Friction clutch assemblies with low-drag disconnect clutch pack having cone clutch synchronizer

A method of assembling a friction clutch assembly for transferring torque from a rotating input member to a rotatable output member, the method comprising:

• receiving a clutch housing configured to attach to one of the input member or the output member;
• rotatably mounting an inner disc hub at least partially inside the clutch housing, the inner disc hub being configured to attach to the other of the input member or the output member;
• rotatably mounting a dynamic disc carrier at least partially inside the clutch housing coaxial with the inner disc hub such that the dynamic disc carrier is axially movable on the inner disc hub;
• positioning a clutch pack within the clutch housing, the clutch pack including a plurality of reaction plates interleaved with a plurality of friction plates, the reaction plates being secured to one of the clutch housing or the dynamic disc carrier for common rotation therewith, and the friction plates being secured to the other of the clutch housing or the dynamic disc carrier for common rotation therewith;
• and
• mounting a cone clutch on the dynamic disc carrier and interposed between the clutch pack and the inner disc hub, wherein axial movement of the dynamic disc carrier causes the cone clutch to frictionally engage the inner disc hub such that the clutch pack compresses to thereby carry torque from the input member, through the clutch housing and inner disc hub, and out to the output member.

A motor vehicle comprising:

• a vehicle body with front and rear axles each rotatably mounting thereon a plurality of road wheels;
• a rear-drive module drivingly connected to the rear axle;
• a prop shaft selectively connectable to the rear-drive module;
• a prime mover attached to the vehicle body and configured to generate torque;
• a multi-speed transmission drivingly connected to the prime mover and configured to receive, modify, and output the torque generated by the prime mover;
• and
• a friction clutch assembly interposed between the transmission and the rear axle, the friction clutch assembly being configured to selectively disconnect the prop shaft from the rear drive module, the friction clutch assembly including:
• a clutch housing with a cylindrical shell and a stub shaft closing off an open end of the cylindrical shell, wherein the stub shaft is splined to the prop shaft;
• an inner disc hub rotatably mounted at least partially inside the cylindrical shell of the clutch housing, wherein the inner disc hub is splined to a pinion shaft of the rear-drive module;
• a dynamic disc carrier rotatably mounted inside the cylindrical shell of the clutch housing concentric with the inner disc hub, wherein the dynamic disc carrier is axially slidable on the inner disc hub;
• a clutch pack disposed within the clutch housing and including a stack of reaction plates interleaved with friction plates, wherein the reaction plates are secured to the cylindrical shell for common rotation therewith, and the friction plates are secured to the dynamic disc carrier for common rotation therewith;
• and
• a cone clutch mounted on the dynamic disc carrier and interposed between the clutch pack and the inner disc hub,
• wherein axial translation of the dynamic disc carrier on the inner disc hub causes the cone clutch to frictionally engage the inner disc hub such that the clutch pack compresses to thereby carry torque from the prop shaft, through the clutch housing and inner disc hub, and out to the rear-drive module.