Office Action 1: Non-Final Rejection (2025-01-29)
Rejection types: 103 - Obviousness

CLAIMS:
What is claimed is:

1\. An electric drive unit, comprising:a motor that drives rotation of a rotor shaft;
a transmission assembly operably coupled with the rotor shaft;
a differential assembly that includes a ring gear that interfaces with a gear of the transmission assembly, such that rotation of the rotor shaft drives rotation of the ring gear; and
a housing, comprising:
a housing body;
a housing cover that cooperates with the housing body to define an interior region of the housing in which the transmission assembly and differential assembly are disposed, wherein the interior region includes a primary oil reservoir; and
a gasket coupled with the housing cover such that the housing cover and the gasket cooperate to define a secondary oil reservoir, the gasket defining an opening and at least one passage, wherein rotation of the ring gear is configured to deliver oil into the secondary oil reservoir from the primary oil reservoir via the opening defined by the gasket, and the at least one passage is configured to convey oil to a portion of the differential assembly.

2\. The electric drive unit of claim 1, wherein the gasket includes at least one elongated tubular conduit that defines the at least one passage, the at least one elongated tubular conduit extending outward from a surface of the gasket that is opposite the secondary oil reservoir.

3\. The electric drive unit of claim 1, wherein gravity propels the oil to the portion of the differential assembly from the secondary oil reservoir via the at least one passage.

4\. The electric drive unit of claim 1, wherein the at least one passage is configured to convey oil to a bearing of the differential assembly.

5\. The electric drive unit of claim 4, wherein the bearing is a side bearing.

6\. The electric drive unit of claim 1, wherein the at least one passage comprises:a first passage that is configured to convey oil to a first side bearing of the differential assembly; and
a second passage that is configured to convey oil to a second side bearing of the differential assembly opposite the first side bearing.

7\. The electric drive unit of claim 1, wherein the opening is axially aligned with the ring gear and is oriented to generally face teeth of the ring gear.

8\. The electric drive unit of claim 1, wherein the opening is axially offset from the ring gear and a portion of the ring gear is positioned radially outboard of a portion of the secondary oil reservoir with respect to the axis about which the ring gear rotates.

9\. The electric drive unit of claim 8, wherein the housing cover includes a plurality of ribs that guide oil delivered onto the housing cover from the ring gear axially toward the opening.

10\. An electric drive unit, comprising:a motor that drives rotation of a rotor shaft;
a transmission assembly;
a differential assembly that is operably coupled with the transmission assembly via a ring gear; and
a housing that defines a primary oil reservoir in which the transmission assembly and the differential assembly are disposed, a secondary oil reservoir, an opening via which the 18 primary oil reservoir and the secondary oil reservoir are in fluid communication, and at least one passage, wherein rotation of the ring gear is configured to deliver oil into the secondary oil reservoir from the primary oil reservoir via the opening, and the at least one passage is configured to convey oil from the secondary oil reservoir to a portion of the differential assembly.

11\. The electric drive unit of claim 10, wherein the at least one passage is defined by at least one elongated tubular conduit.

12\. The electric drive unit of claim 11, wherein the at least one passage comprises:a first passage that is defined by a first elongated tubular conduit; and
a second passage that is defined by a second elongated tubular conduit.

13\. The electric drive unit of claim 12, wherein the first passage conveys oil to a first side bearing of the differential assembly, and the second passage conveys oil to a second side bearing of the differential assembly.

14\. The electric drive unit of claim 11, wherein the at least one elongated tubular conduit angles vertically downward to an outlet, such that the oil is conveyed within the at least one passage by gravity.

15\. The electric drive unit of claim 10, wherein the opening is axially aligned with the ring gear and is oriented to generally face teeth of the ring gear.

16\. The electric drive unit of claim 10, wherein the opening is axially offset from the ring gear and a portion of the ring gear is positioned radially outboard of a portion of the secondary oil reservoir with respect to the axis about which the ring gear rotates.

17\. An assembly, comprising:a gearset; and
a housing that defines a primary oil reservoir in which the gearset is disposed, a secondary oil reservoir, an opening via which the primary oil reservoir and the secondary oil reservoir are in fluid communication, and at least one passage defined by an elongated tubular conduit that is configured to convey oil from the secondary oil reservoir into the primary oil reservoir during operation of the gearset.

18\. The assembly of claim 17, wherein the gearset is a portion of a differential assembly.

19\. The assembly of claim 17, further comprising:a bearing, wherein the elongated tubular conduit defines an outlet of the at least one passage that is proximate to the bearing, such that oil is conveyed to the bearing via the at least one passage.

20\. The assembly of claim 17, wherein the housing comprises:a housing body that defines the primary oil reservoir;
a housing cover; and
a gasket that is disposed between the housing cover and the housing body, wherein the gasket and the housing cover cooperate to define the secondary oil reservoir.

