US 12,492,742 B2
Differentials with face gears for electrical drive systems
Philip R. Kellogg, Macomb, MI (US); Tao Peng, Canton, MI (US); Robert J. Cabrera, Oxford, MI (US); Marcello Ciparullo, Rochester Hills, MI (US); Aaron A. Sinka, Rochester Hills, MI (US); and James S. Bourn, Oxford, MI (US)
Assigned to BorgWarner Inc., Auburn Hills, MI (US)
Filed by BorgWarner Inc., Auburn Hills, MI (US)
Filed on Jul. 31, 2024, as Appl. No. 18/789,864.
Application 18/789,864 is a continuation in part of application No. 18/368,628, filed on Sep. 15, 2023, granted, now 12,253,153.
Prior Publication US 2025/0092943 A1, Mar. 20, 2025
This patent is subject to a terminal disclaimer.
Int. Cl. F16H 48/40 (2012.01); B60K 1/00 (2006.01); F16H 48/08 (2006.01)
CPC F16H 48/40 (2013.01) [B60K 2001/001 (2013.01); F16H 2048/085 (2013.01)] 13 Claims
OG exemplary drawing
 
1. An electric drive system in a battery electric vehicle (BEV), comprising:
an output shaft, configured to couple with a drive wheel of the BEV, having a face gear at a distal end;
a differential, including a pinion gear cage receiving pinion gears rotatably connected to the pinion gear cage via gear pins, having radially-outwardly-facing gear teeth that are oriented at a non-zero angle relative to an axis of rotation; and
a housing receiving the differential that is configured to couple to a rotating electrical machine of the BEV, and engages the radially-outwardly-facing gear teeth preventing radial and axial movement of the differential relative to the housing, wherein the pinion gears engage the face gear and permit angular displacement of the output shaft relative to another output shaft;
wherein the pinion gear cage includes a central hub, spokes, pinion gear slots and apertures on an outer surface of the pinion gear cage that receive the gear pins and rotatable secure the pinion gears relative to the pinion gear cage.