Patents Assigned to Magna Powertrain of America, Inc.
  • Patent number: 11168743
    Abstract: A clutch assembly incorporated into a power transfer assembly (72) of a motor vehicle is presented. The clutch assembly includes a power-operated clutch actuator (306) for moving a clutch sleeve (354) axially between released and engaged positions between two rotatory members. In the released position, relative rotation between two rotary members is prevented. Whereas in the engaged position, relative rotation is permitted. The power-operated clutch actuator (306) further includes an electromagnetic solenoid with an output member having an extended condition and a retracted condition urging the clutch sleeve (354) between positions. A shift isolation linkage mechanism (304) interconnects the output member of the solenoid to the clutch sleeve (354) and permits movement of the output member to its retracted position while a blocked tooth condition inhibits movement of the clutch sleeve (354) to its engaged position.
    Type: Grant
    Filed: May 18, 2018
    Date of Patent: November 9, 2021
    Assignee: MAGNA POWERTRAIN OF AMERICA INC.
    Inventors: Wade Smith, Ryan Shaw, Bradley Ketchel
  • Patent number: 11161408
    Abstract: A multi-speed transfer case equipped with a planetary reduction gearset and a range clutch disposed between an input shaft and an output shaft. A clutch actuation mechanism controls actuation of the range clutch to establish distinct ratio drive connections between the input shaft and the output shaft.
    Type: Grant
    Filed: November 13, 2020
    Date of Patent: November 2, 2021
    Assignee: MAGNA POWERTRAIN OF AMERICA, INC.
    Inventors: John Zalewski, Michael Bujold, Ryan Strand
  • Patent number: 11053988
    Abstract: A vehicle powertrain system and powertrain actuator therefor is provided. The powertrain actuator selectively couples a first rotatable member to a second rotatable member to transfer torque therebetween and selectively decouples the first rotatable member from the second rotatable member to prevent the transfer of torque therebetween. The powertrain actuator includes a tubular cam assembly having a tubular first member and a tubular second member. The tubular first and second tubular members have end surfaces that interact with one another upon energizing a unidirectional solenoid. Upon a first energization of the solenoid, the first and second tubular members interact to operably couple the first and second rotatable members to allow torque to be transferred therebetween, and upon a second energization of the solenoid, the first and second tubular members interact to selectively decouple the first the second rotatable members to prevent the transfer of torque therebetween.
    Type: Grant
    Filed: March 28, 2018
    Date of Patent: July 6, 2021
    Assignee: MAGNA POWERTRAIN OF AMERICA, INC.
    Inventors: Ryan Strand, Wade Smith, Ryan Shaw
  • Patent number: 11021054
    Abstract: An integrated pinion/bearing/coupling (PBC) assembly for use with a hypoid gearset in power transfer assemblies of motor vehicles having mounting features and venting features, The integrated PBC assembly includes a hollow pinion unit made of steel and including a pinion shaft segment and a pinion gear segment, and a coupling unit having a hub segment made of aluminum. A brazing sleeve is used to braze the aluminum hub segment of the coupling unit to the steel pinion shaft segment of the pinion unit.
    Type: Grant
    Filed: February 8, 2017
    Date of Patent: June 1, 2021
    Assignee: MAGNA POWERTRAIN OF AMERICA, INC.
    Inventors: Bradley Ketchel, Wade Smith, Ralph Larson, Ryan Strand
  • Patent number: 10883588
    Abstract: A differential assembly is provided to include a two-piece differential carrier, a differential gearset installed within a gearset chamber formed in the differential carrier, and a ring gear. An interlocking feature mechanically interconnects the ring gear to the first and second case members of the two-piece differential carrier and defines first and second weldment junctions. A first weld seam is located in the first weldment junction and connects the ring gear to the first case member while a second weld seam is located in the second weldment junction and connects the ring gear to the second case member.
    Type: Grant
    Filed: February 8, 2017
    Date of Patent: January 5, 2021
    Assignee: MAGNA POWERTRAIN OF AMERICA, INC.
    Inventors: Bradley Ketchel, Wade Smith, Ryan Shaw
  • Patent number: 10871218
    Abstract: A drive axle unit for use in a motor vehicle having a multi-piece axle housing assembly including at least two housing components interconnected via at least one in-situ molded retainer component. A method for securing at least two housing components of an axle housing assembly by injecting a molten material into a pair of aligned mold indentations formed in the two housing components which solidifies to create an in-situ molded retainer component.
    Type: Grant
    Filed: July 19, 2016
    Date of Patent: December 22, 2020
    Assignee: MAGNA POWERTRAIN OF AMERICA, INC.
    Inventors: Paul W. Schwark, Bradley S. Ketchel
  • Patent number: 10851886
    Abstract: A two-speed transfer case for a four-wheel drive vehicle is provided. The transfer case has a two-speed planetary gearset, a range clutch, and a range shift mechanism. The planetary gearset includes a carrier unit having at least one crack arresting feature configured to limit propagation of a stress crack. The carrier unit includes a plurality of mounting holes for securing planet gears for rotation relative to the carrier unit. The gearset includes a sun gear configured for and a ring gear, with the planet gears in meshed engagement with the sun gear and the ring gear. The crack arresting feature extends at least partially through a portion of the carrier unit and is configured to receive a crack propagating from a central aperture of the carrier unit. The crack arresting feature is disposed radially between the central aperture and the mounting holes.
