CN113494226A

CN113494226A - Power door unit with improved mounting arrangement

Info

Publication number: CN113494226A
Application number: CN202110297068.0A
Authority: CN
Inventors: 朱布·雷蒙德·莱昂纳德; 赛卡特·博斯
Original assignee: Magna Closures Inc
Current assignee: Magna Closures Inc
Priority date: 2020-03-20
Filing date: 2021-03-19
Publication date: 2021-10-12
Also published as: DE102021106708A1

Abstract

The present disclosure relates to a powered door unit having an improved mounting arrangement. The present disclosure also relates to a powered actuator for moving a closure panel of a motor vehicle from a closed position to an open position and a method of constructing the powered actuator. The powered actuator includes an electric motor configured to rotate a driven shaft and a gearbox coupled to the driven shaft. The extendable member extends through the gearbox on one side of the gearbox to a proximal end for attachment to one of the vehicle body or the closure member and on an opposite side of the gearbox to a distal end. The extendable member is configured to move between a retracted position and an extended position in response to rotation of the driven shaft. The contamination cover covers the extendable member between the gear box and the distal end of the extendable member. The contamination-prevention cover moves between respective axially-extended and axially-retracted states as the extendable member moves between the retracted and extended positions.

Description

Power door unit with improved mounting arrangement

Cross Reference to Related Applications

This application claims the benefit of previously filed U.S. provisional patent application No.62/992,817 filed on 20/3/2020 and international patent application No. ca2020051473 filed on 30/10/2020, the contents of which are hereby incorporated by reference in their entirety.

Technical Field

The present disclosure relates to a powered actuator for a vehicle closure. More particularly, the present disclosure relates to a power actuator assembly for a vehicle side door.

Background

This section provides background information related to the present disclosure that is not necessarily prior art.

A closure member of a motor vehicle may be mounted to a vehicle body by one or more hinges. For example, the passenger door may be oriented with one or more hinges and attached to the vehicle body for swinging movement about a substantially vertical pivot axis extending along an edge of a closure face of the passenger door. In such arrangements, each door hinge typically includes a door hinge strap connected to the passenger door, a body hinge strap connected to the vehicle body, and a pivot pin arranged to pivotably connect the door hinge strap to the body hinge strap and defining a pivot axis. Such swinging passenger doors ("swing doors") may be movable by a powered closure member actuation system. In particular, the powered closure member system may be used to automatically swing the passenger door about its pivot axis between an open position and a closed position to assist the user as he or she moves the passenger door and/or to automatically move the passenger door for the user between the closed position and the open position.

Typically, the powered closure member actuation system comprises a powered operating means, such as for example an electric motor and a rotary-to-linear conversion means operable for converting the rotary output of the electric motor into translational movement of the extendable member. The electric motor and the conversion device are typically mounted to the passenger door in spaced relation to the closure face, and the distal end of the extendable member is fixedly secured to the vehicle body. Spaced from the door closing surface, the moment of inertia of the passenger door varies significantly as the door moves between the closed and open positions, resulting in a change in the power required to move the passenger door. Furthermore, to allow the passenger door to swing without mechanical constraints, an intermediate linkage is typically incorporated between the distal end of the extendable member and the vehicle body, adding to the cost, complexity of design and weight of the power operated device. One example of a powered closure member actuation system for a passenger door is shown in commonly owned international publication No. wo2013/013313 to Scheuring et al, which discloses the use of a rotary-to-linear conversion device having an externally threaded lead screw rotationally driven by an electric motor and an internally threaded drive nut meshingly engaged with the lead screw, and an extendable member attached to the internally threaded drive nut. Thus, control of the speed and rotational direction of the lead screw results in control of the speed and direction of translational movement of the drive nut and the extendable member for controlling swinging movement of the passenger door between its open and closed positions. The further the center of mass of the door is from the pivot axis of the door, the greater the force output from the motor required to move the door. Furthermore, the incorporation of the extendable members also places additional strain on the motor and other powertrain components.

