Lock Plate Clutch Pack for Short-Span High-Torque Differentials
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Solution Overview
Problem
Mechanical locking differentials face a challenge in reducing the bearing span while maintaining torque capacity and smooth locking action, as a large number of clutch discs are required to achieve these conditions.
Innovation Solution
A differential design incorporating a clutch pack and a pair of lock plates, where the cam plate has a splined neck with external teeth for actuation, and the clutch pack includes active clutch discs internally splined to the neck, allowing for reduced clutch disc count and bearing span while maintaining torque capacity through a combination of reduced-size clutch packs and lock plates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a large number of clutch discs are used, then torque capacity and smooth locking action are improved, but bearing span increases
Solution Approach 1:
The patent combines lock plates with clutch discs to create a hybrid structure. The lock plates (first lock plate and second lock plate) are integrated with the clutch pack assembly, where the first lock plate has friction surfaces that engage with the second lock plate. This merging allows the structure to provide both positive locking capability and torque transmission through friction, reducing the number of separate clutch discs needed while maintaining torque capacity and reducing bearing span.
2Length of moving object
If the number of clutch discs is reduced, then bearing span decreases, but torque capacity and smooth locking action are compromised
Solution Approach 1:
The clutch pack is segmented into multiple functional components: active clutch discs for torque transmission, inactive clutch discs for structural support and friction engagement, and lock plates for positive locking. This segmentation allows each component to be optimized for its specific function, enabling the system to maintain high torque capacity with fewer total discs by distributing the workload across specialized elements.
Solution Approach 2:
The patent employs a composite structure combining metallic lock plates with friction materials on their surfaces. The first lock plate includes friction surfaces that mate with corresponding surfaces on the second lock plate, creating a composite friction-locking mechanism. This composite approach enables the lock plates themselves to contribute to torque capacity through friction engagement, reducing the need for numerous clutch discs.
3Reliability
If lock plates are added to the clutch pack, then positive locking is improved, but device complexity increases
Solution Approach 1:
The lock plates serve multiple functions within the clutch pack assembly. They provide positive locking through their interlocking toothed sides, transmit torque through their friction surfaces, and structurally support the clutch disc arrangement. The first lock plate and second lock plate work together as an integrated unit that simultaneously achieves locking, torque transmission, and structural stability, reducing the need for separate dedicated components for each function.
Data Source
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AI summary
A differential including a case (5), a side gear (100,200), a first lock plate (1000) having a first side and a toothed side, and a second lock plate (2000) having a first side facing the case and a toothed second side facing the toothed side of the first lock plate (1000). The differential further includes a cam plate (300) between the side gear (100,200) and the first lock plate (1000) and a clutch pack (40) between the cam plate (300) and the first lock plate (1000). The cam plate (300) includes a splined neck (330) extending towards the first lock plate (1000), and the clutch pack (40) includes at least one active clutch disc (20) internally splined to the splined neck (330).