Patent Publication Number: US-2021164572-A1

Title: Axle seal having a multi-edge contact

Description:
RELATED APPLICATIONS 
     This application is a Continuation application of pending U.S. Non-Provisional patent application Ser. No. 16/040,526, filed Jul. 19, 2018 and titled “Axle Seal Having a Multi-Edge Contact” and is related to U.S. Provisional Patent Application Ser. No. 62/534,507 filed Jul. 19, 2017 and entitled “Axle Seal Having a Multi-Edge Contact,” wherein U.S. Non-Provisional patent application Ser. No. 16/040,526 is a continuation-in-part of U.S. Non-Provisional patent application Ser. No. 15/388,068 filed Dec. 22, 2016 and entitled “Axle Seal” and this application claims the benefit of priority of the filing dates of U.S. Provisional Patent Application Ser. No. 62/534,507, U.S. Non-Provisional patent application Ser. No. 15/388,068 and U.S. Non-Provisional patent application Ser. No. 16/040,526, the contents of all of which are incorporated by reference herein in their entireties. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to a seal and more particularly to a self-sealing axel seal with a dual contact lip for use with an automotive, marine and/or industrial axle. 
     BACKGROUND OF THE INVENTION 
     Axle seals are well known in the art and are used on machinery that have a drive train that includes an axle that is connected to a gear box. Typically, the axle seal has two primary functions. The first function is to prevent the gear oil from escaping from the drive train. If the gear oil is allowed to leak from the drive train, the oil would contaminate other various parts of the machinery, such as brake shoes. Additionally, if too much oil is allowed to escape from the drive train, the drive train components, such as the transmission and/or differential, there may not be enough oil to lubricate the drive train components causing them to overheat. The second function is to prevent dirt and other contaminants from entering the drive train which could severely damage delicate gears and other components. 
     Unfortunately, however, as current seal designs become worn the interface between the seal and the axle begins to breakdown thereby letting small amounts of oil to escape and allowing some contaminants to enter the drive train. This is undesirable because as the oil within the axle housing becomes depleted, there is less lubrication between the drive train components and thus, the drive train components experience a greater amount of frictional wear due to overheating and under-lubrication. Additionally, as contaminants, such as sand, dirt and other particles, enter the drive train, these contaminants cause additional wear and structural damage to the drive train components. 
     SUMMARY OF THE INVENTION 
     An axle seal is provided and includes a seal element having a seal element top, a seal element bottom, a seal element mounting lip which extends downwardly from the seal element bottom, and a seal element sleeve, wherein the seal element sleeve is securely and sealingly associated with the seal element mounting lip, and wherein the seal element includes, a first surface having a first edge, and a second surface having a second edge, wherein the first surface and second surface extend circumferentially away from the seal element, and wherein the first surface and second surface are separated from each other to form an edge channel which extends circumferentially around the seal element. 
     An axle seal is provided and includes an axle seal body having a first seal body end and a second seal body end, wherein the axle seal body defines a seal body cavity, a first seal body end opening and second seal body end opening, wherein the first seal body end opening is communicated with the second seal body end opening via the seal body cavity; and a seal element having a seal element top, a seal element bottom, a seal element mounting lip which extends downwardly from the seal element bottom, and a seal element sleeve, wherein the seal element sleeve is securely and sealingly associated with the seal element mounting lip, and wherein the seal element includes, a first surface having a first edge, and a second surface having a second edge, wherein the first surface and second surface extend circumferentially away from the seal element, and wherein the first surface and second surface are separated from each other to form an edge channel which extends circumferentially around the seal element. 
     A seal element for an axle seal is provided and includes a seal element top, a seal element bottom, a seal element mounting lip which extends downwardly from the seal element bottom, and a seal element sleeve, wherein the seal element sleeve is securely and sealingly associated with the seal element mounting lip, and wherein the seal element includes, a first surface having a first edge, and a second surface having a second edge, wherein the first surface and second surface extend circumferentially away from the seal element, and wherein the first surface and second surface are separated from each other to form an edge channel which extends circumferentially around the seal element. 
     An axle seal having a seal element is provided, wherein the seal element includes a seal element top, a seal element bottom, a seal element mounting lip which extends downwardly from the seal element bottom, and a seal element sleeve, wherein the seal element sleeve is securely and sealingly associated with the seal element mounting lip, and wherein the seal element includes a circumferential outer edge portion which extends outwardly from the seal element sleeve to form a circumferential lip around the seal element sleeve and wherein the seal element defines a seal element opening which communicates the seal element top with the seal element bottom. 
     An axle seal is provided and includes an axle seal body having a first seal body end and a second seal body end, wherein the axle seal body defines a seal body cavity, a first seal body end opening and second seal body end opening, wherein the first seal body end opening is communicated with the second seal body end opening via the seal body cavity; and a seal element having a seal element top, a seal element bottom, a seal element mounting lip which extends downwardly from the seal element bottom, and a seal element sleeve, wherein the seal element sleeve is securely and sealingly associated with the seal element mounting lip, and wherein the seal element includes a circumferential outer edge portion which extends outwardly from the seal element sleeve to form a circumferential lip around the seal element sleeve and wherein the seal element defines a seal element opening which communicates the seal element top with the seal element bottom, and wherein the seal element is securingly and sealingly associated with the axle seal body to cover the first seal body end opening. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The foregoing and other features and advantages of the present invention will be more fully understood from the following detailed description of illustrative embodiments, taken in conjunction with the accompanying drawings in which like elements are numbered alike: 
         FIG. 1  is a side view of a multi-edge axle seal for axles, in accordance with one embodiment of the invention. 
