Patents by Inventor Philip J. Francis

Philip J. Francis has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Publication number: 20190249760
    Abstract: A power transmitting component with a differential assembly and a planetary reduction that has a plurality of compound planet gears. Each of the compound planet gears is rotatable about a rotary planet axis and has first and second planet gears that are nonrotatably coupled to one another and spaced axially apart from one another along an associated one of the rotary planet axes. The rotary planet axes are disposed concentrically about a rotational axis of the input to the planetary reduction. Each of the first planet gears is meshingly engaged to the input of the planetary reduction, while each of second planet gears is meshingly engaged with a stationary ring gear. The differential assembly receives rotary power from the planetary reduction and has first and second differential outputs that are disposed along the rotational axis between the first and second planet gears.
    Type: Application
    Filed: February 12, 2018
    Publication date: August 15, 2019
    Inventors: Larry A. Pritchard, Philip J. Francis
  • Patent number: 10378642
    Abstract: A passive lubrication system, for a gear drive system of a drive system, for powering an electric vehicle, includes an oil network, an oil sump region, an oil paddle, and an oil diverter. The oil network is defined by and disposed within, at least, a fixed annular region of the gear drive system and a planetary gear system. The oil sump region is configured to provide oil for distribution about the oil network. The oil paddle is operatively coupled with the planetary gear system, configured to rotate with a component of the planetary gear system, and during rotation, configured to course oil, from the oil sump region. The oil diverter is positioned concentric with the oil paddle and radially outward of the oil paddle and configured to receive oil from an oil source, upon rotation of the oil paddle, and direct the received oil to the oil network.
    Type: Grant
    Filed: November 28, 2017
    Date of Patent: August 13, 2019
    Assignee: BorgWarner Inc.
    Inventors: Larry A. Pritchard, Philip J. Francis
  • Publication number: 20190234508
    Abstract: A powertrain arrangement for a transverse mounted motor for an electric powered automotive passenger vehicle including opposing wheel shafts for powering two parallel mounted wheels, the shafts rotating about a first axis, the shafts having at least one end torsionally connected with a differential, an electrical rotor torsionally connected with the wheel shafts via a planetary gear train, an electrical stator surrounding the rotor, a casing supporting the rotor and the wheel shafts, the casing encompassing the stator, the casing having a floor forming a lubricant reservoir, and a baffle located in the lubricant reservoir, the baffle having barriers generally transverse to the first axis and at least one of the barriers having a lower window allowing fluid communication underneath the barrier.
    Type: Application
    Filed: January 26, 2018
    Publication date: August 1, 2019
    Inventors: Philip J. Francis, Larry A. Pritchard
  • Patent number: 10183577
    Abstract: A transfer case includes primary and secondary output shafts, along with a secondary torque transfer mechanism and a locking mechanism, which are configured to selectively couple the primary and secondary output shafts. The secondary torque transfer mechanism comprises a sprocket coupled to the secondary output shaft, and a plate clutch coupled to the sprocket to selectively form a friction coupling with the primary output shaft. The locking mechanism selectively couples the primary output shaft to the sprocket, and includes a locking sleeve and an actuator that moves the locking sleeve between a first position and a second position. In the first position, the locking sleeve forms a first splined connection with the primary output shaft and forms a second splined connection with the sprocket. In the second position, the locking sleeve forms the first splined connection with the primary output shaft and forms a second splined connection with the sprocket.
    Type: Grant
    Filed: February 14, 2017
    Date of Patent: January 22, 2019
    Assignee: BorgWarner Inc.
    Inventors: Larry A. Pritchard, Thaddeus R. Kopp, Jr., Branden L. Reeves, Philip J. Francis, Joseph D. Mastie
  • Patent number: 10077811
    Abstract: A lubrication system (400) for a transfer case (200) includes a pump (228) selectively supplying a working fluid to a fluid reservoir of an actuator (226) configured to apply force to a clutch assembly (214) to cause the clutch assembly (214) to move between a disengaged position and an engaged position. The lubrication system also includes a relief valve (302) having a relief valve inlet fluidly coupled to the fluid reservoir of the actuator (226) which opens to receive the working fluid based on a threshold pressure level of the working fluid in the fluid reservoir. The lubrication system also includes a trough (306) fluidly coupled to a relief valve outlet of the relief valve (302). The trough (306) carries the working fluid from the relief valve outlet to a bearing assembly (227) associated with at least one of an input shaft (204) and a primary output shaft (206) of the transfer case (200) when the clutch assembly (214) is in the disengaged position.