OFFICE ACTION:
Notice of Pre-AIA  or AIA  Status
The present application, filed on or after March 16, 2013, is being examined under the first inventor to file provisions of the AIA .
This communication is in response to application No. 18/411,853 Electric Drive Unit with a Secondary Oil Reservoir; filed on 01/12/2024. Claims 1 - 20 are currently pending and have been examined. Claims 1 - 20 have been rejected as follows,
Claim Rejections - 35 USC § 103
In the event the determination of the status of the application as subject to AIA  35 U.S.C. 102 and 103 (or as subject to pre-AIA  35 U.S.C. 102 and 103) is incorrect, any correction of the statutory basis (i.e., changing from AIA  to pre-AIA ) for the rejection will not be considered a new ground of rejection if the prior art relied upon, and the rationale supporting the rejection, would be the same under either status.
The following is a quotation of 35 U.S.C. 103 which forms the basis for all obviousness rejections set forth in this Office action:
A patent for a claimed invention may not be obtained, notwithstanding that the claimed invention is not identically disclosed as set forth in section 102, if the differences between the claimed invention and the prior art are such that the claimed invention as a whole would have been obvious before the effective filing date of the claimed invention to a person having ordinary skill in the art to which the claimed invention pertains. Patentability shall not be negated by the manner in which the invention was made.
PNG
media_image1.png
684
518
media_image1.png
Greyscale
Claims 1-8, 10-20 are rejected under 35 U.S.C. 103 as being unpatentable over Onishi (JP 2014 119084 A) in view of Bodary (US 11,440,348 B1).
Regarding Claim 1, Onishi discloses;
a differential assembly (differential apparatus 1; Fig. 1) that includes a ring gear (ring gear 7; Fig. 5) that interfaces with a gear (pinion gear 8), such that an input shaft drives rotation of the ring gear; (paragraph 33 describes the pinion gear as driven by the drive shaft and meshing with the ring gear.)
a housing, comprising: a housing body (differential carrier 2; Fig. 5);
a housing cover (cover 4) that cooperates with the housing body to define an interior region (gear accommodation chamber 3; Fig. 5) of the housing in which the differential assembly is disposed, wherein the interior region includes a primary oil reservoir (Fig. 5 and paragraph 40 describe the lubricating oil (OL) being stored in the lower part of the gear accommodating chamber.);
PNG
media_image2.png
416
686
media_image2.png
Greyscale
a gasket (gasket 10) coupled with the housing cover such that the housing cover and the gasket cooperate to define a secondary oil reservoir (lubricating oil reservoir 18; Fig. 5), the gasket defining an opening (opening 15) and at least one passage (drain hole 16; Fig. 5, paragraph 37), wherein rotation of the ring gear is configured to deliver oil into the secondary oil reservoir from the primary oil reservoir via the opening defined by the gasket, and the at least one passage is configured to convey oil to a portion of the differential assembly. (paragraphs 35-37 describe the gasket and oil flow through the opening and the drain holes.)
Onishi does not disclose an electric drive unit, a transmission assembly or that the housing body also contains the transmission assembly. However Bodary teaches;
An electric drive unit, comprising: a motor that drives rotation of a rotor shaft; (Column 2, lines 11-25 of Bodary describe the axle assembly as being attached to a torque source such as an electric motor or an internal combustion engine. See also Fig. 2)
a transmission assembly operably coupled with the rotor shaft; (Column 3, line 60 to column 5, line 7 of Bodary describe the drop gear set 26 and clutch collar 28 as transmitting power from input shaft 24 to the differential unit at pinion 32. See also Fig. 2)
a transmission assembly, such that a gear (drive pinion 32) of the transmission assembly interfaces with a ring gear (ring gear 180; Fig. 2) of the differential assembly such that rotation of the rotor shaft drives rotation of the ring gear. (Column 5, Lines 8-36 of Bodary describe the differential assembly (34) as receiving torque from the drive pinion (32) via the ring gear (180).)
a housing in which the transmission assembly and differential assembly are disposed, (differential  housing 62, axle housing 60, cover 84; Fig. 2)
A person of ordinary skill in the art before the effective filing date of the claimed invention would have been motivated to modify Onishi to include an electric drive unit comprising a motor that drives rotation of a rotor shaft, a transmission assembly, and a housing which contains the transmission along with the differential assembly as taught by Bodary, as the references and the claimed invention are directed to vehicle drive systems. As disclosed by Bodary, it is well known for a vehicle drive system to consist of an electric drive comprising a motor that drives a rotor shaft, a transmission assembly, and a housing which contains the transmission along with the differential assembly. It would have been obvious to one of ordinary skill in the art before the effective filing date of the claimed invention to modify Onishi to include an electric drive comprising a motor that drives rotation of a rotor shaft, a transmission assembly, and a housing which contains the transmission along with the differential assembly as taught by Bodary, as such a modification would provide the ability to utilize an electric motor as a motive power source for a vehicle.
Regarding Claim 2, Onishi does not disclose, at least one elongated tubular conduit, however Bodary teaches;
wherein at least one elongated tubular conduit (conduits 52, 54; Figs. 3, 4, Column 9, lines 11-22) that defines the at least one passage, the at least one elongated tubular conduit extending outward from the secondary oil reservoir (lubricant reservoir 50, consisting of tanks 220 and 222. Fig. 3, 4).
(Onishi creates a secondary oil reservoir within the cover utilizing a gasket with holes to control the return flow of the lubricant. Bodary teaches an auxiliary lubricant reservoir with conduits to direct returning lubricant to specific bearings. Adding the flow directing conduits of Bodary to the lubricating oil reservoir (created by the gasket, within the cover) of Onishi would provide the conduits as part of the gasket.)
A person of ordinary skill in the art before the effective filing date of the claimed invention would have been motivated to modify Onishi to include an elongated tubular conduits that define a passage as taught by Bodary, as the references and the claimed invention are directed to lubrication methods for vehicle drive systems. As disclosed by Bodary, it is well known for a vehicle drive system lubricate system to include an elongated tubular conduits that defines a passage. It would have been obvious to one of ordinary skill in the art before the effective filing date of the claimed invention to modify Onishi to include an elongated tubular conduits that define a passage as taught by Bodary, as such a modification would provide the ability to direct lubricating oil to specific components of the differential assembly.
Regarding Claim 3, Onishi further discloses;
wherein gravity propels the oil to the portion of the differential assembly from the secondary oil reservoir via the at least one passage. (Fig. 5 and paragraph 40 demonstrates oil returning to the main oil reservoir from the secondary reservoir 18 via the drain hole 16.)
Regarding Claim 4, Onishi does not disclose wherein the at least one passage is configured to convey oil to a bearing of the differential assembly. However, Bodary teaches;
wherein the at least one passage (conduits 52, 54)  is configured to convey oil to a bearing of the differential assembly. (Column 9, lines 11-40 describe the conduits which may deliver oil to input and output shaft bearings.)
A person of ordinary skill in the art before the effective filing date of the claimed invention would have been motivated to modify Onishi to include at least one passage which is configured to convey oil to a bearing of the differential assembly as taught by Bodary, as the references and the claimed invention are directed to vehicle drive systems. As disclosed by Bodary, it is well known for a vehicle drive system to include at least one passage which is configured to convey oil to a bearing of the differential assembly. It would have been obvious to one of ordinary skill in the art before the effective filing date of the claimed invention to modify Onishi to include at least one passage which is configured to convey oil to a bearing of the differential assembly as taught by Bodary, as such a modification would provide the ability to direct lubricating oil to specific drive components.
Regarding Claim 5, Bodary teaches;
wherein the bearing is a side bearing. (Column 9, lines 23-40 describe the bearing as an output shaft bearing.)
Regarding Claim 6, Onishi does not disclose first and second passages that are configured to convey oil to  first and second side bearings of the differential assembly. However, Bodary teaches;
wherein the at least one passage comprises:
