CA2193441A1 - Filter cover assembly for differential housing mechanism - Google Patents

Abstract

A filter assembly is mounted by filling holes in an existing cover and securing the filter assembly in place on the cover.

Description

`- ` 2 193441 FILTER COVER ASSEMBLY FOR DIFFERENTIAL
HOUSING MECHANISM

BACKGROUND OF THE INVENTION

The present invention relates generally to a cover member for a dirrelelltial housing mechanism. More particularly, the present invention relates to a new andimproved filter cover assembly for a dirre~ ial housing mechanism which filters oil through separate levels of m~gn~tir filters and increases oil capacity to enhance lubrication and cooling of the dirre,ell~ial mech~ni~m The dirre~ntial gearing is an arrangement of gears forming a train which has one or more parts traveling around the circumference of another fixed part. Thistrain connects two shafts or axles in the same line, thereby dividing the driving force equally between them, and permitting one shaft to revolve faster than the other. The main purpose of the driveshaft is to deliver the torque from the driveshaft and transfer it to both wheels.
The dirrel~ ial mechanism is not a sealed unit. Every dirrelell~ial has a vent tube at the top. In addition, moisture can enter the dirrelelllial unit each time a vehicle is driven through water, snow, or mud. Water entering the dirrelelllial breaks down the oil contained within the unit and, as a result, wears down the moving parts contained inside the dirÇelelllial. Metal from the wearing parts then circulates in the oil causing further pre-mature wearing. The oil in the dirrelelllial mechanism may also become sulfated due to exposure to extreme prolonged heat.
The resulting sulphated oil cannot lubricate properly.

2 5 Although preventative maintenance on the dirrerelllial mechanism is badly n~edecl, it is rarely performed. One of the reasons for this lack of preventative mahllellallce is the location of the dirrelelllial mechanism. The dirrerelllial mech~ni~m is located at the rear of, and underneath, the vehicle. Furthermore, most rear covers for the dirre~ll~ial mechanism do not contain drainplugs for draining the 3 o oil Therefore, the entire cover for the dirrelelllial mechanism must be removed in order to drain and change the oil. In addition, most automotive repair shops andlube shops will not remove the dirreren~ial cover to change the oil due to the large number of vehicles that are returned with oil leaks as a result of this removal process.
Therefore, there is a need for a new and improved filter cover for a dirÇelenlial mechanism which can protect the dirrerelllial from breakdowns due to inadequate lubrication and promote the serving of the dirrel~ ial by facilit~ting the 5 processes of checking the oil level and ch~n3~ing the oil in the dirrelelltial mech~ni~m .

