Abstract:
A seal protector assembly is provided. The seal protector assembly includes a cavity for encasing a seal. A plug or cap is removably attached to the protector seal. After shipment of the transmission, the plug or cap is removed. Once any potential damage to the seal during assembly has passed, the protector is then removed.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 61/297,499 filed on Jan. 22, 2010, which is hereby incorporated in its entirety herein by reference. 
     
    
     TECHNICAL FIELD 
       [0002]    The invention relates to a seal protector assembly operable to protect a seal during shipping and assembly, and more particularly a seal protector assembly that protects a seal attached to a transmission. 
       BACKGROUND 
       [0003]    A typical multi-speed transmission uses a combination of torque transmitting devices, gear sets, and shafts controlled by an electro-hydraulic control system to provide a plurality of forward and reverse gear ratios for a motor vehicle. These components are encased within a protective transmission case or housing. During assembly of the motor vehicle, the transmission is shipped and washed prior to installation. Accordingly, openings must be sealed during shipment in order to prevent debris from entering the transmission and to prevent water from entering the transmission during washing. In addition, it is desirable to protect exposed components, such as rubber seals, that can be damaged during shipment or installation of the transmission. 
         [0004]    For example, a typical transmission includes an opening for receiving an axle shaft that connects the output of the engine to the input of the transmission. The opening includes an axial seal that seals the transmission once the axle shaft has been installed. However, the typical axle shaft includes a splined end that is inserted into the opening of the transmission. This splined end can damage the axial seal that surrounds the opening, thereby leading to axle seal leaks that can damage the transmission. Accordingly, there is a need for a seal protector assembly that protects the transmission and the seal from damage during transportation and during installation, while remaining easy to remove during assembly. 
       SUMMARY 
       [0005]    A seal protector assembly is provided. The seal protector assembly includes a cavity for encasing a seal. A plug or cap is removably attached to the protector seal. After shipment of the transmission, the plug or cap is removed. Once any potential damage to the seal during assembly has passed, the protector is then removed. 
         [0006]    In one embodiment, the plug snaps onto the seal protector. 
         [0007]    In another embodiment, the plug screws onto the seal protector. 
         [0008]    In yet another embodiment, the plug includes a breakaway feature that separates the seal protector along an axis thereof. 
         [0009]    In yet another embodiment, the plug is a piercable rubber and the seal protector clamps the plug between two hinged members. 
         [0010]    Further features, aspects and advantages of the present invention will become apparent by reference to the following description and appended drawings wherein like reference numbers refer to the same component, element or feature. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. 
           [0012]      FIG. 1  is a cross-sectional view of a seal protector assembly according to the principles of the present invention shown in use with an exemplary axle seal and a portion of an exemplary transmission; 
           [0013]      FIG. 2  is a front view of the seal protector assembly shown in  FIG. 1 ; 
           [0014]      FIG. 3A  is a cross-sectional view of a portion of a transmission having an axle seal with a portion of a seal protector assembly removed during installation of an axle shaft; 
           [0015]      FIG. 3B  is a cross-sectional view of a portion of a transmission having an axle seal sealed to an axle shaft; 
           [0016]      FIG. 4  is a partial cross-sectional view of another embodiment of a seal protector assembly according to the principles of the present invention shown in use with an exemplary axle seal and a portion of an exemplary transmission; 
           [0017]      FIG. 5  is a front view of the seal protector assembly shown in  FIG. 4 ; 
           [0018]      FIG. 6  is a cross-sectional view of another embodiment of a seal protector assembly according to the principles of the present invention shown in use with an exemplary axle seal and a portion of an exemplary transmission; 
           [0019]      FIG. 7  is a front perspective view of the seal protector assembly shown in  FIG. 6  with a portion of the seal protector assembly removed; 
           [0020]      FIG. 8  is a cross-sectional view of a portion of the seal protector assembly taken in the direction of arrow  8 - 8  in  FIG. 6 ; 
           [0021]      FIG. 9  is a partial front view of another embodiment of a seal protector assembly; 
           [0022]      FIG. 10  is a partial cross-sectional view of the seal protector assembly shown in  FIG. 9  shown in use with an exemplary axle seal and a portion of an exemplary transmission; and 
           [0023]      FIG. 11  is a front view of a plug used with the seal protector assembly shown in  FIGS. 10 and 11 . 
