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 gear drive assembly (33) includes a housing (24), an external base (28) movable with respect to the housing, and an external gear member (12) associated with the external base. The assembly includes an internal gear member (14) surrounded by the external gear member and in meshing relation therewith. The assembly also includes a plurality of conductive polymer actuators (26) defining actuator sets. Each actuator set is coupled at one portion thereof to the housing with another portion thereof being coupled to the external base. Each actuator is constructed and arranged to deflect when voltage is applied thereto such that when voltage is selectively applied to the actuator sets, deflection of the actuators causes the external base to move causing the external gear member to move in an orbiting manner with respect to the internal gear member.

Abstract: A method of providing a housing assembly for a permanent magnet electric motor provides a frame holder having external surface features at an end thereof defining bearing support features. A plastic frame is provided over a portion of the frame holder. The plastic frame has internal surfaces features corresponding to the external surface features of the frame holder. The plastic frame has lamination receiving portions. Permanent magnets are placed adjacent to portions of the frame holder and between the lamination receiving portions of the plastic frame. A ferrous lamination is wound over the lamination receiving portions and the magnets to define flux structure.

Abstract: A window lift system (10) includes a support bracket structure (12) including gear structure (18, 20). A fixed rack structure (22, 24) is associated with the gear structure. A motor (16) is carried by the support bracket structure and the motor has a rotatable shaft. A gear train (28, 30, 32, 34) is associated with the shaft and with the gear structure such that rotation of the shaft moves the gear train, with the gear train driving the gear structure so as to move the support bracket structure with respect to the rack structure.

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 power take-off unit for a transaxle is provided with a unique double enveloping worm/worm gear transmission which has a ratio of the number of gear teeth on the worm gear to the number of threads on the worm which is low. The worm/worm gear transmission is more compact than conventional bevel gear systems which have typically been used in power take-off unit applications. The worm and worm gear transmission of the present invention also is quieter in operation and has a higher torque capacity than standard bevel gears of comparable size.

Abstract: A speed reducer is provided with housing having support for a shaft of an enveloping worm and a shaft of a face gear. The enveloping worm placed into meshing engagement with the face gear. They have crossing or intersected axes. The enveloping worm face gears are used for mechanical power transition while reducing the noise and the weight of the speed reducer.

Abstract: A housing (16) is provided for a permanent magnet electric motor. The housing includes a plastic frame (18) defining bearing support features at one end thereof. Permanent magnet structure (28) is associated with the frame so as to be exposed in an interior of the housing. Ferrous lamination material (32), defining flux structure, is wound around an exterior of the magnet structure and portions of the plastic frame.

Abstract: A differential includes a carrier and worm gear assembly that cooperate to provide speed differentiation between first and second output shafts as needed. The carrier is coupled to an axle input gear, such as a ring gear for example, or a transmission shaft. The worm gear assembly includes a first enveloping worm gear that drives the first output shaft and a second enveloping worm gear that drives the second output shaft. First and second gears are supported by the carrier and are each in meshing engagement with the first and second enveloping worm gears in a self-locking arrangement. When the first and second enveloping worm gears rotate they are able to turn the first and second gears during normal road conditions, however, the first and second gears cannot drive or turn the first and second enveloping worm gears during a low traction driving condition.

Abstract: A gear drive assembly (33) includes a housing (24), an external base (28) movable with respect to the housing, and an external gear member (12) associated with the external base. The assembly includes an internal gear member (14) surrounded by the external gear member and in meshing relation therewith. The assembly also includes a plurality of conductive polymer actuators (26) defining actuator sets. Each actuator set is coupled at one portion thereof to the housing with another portion thereof being coupled to the external base. Each actuator is constructed and arranged to deflect when voltage is applied thereto such that when voltage is selectively applied to the actuator sets, deflection of the actuators causes the external base to move causing the external gear member to move in an orbiting manner with respect to the internal gear member.