a first passage (first conduit 52) that is configured to convey oil to a first side bearing of the differential assembly; and
a second passage (second conduit 54) that is configured to convey oil to a second side bearing of the differential assembly opposite the first side bearing.
Bodary describes the oil distribution conduits as supplying oil to the input and output shaft bearings but also states, in Column 10, lines 4-29, that the conduits may supply lubricant, among other components, the differential assembly and the bearings that support it.
A person of ordinary skill in the art before the effective filing date of the claimed invention would have been motivated to modify Onishi to include first and second passages that are configured to convey oil to first and second side bearings of the differential assembly as taught by Bodary, as the references and the claimed invention are directed to vehicle drive systems. As disclosed by Bodary, it is well known for a vehicle drive system to include first and second passages that are configured to convey oil to first and second side bearings of the differential assembly. It would have been obvious to one of ordinary skill in the art before the effective filing date of the claimed invention to modify Onishi to include first and second passages that are configured to convey oil to first and second side bearings of the differential assembly as taught by Bodary, as such a modification would provide the ability to direct lubrication to specific drive components. (Column 10, lines 4-29, Bodary).
Regarding Claim 7, Onishi further discloses;
wherein the opening is axially aligned with the ring gear and is oriented to generally face teeth of the ring gear. (Figs. 5 and 8 shows the opening 15 in gasket 10 aligned such that it faces the ring gear teeth. The opening spans the width of the cover and is thereby axially aligned with the ring gear.)
PNG
media_image3.png
573
700
media_image3.png
Greyscale
Regarding Claim 8, Onishi does not disclose the opening is axially offset from the ring gear and a portion of the ring gear is positioned radially outboard of a portion of the oil reservoir. However, Bodary teaches;
wherein the opening (inlet 230; Fig. 4, Column 6, lines 56-67, Bodary) is axially offset from the ring gear (ring gear 180; Fig. 3) and a portion of the ring gear is positioned radially outboard of a portion of the secondary oil reservoir with respect to the axis about which the ring gear rotates. (Figs. 3-4 demonstrate the tank has an open top (230) and two side compartments (220,222) in which to collect and hold lubricant. The ring gear extends above the bottom panel (242) of the tank such that it can splash lubricant into the open in the upper portion of the tank. Column 6, lines 56-67, Fig. 3)
A person of ordinary skill in the art before the effective filing date of the claimed invention would have been motivated to modify Onishi to include an opening axially offset from the ring gear where a portion of the ring gear is positioned outboard of a portion of the oil reservoir as taught by Bodary, as the references and the claimed invention are directed to vehicle drive systems. As disclosed by Bodary, it is well known for a vehicle drive system to include an opening axially offset from the ring gear where a portion of the ring gear is positioned outboard of a portion of the oil reservoir. It would have been obvious to one of ordinary skill in the art before the effective filing date of the claimed invention to modify Onishi to include an opening axially offset from the ring gear where a portion of the ring gear is positioned outboard of a portion of the oil reservoir as taught by Bodary, as such a modification would provide the ability to provide for the collection of lubricant flung off the ring gear in an auxiliary reservoir thereby reducing drag and churning losses in the differential assembly. (Column 11, lines 14-38, Bodary).
Regarding Claim 10, Onishi discloses;
a differential assembly (differential apparatus 1; Fig. 1) that is operably coupled to a drive source via a ring gear (ring gear 7; Fig. 5); and
a housing (differential carrier 2) that defines a primary oil reservoir (gear accommodation chamber 3) in which the differential assembly is disposed, (see Fig. 5)
a secondary oil reservoir (lubricating oil reservoir 18),
an opening (opening 15) via which the primary oil reservoir and the secondary oil reservoir are in fluid communication, and
at least one passage wherein rotation of the ring gear is configured to deliver oil into the secondary oil reservoir from the primary oil reservoir via the opening, (opening 15 allows oil to be thrown off the ring gear and deposited into the secondary chamber housed in the cover),
the at least one passage is configured to convey oil from the secondary oil reservoir to a portion of the differential assembly. (oil returns to the main chamber via drain holes 16; Fig. 5)
Onishi does not disclose an electric drive unit, a transmission assembly or that the housing body also contains the transmission assembly. However Bodary teaches;
An electric drive unit, comprising: a motor that drives rotation of a rotor shaft; (Column 2, lines 11-25 of Bodary describe the axle assembly as being attached to a torque source such as an electric motor or an internal combustion engine. See also Fig. 2)
a transmission assembly; (Column 3, line 60 to column 5, line 7 describes the drop gear set 26 and clutch collar 28 as transmitting power from input shaft 24 to the differential unit at pinion 32. See also Fig. 2)
coupled with a differential (differential assembly 34)  via a ring gear (ring gear 180; Fig. 2) (Column 5, Lines 8-36 of Bodary describe the differential assembly (34) as receiving torque from the drive pinion (32) via the ring gear (180).)
a housing in which the transmission assembly and differential assembly are disposed, (differential  housing 62, axle housing 60, cover 84; Fig. 2)
A person of ordinary skill in the art before the effective filing date of the claimed invention would have been motivated to modify Onishi to include an electric drive unit comprising a motor that drives rotation of a rotor shaft, a transmission assembly, and a housing which contains the transmission along with the differential assembly as taught by Bodary, as the references and the claimed invention are directed to vehicle drive systems. As disclosed by Bodary, it is well known for a vehicle drive system to consist of an electric drive comprising a motor that drives a rotor shaft, a transmission assembly, and a housing which contains the transmission along with the differential assembly. It would have been obvious to one of ordinary skill in the art before the effective filing date of the claimed invention to modify Onishi to include an electric drive comprising a motor that drives rotation of a rotor shaft, a transmission assembly, and a housing which contains the transmission along with the differential assembly as taught by Bodary, as such a modification would provide the ability to utilize an electric motor as a motive power source for a vehicle.
Regarding Claim 11, Onishi does not disclose, at least one elongated tubular conduit, however Bodary teaches;
wherein the at least one passage (conduits 52, 54; Figs. 3, 4, Column 9, lines 11-22) is defined by at least one elongated tubular conduit.
A person of ordinary skill in the art before the effective filing date of the claimed invention would have been motivated to modify Onishi to include an elongated tubular conduits that define a passage as taught by Bodary, as the references and the claimed invention are directed to lubrication methods for vehicle drive systems. As disclosed by Bodary, it is well known for a vehicle drive system lubricate system to include an elongated tubular conduits that defines a passage. It would have been obvious to one of ordinary skill in the art before the effective filing date of the claimed invention to modify Onishi to include an elongated tubular conduits that define a passage as taught by Bodary, as such a modification would provide the ability to direct lubricating oil to specific components of the differential assembly.
Regarding Claim 12, Onishi further discloses;
wherein the at least one passage comprises: a first passage that is defined by a first elongated tubular conduit; and a second passage that is defined by a second elongated tubular conduit. (Figs. 3, 4 and paragraph 54 describes the lubrication conduits 52 and 54)
Regarding Claim 13, Onishi does not disclose first and second passages that are configured to convey oil to  first and second side bearings of the differential assembly. However, Bodary teaches;
wherein the first passage (first conduit 52)  conveys oil to a first side bearing of the differential assembly, and the second passage (second conduit 54) conveys oil to a second side bearing of the differential assembly.
Bodary describes the oil distribution conduits as supplying oil to the input and output shaft bearings but also states, in column 10, lines 4-29, that the conduits may supply lubricant, among other components, the differential assembly and the bearings that support it.