       
    
    
     DESCRIPTION 
       [0024]    With combined reference to  FIGS. 1 and 2 , a seal protector assembly according to the principles of the present invention is generally indicated by reference number  10 . The seal protector assembly  10  is shown in use with an exemplary transmission  12  having an exemplary axle seal  14 . The transmission  12  includes a typically cast, metal housing or case  16  which encloses and protects the various components of the transmission  12 . The housing  16  includes a variety of apertures, passageways, shoulders and flanges which position and support these components. In particular, the housing  16  defines an input opening  18  that receives an axle shaft or other input from an engine (not shown) of the motor vehicle. The transmission housing  16  further includes a radial slot  20  disposed around the input opening  18 . It should be appreciated that the transmission  12  may be, for example, a front wheel drive transmission, a rear wheel drive transmission, a dual clutch transmission, a hybrid transmission, or any other type of transmission without departing from the scope of the present invention. 
         [0025]    The axle seal  14  is annular and includes a metal flange  22  press fit or otherwise attached to the transmission housing  16  within the radial slot  20 . The flange  22  extends radially inwardly and terminates in a distal end  24 . A rubber seal  26  is connected to the distal end  24  of the flange  22 . The rubber seal  26  is operable to seal against an axle shaft or other component, as will be described in greater detail below, to prevent oil leakage out of the transmission  12  during operation of the motor vehicle. The axle seal  14  also includes an assembly guard  28  and a slinger lip  30 , however, these components may be removed from the axle seal  14  without departing from the scope of the present invention. It should be appreciated that the shape of the axial seal  14  and the specific configuration and materials used may vary without departing from the scope of the present invention. 
         [0026]    The seal protector assembly  10  is operable to close the opening  18  to the transmission  12  during shipment of the transmission  12  and to protect the rubber seal  26  during assembly of the transmission  12  within the motor vehicle. The seal protector assembly  10  includes a seal protector  32  and a plug or cap  33 . The seal protector  32  includes a radial portion  34  and inner and outer annular members  36  and  38 , respectively, connected with the radial portion  34 . The inner and outer annular members  36  and  38  extend in an axial direction relative to the radial portion  34  and are disposed parallel and opposite one another. The inner surface of the radial portion  34 , the inner surface or inner diameter of the outer member  38 , and the outer surface or outer diameter of the inner member  36  cooperate to define a cavity  40 . The cavity  40  is sized to receive a portion of the seal  14  therein. The inner member  36  includes a distal end  42  having a raised portion or annular lip  44  disposed on the outer surface or outer diameter of the inner member  36 . The inner surface or inner diameter of the inner member  36  defines an aperture  46  that communicates with the opening  18  of the transmission housing  16 . 
         [0027]    The outer member  38  includes a pull feature  46  configured to allow a user of the seal protector  32  to grasp the seal protector  32  in order to remove the seal protector  32  from the axle seal  14 . In the embodiment provided, the pull feature  46  is a handle that extends from the outer surface of the outer member  38 . However, it should be appreciated that the pull feature  46  may have various other configurations without departing from the scope of the present invention. In order to aid in the removal of the seal protector  32 , the seal protector  32  includes at least one reduced thickness portion  50  that extends along the axis of the seal protector  32 , best seen in  FIG. 2 , that is configured to break or separate the seal protector  32  along its axis when sufficient pull force is applied to the seal protector  32 . 
         [0028]    The plug  33  is a disc sized to cover the aperture  46  of the seal protector  10 . The plug  33  includes a pull feature  52  configured to allow a user of the seal protector assembly  10  to grasp the plug  33  in order to remove the plug  33  from the seal protector  32 . In the embodiment provided, the pull feature  52  is a handle that extends from the outer surface or outer diameter of the plug  33 . However, it should be appreciated that the pull feature  52  may have various other configurations without departing from the scope of the present invention. 
