# US 12,215,772 B2 · Multi-speed gearbox and assembly method > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,215,772 B2 - Document ID: US12215772B2 - Status: Granted - Kind: B2 - Application number: 17/819,898 - Filed: 2022-08-15 - Published: 2024-02-15 - Granted: 2025-02-04 - Earliest claimed: 2022-08-15 - Assignees: Dana Heavy Vehicle Systems Group, LLC - Applicants: Dana Heavy Vehicle Systems Group, LLC - Inventors: Jordan M. Houser; William F. Waltz; Nicholas W. Smallman - Web page: https://patentgrep.com/patent/US12215772B2 ## CPC - F16H 57/023: Mounting or installation of gears or shafts in the gearboxes, e.g. methods or means for assembly - F16D 11/04: with clutching members movable only axially - F16D 11/10: with clutching members movable only axially - F16D 11/14: with clutching members movable only axially (F16D11/02, F16D11/08 take precedence) - F16H 48/08: comprising bevel gears - F16H 48/24: using positive clutches or brakes - F16H 48/42: characterised by features of the input shafts, e.g. mounting of drive gears thereon - F16H 57/0025: {with gearing elements rigidly connected to a shaft, e.g. securing gears or pulleys by specially adapted splines, keys or methods} - F16H 2048/087: {characterised by the pinion gears, e.g. their type or arrangement} - F16H 2048/423: {characterised by bearing arrangement} - F16H 2057/02052: {Axle units; Transfer casings for four wheel drive} - F16H: GEARING - F16D: COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES ## Abstract Methods and systems for a clutch cartridge are provided. The clutch cartridge includes, a dog clutch including a clutch ring slidingly engaged with a tube shaft and including a first toothed interface and a second toothed interface, where the dog clutch is designed to selectively engage a first gear and a second gear. The clutch cartridge further includes a first bearing coupled to the tube shaft and the first gear and a second bearing coupled to the tube shaft and the second gear. ## Claims ### Claim 1 A clutch cartridge, comprising: a dog clutch including: a clutch ring with a splined interface at an inner diameter, wherein the splined interface of the clutch ring is directly slidingly engaged with an outer diameter of a tube shaft, wherein the clutch ring includes a first toothed interface and a second toothed interface, and wherein the first toothed interface and the second toothed interface are positioned on opposing axial sides of the clutch ring; wherein the dog clutch is designed to: selectively engage the first toothed interface with a first gear toothed interface on a first gear, and selectively engage the second toothed interface with a second gear toothed interface on a second gear; a first bearing coupled to the tube shaft and the first gear; and a second bearing coupled to the tube shaft and the second gear; wherein the first gear includes teeth on an outer circumference; wherein the second gear includes teeth on an outer circumference; and wherein the tube shaft includes an interior splined section and a locational clearance fit section at an inner diameter that are profiled to couple to a pinion shaft. ### Claim 2 (depends on 1) The clutch cartridge of claim 1, wherein: the interior splined section is positioned radially inward from the first gear; and the locational clearance fit section is positioned radially inward from the second gear. ### Claim 3 (depends on 1) The clutch cartridge of claim 1, wherein the pinion shaft includes a pinion gear at a first axial end and a second axial end configured to couple to a nut. ### Claim 4 (depends on 1) The clutch cartridge of claim 1, further comprising a third bearing coupled to the pinion shaft axially outboard from the first gear and a fourth bearing coupled to the pinion shaft axially outboard from the second gear. ### Claim 5 (depends on 4) The clutch cartridge of claim 4, further comprising a first end cap and a second end cap coupled to: opposing ends of the tube shaft; and the pinion shaft axially inboard from the third bearing and the fourth bearing, respectively. ### Claim 6 (depends on 5) The clutch cartridge of claim 5, wherein axial clearances are formed between the first end cap and the first gear and the second end cap and the second gear. ### Claim 7 (depends on 1) The clutch cartridge of claim 1, wherein the first toothed interface is positioned on an axial side of the first gear and the