SUMMARY OF THE INVENTION

Accordingly, it is a principle object of the present invention to provide an improved filter cover assembly for a dirrelelllial mechanism which can protect the dirr~l~nlial mechanism and facilitate the serving of the dirr~lential mech~ni~m.It is a further object of the present invention to provide an improved filter cover assembly for a dirrelelllial mechanism which utilizes separate levels of 5 m~gn~tic wafers to remove worm metal parts from the oil circ~ ting within the dirrerelllial mechanism.
It is a further object of the present invention to provide an improved filter cover assembly for a dirÇelell~ial mechanism which utilizes separate levels of magnetic wafers to remove worn metal parts from the oil circ~ ting within the 2 o dirrelelllial mech~ni~m.
It is still a further object of the present invention to provide a filter cover assembly for a dirrelelllial mechanism which functions to extend the life of thedirrelelllial mechanism and its moving parts.
It is yet a further object of the present invention to provide a filter cover 25 assembly for a dirr~l~lllial m~ch~ni~m which enables an individual to monitor the oil level and temperature range contained within the dirrerelllial mechanism.
It is still a further object of the present invention to provide a filter cover assembly for a dirÇelelllial mechanism which can be adapted to fit all types of vehicles.
In brief, there is a provided a filter cover assembly for a dirrelelllial mechanism which includes a cover member with an interior cavity having a filter housing and a lip member. The shape of the interior cavity forms an enlarged oil reservoir near its lower end which increases the oil capacity of the dirrelelllial mech~ni~m. The lip member is located near a top end of the filter cover assemblyand functions to trap the oil which is picked up by the ring gear contained within a dirrerclllial. The lip member also functions to redirect the oil to an opening in the 5 filter housing. The filter housing contains separate m~gn~tic wafers and filter members which are vertically stacked within the filter housing so that the oil is forced to alternately flow across a top surface of a m~gn~ti~ wafer and then vertically through a filter member. In addition, the filter cover assembly also has a drain hole and drain plug to facilitate draining the oil from the dirrelclllial 10 mech~ni~m, a fill hole and fill plug to facilitate filling the dirrerclltial mechanism with the appropliate amount of oil, and a telllperalule sending unit which monitors the temperature of the dirrelclllial mechanism.
These and other objects, features and advantages of the present invention will become more apparent to those skilled in the art from the following more 15 detailed description of the plcrcll~,d embodiment taken with rcfelellce to the accompallyillg drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. l is a perspective view of a filter cover assembly for a dirrelclltial mech~ni~m in accordance with the present invention with the front cover of the filter assembly shown exploded and the filter housing and lip member shown in phantom.
FIG. 2 is a top elevational view of a filter cover assembly for a dirrerclllial m~ch~ni~m in accordance with the present invention.
FIG. 3 is a cross-sectional view taken along line 3-3 of Fig. 2.
FIG. 4 is a cross-sectional view taken along line 4-4 of Fig. 2.
FIG. 5 is a front elevational view of a filter housing cont~ining filter elements in accordance with the present invention.
3 o FIG. 6 is a top elevational view of filter elements contained within a filter housing in accordance with the present invention.
FIG. 7 is a side elevational view of filter elements contained within a filter - ` 2193441 housing in accordance with the present invention.
FIG. 8 is a front elevational view of a cover member of a filter housing in accordance with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Turning now to the plcfellcd embodiment of the present invention with reference to Fig. 1, the dirrelenlial mechanism filter cover assembly 10 consists primarily of a molded over member 12 with an interior cavity 14 cont~inin~ an oil 0 reservoir 16, a filter assembly 18, and a lip member 20. A predetermined amount of oil is m~int~in~cl within the oil reservoir 16 in order to effectuate the operation of the filter assembly 18. When a vehicle moves forward, the oil in the oil reservoir 16 is picked up by the ring gear and carrier (not shown) of the dirrelcllLial mechanism and slung upward toward the lip member 20. The oil is then trapped under the lip member 20 and directed into the filter assembly 18 by an inlet 22 located under the lip member 20 which opens up into the top end 24 of the filterassembly 18.
The structure of the lip member 20 is more clearly shown in Fig. 4. Fig. 4 illustrates a cross section of the lip member 20 contained within the interior cavity 2 o 14 of the molded cover member 12. During forward movement of a vehicle, the oil picked up by the ring gear and carrier (not shown) is trapped in the are 26 under the lip member 20. The area 26 under the lip member 20 opens into the filter assembly 18 via an inlet 22. The oil is forced through the opening 22 and into the filter assembly 18 as result of the torque from the ring gear and carrier (not shown) 2 5 which pick up the oil and sling it into the area 26 under the lip member 20.
