Patent Publication Number: US-2023160461-A1

Title: Drivetrain component

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-in-part of U.S. patent application Ser. No. 17/886,302 filed on Aug. 11, 2022. This application claims the benefit of U.S. Provisional Application No. 63/233,826, filed Aug. 17, 2021. The disclosures of the above applications are incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention generally relates to drivetrain components such as differentials and, more specifically, to drivetrain components having multiple operating modes. 
     2. Description of Related Art 
     U.S. Pat. No. 8,808,127 discloses a differential assembly and, more particularly, a differential assembly for a motor vehicle driving axle driveable by an electric motor. The differential assembly comprises a driving gear and a differential drive with an input part and two output parts. The output parts are drivingly connected to the input part and, relative to one another, have a differential effect. A coupling is arranged between the driving gear, the differential gear, and the differential drive. In a closed coupling condition, torque is transmitted from the driving gear to the differential drive and, in an open condition of the coupling transmission, torque is interrupted. A controllable actuator actuates the coupling, and a sensor determines at least three switched positions of the coupling. A driving assembly with such a differential assembly is also disclosed. 
     U.S. Published Application No. 2020/0079214 discloses a system for a vehicle differential having multiple gears, including a coil of wire, a drive member moveable in response to a magnetic field generated by the application of electricity to the coil between a first position and a second position, and a lock member coupled to the drive member for movement with the drive member throughout a range of movement of the drive member. The lock member is adapted to engage a gear of the differential when the drive member is in the second position, and the lock member is adapted to be disengaged from the gear when the drive member is in the first position. In this way, the differential may be selectively locked. 
     U.S. Pat. No. 11,047,464 discloses a differential with an overrunning clutch (ORC) assembly. The differential includes a first plain bearing end cap with an interior surface that forms a plain bearing interface with an outer surface of a first side hub. The first plain bearing end cap has a first outer surface portion that engages a first end portion of a roller cage assembly. A second plain bearing end cap with an interior surface that forms a plain bearing interface with an outer surface of the second side hub is also included. The second plain bearing end cap has a first outer surface portion that engages a second end portion of the roller cage assembly. The ORC assembly selectively engages the roller cage assembly during an ORC condition to selectively couple torque between a ring gear and the first and second side hubs. 
     U.S. Published Application No. 2019/0056019 discloses a differential assembly that includes a two-piece differential carrier, a differential gearset installed within a gearset chamber formed in the differential carrier, and a ring gear. An interlocking feature mechanically interconnects the ring gear to the first and second case members of the two-piece differential carrier and defines first and second weldment junctions. A first weld seam is located in the first weldment junction and connects the ring gear to the first case member, while a second weld seam is located in the second weldment junction and connects the ring gear to the second case member. 
     U.S. Published Application No. 2018/0326844 discloses a rear-drive module for an all-wheel drive motor vehicle that includes a differential assembly having an outer differential housing and an inner differential housing. The inner differential housing is fixed for rotation with an output shaft of the differential assembly. A ring gear assembly with a ring gear is mounted and fixed for rotation with the outer differential housing. A disconnect and synch-lock mechanism operates to synchronize and lock the inner differential housing and the outer differential housing and to disconnect the inner differential housing and the outer differential housing to prevent rotation of the outer differential housing and the ring gear. The disconnect and synch-lock mechanism may include a synchronizer clutch and a clutch actuator. The clutch actuator may be a ball-ramp or face cam mechanism configured to control the operation of the synchronizer clutch and locking between the inner and outer differential housings. 
     U.S. Pat. No. 10,591,000, assigned to the assignee of the present application, discloses a coupling member for an engageable coupling assembly, including a coupling face having at least one pocket. Each pocket is sized and shaped to receive and nominally retain a locking member that lays down in its pocket during an overrunning condition of the assembly at a laydown angular velocity of the coupling member about a rotational axis of the assembly. Each pocket has a pocket axis which is angled with respect to a normal to a centerline of the coupling member to improve locking member dynamics regarding strut laydown speed during the overrunning condition. 
     U.S. Pat. No. 10,711,853, also assigned to the assignee of the present application, discloses an overrunning coupling and control assembly, coupling assembly, and locking member having at least one side surface with a draft to improve locking member dynamics. Locking member dynamics are improved with regards to locking member lay down speed. Lay down speed variation caused by a variable frictional coefficient between a pocket surface of a pocket in which the locking member is received and nominally retained and the at least one side surface of the locking member is minimized. 
     U.S. Published Application No. 2020/0124115, also assigned to the assignee of the present application, discloses a high-speed overrunning coupling and control assembly, coupling assembly, and locking member that pivotally moves with substantially reduced friction. At least one pivot projects from a main body portion of the locking member and enables pivotal motion of the locking member. The at least one pivot is sized, shaped, and located with respect to the main body portion so that the at least one pivot makes contact with at least one bearing located between a pocket surface of a pocket and an outer surface of the at least one pivot to reduce friction during pivotal motion. 
     A typical one-way clutch (OWC) consists of an inner ring, an outer ring, and a locking device between the two rings. The OWC is designed to lock in one direction and to allow free rotation (overrun) in the other direction. Two types of OWCs typically used in vehicular, automatic transmissions to prevent an interruption of drive torque (power flow) during specific gear shifts and to allow engine braking during coasting include roller type, which consists of spring-loaded rollers between the inner and outer race of the OWC, roller type can also be used without springs, and sprag type which consists of asymmetrically shaped wedges located between the inner and outer race of the OWC. 
     Controllable or selectable one-way clutches (SOWC) depart from traditional OWC designs. SOWCs may add a second set of locking members in combination with a selector plate. Combining an additional set of locking members and the selector plate adds multiple functions to the SOWC. Depending on the needs of the design, controllable SOWCs are capable of producing a mechanical connection between rotating or stationary members in one or both directions or are capable of overrunning in one or both directions. The selector plate of the SOWC is controlled externally. The movement of the selector plate can be between two or more positions that correspond to different operating modes. 
