Patent Description:
An axle assembly having an electric motor module is disclosed in <CIT>. <CIT> discloses a vehicle drive apparatus that has a planetary gear mechanism that is coupled to a rotor of an electrical machine via a rotor shaft. <CIT> discloses a planetary gear set with rings mounted to opposing ends of a planet gear carrier.

An axle assembly according to the invention is provided as set out in claim <NUM>.

The axle assembly <NUM> may provide torque to one or more traction wheel assemblies that may include a tire mounted on a wheel. The wheel may be mounted to a wheel hub that may be rotatable about a wheel axis.

One or more axle assemblies may be provided with the vehicle. As is best shown with reference to <FIG> and <FIG>, the axle assembly <NUM> may include a housing assembly <NUM> and at least one axle shaft <NUM>, and includes a differential assembly <NUM> and an electric motor module <NUM>. As is best shown in <FIG> and <FIG>, the axle assembly <NUM> may also include a first lubricant passage <NUM>, a second lubricant passage <NUM>, a gear reduction module <NUM>, a shift mechanism <NUM>, or combinations thereof.

The axle housing <NUM> may receive and may support the axle shafts <NUM>. In at least one configuration, the axle housing <NUM> may include a center portion <NUM> and at least one arm portion <NUM>.

The center portion <NUM> may be disposed proximate the center of the axle housing <NUM>. The center portion <NUM> may define a cavity that may at least partially receive the differential assembly <NUM>. As is best shown in <FIG>, a lower region of the center portion <NUM> may at least partially define a sump portion <NUM> that may contain or collect lubricant <NUM>. Lubricant <NUM> in the sump portion <NUM> may be splashed by a ring gear of the differential assembly <NUM> as will be discussed in more detail below.

Referring to <FIG>, the center portion <NUM> may include a carrier mounting surface <NUM>. The carrier mounting surface <NUM> may facilitate mounting of the differential carrier <NUM> to the axle housing <NUM>. For example, the carrier mounting surface <NUM> may face toward and may engage the differential carrier <NUM> and may have a set of holes that may be aligned with corresponding holes on the differential carrier <NUM>. Each hole may receive a fastener, such as a bolt, that may couple the differential carrier <NUM> to the axle housing <NUM>.

Referring to <FIG>, one or more arm portions <NUM> may extend from the center portion <NUM>. For example, two arm portions <NUM> may extend in opposite directions from the center portion <NUM> and away from the differential assembly <NUM>. The arm portions <NUM> may have substantially similar configurations. For example, the arm portions <NUM> may each have a hollow configuration or tubular configuration that may extend around and may receive a corresponding axle shaft <NUM> and may help separate or isolate the axle shaft <NUM> or a portion thereof from the surrounding environment. An arm portion <NUM> or a portion thereof may or may not be integrally formed with the center portion <NUM>. It is also contemplated that the arm portions <NUM> may be omitted.

Referring to <FIG> and <FIG>, the differential carrier <NUM> may be mounted to the center portion <NUM> of the axle housing <NUM>. The differential carrier <NUM> may support the differential assembly <NUM> and may facilitate mounting of the electric motor module <NUM>. As is best shown with reference to <FIG>, the differential carrier <NUM> may include one or more bearing supports <NUM>, a mounting flange <NUM>, and a bearing support wall <NUM>.

Referring primarily to <FIG> and <FIG>, a bearing support <NUM> may support a roller bearing assembly that may rotatably support the differential assembly <NUM>. For example, two bearing supports <NUM> may be received in the center portion <NUM> and may be located proximate opposite sides of the differential assembly <NUM>. The bearing support <NUM> may be provided in various configurations. For example, a bearing support <NUM> may include a pair of legs that extend from the differential carrier <NUM>. A bearing cap may be mounted to the legs and may arch over a roller bearing assembly that may rotatably support the differential assembly <NUM>. As another example, the bearing support <NUM> may be received in a roller bearing assembly, which in turn may support the differential assembly <NUM>.

The mounting flange <NUM> may facilitate mounting of the electric motor module <NUM>. The mounting flange <NUM> may be configured as a ring that may extend outward and away from an axis <NUM> and may extend around the axis <NUM>. The mounting flange <NUM> may include a set of fastener holes that may be configured to receive a fastener that may secure the electric motor module <NUM> to the mounting flange <NUM>.

Referring to <FIG> and <FIG>, the bearing support wall <NUM> may support bearings that may rotatably support other components of the axle assembly <NUM>. For example, the bearing support wall <NUM> may support bearings that may rotatably support a drive pinion <NUM>, bearings that may rotatably support a rotor of the electric motor module <NUM>, or both. The bearing support wall <NUM> may extend in an axial direction away from the axle housing <NUM> and may extend around the axis <NUM>. The bearing support wall <NUM> may define a hole that may receive the drive pinion <NUM>. The bearing support wall <NUM> may be integrally formed with the differential carrier <NUM> or may be a separate component that is fastened to the differential carrier <NUM>.

Referring to <FIG>, <FIG>, and <FIG>, the differential assembly <NUM> may be at least partially received in the center portion <NUM> of the housing assembly <NUM>. The differential assembly <NUM> may be rotatable about a differential axis <NUM> and may transmit torque to the axle shafts <NUM> and wheels. The differential assembly <NUM> may be operatively connected to the axle shafts <NUM> and may permit the axle shafts <NUM> to rotate at different rotational speeds in a manner known by those skilled in the art. The differential assembly <NUM> may have a ring gear <NUM> that may have teeth the mate or mesh with the teeth of a gear portion of a drive pinion <NUM>. Accordingly, the differential assembly <NUM> may receive torque from the drive pinion via the ring gear <NUM> and transmit torque to the axle shafts <NUM>.

The drive pinion <NUM> may provide torque to the ring gear <NUM>. In an axle assembly that includes a gear reduction module <NUM>, the drive pinion <NUM> may operatively connect the gear reduction module <NUM> to the differential assembly <NUM>. In at least one configuration, the drive pinion <NUM> may be rotatable about the axis <NUM> and may be rotatably supported on another component, such as the bearing support wall <NUM>.

Referring to <FIG>, the axle shafts <NUM> may transmit torque from the differential assembly <NUM> to corresponding wheel hubs and wheels. Two axle shafts <NUM> may be provided such that each axle shaft <NUM> extends through a different arm portion <NUM> of axle housing <NUM>. The axle shafts <NUM> may extend along and may be rotatable about an axis, such as the differential axis <NUM>. Each axle shaft <NUM> may have a first end and a second end. The first end may be operatively connected to the differential assembly <NUM>. The second end may be disposed opposite the first end and may be operatively connected to a wheel. Optionally, gear reduction may be provided between an axle shaft <NUM> and a wheel.

Referring to <FIG>, the electric motor module <NUM> may be mounted to the differential carrier <NUM> and is operatively connectable to the differential assembly <NUM>. For instance, the electric motor module <NUM> may provide torque to the differential assembly <NUM> via the drive pinion <NUM>. The electric motor module <NUM> may be primarily disposed outside the differential carrier <NUM>. In addition, the electric motor module <NUM> may be axially positioned between the axle housing <NUM> and the gear reduction module <NUM>. In at least one configuration, the electric motor module <NUM> includes a motor housing <NUM> and a rotor <NUM>, and a cover <NUM> and may include a coolant jacket <NUM>, a stator <NUM>, and at least one rotor bearing assembly <NUM>.

Referring to <FIG>, the motor housing <NUM> may extend between the differential carrier <NUM> and the cover <NUM> and may be mounted to the differential carrier <NUM> and the cover <NUM>. For example, the motor housing <NUM> may extend from the mounting flange <NUM> of the differential carrier <NUM> to the cover <NUM>. As is best shown in <FIG> and <FIG>, the motor housing <NUM> may extend around the axis <NUM> and define a motor housing cavity <NUM>. The motor housing cavity <NUM> may have a generally cylindrical configuration. As is best shown in <FIG>, the motor housing <NUM> may extend continuously around and may be spaced apart from the bearing support wall <NUM> of the differential carrier <NUM>. In at least one configuration and as is best shown in <FIG> and <FIG>, the motor housing <NUM> may have an exterior side <NUM>, an interior side <NUM>, a first end surface <NUM>, a second end surface <NUM>, and one or more ports <NUM>.