A person of ordinary skill in the art before the effective filing date of the claimed invention would have been motivated to modify Onishi to include first and second passages that are configured to convey oil to first and second side bearings of the differential assembly as taught by Bodary, as the references and the claimed invention are directed to vehicle drive system. As disclosed by Bodary, it is well known for a vehicle drive system to include first and second passages that are configured to convey oil to first and second side bearings of the differential assembly. It would have been obvious to one of ordinary skill in the art before the effective filing date of the claimed invention to modify Onishi to include first and second passages that are configured to convey oil to first and second side bearings of the differential assembly as taught by Bodary, as such a modification would provide the ability to direct lubrication to specific drive components. (Column 10, lines 4-29, Bodary).
Regarding Claim 14, Bodary further teaches;
wherein the at least one elongated tubular conduit angles vertically downward to an outlet, such that the oil is conveyed within the at least one passage by gravity. (Column 9, lines 23-40 state that the conduits 52, 54 may slope downwards away from the lubricant reservoir to further facilitate the flow of lubricant.)
Regarding Claim 15, Onishi further discloses;
wherein the opening is axially aligned with the ring gear and is oriented to generally face teeth of the ring gear. (Figs. 5 and 8 shows the opening 15 in gasket 10 aligned such that it faces the ring gear teeth. The opening spans the width of the cover and is thereby axially aligned with the ring gear.)
Regarding Claim 16, Onishi does not disclose the opening is axially offset from the ring gear and a portion of the ring gear is positioned radially outboard of a portion of the oil reservoir. However, Bodary teaches;
wherein the opening (inlet 230; Fig. 4, Column 6, lines 56-67, Bodary) is axially offset from the ring gear (ring gear 180; Fig. 3) and a portion of the ring gear is positioned radially outboard of a portion of the secondary oil reservoir with respect to the axis about which the ring gear rotates. (Figs. 3-4 demonstrate the tank has an open top (230) and two side compartments (220,222) in which to collect and hold lubricant. The ring gear extends above the bottom panel (242) of the tank such that it can splash lubricant into the open in the upper portion of the tank. Column 6, lines 56-67, Fig. 3)
A person of ordinary skill in the art before the effective filing date of the claimed invention would have been motivated to modify Onishi to include an opening axially offset from the ring gear where a portion of the ring gear is positioned outboard of a portion of the oil reservoir as taught by Bodary, as the references and the claimed invention are directed to vehicle drive systems. As disclosed by Bodary, it is well known for a vehicle drive system to include an opening axially offset from the ring gear where a portion of the ring gear is positioned outboard of a portion of the oil reservoir. It would have been obvious to one of ordinary skill in the art before the effective filing date of the claimed invention to modify Onishi to include an opening axially offset from the ring gear where a portion of the ring gear is positioned outboard of a portion of the oil reservoir as taught by Bodary, as such a modification would provide the ability to provide for the collection of lubricant flung off the ring gear in an auxiliary reservoir thereby reducing drag and churning losses in the differential assembly. (Column 11, lines 14-38, Bodary).
Regarding Claim 17, Onishi discloses;
An assembly, comprising: a gearset (ring gear 7 and pinion gear 8; Fig. 5); and
a housing (differential carrier 2) that defines a primary oil reservoir (gear accommodation chamber 3) in which the gearset is disposed,
a secondary oil reservoir (lubricating reservoir 18), an opening via which the primary oil reservoir and the secondary oil reservoir are in fluid communication (opening 15), and
at least one passage (drain hole 16) that is configured to convey oil from the secondary oil reservoir into the primary oil reservoir during operation of the gearset. (Paragraph 69 describes the flow rate through the hole 16 is determined by the amount of oil scooped up by the ring gear and supplied to oil reservoir 18.)
Onishi does not disclose at least one passage defined by an elongated tubular conduit, however Bodary teaches;
wherein the at least one passage (conduits 52, 54; Figs. 3, 4, Column 9, lines 11-22) defined by an elongated tubular conduit.
A person of ordinary skill in the art before the effective filing date of the claimed invention would have been motivated to modify Onishi to include an elongated tubular conduits that define a passage as taught by Bodary, as the references and the claimed invention are directed to lubrication methods for vehicle drive systems. As disclosed by Bodary, it is well known for a vehicle drive system lubricate system to include an elongated tubular conduits that defines a passage. It would have been obvious to one of ordinary skill in the art before the effective filing date of the claimed invention to modify Onishi to include an elongated tubular conduits that define a passage as taught by Bodary, as such a modification would provide the ability to direct lubricating oil to specific components of the differential assembly.
Regarding Claim 18, Onishi further disclose;
wherein the gearset is a portion of a differential assembly. (Paragraph 33 describes the differential device as containing the ring gear 7 and pinion 8)
Regarding Claim 19, Bodary further teaches;
a bearing, wherein the elongated tubular conduit (conduits 52, 54)  defines an outlet of the at least one passage that is proximate to the bearing, such that oil is conveyed to the bearing via the at least one passage. (Column 9, lines 11-40 describe the conduits may delivery oil to input and output shaft bearings.)
A person of ordinary skill in the art before the effective filing date of the claimed invention would have been motivated to modify Onishi to include at least one passage which is configured to convey oil to a bearing of the differential assembly as taught by Bodary, as the references and the claimed invention are directed to vehicle drive systems. As disclosed by Bodary, it is well known for a vehicle drive system to include at least one passage which is configured to convey oil to a bearing of the differential assembly. It would have been obvious to one of ordinary skill in the art before the effective filing date of the claimed invention to modify Onishi to include at least one passage which is configured to convey oil to a bearing of the differential assembly as taught by Bodary, as such a modification would provide the ability to direct lubricating oil to specific drive components.
Regarding Claim 20, Onishi further discloses;
wherein the housing comprises: a housing body (differential carrier 2; Fig. 5) that defines the primary oil reservoir (gear accommodation chamber 3 and lubricant OL; Fig. 5);
a housing cover (cover 4); and
a gasket (gasket 10) that is disposed between the housing cover and the housing body, wherein the gasket and the housing cover cooperate to define the secondary oil reservoir (lubricating sump 18).
PNG
media_image4.png
455
574
media_image4.png
Greyscale
Claim 9 is rejected under 35 U.S.C. 103 as being unpatentable over Onishi, in view of Bodary as applied to claim 8 above, and further in view of Okada (US 2012/0295751 A1).
Regarding Claim 9, Onishi in view of Bodary does not disclose a housing cover which includes a plurality of ribs that guide oil delivered onto the housing cover from the ring gear axially toward the opening. However, Okada teaches;
wherein the housing cover includes a plurality of ribs (guide portion 64; Fig. 11, 13) that guide oil delivered onto the housing cover from the ring gear (ring gear 14) axially toward the opening. (Fig. 11 and paragraph 62 describe the purpose of the sides of passageway 67 to direct oil splashed from the ring gear into the lubricant passageway 67.)
A person of ordinary skill in the art before the effective filing date of the claimed invention would have been motivated to modify Onishi to include a housing cover which includes a plurality of ribs that guide oil delivered onto the housing cover from the ring gear axially towards an opening as taught by Okada, as the references and the claimed invention are directed to lubrication methods for vehicle drive systems. As disclosed by Okada, it is well known for a housing cover to include a plurality of ribs that guide oil delivered onto the housing cover from the ring gear axially towards an opening. It would have been obvious to one of ordinary skill in the art before the effective filing date of the claimed invention to modify Onishi to include a housing cover which includes a plurality of ribs that guide oil delivered onto the housing cover from the ring gear axially towards an opening as taught by Okada, as such a modification would provide the ability to direct splashed oil from the ring gear to desired lubrication points. (Paragraph 64, Okada).
Conclusion
The prior art made of record and not relied upon is considered pertinent to applicant's disclosure. Camping (US 5,476,582); describes a lubrication filter arrang