     A Dynamic Controllable Clutch (DCC) is electrically actuated. A DCC typically has two races; one is a pocket plate, and the other is a notch plate. The pocket plate may contain two locking elements—one for clockwise and the other for counter-clockwise engagement. During engagement, at least one set of locking elements is deployed such that each locking element in the set simultaneously contacts the pocket and notch engagement faces of the pocket and notch plates, respectively, which couples the two plates together to either transmit torque or ground torque, in the case of a brake. The locking elements may be of radial or planar design. 
     For purposes of this application, the term “coupling” should be interpreted to include clutches or brakes wherein one of the plates is drivably connected to a torque delivery element of a transmission, engine, or motor, and the other plate is connected to another torque delivery element or grounded in the case of a brake. The terms “coupling,” “clutch,” and “brake” may be used interchangeably. 
     There is still a need for an overrunning drivetrain component such as a differential disconnect while providing power in reverse and controlling regeneration. 
     SUMMARY OF THE INVENTION 
     A drivetrain component that includes a carrier supporting a differential gear set including a pinion shaft tied to the carrier, pinion gears mounted on the pinion shaft, differential gears engaging the pinion gears, and differential gear shafts connected to the differential gears. The drivetrain component further includes a case having an annular wall portion wherein the annular wall portion includes a plurality of pockets in one side thereof. A first locking structure is in one of pockets and a second locking structure is in one of the pockets. A notch plate is connected to the carrier, with the notch plate having a plurality of notches one side face thereof, the notches facing the pockets. The first locking structure engages one of the notches in the notch plate of the rotatable member and the second locking structure engages one of the notches in the notch plate. 
     Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples while indicating an embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein: 
         FIG.  1    is a perspective, partial view of a drivetrain component in accordance with at least one example of the present invention. 
         FIG.  2 A  is an exploded, partial perspective view taken from the right-hand side of the drivetrain component of  FIG.  1   . 
         FIG.  2 B  is an exploded, partial perspective view taken from the right-hand side of the drivetrain component of  FIG.  1   . 
         FIG.  3 A  is an exploded, partial perspective view taken from the left-hand side of the drivetrain component of  FIG.  1   . 
         FIG.  3 B  is an exploded, partial perspective view taken from the left-hand side of the drivetrain component of  FIG.  1   . 
         FIG.  4    is an exploded perspective view of an actuator assembly of the drivetrain component of  FIG.  1   . 
         FIG.  5    is a perspective view of the drivetrain component of  FIG.  1    with a portion of the actuator assembly removed. 
         FIG.  6    is a perspective view of the carrier assembly of the drive component with the case removed. 
         FIG.  7    is a sectional view of the drive component of  FIG.  1    taken along lines  7 - 7  of  FIG.  1   . 
         FIG.  8 A  is an end view of a carrier of the drive component of  FIG.  1    illustrating locking formations or notches formed on a face of the carrier. 
         FIG.  8 B  is a view similar to the view of  FIG.  7    illustrating locking formations or notches formed on an opposite face of the carrier. 
         FIG.  9    is an exploded, partial perspective view taken from the right-hand side of the drivetrain component in accordance with another example of the present invention. 
         FIG.  10    is an exploded, partial perspective view taken from the left-hand side of the drivetrain component of  FIG.  9   . 
         FIG.  11    is a sectional view of the drive component of  FIG.  9    illustrating engagement of the first locking structure. 
         FIG.  12    is a sectional view of the drive component of  FIG.  9    illustrating engagement of the second locking structure. 
         FIG.  13    is an exploded, partial perspective view taken from the right-hand side of an actuation mechanism for use with the drivetrain component of  FIG.  9   . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or its uses. 
     Detailed embodiments of the present invention are disclosed herein; however, it is understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting but merely as a representative basis for teaching one skilled in the art to variously employ the present invention. In the different figures, identical parts are provided with the same reference signs, because of which they are generally only described once. 
     Referring to  FIGS.  1 - 8 B , a drivetrain component is illustrated, generally indicated at  10 . The drivetrain component may be an electronically controlled, overrunning drivetrain disconnect, having a plurality of operating modes. Such operating modes may include forward, reverse, regenerative, disconnect, and overrunning operating modes. 
     The drivetrain component  10  includes axles or shafts  18 , normally configured to connect to vehicle wheels.  FIG.  1    shows the drivetrain component  10 , including a case  12  and a ring gear  14  connected to the case  12 . The case  12  and ring gear  14  are supported for rotation about a rotational axis  16 . 
       FIGS.  2 A- 2 B and  3 A- 3 B  illustrate exploded views of the drivetrain component  10 . The case  12  includes first and second case members  20 ,  22 . The first and second case members  20 ,  22  are supported for rotation about the rotational axis  16  by bearings  130 ,  136 . The bearings  130 ,  136  are supported in a housing (not shown). The first case member  20  is supported for rotation relative to the housing by the bearing  130  about the rotational axis  16 . The second case member  22  is supported for rotation relative to the housing by the hub  128  and the bearing  136  about the rotational axis  16 . Each of the first and second case members  20 ,  22  have extending flanges  24 ,  26 . A plurality of fasteners  28  join the first and second case members  20 ,  22  at the flanges  24 ,  26 . The fasteners  28  connect the ring gear  14  to the case  12  at the flanges  24 ,  26 . The first and second case members  20 ,  22  form a case or enclosure around a carrier, generally indicated at  30 . 
     The drivetrain component  10  includes a rotatable member, for example, the carrier  30 , which may be comprised of one or more pieces. The carrier  30  has a generally cylindrical shape, including an axially, in the direction of the rotational axis  16 , extending annular outer peripheral surface  32  and first and second radially extending side surfaces  34 ,  36 . First and second collars  38 ,  40  extend axially from the first and second radially extending side surfaces  34 ,  36 . The carrier  30  is supported for rotation about the rotational axis  16 . The carrier  30  includes a differential gear set having a pinion shaft  42 , pinion gears  44 , differential gears  46 , and differential gear shafts  48  connected to or part of the axles or shafts  18 . The pinion shaft  42  extends through apertures  49  in the carrier  30  and is fitted to the carrier  30 . The pinion gears  44  are rotatably mounted on the pinion shaft  42 , the pinion shaft  42  and pinion gears  44  rotate with the carrier  30 . The differential gears  46  engage the pinion gears  44 , rotation of the carrier  30  correspondingly rotates the pinion shaft  42  and pinion gears  44  causing rotation of the differential gears  46  and correspondingly the differential gear shafts  48 . 