The exterior side <NUM> may face away from the axis <NUM> and may define an exterior or outside surface of the motor housing <NUM>.

The interior side <NUM> may be disposed opposite the exterior side <NUM>. The interior side <NUM> may be disposed at a substantially constant radial distance from the axis <NUM> in one or more configurations.

The first end surface <NUM> may extend between the exterior side <NUM> and the interior side <NUM>. The first end surface <NUM> may be disposed at an end of the motor housing <NUM> that may face toward the differential carrier <NUM>. More specifically, the first end surface <NUM> may be disposed adjacent to the mounting flange <NUM> of the differential carrier <NUM>. The motor housing <NUM> and the first end surface <NUM> may or may not be received inside the mounting flange <NUM>.

The second end surface <NUM> may be disposed opposite the first end surface <NUM>. As such, the second end surface <NUM> may be disposed at an end of the motor housing <NUM> that may face toward and may engage the cover <NUM>. The second end surface <NUM> may extend between the exterior side <NUM> and the interior side <NUM> and may or may not be received inside the cover <NUM>.

One or more ports <NUM> may extend through the motor housing <NUM>. The ports <NUM> may be configured as a through holes that may extend from the exterior side <NUM> to the interior side <NUM>. The ports <NUM> may allow coolant, such as a fluid like water, a water / antifreeze mixture, or the like, to flow to and from the coolant jacket <NUM> as will be described in more detail below.

Referring to <FIG>, the coolant jacket <NUM> may help cool or remove heat from the stator <NUM>. The coolant jacket <NUM> may be received in the motor housing cavity <NUM> of the motor housing <NUM> and may engage the interior side <NUM> of the motor housing <NUM>. The coolant jacket <NUM> may extend axially between the differential carrier <NUM> and the cover <NUM>. For example, the coolant jacket <NUM> may extend axially from the differential carrier <NUM> to the cover <NUM>. In addition, the coolant jacket <NUM> may extend around the axis <NUM> and the stator <NUM>. As such, the stator <NUM> may be at least partially received in and may be encircled by the coolant jacket <NUM>. Moreover, the coolant jacket <NUM> may extend in a radial direction from the stator <NUM> to the interior side <NUM> of the motor housing <NUM>. In at least one configuration, the coolant jacket <NUM> may include a plurality of channels <NUM>.

The channels <NUM> may extend around the axis <NUM> and may be disposed opposite the stator <NUM>. The channels <NUM> may be configured with an open side that may face away from the axis <NUM> and toward the interior side <NUM> of the motor housing <NUM>. Coolant may be provided to the coolant jacket <NUM> via a first port <NUM> and may exit the coolant jacket <NUM> via a second port <NUM>. For instance, coolant may flow from the first port <NUM> into the channels <NUM>, receive heat from the stator <NUM> as the coolant flows through the channels <NUM>, and exit at the second port <NUM>. A baffle may be provided with the coolant jacket <NUM> that may reverse the direction of coolant flow to help route coolant from the first port <NUM> to the second port <NUM>.

The stator <NUM> may be received in the motor housing <NUM>. For instance, the stator <NUM> may be received in the motor housing cavity <NUM>. The stator <NUM> may be fixedly positioned with respect to the coolant jacket <NUM>. For example, the stator <NUM> may extend around the axis <NUM> and may include stator windings that may be received inside and may be fixedly positioned with respect to the coolant jacket <NUM>.

The rotor <NUM> may extend around and is rotatable about the axis <NUM>. The rotor <NUM> may be received inside the stator <NUM>, the coolant jacket <NUM>, and the motor housing cavity <NUM> of the motor housing <NUM>. The rotor <NUM> may be rotatable about the axis <NUM> with respect to the differential carrier <NUM> and the stator <NUM>. In addition, the rotor <NUM> may be spaced apart from the stator <NUM> but may be disposed in close proximity to the stator <NUM>. The rotor <NUM> may include magnets or ferromagnetic material that may facilitate the generation of electrical current. The rotor <NUM> may extend around and may be supported by the bearing support wall <NUM>.

One or more rotor bearing assemblies <NUM> may rotatably support the rotor <NUM>. For example, a rotor bearing assembly <NUM> may receive the bearing support wall <NUM> of the differential carrier <NUM> and may be received inside of the rotor <NUM>. The rotor <NUM> may be operatively connected to the drive pinion <NUM>. For instance, a coupling such as a rotor output flange <NUM> may operatively connect the rotor <NUM> to the gear reduction module <NUM>, which in turn may be operatively connectable with the drive pinion <NUM>.

Referring to <FIG> and <FIG>, the cover <NUM> is mounted to the motor housing <NUM> and may be disposed opposite the axle housing <NUM> and the differential carrier <NUM>. For example, the cover <NUM> may be mounted to an end of the motor housing <NUM>, such as upon the second end surface <NUM> of the motor housing <NUM>. The cover <NUM> may be spaced apart from and may not engage the differential carrier <NUM>. The cover <NUM> may be provided in various configurations. In at least one configuration, the cover <NUM> may include a first side <NUM> and a second side <NUM>. The first side <NUM> may face toward and may engage the motor housing <NUM>. The second side <NUM> may be disposed opposite the first side <NUM>. The second side <NUM> may face away from the motor housing <NUM> and may be disposed opposite the motor housing <NUM>. Cover <NUM> may also include a motor cover opening <NUM> in configurations having a gear reduction module <NUM>.

Referring to <FIG> and <FIG>, the first lubricant passage <NUM> may route lubricant <NUM> from the axle housing <NUM> to help lubricate components that are disposed outside of the axle housing <NUM>. The flow of lubricant <NUM> may be represented by the arrowed lines in <FIG>. The first lubricant passage <NUM> may receive lubricant <NUM> that is splashed by the differential assembly <NUM>, such as when the differential assembly <NUM> rotates about the differential axis <NUM>. For example, the ring gear <NUM> may splash lubricant <NUM> from the sump portion <NUM> and some splashed lubricant may enter the first lubricant passage <NUM>. The first lubricant passage <NUM> may deliver lubricant <NUM> to the gear reduction module <NUM>, the shift mechanism <NUM>, components that are located adjacent to or inside the cover <NUM>, or combinations thereof. As an example, the first lubricant passage <NUM> may route lubricant from the axle housing <NUM> to the cover <NUM>. In at least one configuration, the first lubricant passage <NUM> may be completely disposed above the axis <NUM>. In addition, the first lubricant passage <NUM> may have at least one inlet <NUM> and at least one outlet <NUM>.

The inlet(s) <NUM> may receive lubricant <NUM> from the axle housing <NUM> and may be disposed further above the axis <NUM> than the outlet(s) <NUM>. As such, the first lubricant passage <NUM> may slope downward from the inlet(s) <NUM> toward or to the outlet(s) <NUM>.

The outlet(s) <NUM> may be disposed at an end of the first lubricant passage <NUM> that is disposed opposite the inlet(s) <NUM>. The outlet(s) <NUM> may be vertically positioned closer to the axis <NUM> than the inlet(s) <NUM>.

The first lubricant passage <NUM> may be configured as a through hole that may extend through at least the motor housing <NUM>. In at least one configuration, the differential carrier <NUM>, the motor housing <NUM>, and the cover <NUM> may cooperate to at least partially define the first lubricant passage <NUM>. For instance, the first lubricant passage <NUM> may be at least partially defined by through holes in the differential carrier <NUM>, the motor housing <NUM>, and the cover <NUM>. These through holes may be fluidly connected to each other. The text below primarily describes the first lubricant passage <NUM> that may be defined by these three components.

Referring to <FIG>, <FIG>, and <FIG>, the differential carrier <NUM> may define the inlet <NUM> and a first portion <NUM> of the first lubricant passage <NUM>. The first portion <NUM> may also be referred to as the portion of the first lubricant passage <NUM> that is defined by the differential carrier <NUM>. The inlet <NUM> and the first portion <NUM> may be disposed proximate the top of the differential carrier <NUM>. In at least one configuration, the inlet <NUM> and the first portion <NUM> may be disposed above the case or housing of the differential assembly <NUM>. The first portion <NUM> may extend from the inlet <NUM> to a first outlet port <NUM>, which is best shown in <FIG>. For example, the first portion <NUM> may extend in a generally horizontal direction from the inlet <NUM> toward an exterior side of the differential carrier <NUM> or to the left from the perspective shown in <FIG>. The first portion <NUM> may then change direction at a bend <NUM>, which is best shown in <FIG>, and may extend toward the mounting flange <NUM> and the motor housing <NUM> and to the first outlet port <NUM>.

