Patent ID: 12208676

DESCRIPTION OF THE PREFERRED EMBODIMENTS

For the purposes of promoting an understanding of the principles of the invention, reference will now be made to certain embodiments and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the described invention, and such further applications of the principles of the invention as illustrated therein, being contemplated as would normally occur to one skilled in the art to which the invention relates.

In one embodiment the present invention provides an assembly for mounting a portal gear box to an all-terrain vehicle or a utility task vehicle. As previously indicated, portal boxes are typically mounted to an ATV/UTV by mounting a backing plate to the portal box, and by mounting the suspension of the vehicle to the backing plate. The inventive portal box/mounting assembly avoids using a backing plate, and instead uses a portal box housing having integral mounting brackets. The use of integral mounting brackets provides a more secure and robust mounting of the box.

The inventive portal box/mounting assembly preferably comprises a housing having a rear wall, a front wall, and a side wall. The rear wall has an opening to receive an axle of an all-terrain vehicle or a utility task vehicle. The front wall has an opening to allow an output shaft to extend outward from the housing, with the vehicle wheels being mounted to the output shaft. A linking mechanism is provided in the housing, and is effective for linking the vehicle axle to the output shaft.

The inventive portal box/mounting assembly may be adapted to receive any axle of an all-terrain vehicle or a utility task vehicle. The axle may be referred to as a “stock axle,” and may be any axle that is powered by the drive train, regardless of whether it is an OEM axle or a replacement part. The axle may be an extended length axle, such as, for example, when the portal box assembly is installed with a lift kit which uses, and may even require, an extended length axle.

To allow the assembly to be mounted to a vehicle, the rear wall of the housing includes one or more integral mounting brackets effective to allow a vehicle suspension component to connect directly to the rear wall. The vehicle suspension component may be, for example, an A-arm, a trailing arm, a swing arm, etc. However, it is to be appreciated that other suspension components useful for mounting the vehicle to the portal box assembly (preferably such that the vehicle is ultimately supported by the wheels mounted on the output axle extending from the portal box) may be used, depending on the suspension system used in the vehicle being provided with the portal box assembly.

When the wheel is to be steered, the inventive portal box/mounting assembly also provides a structure to connect the assembly to the steering linkage, such as the tie rod to the rack and pinion. In the most preferred embodiments the structure for connecting the portal box assembly to the steering component is also made integral with the portal box housing, however, that is not required in all embodiments.

As previously indicated, the mounting brackets used to connect the suspension and/or the steering component(s) to the portal box are made into the rear wall of the housing, and are integral with it. For the purposes of this description, describing mounting brackets as being “integral” with the rear wall means that the brackets and rear wall are formed as a unit, and are not distinct parts, as would be the case with a traditional portal box-plus-backing plate construction. Accordingly, the backing plates used in prior art portal box assemblies are unnecessary, and are thus avoided. This use of a single piece to cover the rear portion of the portal box and to provide a structure for mounting the suspension to the box, provides benefits in strength and structural integrity that are not provided by prior art, two-piece constructions.

The integral brackets are preferably machined into the metal used to form the rear wall of the portal box, as opposed to being bolted on as would be the case if the brackets were made of sheet steel as prior art mounting brackets are. Alternatively, the rear wall/mounting bracket component may be forged, or cast, or otherwise made as a single piece of material.

In one preferred embodiment of the present invention the rear wall of the housing includes a first integral mounting bracket that is effective to allow an upper A-arm to connect directly to the rear wall, and a second integral mounting bracket that is effective to allow a lower A-arm to connect directly to the rear wall. In other embodiments the rear wall of the housing includes one or more integral mounting brackets effective to allow a trailing arm, or a swing arm, or some other suspension component to connect directly to the rear wall,

In other embodiments the rear wall of the housing includes one or more integral mounting brackets effective to allow a vehicle steering component to connect directly to the rear wall. For example, the integral mounting bracket may be effective to allow a steering linkage to connect directly to the rear wall.