     The carrier  30  is rotatably supported in the case  12  for movement relative to and independent of the case  12 . The carrier  30  freely rotates in the case  12  about the rotational axis  16  in both a first, clockwise direction and a second, counter-clockwise direction. For example, the first and second collars  38 ,  40  are used to rotatably mount the carrier  30  in the case  12 . 
     The ring gear  14  connects to a drive shaft, which is not shown. Rotation of the drive shaft correspondingly rotates the ring gear  14 , which then rotates the case  12 . Because the carrier  30  rotates freely in the case  12 , the case  12  may rotate without the carrier  30  rotating, and no torque is transferred from the case  12  to the carrier  30 . The drivetrain component  10  includes a first locking structure, generally indicated at  50 , and in another example, a second locking structure, generally indicated at  52 , for selectively coupling the case  12  and carrier  30 . 
     The first locking structure  50  includes a plate-like member  54 , having a plurality of pockets  56  in a face or surface  58 . The plate-like member  54  may be referred to as a pocket plate. The plate-like member  54  or pocket plate is connected to and rotates with the case  12 .  FIG.  2 A  shows an outer peripheral radial surface  68  of the plate-like member  54  having a plurality of splines  70 , which engage complementary splines  72  on an inner peripheral surface  74  of the first case member  20  of the case  12 . The face or surface  58  of the plate-like member  54  may also be referred to as a first coupling face  20   a . A plurality of the locking elements or struts  60  are positioned in the pockets  56 . A resilient member or spring  62  positioned in the pocket between the plate-like member  54  and the strut  60  applies a force on the strut  60  urging it outward past the face or surface  58 . The first locking structure  50  also includes a plurality of notches  66  in the first side surface  34  of the carrier  30 . The first side surface  34  of the carrier  30  may also be referred to as a first coupling face of the carrier  30 . 
     Locking structure refers to a structure assembly capable of producing a mechanical connection. As illustrated, the first locking structure  50  includes a passive locking element, for example, the strut  60 , located in the pocket  56  of the plate-like member  54  connected to the first case member  20  of the case  12 . The strut  60  is continuously urged out of the pocket  56  by the resilient member or spring  62 . The first locking structure  50  is passive in that the strut  60  constantly extends outward of the side face or surface  58 ; the resilient member or spring  62  constantly urges the strut  60  out of the pocket  56  in the side face or surface  58  of the plate-like member  54 . The resilient member or spring  62  constantly urges the strut  60  to a deployed position, wherein the strut  60  extends from the plate-like member  54 , out of the pocket  56 , and past or above the side face or surface  58 . 
     Because the strut  60  is in a deployed position and the side face or surface  58  of the plate-like member  54  and the first side surface  34  of the carrier  30  are in close-spaced opposition, close-spaced opposition is currently defined as a minimum of 0 to a maximum of 2.5 millimeters, the strut  60  engages the notch  66  in the first side surface  34  of the carrier  30  mechanically connecting the case  12  to the carrier  30  in one direction of rotation. The case  12  transmits torque to the carrier  30  in one direction only; while allowing relative rotation between the case  12  and carrier  30  in the opposite direction. 
     The resilient members or springs  62  apply a force on the struts  60  to urge them into engagement with the notches  66  on the first side surface  34  of the carrier  30 . Using the resilient members or springs  62  to apply an engagement force allows for ratcheting or overrunning. 
     In one example, the first locking structure  50  may be a one-way or overrunning clutch, for example, a passive one-way clutch wherein the strut  60  constantly extends from the pocket  56 . The strut  60 , and correspondingly the first locking structure or first one-way clutch  50 , is always deployed, creating a drive connection between rotating components, for example, the case  12  and carrier  30 , when their relative rotation is in one direction and overrunning when relative rotation is in the opposite direction and producing a drive connection when their relative rotation is in one direction and overrunning when their relative rotation is in the same direction, the driven member rotates faster than the drive member. The one-way clutch imposes torque in one direction and overruns in the opposite direction. The overrun state effectively or passively disconnects the case  12  and the carrier  30  and correspondingly disconnects the drive or power source from the wheels. 
     In some aspects, the second locking structure  52  is similar to the first locking structure  50 . For example, the second locking structure  52  has a plate-like member  80 , having a plurality of pockets  82  in a face or surface  84 . The plate-like member  80  may also be referred to as a pocket plate. The plate-like member  80  or pocket plate is connected to and rotates with the case  12 .  FIG.  2 B  shows an outer peripheral radial surface  86  of the plate-like member  80  having a plurality of splines  88  which engage complementary splines  90  on an inner peripheral surface  92  of the second case member  22  of the case  12 . The face or surface  84  of the plate-like member  80  may be referred to as a second coupling face  22   a . A plurality of locking elements or struts  94  are positioned in the pockets  82 . 
     A resilient member or return spring  96  positioned in the pocket  82  between the plate-like member  80  and the strut  94  applies a force on the strut  94  urging it inward into the pocket  82 , wherein the strut is at or below the face or surface  84 . The second locking structure  52  also includes a plurality of notches  98  in the second side surface  36  of the carrier  30 . The second side surface  36  of the carrier  30  may also be referred to as a second coupling face of carrier  30 . 
     As illustrated, the second locking structure  52  includes an active assembly, for example, the strut  94 , located in the pocket  82  of the plate-like member  80 , connected to the second case member  22  of the case  12 . In an active assembly, an actuator assembly, generally indicated at  100 , moves the strut  94 , located in the pocket  82  of the plate-like member  80 , between a non-deployed position—the strut  94  located in the pocket  82  and a deployed position—the strut  94  extending outwardly from the pocket  82  and beyond or past the face or surface  84  of the plate-like member  80 . The strut  94  moves between a deployed position and a non-deployed position. 
