One-Piece Torque-Transfer Component for Vehicle Transfer Case
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Solution Overview
Problem
Existing transfer case assemblies for vehicles require multiple components and significant axial packaging space due to separate output sprockets and mounting flanges, leading to increased manufacturing costs and complexity.
Innovation Solution
A one-piece torque-transfer component with a sprocket portion and an output flange portion that rotate in unison, reducing the need for intermediate shafts and splined interfaces, and utilizing powdered metal for manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If separate output sprockets and mounting flanges are used, then torque transfer function is achieved, but the number of components and device complexity increase
Solution Approach 1:
The patent combines the output sprocket and mounting flange into a single integrated one-piece torque-transfer component. This merging eliminates the need for separate components and their associated interfaces (such as splined interfaces and intermediate shafts), thereby reducing device complexity while maintaining the torque transfer function through the unified structure.
Solution Approach 2:
The one-piece torque-transfer component performs multiple functions simultaneously: it acts as both the output sprocket for chain engagement and the mounting flange for shaft attachment. This multi-functionality reduces the number of separate components needed while ensuring reliable torque transfer to both rear and front wheels.
2Length of stationary object
If separate output sprocket and mounting flange with intermediate shaft are used, then torque transfer is achieved, but axial packaging space increases
Solution Approach 1:
By merging the output sprocket and mounting flange into one integrated component, the patent eliminates the intermediate shaft that would otherwise be required to connect them. This consolidation significantly reduces the axial space occupied by the transfer case assembly while maintaining full torque transfer capability through the unified structure.
Solution Approach 2:
The one-piece torque-transfer component is designed with a hollow inner cavity that can accommodate bearings and other internal components. This nesting arrangement allows the component to house necessary elements within its structure, further reducing the overall axial packaging space required.
3Ease of manufacture
If separate components with splined interfaces are used, then torque transfer is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent integrates the output sprocket and mounting flange into a single component, eliminating the need for complex splined interfaces and intermediate shafts. This reduction in part count and interface complexity directly lowers manufacturing costs while maintaining reliable torque transfer through the simplified unified structure.
Solution Approach 2:
The one-piece torque-transfer component can be manufactured using near-net-shape processes such as powdered metal forming. This manufacturing approach reduces the need for secondary machining operations that would otherwise be required for splined interfaces, thereby lowering manufacturing complexity and cost while ensuring reliable torque transfer.
Data Source
AI summary
A transfer case assembly for a vehicle has a one-piece torque-transfer component with both a sprocket portion configured to receive torque and an output flange portion configured to transfer the torque received. The sprocket portion and the output flange portion rotate in unison about a common axis and are axially adjacent one another.