         FIG. 2  is a sectional side view of the multi-edge axle seal of  FIG. 1 . 
         FIG. 3  is a top down view of the multi-edge axle seal of  FIG. 1   
         FIG. 4  is a side view of the axle seal assembly incorporating the multi-edge axle seal of  FIG. 1 , in accordance with one embodiment of the invention. 
         FIG. 5  is an exploded side view of the axle seal assembly of  FIG. 4 . 
         FIG. 6  is a top down side perspective view of the axle seal assembly of  FIG. 4 . 
         FIG. 7  is a sectional side view of one side of the axle seal assembly of  FIG. 4 . 
         FIG. 8  is a sectional side view of the axle seal assembly of  FIG. 4 , located within an axle housing and associated with an axle, in accordance with one embodiment of the invention. 
         FIG. 9  is a sectional side view of the axle seal assembly of  FIG. 4 , located within an axle housing and associated with an axle. 
         FIG. 10  is a sectional side view of the axle seal assembly of  FIG. 4 , located within an axle housing and associated with an axle. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     In accordance with the present invention, an axle seal for use with automotive, marine and/or industrial machinery having an axle is provided and discussed herein with regards to an axle for an automobile. It should be appreciated that in one embodiment, the unique multi-edge axle seal of the present invention may be used on vehicles that operate in dirt or mud, such as a vehicle that races on dirt and/or mud tracks. The unique and novel design of the multi-edge axle seal of the present invention acts to keep dirt, mud and other contaminants out of the axle housing, thereby minimizing damage and/or wear and tear. It should be further appreciated that although the axle seal of the present invention is discussed herein with regards to an automobile axle, the axle seal of the present invention may be used with any type of axle suitable to the desired end purpose. 
     Referring to  FIG. 1 ,  FIG. 2  and  FIG. 3 , a multi-edge axle seal  100  is shown in accordance with one embodiment of the invention and includes a seal element  102  having a seal element top  104 , a seal element bottom  106 , a seal element mounting lip  108  and a multi-edge contact interface  110 , wherein the seal element mounting lip  108  extends downwardly from the seal element bottom  106 . The seal element  102  further includes a seal element sleeve  112  which is securely associated with the seal element  102  via the seal element mounting lip  108 . In one embodiment, the seal element sleeve  112  is attached to, fused to or otherwise bonded to the seal element mounting lip  108  via an adhesive bonding, a chemical bonding, a mechanical means of attachment and/or any attachment, fusing and/or bonding method as desired and known in the art and suitable to the desired end purpose. 
     The seal element  102  defines an axle opening  114  having an axle opening diameter D, wherein the axle opening  114  is located in and/or proximate to the center of the seal element  102 , where in one embodiment the axle opening diameter D may be about 0.875 inches. The seal element  102  includes a first surface  116  which may or may not be flat and which extends outwardly from and around the circumference of the seal element sleeve  110 . The first surface  116  is angled downwardly from the horizontal at an angle β, wherein β may be about 21° (it is contemplated that other angles between 0° (horizontal) and 90° (downward) may be used as desired) and forms the first edge  118  of the multi-edge contact surface  110 . The seal element  102  further includes a second surface  120  which may or may not be flat and which extends outwardly from and around the circumference of the seal element sleeve  110 . The second surface  120  is angled downwardly from the horizontal at an angle δ, wherein δ may be about 21° (it is contemplated that other angles between 0° (horizontal) and 90° (downward) may be used as desired) and forms the second edge  122  of the multi-edge contact surface  110 . It should be appreciated that the first edge  118  and second edge  122  are separated vertically from each other by a width W, which in one embodiment may be about 0.09 inches (it is contemplated that other Widths W may be used as desired), to form an edge channel  124  which also extends circumferentially around the seal element sleeve  110 . 
     Additionally, the seal element top  104  includes a first raised portion  126  and a second raised portion  128  separated by a first valley portion  130 , wherein the first raised portion  126  and second raised portion  128  are located inward from the seal element mounting lip  108  toward the center of the seal element  102 . The seal element  102  also includes a substantially flat center portion  132  located between the second raised portion  128  and the axle opening  114 . It should be appreciated that the surface between the first and second raised portions  126 ,  128  and the first valley portion  130  and the center portion  132  and the second raised portion  128  are angled to provide a gradual transition. The axle opening  114  is preferably sized such that the axle opening diameter D is smaller than the diameter of an axle passing there-through by about 20% (range of 10% to 40%). Moreover, it is contemplated that the seal element  102  is preferably constructed from a material that is resilient to sealingly interact act with the axle when the axle is located within the axle opening  114 . For example, the seal element  102  may be constructed from a polymer material, such as nitrile, neoprene, plastic, rubber and/or any other material suitable to the desired end purpose.  FIG. 2  illustrates the size of a seal element  102  in accordance with one embodiment of the invention, wherein the dimensions shown are in inches. 