    Type: Grant
    Filed: August 22, 2019
    Date of Patent: December 1, 2020
    Assignee: MAGNA POWERTRAIN OF AMERICA INC.
    Inventors: Michael Bujold, Ralph Larson
  • Patent number: 10759274
    Abstract: An integrated pinion/bearing/coupling (PBC) assembly for use with a hypoid gearset in power transfer assemblies of motor vehicles having mounting features and venting features. The integrated PBC assembly includes a hollow pinion unit made of steel and including a pinion shaft segment and a pinion gear segment, and a coupling unit having a hub segment made of aluminum. A brazing sleeve is used to braze the aluminum hub segment of the coupling unit to the steel pinion shaft segment of the pinion unit. The PBC assembly can further include a constant velocity joint (CVJ) unit connected to, or formed as part of, the coupling unit.
    Type: Grant
    Filed: February 8, 2017
    Date of Patent: September 1, 2020
    Assignee: MAGNA POWERTRAIN OF AMERICA, INC.
    Inventors: Bradley Ketchel, Wade Smith, Ralph Larson, Ryan Strand
  • Patent number: 10710453
    Abstract: A transfer case for a four-wheel drive vehicle having a disconnectable secondary axle assembly. The transfer case is configured to include a pumpless lubrication sump maintained in relation to a mainshaft for lubricating rotary components surrounding the mainshaft.
    Type: Grant
    Filed: February 23, 2016
    Date of Patent: July 14, 2020
    Assignee: MAGNA POWERTRAIN OF AMERICA, INC.
    Inventors: Devin P. Ryman, Timothy J. Filkins
  • Patent number: 10662884
    Abstract: A power transfer assembly for a motor vehicle includes a clutch protection system to prevent damage to an actively-controlled multi-plate mode clutch of the power transfer assembly. The clutch protection system includes a transfer case control module (TCCM) and an engine control module (ECM) configured to regulate the distribution of torque applied from an engine to front and rear output shafts of the power transfer assembly. The TCCM is in operable communication with the engine control module ECM, wherein TCCM is configured to detect slip in the actively-controlled multi-plate friction clutch and to communicate with the ECM to selectively reduce the output torque of the engine in response to detected slip.
    Type: Grant
    Filed: January 3, 2019
    Date of Patent: May 26, 2020
    Assignee: MAGNA POWERTRAIN OF AMERICA, INC.
    Inventor: Benjamin Northrup
  • Patent number: 10550915
    Abstract: A power transmission assembly includes an input member adapted to receive drive torque from a source of torque, an output member adapted to provide drive torque to an output device and a bi-directional roller clutch including a first ring fixed for rotation with one of the input and output members. A second ring is spaced apart from the other of the input and output members. Rollers are positioned in aligned cam tracks formed in facing surfaces of the first and second rings. Neither the first ring nor the second ring support the input member or the output member on the other. The second ring may circumferentially index relative to the first ring for causing the rollers to ride up the cam tracks and force the second ring to frictionally engage the other of the input and output members, thereby establishing a drive connection between the input and output members.
    Type: Grant
    Filed: November 19, 2015
    Date of Patent: February 4, 2020
    Assignee: MAGNA POWERTRAIN OF AMERICA, INC.
    Inventor: Brian M. Fitzgerald
  • Patent number: 10539214
    Abstract: An integrated pinion, bearing and coupling (PBC) assembly for use with a hypoid gearset in power transfer assemblies of motor vehicles. The PBC assembly includes a pinion unit having a pinion gear segment and a pinion stub shaft segment, and a coupler unit having a coupling flange segment and a coupler shaft segment. The pinion stub shaft segment surrounds and is in press fit engagement with the coupler shaft segment. A portion of the coupler shaft segment is deformed to be retained within one of a receiver groove and raised projections formed in the pinion stub shaft segment so as to fixedly secure the coupler unit to the pinion unit.
    Type: Grant
    Filed: July 26, 2017
    Date of Patent: January 21, 2020
    Assignee: MAGNA POWERTRAIN OF AMERICA, INC.
    Inventors: Michael P. Bujold, Brad Ketchel, Wade Smith
  • Patent number: 10525829
    Abstract: An AWD drivetrain is configured to primarily direct drive torque from a transversely-aligned powertrain assembly through an auxiliary power transfer unit to a rear driveline and selectively transmit drive torque to a front driveline via actuation of at least one power-operated clutch. The auxiliary power transfer unit includes an input component drivingly connected to the powertrain assembly, and an output component connected to the input component by a hypoid gearset The output component is operatively connected to the rear driveline and is configured to normally transfer the drive torque to the rear driveline.