In view of the above, it can be seen that in one embodiment preferred for use on wheels that will be steered (presumably, the front wheels), the rear wall of the housing includes an integral mounting bracket effective to allow an upper A-arm to connect directly to the rear wall, an integral mounting bracket effective to allow a lower A-arm to connect directly to the rear wall, and an integral mounting bracket effective to allow a steering linkage to connect directly to the rear wall. Similarly, in one embodiment preferred for use on wheels that will not be steered (presumably, the rear wheels), the rear wall of the housing includes an integral mounting bracket effective to allow an upper A-arm to connect directly to the rear wall, and an integral mounting bracket effective to allow a lower A-arm to connect directly to the rear wall.

Referring now to the drawings,FIG.1shows a prior art assembly in which a backing plate is required to connect the portal gear box to the vehicle suspension. Backing plate1is bolted onto gear box case5to provide the structure that is necessary to attach the gear box to the vehicle suspension. In particular, the backing plate1, case5, and cover7are held together by bolts passing through respective holes in these components.

In the prior art assemblies, each backing plate1is provided with upper and lower mounting brackets3and4, respectively. Four spaced portal box mounting bolt holes2are provided about the periphery of the plate. The brackets3,4, are attached to the plate1, preferably by welding.

The peripheral wall of prior art case5has a set of through holes6alignable with the mounting holes2in the backing plate1. Holes6may therefore be used to secure case5to backing plate1. Similarly, the cover7of the prior art assembly has holes8that align with holes6, and thereby may be used to secure cover7to the case5.

Mounting/securing bolts are used to secure cover7to case5and to backing plate1. The mounting/securing bolts extend through holes8in cover7, and then through holes6in case5, to secure cover7and case5and to backing plate1.

FIGS.2-10show various embodiments of the inventive portal box assembly that avoids the need for a backing plate. In the illustrated embodiments the required mounting hardware is provided on the rear wall of the box, and is made integral with it to avoid the need to mount the mounting hardware to the back plate of the box. This improved, one-piece construction provides a more secure attachment that reduces flex and increases the strength and rigidity compared with prior art assemblies.

InFIG.2, housing member11has a rear wall12and a side wall13. Rear wall12includes a vehicle axle opening17effective to receive the end of an axle of an all-terrain vehicle or a utility task vehicle. Rear wall12also includes an integral mounting bracket14effective to allow an upper A-arm to connect directly to the rear wall at connection location141, and an integral mounting bracket15effective to allow a lower A-arm to connect directly to the rear wall at connection location151. An integral mounting bracket16effective to allow a steering linkage to connect directly to the rear wall is also provided. The embodiment shown inFIG.2is the embodiment that is typically used on the front wheels which are steered via the steering linkage.

FIG.3shows a housing member21with a rear wall22and a side wall23. Rear wall22includes a vehicle axle opening27effective to receive the end of an axle of an all-terrain vehicle or a utility task vehicle. Rear wall22also includes an integral mounting bracket24effective to allow an upper A-arm to connect directly to the rear wall at connection location241, and effective to allow a lower A-arm to connect directly to the rear wall at connection location242. The embodiment shown inFIG.3is the embodiment that is typically used on the rear wheels which are not steered via a steering linkage.

FIG.4shows another perspective view of the housing ofFIG.2. Housing member11has a rear wall12and a side wall13. Rear wall12includes an integral mounting bracket14effective to allow an upper A-arm to connect directly to the rear wall at connection location141, and an integral mounting bracket15effective to allow a lower A-arm to connect directly to the rear wall at connection location151. An integral mounting bracket16effective to allow a steering linkage to connect directly to the rear wall is also illustrated.

FIG.5shows another perspective view of the housing ofFIG.2. Housing member11has a rear wall12and a side wall13, and rear wall12includes a vehicle axle opening17effective to receive the end of an axle of an all-terrain vehicle or a utility task vehicle. Portions of an integral mounting structure of the type typically used on a front wheel is illustrated. Threaded holes18allow a cover plate to be mounted to the housing to protect the internal components.