    Type: Grant
    Filed: July 7, 2016
    Date of Patent: September 18, 2018
    Assignee: BorgWarner Inc.
    Inventors: Philip J. Francis, William C. Dodge
  • Patent number: 10023041
    Abstract: A drive unit includes a housing, a main shaft, an output shaft, an electric motor, a first planetary gear set, and a second planetary gear set. The main shaft is rotatably disposed in the housing, and with the housing cooperatively defines an axis of rotation. The output shaft is disposed at least in part in the housing and is rotatable about the axis. The electric motor is disposed in the housing and has a rotor centered on and rotatable about the axis. The first planetary gear set is centered on the axis and provides a first speed reduction ratio between the rotor and a second planetary gear set. The second planetary gear set provides a second speed reduction ratio between the first planetary gear set and the output shaft.
    Type: Grant
    Filed: May 15, 2017
    Date of Patent: July 17, 2018
    Assignee: BorgWarner Inc.
    Inventors: Larry A. Pritchard, Philip J. Francis
  • Publication number: 20180156326
    Abstract: A passive lubrication system, for a gear drive system of a drive system, for powering an electric vehicle, includes an oil network, an oil sump region, an oil paddle, and an oil diverter. The oil network is defined by and disposed within, at least, a fixed annular region of the gear drive system and a planetary gear system. The oil sump region is configured to provide oil for distribution about the oil network. The oil paddle is operatively coupled with the planetary gear system, configured to rotate with a component of the planetary gear system, and during rotation, configured to course oil, from the oil sump region. The oil diverter is positioned concentric with the oil paddle and radially outward of the oil paddle and configured to receive oil from an oil source, upon rotation of the oil paddle, and direct the received oil to the oil network.
    Type: Application
    Filed: November 28, 2017
    Publication date: June 7, 2018
    Inventors: Larry A. Pritchard, Philip J. Francis
  • Publication number: 20180076687
    Abstract: A drive system for powering the wheels of an electric vehicle is disclosed. The drive system includes an electric motor having a stator and a rotor, and one or more planetary gear sets operably connected to the electric motor and the wheels. The drive system includes one or more configurations that reduce packaging space, reduce the weight of the drive system, and/or provide cooling functions.
    Type: Application
    Filed: September 12, 2017
    Publication date: March 15, 2018
    Inventors: Larry A. PRITCHARD, Philip J. FRANCIS
  • Publication number: 20180010650
    Abstract: A lubrication system (400) for a transfer case (200) includes a pump (228) selectively supplying a working fluid to a fluid reservoir of an actuator (226) configured to apply force to a clutch assembly (214) to cause the clutch assembly (214) to move between a disengaged position and an engaged position. The lubrication system also includes a relief valve (302) having a relief valve inlet fluidly coupled to the fluid reservoir of the actuator (226) which opens to receive the working fluid based on a threshold pressure level of the working fluid in the fluid reservoir. The lubrication system also includes a trough (306) fluidly coupled to a relief valve outlet of the relief valve (302). The trough (306) carries the working fluid from the relief valve outlet to a bearing assembly (227) associated with at least one of an input shaft (204) and a primary output shaft (206) of the transfer case (200) when the clutch assembly (214) is in the disengaged position.
    Type: Application
    Filed: July 7, 2016
    Publication date: January 11, 2018
    Applicant: BorgWarner Inc.
    Inventors: Philip J. Francis, William C. Dodge
  • Patent number: 9752671
    Abstract: A transfer case is provided with a primary shaft which is selectively engagable with a secondary shaft via a clutch mechanism. The clutch mechanism is inclusive of a friction pack. A hub of the clutch mechanism is connected on the primary shaft and the clutch housing is torsionally fixed with a primary sprocket rotatively mounted on the primary shaft. A passive or active controlled lubricant collection receptacle is provided which maximize fluid retention in conditions wherein there is not a high demand of torque for the clutch system of the transfer case thereby minimizing fluid that is unnecessarily churned by engagement with the hub connected with the secondary shaft.