         [0029]    The plug  33  is secured to the seal protector  32  via a plug retention feature  60 . The plug retention feature  60  is configured to releasably secure the plug  33  to the seal protector  32  during shipment of the transmission  12  in order to close off or seal the aperture  46  that leads to the opening  18  in the transmission case  16 . The retention feature  60  includes at least one radially extending curved annular rib  62  disposed on the outer surface of the outer member  38  proximate the radial portion  34 . In the example provided, the seal protector  32  includes three annular ribs  62 . The retention feature  60  also includes an axially extending annular tab  64  disposed on a surface of the plug  33 . The annular tab  64  includes a hooked distal end  66  configured to grab the bent ribs  62 . Accordingly, the retention feature  60  provides a snap-fit between the plug  33  and the seal protector  10 . When installed, the plug  33  is parallel with the radial portion  34  of the seal protector  10  and covers the aperture  46 . To provide additional sealing, seals  68  may be located between the plug  33  and the radial portion  34 . The seals  68  may include separate compressible components or may include a compressible raised portion integrated with the radial portion  34 . 
         [0030]    In the example provided, the plug  33  is a unitary plastic component and the seal protector  32  is also a unitary plastic component. Both the plug  33  and the seal protector  32  may be created using known injection molding techniques. It should be appreciated, however, that the plug  33  and seal protector  32  may be made of different materials, in different manners, and from separate pieces without departing from the scope of the present invention. 
         [0031]    During shipment or storage of the transmission  12 , the seal protector  32  is inserted into the opening  18  such that the rubber seal portion  26  and a portion of the flange  22  are enclosed within the cavity  40  of the seal protector  32 . The annular lip  44  prevents the seal protector  32  from slipping off the transmission  12 . The plug  33  is press fit onto the seal protector  32 . 
         [0032]    In order to assemble the transmission  12  with the motor vehicle, the plug  33  is removed by employing the pull feature  52 , thereby revealing the aperture  46  that communicates with the opening  18  in the transmission  12 . Turning to  FIG. 3A , once the plug  33  has been removed, an axle shaft  70  is inserted into the aperture  46  and into the opening  18  of the transmission  12 . The axle shaft  70  has splines  72  on an end thereof as well as a reduced diameter portion  74  and an increased diameter portion  76 . The seal protector  32 , specifically the inner member  36 , protects the rubber seal portion  26  from any contact with the splines  72  as the axle shaft  70  passes into the opening. Once the splines  72  have passed the rubber seal portion  26  but before the increased diameter portion  76  has reached the seal protector  32 , the seal protector  32  is removed using the pull feature  46 . The seal protector  32  separates at the reduced thickness portion  50  and the seal protector  32  is able to deflect and be pulled off the axle seal  14  and the axle shaft  70 . Turning to  FIG. 3B , the axle shaft  70  is then further inserted until the axle seal  14  seals to the increased diameter portion  76  of the axle shaft  70 . 
         [0033]    With reference to  FIGS. 4 and 5 , an alternate seal protector assembly is generally indicated by reference number  100 . The seal protector assembly  100  is similar to the seal protector assembly  10  and therefore like components are indicated by like reference numbers. However, the seal protector assembly  100  includes a retention feature  102  and the plug  33  includes a pull feature  104 . The retention feature  102  is comprised of threads  106  disposed on the outer surface of the outer member  38  of the seal protector  32  and matching threads  108  disposed on an inner surface of the annular tab  64 . Therefore, the retention feature  102  provides a screw fit between the plug  33  and the seal protector  32 . 
         [0034]    The pull feature  102  is comprised of a hex nut or other feature located centrally on an outer surface of the plug  33 . Accordingly, the plug  33  may be screwed on and off the seal protector  32  using a mechanical device. Alternative pull features  102  may include, for example, a handle for turning the plug  33  manually. The seal protector assembly  100  otherwise operates in a manner similar to the seal protector assembly  10  as described above. 
