Modular bi-directional clutch assembly

A power transmission device comprising:

• a rotary input member adapted to receive drive torque from a source of torque;
• a rotary output member adapted to provide drive torque to an output device;
• and
• a torque transfer mechanism operable for transferring drive torque from said input member to said output member, said torque transfer mechanism including a bi-directional overrunning mode clutch having a first ring driven by said rotary input member, a second ring non-rotatably coupled to said first ring, a third ring positioned on said rotary output member and rollers disposed in aligned cam tracks formed in facing surfaces of said second and third rings, said third ring adapted to circumferentially index relative to said second ring to cause said rollers to ride up said cam tracks and cause-said third ring to frictionally engage said rotary output member, and a mode actuator that is moveable between a first position and a second position to establish corresponding AUTO and LOCK modes, said overrunning clutch being operable in its AUTO mode to permit relative rotation between said rotary input member and said rotary output member in a first direction and prevent relative rotation therebetween in a second direction, and said overrunning clutch being operable in its LOCK mode to prevent relative rotation between said rotary input member and said rotary output member in both directions.

A power transmission device comprising:

• a rotary input member adapted to receive drive torque from a source of torque;
• a rotary output member adapted to provide drive torque to an output device;
• and
• a bi-directional overrunning clutch operable for transferring drive torque from said input member to said output member, said bi-directional overrunning clutch including a first ring driven by said rotary output member, a second ring non-rotatably coupled to said rotary input member, a third ring positioned between said first ring and said second ring and rollers disposed in aligned cam tracks formed in facing surfaces of said second and third rings, said third ring adapted to circumferentially index relative to said second ring to cause said rollers to ride up said cam tracks and cause said third ring to frictionally engage said first ring.

A power transmission coupling comprising:

• a first coupling member including a first friction surface;
• a second coupling member including a first cylindrical bearing surface;
• a third coupling member including a second cylindrical bearing surface and a third cylindrical bearing surface, said third bearing surface including a plurality of first recesses;
• a tubular slipper positioned between said first and third coupling members, said tubular slipper including a second friction surface for engagement with said first friction surface, and a fourth cylindrical bearing surface including a plurality of second recesses, each of said first recesses together with their respective one of said second recesses defining a pocket;
• a plurality of roller elements disposed in said pockets for coupling said first coupling member to said second coupling member when said tubular slipper and said third coupling member rotate relative to one another;
• and
• an actuator for controlling rotational movement of said tubular slipper relative to said third coupling member.

A method of making a power transmission device comprising:

• determining a distance between a first bearing surface of a first coupling member and a first friction surface of a second coupling member;
• selecting a third coupling member from a group of coupling members having different thicknesses, said selection being based on said distance, said third coupling member including a second bearing surface and a third bearing surface;
• engaging said first bearing surface with said second bearing surface to non-rotatably couple said third coupling member to said first coupling member;
• positioning a plurality of rollers between said third coupling member and a tubular slipper, said tubular slipper having a second friction surface and a fourth bearing surface, said third and fourth bearing surfaces having cam tracks formed thereon to receive said plurality of rollers;
• and
• positioning said second friction surface spaced apart from said first friction surface to allow selective coupling of said first coupling member and said second coupling member by rotating said tubular slipper relative to said third coupling member.

A transfer case for transferring drive torque from a powertrain to first and second drivelines of a motor vehicle, said transfer case comprising:

• a first shaft adapted to transfer drive torque from the powertrain to the first driveline;
• a second shaft adapted for connection to the second driveline;
• a transfer assembly including a first sprocket driven by said first shaft, a second sprocket surrounding said second shaft, and a drive mechanism interconnecting said second sprocket to said first sprocket;
• and
• a mode clutch for selectively coupling said second shaft for rotation with said second sprocket, said mode clutch including a first ring having an outer surface engaging an inner surface of said second sprocket and an inner surface with first cam surfaces, a second ring having an inner surface mounted on an outer surface of said second shaft and an outer surface with second cam surfaces, and rollers disposed between aligned sets of said first and second cam surfaces, said second ring adapted to circumferentially index relative to said first ring to cause said rollers to ride up said cam surfaces and cause said inner surface of said second ring to frictionally engage said outer surface of said second shaft.

A transfer case for transferring drive torque from a powertrain to first and second drivelines of a motor vehicle, said transfer case comprising:

• a first shaft adapted to transfer drive torque from the powertrain to the first driveline;
• a second shaft adapted for connection to the second driveline;
• a transfer assembly including a first sprocket surrounding said first shaft, a second sprocket fixed to said second shaft, and a drive mechanism interconnecting said first sprocket to said second sprocket;
• and
• a mode clutch for selectively coupling said first sprocket for rotation with said first shaft, said mode clutch including a first ring having an outer surface engaging an inner surface of said first sprocket and an inner surface with first cam surfaces, a second ring having an inner surface mounted on an outer surface of said first shaft and an outer surface with second cam surfaces, and rollers disposed between aligned sets of said first and second cam surfaces, said second ring adapted to circumferentially index relative to said first ring to cause said rollers to ride up said cam surfaces and cause said inner surface of said second ring to frictionally engage said outer surface of said first shaft.

A transfer case for transferring drive torque from a powertrain to first and second drivelines of a motor vehicle, said transfer case comprising:

• a first shaft adapted to transfer drive torque from the powertrain to the first driveline;
• a second shaft adapted for connection to the second driveline;
• a transfer assembly including a first sprocket driven by said first shaft, a second sprocket surrounding said second shaft, and a drive mechanism interconnecting said second sprocket to said first sprocket;
• and
• a mode clutch for selectively coupling said second shaft for rotation with said second sprocket, said mode clutch including a first ring having an outer surface engageable with an inner surface of said second sprocket and an inner surface with first cam surfaces, a second ring having an inner surface secured to an outer surface of said second output shaft and an outer surface with second cam surfaces, and rollers disposed between aligned sets of said first and second cam surfaces, said first ring adapted to circumferentially index relative to said second ring to cause said rollers to ride up said cam surfaces and cause said outer surface of said first ring to frictionally engage said inner surface of said second sprocket.

A transfer case for transferring drive torque from a powertrain to first and second drivelines of a motor vehicle, said transfer case comprising:

• a first shaft adapted to transfer drive torque from the powertrain to the first driveline;
• a second shaft adapted for connection to the second driveline;
• a transfer assembly including a first sprocket surrounding said first shaft, a second sprocket fixed to said second shaft, and a drive mechanism interconnecting said second sprocket to said first sprocket;
• and
• a mode clutch for selectively coupling said first sprocket for rotation with said first shaft, said mode clutch including a first ring having an outer surface engageable with an inner surface of said first second sprocket and an inner surface with first cam surfaces, a second ring having an inner surface secured to an outer surface of said second output shaft and an outer surface having second cam surfaces, and rollers disposed between aligned sets of said first and second cam surfaces, said first ring adapted to circumferentially index relative to said second ring to cause said rollers to ride up said cam surfaces and cause said outer surface of said first ring to frictionally engage said inner surface of said first sprocket.