions. In certain examples, the slot 170 forms a ring around the retainer passage 120. The slot 170 is sized to receive at least the distal end 166 of the arm 160 of the shaft retainer 150 (e.g., see FIG. 2). In certain examples, at least the fastener aperture 164 defined through the arm 160 is disposed within the slot 170 when the shaft retainer 150 is mounted to the differential case 102. In certain examples, the retainer 164 passes through the slot 170 when the shaft retainer 150 is mounted to the differential case 102.

[0023] In certain implementations, the differential case 102 is configured to recess the fastener 164 within an outer footprint of the differential case 102. For example, the differential case 102 may define a recessed fastener support surface 172 that partially bounds the slot 170. The fastener support surface 172 defines a fastener aperture 174 that aligns with the fastener aperture 164 of the shaft retainer 150 when the shaft retainer 150 is mounted to the differential case 102. Accordingly, when the fastener 164 is inserted to secure the shaft retainer 150 to the differential case 102, the fastener 164 is recessed below or is flush with the exterior surface of the differential case (e.g., see FIGS. 1 and 2).

[0024] In use, the shaft retainer 150 can be installed at the differential case 102 before the axle shafts Al, A2 are mounted. In such cases, the shaft retainer 150 is removed from the differential case 102 immediately prior to installing the axle shafts Al, A2. In an example, to remove the shaft retainer, only a single fastener 164 needs to be removed, thereby facilitatingthe removal process. Once the fastener 164 is removed, the arm 160 can be pulled out of the slot 170 by angling the shaft retainer 150 within the retainer passage 120. The shaft retainer 150 can then be lifted out of the retainer passage 120 as a unit.

[0025] An end of each axle shaft Al, A2 is inserted through its respective axle shaft passage 108, 112 towards the cavity 110. A respective clip or other such structure is attached to the end of each axle shaft Al, A2 at the cavity 110 to inhibit removal of the axle shaft Al, A2. The clip or other such structure is then pulled back into the respective pocket Pl, P2 at the end of the shaft passage 108, 112. The shaft retainer 150 is then reinserted through the retainer passage 120 as a unit so that the shaft retainer 150 is disposed between the two axle shafts Al, A2. Accordingly, the spacer 156 of the shaft retainer 150 inhibits the axle shafts Al, A2 from shifting sufficiently axially to dislodge the clip or other such structure from the respective pocket Pl, P2.

[0026] The shaft retainer 150 is manipulated within the retainer passage 120 until the spacer 156 of the shaft retainer 150 is disposed between the central longitudinal axes of the axle shafts Al, A2. In certain implementations, during reinsertion, the shaft retainer 150 is tilted within the retainer passage 120 to insert the arm 160 or a portion thereof into the slot 170. The fastener 164 is then reinserted back through the fastener support surface 172 and the fastener aperture 162 in the arm 160.Example Aspects of the Disclosure

[0027] Aspect 1. A differential assembly comprising: a differential case defining first and second axle passages leading to a cavity, the first and second axle passages being aligned with each other, the differential case also defining a retainer passage leading to the cavity; an axle shaft retainer configured to mount within the retainer passage of the differential case, the axle shaft retainer including: a stem extending between opposite first and second ends, a spacer disposed at the first end of the stem, and an arm extending from the second end of the stem towards a distal end, the arm being configured to attach to the differential case.

[0028] Aspect 2. The differential assembly of aspect 1, further comprising a fastener configured to attach the arm of the axle shaft retainer to the differential case.

[0029] Aspect 3. The differential assembly of aspect 2, wherein the fastener attaches the distal end of the arm to the differential case.

[0030] Aspect 4. The differential assembly of aspect 2, wherein the fastener is recessed within an outer footprint of the differential case when attaching the arm to the differential case.

[0031] Aspect 5. The differential assembly of aspect 1, wherein the distal end of the arm attaches to the differential case.

