Transfer case for multiple drive axle vehicle

Claim 2

A transfer case for a vehicle drive train having a transmission comprising: a housing; input means for receiving the torque output from the vehicle transmission; a first output shaft and first means for rotatably supporting said first output shaft in said housing; a second output shaft and second means for rotatably supporting said second output shaft in said housing; and means for selectively driving said first and second output shafts in response to actuation of said input means, said means for selectively driving comprising a planetary gear set having an annulus, a first set of first planet gears engaged with said annulus, a second set of second planet gears, each second planet gear being engaged with one of said first planet gears, a sun gear engaged with said second planet gears, third means for rotatably mounting said sun gear in said housing and a planet carrier having means for rotatably supporting said first and second planet gears and co-axially secured to said first output shaft for rotation therewith, and further comprising clutch means for selectively engaging said sun gear with said planet carrier and said second output shaft, wherein said input means comprises means for rotatably driving said annulus.

Claim 3

The invention as described in claim 1 wherein said first and second output shafts are axially aligned, and wherein said clutch means comprises a clutch collar and means for co-axially displacing said clutch collar along the axis of said output shafts.

Claim 4

The invention as defined in claim 1 wherein said vehicle transmission is an automatic transmission.

Claim 5

A transfer case for coupling the output of a vehicle transmission whose axis is longitudinally aligned with the vehicle to at least two axle drive mechanisms comprising: a housing; an input means for receiving the torque output from the vehicle transmission; a first output shaft and first means for rotatably supporting said first output shaft in said housing; a second output shaft and second means for rotatably supporting said second output shaft in said housing; means for selectively driving said first and second output shafts in response to activation of said input means, said means for selectively driving comprising differential means for driving said first output shaft at a first variable rotary speed in response to actuation of said input means and driving said second output shaft at a second variable rotary speed in response to activation of said input means, and further comprising clutch means for selectively engaging said second output shaft for rotation with said first output shaft; wherein said differential means comprises a planetary gear set having an outer annulus and wherein said input means includes said annulus; wherein said first and second output shafts are axially aligned and parallel to said transmission axis.

Claim 6

A transfer case for coupling the output of a vehicle transmission whose axis is longitudinally aligned with the vehicle to at least two axle drive mechanisms comprising: a housing; an input means for receiving the torque output from the vehicle transmission; a first output shaft and first means for rotatably supporting said first output shaft in said housing; a second output shaft and second means for rotatably supporting said second output shaft in said housing; means for selectively driving said first and second output shafts in response to activation of said input means, said means for selectively driving comprising differential means for driving said first output shaft at a first variable rotary speed in response to actuation of said input means and driving said second output shaft at a second variable rotary speed in response to activation of said input means, and further comprising clutch means for selectively engaging said second output shaft for rotation with said first output shaft; wherein said differential means comprises a planetary gear set having an outer annulus and wherein said input means includes said annulus; wherein said first and second output shafts are axially aligned and parallel to said transmission axis.

Claim 7

The invention as described in claim 4 wherein said planetary gear set comprises an annulus, a first set of first planetary gears engaged with said annulus, a second set of second planet gears, each second planet gear being engaged with a corresponding one of said first planet gears, a sun gear engaged with said second set of second planet gears, means for rotatably supporting said sun gear about the axis of said first output shaft, and a planet carrier, having means for rotatably supporting said first and second planet gears, co-axially secured to said first output shaft for rotation therewith.

Claim 8

The invention as described in claim 5 wherein said clutch means comprises a clutch collar and means for coaxially displacing said clutch collar along the axis of said output shafts.

Claim 9

A transfer case for coupling the output of a vehicle transmission to at least two axle drive mechanisms comprising: a housing; an input means for receiving the torque output from the vehicle transmission; a first output shaft and first means for rotatably supporting said first output shaft in said housing; a second output shaft and second means for rotatably supporting said second output in said housing; and means for selectively driving said first and second output shafts in response to activation of said input means, said means for selectively driving comprising differential means for driving said first output shaft at a first variable rotary speed in response to actuation of said input means and driving said second output shaft at a second variable rotary speed in response to activation of said input means, and further comprising clutch means for selectively engaging said second output shaft for rotation with said first output shaft; wherein said differential means comprises a planetary gear set having an outer annulus and wherein said input means includes said annulus; and wherein said clutch means comprises automatic clutch means for automatically engaging said second output shaft with said first output shaft for rotation therewith when the difference between said first rotary speed and said second rotary speed exceeds a predetermined value.

