Abstract: A dual disconnect differential assembly for four-wheel drive (4WD) vehicle is disclosed. This disconnect differential assembly connects/disconnects both axle shafts of a differential assembly simultaneously from the side gears of the differential assembly. Both axle shafts are interconnected to provide simultaneous sliding along an axial direction. A clutch mechanism associated with the two differential side gears (which may be otherwise conventional) and with the axle shafts is provided for simultaneous connection and simultaneous disconnection of the axle shafts. The dual disconnect differential assembly herein is simple, compact, and reliable. It overcomes the disadvantages associated with single axle disconnect mechanisms presently in use. It also provides a simpler, more compact, and more reliable dual disconnect differential mechanism than any such mechanism presently known.

Abstract: An axle disconnect system is provided whereby axles of a tandem or multi-axle vehicle may be easily and quickly engaged and disengaged as required and whereby the ring gear and differential gears remain stationary when the axle is disengaged. In multi-axle vehicles, a dual disconnect mechanism is contained in the front and auxiliary rear axles. When only the primary rear axle is necessary to propel the vehicle (e.g., during highway use) the transfer case interrupts torque to the front axle. Similarly, a clutch also interrupts torque transmission to the auxiliary rear axle. In this mode, the dual disconnect mechanism prevents the axle output shafts from back-driving the differential, thereby reducing parasitic losses and wear.

Abstract: A dual disconnect differential assembly for four-wheel drive (4WD) vehicle is disclosed. This disconnect differential assembly connects/disconnects both axle shafts of a differential assembly simultaneously from the side gears of the differential assembly. Both axle shafts are interconnected to provide simultaneous sliding along an axial direction. A clutch mechanism associated with the two differential side gears (which may be otherwise conventional) and with the axle shafts is provided for simultaneous connection and simultaneous disconnection of the axle shafts. The dual disconnect differential assembly herein is simple, compact, and reliable. It overcomes the disadvantages associated with single axle disconnect mechanisms presently in use. It also provides a simpler, more compact, and more reliable dual disconnect differential mechanism than any such mechanism presently known.

Abstract: An axle case assembly is provided with a speed sensitive torque coupling mechanism used to transmit torque from the ring gear to a planetary differential assembly. The differential assembly provides torque transfer proportional to the speed difference between the ring gear sub-assembly and a planetary gear set sub-assembly, wherein the invention splits a differential case assembly into two primary pieces and a speed sensitive mechanism is installed between each piece. The mechanism is entirely contained inside an axle differential case assembly. An optional limited slip device may be provided for the differential gears. The torque transmission coupling assembly eliminates the need for a center differential in the transfer case, i.e. an interaxle differential, thereby reducing the driveline complexity and cost without requiring a separate torque coupling in the transfer case or in-line with the driveline.

Abstract: A gerotor assembly includes a pressure chamber with an integral eccentric ring for a motor vehicle hydraulic differential for use in hydraulic limited slip differentials for axles, transfer case center differentials and similar devices. The gerotor pump assembly in accordance with the present invention includes a housing having an integral ring which provides a pressure chamber for a piston, an eccentrically positioned recess for a inner rotor and an outer rotor and a location for a pressure limiting system. The gerotor pump assembly is of a non-reversing gerotor pump configuration using known methods to produce a unidirectional fluid flow.

Abstract: A control valve of a hydraulic coupling controls pumping through a casing inlet port by a hydraulic pump and/or through a casing outlet port to control coupling between two rotary members such as by operation of a clutch. The casing is connected to one of the rotary members while a pumping component embodied by an impeller is connected to the other rotary member and meshed with an internal ring gear having one more tooth than the number of impeller teeth to provide sufficient pumping capacity so that the pump can act as a brake while still having relatively constant pumping pressure. A pressure port plate creates a hydraulic flow path for a gerotor pump and maintains pressure equalization about the gerotor pump. The pressure/torque controlling groove formed in the grooved port plate creates an efficient use of space, and the dimensions and cross sectional area of the groove can be changed easily to produce different pressure/torque curves.

Abstract: A motor vehicle differential bearing pre-load mechanism which provides for the simultaneous use of a collapsible spacer which plastically deforms and has a close to linear load to deflection band on one side of a motor vehicle differential assembly and a threaded adjuster on the other side of the motor vehicle differential assembly to axially pre-load the differential bearings in motor vehicle differential axles or on any shaft with bearings which requires an axial pre-load. Typically, the axial pre-load of the differential bearings decreases as wear of the differential bearings occurs when mechanical shims or a threaded adjuster without a collapsible spacer have been used.