Referring to <FIG>, the region of the first portion <NUM> that extends from the bend <NUM> to the first outlet port <NUM> may have an inner wall <NUM> and an outer wall <NUM>. The inner wall <NUM> may be disposed closer to the axis <NUM> than the outer wall <NUM>. The inner wall <NUM>, the outer wall <NUM>, or both may extend along an arc. For instance, the inner wall <NUM>, the outer wall <NUM>, or both may have a portion that may be radially disposed with respect to the axis <NUM>.

The first outlet port <NUM> may also have a top wall <NUM> and a bottom wall <NUM>. The top wall <NUM> may be disposed above the bottom wall <NUM> and may extend from the inner wall <NUM> to the outer wall <NUM>. The bottom wall <NUM> may be spaced apart from the top wall <NUM> and may extend from the inner wall <NUM> to the outer wall <NUM>. The first outlet port <NUM> may have a height H<NUM> that may extend from the top wall <NUM> to the bottom wall <NUM>.

Referring to <FIG>, <FIG> and <FIG>, the motor housing <NUM> may define a second portion <NUM> of the first lubricant passage <NUM>. The second portion <NUM> may also be referred to as the portion of the first lubricant passage <NUM> that is defined by the motor housing <NUM>.

The second portion <NUM> may be disposed between the exterior side <NUM> and the interior side <NUM> of the motor housing <NUM>. In addition, the second portion <NUM> may be radially positioned further from the axis <NUM> than the stator <NUM> and the coolant jacket <NUM>. For instance, the second portion <NUM> may be disposed between the coolant jacket <NUM> and the exterior side <NUM> of the motor housing <NUM>. The second portion <NUM> may extend substantially parallel to the axis <NUM>. It is noted that the second portion <NUM> extends substantially parallel to the axis <NUM> in <FIG> but appears to be tapered from the differential carrier <NUM> to the cover <NUM> due to the angularity of the section plane and the curvature of the second portion <NUM>. The second portion <NUM> may have a second inlet port <NUM> and a second outlet port <NUM> and may extend from the second inlet port <NUM> to the second outlet port <NUM>.

The second inlet port <NUM> may be disposed at a first end surface <NUM> of the motor housing <NUM>. In at least one configuration, the second inlet port <NUM> may be at least partially disposed above the second outlet port <NUM>. The second inlet port <NUM> may be disposed adjacent to the first outlet port <NUM> and may be fluidly connected to the first outlet port <NUM>. In at least one configuration, the second inlet port <NUM> may have an upper end <NUM> and a lower end <NUM> as is best shown in <FIG>.

The upper end <NUM> may be disposed at the top of the second inlet port <NUM>.

The lower end <NUM> may be disposed opposite the upper end <NUM> and may be disposed proximate the bottom of the second inlet port <NUM>. The second inlet port <NUM> may have a height H<NUM> that may extend from the upper end <NUM> to the lower end <NUM>. The height H<NUM> of the second inlet port <NUM> may be greater than the height H<NUM> of the first outlet port <NUM>. For instance, the upper end <NUM> may be disposed above and may be spaced apart from the top wall <NUM> of the first outlet port <NUM>, the lower end <NUM> may be disposed below and may be spaced apart from the bottom wall <NUM> of the first outlet port <NUM>, or both.

Providing a second inlet port <NUM> with a greater height than the first outlet port <NUM> may allow the motor housing <NUM> to be standardized while allowing the motor housing <NUM> to fluidly connect with different differential carrier designs that may position the first outlet port <NUM> at different locations. For instance, the top wall <NUM> of the first outlet port <NUM> may be positioned at a higher elevation or closer to the upper end <NUM> in configurations where the differential carrier <NUM> supports a larger differential assembly <NUM> or a differential assembly <NUM> having a larger diameter ring gear <NUM>. Conversely, the bottom wall <NUM> of the first outlet port <NUM> may be positioned at a lower elevation or closer to the lower end <NUM> in configurations where the differential carrier <NUM> supports a smaller differential assembly <NUM> or a differential assembly <NUM> having a smaller diameter ring gear <NUM>.

Referring to <FIG>, the second outlet port <NUM> may be disposed at the second end surface <NUM> that may be disposed opposite the first end surface <NUM>.

Referring to <FIG> and <FIG>, the cover <NUM> may define a third portion <NUM> of the first lubricant passage <NUM>. The third portion <NUM> may also be referred to as the portion of the first lubricant passage <NUM> that is defined by the cover <NUM>.

The third portion <NUM> may be configured as a through hole that may extend through the cover <NUM>. As such, the third portion <NUM> may be disposed between an exterior side of the cover <NUM> and an interior side of the cover <NUM>. The third portion <NUM> may extend from a third inlet port <NUM> to the outlet <NUM>. Accordingly, the cover <NUM> may define the outlet <NUM> of the first lubricant passage <NUM> in at least one configuration.

The third inlet port <NUM> may be fluidly connected to the second outlet port <NUM>. The third inlet port <NUM> may be disposed at an end of the cover <NUM> that may face toward and may engage the second end surface <NUM> of the motor housing <NUM>. In at least one configuration, the third portion <NUM> may extend axially or substantially parallel to the axis <NUM> from the third inlet port <NUM> to a bend <NUM>, which is best shown in <FIG>. The third portion <NUM> may then change direction at the bend <NUM> and may extend toward the axis <NUM> and to the outlet <NUM>. Lubricant <NUM> may exit the outlet <NUM> and may be provided to components that may be remotely positioned from the axle housing <NUM>, such as the gear reduction module <NUM> and the shift mechanism <NUM>.

Referring to <FIG> and <FIG>, the second lubricant passage <NUM> may return lubricant <NUM> to the axle housing <NUM>. The flow of lubricant <NUM> may be represented by the arrowed lines in <FIG>. For instance, the second lubricant passage <NUM> may route lubricant from the gear reduction module <NUM>, the shift mechanism <NUM>, the cover <NUM>, or combinations thereof to the axle housing <NUM>. The second lubricant passage <NUM> may be partially or completely disposed below the axis <NUM>. With additional reference to <FIG>, the second lubricant passage <NUM> may have at least one inlet <NUM>, <NUM>' and at least one outlet <NUM>.

The inlet(s) <NUM> may receive lubricant <NUM> from the cover <NUM> and may be disposed further above the axis <NUM> than the outlet(s) <NUM>. As such, the second lubricant passage <NUM> or a portion thereof may slope downward from the inlet(s) <NUM>, <NUM>' toward or to the outlet(s) <NUM>.

The second lubricant passage <NUM> may be configured as a through hole that may extend through at least the motor housing <NUM>. In at least one configuration, the differential carrier <NUM>, the motor housing <NUM>, and the cover <NUM> may cooperate to at least partially define the second lubricant passage <NUM>. For instance, the second lubricant passage <NUM> may be at least partially defined by through holes in the differential carrier <NUM>, the motor housing <NUM>, and the cover <NUM>. These through holes may be fluidly connected to each other. The text below primarily describes the second lubricant passage <NUM> that may be defined by these three components.

Referring to <FIG> and <FIG>, the cover <NUM> may define the inlet(s) <NUM>, <NUM>' and a first portion <NUM> of the second lubricant passage <NUM>. The first portion <NUM> may also be referred to as the portion of the second lubricant passage <NUM> that is defined by the cover <NUM>. As is best shown in <FIG>, the cover <NUM> may include multiple inlets for the second lubricant passage <NUM>. For clarity in reference, reference number <NUM> may designate a first inlet while reference number <NUM>' may designate a second inlet. The first inlet <NUM>, the second inlet <NUM>', or both may be disposed further above the axis <NUM> than the outlet <NUM>.

