Abstract: A motor assembly (10) includes a permanent magnet DC motor (16) having a shaft (24) mounted for rotation with a face gear pinion (26) associated with the shaft. A jack shaft and clutch assembly (18) is associated with the face gear pinion and is constructed and arranged to prevent back drive of the motor under certain operating conditions. A spur or helical pinion (40) is operatively associated with the jack shaft and clutch assembly. A drive member (56) is operatively associated with the spur or helical pinion such that movement of the shaft and face gear pinion moves the spur or helical pinion to drive the drive member. A housing structure is defined by an upper housing (14) joined with a lower housing (12). The motor, the face gear pinion, the jack shaft and clutch assembly, the spur or helical pinion and the drive member are housed within the housing structure. Only one of the upper or lower housings includes mounting structure (25) constructed and arranged to mount the motor assembly to another object.

Abstract: A window lift system includes a motor drive assembly (10) constructed and arranged to control movement window glass of a vehicle, and a door module (35) to which the drive assembly is coupled. The door module has surface features (36) disrupting a surface (37) of the door module to reduce the transfer of vibration energy from the door module to the drive assembly or vise versa. In an embodiment, the door module includes a diaphragm (34) and the surface features are annular, undulating, wave-like features in the diaphragm.

Abstract: A housing assembly 30 is provided for a permanent magnet motor. The housing assembly includes a ferrous flux ring structure 38 having an exterior 39 and an interior 36. Magnet structure 34 is carried within the interior of the flux ring structure 38. A plastic housing 32 substantially encapsulates the exterior of the flux ring structure 38 and at least portions of the magnet structure 34. A bearing 42 may be provided in a closed end of the housing 32.

Abstract: A clutch assembly 10 for use in a housing 26 has a race surface 32 and includes a shaft 13; an output structure 11; a cam 16; and a clutch plate 18. Follower structure 28 is associated with the cam. An input structure 14 is mounted on the shaft for rotation with respect to the shaft. The input structure 14 receives an input motion such that rotation of the input structure causes rotation of the cam 16 and shaft 13 so as to drive the output structure 11. During a back drive condition of the motor, when the output structure 11 is driving and torque is transmitted to the shaft 13 and thus to the cam 16, the cam causes the follower structure 28 to contact and exert pressure on the race surface 32 thereby preventing rotation of the shaft 13.

Abstract: A clutch assembly 100 is provided for a motor having an armature shaft and a worm shaft having a worm constructed and arranged to engage a gear. The clutch assembly includes a clutch housing 112 including a race surface 132; a cam 117 coupled to the worm shaft; follower structure 122 operatively associated with the cam; a clutch plate 114, and a clutch coupler 118 associated with the clutch plate, the cam, and the follower structure. The coupler is coupled to the armature shaft for rotation therewith, such that rotation of the coupler rotates the clutch plate, the cam and follower structure, and thus the worm shaft. During a back drive condition of the motor, when torque is transmitted to the worm shaft and thus to the cam, the cam is constructed and arranged to causes the follower structure 122 to contact and exert pressure on the race surface 132 thereby preventing rotation of the worm shaft.

Abstract: A drive assembly 21 is provided for an electric motor 10 having a rotatable shaft 12 including a worm 14. The drive assembly includes an output gear 16 constructed and arranged to mesh with the worm. The output gear includes a plurality of arms 22 extending generally from a periphery of the output gear radially towards a center of the output gear. A driver 18 is operatively associated with the output gear to rotate therewith. The driver includes a plurality of cams 24 near a periphery thereof. The cams are operatively associated with the arms so that when the driver stops rotating while the output gear continues to rotate, each cam engages an associated arm to absorb kinetic energy of the output gear while the motor stalls.

Abstract: A clutch assembly 10 is provided for a motor having a shaft 36, a worm 40 associated with the shaft and an output gear 42 engaged by the worm. The clutch assembly includes a clutch body 12 having a plurality of pockets 22 in a surface thereof. Each pocket has a cam surface 24 defined by a depth of the pocket that gradually increases from a deep end to a shallow end. A ball bearing 18 is disposed in each of the pockets 22. Spring structure 16 maintains the ball bearings in the pockets. A pressure plate 14 is operatively associated with the clutch body and is constructed and arranged to be coupled with the shaft 36 of the motor. Under certain conditions, the ball bearings wedge between the pressure plate and surfaces defining the associated pocket, thereby preventing rotation of the shaft when coupled with the pressure.

Abstract: A clutch mechanism 20 is provided for a motor 10. The motor has a shaft 12, a worm 14 associated with the shaft, a gear 16 engaged by the worm, and a friction surface 27. The clutch mechanism 20 includes a pressure plate 22 mounted for movement with respect to the shaft toward and away from the friction surface 27. A spring 26 is constructed and arranged to bias the pressure plate towards the friction surface. A stop 30 is constructed and arranged to limit movement of the pressure plate in a direction away from the friction surface. Whereby, under a back drive condition of the motor when the motor is not energized and the gear is moved by an externally applied torque causing an axial force to be exerted on the worm inducing an axial and an angular movement to the shaft, the pressure plate is constructed and arranged to move towards and engage the friction surface thereby impeding rotation of the shaft.

Abstract: A clutch mechanism 20 is provided for a motor 10. The motor has a shaft 12, a worm 14 associated with the shaft, a gear 16 engaged by the worm, and a friction surface 27. The clutch mechanism 20 includes a pressure plate 22 mounted for movement with respect to the shaft toward and away from the friction surface 27. A spring 26 is constructed and arranged to bias the pressure plate towards the friction surface. A stop 30 is constructed and arranged to limit movement of the pressure plate in a direction away from the friction surface. Whereby, under a back drive condition of the motor when the motor is not energized and the gear is moved by an externally applied torque causing an axial force to be exerted on the worm inducing an axial and an angular movement to the shaft, the pressure plate is constructed and arranged to move towards and engage the friction surface thereby impeding rotation of the shaft.

Abstract: A clutch assembly 10 is provided for a motor having a shaft 36, a worm 40 associated with the shaft and an output gear 42 engaged by the worm. The clutch assembly includes a clutch body 12 having a plurality of pockets 22 in a surface thereof. Each pocket has a cam surface 24 defined by a depth of the pocket that gradually increases from a deep end to a shallow end. A ball bearing 18 is disposed in each of the pockets 22. Spring structure 16 maintains the ball bearings in the pockets. A pressure plate 14 is operatively associated with the clutch body and is constructed and arranged to be coupled with the shaft 36 of the motor. Under certain conditions, the ball bearings wedge between the pressure plate and surfaces defining the associated pocket, thereby preventing rotation of the shaft when coupled with the pressure plate.