NEXT OFFICE ACTION: Notice of Pre-AIA  or AIA  Status
The present application, filed on or after March 16, 2013, is being examined under the first inventor to file provisions of the AIA .
This communication is in response to application No. 18/411,853 Electric Drive Unit with a Secondary Oil Reservoir; filed on 01/12/2024 and amended on 04/29/2025. Claims 1-7, and 10-19 are currently pending and have been examined. Claims 8, 9 and 20 have been cancelled by amendment.
Claim Objections
Claim 1 objected to because of the following informalities: Line The corrected limitation matches the description of the ring gear in claim 16. Appropriate correction is required.
Claim Rejections - 35 USC § 112
The following is a quotation of 35 U.S.C. 112(b):
(b)  CONCLUSION.—The specification shall conclude with one or more claims particularly pointing out and distinctly claiming the subject matter which the inventor or a joint inventor regards as the invention.
The following is a quotation of 35 U.S.C. 112 (pre-AIA ), second paragraph:
The specification shall conclude with one or more claims particularly pointing out and distinctly claiming the subject matter which the applicant regards as his invention.
Claims 10-16 are rejected under 35 U.S.C. 112(b) or 35 U.S.C. 112 (pre-AIA ), second paragraph, as being indefinite for failing to particularly point out and distinctly claim the subject matter which the inventor or a joint inventor (or for applications subject to pre-AIA  35 U.S.C. 112, the applicant), regards as the invention.
Claim 10 discloses “a housing” but does not disclose “a housing cover” or “a gasket”. As amended , claim 10 describes the secondary oil reservoir and the plurality of ribs as being part of the differential housing, however the Specification places the ribs within the removable housing cover adjacent to the secondary oil reservoir. The previous independent claim 1, introduces a housing cover and gasket which define a secondary oil reservoir and then describes the ribs as located within the housing cover.
Claim 10 line 6 should state “a housing cover that includes a plurality of ribs”
Claim 10 line 10 should state that oil is delivered onto “a portion of the housing cover that includes the plurality of ribs”.
Claim 10 should state “a gasket coupled with the housing cover such that the housing cover and the gasket cooperate to define a secondary oil reservoir”
Claim 11, line 1 recites the limitation ...the at least one passage... in line 1.  There is insufficient antecedent basis for this limitation in the claim. This has occurred because language introducing “… at least one passage…” was removed from independent claim 10.
Claims 12-16 are rejected as depending from claim 10 or 11.
The following is a quotation of 35 U.S.C. 112(d):
(d) REFERENCE IN DEPENDENT FORMS.—Subject to subsection (e), a claim in dependent form shall contain a reference to a claim previously set forth and then specify a further limitation of the subject matter claimed. A claim in dependent form shall be construed to incorporate by reference all the limitations of the claim to which it refers.
The following is a quotation of pre-AIA  35 U.S.C. 112, fourth paragraph:
Subject to the following paragraph [i.e., the fifth paragraph of pre-AIA  35 U.S.C. 112], a claim in dependent form shall contain a reference to a claim previously set forth and then specify a further limitation of the subject matter claimed. A claim in dependent form shall be construed to incorporate by reference all the limitations of the claim to which it refers.
Claims 7 and 15 rejected under 35 U.S.C. 112(d) or pre-AIA  35 U.S.C. 112, 4th paragraph, as being of improper dependent form for failing to further limit the subject matter of the claim upon which it depends, or for failing to include all the limitations of the claim upon which it depends.  Dependent claims 7 and 15 state the opening is axially aligned with the ring gear and is oriented to generally face teeth of the ring gear. However, amended, independent claims 1 and 10 state opening that is axially offset from the ring gear. Therefore, claims 7 and 15 fail to include all the limitations of the independent claims by contradicting independent claims 1 and 10 since the opening (in the housing) cannot be both axially aligned and axially offset from the ring gear. For purposes of examination, claims 7 and 15 will be interpreted to include the limitations as described in claims 1 and 10, so that the opening (to the secondary oil reservoir) is axially offset from the ring gear.
Applicant may cancel the claim(s), amend the claim(s) to place the claim(s) in proper dependent form, rewrite the claim(s) in independent form, or present a sufficient showing that the dependent claim(s) complies with the statutory requirements.
Claim Rejections - 35 USC § 103
In the event the determination of the status of the application as subject to AIA  35 U.S.C. 102 and 103 (or as subject to pre-AIA  35 U.S.C. 102 and 103) is incorrect, any correction of the statutory basis (i.e., changing from AIA  to pre-AIA ) for the rejection will not be considered a new ground of rejection if the prior art relied upon, and the rationale supporting the rejection, would be the same under either status.
The following is a quotation of 35 U.S.C. 103 which forms the basis for all obviousness rejections set forth in this Office action:
A patent for a claimed invention may not be obtained, notwithstanding that the claimed invention is not identically disclosed as set forth in section 102, if the differences between the claimed invention and the prior art are such that the claimed invention as a whole would have been obvious before the effective filing date of the claimed invention to a person having ordinary skill in the art to which the claimed invention pertains. Patentability shall not be negated by the manner in which the invention was made.
PNG
media_image1.png
684
518
media_image1.png
Greyscale
Claims 1, 3-7, 10, 15 and 16 are rejected under 35 U.S.C. 103 as being unpatentable over Onishi (JP 2014 119084 A) in view of Bodary (US 11,440,348 B1) and further in view of Okada (US 2021/0295751 A1).
Regarding Claim 1, Onishi discloses;
a differential assembly (differential apparatus 1; Fig. 1) that includes a ring gear (ring gear 7; Fig. 5) that interfaces with a gear (pinion gear 8), such that an input shaft drives rotation of the ring gear; (paragraph 33 describes the pinion gear as driven by the drive shaft and meshing with the ring gear.)
a housing, comprising: a housing body (differential carrier 2; Fig. 5);
a housing cover (cover 4) that cooperates with the housing body to define an interior region (gear accommodation chamber 3; Fig. 5) of the housing in which the differential assembly is disposed, wherein the interior region includes a primary oil reservoir (Fig. 5 and paragraph 40 describe the lubricating oil (OL) being stored in the lower part of the gear accommodating chamber.);
a gasket (gasket 10) coupled with the housing cover such that the housing cover and the gasket cooperate to define a secondary oil reservoir (lubricating oil reservoir 18; Fig. 5), the gasket defining an opening (opening 15) and at least one passage (drain hole 16; Fig. 5, paragraph 37), wherein rotation of the ring gear is configured to deliver oil into the secondary oil reservoir from the primary oil reservoir via the opening defined by the gasket, and the at least one passage is configured to convey oil to a portion of the differential assembly. (paragraphs 35-37 describe the gasket and oil flow through the opening and the drain holes.)
Onishi does not disclose an electric drive unit, a transmission assembly or that the housing body also contains the transmission assembly. However Bodary teaches;
An electric drive unit, comprising: a motor that drives rotation of a rotor shaft; (Column 2, lines 11-25 of Bodary describe the axle assembly as being attached to a torque source such as an electric motor or an internal combustion engine. See also Fig. 2)
a transmission assembly operably coupled with the rotor shaft; (Column 3, line 60 to column 5, line 7 of Bodary describe the drop gear set 26 and clutch collar 28 as transmitting power from input shaft 24 to the differential unit at pinion 32. See also Fig. 2)
a transmission assembly, such that a gear (drive pinion 32) of the transmission assembly interfaces with a ring gear (ring gear 180; Fig. 2) of the differential assembly such that rotation of the rotor shaft drives rotation of the ring gear. (Column 5, Lines 8-36 of Bodary describe the differential assembly (34) as receiving torque from the drive pinion (32) via the ring gear (180).)
a housing in which the transmission assembly and differential assembly are disposed, (differential  housing 62, axle housing 60, cover 84; Fig. 2)
A person of ordinary skill in the art before the effective filing date of the claimed invention would have been motivated to modify Onishi to include an electric drive unit comprising a motor that drives rotation of a rotor shaft, a transmission assembly, and a housing which contains the transmission along with the differential assembly as taught by Bodary, as the references and the claimed invention are directed to vehicle drive systems. As disclosed by Bodary, it is well known for a vehicle drive system to consist of an electric drive comprising a motor that drives a rotor shaft, a transmission assembly, and a housing which contains the transmission along with the differential assembly. It would have been obvious to one of ordinary skill in the art before the effective filing date of the claimed invention to modify Onishi to include an electric drive comprising a motor that drives rotation of a rotor shaft, a transmission assembly, and a housing which contains the transmission along with the differential assembly as taught by Bodary, as such a modification would provide the ability to utilize an electric motor as a motive power source for a vehicle.
Onishi does not disclose;
the opening is axially offset from the ring gear,
a portion of the ring gear is positioned radially outboard of a portion of the oil reservoir with respect to the axis about which the ring gear rotates,
the housing cover includes a plurality of ribs that guide oil delivered onto the housing cover from the ring gear axially toward the opening.
PNG
media_image2.png
534
653
media_image2.png
Greyscale
PNG
media_image3.png
542
713
media_image3.png
Greyscale
However, Okada teaches;
the opening is axially offset from the ring gear (14; Fig. 3) and a portion of the ring gear is positioned radially outboard of a portion of the secondary oil reservoir with respect to the axis about which the ring gear rotates. (Fig. 3 demonstrates a portion of the ring gear 14 extends beyond the main housing and into the cover. Fig. 6 illustrates a reservoir within the cover and axially offset from the ring gear. A combination of the secondary reservoir of Onishi contained within the cover by the gasket, with the offset reservoir of Okada would result in an axially offset, secondary oil reservoir defined by the gasket with an opening that is also axially offset.)
the housing cover includes a plurality of ribs that guide oil delivered onto the housing cover from the ring gear axially toward the opening. (Okada, Fig. 11 and paragraph 62 describe the purpose of the sides of passageway 67 to direct oil splashed from the ring gear into the lubricant passageway 67. Figs. 3 and 6 demonstrate the passageway is defined by two ribs and a corresponding trough for directing oil flow towards the opening. )
A person of ordinary skill in the art before the effective filing date of the claimed invention would have been motivated to modify Onishi to include a housing where a portion of the ring gear is positioned radially outboard of a portion of the oil reservoir with respect to the axis about which the ring gear rotates and a housing cover which includes a plurality of ribs that guide oil delivered onto the housing cover from the ring gear axially towards an opening as taught by Okada, as the references and the claimed invention are directed to lubrication methods for vehicle drive systems. As disclosed by Okada, it is well known for a portion of the ring gear to be positioned radially outboard of a portion of the oil reservoir with respect to the axis about which the ring gear rotates and a housing cover to include a plurality of ribs that guide oil delivered onto the housing cover from the ring gear axially towards an opening. It would have been obvious to one of ordinary skill in the art before the effective filing date of the claimed invention to modify Onishi to include a housing where a portion of the ring gear is positioned radially outboard of a portion of the oil reservoir with respect to the axis about which the ring gear rotates and a housing cover which includes a plurality of ribs that guide oil delivered onto the housing cover from the ring gear axially towards an opening taught by Okada, as such a modification would provide the ability to direct splashed oil from the ring gear to desired lubrication points. (Paragraph 64, Okada).
Regarding Claim 3, Onishi further discloses;
wherein gravity propels the oil to the portion of the differential assembly from the secondary oil reservoir via the at least one passage. (Fig. 5 and paragraph 40 demonstrates oil returning to the main oil reservoir from the secondary reservoir 18 via the drain hole 16.)
Regarding Claim 4, Onishi does not disclose wherein the at least one passage is configured to convey oil to a bearing of the differential assembly. However, Bodary teaches;
wherein the at least one passage (conduits 52, 54)  is configured to convey oil to a bearing of the differential assembly. (Column 9, lines 11-40 describe the conduits which may deliver oil to input and output shaft bearings.)