The first inlet <NUM> may face toward the axis <NUM>. In at least one configuration, the first inlet <NUM> may face inward toward the axis <NUM>. As such, the first inlet <NUM> may be disposed closer to the axis <NUM> than the second inlet <NUM>'. In addition, the first inlet <NUM> may be axially positioned along the axis <NUM> closer to the motor housing <NUM> than the second inlet <NUM>' as is best shown with respect to <FIG>. The first inlet <NUM> may also be disposed above the second inlet <NUM>'. The first inlet <NUM> is not visible in <FIG> due to the positioning of the section plane.

The second inlet <NUM>' may be spaced apart from the first inlet <NUM>. In at least one configuration, the second inlet <NUM>' may be disposed in the second side <NUM> of the cover <NUM>. As such, the second inlet <NUM>' may face away from the motor housing <NUM>.

Referring to <FIG> and <FIG>, the first portion <NUM> may have a first branch <NUM> and a second branch <NUM>. The first branch <NUM> may extend from the first inlet <NUM> in a generally horizontal direction from the first inlet <NUM> toward an exterior side of the cover <NUM> or to the left from the perspective shown in <FIG>. Referring to <FIG>, the second branch <NUM> may extend in a generally axial direction from the second inlet <NUM>' to the first branch <NUM>. As such, the first branch <NUM> may be fluidly connected to the second branch <NUM> in at least one configuration.

Referring to <FIG>, the first branch <NUM> may change direction at a bend <NUM> and may extend toward the motor housing <NUM> and to a first outlet port <NUM> of the first portion <NUM>.

Referring to <FIG>, <FIG> and <FIG>, the motor housing <NUM> may define a second portion <NUM> of the second lubricant passage <NUM>. The second portion <NUM> may also be referred to as the portion of the second lubricant passage <NUM> that is defined by the motor housing <NUM>.

The second portion <NUM> may be disposed between the exterior side <NUM> and the interior side <NUM> of the motor housing <NUM>. In addition, the second portion <NUM> may be radially positioned further from the axis <NUM> than the stator <NUM> and the coolant jacket <NUM>. For instance, the second portion <NUM> may be disposed between the coolant jacket <NUM> and the exterior side <NUM> of the motor housing <NUM>. The second portion <NUM> may extend substantially parallel to the axis <NUM>. The second portion <NUM> may have a second inlet port <NUM> and a second outlet port <NUM> and may extend from the second inlet port <NUM> to the second outlet port <NUM>.

The second inlet port <NUM> may be disposed at the second end surface <NUM> of the motor housing <NUM> and may face toward the cover <NUM>. The second inlet port <NUM> may be fluidly connected to the first outlet port <NUM>.

The second outlet port <NUM> may be disposed at the first end surface <NUM> of the motor housing <NUM> and may face toward the differential carrier <NUM>. The second outlet port <NUM> may be at least partially disposed below the second inlet port <NUM>. In at least one configuration, the second outlet port <NUM> may have an upper end <NUM> and a lower end <NUM> as is best shown in <FIG>.

The upper end <NUM> may be disposed at the top of the second outlet port <NUM>.

The lower end <NUM> may be disposed opposite the upper end <NUM> and may be disposed proximate the bottom of the second outlet port <NUM>. The second outlet port <NUM> may have an outlet port height H<NUM> that may extend from the upper end <NUM> to the lower end <NUM>.

Referring to <FIG>, <FIG>, and <FIG>, the differential carrier <NUM> may define the outlet <NUM> and a third portion <NUM> of the second lubricant passage <NUM>. The third portion <NUM> may also be referred to as the portion of the second lubricant passage <NUM> that is defined by the differential carrier <NUM>.

The third portion <NUM> may be configured as a through hole that may extend through the differential carrier <NUM>. As such, the third portion <NUM> may be disposed between an exterior side of the differential carrier <NUM> and an interior side of the differential carrier <NUM>. The third portion <NUM> may extend from the third inlet port <NUM> to the outlet <NUM>.

The third inlet port <NUM> may be fluidly connected to the second outlet port <NUM>. The third inlet port <NUM> may be disposed at an end of the differential carrier <NUM> that may face toward and may engage the first end surface <NUM> of the motor housing <NUM>. The third portion <NUM> may generally extend axially from the third inlet port <NUM> to the outlet <NUM>.

Referring to <FIG>, one or more bends may be provided between the third inlet port <NUM> and the outlet <NUM>. For instance, the third portion <NUM> may extend from the third inlet port <NUM> to a first bend <NUM> at which the third portion <NUM> may extend inward toward the axis <NUM>. The third portion <NUM> may then extend to a second bend <NUM> at which the third portion <NUM> may then resume extending in an axial direction toward the axle housing <NUM>. The third portion <NUM> may then extend to a third bend <NUM> at which the third portion <NUM> may extend away from the axis <NUM> and then may extend in a generally axial direction toward the axle housing <NUM> and to the outlet <NUM>. In such a configuration, the outlet <NUM> may be disposed outboard from a bearing support <NUM> and a bearing that may rotatably support the differential assembly <NUM>. It is contemplated that a greater or lesser number of bends may be provided.

Referring to <FIG>, the third portion <NUM> or a region thereof may have an inner wall <NUM> and an outer wall <NUM>. The inner wall <NUM> may be disposed closer to the axis <NUM> than the outer wall <NUM>. The inner wall <NUM>, the outer wall <NUM>, or both may extend along an arc. For instance, the inner wall <NUM>, the outer wall <NUM>, or both have a portion that may be radially disposed with respect to the axis <NUM>.

The third inlet port <NUM> may also have a top wall <NUM> and a bottom wall <NUM>. The top wall <NUM> may be disposed above the bottom wall <NUM> and may extend from the inner wall <NUM> to the outer wall <NUM>. The bottom wall <NUM> may be spaced apart from the top wall <NUM> and may extend from the inner wall <NUM> to the outer wall <NUM>. The third inlet port <NUM> may have a height H<NUM> that may extend from the top wall <NUM> to the bottom wall <NUM>. The height H<NUM> of the second outlet port <NUM> may be greater than the height H<NUM> of the third inlet port <NUM>. For instance, the upper end <NUM> of the second outlet port <NUM> may be disposed above and may be spaced apart from the top wall <NUM> of the third inlet port <NUM>, the lower end <NUM> of the second outlet port <NUM> may be disposed below and may be spaced apart from the bottom wall <NUM> of the third inlet port <NUM>, or both. Such a configuration may provide compatibility with different differential carriers <NUM> and different sized differential assemblies <NUM> as previously discussed.

Referring to <FIG> and <FIG>, the first lubricant passage <NUM> and the second lubricant passage <NUM> may be disposed on opposite sides of a center plane <NUM> that may extend vertically through the axis <NUM>. The axis <NUM> may be completely disposed in the center plane <NUM>.

The first lubricant passage <NUM> and the second lubricant passage <NUM> may allow lubricant <NUM> to be circulated between different portions of the axle assembly <NUM>, such as the sump portion <NUM> and the gear reduction module <NUM>. As such, the first lubricant passage <NUM> and the second lubricant passage <NUM> may allow a common lubricant to be used to lubricate components of the differential assembly <NUM> and the gear reduction module <NUM>. Moreover, this configuration may allow the housing assembly <NUM> to be provided without separate lubricant reservoirs or separate sump portions for the axle housing <NUM> and the gear reduction module <NUM>, which may allow seals that separate the lubricant reservoirs to be eliminated.

In addition, the first lubricant passage <NUM> and the second lubricant passage <NUM> may provide a flow path that is separate from the drive pinion <NUM> or cavity that receives the drive pinion <NUM>. Routing lubricant through the drive pinion <NUM> or a cavity that receives the drive pinion <NUM> may make it difficult to return lubricant <NUM> to the sump portion <NUM> due to the obstruction or narrower flow path presented by the drive pinion <NUM> and its supporting bearings. Routing lubricant <NUM> via the first lubricant passage <NUM> and the second lubricant passage <NUM> may reduce the level of lubricant <NUM> around the drive pinion <NUM>, which in turn may reduce drag on the drive pinion <NUM> and may help improve operating efficiency of the axle assembly <NUM>.

The first lubricant passage <NUM> and the second lubricant passage <NUM> may allow lubricant <NUM> to be circulated inside the axle assembly <NUM> and without conduits or hoses that are routed outside the housing assembly <NUM> where they may be susceptible to damage.