second toothed interface is positioned on an axial side of the second gear. ### Claim 8 (depends on 1) The clutch cartridge of claim 1, wherein the splined interface of the clutch ring is positioned radially inward from an inner diameter of the first gear. ### Claim 9 (depends on 8) The clutch cartridge of claim 8, wherein the clutch ring includes a ring around its circumference. ### Claim 10 A multi-speed gearbox assembly, comprising: a clutch cartridge, comprising: a dog clutch including a clutch ring slidingly engaged with an outer diameter of a tube shaft via a splined interface; wherein the dog clutch is designed to selectively engage a first gear and a second gear; and a first bearing coupled to the tube shaft and the first gear; and a second bearing coupled to the tube shaft and the second gear; wherein the first gear includes teeth on an outer circumference; wherein the second gear includes teeth on an outer circumference; wherein the dog clutch, the tube shaft, the first bearing, and the second bearing form a continuous structure; wherein the tube shaft includes an interior splined section and a locational clearance fit section that are positioned at an inner diameter and are profiled to couple to an outer diameter of a pinion shaft; and wherein the clutch ring includes a first toothed interface and a second toothed interface which are positioned on opposing axial sides of the clutch ring. ### Claim 11 (depends on 10) The multi-speed gearbox assembly of claim 10, wherein: the interior splined section is positioned radially inward from the first gear; and the locational clearance fit section is positioned radially inward from the second gear. ### Claim 12 (depends on 10) The multi-speed gearbox assembly of claim 10, wherein the pinion shaft is coupled to and extends through the tube shaft and a pinion gear is positioned at a first end of the pinion shaft. ### Claim 13 (depends on 12) The multi-speed gearbox assembly of claim 12, wherein: the clutch cartridge is positioned axially between a third bearing and a fourth bearing; the third bearing is coupled to the pinion shaft axially outboard from the first gear and the fourth bearing is coupled to the pinion shaft axially outboard from the second gear; the pinion shaft includes a nut threaded onto a second end of the pinion shaft or a preload ring is positioned in a housing; and the nut or preload ring when tightened applies a preload to the clutch cartridge. ### Claim 14 (depends on 10) The multi-speed gearbox assembly of claim 10, wherein the multi-speed gearbox assembly is included in a vehicle. ### Claim 15 A method for assembling a multi-speed gearbox assembly, comprising: attaching a clutch ring of a dog clutch, a first gear, a second gear to an outer diameter of a tube shaft to form a clutch cartridge; and coupling an inner diameter of the clutch cartridge to a pinion shaft; wherein the first gear includes teeth on an outer circumference; wherein the second gear includes teeth on an outer circumference; wherein the clutch ring includes a splined interface at an inner diameter; wherein the splined interface of the clutch ring is attached to the outer diameter of the tube shaft; wherein the tube shaft includes an interior splined section and a locational clearance fit section at an inner diameter that are profiled to couple to the pinion shaft; wherein attaching the first gear and the second gear to the tube shaft includes attaching a first bearing and a second bearing to the tube shaft and attaching the first and second gears to the first bearing and the second bearing; and wherein the clutch ring includes a first toothed interface and a second toothed interface which are positioned on opposing axial sides of the clutch ring. ### Claim 16 (depends on 15) The method of claim 15, wherein the splined interface of the clutch ring is positioned radially inward from an inner diameter of the first gear. ### Claim 17 (depends on 16) The method of claim 16, wherein: the locational clearance fit section is positioned radially inward from the second gear. ### Claim 18 (depends on 15) The method of claim 15, further comprising applying a preload to bearings coupled to the pinion shaft via tightening of a nut on a threaded portion of the pinion shaft or via tightening a preload ring in a housing. ### Claim 19 (depends on 15) The method of claim 15, wherein the pinion shaft is positioned in a housing.