     Because the side face or surface  84  of the plate-like member  80  and the second side surface  36  of the carrier  30  are in close-spaced opposition, when the strut  94  is moved to the deployed position, the strut  94  engages a notch  98  in the second side surface  36  of the carrier  30 , mechanically connecting the case  12  to the carrier  30  in one direction of rotation. 
     The drivetrain component  10  may also include an actuator or actuation mechanism, generally indicated at  100 . Examples of an actuator or actuation mechanism  100  include, but are not limited to, a linear actuator, a lead screw actuator, a shift fork, or any other system or assembly moving the locking member. The actuator or actuation mechanism  100  interacts with and moves a locking member, for example, the strut  94 . In one example, the actuator or actuation mechanism  100  acts on a spring plate  102 . The spring plate  102  connects to a spring  104 . The spring  104  extends through an opening or passage  114  in the plate-like member  80  and engages the strut  94 . Axial movement of the spring plate  102  compresses the spring  104 . The spring  104  acts on the strut  94  and overcomes the force of the resilient member or return spring  96 , causing the strut  94  to extend out of the pocket  82  and past the face or surface  84  of the annular or plate-like member  80  connected to the second case member  22  of the case  12 . 
     Both resilient members or springs  62 ,  104  apply a force on the struts  60 ,  94  urging them into engagement with the notches  66 ,  98  first and second side surfaces  34 ,  36  of the carrier  30 . Using the resilient members or springs  62 ,  104  to apply an engagement force allows for ratcheting or overrunning. 
     In one example, the second locking structure  52  may be an active one-way clutch or overrunning clutch, for example, a dynamically controllable clutch (DCC) selectively producing a drive connection between rotating components, for example, the case  12  and the carrier  30 , when their relative rotation is in one direction and overrunning when relative rotation is in the opposite direction and producing a drive connection when their relative rotation is in one direction and overrunning when their relative rotation is in the same direction, the driven member rotates faster than the drive member. The active one-way clutch imposes torque in one direction and overruns in the opposite direction. 
     In another example, the drivetrain components  10  include the case  12  and the carrier  30 . The case  12  includes a first case member  20  and a second case member  22 . The first case member  20  has a coupling face  20   a  and the second case member  22  has a coupling face  22   a . The first coupling face  20   a  in a close spaced opposition with a first coupling face, for example, the first side surface  34 , of the carrier  30  and the second coupling face  22   a  of the case  12  in close spaced opposition with a second coupling face, for example, the second side surface  36 , of the carrier  30 . The coupling faces  20   a ,  22   a  of the case  12  may include pockets, and the coupling faces of the carrier  30  may include locking formations or notches. 
     The strut  60  mechanically couples the case  12  and the carrier  30  at the first coupling face  20   a  of the case  12  and the first coupling face, first side surface  34  of the carrier  30 , and the strut  94  selectively mechanically couples the case  12  and the carrier  30  the second coupling face  22   a  of the case  12  and the second coupling face, second side surface  36  of the carrier  30 . The struts  60 ,  94  are disposed between the respective faces. 
     The actuator or actuation mechanism  100  of the drivetrain component  10  may include an electrically switchable linear actuator device or control subassembly, generally indicated at  106 . The linear actuator  106  actively controls an operating mode of the drivetrain component  10  by generating an electromagnetic force interacting with a translator structure  108 , causing the struts  94  to move between the first coupling face of the case  12  and the first coupling face of the carrier  30 . The struts  60  passively control an operating mode of the drivetrain component  10 . In one passive operating mode, the case  12  overruns the carrier  30 . 
     As illustrated, the drivetrain component  10  typically includes conventional parts such as shafts  18  configured to fit vehicle wheels, differential gears  46  mounted within the carrier  30  for rotation on one end of the differential gear shafts  48 , and pinion gears  44  mounted at opposite ends of the pinion shaft  42  in mating engagement with the differential gears  46  for differential rotation within the carrier  30 . The carrier  30  is encased within the subassembly of the joined first and second case members  20 ,  22  to rotate therewith about the rotational axis  16 . 
     Due to the needs of various vehicles, the drivetrain component  10  can serve as an overrunning secondary axle differential. This increases efficiency by not allowing the E-motor to drag on the system when the motor is off. 
     The drivetrain component  10  is a fully contained, open, locked, limited slip, or the like differential controlled by first and second sets of clutching elements or locking members, for example, the struts  60 ,  94 . The first locking structure  50 , and correspondingly the struts  60 , provides a locking action between the case  12  and the carrier  30  preventing the case  12  from exceeding the rotational velocity of the carrier  30 . The second locking structure  52 , including the struts  94 , is controllable and provides a locking action between the case  12  and the carrier  30 , with the input provided by the ring gear  14 . 
     The system or disconnect design of at least one example of the drivetrain component  10  may operate as a differential with the added ability to overrun. For example, the system functions as differential during a turn by allowing the wheels to spin at different speeds. The new feature disclosed herein allows the system to overrun when both wheels exceed the ring gear speed in the forward direction during the off condition. The passive engagement of the system allows power to be sent through the system in the forward direction without the need for controls. The passive engagement reduces torque delay. 
     The actuation mechanism  100  operates to lock the clutching elements or locking members, for example, the struts  94 . This allows the vehicle to provide torque in the opposite direction, for example, the reverse direction. 
     Typically, systems needed to be in a controlled “on” to carry torque when going back and forth between regeneration/reverse and forward or, in some cases, coast and power forward. The disconnect ability of the drivetrain component  10  allows the user to bounce back and forth with little torque delay and with potentially lower noise, vibration, and harshness. The design can be used in an internal combustion engine, hybrid, or electric vehicle for a passive system or a semi-controllable transfer case. 