FIG.6shows another perspective view of the housing ofFIG.2, showing integral mounting brackets of the type typically used on a front wheel. Housing member11has a rear wall12that includes an integral mounting bracket14effective to allow an upper A-arm to connect directly to the rear wall at connection location141, and an integral mounting bracket15effective to allow a lower A-arm to connect directly to the rear wall at connection location151. An integral mounting bracket16effective to allow a steering linkage to connect directly to the rear wall is also shown in the Figure.

FIG.7shows a perspective view of the housing ofFIG.3showing integral mounting brackets of the type typically used on a rear wheel. Rear wall22includes an integral mounting bracket24effective to allow an upper A-arm to connect directly to the rear wall at connection location241, and effective to allow a lower A-arm to connect directly to the rear wall at connection location242.

FIG.8shows a perspective view of the housing ofFIG.3, showing integral mounting brackets of the type typically used on a rear wheel. Rear wall22includes an integral mounting bracket24effective to allow an upper A-arm to connect directly to the rear wall at connection location241, and effective to allow a lower A-arm to connect directly to the rear wall at connection location242.

FIG.9shows another perspective view of the housing ofFIG.3, showing integral mounting brackets of the type typically used on a rear wheel. Rear wall22includes a vehicle axle opening27effective to receive the end of an axle of an all-terrain vehicle or a utility task vehicle. Rear wall22also includes an integral mounting bracket24effective to allow an upper A-arm to connect directly to the rear wall at connection location241, and effective to allow a lower A-arm to connect directly to the rear wall at connection location242.

FIG.10shows an exploded view of a portal gear box assembly according to one embodiment of the present invention, showing the housing, linking mechanism, output shaft, and outer cover. Housing11includes integral mounting brackets14and15, and steering linkage connection bracket16. A linking mechanism comprising an input gear31, an idler gear32, and an output gear33are housed in the housing, and effective for linking an axle30received in the vehicle axle opening to an output shaft40.

FIG.11is a perspective view of the portal gear box assembly ofFIG.10as the two halves of the housing are moved toward each other to be bolted together. This Figure shows the trailing edge of the front side wall being moved to match and mate with the leading edge of the rear side wall so that the front housing member is connected to the rear housing member to provide a two-piece housing having a side wall comprising a rear side wall portion and a front sidewall portion.

FIG.12is a perspective view of the portal gear box assembly ofFIG.10after the two halves of the housing have been moved to each other and bolted together. This Figure shows assembly after the trailing edge of the front side wall has been moved to match and mate with the leading edge of the rear side wall so that the front housing member is connected to the rear housing member to provide a two-piece housing having a side wall comprising a rear side wall portion and a front sidewall portion.

The illustrated linking mechanism includes gears sized to be effective for providing a gear reduction between the input shaft (vehicle axle) and the output shaft. A cover37including an opening38for output shaft40may be secured to housing11, preferably with bolts-passing through bolt homes18.

The inventive portal box assembly is stronger and provides a better fitment due to the tighter tolerances of machining vs sheet steel and tubing.

While the invention has been illustrated and described in detail in the drawings and foregoing description, the same are to be considered as illustrative and not restrictive, it being understood that only certain preferred embodiments have been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected. In addition, it is to be appreciated that the present invention may comprise or consist essentially of any or all of the described or illustrated features. For example, the present invention includes devices and methods comprising any or all of the features described or illustrated in specification or drawings, and the present invention includes devices and methods consisting essentially of any or all of the features illustrated in the specification or drawings. Additionally, any or all of the features and/or embodiments disclosed herein may be combined with any or all of the other features and/or embodiments disclosed herein to provide a device or method that comprises or consists essentially of such features.

Finally, the grammatical device “and/or” (such as in “A and/or B”) is used in this disclosure to mean A alone, or B alone, or both A and B.