[0032] Aspect 6. The differential assembly of aspect 1, further comprising: a first axle shaft disposed in the first axle passage; and a second axle shaft disposed in the second axle passage, the second axle shaft being axially aligned with the first axle shaft; wherein the spacer is axially disposed between the first and second axle shafts.

[0033] Aspect ?. The differential assembly of aspect 1, wherein the differential case defines a slot extending outwardly from the retainer passage, wherein the distal end of the arm extends into the slot when the axle shaft retainer is mounted within the retainer passage of the differential case.

[0034] Aspect 8. The differential assembly of aspect 7, wherein the differential case defines a fastener opening disposed so that a fastener received within the fastener opening passes through the slot.

[0035] Aspect 9. The differential assembly of aspect 1, wherein the stem is cylindrical.

[0036] Aspect 10. The method of aspect 14, wherein the axle shaft retainer is cantilevered off the differential case when mounted to the differential case.

[0037] Aspect 11. A differential case comprising a body extending along a length between opposite first and second ends, the body defining a peripheral sidewall extending between the first and second ends, the body defining a first axle passage leading along the length from the first end of the body to an internal cavity, the body also defining a second axle passage leading along the length from the second end of the body to the internal cavity, the first and second axle passages being aligned with each other, the body also defining a retainer passage extending between the internal cavity and an exterior of the peripheral side wall, the body also defining a ring-shaped cavity coaxial with the retainer passage, the body also defining a fastener support surface partially bounding the ring-shaped cavity, the fastener support surface being recessed inwardly from an exterior of the peripheral sidewall.

[0038] Aspect 12. The differential case of aspect 11, wherein an open end of the retainer passage at the peripheral sidewall has a rectangular shape.

[0039] Aspect 13. The differential case of aspect 11, wherein the fastener support surface aligns with an aperture leading from the fastener support surface to an exterior of the peripheral side wall.

[0040] Aspect 14. The differential case of aspect 13, wherein the aperture extends beyond the footprint of the open end of the retainer passage.

[0041] Aspect 15. A method of installing axles at a differential case, the method comprising: mounting a first axle at a first axle shaft of the differential case; mounting a second axle at a second axle shaft of the differential case so that an end of the second axle opposes an end of the first axle; sliding an axle shaft retainer into a retainer passage of the differential case until a first end of the axle shaft retainer is disposed at least partially between the opposing ends of the first and second axle shafts, the axle shaft retainer being monolithically formed; and securing a second end of the axle shaft retainer to the differential case.

[0042] Aspect 16. The method of aspect 15, wherein sliding the axle shaft retainer into the retainer passage comprises angling the axle shaft retainer so that an arm of the axle shaft retainer slides into a slot extending beyond the retainer passage.

[0043] Aspect 17. The method of aspect 15, wherein securing the second end of the axle shaft retainer comprises inserting a fastener through the arm and through the slot.

[0044] Aspect 18. The method of aspect 15, further comprising removing the axle shaft retainer from the differential case prior to mounting the first and second axles.

[0045] Aspect 19. The method of aspect 18, wherein removing the axle shaft retainer includes: removing a fastener; and pulling the axle shaft retainer out of the retainer passage.

[0046] Aspect 20. The method of aspect 19, wherein pulling the axle shaft retainer out of the retainer passage comprises: angling the axle shaft retainer to remove a portion of the axle shaft retainer from a slot extending outwardly from the retainer passage; and pulling the axle shaft retainer out through an open end of the retainer slot.

[0047] Having described the preferred aspects and implementations of the present disclosure, modifications and equivalents of the disclosed concepts may readily occur to one skilled in the art. However, it is intended that such modifications and equivalents be included within the scope of the claims which are appended hereto.