     The case  12  includes first and second coupling faces  20   a ,  20   b , each including pockets—the case  12  functions as a first pocket plate and a second pocket plate. The carrier  30  includes first and second coupling faces  34 ,  36 , each including notches, wherein the carrier  30  functions as a first and second notch plate. The respective orientation of both the coupling faces  20   a ,  20   b  of the case  12  and the coupling faces  34 ,  36  of the carrier  30  may vary. While the first and second coupling faces  20   a ,  20   b  of the case  12  are generally annular and extend radially to the rotational axis  16 , they may extend into other directions, for example, radial, axial, or some combination thereof. The orientation is relevant only in that adjacent coupling faces of the case  12  and the carrier  30  are arranged so that a locking element, such as a strut, mechanically couples the case  12  and carrier  30 . 
     Referring specifically to  FIG.  4   , the linear actuator device or subassembly  106  includes a stator structure  110  and a translator structure  108 . The stator structure  110  is connected to the housing (not shown), remains stationary, and does not rotate. The translator structure  108  is connected to the case  12  and rotates about the rotational axis  16 . It is supported for translational movement relative to the stator structure  110  along the rotational axis  16  between the first and second axial end positions, which correspond to different operating modes of the drivetrain component  10 . A coupler  112  provides electrical power to the stator structure  110 . 
       FIG.  5    illustrates the openings or passages  114  in the second case member  22 , specifically the plate-like member  80 . The passages  114  communicate with respective pockets  82 . The locking members or struts  94  located in the pockets  82 . The passage  114  provides actuating force access to the strut  94  within the pocket  82 . 
     The translator structure  108  includes a plurality of plungers, shown in the form of springs  104 . Each spring  104  is configured to move within one of the passages  114  and engage one of the locking members or struts  94  within its pocket  82  to actuate its locking member or strut  94  for selective strut  94  movement. Other types of elastically deformable plungers or actuators may be used to provide the actuating forces. The walls of the passages  114  are rigid so that the springs  104  are radially supported at the potentially high rotational speeds of the case  12 . 
     Preferably, the first and second locking structures  50 ,  52  include planar struts. Alternatively, the first and second locking structures  50 ,  52  may include radial/planar struts, i.e., the first locking members are radial struts, and the second locking members are planar struts; planar/radial struts, i.e., the first locking members are planar struts, and the second locking members are radial struts; or radial/radial struts, i.e., both the first and second locking members are radial struts. 
     The first locking members or struts  60  transmit torque between the first case member  20  and the carrier  30  in one direction while allowing relative motion between the case  12  and the carrier  30  in the other direction. The case  12  may include a first case member  20  and a second case member  22 . The first case member  20  may be referred to as a pocket plate and has the generally flat, annular coupling face  20   a  opposed to the first coupling face or first side surface  34  of the carrier  30  and is oriented to face axially along the rotational axis  16 . The coupling face  20   a  of the first case member  20  has pockets  56 , each sized and shaped to receive and nominally retain the first locking members or struts  60 . The pockets  56  are angularly spaced about the rotational axis  16 . The first coupling face or first side surface  36  of the carrier  30  has a plurality of locking formations or notches  66  that are engaged by the first locking members or struts  60  projecting or pivoting from pockets  56  formed in the second case member  22  to transmit torque and prevent relative rotation of the second case member  22  and correspondingly the case  12  and the carrier  30  with respect to each other in at least one direction about the rotational axis  16 . 
     The second locking members or struts  94  controllably transmit torque between the case  12  and the carrier  30 . The second case member  22  may be referred to as a pocket plate having a generally flat, annular coupling face  22   a  opposed to the second coupling face or second side surface  36  of the carrier  30  and oriented to face axially along the rotational axis  16 . The coupling face  22   a  of the second case member  22  has pockets  82 , each sized and shaped to receive and nominally retain the first locking members or struts  94 . The pockets  82  are angularly spaced about the rotational axis  16 . The second coupling face or second side surface  36  of the carrier  30  has a plurality of locking formations or notches  98  that are engaged by the first locking members or struts  94  projecting or pivoting from pockets  82  formed in the second case member  22  to transmit torque and prevent relative rotation of the second case member  22  and correspondingly the case  12  and the carrier  30  with respect to each other in at least one direction about the rotational axis  16 . 
     An apertured retainer cover or element cover  120  may be supported between the second case member  22  and the carrier  30 . The retainer element  120  has a plurality of spaced openings extending completely therethrough to allow the second locking members or struts  94  to extend therethrough and lock the second case member  22  and correspondingly the case  12  to the carrier  30 . The retainer cover or element cover  120  may be prevented from rotating relative to the second case member  22  by shoulders circumferentially spaced about the outer periphery of the retainer cover or element cover  120  fitting within corresponding apertures formed in an inner axial surface of the second case member  22 . 
     The stator structure  110  includes a ferromagnetic housing  122  having spaced apart fingers with the electromagnetically inductive coils  124  housed between adjacent fingers. As shown in  FIG.  6   , the stator structure  110  has two electromagnetically inductive coils  124  to create a magnetic flux when one or both electromagnetically inductive coils  124  are energized. The stator structure  110  applies a first magnetic control force to the translator one way when the electromagnetically inductive coils  124  are energized to cause the translator to move along the rotational axis  16 . The translator structure  108  reacts to the magnetic control force by moving the spring plate  102  and corresponding springs  104  along the rotational axis  16 . By reversing the current direction in the electromagnetically inductive coils  124 , the translator structure  108  causes the spring plate  102  and corresponding springs  104  to move in the opposite direction along the rotational axis  16 . 
     The translator structure  108  is configured for coupling with the second case member  22  to rotate therewith. The translator structure  108  is supported for rotation relative to the housing by the hub  128  and bushing or bearing  136  about the rotational axis  16 . The translator structure  108  may include a permanent magnet latch mechanism to hold the translator structure  108  in its “on” position and its “off” position without using any electrical energy. The magnetic latch mechanism of the translator structure  108  allows for lower energy usage, which means better vehicle efficiencies, less damage, and wear to the components. Each of the springs  104  has a free end portion adapted to move within its passage  114  and engage a locking member or strut  94  for selective locking member or strut movement. 
