Clutch assembly for a hybrid-electric aircraft propulsion system

A method for coupling an engine of an aircraft propulsion system with a propulsor, the propulsor driven by an output shaft, an engine drive gear driven by the engine decoupled from the output shaft by a clutch assembly in a disengaged state, the method comprising:

• driving rotation of the propulsor about a rotational axis with an electric machine coupled with the propulsor by the output shaft;
• moving a second coupling assembly of the clutch assembly by controlling an actuator to axially move the second coupling assembly from a first axial position to a second axial position, the second coupling assembly in the first axial position disengaged from a first coupling assembly of the clutch assembly, the second coupling assembly in the second axial position engaged with the first coupling assembly, the second coupling assembly moveable on the output shaft between the first axial position and the second axial position, the first coupling assembly including a first coupling body moveably mounted on the engine drive gear, the second coupling assembly including a second coupling body;
• magnetically coupling, with the second coupling assembly in the second axial position, a plurality of second magnet members mounted at the second coupling body with a plurality of first magnet members mounted at the first coupling body;
• and
• driving rotation of the propulsor about the rotational axis with the engine through the engine drive gear, the first coupling assembly, and the second coupling assembly.

An aircraft propulsion system comprising:

• an engine;
• an electric machine;
• a gearbox including an output shaft, an electric machine drive gear, an engine drive gear, and a clutch assembly, the output shaft having a rotational axis, the electric machine drive gear mounted on the output shaft, the electric machine drive gear driven by the electric machine, the engine drive gear selectively couplable with the output shaft by the clutch assembly, the clutch assembly including a bearing disposed between the output shaft and the engine drive gear, the engine drive gear rotatable relative to the output shaft on the bearing, the clutch assembly selectively coupling the engine drive gear with the output shaft, the clutch assembly configurable in a disengaged state and an engaged state, the clutch assembly further including a first coupling assembly, a second coupling assembly, and a magnetic alignment system,
• the first coupling assembly including a first coupling body and a plurality of first axial springs, the first coupling body moveably mounted on the engine drive gear, the plurality of first axial springs biasing the first coupling body axially outward from the engine drive gear toward the second coupling assembly,
• the second coupling assembly including a sliding coupling housing, a second coupling body, and a plurality of second axial springs, the sliding coupling housing moveably mounted on the output shaft, the sliding coupling housing axially moveable between a first axial position and a second axial position, the second coupling body moveably mounted on the sliding coupling housing, the second coupling body disengaged from the first coupling body with the sliding coupling housing in the first axial position, the second coupling body engaged with the first coupling body with the sliding coupling housing in the second axial position, the plurality of second axial springs biasing the second coupling body axially outward from the sliding coupling housing toward the first coupling assembly, and
• a magnetic alignment system including a plurality of first magnet members and a plurality of second magnet members, the plurality of first magnet members mounted at the first coupling body as a first circumferential arrangement, the plurality of second magnet members mounted at the second coupling body as a second circumferential arrangement;
• and
• a propulsor driven by the output shaft.