Abstract: A limited slip differential for a motor vehicle having a hydraulic medium plenum and pickup tube assembly which draws hydraulic medium from an axle sump by a vacuum generated by a hydraulic pump and transports the hydraulic medium to a hydraulic pump intake sump reservoir, the hydraulic medium plenum pickup tube assembly having a cross-sectional configuration which maintains the desired hydraulic medium flow rate, while being “thin” in at least one direction to filter out particulate contamination.

Abstract: A control valve of a hydraulic coupling controls pumping through a casing inlet port by a hydraulic pump and/or through a casing outlet port to control coupling between two rotary members such as by operation of a clutch. The casing is connected to one of the rotary members while a pumping component embodied by an impeller is connected to the other rotary member and meshed with an internal ring gear having one more tooth than the number of impeller teeth to provide sufficient pumping capacity so that the pump can act as a brake while still having relatively constant pumping pressure. The control valve includes a valve system through which pressurized hydraulic fluid selectively flows to control the coupling of the pair of rotary members. The instant invention provides a thin-plate check valve and pressure port stack which creates a hydraulic flow path for a gerotor pump and maintains pressure equalization about the gerotor pump.

Abstract: A tubular beam motor vehicle differential axle assembly having two (2) tubular shafts, each of the tubular shafts having gear teeth formed on one end thereof, or alternatively having a gear mechanically connected to the end of the tubular shaft by, for example, a chemical bonding material, a weld, an interference fit and/or one or more mechanical fastener(s), and the other end of each of the tubular shafts having a flange to which a motor vehicle wheel is mounted. A tubular differential case partially houses the two (2) tubular shafts, a set of pinion mate gears and a pinion mate gear shaft. A ring gear is positioned outboard of the tubular differential case which receives rotational power from an input shaft.

Abstract: The present invention relates generally to hydraulically actuated limited slip differentials. More particularly, the present invention relates to a hydraulic limited slip differential which utilizes a variable pressure relief check valve used to vary the maximum hydraulic pressure available within the differential case in a manner that the limited slip feature can be adjusted anywhere between a full “ON” and a full “OFF” configuration. Hydraulic fluid will not flow through the check valve until the hydraulic pressure within the case results in a reaction force larger than the check valve activation pressure, thus providing a maximum pressure limit in the hydraulic system. The activation pressure of the check valve can be selectively controlled by an actuator. The movement of the actuator corresponds to a change the retaining force of the check valve. Dynamic control of the system in response to vehicle operational parameters may also be performed.

Abstract: An angular transmission using magnetorheological fluid (MR fluid) to transmit movement between two (2) shafts not aligned on the same axis to each other to provide an infinite variable ratio instead of the fixed ratios present in known prior art gear driven angular transmissions by controlling the magnetic field applied to the magnetorheological fluid (MR fluid) through the use of one (1) or more electric coil(s) generating a magnetic field. In particular, the angular transmission using magnetorheological fluid (MR fluid) in accordance with a preferred embodiment of the present invention includes a pair of conical shaped hollow heads, one connected to an input shaft and one connected to an output shaft, the input shaft, the output shaft and the conical shaped hollow heads being assembled inside of a housing where the input shaft and the output shaft are mounted at an angle to each other (i.e.

Abstract: An axle case assembly is provided with a speed sensitive torque coupling mechanism used to transmit torque from the ring gear to a planetary differential assembly. The differential assembly provides torque transfer proportional to the speed difference between the ring gear sub-assembly and a planetary gear set sub-assembly, wherein the invention splits a differential case assembly into two primary pieces and a speed sensitive mechanism is installed between each piece. The mechanism is entirely contained inside an axle differential case assembly. An optional limited slip device may be provided for the differential gears. The torque transmission coupling assembly eliminates the need for a center differential in the transfer case, i.e. an interaxle differential, thereby reducing the driveline complexity and cost without requiring a separate torque coupling in the transfer case or in-line with the driveline.

Abstract: A vehicle differential unit including adjustable bearing assemblies has a differential carrier adapted to support a differential case assembly including differential case bearings associated therewith The differential case bearing assemblies rotatably support the differential case assembly within the carrier of the differential unit. Adjusting rings are provided and supported internally in a pair of axle tubes associated with the differential carrier. The adjusting rings are selectively biased against the bearing assemblies to impart the desired bearing preload and backlash within the differential unit. The adjusting rings replace the use of adjustment shims, and are accessible to permit adjustment if necessary without the need to remove the differential case assembly. The adjusting rings are threadably supported within the axle tubes to provide a rigid construction which simplifies constuction and adjustment of the differential unit.