Collar-Type Differential with Selective Locking and Limited Slip

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Solution Overview

Problem

Conventional limited slip differentials (LSDs) lack full locking capability and are noisy, leading to rapid tire wear.

Innovation Solution

A differential assembly with a locking collar and electric actuator mechanism that selectively locks the differential, combining limited slip and locking capabilities, using clutch packs and an electric actuator to engage the locking collar with the differential gear set.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a conventional limited slip differential is used, then limited slip capability is provided, but full locking capability is not achieved

Engineering Contradiction:

Improvelocking capabilityVSAvoidhandling and off-road capability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent combines limited slip differential capability and full locking capability into a single integrated system. The locking collar with teeth engages with the differential gear set to provide full locking, while clutch packs provide limited slip functionality, allowing the system to operate in multiple modes depending on driving conditions

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The differential assembly allows dynamic switching between limited slip mode and full locking mode. An electric actuator mechanism selectively moves the locking collar into engagement with the differential gear set, enabling the system to adapt its locking characteristics based on real-time driving conditions and terrain requirements

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If prior art locking differentials are used, then full locking capability is achieved, but noise increases and tire wear accelerates

Engineering Contradiction:

Improvelocking capabilityVSAvoidnoise and tire wear

Core Design Contradiction:

Adaptability or versatilityVSObject-generated harmful factors

Solution Approach 1:

The system applies locking action selectively and partially when needed, rather than continuously. The electric actuator engages the locking collar only in specific off-road or low-traction conditions, allowing the differential to operate in limited slip mode during normal driving, thereby reducing noise and tire wear while maintaining full locking capability when required

Inventive Principle:

Principle #16Partial or excessive action

Data Source

PatentUS12410856B2Collar type differential which combines limited slip and locking capability

Publication Date: 2025.09.09 EATON INTELLIGENT POWER LTD

AI summary

A differential assembly includes a first case half. A second case half is connected to the first case half. The first and second case halves define a gear chamber. The first and second case halves each include pockets formed therein. A differential gear set is disposed in the gear chamber. First and second clutch packs are disposed in the pockets between the first and second case halves and differential gear set. The clutch packs engage the first and second case halves and the differential gear set defining a limited slip. A locking collar is disposed in a cavity formed in one of the first or second case halves. An electric actuator mechanism is coupled to the locking collar selectively moving the locking collar into engagement with the differential gear set locking the differential.