Electric transfer case with active hybrid engagement

An electrified transfer case for a vehicle having an engine, a transmission, and front and rear drivelines, the transfer case comprising:

• a first output shaft configured for connection to the rear driveline;
• a second output shaft configured for connection to the front driveline;
• an input shaft configured for connection to an output of the transmission;
• an electric motor having a motor output;
• a gear set driven by the motor output, wherein the gear set selectively provides torque multiplication from the motor output to the first output shaft;
• a controllable multi-position connection system that selectively sets one of a plurality of torque transferring operation modes;
• a controllable torque transfer system that selectively transfers torque between the first output shaft and the second output shaft;
• and
• a synchronization device operatively connected between the input shaft and the first output shaft;
• wherein the gear set includes a layshaft and a layshaft gear in meshed engagement with an output gear of the electric motor, wherein the layshaft gear is rotatable relative to the layshaft, and is configured for being selectively rotatably fixed with the layshaft;
• wherein the multi-position connection system includes a main shaft shift sleeve coaxial with the input shaft and the first output shaft and a layshaft shift sleeve coaxial with the layshaft and the layshaft gear, wherein an axial position of the layshaft shift sleeve and the main shaft shift sleeve are controllably axially shiftable to define different torque transferring operating modes;
• wherein the main shaft shift sleeve is rotatably fixed to the input shaft and selectively shiftable into and out of engagement with the first output shaft, and wherein the layshaft shift sleeve is rotatably fixed to the layshaft and selectively shiftable into and out of engagement with the layshaft gear;
• wherein the layshaft includes an idler gear that rotates with the layshaft, wherein the idler gear is meshed with a front output gear and a rear output gear, wherein driven rotation of the layshaft transfers torque to both the front output gear and the rear output gear via the idler gear.

An electrified transfer case for a vehicle having an engine, a transmission, and front and rear drivelines, the transfer case comprising:

• a first output shaft configured for connection to the rear driveline;
• a second output shaft configured for connection to the front driveline;
• an input shaft configured for connection to an output of the transmission;
• an electric motor having a motor output;
• a gear set driven by the motor output, wherein the gear set selectively provides torque multiplication from the motor output to the first output shaft;
• a controllable multi-position connection system that selectively sets one of a plurality of torque transferring operation modes;
• a controllable torque transfer system that selectively transfers torque between the first output shaft and the second output shaft;
• and
• a synchronization device operatively connected between the input shaft and the first output shaft;
• wherein the gear set includes a planetary gear assembly having a carrier, a fixed ring gear, and a plurality of planet gears carried on the carrier, and a sun gear, wherein the planet gears are in meshed engagement with the fixed ring gear and the sun gear;
• wherein the sun gear is fixed for rotation with the electric motor output;
• wherein the carrier includes a body portion to which the planet gears are attached and an extension;
• wherein the extension is selectively coupled for fixed rotation with the input shaft based on a position of the multi-position connection system;
• wherein the multi-position connection system includes a shift sleeve fixed for rotation with the first output shaft and shiftable into selective engagement with a cup portion fixed for rotation with the input shaft at a first axial position of the shift sleeve, both the cup portion and the extension of the carrier at a second axial position of the shift sleeve, the extension of the carrier at a third axial position of the shift sleeve, and neither the cup portion nor the extension at a fourth axial position of the shift sleeve.