# US 12,600,222 B2 · Electric transfer case with active hybrid engagement > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,600,222 B2 - Document ID: US12600222B2 - Status: Granted - Kind: B2 - Application number: 19/230,375 - Filed: 2025-06-06 - Published: 2025-12-11 - Granted: 2026-04-14 - Earliest claimed: 2024-06-06 - Assignees: Magna Powertrain of America, Inc. - Applicants: Magna Powertrain of America, Inc. - Inventors: Douglas Botto; Jeffrey Botticello; Jeremy Bakker; Lee McCay; Shawn Donaldson; Devin Ryman - Web page: https://patentgrep.com/patent/US12600222B2 ## CPC - B60K 6/365: with the gears having orbital motion - B60K 6/383: One-way clutches or freewheel devices - B60K 6/387: Actuated clutches, i.e. clutches engaged or disengaged by electric, hydraulic or mechanical actuating means - B60K 6/48: Parallel type - B60K 6/52: Driving a plurality of drive axles, e.g. four-wheel drive - B60K 23/0808: {for varying torque distribution between driven axles, e.g. by transfer clutch} - F16H 57/02: Gearboxes; Mounting gearing therein - B60K 2006/4808: {Electric machine connected or connectable to gearbox output shaft} - F16H 2057/02052: {Axle units; Transfer casings for four wheel drive} - Y02T 10/62: Hybrid vehicles - B60K: ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES - F16H: GEARING - Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION ## Abstract An electrified transfer case for a vehicle having an engine, a transmission, and front and rear drivelines is provided. The electrified transfer case includes a first output shaft adapted for connection to the rear driveline, a second output shaft adapted for connection to the front driveline, and an input shaft connected to the output of the transmission. The transfer case may further include a gear set engaged to an electric motor for torque multiplication, a multi-position torque transferring mode connection system, and a controllable torque transfer system between the first output shaft and the second output shaft. A synchronizing device is operatively connected between the input and first output shaft, which may utilize a one-way clutch. ## Claims ### Claim 1 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 synchronization device permits the first output shaft to overrun the input shaft; wherein the input shaft will engage the first output shaft via the synchronization device when the first output shaft no longer overruns the input shaft; wherein the multi-position connection system is operable to lock out the synchronization device, such that torque transfers between the first output shaft and the input shaft in both rotational directions. ### Claim 2 (depends on 1) The transfer case of claim 1, wherein the synchronization device synchronizes a rotational speed of both the input shaft and the first output shaft, such that the connection system is moveable into a positive connection engagement with both the input shaft and the first output shaft, wherein the positive connection links the rotational speed of the input shaft and the first output shaft in both rotational directions. ### Claim 3 (depends on 1) The transfer case of claim 1, wherein the synchronization device is a one-way clutch. ### Claim 4 (depends on 1) The transfer case of claim 1, 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. ### Claim 5 (depends on 4) The transfer case of claim 4, 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. ### Claim 6 (depends on 5) The transfer case of claim 5, 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. ### Claim 7 (depends on 1) The transfer case of claim 1, 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. ### Claim 8 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. ### Claim 9 (depends on 8) The transfer case of claim 8, wherein the controllable torque transfer system includes a controllable friction clutch disposed between the front output gear and the second output shaft, and wherein the rear output gear is fixed to the first output shaft, wherein when the clutch is engaged torque transfers between the front output gear and the rear output gear. ### Claim 10 (depends on 9) The transfer case of claim 9, wherein in a traditional operating mode, the main shaft shift sleeve is shifted into engagement with the first output shaft, and the layshaft shift sleeve is shifted out of engagement with the layshaft gear, such that the input shaft provides power at least to the first output shaft. ### Claim 11 (depends on 10) The transfer case of claim 10, wherein in a hybrid operating mode, the main shaft shift sleeve is shifted into engagement with the first output shaft, and the layshaft shift sleeve is shifted into engagement with the layshaft gear, wherein the input shaft and the electric motor both provide power to the first output shaft. ### Claim 12 (depends on 11) The transfer case of claim 11, wherein in an electric operating mode, the main shaft shift sleeve is shifted out of engagement with the first output shaft, and the layshaft shift sleeve is shifted into engagement with the layshaft, wherein the electric motor provides power to the first output shaft. ### Claim 13 (depends on 12) The transfer case of claim 12, wherein in a flat tow operating mode, the main shaft shift sleeve is shifted out of the engagement with the first output shaft, and the layshaft shift sleeve is shifted out of engagement with the layshaft gear, such that first and second output gears are rotatable in at least one rotatable direction without backdriving the input shaft or the electric motor. ### Claim 14 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. ### Claim 15 (depends on 14) The transfer case of claim 14, wherein the synchronization device is a one-way clutch disposed radially between the first output shaft and the cup portion, wherein an engaging portion of the shift sleeve is disposed radially between the cup portion and the extension. ### Claim 16 (depends on 15) The transfer case of claim 15, wherein the controllable torque transfer system transfers torque between a drive sprocket fixed to the first output shaft and a driven sprocket fixed to controllable friction clutch disposed between the driven sprocket and the second output shaft, wherein when the friction clutch is engaged torque transfers between the first output shaft and the second output shaft. ### Claim 17 (depends on 14) The transfer case of claim 14, wherein in the first axial position of the shift sleeve, the input shaft provides power to the first output shaft, wherein in the second axial position the input shaft and the electric motor provide power to the first output shaft, wherein in the third axial position the electric motor provides power to the first output shaft, wherein the in the fourth axial position, the input shaft and the electric motor are decoupled from the first and second output shafts, such that rotation of the first and second output shafts in at least one rotation direction will not backdrive the input shaft or the electric motor. ### Claim 18 (depends on 14) The transfer case of claim 14, wherein the synchronization device permits the first output shaft to overrun the input shaft. ### Claim 19 (depends on 18) The transfer case of claim 18, wherein the input shaft will engage the first output shaft via the synchronization device when the first output shaft no longer overruns the input shaft. ### Claim 20 (depends on 19) The transfer case of claim 19, wherein the multi-position connection system is operable to lock out the synchronization device, such that torque transfers between the first output shaft and the input shaft in both rotational directions.