The first lubricant passage <NUM> and the second lubricant passage <NUM> may facilitate heat transfer. Thermal energy or heat may be transferred between the coolant in the coolant jacket <NUM> and the lubricant <NUM> in the first lubricant passage <NUM>, the second lubricant passage <NUM>, or both. As an example, heat may be transferred from the coolant to the lubricant <NUM> when the coolant temperature exceeds the lubricant temperature or vice versa. Heat transfer from the coolant to the lubricant <NUM> may help heat the lubricant <NUM> in cold operating conditions, which may help improve lubricant flow and/or lubricating performance. Heat transfer from the lubricant <NUM> to the coolant may help reduce the lubricant temperature, which may help extend the life of the lubricant <NUM>.

Referring to <FIG>, the gear reduction module <NUM>, if provided, may transmit torque from the electric motor module <NUM> to the differential assembly <NUM>. As such, the gear reduction module <NUM> may be operatively connected to the electric motor module <NUM> and may be operatively connectable to the differential assembly <NUM>. The gear reduction module <NUM> may be disposed outside of the differential carrier <NUM> and may be primarily disposed outside of the electric motor module <NUM> or entirely disposed outside the electric motor module <NUM>, thereby providing a modular construction that may be mounted to the electric motor module <NUM> when gear reduction is desired.

The gear reduction module <NUM> may be provided in various configurations, such as planetary gear set configurations and non-planetary gear set configurations. In <FIG>, an example of a gear reduction module <NUM> that has a planetary gear set is shown. In such a configuration, the gear reduction module <NUM> may include a sun gear <NUM>, planet gears <NUM>, a planetary ring gear <NUM>, and a planet gear carrier <NUM>. The gear reduction module <NUM> may also include a lubricant catching ring <NUM>.

The sun gear <NUM> may be operatively connected to the rotor <NUM>, such as via the rotor output flange <NUM>. As such, the sun gear <NUM> may be rotatable about the axis <NUM> with the rotor <NUM> and the rotor output flange <NUM>. The sun gear <NUM> may receive the drive pinion <NUM>.

Referring to <FIG>, <FIG> and <FIG>, the planet gears <NUM> may be rotatably disposed between the sun gear <NUM> and the planetary ring gear <NUM>. Each planet gear <NUM> may have teeth that mesh with the sun gear <NUM> and the planetary ring gear <NUM>.

Referring to <FIG> and <FIG>, the planetary ring gear <NUM> may extend around the axis <NUM> and may receive the planet gears <NUM>. In at least one configuration, the planetary ring gear <NUM> may be received in the cover <NUM> and may be fixedly disposed on the cover <NUM> such that the planetary ring gear <NUM> may not be rotatable about the axis <NUM>.

Referring to <FIG> and <FIG>, the planet gear carrier <NUM> is rotatable about the axis <NUM> and rotatably supports the planet gears <NUM>. In at least one configuration, the planet gear carrier <NUM> has a first side <NUM> and a second side <NUM>, which are best shown with reference to <FIG>. The first side <NUM> faces toward the cover <NUM>, or to the left from the perspective shown in <FIG>. The second side <NUM> may be disposed opposite the first side <NUM>, or to the right from the perspective shown in <FIG>. As such, the second side <NUM> may face away from the cover <NUM>.

Referring to <FIG>, the lubricant catching ring <NUM> is mounted to the planet gear carrier <NUM>. For instance, the lubricant catching ring <NUM> is mounted to the first side <NUM> of the planet gear carrier <NUM> with one or more fasteners such as bolts. As such, the lubricant catching ring <NUM> may not rotate with respect to the planet gear carrier <NUM> and may be rotatable about the axis <NUM> with the planet gear carrier <NUM>. The lubricant catching ring <NUM> extends continuously around the axis <NUM> and defines a lubricant catching ring hole <NUM> through which various components of the axle assembly <NUM>, such as the drive pinion <NUM> and the sun gear <NUM>, may extend. In addition, lubricant <NUM> that exits the first lubricant passage <NUM> may pass through the lubricant catching ring hole <NUM> to help lubricate the planetary gear set as will be discussed in more detail below. The flow of lubricant <NUM> may be represented by the arrowed lines in <FIG>. As is best shown in <FIG>, the lubricant catching ring <NUM> cooperates with the planet gear carrier <NUM> to define a chamber <NUM> that captures lubricant <NUM> that passes through or enters the lubricant catching ring hole <NUM>.

The lubricant catching ring <NUM> may have any suitable configuration. In at least one configuration, the lubricant catching ring <NUM> may have a first end <NUM>, a second end <NUM>, a first portion <NUM>, a second portion <NUM>, and an intermediate portion <NUM>.

The first end <NUM> may face away from the axis <NUM>. The first end <NUM> may be an outside circumference or outside circumferential surface of the lubricant catching ring <NUM>.

The second end <NUM> may be disposed opposite the first end <NUM>. As such, the second end <NUM> may face toward the axis <NUM>. The second end <NUM> may at least partially define the lubricant catching ring hole <NUM>.

The first portion <NUM> may extend from the first end <NUM> toward the axis <NUM>. For instance, the first portion <NUM> may extend from the first end <NUM> to the intermediate portion <NUM>. A side of the first portion <NUM> that faces toward the planet gear carrier <NUM> may be mounted to and may contact or engage the first side of the planet gear carrier <NUM>. The first portion <NUM> may be partially spaced apart from the planet gear carrier <NUM> such that the first portion <NUM> and the planet gear carrier <NUM> may cooperate to at least partially define the chamber <NUM> that may receive and hold lubricant <NUM>.

The second portion <NUM> may extend from the second end <NUM> away from the axis <NUM>. The second portion <NUM> may be offset from the first portion <NUM>. For instance, the second portion <NUM> may be spaced apart from the planetary gear set and may be axially positioned further from the planet gear carrier <NUM> than the first portion <NUM>. The first portion <NUM> and the second portion <NUM> may be disposed substantially parallel to each other in one or more configurations. Alternatively, the second portion <NUM> may be disposed at an angle with respect to the first portion <NUM>. It is also contemplated that the second portion <NUM> may be omitted.

The intermediate portion <NUM> may extend from the first portion <NUM> to the second portion <NUM>. For instance, the intermediate portion <NUM> may extend from an end of the first portion <NUM> to an end of the second portion <NUM> and may be spaced apart from the planetary gear set. In the configuration shown, the intermediate portion <NUM> extends at an oblique angle from the first portion <NUM> and may extend further from the planet gear carrier <NUM> in a direction extending toward the axis <NUM>. The intermediate portion <NUM> may be positioned at a distance from the axis <NUM> that may be generally aligned with a planet pin <NUM> that may rotatably support a planet gear <NUM>. It is also contemplated that the intermediate portion <NUM> may be omitted.

Referring to <FIG>, each planet gear <NUM> may be rotatable with respect to a planet pin <NUM>. A planet pin <NUM> may be fixed to the planet gear carrier <NUM> such that the planet pin <NUM> may not rotate with respect to the planet gear carrier <NUM>. For instance, a planet pin <NUM> may be received in one or more holes of the planet gear carrier <NUM> and may extend between the first side <NUM> and the second side <NUM> of the planet gear carrier <NUM>. In at least one configuration, each planet pin <NUM> may be generally cylindrical and may extend along a planet pin axis <NUM>. Each planet pin <NUM> may be spaced apart from the lubricant catching ring <NUM>. In at least one configuration, a planet pin <NUM> may include a first end surface <NUM>, a second end surface <NUM>, an outer side <NUM>, an inner side <NUM>, and an axial bore <NUM>.

The first end surface <NUM> may face toward the electric motor module <NUM> and the lubricant catching ring <NUM>, or to the left from the perspective shown.

The second end surface <NUM> may be disposed opposite the first end surface <NUM>. The second end surface <NUM> may face away from the electric motor module <NUM>.

The outer side <NUM> may extend from the first end surface <NUM> to the second end surface <NUM>. The outer side <NUM> may face away from the planet pin axis <NUM> and the axial bore <NUM>. Optionally, one or more bearing assemblies <NUM> that rotatably support a planet gear <NUM> may be disposed on and may extend around the outer side <NUM>. A bearing assembly <NUM> may be received inside a hole in the planet gear <NUM> and may extend from the outer side <NUM> to the planet gear <NUM>.