     Referring specifically to  FIG.  4   , the translator structure  108  is operatively connected to the springs  104  via a spring plate  102  to linearly move the spring  104  in unison. The spring  104  is supported on the spring plate  102  by spring supports formed on the spring plate  102 . The translator structure  108  moves upon receiving a net translational magnetic force to move the translator structure  108  linearly and correspondingly, the springs  104  within their passages  114 . The selective bi-directional shifting movement of the translator structure  108  along the rotational axis  16  between a first position corresponding to a first mode of the drivetrain component  10  and a second position corresponding to a second mode of the drivetrain component  10 . The first and second operating modes may be a locked mode and an unlocked—free-wheeling mode. 
     Each pocket  82  has an inner recess for receiving a return spring  132 . The return spring  132  acts on the locking member or strut  94  to resist pivotal motion of the locking member or strut  94  towards a deployed or engaged position. The spring  104  acts on the locking member or strut  94  to pivot the locking member or strut  94  over the force of the return spring  132 . 
     The linear actuator  106  may include the hub  128  adapted for coupling with the second case member  22 . The second case member  22  is supported for rotation relative to the housing by the hub  128  and the bearing  136  about the rotational axis  16 . A snap ring  138  holds the bearing  136  against the hub  128 . The hub  128  also slidably supports the spring plate  102  and the translator structure  108  during its shifting movement along the rotational axis  16 . 
     The translator structure  108  of the linear actuator  106  includes an annular outer subassembly or translator ring  116  connected to the translator hub  144 , a spacer  146 , and a snap ring  148 . The translator ring  116  includes magnetic annular ring segments sandwiched between a pair of ferromagnetic backing rings acted upon by the stator coil electromagnetic force, which moves the translator structure  108 , spring plate  102 , and springs  104  between the “off” and “on” positions. The spring plate  102  and springs  104  move axially along the translator hub  144 . 
     The linear actuator  106  may include a set of spaced guide pins sandwiched between the inner surface of the translator hub  144  and an outer surface of the second case member  22  and extending along the rotational axis  16 . The inner and outer surfaces may have V-shaped grooves or notches formed therein to hold the guide pins. The translator hub  144  slides on the guide pins during axial movement of the spring plate  102  and the springs  104  along the rotational axis  16 . 
     When the actuation mechanism  100  is commanded to disengage the active locking member or strut  94 , the centrifugal force generated by the rotating locking member or strut  94  can cause the locking member or strut  94  to stick in the notch  98  of the second side surface  36  of the carrier  30  and keep a disengagement of the locking member or strut  94  from occurring. To overcome these forces, the resilient member or return spring  96  can be used. In embodiments of the present invention, the locking member or strut  94  is disengaged by the spring force of the resilient member or return spring  96 . 
     At least one example of the present invention includes a drivetrain component providing an electronically controlled, overrunning drivetrain disconnect having a plurality of operating modes that can be both actively and passively controlled. The provided electronically controlled, overrunning drivetrain disconnect has a plurality of operating modes. The operating modes may include a forward operating mode wherein forward torque is controlled passively, a reverse operating mode, a regenerative operating mode, a disconnect operating mode, and a non-synchronous clutch mode, meaning the driving member does not have to synchronize its rotational speed with the clutch before it can re-engage the driven member. 
     The drivetrain component functions as a disconnect, disconnecting drivetrain input from the drive wheels at the differential. The disconnect occurs at the differential between a differential case and a carrier. The carrier includes the differential gear set. The carrier and differential gear set is aligned for rotation inside the differential case and rotates on the same central axis as the differential case. The carrier rotates in the differential case relative to and independent of the differential case. At least one locking structure is used to couple the differential case to the carrier to transmit torque from the differential case to the carrier. 
     The drivetrain component may include a linear actuator selectively actuating a second locking structure used to couple the differential case to the carrier to transmit torque from the differential case to the carrier. 
     The linear actuator may be used to actively control the operating modes of the drivetrain component by activating one of the locking members or struts for selective movement between coupling faces. Wherein the other set of locking members or struts passively controls operating modes between the coupling faces and allows them to overrun with respect to each other in one of the operating modes. 
       FIGS.  9 - 13    illustrate an additional example of a drivetrain component  200 . Like the forgoing example, the drivetrain component  200  includes a rotatable member, for example, the carrier  202 , which may comprise one or more pieces. The carrier  202  has a generally cylindrical shape, including an axially, in the direction of the rotational axis  16 , extending annular outer peripheral surface  204  and first and second radially extending side surfaces  206 ,  208 . First and second collars  210 ,  212  extend axially from the first and second radially extending side surfaces  206 ,  208 . The carrier  202  is supported for rotation about the rotational axis  16 . The carrier  202  includes a differential gear set having a pinion shaft  214 , pinion gears  216 , and differential gears  218 . The differential gears  218  connect to differential gear shafts (not shown) connected to or part of the axles or shafts  18 . The pinion shaft  214  extends through an aperture  224  in the carrier  202  and is secured to the carrier  202  by a pin  220 . The pinion gears  216  are rotatably mounted on the pinion shaft  214  inside the carrier  202 . Thrust washers  222  are between the pinion gears  216  and the carrier  202 . The pinion shaft  214  and the pinion gears  216  rotate with the carrier  202 . Thrust washers  244 ,  254  are between the differential gears  218  and the carrier  202 . The differential gears  218  engage the pinion gears  216 , and rotation of the carrier  202  correspondingly rotates the pinion shaft  214  and pinion gears  216  causing rotation of the differential gears  218  and correspondingly the differential gear shafts and axles or shafts  18 . 
     The drivetrain component  200  includes a case  230 . The case  230  includes a cup-shaped housing  232  with a radially extending flange  233 . Threaded fasteners  234  extend through the radial extending flange  233  and connect the cup-shaped housing  232  to a side surface  236  of a ring gear  238 . The cup-shaped housing  232  includes an internal bore or socket  240 . A bushing  242  rotatably support the first collar  210  of the carrier  202  in the internal bore or socket  240 . 