Abstract: A window lift system (10) includes a support bracket structure (12) including gear structure (18, 20). A fixed rack structure (22, 24) is associated with the gear structure. A motor (16) is carried by the support bracket structure and the motor has a rotatable shaft. A gear train (28, 30, 32, 34) is associated with the shaft and with the gear structure such that rotation of the shaft moves the gear train, with the gear train driving the gear structure so as to move the support bracket structure with respect to the rack structure.

Abstract: A differential includes a carrier and worm gear assembly that cooperate to provide speed differentiation between first and second output shafts as needed. The carrier is coupled to an axle input gear, such as a ring gear for example, or a transmission shaft. The worm gear assembly includes a first enveloping worm gear that drives the first output shaft and a second enveloping worm gear that drives the second output shaft. First and second gears are supported by the carrier and are each in meshing engagement with the first and second enveloping worm gears in a self-locking arrangement. When the first and second enveloping worm gears rotate they are able to turn the first and second gears during normal road conditions, however, the first and second gears cannot drive or turn the first and second enveloping worm gears during a low traction driving condition.

Abstract: A rack and pinion transmission is provided with a unique enveloping worm, spiral bevel or hypoid pinion in the engagement with a rack. These pinions have tapered shape which is modified by reposition of drive or/and coast face of said thread from original position. The new rack and pinion transmission is more efficient, quite and compact than conventional systems with worm or helical gear pinions. The rack and pinion transmission of the present invention is easily manufactured.

Abstract: Face enveloping gears are machined by face milling type cutting tool or gear shaper. This process includes the following steps: positioning of the cutting tool in tangential relation relative to the meshing enveloping pinion thread with face gear by the smallest pitch diameter of threads with face gear teeth; turning rotating cutter relative to axis of rotation of an imaginary enveloping wheel until generating tooth is on the outer circle of the face gear. For generation of enveloping pinion the complementary cutting tool has additional motion around axis of pinion rotation. In another method tooth shaper or helical hob rotating tool rotates around axis of rotation of a theoretical generating gear for enveloping pinion with a predetermined relative motion to axis of rotation of work gear. This reduces production cost and makes manufacturing easier.

Abstract: Epicyclic gear train is comprised of a first gear coaxial to second gear and a satellite gear in a mesh with first and second gears. Satellite gear is an enveloping worm and is placed on a rotating carrier for supporting said satellite where carrier is coaxial to first and second gears. Axis of enveloping worm and axis of first and second matting gears are parallel, intersection or crossing. Epicyclic gear train could also be comprised of the first gear coaxial to the second gear and two coaxial enveloping worms attached to each other to rotate together in mesh with first and second gears. Enveloping worms are placed on a rotating carrier for supporting said satellites where carrier is coaxial to first and second gears. Axis of enveloping worms and axis of first and second matting gears are parallel or intersected.

Abstract: An enveloping worm transmission is provided with a unique enveloping worm and worm gear with modified enveloping worm thread surfaces. Enveloping worm has general arrangements with worm gear on the face of worm gear. This invention offers combinations of enveloping worm with mating face worm gear where worm gear axis intersected, crossed or parallel to enveloping worm axis. The enveloping worm gear transmission is more efficient, quite and compact than conventional gear systems which have typically been used in power applications. The enveloping worm transmission of the present invention is easy manufacturing.

Abstract: A speed reducer is provided with housing having bearing support for a shaft of an enveloping worm and a shaft of a face gear. The enveloping worm placed into meshing engagement with the face gear. They have crossing, intersected or parallel axes. The enveloping worm face gears are used for mechanical power transition while reducing the noise and the weight of the speed reducer.

Abstract: Epicyclic gear train is comprised of a first gear coaxial to second gear and a satellite gear in a mesh with first and second gears. Satellite gear is an enveloping worm and is placed on a rotating carrier for supporting said satellite where carrier is coaxial to first and second gears. Axis of enveloping worm and axis of first and second matting gears are parallel, intersection or crossing. Epicyclic gear train could also be comprised of the first gear coaxial to the second gear and two coaxial enveloping worms attached to each other to rotate together in mesh with first and second gears. Enveloping worms are placed on a rotating carrier for supporting said satellites where carrier is coaxial to first and second gears. Axis of enveloping worms and axis of first and second matting gears are parallel or intersected.