         [0035]    Turning now to  FIGS. 6 and 7 , another alternate seal protector assembly is generally indicated by reference number  200 . The seal protector assembly  200  is similar to the seal protector assembly  10  and therefore like components are indicated by like reference numbers. However, the seal protector assembly  200  includes a system that replaces the reduced thickness portion  50  in the seal protector  32  to facilitate the removal of the seal protector  32  from the axle seal  14  and the axle shaft  70 . Specifically, the plug  33  includes a base  202  located centrally on an inner surface of the plug  33 . A cord  204  is connected at one end thereof to the base  202 . The cord  204  is connected at an opposite end thereof with a zip feature  206  formed in the inner surface of the inner member  36 . Turning briefly to  FIG. 8 , the zip feature  206  includes a thick portion  208  defined by two divots or reduced thickness portions  210 A and  210 B located on each side of the thick portion  208 . Both the cord  204  and the thick portion  208  may include a metal wire core  212  in order to strengthen the cord  204  and the zip feature  206 . The seal protector assembly  100  is a unitary piece wherein the plug  33  is connected to the seal protector  32  via the cord  204 . 
         [0036]    Turning to  FIG. 7 , when the plug  33  is removed from the seal protector  32 , the cord  204  pulls the zip feature  206  causing the thick portion  208  to separate at the divots  210 A and  210 B. Once the zip feature  206  is fully removed, the seal protector  32  is separated and a gap  211  is formed in the seal protector along an axis thereof and the seal protector  32  can easily be removed from the axle seal  14  and the axle shaft  70  as the amount of force required to remove the seal protector  32  is only that needed to deflect the seal protector  32  and does not include the force necessary to separate the seal protector  32 . The seal protector assembly  200  otherwise operates in a manner similar to the seal protector assembly  10  as described above. 
         [0037]    With reference to  FIGS. 9 and 10 , another alternate seal protector assembly is generally indicated by reference number  300 . The seal protector assembly  300  is similar to the seal protector assembly  10  and therefore like components are indicated by like reference numbers. However, the seal protector assembly  300  includes a modified seal protector  302  and plug  304 . The seal protector  302  includes a clamp portion  306 . The clamp portion  306  is hinged to the outer member  38  at a hinge joint  308 . The clamp portion  306  is annular and has a plurality of tab members  310  that extend radially outwards. The tab members  310  are aligned with a plurality of clips  312  that extend radially outward from the outer surface of the outer member  38 . 
         [0038]    Turning to  FIG. 11 , the plug  304  is a rubber or other flexible disc having an annular bead  314  located along a periphery of the plug  304 . In addition, the plug  304  has thin sections  316  that extend across the plug  304 . In the example provided, the thin sections  316  divide the plug  304  into four thick sections  318 . However, additional thin sections  316  may be provided without departing from the scope of the present invention. 
         [0039]    Returning to  FIG. 10 , the seal protector  302  is installed over the axle seal  14 . The plug  304  is placed adjacent the radial portion  34 . The bead  314  fits within an annular groove  320  located in the radial portion  34 . The plug  304  is secured to the seal protector  302  by closing the clamp portion  306  until the tabs  310  are secured within the clips  312 . 
         [0040]    During assembly of the transmission  12 , the plug  304  is not removed from the seal protector  302 . Instead, the axle shaft  70  pierces the plug  304  by separating the plug along the thin sections  316 . The seal protector  302  protects the axle seal  14  as described above in prior embodiments. To remove the seal protector  302  and plug  304 , the seal protector is pulled at the hinged joint  308  or at another pull feature and the seal protector  302  separates at reduced thickness portions  322  located on the seal protector  302  and the clamp  306 . The plug  304 , despite being pierced, is retained by the clamp  306  and the seal protector  302 , thereby preventing debris from the plug  304  from remaining with the transmission  12 . 
         [0041]    The description of the invention is merely exemplary in nature and variations that do not depart from the general essence of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.