Captive molding with dissimilar material insert

• US 6,189,413 B1
• Filed: 07/12/1999
• Issued: 02/20/2001
• Est. Priority Date: 07/12/1999
• Status: Expired due to Term

• Current Assignee: American AXLE & Manufacturing Incorporated (American AXLE & Manufacturing Holdings Incorporated)
• Original Assignee: American AXLE & Manufacturing Incorporated (American AXLE & Manufacturing Holdings Incorporated)
• Inventors: Morse, David M., Kumashi, Rajendra G.
• Primary Examiner(s): Wright, Dirk
• Application Number:
  US09/351,612
• Time in Patent Office: 589 Days
• Field of Search: 746/06.R, 746/07
• US Class Current: 74/607
• CPC Class Codes: B22D 19/0036 gears
• CPC Class Codes: B22D 19/0081 pretreatment of the insert, e.g. for enhancing the bonding between insert and surrounding cast metal
• CPC Class Codes: B22D 19/02 for making reinforced articles B22D19/14 takes precedence
• CPC Class Codes: B22D 19/16 for making compound objects cast of two or more different metals, e.g. for making rolls for rolling mills casting compound ingots B22D7/02
• CPC Class Codes: B22D 21/007 with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C
• CPC Class Codes: B60K 17/16 of differential gearing
• CPC Class Codes: F16H 2057/02017 characterised by special features related to the manufacturing of the gear case, e.g. special adaptations for casting
• CPC Class Codes: F16H 2057/02043 for vehicle transmissions
• CPC Class Codes: F16H 57/032 characterised by the materials used
• CPC Class Codes: F16H 57/037 Gearboxes for accommodating differential gearings rotating cases for differential gearings F16H48/40
• CPC Class Codes: Y10T 74/2188 Axle and torque tubes

Abstract

An improved housing, particularly one for an automotive differential assembly, is provided. The housing has a cast portion formed from a first material and a preformed insert member formed from a second material which is cast into the cast portion. The insert member is strategically placed in an area of the housing to selectively enhance or alter the properties of the housing at that location. The insert member may be encased in a wall of the cast portion or may extend partially through a wall of cast portion depending upon the characteristics which are being enhanced or altered. The properties which may be enhanced or altered include, for example the strength, electric or thermal conductivity, magnetic potential, chemical compatibility or the coefficient of friction.

Claims

1. A housing for a differential assembly, said housing comprising:

a cast portion having a wall member, said wall member including an interior surface defining inwardly of said surface an interior aperture, said cast portion formed from a first material permitting manufacture of said cast portion as a casting, said wall member adapted for supporting a shaft for rotation within said interior aperture and receiving a reaction force in response thereto; and

an insert member formed from a second material and at least partially embedded in said wall member outwardly of said interior surface, said insert member distributing said reaction force within said cast portion in a predetermined manner to increase the strength of said housing.

2. The housing of claim 1 wherein said first material is an aluminum material and said second material is a steel material.

3. The housing of claim 1 wherein said insert member is a generally tubular member.

4. The housing of claim 1 wherein said second material has a tensile strength greater than a tensile strength of said first material.

5. The housing of claim 1 wherein said insert member extends inwardly from said interior surface into said interior aperture.

6. The housing of claim 1 wherein said insert member is substantially completely embedded in said wall member outwardly of said interior surface.

7. The housing of claim 1 wherein said cast portion is formed in a casting process from the group of die casting, investment casting and sand casting.

8. A differential assembly for an automotive vehicle, said differential assembly comprising:

an shaft operable for transmitting drive torque;

a housing having a cast portion and an insert member, said a cast portion including a wall member with an interior surface defining inwardly of said surface an interior aperture, said wall member supporting said shaft for rotation within said interior aperture and receiving a reaction force in response thereto, said insert member formed from a second material and being at least partially embedded in said wall member outwardly of said interior surface, said insert member distributing said reaction force within said cast portion in a predetermined manner to increase the strength of said housing.

9. The differential assembly of claim 8 wherein said first material is an aluminum material and said second material is a steel material.

10. The differential assembly of claim 8 wherein said insert member is a generally tubular member.

11. The differential assembly of claim 8 wherein said second material has a tensile strength greater than a tensile strength of said first material.

12. The differential assembly of claim 8 wherein said insert member extends inwardly from said interior surface into said interior aperture.

13. The differential assembly of claim 8 wherein said insert member is substantially completely embedded in said wall member outwardly of said interior surface.

14. The differential assembly of claim 8 wherein said cast portion is formed in a casting process from the group of die casting, investment casting and sand casting.

15. A housing comprising:

a cast portion having a wall member, said wall member including an interior surface defining inwardly of said surface an interior aperture, said cast portion formed from a first material permitting manufacture of said cast portion as a casting; and

an insert member formed from a second material and embedded in said wall member so as to extend inwardly from said interior surface into said interior aperture.

16. The housing of claim 15 wherein said first material is an aluminum material and said second material is a steel material.

17. The housing of claim 15 wherein said first material is an aluminum material and said second material is a nitrile material.

18. The housing of claim 15 wherein said second material has a coefficient of friction smaller than a coefficient of friction of said first material.

19. The housing of claim 15 wherein said insert member is a generally tubular member.

20. The housing of claim 15 wherein said cast portion is formed in a casting process from the group of die casting, investment casting and sand casting.