Vehicle transfer case assembly with one-piece torque-transfer component having sprocket portion and output flange portion

Patent metadata

Field	Value
Publication number	US-9671006-B2
Application number	US-201414533140-A
Country	US
Kind code	B2
Filing date	Nov 5, 2014
Priority date	Nov 5, 2014
Publication date	Jun 6, 2017
Grant date	Jun 6, 2017

Abstract

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.

First claim

The invention claimed is:

1. A transfer case assembly for a vehicle, the transfer case assembly comprising:
a one-piece torque-transfer component having a sprocket portion configured to receive torque and an output flange portion configured to transfer the torque received; and
wherein the sprocket portion and the output flange portion rotate in unison about a common axis and are axially adjacent one another;
wherein the output flange portion has an inner surface defining an inner cavity;
wherein the output flange has a plurality of bosses extending radially inward at the inner surface into the inner cavity; and
wherein the bosses have axially-extending openings for receiving mounting features at the output flange portion.

2. The transfer case assembly of claim 1 , wherein the sprocket portion has an inner annular surface defining an inner cavity; and further comprising:
a bearing in the inner cavity interfacing with the sprocket portion at the inner annular surface.

3. The transfer case assembly of claim 1 , wherein the output flange portion has an outer surface, and further comprising:
an annular seal supported on the outer surface of the output flange portion.

4. The transfer case assembly of claim 1 , wherein the sprocket portion radially overlaps the plurality of bosses.

5. The transfer case assembly of claim 1 , wherein the one-piece torque-transfer component has an inner cavity extending axially through the sprocket portion and the output flange portion such that the one-piece torque-transfer component is hollow.

6. The transfer case assembly of claim 5 , wherein the one-piece torque-transfer component is powdered metal.

7. The transfer case assembly of claim 5 , further comprising:
a plate operatively connected to the one-piece torque-transfer component within the inner cavity; and wherein the plate closes the inner cavity.

8. The transfer case assembly of claim 1 , wherein the sprocket portion has an inner annular surface defining an inner cavity; and further comprising:
a transfer case housing radially surrounding the one-piece torque-transfer component;
a support post extending from the transfer case housing into the inner cavity;
a bearing supported on the support post in the inner cavity and interfacing with the sprocket portion at the inner annular surface such that the one-piece torque-transfer component is rotatably supported on the support post by the bearing.

9. The transfer case assembly of claim 8 , wherein the transfer case housing has an opening at which the output flange portion is positioned; wherein the output flange portion has an annular outer surface; and further comprising:
an annular seal supported on and surrounding the annular outer surface of the output flange portion at the opening.

10. The transfer case assembly of claim 8 , wherein the bearing is a first bearing; wherein the transfer case housing has an axially-extending flange; wherein the sprocket portion has a toothed outer surface; wherein the output flange portion has an axially-extending outer surface with a diameter less than a diameter of the toothed outer surface of the sprocket portion; and further comprising:
a second bearing supported on the annular outer surface of the output flange portion and the axially-extending flange of the transfer case housing such that the second bearing is positioned radially between the transfer case housing and the sprocket portion.

11. A transfer case assembly comprising:
a one-piece torque-transfer component having a sprocket portion configured to receive torque and an output flange portion configured to transfer the torque received; wherein the sprocket portion and the output flange portion rotate in unison about a common axis and are axially adjacent one another; wherein the sprocket portion has an annular inner surface defining an inner cavity;
a transfer case housing radially surrounding the one-piece torque-transfer component;
a support post extending from the transfer case housing into the inner cavity;
a bearing supported on the support post in the inner cavity and interfacing with the sprocket portion at the annular inner surface such that the one-piece torque-transfer component is rotatably supported on the support post by the bearing;
wherein the output flange portion has an annular outer surface; and
an annular seal supported on the annular outer surface of the output flange portion.

12. The transfer case assembly of claim 11 , wherein the transfer case housing has an opening and an axially-extending flange at the opening; wherein the output flange portion has an annular outer surface; and wherein the annular seal is supported on the axially-extending flange of the transfer case housing and surrounds the opening.

13. The transfer case assembly of claim 11 , wherein the one-piece torque-transfer component has an inner cavity extending axially through the sprocket portion and the output flange portion such that the one-piece torque-transfer component is hollow; and further comprising:
a plate operatively connected to the one-piece torque-transfer component within the inner cavity; and wherein the plate closes the inner cavity.

14. A transfer case assembly for a vehicle, the transfer case assembly comprising:
a one-piece torque-transfer component having a sprocket portion configured to receive torque and an output flange portion configured to transfer the torque received;
wherein the sprocket portion and the output flange portion rotate in unison about a common axis and are axially adjacent one another;
wherein the sprocket portion has an inner annular surface defining an inner cavity; and further comprising:
a bearing in the inner cavity interfacing with the sprocket portion at the inner annular surface.

15. The transfer case assembly of claim 14 , wherein the one-piece torque-transfer component is powdered metal.

16. The transfer case assembly of claim 14 , wherein the output flange portion has an outer surface, and further comprising:
an annular seal supported on the outer surface of the output flange portion.

Assignees

• Gm Global Tech Operations Llc

Inventors

• Modisett William Marc
• Sterba Gregory

Classifications

• B60K17/344

  having a transfer gear · CPC title

• F16H55/06

  Use of materials; Use of treatments of toothed members or worms to affect their intrinsic material properties · CPC title

• F16H57/021

  Shaft support structures, e.g. partition walls, bearing eyes, casing walls or covers with bearings · 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

• F16H7/06

  with chains · CPC title