A person of ordinary skill in the art before the effective filing date of the claimed invention would have been motivated to modify Onishi to include at least one passage which is configured to convey oil to a bearing of the differential assembly as taught by Bodary, as the references and the claimed invention are directed to vehicle drive systems. As disclosed by Bodary, it is well known for a vehicle drive system to include at least one passage which is configured to convey oil to a bearing of the differential assembly. It would have been obvious to one of ordinary skill in the art before the effective filing date of the claimed invention to modify Onishi to include at least one passage which is configured to convey oil to a bearing of the differential assembly as taught by Bodary, as such a modification would provide the ability to direct lubricating oil to specific drive components.
Regarding Claim 5, Bodary teaches;
wherein the bearing is a side bearing. (Column 9, lines 23-40 describe the bearing as an output shaft bearing.)
Regarding Claim 6, Onishi does not disclose first and second passages that are configured to convey oil to  first and second side bearings of the differential assembly. However, Bodary teaches;
wherein the at least one passage comprises:
a first passage (first conduit 52) that is configured to convey oil to a first side bearing of the differential assembly; and
a second passage (second conduit 54) that is configured to convey oil to a second side bearing of the differential assembly opposite the first side bearing.
Bodary describes the oil distribution conduits as supplying oil to the input and output shaft bearings but also states, in Column 10, lines 4-29, that the conduits may supply lubricant, among other components, the differential assembly and the bearings that support it.
A person of ordinary skill in the art before the effective filing date of the claimed invention would have been motivated to modify Onishi to include first and second passages that are configured to convey oil to first and second side bearings of the differential assembly as taught by Bodary, as the references and the claimed invention are directed to vehicle drive systems. As disclosed by Bodary, it is well known for a vehicle drive system to include first and second passages that are configured to convey oil to first and second side bearings of the differential assembly. It would have been obvious to one of ordinary skill in the art before the effective filing date of the claimed invention to modify Onishi to include first and second passages that are configured to convey oil to first and second side bearings of the differential assembly as taught by Bodary, as such a modification would provide the ability to direct lubrication to specific drive components. (Column 10, lines 4-29, Bodary).
Regarding Claim 10, Onishi discloses;
a differential assembly (differential apparatus 1; Fig. 1) that is operably coupled to a drive source via a ring gear (ring gear 7; Fig. 5); and
a housing (differential carrier 2) that defines a primary oil reservoir (gear accommodation chamber 3) in which the differential assembly is disposed, (see Fig. 5)
a secondary oil reservoir (lubricating oil reservoir 18),
an opening (opening 15) via which the primary oil reservoir and the secondary oil reservoir are in fluid communication, and
wherein rotation of the ring gear is configured to deliver oil into the secondary oil reservoir from the primary oil reservoir via the opening, (opening 15 allows oil to be thrown off the ring gear and deposited into the secondary chamber housed in the cover),
Onishi does not disclose an electric drive unit, a transmission assembly or that the housing body also contains the transmission assembly. However Bodary teaches;
An electric drive unit, comprising: a motor that drives rotation of a rotor shaft; (Column 2, lines 11-25 of Bodary describe the axle assembly as being attached to a torque source such as an electric motor or an internal combustion engine. See also Fig. 2)
a transmission assembly; (Column 3, line 60 to column 5, line 7 describes the drop gear set 26 and clutch collar 28 as transmitting power from input shaft 24 to the differential unit at pinion 32. See also Fig. 2)
coupled with a differential (differential assembly 34)  via a ring gear (ring gear 180; Fig. 2) (Column 5, Lines 8-36 of Bodary describe the differential assembly (34) as receiving torque from the drive pinion (32) via the ring gear (180).)
a housing in which the transmission assembly and differential assembly are disposed, (differential  housing 62, axle housing 60, cover 84; Fig. 2)
A person of ordinary skill in the art before the effective filing date of the claimed invention would have been motivated to modify Onishi to include an electric drive unit comprising a motor that drives rotation of a rotor shaft, a transmission assembly, and a housing which contains the transmission along with the differential assembly as taught by Bodary, as the references and the claimed invention are directed to vehicle drive systems. As disclosed by Bodary, it is well known for a vehicle drive system to consist of an electric drive comprising a motor that drives a rotor shaft, a transmission assembly, and a housing which contains the transmission along with the differential assembly. It would have been obvious to one of ordinary skill in the art before the effective filing date of the claimed invention to modify Onishi to include an electric drive comprising a motor that drives rotation of a rotor shaft, a transmission assembly, and a housing which contains the transmission along with the differential assembly as taught by Bodary, as such a modification would provide the ability to utilize an electric motor as a motive power source for a vehicle.
Onishi does not disclose;
the opening is axially offset from the ring gear,
a portion of the housing cover includes a plurality of ribs, and the plurality of ribs are configured to guide the oil into a secondary oil reservoir,
However, Okada teaches;
the opening is axially offset from the ring gear (14) (Fig. 6 illustrates a reservoir within the cover and axially offset from the ring gear. A combination of the secondary reservoir of Onishi contained within the cover by the gasket, with the offset reservoir of Okada would result in an axially offset, secondary oil reservoir defined by the gasket with an opening that is also axially offset.)
a housing cover that includes a plurality of ribs; a portion of the housing cover includes a plurality of ribs and the plurality of ribs are configured to guide the oil into a secondary oil reservoir. (Okada, Fig. 11 and paragraph 62 describe the purpose of the sides of passageway 67 to direct oil splashed from the ring gear into the lubricant passageway 67. Figs. 3 and 6 demonstrate the passageway is defined by two ribs and a corresponding trough for directing oil flow towards the opening. A combination of the secondary reservoir of Onishi contained within the cover by the gasket, with the plurality of ribs of Okada would result in the ribs being configured to guide oil into a secondary oil reservoir.)
A person of ordinary skill in the art before the effective filing date of the claimed invention would have been motivated to modify Onishi to include an opening axially offset from the ring gear and a housing cover including a plurality of ribs and the plurality of ribs are configured to guide the oil into a secondary oil reservoir as taught by Okada, as the references and the claimed invention are directed to lubrication methods for vehicle drive systems. As disclosed by Okada, it is well known to include an opening axially offset from the ring gear and a housing cover including a plurality of ribs and the plurality of ribs are configured to guide the oil into a secondary oil reservoir. It would have been obvious to one of ordinary skill in the art before the effective filing date of the claimed invention to modify Onishi to include an opening axially offset from the ring gear and a housing cover including a plurality of ribs and the plurality of ribs are configured to guide the oil into a secondary oil reservoir taught by Okada, as such a modification would provide the ability to direct splashed oil from the ring gear to desired lubrication points. (Paragraph 64, Okada).
Regarding Claim 16, Onishi does not disclose a portion of the ring gear is positioned radially outboard of a portion of the oil reservoir. However, Okada teaches;
a portion of the ring gear is positioned radially outboard of a portion of the secondary oil reservoir with respect to the axis about which the ring gear rotates. (Fig. 3 demonstrates a portion of the ring gear 14 extends beyond the main housing and into the cover. Fig. 6 illustrates a reservoir within the cover and axially offset from the ring gear. A combination of the secondary reservoir of Onishi contained within the cover by the gasket, with the offset reservoir of Okada would result in an axially offset, secondary oil reservoir defined by the gasket with an opening that is also axially offset.)
A person of ordinary skill in the art before the effective filing date of the claimed invention would have been motivated to modify Onishi to include a housing where a portion of the ring gear is positioned radially outboard of a portion of the oil reservoir with respect to the axis about which the ring gear rotates as taught by Okada, as the references and the claimed invention are directed to lubrication methods for vehicle drive systems. As disclosed by Okada, it is well known for a portion of the ring gear to be positioned radially outboard of a portion of the oil reservoir with respect to the axis about which the ring gear rotates. It would have been obvious to one of ordinary skill in the art before the effective filing date of the claimed invention to modify Onishi to include a housing where a portion of the ring gear is positioned radially outboard of a portion of the oil reservoir with respect to the axis about which the ring gear rotates as taught by Okada, as such a modification would provide the ability to direct splashed oil from the ring gear to desired lubrication points. (Paragraph 64, Okada).
Regarding claims 7 and 15;
As noted above in the 112(d) Rejections, these claims do not include the limitations of the independent claims (1 and 10) from which they depend. These claims will be interpreted to include the limitations as described in claims 1 and 10, so that the opening (to the secondary oil reservoir) is axially offset from the ring gear. Claims 7 and 15 then become duplicates of limitations included within claims 1 and 10 and are rejected by the references as noted for claims 1 and 10 above.
Allowable Subject Matter
Claim 17-19 allowed.
The following is an examiner’s statement of reasons for allowance: Independent claim 17 includes the limitation that the tubular conduits are formed as part of the gasket which separates the housing and the housing cover and the primary and secondary oil reservoirs. Claims 18 and 19 depend from independent claim 17.
Claims 2 and 11-14 objected to as being dependent upon a rejected base claim, but would be allowable if rewritten in independent form including all of the limitations of the base claim and any intervening claims.
The following is an examiner’s statement of reasons for allowance: Dependent claim 2 includes the limitation that the tubular conduits are formed as part of the gasket which separates the housing and the housing cover and the primary and secondary oil reservoirs.
Any comments considered necessary by applicant must be submitted no later than the payment of the issue fee and, to avoid processing delays, should preferably accompany the issue fee.  Such submissions should be clearly labeled “Comments on Statement of Reasons for Allowance.”
Response to Arguments
Applicant’s arguments, see page 7, filed 04/29/2025, with respect to the rejection(s) of claim(s) 1 and 10 under 35 U.S.C. 103 have been fully considered and are persuasive.  Therefore, the rejection has been withdrawn.  However, upon further consideration, a new ground(s) of rejection is made in view of Okada (US 2021/0295751 A1). Okada describes an oil directi
Applicant’s arguments, see page 9 line 10, filed 04/29/2025, with respect to the elongated tubular conduits being formed as part of the gasket between the housing, containing the primary oil reservoir, and the housing cover, containing a secondary oil reservoir, have been fully considered and are persuasive.  The rejection of claims 17-19 has been withdrawn. Applicant has made a persuasive argument that it would not have been obvious to combine the elongated tubular conduits of Bodary with the gasket and oil drain of Onishi.
Conclusion
The prior art made of record and not relied upon is considered pertinent to applicant's disclosure.
Camping (US 5,476,582); describes a lubrication filter arrang
Corless (US 2007/0191168 A1); describes a cover with oil collecting and directing features.
THIS ACTION IS MADE FINAL. Applicant is reminded of the extension of time policy as set forth in 37 CFR 1.136(a).
A shortened statutory period for reply to this final action is set to expire THREE MONTHS from the mailing date of this action. In the event a first reply is filed within TWO MONTHS of the mailing date of this final action and the advisory action is not mailed until after the end of the THREE-MONTH shortened statutory period, then the shortened statutory period will expire on the date the advisory action is mailed, and any nonprovisional extension fee (37 CFR 1.17(a)) pursuant to 37 CFR 1.136(a) will be calculated from the mailing date of the advisory action. In no event, however, will the statutory period for reply expire later than SIX MONTHS from the mailing date of this final action.