In view of the above, there remains a need to develop powered closure member actuation systems that: the powered closure member actuation system addresses and overcomes limitations and disadvantages associated with known powered closure member actuation systems and provides increased convenience and enhanced operational capabilities.

Disclosure of Invention

This section provides a general summary of some of the objects, advantages, aspects, and features provided by the inventive concepts associated with the present disclosure. This section is not intended, however, to be an exhaustive and comprehensive list of all of the objects, advantages, aspects and features of the present disclosure.

In one aspect, the present disclosure is directed to a vehicle closure panel and a powered actuator for a vehicle closure panel that motivates the development of, and improves upon, currently known vehicle closure panels and powered actuators for such vehicle closure panels.

In another aspect, the present disclosure is directed to a method of constructing a power actuator for a closure panel of a motor vehicle that motivates the development of the art and improves upon currently known methods of constructing power actuators for closure panels of vehicles.

A related aspect provides a power actuator that is reliable, compact, and economical to manufacture, assemble, and use.

A related aspect provides a powered actuator: the powered actuator reduces the moment of inertia of the closure panel, thereby facilitating reliable opening and closing of the closure panel with a reduced size electric motor.

A related aspect provides a powered actuator: the power actuator eliminates the need for an intermediate linkage connecting the distal end of the extendable member to one of the vehicle body and the passenger door, thereby reducing the cost, complexity and weight of the power actuator.

A related aspect provides a powered actuator: the powered actuator is readily adaptable for use with a variety of closure panel configurations, both during original equipment manufacture and after-market.

In accordance with these and other aspects, a powered actuator for moving a closure panel of a motor vehicle from a closed position to an open position is provided. The powered actuator includes an electric motor configured to rotate a driven shaft and a gearbox coupled to the driven shaft. The extendable member is disposed through the gearbox to extend along the axis from one side of the gearbox to the proximal end and to extend at an opposite side of the gearbox to the distal end. The proximal end of the extendable member is configured to be pivotably coupled to one of the vehicle body or the closure member. The extendable member is configured to move between a retracted position corresponding to a closed position of the closure panel and an extended position corresponding to an open position of the closure panel in response to rotation of the driven shaft. The contamination-resistant cover covers at least a portion of the extendable member extending between the gear case and the distal end of the extendable member. The contamination cap is configured to automatically move between an axially extended state having a first length when the extendable member is in the retracted position and an axially retracted state having a second length when the extendable member is in the extended position, wherein the first length is greater than the second length. The reduced second length provides the power actuator and the extendable member of the power actuator with the ability to pivot within the internal cavity housing the power actuator, thereby avoiding interference of the power actuator with any internal components of the closure panel or vehicle body.

According to another aspect of the present disclosure, a contamination-resistant cap may be provided having a plurality of cap portions configured for axial movement relative to one another along an axis to automatically transition the contamination-resistant cap between a first length and a second length.

According to another aspect of the present disclosure, the plurality of cover portions may be configured to nest with one another when the contamination-resistant cover is in the retracted state.

According to another aspect of the disclosure, one of the cover parts may be directly fixed to the gearbox.

According to another aspect of the disclosure, one of the cover portions may be secured to the distal end of the extendable member such that the cover portion secured to the distal end of the extendable member is moved axially in simultaneous relation to the distal end of the extendable member.

According to another aspect of the present disclosure, the mounting bracket may be pivotally attached to the gearbox, wherein the mounting bracket provides pivotal movement of the gearbox relative to the mounting bracket.

According to another aspect of the disclosure, a mounting bracket may be provided having a clearance opening through which the extendable member extends, wherein the extendable member may be configured to pivot within the clearance opening as the extendable member moves between the extended and retracted positions.

According to another aspect of the disclosure, the axis of the extendable member may be arranged to: in a substantially perpendicular relationship to the plane of the mounting plate when the powered actuator is in the retracted position, and transitions into an inclined relationship with the plane of the mounting plate when the powered actuator is in the extended position.