    Type: Grant
    Filed: February 19, 2015
    Date of Patent: September 5, 2017
    Assignee: BorgWarner Inc.
    Inventors: Daniel Kampe, Johan Nilsson, Philip J. Francis, Garrett W. Gage, Michael F. Boyer
  • Publication number: 20170240043
    Abstract: A transfer case comprises a primary output shaft, and a secondary output shaft selectively coupleable to the primary output shaft with a plate clutch to transfer torque therebetween. The plate clutch includes a housing, a plurality of interleaved plates that are engaged alternatingly with the primary output shaft and the housing to rotate therewith, and an apply plate non-selectively coupled to the primary output shaft to rotate therewith. The apply plate is moveable axially along the primary output shaft into a first configuration in which the apply plate is positively coupled to the housing to rotate therewith, a second configuration in which the apply plate rotates independent of the housing, and a third configuration in which the apply plate compresses the interleaved plates to form a friction coupling between the primary output shaft and the housing.
    Type: Application
    Filed: February 22, 2017
    Publication date: August 24, 2017
    Applicant: BorgWarner Inc.
    Inventors: Larry A. Pritchard, Thaddeus R. Kopp, JR., Branden L. Reeves, Philip J. Francis, Joseph D. Mastie
  • Publication number: 20170232840
    Abstract: A transfer case includes primary and secondary output shafts, along with a secondary torque transfer mechanism and a locking mechanism, which are configured to selectively couple the primary and secondary output shafts. The secondary torque transfer mechanism comprises a sprocket coupled to the secondary output shaft, and a plate clutch coupled to the sprocket to selectively form a friction coupling with the primary output shaft. The locking mechanism selectively couples the primary output shaft to the sprocket, and includes a locking sleeve and an actuator that moves the locking sleeve between a first position and a second position. In the first position, the locking sleeve forms a first splined connection with the primary output shaft and forms a second splined connection with the sprocket. In the second position, the locking sleeve forms the first splined connection with the primary output shaft and forms a second splined connection with the sprocket.
    Type: Application
    Filed: February 14, 2017
    Publication date: August 17, 2017
    Applicant: BorgWarner Inc.
    Inventors: Larry A. Pritchard, Thaddeus R. Kopp, Jr., Branden L. Reeves, Philip J. Francis, Joseph D. Mastie
  • Patent number: 9651136
    Abstract: A transfer case for a normally rear wheel drive vehicle having selectively engageable front wheel drive is provided. The transfer case includes a rear housing with a main drive shaft aperture and an aluminum cast front housing threadably connected with the rear housing. The front housing has a main drive shaft aperture axially aligned with the rear housing main drive shaft aperture. The front housing has an integrally formed cylindrical yoke forming an isolation mount for receiving a polymeric isolator allowing for connection of the transfer case with a chassis structure of the vehicle. The cylindrical yoke has a cylindrical preform therein.
    Type: Grant
    Filed: April 1, 2015
    Date of Patent: May 16, 2017
    Assignee: BorgWarner Inc.
    Inventors: Philip J. Francis, Thomas Knox, Greg Bartman, Arun Narayanan
  • Patent number: 9506504
    Abstract: A transfer case is provided with a primary shaft which is selectively engagable with a secondary shaft via a clutch mechanism. The clutch mechanism is inclusive of a friction pack. A hub of the clutch mechanism is connected on the primary shaft and the clutch housing is torsionally fixed with a primary sprocket rotatively mounted on the primary shaft. A reservoir system is provided for delivering splashed oil axially along the primary shaft overlapping the friction pack. The reservoir system has a collective fluid receptacle that is connected via a stationary passage with a lubrication passage radially inward of the friction pack of the hub.
    Type: Grant
    Filed: August 22, 2014
    Date of Patent: November 29, 2016
    Assignee: BorgWarner Inc.
    Inventors: Philip J. Francis, Michael F. Boyer, Garrett W. Gage, Johan Nilsson, Daniel Kampe
  • Publication number: 20160290474
    Abstract: A transfer case for a normally rear wheel drive vehicle having selectively engageable front wheel drive is provided. The transfer case includes a rear housing with a main drive shaft aperture and an aluminum cast front housing threadably connected with the rear housing. The front housing has a main drive shaft aperture axially aligned with the rear housing main drive shaft aperture. The front housing has an integrally formed cylindrical yoke forming an isolation mount for receiving a polymeric isolator allowing for connection of the transfer case with a chassis structure of the vehicle. The cylindrical yoke has a cylindrical preform therein.