pcetllrning now to Fig. 1, the molded cover member 12 also has three holes or openings passing through it which assist in carrying out various functions. A fill opening 28 is used to facilitate in filling the filter cover assembly 10 with oil or another lubricant to a predetermined level thereby providing an adequate amount of 3 o oil for lubrication and cooling. The fill opening is located at the recommended oil level and a fill plug (not shown) is used to seal the opening. A dMin opening 30 is also provided in order to facilitate the removal of the old and cont~min~te~l oil from - "~ ` 2~93441 the molded cover member 12. The drain opening 30 is located near a bottom of theoil reservoir 16 and a drain plug (not shown) is used to seal the opening after the oil has drained from the molded cover member 12. Finally, an opening an da threaded plug 32 is provided for the optional in~t~ tion of a temperature sending 5 unit which can enable the driver to monitor the temperature of the dirrelclllial m~ch~ni.cm (not shown).
As previously described with reference to Figs. 1 and 4, the oil picked up by the ring gear and carrier (not shown) is trapped by the lip member 20 and directed through the inlet 22 into the filter assembly 18. The filter assembly 18 o comprises a vertically positioned rectangular housing 34 having a series of vertically spaced filter members 36 and wafer m~gnPt~ 38 which can be seen more clearly in Figs. 3, 5, and 7. The filter assembly further comprises an outlet 40 (See Fig. 2) located in a back side of the housing 34 near a bottom of the filter assembly 18.
After the oil has circulated through the series of vertically spaced filter members 36 and wafer m~gn~,t~ 38, the oil exits the filter assembly 18 through the outlet 40 in the housing 34 and returns to the oil reservoir 16 contained within the molded cover member 12. The housing 34 also comprises a transparent front cover 42 which may removable and ~tt~ch~ble by means of a series of holes 44 drilled around the perimeter of the transparent front cover 42 and the sides of the housing 34 such that 2 o the transparent front cover 42 can be secured to the housing 34 with screws 46. The front cover member 42 is llal~palelll so that the condition of the oil and the level of the oil can be easily ~sessed. In addition, the trans~alcnl front cover 42 enables a determination of whether the metal shavings or particles collected on any of the wafer m~gntq,t~ 38 need to be cleared or removed so that the filter assembly 18 functions properly.
The cover member 12 also comprises a rim 48 having holes 50 drilled through the rim 48 so that the filter cover assembly 10 can be secured to the dirrelcllLial housing mech~ni~m (not shown) by bolts or screws.
Fig. 2 shows a top elevational view of the filter cover assembly 10. The ring 3 o gear (not shown) of the dirrelcnlial mech~ni~m (not shown) rotates through the oil reservoir 16 of the molded cover member 12 and throws the oil upward toward the lip member 20. The oil is trapped by the lip member 20 and the oil flow 52 is `- 2 ~ ~ 3 4 4 1 directed through the inlet 22 contained within the filter assembly 18 which is located near the top end 24 of the filter assembly 18. The oil flow 52 then proceeds through the filter members 36 and wafer magnets 38 contained within the filter assembly 18 and out through the outlet 40 located in the back side of the filter assembly 18 near 5 the bottom end 54 of the filter assembly 18.
A more defined path of the oil flow 52 through the filter assembly 18 is illustrated in Fig. 3 which is a cross section taken along line 3-3 of Fig. 2. The oil flow 52 travels through the inlet 22 of the filter assembly 18, over the top of a wafer magnet 38, through a filter member 36, then alternates between flowing over 10 additional wafer magnets 38 and through additional filter members 36 which are vertically stacked with respect to one another, and finally through the outlet 40 contained within the filter assembly 18.
As shown in Fig. 5, the filter members 36 and wafer m~gn~ts 38 are paired and then vertically interdisposed within the rectangular housing 34 of the filter assembly 18. The filter members 36 extend from one side of the housing 34 to theother and can alternately exist as solid shelf members with openings 56 for the oil flow 52 located at opposite ends from those ends holding a wafer magnet 38. The wafer magnets 38 are alternately staggered toward opposite sides of the housing 34 so that the oil flow 52 will tMvel across each wafer magnet 38 contained within the 20 filter assembly 18 before dropping down to the next filter level cont~inin~ a wafer magnet 38 and filter member 36.
Fig. 6 illustrates a top elevational view of the filter assembly 18 showing the top filter level contained within the housing 34. The top filter level comprises a wafer magnet 38 which is placed on top of a solid shelf member 60. The oil flow 25 travels through the inlet 22, across the wafer magnet 38, across the solid shelf member 60, and finally through the opening 56 passing through the solid shelf member 60 in order to gain access to the second filter level. The oil passing through the opening 56 falls directly on top of the wafer magnet which comprisesa part of the second filter level. A side elevational view of the filter assembly 18 30 is shown in Fig. 7. Each filter level contained within the filter assembly 18comprises a wafer magnet 38 and a solid shelf member 60 where each solid shelf member 60 contains an opening passing through it so that the oil can filter through 2 ~ 9 3 4 4 1 to the next lower filter level.