CITED REFERENCE SUMMARIES: Ref US11440348B1: Claims:
An axle assembly comprising: a differential assembly that is rotatable about an axis and that has a ring gear; a housing assembly that has an axle housing and a differential carrier that supports the differential assembly, wherein the differential carrier is mounted to the axle housing and the axle housing receives the differential assembly; a lubricant reservoir that is disposed inside the axle housing above the differential assembly and that captures lubricant that is splashed by the ring gear, the lubricant reservoir having a first tank and a second tank that is spaced apart from the first tank; a first conduit that routes lubricant from the first tank to an input shaft bearing; and a second conduit that routes lubricant from the second tank to an output shaft bearing.
a differential assembly that is rotatable about an axis and that has a ring gear;
a housing assembly that has an axle housing and a differential carrier that supports the differential assembly, wherein the differential carrier is mounted to the axle housing and the axle housing receives the differential assembly;
a lubricant reservoir that is disposed inside the axle housing above the differential assembly and that captures lubricant that is splashed by the ring gear, the lubricant reservoir having a first tank and a second tank that is spaced apart from the first tank;
a first conduit that routes lubricant from the first tank to an input shaft bearing; and
a second conduit that routes lubricant from the second tank to an output shaft bearing.
The axle assembly of claim 1 wherein the ring gear extends between the first tank and the second tank.
The axle assembly of claim 1 wherein the first tank is disposed above the output shaft.
The axle assembly of claim 1 wherein the second tank is disposed above a differential bearing support that receives a bearing that rotatably supports the differential assembly.
The axle assembly of claim 1 wherein the lubricant reservoir includes a bridge that extends above the ring gear and that interconnects the first tank and the second tank.
The axle assembly of claim 5 wherein the bridge directs lubricant that is splashed by the ring gear to the first tank and the second tank.
The axle assembly of claim 5 wherein the lubricant reservoir has a lip that engages the axle housing and that extends over the bridge, wherein the lip extends from the first tank to the second tank.
The axle assembly of claim 7 wherein the lubricant reservoir has a main panel that extends from the bridge to the lip and that partially defines the first tank and the second tank.
The axle assembly of claim 7 wherein the lubricant reservoir has a main panel that partially defines the first tank and the second tank and that faces toward the differential carrier.
The axle assembly of claim 9 wherein the first tank has an end panel that is disposed opposite the main panel and a bottom panel that slopes downward from the end panel to the main panel.
The axle assembly of claim 10 wherein the first conduit extends from the main panel.
The axle assembly of claim 10 wherein the second tank has an end panel that is disposed opposite the main panel and a bottom panel that slopes downward from the main panel to the end panel.
The axle assembly of claim 12 wherein the second conduit extends from the end panel.
The axle assembly of claim 12 wherein the bottom panel of the first tank is disposed further from a sump portion of the axle housing than the bottom panel of the second tank is disposed from the sump portion.
An axle assembly comprising: a differential assembly that is rotatable about an axis and that has a ring gear; a housing assembly that receives the differential assembly; a lubricant reservoir that is disposed above the differential assembly and that captures lubricant that is splashed by the ring gear; and a lubricant distribution trough that receives lubricant from the lubricant reservoir, the lubricant distribution trough including: a first trough that receives lubricant from the lubricant reservoir; a second trough that is disposed below the first trough; and a dam that separates the first trough from the second trough.
a housing assembly that receives the differential assembly;
a lubricant reservoir that is disposed above the differential assembly and that captures lubricant that is splashed by the ring gear; and
a lubricant distribution trough that receives lubricant from the lubricant reservoir, the lubricant distribution trough including: a first trough that receives lubricant from the lubricant reservoir; a second trough that is disposed below the first trough; and a dam that separates the first trough from the second trough.
a first trough that receives lubricant from the lubricant reservoir;
a second trough that is disposed below the first trough; and
a dam that separates the first trough from the second trough.
The axle assembly of claim 15 wherein the first trough provides lubricant to an input shaft bearing that rotatably supports an input shaft.
The axle assembly of claim 16 wherein the second trough provides lubricant to an interaxle differential unit and a drop gear set that is operatively connected to the input shaft and to a drive pinion that meshes with the ring gear of the differential assembly.
The axle assembly of claim 15 wherein the second trough receives lubricant that is splashed by the differential assembly.
The axle assembly of claim 15 wherein the second trough is divided into an upper portion and a lower portion, wherein the upper portion extends from the dam to the lower portion and is elevated with respect to the lower portion.
The axle assembly of claim 19 wherein the upper portion provides lubricant to an interaxle differential unit and a drop gear set and the lower portion receives lubricant that is splashed by the differential assembly.
Ref US20120295751A1: Claims:
A differential apparatus, comprising: a differential case for accommodating therein a differential mechanism having a central portion, a housing for accommodating therein and rotatably supporting the differential case, a ring gear secured to the differential case to be rotatable together with the differential case and having an outer circumferential portion, wherein the differential case having inner and outer spaces and formed with at least one through bore radially extending between the inner and outer spaces to have the inner and outer spaces held in communication with each other, and the housing has a lubricant oil reservoir portion positioned below the differential case to reserve lubricant oil therein, and a lubricant oil flow guide portion extending in the vicinity of and in side-by-side relationship with the outer circumferential portion of the ring gear, the lubricant oil flow guide portion having a lower end portion soaked in the lubricant oil of the lubricant oil reservoir portion and an upper end portion positioned in the vicinity of the central portion of the differential mechanism to guide the lubricant oil stirred up from the lubricant oil reservoir portion with the rotation of the ring gear to ensure that the lubricant oil is discharged toward the central portion of the differential mechanism through the through bore.
a differential case for accommodating therein a differential mechanism having a central portion,
a housing for accommodating therein and rotatably supporting the differential case,
a ring gear secured to the differential case to be rotatable together with the differential case and having an outer circumferential portion, wherein
the differential case having inner and outer spaces and formed with at least one through bore radially extending between the inner and outer spaces to have the inner and outer spaces held in communication with each other, and
the housing has a lubricant oil reservoir portion positioned below the differential case to reserve lubricant oil therein, and a lubricant oil flow guide portion extending in the vicinity of and in side-by-side relationship with the outer circumferential portion of the ring gear, the lubricant oil flow guide portion having a lower end portion soaked in the lubricant oil of the lubricant oil reservoir portion and an upper end portion positioned in the vicinity of the central portion of the differential mechanism to guide the lubricant oil stirred up from the lubricant oil reservoir portion with the rotation of the ring gear to ensure that the lubricant oil is discharged toward the central portion of the differential mechanism through the through bore.
The differential apparatus as set forth in claim 1 , wherein the housing is constituted by a differential carrier accommodating therein and rotatably supporting the differential case, and a carrier cover secured to the differential carrier forming together with the differential carrier a housing chamber accommodating therein the differential case and the ring gear, the lubricant oil reservoir portion has a reservoir chamber formed to occupy the lower portion of the housing chamber by the lower portions of the differential carrier and the carrier cover to reserve the lubricant oil therein, the lubricant oil flow guide portion having a flow guide groove formed in the inner wall of the carrier cover to extend in the vicinity of and in side-by-side relationship with the outer circumferential portion of the ring gear and to be open toward the central portion of the differential mechanism, the flow guide groove having a lower end portion soaked in the lubricant oil of the reservoir chamber, and an upper end portion positioned in the vicinity of the central portion of the differential mechanism.
the housing is constituted by a differential carrier accommodating therein and rotatably supporting the differential case, and a carrier cover secured to the differential carrier forming together with the differential carrier a housing chamber accommodating therein the differential case and the ring gear,
