Differential assembly with features for improved lubrication

An axle assembly comprising:

• an axle housing assembly including a housing structure having an interior cavity with a sump;
• a lubricant disposed in the sump having a liquid lubricant level;
• and
• a differential mounted in the axle housing assembly for rotation about a first axis, the differential including a ring gear, the ring gear generating an annular stream of lubricant adjoining the ring gear above the liquid lubricant level during operation of the differential at a rotational speed greater than a predetermined rotational speed and in a predetermined rotational direction;
• a first deflector means including a first face extending into the stream and directing a portion of the stream in a first path along the first face transverse to a second path of the portion of the stream when the stream first comes into contact with the first face;
• and
• a second deflector means including an edge adjoining the first face, the edge dispersing the portion of the stream away from the interior surface into the cavity;
• wherein said second deflector means disperses the portion of the stream into a spray.

A method for lubricating a differential mounted in a housing structure of an axle assembly, the method comprising:

• generating a stream of lubricant above a liquid lubricant level of a lubricant disposed in a sump of the housing structure by rotating a ring gear of the differential through the lubricant at a rotational speed greater than a predetermined rotational speed;
• deflecting a portion of the stream in a first path along a first face of a deflector coupled to an interior surface of the housing structure, the first face extending into the stream, the first path being transverse to a second path of the portion of the stream when the stream first impinges the first face;
• and
• dispersing the portion of the stream into a spray using an edge of the deflector adjoining the first face after the deflecting.