The transparent front cover 42 of the housing 34 which comprises the filter assembly 18 is shown in Fig. 8. An oil level marker 64 is indicated on the top of the front cover 42 so that the oil level contained within a dirrelelltial housing can be easily determined and assess without (li~m~ntling the dirrelelllial.
The molded cover member 12 is preferably made of allllllill.l,,, in order to deter the cont~min~tion of the oil and facilitate in the cooling of the oil.
Furthermore, the filter 18 assembly preferably comprises at least three filter levels each of which includes a wafer magnet 38. Also, the oil reservoir 16 contained o within the molded cover member 12 is preferably larger than any of the existing oil reservoirs for dirr~lelllial mech~nicm~.
The filter cover assembly 10 of the present invention was specifically designed to extend the life of the working parts inside the dirrerelllial and tofacilitate the servicing of the dirrerellLial by providing 1) a tiered oil filtering system 1 5 which uses magnets to remove metal particles, 2) an increased oil capacity, 3) a fill plug which is easily accessible, 4) a drain plug which is easily accessible, 5) a threaded hole temperature sending unit which enables a driver to monitor the temperature of the dirrel~lllial, and 6) ~ minnm construction which facilitates in cooling the oil.
Another embodiment of the invention is illustrated in Figs. 9 to 14, and includes a mount assembly 65 and filter assembly which are secured to the cover 61 of an existing dirrele.llial housing 60 on a vehicle. A ring gear 62 turns inside housing 60. Apertures 63 and 64 are drilled in the cover 61. Aperture 63 receives oil catch 76. Return 70 is aligned with aperture 64.
2 5 After mount assembly 65 is positioned against cover 61 in the marmer shown in Fig. 9 (with catch 76 extending through aperture 63 and return 70 aligned with aperture 64), then assembly 65 is welded or otherwise affixed to cover 61. Filter assembly 66 is affixed to mount assembly 65 by turning bolts into each aligned pair of apertures 68--66. Fig. 9 illustrates filter assembly 66 and mount assembly 653 o assembled on cover 61.
In Figs. 11 and 12, filter assembly includes flange 67 provided with spaced apart bolt holes 68. Inlet hole 69 extends from mount assembly 65 into filter assembly 66. Return hole 70 extends from filter assembly 66 through mount assembly 65. Filter assembly 66 includes magnets 71 to 73, clear plastic window 74, and retainer 75 for window 74.
In Figs. 13 and 14, mount assembly 65 includes internally threaded apertures 66 and oil catch 76. Inlet 69 tapers into an oval cross section. Assembly 65 also includes oil return 77.
Figs. 15 and 16 illustrate a filter assembly 80 for filtering hydraulic oil. Oilflows into assembly 80 through an opening in bolt 81. Apertures 82 are formed inassembly 80 for bolts used to mount assembly 80. Oil exists assembly 80 through an opening in bolt 89. Assembly 80 includes magnets 83 to 86. Magnets 83 to 86 and the other magnets described herein can take on any desired shape and dimension. Pins 87, 88 create turbulence in oil flowing through assembly 80.
Retainer 90 holds clear plastic window 91 in place. Filter assembly is presently, though not n~cess~rily, mounted "in-line" so that hydraulic oil flowing through a tubing flows into and out of assembly 80.
The filter assembly 66 and mounting assembly 65 can comprise a single unit.
The filter assembly 66 can be adapted to be installed over the PTO (Power Take Off) opening adjacent the tr~n.~mi~sion of a vehicle so that assembly 66 can filter tr~n.~mi~sion fluid. Flange 67, is shaped and dimensioned to fit over, conform 2 o to, bolt to, and cover and seal the PTO opening after the PTO cover is removed from the PTO opening. A catch, in~licated by dashed lines 69A in Fig. 11, is secured to flange 67 to catch a portion of tr~n~mi.~sion fluid which is thrown against flange 67 by gear wheels in the tr~n~mi.~sion. Catch 69A directs tr~n~mi~ion fluid in the direction of arrow 69B through inlet 69, through assembly 66, past magnets 71 to 73, and out return 70. Since assembly 66 is modified by the addition of catch 69A and by the shaping of flange 67 to conform to the PTO opening, mount assembly 65 is not utili7e~
Having described my invention in such terms as to enable those skilled in the art to understand and practice it, and having described the presently prcrcllcd 3 o embodiments thereof, I Claim:

Claims (2)

1. A filter apparatus including (a) a mounting assembly including (i) a fluid catch, and (ii) a fluid return; and, (b) a filter assembly attached to said mounting assembly.

2. A method for mounting a filter apparatus on a cover, said filter apparatus including a fluid catch, a fluid return, and a filter assembly, said method including the steps of (a) forming a first opening in said cover; and, (b) mounting said filter apparatus with said fluid catch extending through said first opening.