the lubricant oil reservoir portion has a reservoir chamber formed to occupy the lower portion of the housing chamber by the lower portions of the differential carrier and the carrier cover to reserve the lubricant oil therein,
the lubricant oil flow guide portion having a flow guide groove formed in the inner wall of the carrier cover to extend in the vicinity of and in side-by-side relationship with the outer circumferential portion of the ring gear and to be open toward the central portion of the differential mechanism, the flow guide groove having a lower end portion soaked in the lubricant oil of the reservoir chamber, and an upper end portion positioned in the vicinity of the central portion of the differential mechanism.
The differential apparatus as set forth in claim 1 , wherein the lubricant oil flow guide portion has a lubricant oil inlet port positioned in the reservoir chamber to have the lubricant oil introduced therethrough from the lubricant oil reservoir portion, a lubricant oil outlet port open toward the central portion of the differential mechanism to have the lubricant oil discharged toward the central portion of the differential mechanism, and a lubricant oil passageway extending between the lubricant oil inlet port and the lubricant oil outlet port to have the lubricant oil inlet port held in communication with the lubricant oil outlet port.
the lubricant oil flow guide portion has a lubricant oil inlet port positioned in the reservoir chamber to have the lubricant oil introduced therethrough from the lubricant oil reservoir portion, a lubricant oil outlet port open toward the central portion of the differential mechanism to have the lubricant oil discharged toward the central portion of the differential mechanism, and a lubricant oil passageway extending between the lubricant oil inlet port and the lubricant oil outlet port to have the lubricant oil inlet port held in communication with the lubricant oil outlet port.
The differential apparatus as set forth in claim 3 , wherein the lubricant oil passageway has a width perpendicular to the flow direction of the lubricant oil flowing from the lubricant oil inlet port to the lubricant oil outlet port, the width being gradually decreased from the lubricant oil inlet port to the lubricant oil outlet port.
the lubricant oil passageway has a width perpendicular to the flow direction of the lubricant oil flowing from the lubricant oil inlet port to the lubricant oil outlet port, the width being gradually decreased from the lubricant oil inlet port to the lubricant oil outlet port.
Ref US5476582A: Claims:
A filter cover apparatus for a differential mechanism comprising: (a) a cover member defining an interior cavity, said cover member having an open rear end for attachment to said differential mechanism, a front end, an upper end, and a lower end, said cavity defining an oil reservoir near said lower end; (b) a lip member near said upper end such that a gear from a power transmitting gear unit of said differential mechanism is adjacent said lip member; (c) a filter housing including a first end adjacent said upper end, a second end adjacent said lower end, an inlet near the first end, an outlet near the second end of the housing, and at least two perforated members interposed between the first and second ends of the housing, each said perforated member having a first side facing the first end of the filter housing; and (d) a wafer magnet located on the first side of each of said perforated members; wherein said filter housing and lip member being positioned within said interior cavity and shaped and dimensioned such that said lip member opens into the inlet of and extends outwardly from the filter housing; said perforated members being parallel panel shaped members and each of said wafer magnets being positioned such that said wafer magnets on adjacent perforated members are not aligned along a common line perpendicular to said perforated members.
(a) a cover member defining an interior cavity, said cover member having an open rear end for attachment to said differential mechanism, a front end, an upper end, and a lower end, said cavity defining an oil reservoir near said lower end;
(b) a lip member near said upper end such that a gear from a power transmitting gear unit of said differential mechanism is adjacent said lip member;
(c) a filter housing including a first end adjacent said upper end, a second end adjacent said lower end, an inlet near the first end, an outlet near the second end of the housing, and at least two perforated members interposed between the first and second ends of the housing, each said perforated member having a first side facing the first end of the filter housing; and
(d) a wafer magnet located on the first side of each of said perforated members;
wherein said filter housing and lip member being positioned within said interior cavity and shaped and dimensioned such that said lip member opens into the inlet of and extends outwardly from the filter housing;
said perforated members being parallel panel shaped members and each of said wafer magnets being positioned such that said wafer magnets on adjacent perforated members are not aligned along a common line perpendicular to said perforated members.
The filter cover apparatus of claim 1 wherein said perforated members are screen members.
The filter cover apparatus of claim 2 wherein said filter housing further comprises a transparent cover forming a portion of the front end of said cover member and positioned adjacent said perforated members.
The filter cover apparatus of claim 3 wherein said cover member has a fill hole passing through the front end of said cover member and a fill plug for sealing the fill hole, said fill hole being adjacent said filter housing.
The filter cover apparatus of claim 4 wherein said cover member has a drain hole passing through the front end of said cover member and a drain plug for sealing the drain hole, said drain hole being positioned proximate said lower end.
The filter cover apparatus of claim 5 wherein said cover member further comprises a temperature sending unit extending through the front end of said cover member to allow a driver to monitor the temperature in the differential mechanism, said temperature sending unit being positioned between the filter housing and said lower end.
The filter cover apparatus of claim 1 wherein said perforated members each comprise a solid shelf having a first end, a second end, and an opening passing through said first end of said shelf; said wafer magnets being located on a said second end of said shelves.
The filter cover apparatus of claim 7 wherein said filter housing further comprises a transparent front cover forming a portion of said front end and secured to said filter housing adjacent said perforated members with fastening means which permit said front cover to be removed from the filter housing.
The filter cover apparatus of claim 8 wherein said cover member has a fill hole passing through the front end of said cover member and a fill plug for sealing the fill hole, said fill hole being adjacent said filter housing.
The filter cover apparatus of claim 9 wherein said cover member has a drain hole passing through the front end of said cover member and a drain plug for sealing the drain hole, said drain hole being proximate said lower end.
The filter cover apparatus of claim 10 wherein said cover member further comprises a temperature sending unit extending through the front end of said cover member to allow a driver to monitor the temperature in the differential mechanism, said temperature sending unit being positioned between the filter housing and said lower end.
The filter cover apparatus of claim 1 wherein said wafer magnets on alternate perforated members are aligned along a common line perpendicular to said perforated members.
A filter cover assembly for a differential housing mechanism comprising: a cover member having an interior cavity, said cover member having an open rear end for attachment to the differential housing mechanism, a front end, an upper end, and a lower end, said cavity defining an oil reservoir near said lower end; a lip member attached to said cover member near said upper end of said interior cavity; and, a filter housing mounted in said cavity and including a first end adjacent said upper end, a second end adjacent said lower end, at least two spaced apart wafer magnets interposed between the first and second ends of said filter housing, an inlet in the first end of said filter housing, an outlet in the second end of the filter housing and opening into said interior cavity of said cover member, first and second spaced apart solid shelf members which each carry one of the wafer magnets, and a transparent cover forming a portion of said front end and being attached to said filter housing and positioned adjacent said shelf members; the first shelf member having an opening through which oil can flow toward the wafer magnet on the second shelf member; the second shelf member having an opening through which oil can flow toward said outlet; said filter housing and lip member being positioned within said interior cavity and shaped and dimensioned such that said lip member opens into the inlet of said filter housing to direct an oil flow through said inlet, over each of said magnet, and out said outlet into said interior cavity.
a cover member having an interior cavity, said cover member having an open rear end for attachment to the differential housing mechanism, a front end, an upper end, and a lower end, said cavity defining an oil reservoir near said lower end;
a lip member attached to said cover member near said upper end of said interior cavity; and,
a filter housing mounted in said cavity and including a first end adjacent said upper end, a second end adjacent said lower end, at least two spaced apart wafer magnets interposed between the first and second ends of said filte
[Truncated to input limit]