     A coupling member, for example, a plate-like member having a plurality of pockets, commonly referred to as a pocket plate  246 , is secured to the inner peripheral surface  248  of the ring gear  238  and rotates with the ring gear  238 . The pocket plate  246  may be integral with the ring gear  238  or the individual components may be secured together, for example, by fasteners, press fitting, welding, or in other suitable ways. The pocket plate  246  has an internal bore or socket  250 . A bushing  252  rotatably support the second collar  212  of the carrier  202  in the internal bore or socket  250 . The carrier  202  rotates within the cup-shaped housing  232  independently of the pocket plate  246 . 
     A rotatable member, for example, a notch plate  258 , is shown in the present example as an annular member  260  having an inner peripheral surface  262  and opposing first and second side surfaces or faces  264 ,  266 . The inner peripheral surface  262  includes a plurality of splines  268 . The outer peripheral surface  204  of the carrier  202  includes a plurality of splines  256 . The splines  256  of the carrier  202  mesh with the splines  268  of the notch plate  258  and connect the notch plate  258  to the carrier  202 , enabling torque transfer between the notch plate  258  and the carrier  202 . 
     The notch plate  258  may be formed integrally with the carrier  202 . In addition to the splined connection, other suitable mechanisms connecting the notch plate  258  to the carrier  202  may be used, provided there is no relative rotation between the notch plate  258  and carrier  202 . 
     The notch plate  258  includes angularly spaced recesses or notches  270  in the second side surface or face  266  of the notch plate  258 . The angularly spaced recesses or notches  270  in the present example providing a locking abutment, a part of the notch plate  258  that directly receives force or pressure. In addition to being notches  270 , the locking abutments could be projections or some other force or pressure receiving element. The second side surface or face  266  of the notch plate  258  may also be referred to as a coupling face. 
     The pocket plate  246  includes angularly spaced recesses or pockets  272 ,  273  in a side surface or face  274  of the pocket plate  246 . The side surface or face  274  of the pocket plate  246  may also be referred to as a coupling face. Struts  280 ,  284  are held in their respective pockets  272 ,  273  by a retainer plate  292 . 
     The ring gear  238  connects to a drive shaft that rotates the ring gear  238 , which then rotates the case  230 . Because the carrier  202  rotates freely in the case  230 , the case  230  may rotate without the carrier  202  rotating, and no torque is transferred from the case  230  to the carrier  202 . The drivetrain component  200  includes a first locking structure, generally indicated at  276 , and a second locking structure, generally indicated at  278 , for selectively coupling the case  230  and carrier  202 . 
     Locking structure refers to a structure assembly capable of producing a mechanical connection. As illustrated, the first locking structure  276  includes a passive locking element, for example, the strut  280 , in the pocket  272  of the pocket plate  246  connected to the ring gear  238 . The strut  280  is continuously urged out of the pocket  272  by a resilient member or spring  282 . The first locking structure  276  is passive because the strut  280  constantly extends outward of the side surface or face  274  of the pocket plate  246 ; the resilient member or spring  282  constantly urges the strut  280  out of the pocket  272  in the side surface or face  274  of the pocket plate  246 . The resilient member or spring  282  constantly urges the strut  280  to a deployed position, wherein the strut  280  extends from the pocket plate  246 , out of the pocket  272 , and past or above the side surface or face  274 . 
     Because the strut  280  is in a deployed position and the side surface or face  274  of the pocket plate  246  and the second side surface or face  266  of the notch plate  258  are in close-spaced opposition, close-spaced opposition is currently defined as a minimum of 0 to a maximum of 2.5 millimeters, the strut  280  engages a notch  270  in the second side surface or face  266  of the notch plate  258  mechanically connecting the pocket plate  246  and notch plate  258  and correspondingly the case  230  to the carrier  202  in one direction of rotation. The first locking structure  276  enables torque transmission from the case  230  to the carrier  202  in one direction only; while allowing relative rotation between the  230  and carrier  202  in the opposite direction. 
     In the present example, the first locking structure  276  is a one-way or overrunning clutch, for example, a passive one-way clutch wherein the strut  280  constantly extends from the pocket  272 . The strut  280 , and correspondingly the first one-way clutch or first locking structure  276 , is always deployed, creating a drive connection between rotating components, for example, the case  230  and carrier  202 , when their relative rotation is in one direction and overrunning when relative rotation is in the opposite direction and producing a drive connection when their relative rotation is in one direction and overrunning when their relative rotation is in the same direction, the driven member rotates faster than the drive member. The one-way clutch imposes torque in one direction and overruns in the opposite direction. The overrun state effectively or passively disconnects the case  230  and the carrier  202  and correspondingly disconnects the drive or power source from the wheels. 
     In some aspects, the second locking structure  278  is like the first locking structure  276 . For example, the second locking structure  278  includes a locking element, the strut  284 , in a pocket  273  of the plate-like member or pocket plate  246  connected to the ring gear  238 . A resilient member or return spring  286  positioned in the pocket  273  between the pocket plate  246  and the strut  284  applies a force on the strut  284  urging it inward into the pocket  273 , wherein the strut  284  is at or below the side surface or face  274  of the pocket plate  246 . The second locking structure  278  utilizes the same notches  270  in the second side surface or face  266  of the notch plate  258  as the first locking structure  276 . 
     As illustrated, the second locking structure  278  includes an active locking element; for example, the strut  284 , in the pocket  273  of the pocket plate  246 . The pocket plate  246  is connected to the ring gear  238 , forming part of the case  230 . The strut  284  moves between a deployed position and a non-deployed position. In an active assembly, an actuator assembly, generally indicated at  300 , acts on an actuation spring  294  that engages and moves the strut  284 , in the pocket  273  of the pocket plate  246 , between a non-deployed position—the strut  284  in the pocket  273  and a deployed position—the strut  284  extending outwardly from the pocket  273  and beyond or past the side surface or face  274  of the plate-like member or pocket plate  246 . 
     Because the side surface or face  274  of the pocket plate  246  and the second side surface or face  266  of the notch plate  258  are in close-spaced opposition when the strut  284  moves to the deployed position the strut  284  engages a notch  270  in the second side surface or face  266  of the notch plate  258 , mechanically connecting the pocket plate  246  and notch plate  258  and correspondingly the case  230  to the carrier  202  in one direction of rotation. The second locking structure  278  enables torque transmission from the case  230  to the carrier  202  in one direction only; while allowing relative rotation between the  230  and carrier  202  in the opposite direction. 