The inner side <NUM> may be disposed opposite the outer side <NUM>. As such, the inner side <NUM> may face toward the planet pin axis <NUM>. The inner side <NUM> may at least partially define the axial bore <NUM>.

The axial bore <NUM> may receive lubricant <NUM> and help route lubricant <NUM> to the planet gears <NUM> and to the bearing assemblies <NUM>. The axial bore <NUM> may extend along and may be centered about the planet pin axis <NUM> and may extend partially or completely through the planet pin <NUM>. In the configuration shown, the axial bore <NUM> is configured as a through hole that extends completely through the planet pin <NUM> from the first end surface <NUM> to the second end surface <NUM>. In such a configuration, the axial bore <NUM> may have a first opening <NUM>, a second opening <NUM>, and a connecting passage <NUM>. Optionally, the axial bore <NUM> may be subdivided into a first axial bore portion <NUM> and a second axial bore portion <NUM>.

The first opening <NUM> may be disposed in the first end surface <NUM> and may face toward the lubricant catching ring <NUM>. The first opening <NUM> may receive lubricant <NUM> that is captured by the lubricant catching ring <NUM>.

The second opening <NUM>, if provided, may be disposed opposite the first opening <NUM>. As such, the second opening <NUM> may be disposed opposite the first opening <NUM>.

One or more connecting passages <NUM> may extend from the inner side <NUM> and the axial bore <NUM> to the outer side <NUM> of the planet pin <NUM>. In at least one configuration, the connecting passage <NUM> may extend from a first axial bore portion <NUM> to the outer side <NUM> of the planet pin <NUM>. A connecting passage <NUM> may be oriented such that the connecting passage <NUM> or a portion thereof extends away from the axis <NUM>. For instance, a connecting passage <NUM> may be positioned such that the connecting passage <NUM> is disposed further from the axis <NUM> than the planet pin axis <NUM> is disposed from the axis <NUM>. Such positioning may help direct lubricant <NUM> into a connecting passage <NUM> during operation of the planetary gear set. For instance, centrifugal force that occurs when the planet gear carrier <NUM> and the planet pins <NUM> rotate about the axis <NUM> may urge lubricant <NUM> in the axial bore <NUM> to move away from the axis <NUM>. Thus, positioning a connecting passage <NUM> further outward from or at a greater distance from the axis <NUM> than the planet pin axis <NUM> is positioned from the axis <NUM> may facilitate the flow of lubricant <NUM> into the connecting passage <NUM>. It is also contemplated that a connecting passage <NUM> or a portion thereof may not be disposed further from the axis <NUM> than the planet pin axis <NUM> is positioned from the axis <NUM>.

The first axial bore portion <NUM> may extend from the first end surface <NUM> toward the second end surface <NUM>. For instance, the first axial bore portion <NUM> may extend from the first opening <NUM> toward the second opening <NUM>.

The second axial bore portion <NUM> may extend from the second end surface <NUM> toward the first end surface <NUM>. For instance, the second axial bore portion <NUM> may extend from the second end surface <NUM> and the second opening <NUM> to the first axial bore portion <NUM>. The second axial bore portion <NUM> may serve one or more purposes. For example, the second axial bore portion <NUM> may act as a flow restrictor with respect to the first axial bore portion <NUM> to help route lubricant <NUM> through the connecting passage <NUM>. This may be accomplished by providing the first axial bore portion <NUM> with a larger diameter than the second axial bore portion <NUM>. As another example, the second axial bore portion <NUM> may be an overflow passage that may allow excess lubricant <NUM> to exit the axial bore <NUM> via the second opening <NUM>. Permitting lubricant <NUM> to overflow through the second axial bore portion <NUM> may encourage or maintain lubricant flow into or through the axial bore <NUM> and may help supply lubricant <NUM> to the planet gear <NUM> and its associated bearing assemblies <NUM> if provided.

Referring to <FIG>, <FIG>, a washer <NUM> may be positioned between a planet gear <NUM> in the planet gear carrier <NUM>. For instance, a washer <NUM> is axially positioned between an end of a planet gear <NUM> and the planet gear carrier <NUM>. In at least one configuration and as is best shown in <FIG>, the washer <NUM> may include a first washer side <NUM>, a second washer side <NUM>, and includes an outside washer surface <NUM>, optionally an inside washer surface <NUM>, and a washer hole <NUM>. The washer <NUM> includes one or optionally more elliptical grooves <NUM>.

The first washer side <NUM> may be generally planar. The first washer side <NUM> may face toward the planet gear <NUM>.

The second washer side <NUM> may be disposed opposite the first washer side <NUM>. As such the second washer side <NUM> may face away from the planet gear <NUM>. The second washer side <NUM> may also be generally planar. It is contemplated that the first washer side <NUM> and the second washer side <NUM> may be reversed from the designations shown.

The outside washer surface <NUM> may extend from the first washer side <NUM> to the second washer side <NUM>. The outside washer surface <NUM> faces away from the washer hole <NUM> and may be an outside circumference surface of the washer <NUM>.

The inside washer surface <NUM> may be disposed opposite the outside washer surface <NUM>. The inside washer surface <NUM> may at least partially define the washer hole <NUM>. The inside washer surface <NUM> may have a circular or a non-circular configuration. In the configuration shown, the inside washer surface <NUM> is shown with a noncircular configuration that may include a set of arcuate surfaces <NUM> that may be configured to contact the outer side <NUM> of the planet pin <NUM> and a set of connecting surfaces <NUM> that may face toward but may be spaced apart from the outer side <NUM> of the planet pin <NUM> to permit lubricant <NUM> to flow through the washer hole <NUM>. Each member of the set of connecting surfaces <NUM> may extend between an adjacent pair of members of the set of arcuate surfaces <NUM>. Moreover, a portion of each member of the set of connecting surfaces <NUM> may extend further from the planet pin axis <NUM> than the members of the set of arcuate surfaces <NUM>.

The washer hole <NUM> may be a through hole that may extend through the washer <NUM>. The washer hole <NUM> receives a planet pin <NUM>.

Referring to <FIG>, an elliptical groove <NUM> may be provided in the first washer side <NUM>, the second washer side <NUM>, or both. The elliptical groove <NUM> may help route lubricant <NUM> away from the planet pin <NUM> and thus may help facilitate the flow of lubricant <NUM> from the inside the planet gear <NUM> and from the bearing assembly <NUM>. As such, the elliptical groove <NUM> may improve lubricant flow between the washer <NUM> and a planet gear <NUM>, between the washer <NUM> and the planet gear carrier <NUM>, or both. An elliptical groove <NUM> may be at least partially defined by a first elliptical edge <NUM> and a second elliptical edge <NUM>.

The first elliptical edge <NUM> may extend along an ellipse or an elliptical path. The first elliptical edge <NUM> may intersect the outside washer surface <NUM> at two different points. The first elliptical edge <NUM> may be disposed tangential to the washer hole <NUM>.

The second elliptical edge <NUM> may be spaced apart from the first elliptical edge <NUM>. The second elliptical edge <NUM> may intersect the washer hole <NUM> at two different points. In addition the second elliptical edge <NUM> may be spaced apart from and may not intersect the outside washer surface <NUM>. In at least one configuration, the second elliptical edge <NUM> may be approximately centered inside of the first elliptical edge <NUM> or with respect to the first elliptical edge <NUM>.

In configurations having an elliptical groove <NUM> provided on the first washer side <NUM> and the second washer side <NUM>, the elliptical grooves <NUM> may have the same or different positioning. In the configuration shown in <FIG>, the elliptical groove <NUM> in the first washer side <NUM> is shown with solid lines while the elliptical groove <NUM> in the second washer side <NUM> is shown with hidden lines. In the illustrated configuration, the elliptical grooves <NUM> extend in opposite directions from the washer hole <NUM>. Such a configuration may help ensure that at least a portion of one elliptical groove <NUM> extends away from the axis <NUM> when installed so that centrifugal force may help urge lubricant <NUM> to flow through an elliptical groove <NUM> from the washer hole <NUM> toward the outside washer surface <NUM>, such as when the planetary gear set is rotating about the axis <NUM>. Providing elliptical grooves in different positions in the first washer side <NUM> and the second washer side <NUM> may allow the planetary gear set to be assembled without needing to maintain a particular rotational orientation of a washer <NUM> yet may help ensure that at least one elliptical groove <NUM> or a portion thereof will be positioned to take advantage of centrifugal forces to help route lubricant <NUM> through an elliptical groove <NUM> and away from the planet pin <NUM>.

