Portal Wheel End Housing With Integral Brackets for Rigid Suspension Mounting

Solution Overview

Problem

The connection between the portal box and the vehicle suspension has not been optimized to improve the strength and fitment of the mounting structure in existing portal gear box assemblies.

Innovation Solution

A portal gear box assembly with a housing that includes integral mounting brackets on the rear wall, allowing direct connection of the vehicle suspension components, such as A-arms, trailing arms, or swing arms, and steering linkages, eliminating the need for a backing plate.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a backing plate is used to mount the portal box to the vehicle suspension, then the mounting structure can be assembled, but the strength and rigidity of the mounting structure is insufficient

Engineering Contradiction:

Improvemounting structure strengthVSAvoidmounting structure complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The mounting bracket is merged with the portal box housing to form an integrated one-piece structure. The bracket is formed as an integral part of the housing through casting or forging operations, eliminating the need for separate backing plates and multiple fasteners. This integration directly strengthens the mounting structure by creating a rigid, unified component that resists flexing and failure under load.

Inventive Principle:

Principle #5Merging (Combining)

2Stability of the object's composition

If a separate backing plate is used for mounting, then the portal box can be mounted to the vehicle suspension, but flex and reduced rigidity occur in the mounting structure

Engineering Contradiction:

Improvemounting structure rigidityVSAvoidmanufacturing complexity

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The mounting bracket and portal box housing are combined into a single integrated component. The bracket extends from the housing as an integral structure, eliminating gaps and potential flex points between separate parts. This integration maximizes rigidity and structural stability while the housing itself serves as the mounting interface.

Inventive Principle:

Principle #5Merging (Combining)

3Strength

If multiple separate components are used for mounting (housing, backing plate, brackets), then assembly is possible, but the overall strength and fitment are compromised

Engineering Contradiction:

Improvemounting structure strengthVSAvoidnumber of parts

Core Design Contradiction:

StrengthVSQuantity of substance

Solution Approach 1:

The mounting bracket is merged with the portal box housing to form an integrated one-piece structure. The bracket is formed as an integral part of the housing through casting or forging operations, eliminating the need for separate backing plates and multiple fasteners. This integration directly strengthens the mounting structure by creating a rigid, unified component that resists flexing and failure under load.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS12208676B2One-piece portal wheel end mounting system

Publication Date: 2025.01.28 SUPER ATV LLC

AI summary

A mounting system for a portal lift assembly of an off-road vehicle includes a housing having a rear wall, a front wall, and a side wall. The rear wall includes an opening to receive the end of one of the vehicle's axles, and the front wall includes an opening to allow an output shaft to extend outward from the housing. The rear wall also includes an integral mounting brackets effective to mount the box to an upper A-arm to the rear wall, and a lower A-arm to the rear wall.