Claim 10

A transfer case for coupling the output of a vehicle transmission to at least two axle drive mechanisms comprising: a housing; an input means for receiving the torque output from the vehicle transmission; a first output shaft and first means for rotatably supporting said first output shaft in said housing; a second output shaft and second means for rotatably supporting said second output in said housing; and means for selectively driving said first and second output shafts in response to activation of said input means, said means for selectively driving comprising differential means for driving said first output shaft at a first variable rotary speed in response to actuation of said input means and driving said second output shaft at a second variable rotary speed in response to activation of said input means, and further comprising clutch means for selectively engaging said second output shaft for rotation with said first output shaft; wherein said differential means comprises a planetary gear set having an outer annulus and wherein said input means includes said annulus; and wherein said clutch means comprises automatic clutch means for automatically engaging said second output shaft with said first output shaft for rotation therewith when the difference between said first rotary speed and said second rotary speed exceeds a predetermined value.

Claim 11

The invention as described in claim 7 wherein said automatic clutch means comprises a viscous clutch.

Claim 12

The invention as described in claim 8 wherein said planetary gear set includes a first set of first planet gears, each said first planet gears engaged with said annulus, a second set of second planet gears corresponding in number to said first planet gears and engaged with a corresponding first planet gear, a sun gear engaged with said second planet gears, means for coaxially mounting said sun gear to said first output shaft for rotation therewith, a planet carrier and means for rotatably mounting said first and second planet gears to said planet carrier.

Claim 13

The invention as described in claim 9 wherein said viscous clutch comprises an outer housing, an inner housing, means for concentrically rotatably supporting said outer housing on said inner housing and means for viscously coupling said outer housing for rotation with said inner housing, and further comprising means for coupling said outer housing to said planet carrier for rotation therewith, means for coupling said inner housing to said first output shaft for rotation therewith, and means for coupling said outer housing to said second output shaft for rotation therewith.

Claim 14

The invention as described in claim 10 wherein said first and second output shafts are axially aligned.

Claim 15

The invention as described in claim 7 and wherein said transmission is an automatic transmission.

Claim 16

A transfer case for coupling the output of a vehicle transmission to at least two axle drive mechanisms comprising: a housing; an input means for receiving the torque output from the vehicle transmission; a first output shaft and first means for rotatably supporting said first output shaft in said housing; a second output shaft and second means for rotatably supporting said second output shaft in said housing; and means for selectively driving said first and second output shafts in response to activation of said input means, said means for selectively driving comprising differential means for driving said first output shaft at a first variable rotary speed in response to actuation of said input means and driving said second output shaft at a second variable rotary speed in response to activation of said input means, and further comprising clutch means for selectively engaging said second output shaft for rotation with said first output shaft; wherein said differential means comprises a planetary gear set having an outer annulus and wherein said input means includes said annulus; wherein said planetary gear set comprises an annulus, a first set of first planetary gears engaged with said annulus, a second set of second planet gears, each second planet gear being engaged with a corresponding one of said first planet gears, a sun gear engaged with said second set of second planet gears, means for rotatably supporting said sun gear about the axis of said first output shaft, and a planet carrier, having means for rotatably supporting said first and second planet gears, co-axially secured to said first output shaft for rotation therewith; wherein said clutch means comprises means for selectively engaging said sun gear with said second output shaft; and wherein said clutch means further comprises means for selectively engaging said sun gear with said planet carrier.

Claim 17

A transfer case for coupling the output of a vehicle transmission to at least two axle drive mechanisms comprising: a housing; an input means for receiving the torque output from the vehicle transmission; a first output shaft and first means for rotatably supporting said first output shaft in said housing; a second output shaft and second means for rotatably supporting said second output shaft in said housing; and means for selectively driving said first and second output shafts in response to activation of said input means, said means for selectively driving comprising differential means for driving said first output shaft at a first variable rotary speed in response to actuation of said input means and driving said second output shaft at a second variable rotary speed in response to activation of said input means, and further comprising clutch means for selectively engaging said second output shaft for rotation with said first output shaft; wherein said differential means comprises a planetary gear set having an outer annulus and wherein said input means includes said annulus; wherein said planetary gear set comprises an annulus, a first set of first planetary gears engaged with said annulus, a second set of second planet gears, each second planet gear being engaged with a corresponding one of said first planet gears, a sun gear engaged with said second set of second planet gears, means for rotatably supporting said sun gear about the axis of said first output shaft, and a planet carrier, having means for rotatably supporting said first and second planet gears, co-axially secured to said first output shaft for rotation therewith; wherein said clutch means comprises means for selectively engaging said sun gear with said second output shaft; and wherein said clutch means further comprises means for selectively engaging said sun gear with said planet carrier.