Referring to <FIG>, the shift mechanism <NUM> may cooperate with the gear reduction module <NUM> to provide a desired gear reduction ratio to change the torque provided from the electric motor module <NUM> to the differential assembly <NUM>, and hence to the axle shafts <NUM> of the axle assembly <NUM>. For example, the shift mechanism <NUM> may operatively connect the sun gear <NUM> to the drive pinion <NUM> to provide a first drive gear ratio and may operatively connect the planet gear carrier <NUM> to the drive pinion <NUM> to provide a second drive gear ratio that may differ from the first drive gear ratio.

The shift mechanism <NUM> may have any suitable configuration. For instance, the shift mechanism <NUM> may include an actuator <NUM>, which is best shown in <FIG>. The shift mechanism <NUM> may also include a shift collar <NUM>, which is best shown in <FIG> and <FIG>.

Referring to <FIG>, the actuator <NUM> may be configured to move the shift collar <NUM> along the axis <NUM> to selectively couple the planetary gear set to the drive pinion <NUM> or decouple the planetary gear set from the drive pinion <NUM>. The actuator <NUM> may be of any suitable type.

Referring to <FIG> and <FIG>, the shift collar <NUM> may be movable along the axis <NUM> to selectively couple the planetary gear set to the drive pinion <NUM>. For instance, the shift collar <NUM> may be disposed on the drive pinion <NUM> such that the shift collar <NUM> may be rotatable about the axis <NUM> with the drive pinion <NUM> and may be movable in an axial direction or along the axis <NUM> with respect to the drive pinion <NUM>. The shift collar <NUM> may include teeth that may extend away from the axis <NUM> that may be selectively engageable with corresponding teeth of the sun gear <NUM> or the planet gear carrier <NUM> of the planetary gear set to facilitate the transmission of torque between the electric motor module <NUM> and the differential assembly <NUM> at a desired torque ratio. The shift collar <NUM> may be provided in various configurations. In at least one configuration, the shift collar <NUM> may have an outer shift collar side <NUM>, an inner shift collar side <NUM>, a shift collar hole <NUM>, and one or more shift collar lubricant holes <NUM>.

The outer shift collar side <NUM> may face away from the axis <NUM>.

The inner shift collar side <NUM> may be disposed opposite the outer shift collar side <NUM>. As such, the inner shift collar side <NUM> may face toward the axis <NUM>. The inner shift collar side <NUM> may at least partially define the shift collar hole <NUM>.

The shift collar hole <NUM> may be a through hole that may extend through the shift collar <NUM>. The shift collar hole <NUM> may receive a shaft portion of the drive pinion <NUM>. A set of splines may extend into the shift collar hole <NUM> to rotatably couple the shift collar <NUM> to the drive pinion <NUM>.

One or more shift collar lubricant holes <NUM> may extend through the shift collar <NUM>. A shift collar lubricant hole <NUM> may be a through hole that may extend from the inner shift collar side <NUM> to the outer shift collar side <NUM>. One or more shift collar lubricant holes <NUM> may be disposed substantially perpendicular to the axis <NUM>. A shift collar lubricant hole <NUM> may allow lubricant <NUM> to exit the shift collar hole <NUM> to help lubricate various components, such as a thrust bearing <NUM> that may extend between the sun gear <NUM> and the planet gear carrier <NUM> as is best shown in <FIG>. In addition, lubricant <NUM> that exits the shift collar lubricant hole <NUM> may flow along the shift collar <NUM> to help lubricate the teeth of the shift collar <NUM>.

Referring to <FIG> and <FIG>, a support tube <NUM> may be received in the shift collar lubricant hole <NUM>. The support tube <NUM> may help support the shift collar <NUM> on the drive pinion <NUM> and may inhibit deflection of the shift collar <NUM> with respect to the axis <NUM>. The support tube <NUM> may be fastened to the drive pinion <NUM>. For instance, the support tube <NUM> may be attached to an end of the drive pinion <NUM> with a fastener <NUM>, such as a bolt. In at least one configuration, the support tube <NUM> may have an outer support tube side <NUM>, an inner support tube side <NUM>, a support tube hole <NUM>, and a support tube lubricant hole <NUM>.

The outer support tube side <NUM> may face away from the axis <NUM>. The outer support tube side <NUM> may engage or contact the inner shift collar side <NUM> of the shift collar <NUM>.

The inner support tube side <NUM> may be disposed opposite the outer support tube side <NUM>. The inner support tube side <NUM> may face toward the axis <NUM>. The inner support tube side <NUM> may at least partially define the support tube hole <NUM>.

The support tube hole <NUM> may extend from an end of the support tube <NUM> toward the drive pinion <NUM> or to the drive pinion <NUM>. In at least one configuration, the support tube hole <NUM> may receive the fastener <NUM>. The support tube <NUM> may receive a portion of a lubricant chute <NUM> that extends from a shift mechanism housing cover <NUM> as will be discussed in more detail below.

One or more support tube lubricant holes <NUM> may extend through the support tube <NUM>. A support tube lubricant hole <NUM> may extend from the inner support tube side <NUM> to the outer support tube side <NUM>. One or more support tube lubricant holes <NUM> may be disposed substantially perpendicular to the axis <NUM>. Lubricant that enters the support tube hole <NUM> may pass through a support tube lubricant hole <NUM> such that the lubricant <NUM> may be positioned in a cavity located between the outer support tube side <NUM> of the support tube <NUM> and the inner shift collar side <NUM> of the shift collar <NUM>. Lubricant may then exit the cavity via a shift collar lubricant hole <NUM> as previously described.

Referring to <FIG> and <FIG>, the shift mechanism <NUM> may be received in a shift mechanism housing <NUM>. The shift mechanism housing <NUM> may be disposed on the cover <NUM> and may be mounted to a side of the cover <NUM> that may be disposed opposite the differential carrier <NUM>. Optionally, the shift mechanism housing <NUM> may facilitate mounting of the actuator <NUM>. In at least one configuration, the shift mechanism housing <NUM> may include an inner housing side <NUM> and a wall <NUM>. A shift mechanism housing cover <NUM> may be disposed proximate an end of the shift mechanism housing <NUM> that may face away from the cover <NUM>.

Referring to <FIG> and <FIG>, the inner housing side <NUM> may face toward the axis <NUM> and may extend around the axis <NUM>. The inner housing side <NUM> may include a first portion <NUM> and a second portion <NUM>.

Referring to <FIG>, the first portion <NUM> may extend from an end of the shift mechanism housing <NUM> toward or to the second portion <NUM>. The first portion <NUM> may extend around a portion of the planetary gear set and may be axially positioned between the cover <NUM> and the wall <NUM>. The first portion <NUM> may have a larger diameter than the second portion <NUM> and may cooperate with the wall <NUM> to help define an annular cavity <NUM> that may extend around the axis <NUM>.

The second portion <NUM> may generally extend between the wall <NUM> and the shift mechanism housing cover <NUM>. The second portion <NUM> may have a smaller diameter than the first portion <NUM>.

Referring to <FIG> and <FIG>, the wall <NUM> may extend from the inner housing side toward the axis <NUM>. For instance, the wall <NUM> or a portion thereof may be disposed substantially perpendicular to the axis <NUM>. The wall <NUM> may be axially positioned between the planetary gear set and the shift mechanism housing cover <NUM>. The wall <NUM> may help support the planet gear carrier <NUM>. For instance, the wall <NUM> may extend around a bearing assembly <NUM> that may rotatably support the planet gear carrier <NUM>. In at least one configuration, the wall <NUM> may include a first wall side <NUM>, a second wall side <NUM>, and an inner wall side <NUM>. In addition, the wall <NUM> may define one or more lubricant openings <NUM>.

The first wall side <NUM> may extend from the inner housing side <NUM> toward the axis <NUM>. The first wall side <NUM> may face toward the planetary gear set, or to the left from the perspective shown in <FIG>.

