Office Action 3: Notice of Allowance (2025-10-15)

CLAIMS:
AMENDMENTS TO THE CLAIMS

This listing of claims will replace all prior versions and listings of claims in the application.

Listing of Claims:

1\. (Currently Amended) 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 that is axially offset from the ring gear and at least one passage, wherein 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, 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, and 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, 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.

2\. (Canceled)

3\. (Original) 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\. (Original) 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\. (Original) The electric drive unit of claim 4, wherein the bearing is a side bearing.

6\. (Original) 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\. (Currently Amended) The electric drive unit of claim 1, wherein the opening is riented to generally face teeth of the ring gear.

8\. - 9. (Canceled)

10\. (Currently Amended) 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;
a housing cover that includes a plurality of ribs and 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 primary oil reservoir and the secondary oil reservoir are in fluid communication, the opening being axially offset from the ring gear, and at least one

passage, wherein the at least one passage is defined by at least one elongated tubular conduit, wherein rotation of the ring gear is configured to deliver oil onto a portion of the housing cover that includes the plurality of ribs, and the plurality of ribs are configured to guide the oil into the secondary oil reservoir from the primary oil reservoir via the opening-;anda gasket coupled with the housing cover such that the housing cover and the gasket cooperate to define a secondary oil reserve.

11\. (Canceled)

12\. (Currently Amended) The electric drive unit of laim 10, 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\. (Original) 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\. (Currently Amended) The electric drive unit of laim 10, 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\. (Currently Amended) The electric drive unit of claim 10, wherein the opening is riented to generally face teeth of the ring gear.

16\. (Previously Presented) The electric drive unit of claim 10, wherein 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.

Appln. No.: 18/411,853

17\. (Previously Presented) 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, wherein the housing includes a housing body that defines the primary reservoir, a housing cover, and a gasket that is disposed between the housing cover and the housing body and that forms the elongated tubular conduit.

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

19\. (Original) 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\. (Canceled)

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 01/12/2025 and amended on 08/27/2025. Claims 1, 3-7, 10, and 12-19 are currently pending and have been examined. Claims 2 and 11, as well as 8, 9, and 20 have been cancelled by amendment.
EXAMINER’S AMENDMENT
Authorization for this examiner’s amendment was given in an interview with Attorney Kevin T. Grzelak on 09/25/2025.
Claim 10, lines 14-15 is amended such that the limitation reads “a gasket including the at least one elongated tubular conduit, coupled with the housing cover such that the housing cover and the gasket cooperate to define a secondary oil reserve.”
This amendment adds the words including the at least one elongated tubular conduit after the words a gasket.
Allowable Subject Matter
Claims 1, 3-7, 10, 12-19 allowed.
The following is an examiner’s statement of reasons for allowance:
Independent claims 1, 10, and 17 are allowable because none of the cited references either alone or in combination disclose the combination of limitations as claimed. Specifically, the references fail to disclose;
Regarding 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.
Regarding claim 10;
a gasket including the at least one elongated tubular conduit coupled with the housing cover such that the housing cover and the gasket cooperate to define a secondary oil reserve.
Regarding claim 17;
a gasket that is disposed between the housing cover and the housing body and that forms the elongated tubular conduit.
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.”

APPLICANT REBUTTAL: REMARKS
By way of this amendment, claims 1, 7, 10, 12 and 14-15 have been amended, and claims
2 and 11 have been canceled. Claims 8, 9 and 20 were previously canceled. Claims 1, 3-7, 10 and 12-19 remain pending. Applicant respectfully requests reconsideration and allowance of the present application.
Applicant has amended the claim 1 to change the language as suggested by the Examiner, thereby rendering the objection moot.
The Examiner rejected claims 10-16 under 35 U.S.C. @ 112(b) as being indefinite for failing to particularly point out and distinctly claim the subject matter which the inventor or a joint inventor regards as the invention. Applicant has amended claim 10 as suggested by the Examiner to clarify the claim language and respectfully requests that the rejection to the claims under 35 U.S.C. @ 112(b) therefore be withdrawn.
The Examiner further rejected claims 7 and 15 under 35 U.S.C. @ 112(d) 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. Applicant has amended claims 7 and 15 to remove the potentially contradictory language with the opening axially aligned with the ring gear, and respectfully requests that the rejection to the claims under 35 U.S.C. @ 112(d) therefore be withdrawn.
Claims 1, 3-7, 10, 15 and 16 under 35 U.S.C. @ 103 as being unpatentable over Onishi (JP 20141 19084A) in view of Bodary (U.S. Patent No. 11,440,348) and Okada (U.S. Patent Application Publication No. 2021/029575 1). Additionally, the Examiner has acknowledged allowable subject matter in that claims 17-19 are allowed, and claims 2 and 11-14 are 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.
Applicant appreciates the Examiner's acknowledgment of allowable subject matter. In order to expedite allowance of the present application, Applicant has amended the claims to incorporate the allowable subject matter. Specifically, independent claim 1 has been amended to incorporate the limitations of allowable dependent claim 2, and has canceled claim 2.
Additionally, Applicant has amended independent claim 10 to incorporate the allowable limitations of dependent claim 11, and has canceled claim 11.
Accordingly, Applicant submits that all of the claims incorporate allowable subject
matter, such that all of the pending claims are now in condition for allowance, which action is respectfully solicited.
If any issues remain pending after consideration of this response, Applicant respectfully requests the Examiner to contact the undersigned attorney.
Respectfully submitted,


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]