Claim 18

The invention as defined in claim 13 wherein said first and second output shafts are axially aligned and said clutch means comprises a clutch collar and means for coaxially displacing said clutch collar along the axis of said output shafts.

Claim 19

A transfer case for coupling the output of a vehicle transmission to at least two axle drive mechanisms comprising: a housing; an input means for receiving the torque output from the vehicle transmission; a first output shaft and first means for rotatably supporting said first output shaft in said housing; a second output shaft and second means for rotatably supporting said second output shaft in said housing; and means for selectively driving said first and second output shafts in response to activation of said input means, said means for selectively driving comprising differential means for driving said first output shaft at a first variable rotary speed in response to actuation of said input means and driving said second output shaft at a second variable rotary speed in response to activation of said input means, and further comprising clutch means for selectively engaging said second output shaft for rotation with said first output shaft; wherein said differential means comprises a planetary gear set having an outer annulus and wherein said input means includes said annulus; wherein said transfer case further comprises means for coupling one of said first and second output shafts to said one of said axle drive mechanisms; and wherein said coupling means comprises a bevel gear secured at one end of said one shaft.

Claim 20

A transfer case for coupling the output of a vehicle transmission to at least two axle drive mechanisms comprising: a housing; an input means for receiving the torque output from the vehicle transmission; a first output shaft and first means for rotatably supporting said first output shaft in said housing; a second output shaft and second means for rotatably supporting said second output shaft in said housing; and means for selectively driving said first and second output shafts in response to activation of said input means, said means for selectively driving comprising differential means for driving said first output shaft at a first variable rotary speed in response to actuation of said input means and driving said second output shaft at a second variable rotary speed in response to activation of said input means, and further comprising clutch means for selectively engaging said second output shaft for rotation with said first output shaft; wherein said differential means comprises a planetary gear set having an outer annulus and wherein said input means includes said annulus; wherein said transfer case further comprises means for coupling one of said first and second output shafts to said one of said axle drive mechanisms; and wherein said coupling means comprises a bevel gear secured at one end of said one shaft.

Claim 21

The invention as defined in claim 15 wherein said vehicle transmission is an automatic transmission.

Claim 22

A transfer case for coupling the output of a vehicle transmission to at least two axle drive mechanisms comprising: a housing; an input means for receiving the torque output from the vehicle transmission; a first output shaft and first means for rotatably supporting said first output shaft in said housing; a second output shaft and second means for rotatably supporting said second output shaft in said housing; means for selectively driving said first and second output shafts in response to activation of said input means, said means for selectively driving comprising differential means for driving said first output shaft at a first variable rotary speed in response to actuation of said input means and driving said second output shaft at a second variable rotary speed in response to activation of said input means, and further comprising clutch means for selectively engaging said second output shaft for rotation with said first output shaft; wherein said differential means comprises a planetary gear set having an outer annulus and wherein said input means includes said annulus; and wherein said housing comprises a first housing part having an aperture means for exposing said input means, and wherein said input means comprises a sleeve gear engaged with said annulus, and means for rotatably supporting said sleeve gear in registration with said aperture means.

Claim 23

A transfer case for coupling the output of a vehicle transmission to at least two axle drive mechanisms comprising: a housing; an input means for receiving the torque output from the vehicle transmission; a first output shaft and first means for rotatably supporting said first output shaft in said housing; a second output shaft and second means for rotatably supporting said second output shaft in said housing; means for selectively driving said first and second output shafts in response to activation of said input means, said means for selectively driving comprising differential means for driving said first output shaft at a first variable rotary speed in response to actuation of said input means and driving said second output shaft at a second variable rotary speed in response to activation of said input means, and further comprising clutch means for selectively engaging said second output shaft for rotation with said first output shaft; wherein said differential means comprises a planetary gear set having an outer annulus and wherein said input means includes said annulus; and wherein said housing comprises a first housing part having an aperture means for exposing said input means, and wherein said input means comprises a sleeve gear engaged with said annulus, and means for rotatably supporting said sleeve gear in registration with said aperture means.

Claim 24

The invention as defined in claim 17 wherein said vehicle transmission is an automatic transmission.