The second wall side <NUM> may be disposed opposite the first wall side <NUM>. The second wall side <NUM> may also extend from the inner housing side <NUM> toward the axis <NUM>. The second wall side <NUM> may face away from the planetary gear set or may face to the right from the perspective shown in <FIG>.

The inner wall side <NUM> may extend between the first wall side <NUM> and the second wall side <NUM>. The inner wall side <NUM> may receive and may engage the bearing assembly <NUM>.

One or more lubricant openings <NUM> may be provided in the wall <NUM>. In the configuration shown in <FIG>, two lubricant openings <NUM> are shown; however, it is contemplated that a greater or lesser number of lubricant openings <NUM> may be provided. A lubricant opening <NUM> may be configured as a through hole that may extend from the first wall side <NUM> to the second wall side <NUM>. A lubricant opening <NUM> may be disposed proximate the inner housing side <NUM>. In at least one configuration, a lubricant opening <NUM> may be partially defined by the inner housing side <NUM>. As is best shown in <FIG>, a lubricant opening <NUM> may extend along a curve or an arc. For instance, a lubricant opening <NUM> may have an outer lubricant opening side <NUM> and an inner lubricant opening side <NUM> that may extend along a curve or an arc. The outer lubricant opening side <NUM>, the inner lubricant opening side <NUM>, or both may be radially disposed with respect to the axis <NUM>. A first lubricant opening side <NUM> and a second lubricant opening side <NUM> may be disposed at opposite ends of the lubricant opening <NUM>. The first lubricant opening side <NUM> may extend from a first end of the outer lubricant opening side <NUM> to a first end of the inner lubricant opening side <NUM>. The second lubricant opening side <NUM> may extend from a second end of the outer lubricant opening side <NUM> to a second end of the inner lubricant opening side <NUM>.

Referring to <FIG>, <FIG> and <FIG>, a deflector <NUM> may be mounted to the shift mechanism housing <NUM> proximate the lubricant opening <NUM>. The deflector <NUM> may be axially positioned between the planetary gear set and the wall <NUM>. The deflector <NUM> may direct lubricant <NUM> through one or more lubricant openings <NUM>. The deflector <NUM> may be mounted to the first wall side <NUM> of the wall <NUM> and may be spaced apart from the inner housing side <NUM> of the shift mechanism housing <NUM>. In at least one configuration, the deflector <NUM> may include a ring portion <NUM> and one or more deflector portions <NUM>.

The ring portion <NUM>, if provided, may extend continuously around the axis <NUM>. The ring portion <NUM> may include one or more fastener holes that may receive fasteners that may mount the deflector <NUM> to the wall <NUM>.

One or more deflector portions <NUM> may extend from the ring portion <NUM>. In <FIG> and <FIG>, four deflector portions <NUM> are shown; however, it is contemplated that a greater or lesser number of deflector portions <NUM> may be provided. A deflector portion <NUM> may be disposed along a radial line with respect to the axis <NUM>. In addition, a deflector portion <NUM> may be positioned at or near the center of a lubricant opening <NUM>. For instance, a deflector portion <NUM> may be generally positioned halfway between the first lubricant opening side <NUM> and the second lubricant opening side <NUM> as is best shown in <FIG>. In at least one configuration, a deflector portion <NUM> may be spaced apart from the first portion <NUM> of the inner housing side <NUM>. In at least one configuration, a deflector portion <NUM> may include a stem <NUM> and an enlarged head <NUM>.

The stem <NUM> may extend from the ring portion <NUM> in a direction that extends away from the axis <NUM>. In at least one configuration, the stem <NUM> may be narrower than the enlarged head <NUM>.

The enlarged head <NUM> may be disposed at the end of the stem <NUM>. In at least one configuration, the stem <NUM> and the enlarged head <NUM> may cooperate to define a first deflection surface <NUM> and a second deflection surface <NUM>. The first deflection surface <NUM> and the second deflection surface <NUM> may be disposed opposite each other. In at least one configuration, the first deflection surface <NUM> and the second deflection surface <NUM> may have mirror symmetry with respect to each other. The first deflection surface <NUM>, the second deflection surface <NUM>, or both may be tapered such that the first deflection surface <NUM> and/or the second deflection surface <NUM> become closer together in an axial direction that may extend along the axis <NUM> toward the lubricant opening <NUM>. A tapered configuration may help direct lubricant <NUM> toward a lubricant opening <NUM>.

Rotation of the planetary gear set may cause lubricant <NUM> in the annular cavity <NUM> of the shift mechanism housing <NUM> to move along the inner housing side <NUM> about the axis <NUM>. As such, rotation of the planetary gear set may cause lubricant <NUM> to move in a circumferential direction about the axis <NUM>. The deflector <NUM> may redirect the lubricant <NUM> from moving in a circumferential direction to moving in an axial direction and through the lubricant opening <NUM>. Providing a tapered configuration on the first deflection surface <NUM> and the second deflection surface <NUM> may help direct lubricant <NUM> in the annular cavity <NUM> toward the lubricant opening <NUM> as the planetary gear set rotates in either direction about the axis <NUM>.

Referring to <FIG>, <FIG> and <FIG>, a lubricant chute <NUM> may be mounted to the wall <NUM>. The lubricant chute <NUM> may be disposed on the second wall side <NUM> and thus may be disposed opposite the deflector <NUM>. The lubricant chute <NUM> may be aligned with or may be disposed adjacent to a lubricant opening <NUM>. As such, the lubricant chute <NUM> may receive lubricant <NUM> that passes through the lubricant opening <NUM> or lubricant <NUM> that is deflected by the deflector <NUM> through the lubricant opening <NUM>. In at least one configuration, the lubricant chute <NUM> may be disposed above the axis <NUM>, above the drive pinion <NUM>, above the shift collar <NUM> or combinations thereof.

The lubricant chute <NUM> may extend in a direction that extends away from the wall <NUM> and toward the shift mechanism housing cover <NUM>. The lubricant chute <NUM> may slope downward or become progressively closer to the axis <NUM> as the distance from the wall <NUM> increases. Optionally, the lubricant chute <NUM> may become narrower as the distance from the wall <NUM> increases. As is best shown in <FIG>, the lubricant chute <NUM> may be provided with an axial length that may route lubricant <NUM> past the end of the shift collar <NUM> that is disposed closest to the shift mechanism housing cover <NUM>. For instance, the lubricant chute <NUM> may extend away from the wall <NUM> and past the end of the shift collar <NUM> that is disposed opposite the drive pinion <NUM>.

Claim 1:
An axle assembly (<NUM>) comprising:
an electric motor module (<NUM>) that is operatively connectable to a differential assembly (<NUM>), the electric motor module (<NUM>) having a motor housing (<NUM>) that receives a rotor (<NUM>) that is rotatable about an axis (<NUM>);
a cover (<NUM>) that is mounted to an end of the motor housing (<NUM>), wherein the cover (<NUM>) receives a planetary gear set that is operatively connected to the rotor (<NUM>), wherein the planetary gear set includes:
a planet gear carrier (<NUM>) that is rotatable about the axis (<NUM>) and that rotatably supports a planet gear (<NUM>) that meshes with a planetary ring gear (<NUM>) and a sun gear (<NUM>), wherein the planet gear carrier (<NUM>) has a first side (<NUM>) that faces toward the cover (<NUM>);
a lubricant catching ring (<NUM>) that extends around the axis (<NUM>) and that is mounted to the first side (<NUM>), wherein the lubricant catching ring (<NUM>) defines a lubricant catching ring hole (<NUM>) and cooperates with the planet gear carrier (<NUM>) to define a chamber (<NUM>) that captures lubricant (<NUM>) that passes through the lubricant catching ring hole (<NUM>); and
a washer (<NUM>) that is axially positioned between an end of the planet gear (<NUM>) and the planet gear carrier (<NUM>), the washer (<NUM>) defining a washer hole (<NUM>) that receives a planet pin (<NUM>), an outside washer surface (<NUM>) that faces away from the washer hole (<NUM>), characterized in that the washer (<NUM>) has an elliptical groove (<NUM>) that extends from the washer hole (<NUM>) to the outside washer surface (<NUM>).