IP Library › Granted Patent US 8,500,594
Granted Patent B2
US 8,500,594 · App. 12/288,230 · Granted Aug 6, 2013

Differential assembly and method for manufacturing same

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Quick Facts
Patent No.
US 8,500,594
App. No.
12/288,230
Granted
Aug 6, 2013
Kind
B2
Abstract

A differential assembly and method of manufacturing such an assembly are provided. A method for manufacturing a differential assembly includes forming a first portion of a differential carrier; forming a second portion of the differential carrier; securing the first portion to the second portion to form the differential carrier; forming a differential housing; and securing the differential carrier to the differential housing to form a differential assembly. A sintering process may be used to form the first portion and second portion of the differential carrier, and the first and second portions may be secured together by a brazing process. The forming of the first and second portions of the differential carrier and the securing of the first and second portions to form a differential carrier may be achieved by a sinter-brazing process.

Claims (13)

1. A method of forming a differential assembly comprising:

forming a differential carrier including the steps:

sintering powder metal to form a unitary carrier body having a generally planar surface and a plurality of legs extending from the surface;

sintering powder metal to form a cap having a generally planar surface;

securing the cap to the unitary carrier such that the generally planar surface or the cap is arranged substantially parallel to the generally planar surface of the carrier body; and

brazing a differential housing to the differential carrier.

2. The method of claim 1 where:

the differential carrier further includes a first aperture;

the differential housing further includes a second aperture; and

the differential assembly further includes a fastener positioned at least partially in the first aperture and second aperture.

3. The method of claim 1 , further comprising applying a brazing material layer between the first sintered portion and the second sintered portion.