     Referring to  FIG. 4  to  FIG. 7 , an axle seal assembly  200  is shown in accordance with one embodiment of the invention and includes a substantially rigid seal body  202 , wherein the seal body  202  includes a first seal body end  204  defining a first seal body end opening  206  and a second seal body end  208  defining a second seal body end opening  210 . The seal body  202  is substantially cylindrical in shape and defines a seal cavity  212  having a seal cavity length L, wherein the seal cavity  212  communicates the first seal body end opening  206  with the second seal body end opening  210 . The axle seal assembly  200  further includes a first multi-edge axle seal  100 ,  214  securely associated with the first seal body end  204  and a second multi-edge axle seal  100 ,  216  securely associated with the second seal body end  208 . The first multi-edge axle seal  100 ,  214  and second multi-edge axle seal  100 ,  216  are securely associated with the first seal body end  204  and second seal body end  208 , respectively, via the seal element sleeve  112  which is securely associated with the seal body  202  to cover the first and second seal body end opening  206 ,  208 , respectively. As such, the axle seal assembly  200  is configured to associate with the axle such that the axle is contained within the seal cavity  212  and extends out of the axle openings  114  of both the first multi-edge axle seal  100 ,  214  and the second multi-edge axle seal  100 ,  216 . 
     It should be appreciated that the seal cavity  212  defined between the first multi-edge axle seal  214  and second multi-edge axle seal  216  may have a lubricant deposited therein to further reduce rotational friction and to improve seal integrity, wherein the seal cavity  212  acts as a reservoir for the lubricant. Because the axle opening  114  is smaller than the axle that is contained therein, the material around the axle opening  114  compressingly contacts the axle creating a seal between the seal element  102  and the axle which causes the lubricant to be contained within the seal cavity  212  to provide constant lubricant for the axle. 
     Referring to  FIG. 8 ,  FIG. 9  and  FIG. 10 , when the axle seal assembly  200  is located within an axle housing  300 , each of the first edge  118  and second edge  122  of the multi-edge contact surface  100  of the seal element  102  is compressed against the inner wall  302  of the axle housing (tube)  300 . This advantageously forms a seal between the first edge  118  and second edge  122  of the multi-edge contact surface  100  of the seal element  102  and the inner wall  302  of the axle housing  300 . Upon insertion of the axle seal assembly  200  into the axle housing  300 , the axle seal  100 ,  200  will be securely held inside the axle housing (tube). This is due to the friction between the first edge  118  and second edge  122  of the multi-edge contact surface  100  of the seal element  102  and the inner wall  302  of the axle housing  300  (similar to a “finger trap” device). This locking method is what holds the axle seal assembly  200  inside of the axle housing (tube)  300  thus preventing and/or minimizing leakage of lubricant. It should be appreciated that the axle seal assembly  200  is configured to associate with an axle  234  such that the axle  234  is contained within the seal cavity  212  and extends out of the axle openings  114  of both the first multi-edge axle seal  100 ,  214  and the second multi-edge axle seal  100 ,  216 . When the axle seal assembly  200  is associated with the axle  234 , the material of the center portion  132  of the seal element  102  that surrounds the axle opening  114  will heat up (to approximately 270°-300°) as the axle  234  spins upon initial operation. This advantageously causes the material of the center portion  132  that contacts the axle  234  to become harder and more rigid (less pliable), thus preventing and/or minimizing leakage of lubricant from the lubricant reservoir within the seal cavity  212 . It should be appreciated that the lubricant within the reservoir within the seal cavity  212  may be any lubricant desired suitable to the desired end purpose, such as a low temperature melt grease. Additionally, the material of the seal element  102  that includes the first raised portion  126 , the second raised portion  128  and the first valley portion  130  does not heat up as much as the center portion  132  and remains pliable thereby allowing the seal element  102  to flex during operation of the axle  234 . It should be appreciated that the edge channel  124  may advantageously act as a lubricant reservoir and/or a ‘catch’ channel to prevent/limit debris from going into the seal cavity  212 . 
     Moreover, additional information is provided in the attached appendix where the information does not and is not intended to limit the scope of the invention. Accordingly, all of the information contained herein may be combined together (individually or wholly) or taken singly to achieve varying embodiments of the invention and to add to the scope of the invention without limiting the invention to a particular embodiment. 
     It should be appreciated that while the invention has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that some or all of the elements of the embodiments disclosed herein may be combined in whole or in part and that various changes, omissions and/or additions may be made and equivalents may be substituted for elements thereof without departing from the spirit and scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the scope thereof. Moreover, it is contemplated that elements of one embodiment may be combined with elements of other embodiments as desired. Therefore, it is intended that the invention not be limited to a particular embodiment disclosed herein as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments (individually and/or combined) falling within the scope of the appended claims and/or information. Moreover, unless specifically stated any use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another.