    Type: Application
    Filed: April 1, 2015
    Publication date: October 6, 2016
    Inventors: Philip J. Francis, Thomas Knox, Greg Bartman, Arun Narayanan
  • Publication number: 20150240935
    Abstract: A transfer case is provided with a primary shaft which is selectively engagable with a secondary shaft via a clutch mechanism. The clutch mechanism is inclusive of a friction pack. A hub of the clutch mechanism is connected on the primary shaft and the clutch housing is torsionally fixed with a primary sprocket rotatively mounted on the primary shaft. A passive or active controlled lubricant collection receptacle is provided which maximize fluid retention in conditions wherein there is not a high demand of torque for the clutch system of the transfer case thereby minimizing fluid that is unnecessarily churned by engagement with the hub connected with the secondary shaft.
    Type: Application
    Filed: February 19, 2015
    Publication date: August 27, 2015
    Inventors: Daniel KAMPE, Johan NILSSON, Philip J. FRANCIS, Garrett W. GAGE, Michael F. BOYER
  • Publication number: 20150060228
    Abstract: A transfer case is provided with a primary shaft which is selectively engagable with a secondary shaft via a clutch mechanism. The clutch mechanism is inclusive of a friction pack. A hub of the clutch mechanism is connected on the primary shaft and the clutch housing is torsionally fixed with a primary sprocket rotatively mounted on the primary shaft. A reservoir system is provided for delivering splashed oil axially along the primary shaft overlapping the friction pack. The reservoir system has a collective fluid receptacle that is connected via a stationary passage with a lubrication passage radially inward of the friction pack of the hub.
    Type: Application
    Filed: August 22, 2014
    Publication date: March 5, 2015
    Inventors: Philip J. Francis, Michael F. Boyer, Garrett W. Gage, Johan Nilsson, Daniel Kampe
  • Patent number: 8235198
    Abstract: A hydraulic clutch assembly for a motor vehicle driveline is provided. The clutch assembly comprises an input member, and output member and a friction clutch pack operably disposed therebetween for controlling torque transfer. A first fluid circuit contains hydraulic based fluid at a first pressure and is in fluid communication with the friction clutch pack for lubrication thereof. A second fluid circuit is in fluid communication with the first fluid circuit for replenishing the second fluid circuit with the hydraulic based fluid at a second pressure that is less than the first pressure. The clutch assembly further comprises a motor and a gear train. A first piston is in fluid communication with the second fluid circuit for delivering the hydraulic based fluid thereto A second piston is translated by the hydraulic based fluid displaced by the first piston to actuate the friction clutch pack.
    Type: Grant
    Filed: November 20, 2009
    Date of Patent: August 7, 2012
    Assignee: Borgwarner, Inc.
    Inventors: Larry A. Pritchard, Philip J. Francis, Thad Kopp, Tsunlock A. Yu
  • Patent number: 8191698
    Abstract: A hydraulic system having a clutch assembly (30) which is hydraulically actuated, a pressure device (32) in fluid communication with the clutch assembly, and a multi-position actuator device (34) in fluid communication with the pressure device and the clutch assembly. The position of the actuator device includes at least a first position in order for the pressure device to fluidly communicate with the clutch assembly, a second position for maintaining fluid pressure in the clutch assembly, and a third position for bleeding the hydraulic system.
    Type: Grant
    Filed: June 27, 2007
    Date of Patent: June 5, 2012
    Assignee: Borgwarner Inc.
    Inventors: Larry Pritchard, Eric Christopher Sandstrom, Philip J. Francis
  • Patent number: 7828130
    Abstract: A pump system that pressurizes a fluid includes a shaft, a first rotor and a second rotor that is selectively driven by the shaft. Relative rotation between the first rotor and the second rotor generates variable sized pockets therebetween to pressurize the fluid. A clutch regulates a degree of coupling of the rotor to the shaft between a decoupled state and a coupled state to regulate the relative rotation between the first and second rotors.
    Type: Grant
    Filed: November 3, 2009
    Date of Patent: November 9, 2010
    Assignee: MAGNA Powertrain USA, Inc.
    Inventors: Todd Ekonen, Philip J. Francis