4. The method of claim 1 , further comprising the step of sintering powder metal to form the differential housing.

5. The method of claim 1 wherein the differential assembly further comprises a spline.

Assignments (21)
SECURITY INTEREST Recorded Oct 3, 2025
From: AMERICAN AXLE MANUFACTURING, INC.; MD INVESTORS CORPORATION; AAM NORTH AMERICA, INC.
To: U.S. BANK TRUST COMPANY, NATIONAL ASSOCIATION, AS NOTES COLLATERAL AGENT
Reel/Frame 073005/0001 →
MERGER Recorded Jul 26, 2022
From: METALDYNE, LLC
To: MD INVESTORS CORPORATION
Reel/Frame 060622/0528 →
SECURITY INTEREST Recorded May 31, 2022
From: AMERICAN AXLE & MANUFACTURING, INC.
To: JPMORGAN CHASE BANK, N.A., AS COLLATERAL AGENT
Reel/Frame 060244/0001 →
SECURITY INTEREST Recorded Jun 8, 2017
From: AMERICAN AXLE & MANUFACTURING, INC.; CLOYES GEAR AND PRODUCTS, INC.; GREDE LLC; GREDE II LLC; METALDYNE, LLC; METALDYNE BSM, LLC; MSP INDUSTRIES CORPORATION
To: JPMORGAN CHASE BANK, N.A., AS COLLATERAL AGENT
Reel/Frame 042734/0001 →
RELEASE OF SECURITY INTEREST IN PATENTS RECORDED AT R/F 034024/0440 Recorded Apr 6, 2017
From: GOLDMAN SACHS BANK USA, AS AGENT
To: METALDYNE, LLC
Reel/Frame 042178/0559 →
CORRECTIVE ASSIGNMENT TO CORRECT THE INCORRECT PATENT NO. 7753596 PREVIOUSLY RECORDED AT REEL: 029495 FRAME: 0370. ASSIGNOR(S) HEREBY CONFIRMS THE SECURITY AGREEMENT. Recorded Nov 25, 2014
From: METALDYNE, LLC
To: BANK OF AMERICA, N.A.
Reel/Frame 034502/0415 →
RELEASE OF SECURITY INTEREST (RELEASE OF 029495/0370) Recorded Oct 21, 2014
From: BANK OF AMERICA, N.A.
To: METALDYNE, LLC
Reel/Frame 034030/0232 →
PATENT SECURITY AGREEMENT Recorded Oct 20, 2014
From: METALDYNE, LLC
To: GOLDMAN SACHS BANK USA, AS COLLATERAL AGENT
Reel/Frame 034024/0440 →
TERMINATION OF SECURITY INTEREST Recorded Mar 12, 2013
From: BANK OF AMERICA, N.A., AS COLLATERAL AGENT
To: METALDYNE, LLC; METALDYNE SINTERFORGED PRODUCTS, LLC; METALDYNE POWERTRAIN COMPONENTS, INC.; METALDYNE SINTERED RIDGWAY, LLC; METALDYNE BSM, LLC; METALDYNE M&A BLUFFTON, LLC; METALDYNE TUBULAR COMPONENTS, LLC; PUNCHCRAFT MACHINING AND TOOLING, LLC; MD INVESTORS CORPORATION
Reel/Frame 029972/0039 →
TERMINATION OF SECURITY INTEREST Recorded Mar 5, 2013
From: DEUTSCHE BANK TRUST COMPANY AMERICAS, AS COLLATERAL AGENT
To: METALDYNE, LLC
Reel/Frame 029920/0611 →
SECURITY AGREEMENT Recorded Dec 18, 2012
From: METALDYNE, LLC
To: BANK OF AMERICA, N.A., AS COLLATERAL AGENT
Reel/Frame 029495/0370 →
SECURITY AGREEMENT/METALDYNE PATENTS GRANT Recorded May 31, 2011
From: METALDYNE, LLC
To: DEUTSCHE BANK TRUST COMPANY AMERICAS, AS COLLATERAL AGENT
Reel/Frame 026362/0100 →
RELEASE OF SECURITY INTEREST/FIRST LIEN PATENTS Recorded May 31, 2011
From: DEUTSCHE BANK TRUST COMPANY AMERICAS, AS COLLATERAL AGENT
To: METALDYNE, LLC
Reel/Frame 026362/0922 →
PATENT SECURITY AGREEMENT Recorded Oct 27, 2010
From: METALDYNE, LLC
To: DEUTSCHE BANK TRUST COMPANY AMERICAS, AS COLLATERAL AGENT
Reel/Frame 025192/0669 →
RELEASE OF SECURITY INTEREST IN PATENTS SECOND LIEN RECORDED AT REEL/FRAME 023409/0512 Recorded Oct 22, 2010
From: WILMINGTON TRUST FSB, AS COLLATERAL AGENT
To: METALDYNE TUBULUAR COMPONENTS, LLC; METALDYNE BSM, LLC; METALDYNE, LLC
Reel/Frame 025183/0442 →
RELEASE OF SECURITY INTEREST IN PATENTS FIRST LIEN RECORDED AT REEL/FRAME 023409/0063 Recorded Oct 22, 2010
From: WILMINGTON TRUST FSB, AS COLLATERAL AGENT
To: METALDYNE TUBULUAR COMPONENTS, LLC; METALDYNE BSM, LLC; METALDYNE, LLC
Reel/Frame 025182/0986 →
SECURITY AGREEMENT Recorded Apr 5, 2010
From: METALDYNE, LLC
To: BANK OF AMERICA, N.A., AS AGENT
Reel/Frame 024170/0962 →
SECOND LIEN SECURITY INTEREST Recorded Oct 23, 2009
From: METALDYNE, LLC; METALDYNE CHASSIS PRODUCTS, LLC; METALDYNE TUBULAR COMPONENTS, LLC; METALDYNE BSM, LLC
To: WILMINGTON TRUST FSB, AS COLLATERAL AGENT
Reel/Frame 023409/0512 →
FIRST LIEN SECURITY INTEREST Recorded Oct 22, 2009
From: METALDYNE, LLC; METALDYNE CHASSIS PRODUCTS, LLC; METALDYNE TUBULAR COMPONENTS, LLC; METALDYNE BSM, LLC
To: WILMINGTON TRUST FSB, AS COLLATERAL AGENT
Reel/Frame 023409/0063 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Oct 21, 2009
From: METALDYNE CORPORATION; METALDYNE COMPANY LLC; METALDYNE SINTERED COMPONENTS, LLC; NC-M CHASSIS SYSTEMS, LLC; METALDYNE TUBULAR PRODUCTS, INC.; METALDYNE MACHINING AND ASSEMBLY COMPANY, INC.
To: METALDYNE, LLC
Reel/Frame 023401/0190 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jan 9, 2009
From: SEFCIK, MICHAEL; VELDMAN, ROBERT; LUBBEN, JEFF
To: METALDYNE COMPANY LLC
Reel/Frame 022082/0235 →