Claims

What is claimed is:

1. A differential assembly comprising: a differential case defining first and second axle passages leading to a cavity, the first and second axle passages being aligned with each other, the differential case also defining a retainer passage leading to the cavity; an axle shaft retainer configured to mount within the retainer passage of the differential case, the axle shaft retainer including: a stem extending between opposite first and second ends, a puck disposed at the first end of the stem, and an arm extending from the second end of the stem towards a distal end, the arm being configured to attach to the differential case.

2. The differential assembly of claim 1, further comprising a fastener configured to attach the arm of the axle shaft retainer to the differential case.

3. The differential assembly of claim 2, wherein the fastener attaches the distal end of the arm to the differential case.

4. The differential assembly of claim 2, wherein the fastener is recessed within an outer footprint of the differential case when attaching the arm to the differential case.

5. The differential assembly of claim 1, wherein the distal end of the arm attaches to the differential case.

6. The differential assembly of claim 1, further comprising: a first axle shaft disposed in the first axle passage; and a second axle shaft disposed in the second axle passage, the second axle shaft being axially aligned with the first axle shaft; wherein the puck is axially disposed between the first and second axle shafts.

7. The differential assembly of claim 1, wherein the differential case defines a ringshaped cavity coaxial with the retainer passage, wherein the distal end of the arm extends intothe ring-shaped cavity when the axle shaft retainer is mounted within the retainer passage of the differential case.

8. The differential assembly of claim 7, wherein the differential case defines a fastener opening disposed so that a fastener received within the fastener opening passes through the ring-shaped cavity.

9. The differential assembly of claim 1, wherein the stem is cylindrical.

10. The method of claim 14, wherein the axle shaft retainer is cantilevered off the differential case when mounted to the differential case.

11. A differential case comprising a body extending along a length between opposite first and second ends, the body defining a peripheral sidewall extending between the first and second ends, the body defining a first axle passage leading along the length from the first end of the body to an internal cavity, the body also defining a second axle passage leading along the length from the second end of the body to the internal cavity, the first and second axle passages being aligned with each other, the body also defining a retainer passage extending between the internal cavity and an exterior of the peripheral sidewall, the body also defining a ring-shaped cavity coaxial with the retainer passage, the body also defining a fastener support surface partially bounding the ring-shaped cavity, the fastener support surface being recessed inwardly from an exterior of the peripheral sidewall.

12. The differential case of claim 11, wherein an open end of the retainer passage at the peripheral sidewall has a rectangular shape.

13. The differential case of claim 11, wherein the fastener support surface aligns with an aperture leading from the fastener support surface to an exterior of the peripheral sidewall.

14. The differential case of claim 13, wherein the aperture extends beyond the footprint of the open end of the retainer passage.

15. A method of installing axles at a differential case, the method comprising: mounting a first axle at a first axle shaft of the differential case;mounting a second axle at a second axle shaft of the differential case so that an end of the second axle opposes an end of the first axle; sliding an axle shaft retainer into a retainer passage of the differential case until a first end of the axle shaft retainer is disposed at least partially between the opposing ends of the first and second axle shafts, the axle shaft retainer being monolithically formed; and securing a second end of the axle shaft retainer to the differential case.

16. The method of claim 15, wherein sliding the axle shaft retainer into the retainer passage comprises angling the axle shaft retainer so that an arm of the axle shaft retainer slides into a slot extending beyond the retainer passage.

17. The method of claim 15, wherein securing the second end of the axle shaft retainer comprises inserting a fastener through the arm and through the slot.

18. The method of claim 15, further comprising removing the axle shaft retainer from the differential case prior to mounting the first and second axles.

19. The method of claim 18, wherein removing the axle shaft retainer includes: removing a fastener; and pulling the axle shaft retainer out of the retainer passage.

20. The method of claim 19, wherein pulling the axle shaft retainer out of the retainer passage comprises: angling the axle shaft retainer to remove a portion of the axle shaft retainer from a slot extending outwardly from the retainer passage; and pulling the axle shaft retainer out through an open end of the retainer slot.

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