     The non-deployed position is characterized by non-abutting engagement of a locking strut  284  with a load-bearing shoulder of a notch  270  of the notch plate  258 . The engaged position is characterized by the abutting engagement of a locking strut  284  with a load-bearing surface of the corresponding pocket  272  of pocket plate  246  and a load-bearing shoulder of a notch  270  of notch plate  258 . 
     The side surface or face  274  of the pocket plate  246  includes spaced first pockets  272  and spaced second pockets  273 . The spaced first and second pockets  272 ,  273  are associated with a direction of rotation or a direction of vehicle movement—forward or reverse. As shown, both the spaced first pockets  272  and spaced second pockets  273 , housing the respective first and second struts  280 ,  284  of the first locking structure  276  and second locking structure  278  are in the same side surface or face  274  of the pocket plate  246 . Both the first strut  280  and the second strut  284  extend above the side surface or face  274  of the pocket plate  246 . 
     A plurality of struts  280  and struts  284  are provided. The struts  280  alternating with the struts  284 . It is understood that a particular number of each strut may be provided, and a greater or lesser number of struts  284  may be provided. 
     The notch plate  258  includes a plurality of notches  270 , the respective struts  280 ,  284  of the first and second locking structures  276 ,  278  engaging the notches  270 . Each notch  270  has opposing engagement surfaces  288 ,  290  at opposite ends of the notch  270 . The engagement surface  288  is configured to receive and engage the strut  280  of the first locking structure  276 , and the engagement surface  290  is configured to receive and engage the strut  284  of the second locking structure  278 . In the present example, both struts  280 ,  284  act on the same notch  270 , on opposite ends of the notch  270 . The radial width of the respective strut  280  and the second strut  284  is different, with the passive or overrunning strut, the strut  280  of the first locking structure  276 , having a greater width. The notch  270  also includes ramp surfaces  296  on each side forming a narrow portion adjacent the engagement surface  290  associated with the strut  284  of the second locking structure. The ramp surfaces  296  provide side or lateral support for the strut  284  and cooperate with the strut  280  during overrunning. 
       FIG.  11    shows the strut  284  of the second locking structure  278  in the pocket  273  associated with the second locking structure  278  while the strut  280  of the first locking structure  276  engages an engagement surface  288  of the notch  270  whereby torque is transferred in one direction. 
       FIG.  12    shows the strut  284  of the second locking structure  278  extending from the pocket  273  associated with the second locking structure  278 , wherein the strut  284  of the second locking structure  278  engages the opposite engagement surface  290  of the notch  270  and torque is transferred in the opposite direction. When torque is transferred in the opposite direction, the strut  280  of the first locking structure  276  is placed in an overrun condition. 
     The notches  270  cooperate with the struts  280  of the first locking structure  276  to lock the notch plate  258  to the pocket plate  246  in one direction about the axis  16  while allowing free-wheeling in the opposite direction about the axis  16 . In like fashion, the notches  270  allow the struts  284  of the second locking structure  278  to lock the notch plate  258  to the pocket plate  246  in the opposite direction about the axis  16 . 
     While the notches  270  cooperate with the first and second locking structures  276 ,  278 , two sets of notches could be formed in the notch plate  258 , one set cooperating with the first locking structure and the second set cooperating with the second locking structure. The notches could be radially spaced at different radial distances from the center of the notch plate  258 . 
     The notches  270  are formed on only one side of the notch plate  258 , and the pockets  272 ,  273  associated with the first and second locking structures  276 ,  278  are formed on only one side of the pocket plate  246 . The respective second side surface or face  266  of the notch plate, having the notches  270 , is positioned adjacent to and in a close-spaced relationship with the side surface or face  274  of the pocket plate  246 . 
       FIG.  13    shows, like the previous example, an actuator  300  for use with the drivetrain component  200 . The stator structure  302  includes a ferromagnetic housing  304  with spaced apart fingers and electromagnetically inductive coils  306  housed between adjacent fingers. As shown in  FIGS.  11  and  12   , the stator structure  302  has two electromagnetically inductive coils  306  to create a magnetic flux when one or both electromagnetically inductive coils  306  are energized. The stator structure  302  applies a first magnetic control force to the translator one way when the electromagnetically inductive coils  306  are energized to cause the translator  308  to move along the rotational axis  16 . The translator  308  reacts to the magnetic control force and moves the spring plate  310  and corresponding actuation springs  294  along the rotational axis  16 . By reversing the current direction in the electromagnetically inductive coils  306 , the translator structure  308  causes the spring plate  310  and corresponding actuation springs  294  to move in the opposite direction along the rotational axis  16 . 
     The translator structure  308  is configured for operation with the pocket plate  246  and rotates with the pocket plate  246 . The translator structure  308  is supported for rotation relative to the housing by a hub portion  322  of the pocket plate  246 . Each actuation spring  294  of the second locking structure  278  has a free end portion adapted to move within a passage  312  and engage the strut  284  of the second locking structure  278 . The actuator  300  includes a translator hub  314 , a spacer  316 , and snap rings  318 ,  320 . 
     The translator structure  308  moves upon receiving a net translational magnetic force which moves the translator structure  308  linearly and correspondingly, the actuation springs  294  within their passages  312 . The translator structure  308  is operatively connected to the actuation springs  294  via the spring plate  310  to linearly move the actuation springs  294  in unison. The selective bi-directional shifting movement of the translator structure  308  is along the rotational axis  16 , between a first position corresponding to a first mode of the drivetrain component  200  and a second position corresponding to a second mode of the drivetrain component  200 . The first and second operating modes may be a locked mode and an unlocked—free-wheeling mode. 
     While exemplary embodiments are described above, it is not intended these embodiments describe all possible forms of the present invention. Rather, the words used in the specification are words of description rather than limitation. It is understood that various changes may be made without departing from the spirit and scope of the present invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the present invention. 
     The description of the invention is merely exemplary in nature; thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.