    Type: Grant
    Filed: September 11, 2015
    Date of Patent: January 7, 2020
    Assignee: MAGNA POWERTRAIN OF AMERICA, INC.
    Inventors: Matthew G. Girlando, John D. Zalewski
  • Patent number: 10479198
    Abstract: A transfer case for use in a four-wheel drive vehicle and having a clutch assembly disposed on a front output and a pass-through rear output arrangement. The front output is a front output shall. The rear output is established by directly interconnecting a transmission output shaft to an end segment of a rear propshaft. A transfer assembly is driven by the transmission output shaft and can be selectively coupled to the front output shaft via the clutch assembly.
    Type: Grant
    Filed: January 5, 2016
    Date of Patent: November 19, 2019
    Assignee: MAGNA POWERTRAIN OF AMERICA, INC.
    Inventor: Daniel M. Drill
  • Patent number: 10464415
    Abstract: A two-speed transfer case for a four-wheel drive vehicle is provided. The transfer case has a two-speed gear reduction unit, a range clutch, and a range shift mechanism. The range shift mechanism is operably disposed between an input shaft and a rear output shaft and includes a range cam defining a guide slot having a unique profile for converting rotation thereof into linear movement of the range clutch. The guide slot includes low-range dwell segment and a high-range dwell segment interconnected by a range shift segment. The range shift segment defines a plurality of interconnected cam portions, wherein each cam portion is associated with a different load required to move the range clutch between a high-range and low-range position. The transfer case further includes a mode shift mechanism for establishing a high-range drive connection and a low-range drive connection associated with the dwells of the range cam.
    Type: Grant
    Filed: November 28, 2017
    Date of Patent: November 5, 2019
    Assignee: MAGNA POWERTRAIN OF AMERICA, INC.
    Inventors: Anupam Sharma, Pete Jarzyna, Dan Harmon, Daniel M. Drill
  • Patent number: 10330183
    Abstract: A two-speed active transfer case includes an input shaft adapted to receive drive torque from a powertrain, a rear output shaft adapted for connection to a rear driveline and aligned with the input shaft for rotation about a first rotary axis, a front output shaft adapted for connection to a front driveline and aligned for rotation about a second rotary axis, and a transfer mechanism driven by the rear output shaft. The transfer case also includes a two-speed range mechanism operably disposed between the input shaft and the rear output shaft, a range shift mechanism for controlling operation of the two-speed range mechanism, a mode mechanism operably disposed between the transfer mechanism and the front output shaft, and a mode shift mechanism for controlling operation of the mode mechanism.
    Type: Grant
    Filed: June 2, 2016
    Date of Patent: June 25, 2019
    Assignee: MAGNA POWERTRAIN OF AMERICA, INC.
    Inventors: Joseph P. McNally, Daniel M. Drill
  • Patent number: 10330189
    Abstract: An active transfer case is disclosed having a multi-plate friction clutch installed on the front output shaft. A splash recovery lubrication system is provided to capture lubricant splashed from the sump in response to rotation of the friction clutch and transfer the captured lubricant to a central clutch feed chamber to cool and lubricate the components of the friction clutch.
    Type: Grant
    Filed: February 14, 2017
    Date of Patent: June 25, 2019
    Assignee: MAGNA POWERTRAIN OF AMERICA, INC.
    Inventors: Daniel M. Drill, Borin Reth, Julio Cesar Martinez Frausto
  • Patent number: 10245946
    Abstract: A two-speed transfer case configured for use in heavy-duty four-wheel drive vehicles and which is equipped with a low-torque power transfer arrangement and a high-torque power transfer arrangement.
    Type: Grant
    Filed: March 2, 2016
    Date of Patent: April 2, 2019
    Assignee: MAGNA POWERTRAIN OF AMERICA, INC.
    Inventor: Joseph McNally
  • Publication number: 20190024772
    Abstract: An integrated pinion/bearing/coupling (PBC) assembly for use with a hypoid gearset in power transfer assemblies of motor vehicles having mounting features and venting features. The integrated PBC assembly includes a hollow pinion unit made of steel and including a pinion shaft segment and a pinion gear segment, and a coupling unit having a hub segment made of aluminum. A brazing sleeve is used to braze the aluminum hub segment of the coupling unit to the steel pinion shaft segment of the pinion unit.
    Type: Application
    Filed: February 8, 2017
    Publication date: January 24, 2019
    Applicant: MAGNA POWERTRAIN OF AMERICA, INC.
    Inventors: Bradley Ketchel, Wade Smith, Ralph Larson, Ryan Strand
  • Publication number: 20180264939
    Abstract: A transfer case for a four-wheel drive vehicle having a disconnectable secondary axle assembly. The transfer case is configured to include a pumpless lubrication sump maintained in relation to a mainshaft for lubricating rotary components surrounding the mainshaft.
    Type: Application
    Filed: February 23, 2016
    Publication date: September 20, 2018
    Applicant: Magna Powertrain of America, Inc.
    Inventors: Devin P. Ryman, Timothy J. Filkins