TECHNICAL FIELD

The present disclosure relates generally to washers such as may be used with gears in a vehicle differential.

BACKGROUND

In general, vehicles include drivelines that transmit torque from an engine to one or more wheels. Automotive drivelines are commonly equipped with a differential between sideshafts of a front axle, between sideshafts of a rear axle, or between both axles. Each axle typically includes a left sideshaft and a right sideshaft. Open differentials, in particular, allow a wheel on one sideshaft to spin faster or slower than a wheel on the other sideshaft. This occurs, for instance, when an automobile is turning a corner. Differentials also apportion driven torque between sideshafts. All-wheel drive (AWD) automotive drivelines can also be equipped with a differential between its front and rear axles to perform similar functions therebetween.

SUMMARY

In at least some implementations, a differential has a washer for a gear in a differential housing that includes an outer edge at a maximum radial distance from an axis, and an inner edge defining an opening, the inner edge defined in part by an innermost portion at a minimum radial distance from the axis and the inner edge having an outward portion spaced radially outwardly from the innermost portion. The washer also includes an axially and radially inclined sidewall extending at least part of the way between the outer edge and the innermost portion.

In at least some implementations, the innermost portion may include multiple segments that each have an inner surface that defines part of the innermost portion. The inner surfaces of the segments may be at a common radial distance from the axis. The innermost portion may comprise between 10% and 90% of the circumference of a circle bounded by the innermost portion. The outward portion may be defined by multiple voids, each void being defined between two segments. The outward portion may include a surface that is at least 0.5 mm radially outwardly spaced from the innermost portion. The voids may comprise between 10% and 90% of the circumference of a circle bounded by the innermost portion. And each void may be at least 1 mm in circumferential dimension at an imaginary circle bounded by the innermost portion.

In at least some implementations, the washer may also include a rim, and the sidewall may extend from a first end at the outer edge to a second end that is axially spaced from the outer edge, and the rim may extend from the second sidewall end to the inner edge. And the rim may be axially inclined so that the inner edge is axially between the first and second ends of the sidewall. The sidewall may be contoured such that the peripheral length of the first end is greater than the peripheral length of the second end.

At least some implementations of a washer for a gear in a differential housing may include a contoured sidewall having a first end and a second end. The first end has a first peripheral length relative to an axis of the washer, and the second end is axially offset from the first end and has a second circumferential length relative to the axis that is less than the first circumferential length. An inner edge defines an opening that is not circular, and the inner edge is defined in part by an innermost portion at a minimum radial distance from the axis and the inner edge has an outward portion spaced radially outwardly from the innermost portion. The innermost portion may be located radially inwardly of the sidewall and axially between the first end and second end of the sidewall.

