Driveline component having ring gear integrally formed with tubular drive member

Patent metadata

Field	Value
Publication number	US-2016109013-A1
Application number	US-201514880334-A
Country	US
Kind code	A1
Filing date	Oct 12, 2015
Priority date	Oct 17, 2014
Publication date	Apr 21, 2016
Grant date	—

Abstract

The present teachings provide for a power transfer device and method of forming a power transfer device that includes a unitarily formed transfer member and a support member. The transfer member can be supported within a housing for rotation about an input member and can be coupled to the input member to receive rotational power therefrom. A ring gear defined by the transfer member can meshingly engage with a pinion gear. The support member can be disposed concentrically about the input member and be rotatable about a first axis relative to the housing. The support member can have a first end and a second end. The first end of the support member can be supported for rotation relative to the housing by a support bearing. The second end of the support member can be received within a bore defined by the transfer member and fixedly coupled thereto for common rotation.

First claim

What is claimed is:

1 . A power transfer device comprising:
a housing; an input member disposed within the housing and supported for rotation about a first axis; a pinion disposed within the housing and supported for rotation about a second axis that is transverse to the first axis; a unitarily formed transfer member supported within the housing for rotation about the input member and coupled to the input member to receive rotational power therefrom, the transfer member defining a bore and a ring gear, the ring gear being meshingly engaged with the pinion gear; a support bearing; and a support member that is disposed concentrically about the input member and rotatable about the first axis relative to the housing, the support member having a first end and a second end, wherein the first end of the support member is supported for rotation relative to the housing by the support bearing, and the second end of the support member is received within the bore and fixedly coupled to the transfer member for common rotation.

2 . The power transfer device of claim 1 , wherein the second end of the support member and the bore of the transfer member are coupled for common rotation by an interference fit.

3 . The power transfer device of claim 1 , wherein the bore is defined on a first end of the transfer member and the input member extends axially from the first end of the transfer member to a second end of the transfer member, the input member and transfer member being coupled at the second end of the transfer member.

4 . The power transfer device of claim 1 , further comprising a clutch including:
a clutch element movable between a first position, wherein the clutch couples the input member and the transfer member for common rotation, and a second position, wherein the input member and transfer member are rotationally decoupled; and an actuator configured to move the clutch element between the first and second positions.

5 . The power transfer device of claim 4 , wherein the clutch element is a collar that defines a first spline and a second spline;
wherein the input member defines a third spline, and the transfer member defines a fourth spline; wherein when the clutch element is in the first position, the first spline is meshingly engaged with the third spline, and the second spline is meshingly engaged with the fourth spline; and wherein when the clutch element is in the second position, one of the first and second splines is not engaged with a respective one of the third and fourth splines.

6 . The power transfer device of claim 5 , wherein the ring gear and bore are defined by a first end of the transfer member and the fourth spline is defined by a second end of the transfer member, opposite the first end of the transfer member; and
wherein a first end of the input member is adapted to be coupled to an output of a transmission to receive rotary power therefrom, and a second end of the input member extends axially through the transfer member from the first end of the transfer member to the second end of the transfer member, the second end of the input member defining the third spline.

7 . The power transfer device of claim 1 , wherein the ring gear and pinion gear form a hypoid gear set.

8 . The power transfer device of claim 1 , wherein the transfer member is formed from a single forging.

9 . The power transfer device of claim 1 , further comprising:
a differential including a differential case and a pair of differential outputs, wherein the differential case is drivingly coupled to the input member and adapted to be coupled to an output of a transmission to receive rotary power therefrom, and wherein each of the differential outputs is adapted to be drivingly coupled to one of a pair of first drive wheels.

10 . The power transfer device of claim 9 , further comprising a drive module, the drive module having a module input and a pair of module outputs, the module input being coupled to receive rotary power from the pinion, and each of the module outputs being adapted to be drivingly coupled to one of a pair of second drive wheels.

11 . A power transfer device comprising:
a housing; an input member having a generally tubular shape, the input member being disposed within the housing and supported for rotation relative to the housing about a first axis; a pinion supported within the housing for rotation about a second axis that is transverse to the first axis; a support bearing; a power member, the power member being a single-piece body that defines a ring gear and a first tube, wherein the ring gear is meshingly engaged with the pinion and defines a bore that is concentric with the input member, wherein the first tube extends in a first axial direction from the ring gear, and wherein the first tube is coupled to the input member for transmission of rotary power therebetween; and a second tube having a first end and a second end, wherein the first end of the second tube is supported for rotation relative to the housing by the support bearing, and wherein the second end is received within the bore and fixedly coupled to the power member for common rotation.

12 . The power transfer device of claim 11 , wherein the second end of the tubular shaft and the bore of the ring gear are coupled for common rotation by an interference fit.

13 . The power transfer device of claim 11 , further comprising a clutch including:
a clutch element movable between a first position, wherein the clutch couples the input member and the first tube for common rotation, and a second position, wherein the input member and power member are decoupled for relative rotation; and an actuator configured to move the clutch element between the first and second positions.

14 . The power transfer device of claim 13 , wherein the clutch element is a collar that defines a first spline and a second spline;
wherein the input member defines a third spline, and the first tube defines a fourth spline; wherein when the clutch element is in the first position, the first spline is meshingly engaged with the third spline, and the second spline is meshingly engaged with the fourth spline; and wherein when the clutch element is in the second position, one of the first and second splines is not engaged with a respective one of the third and fourth splines.

15 . The power transfer device of claim 11 , wherein the ring gear and pinion gear form a hypoid gear set.

16 . The power transfer device of claim 11 , further comprising:
a differential including a differential case and a pair of differential outputs, wherein the differential case is drivingly coupled to the input member and adapted to be coupled to an output of a transmission to receive rotary power therefrom, and wherein each of the differential outputs is adapted to be drivingly coupled to one of a pair of first drive wheels

17 . The power transfer device of claim 16 , further comprising a drive module, the drive module having a module input and a pair of module outputs, the module input being coupled to receive rotary power from the pinion, and each of the module outputs being adapted to be drivingly coupled to one of a pair of second drive wheels.

18 . A method of forming a power transfer device, the method comprising:
providing a PTU housing, a support tube, an input member, and a pinion; forging a first body to have an annular portion and a tubular portion extending concentrically from the annular portion; forming a first set of gear teeth into the annular portion; supporting a first end o

Assignees

• American Axle & Mfg Inc

Inventors

• Li Yongwei

Classifications

• B60K2023/0858

  with electric means, e.g. electro-hydraulic means · CPC title

• B60K2023/0833

  for adding torque to the rear wheels · CPC title

• B60K23/08

  for changing number of driven wheels {, for switching from driving one axle to driving two or more axles (B60K17/3515 takes precedence)} · CPC title

• B60K17/344

  having a transfer gear · CPC title

• B60K17/02

  characterised by arrangement, location, or kind of clutch · CPC title