According to another aspect of the disclosure, the mounting bracket may be configured to be secured to the other of the body or the closure member other than the proximal end of the extendable member.

According to another aspect of the present disclosure, the proximal end of the extendable member may be configured to be pivotably coupled to the vehicle body, and the mounting bracket may be configured to be secured to the closure member.

According to another aspect of the present disclosure, a mounting bracket is fixed to one side of a gear case, and a contamination-preventive cover is fixed to an opposite side of the gear case.

According to another aspect of the present disclosure, a method of configuring a powered actuator for moving a closure panel of a motor vehicle between a closed position and an open position is provided. The method includes configuring an electric motor to drive a driven shaft and coupling a gearbox to the driven shaft. An extendable member is disposed through the gearbox, wherein the extendable member extends to a proximal end on one side of the gearbox and to a distal end on an opposite side of the gearbox, and a proximal end configured to be pivotably coupled to one of the body or the closure member is provided. Further, the extendable member is configured to move between a retracted position corresponding to a closed position of the closure panel and an extended position corresponding to an open position of the closure panel in response to rotation of the driven shaft. Further, at least a portion of the extendable member extending between the gear case and the distal end is covered with a contamination-proof cover. And, configuring the contamination-preventive cover to move between an axially-extended state having a first length when the extendable member is in the retracted position and an axially-retracted state having a second length when the extendable member is in the extended position, wherein the first length is greater than the second length.

According to another aspect of the disclosure, the method may include: a contamination-prevention cover is provided having a plurality of cover portions configured to move telescopically relative to one another when the contamination-prevention cover is moved between an axially-extended state and an axially-retracted state.

According to another aspect of the disclosure, the method may include: the extendable member is configured for attachment to one of the body and the closure member without incorporating an intermediate linkage between the extendable member and the one of the body and the closure member.

According to another aspect of the disclosure, the method may include: pivotally attaching a mounting bracket to the gearbox to provide pivotal movement of the gearbox relative to the mounting bracket, wherein the mounting bracket is configured for direct attachment to one of the closure member and the vehicle body.

According to another aspect of the disclosure, the method may include: the method may further include providing a mounting bracket having a clearance opening and extending the extendable member through the clearance opening, wherein the extendable member may be configured to pivot within the clearance opening as the extendable member moves between the extended position and the retracted position.

According to another aspect of the disclosure, the method may include: the method includes pivotally attaching a mounting bracket to one side of the gearbox, securing one of the cover portions directly to an opposite side of the gearbox, and securing the other of the cover portions to a distal end of the extendable member.

According to another aspect of the present disclosure, a powered actuator for moving a closure panel of a motor vehicle between a closed position and an open position comprises: an electric motor configured to rotate the driven shaft; a gearbox coupled to the driven shaft; a gearbox housing enclosing the gearbox and having two bores each connected to an interior space of the gearbox housing; an extendable member extending through the two apertures and through the gearbox and having a proximal end configured to be pivotably coupled to one of the vehicle body or the closure panel, the extendable member configured to move between a retracted position corresponding to a closed position of the closure panel and an extended position corresponding to an open position of the closure panel in response to rotation of the driven shaft; a first cover connected to the housing for sealing an extendable member extending from one of the bores; and a second cover connected to the housing for sealing the extendable member extending from another one of the apertures. In a related aspect, the first and second covers are collapsible. In another related aspect, the first and second covers are separate and distinct from each other. In a related aspect, the first and second covers are formed of a flexible material.

Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

Drawings

The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure. Other advantages of the present embodiments, other than those explicitly discussed herein, will be readily appreciated and better understood by reference to the following detailed description and appended claims when considered in connection with the accompanying drawings, wherein:

FIG. 1 is a side view of an example motor vehicle equipped with a powered closure member actuation system between a front passenger swing door and a vehicle body, according to aspects of the present disclosure;

FIG. 2 is an internally cut-away side view of the closure member shown in FIG. 1 with parts associated with portions of the vehicle body removed for clarity only and the closure member equipped with a powered closure member actuation system according to aspects of the present disclosure;

FIG. 3A illustrates a first powered actuator in accordance with aspects of the present disclosure;

FIG. 3B illustrates an exploded view of components within the first powered actuator of FIG. 3A, in accordance with aspects of the present disclosure;

FIG. 4 illustrates a side, partial cross-sectional view of a first powered actuator in accordance with aspects of the present disclosure;

FIG. 5 illustrates a front cross-sectional view of a first powered actuator, according to aspects of the present disclosure;

fig. 6A illustrates a rear perspective view of a second powered actuator having a telescoping cover in a deployed state, similar to the first powered actuator of fig. 3A, in accordance with aspects of the present disclosure;

FIG. 6B illustrates a rear perspective view of the second powered actuator of FIG. 6A with the telescoping cover in a collapsed state, according to aspects of the present disclosure;

fig. 7 illustrates a front perspective view of the second powered actuator of fig. 6A, in accordance with aspects of the present disclosure;

FIG. 8 illustrates a top view of the second powered actuator of FIG. 6A with the telescoping cover in a deployed state, in accordance with aspects of the present disclosure;

FIG. 9 illustrates a top view of the second powered actuator of FIG. 6A with the telescoping cover in a retracted state, and the second powered actuator in a pivoted position relative to the position shown in FIG. 8, in accordance with aspects of the present disclosure;

FIG. 10 illustrates a schematic block diagram of components within a prior art power actuator.

FIG. 11 illustrates a schematic block diagram of components within a power actuator, in accordance with aspects of the present disclosure;

FIG. 12 is a flow chart illustrating a method of configuring a powered actuator for moving a closure panel of a motor vehicle between a closed position and an open position in accordance with another aspect of the present disclosure;

FIG. 13 is a top partial cross-sectional view of the closure panel in the closed position with the closure panel having the extendable member in the retracted position but extending substantially within the internal cavity of the closure panel and with the shroud or cover in the extended position, further showing the window pane and the inner panel adjacent the extendable member in a non-interfering manner;

FIG. 14 is a top partial cross-sectional view of the closure panel in an open position with the closure panel having the extendable member in an extended position but not substantially extending within the internal cavity of the closure panel and having the shroud or cover in a collapsed position, further illustrating the window pane and the inner panel adjacent the extendable member in a manner that does not interfere with the extendable member and the shroud;

fig. 15 illustrates a front perspective view of a third powered actuator having an extendable member in an extended position corresponding to a door open position, in accordance with aspects of the present disclosure;

fig. 16 illustrates a front perspective view of the third powered actuator of fig. 15 having an extendable member in a retracted position corresponding to a door closed position, in accordance with an aspect of the present disclosure; and

fig. 17 is a cross-sectional view of the powered actuator of fig. 15 illustrating a support arrangement for a torque tube, in accordance with aspects of the present disclosure.

Corresponding reference characters indicate corresponding parts throughout the several views of the drawings.

Detailed Description

Example embodiments will now be described more fully with reference to the accompanying drawings. Example embodiments are provided so that this disclosure will be thorough and will fully convey the scope to those skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.

Referring initially to fig. 1, an example motor vehicle 10 is shown to include a first passenger door 12, the first passenger door 12 being pivotally mounted to a vehicle body 14 via upper and lower door hinges 16, 18 shown in phantom. In accordance with the present disclosure, a powered closure member actuation system 20 is pivotally connected between the first passenger door 12 and the vehicle body 14. According to a preferred configuration, the powered closure member actuation system 20 generally includes a power-operated actuator mechanism or actuator 22, the power-operated actuator mechanism 22 being secured within the interior cavity of the passenger door 12, and a rotary drive mechanism driven by the power-operated actuator mechanism 22 and drivingly coupled to the vehicle body 14. The driving rotation of the rotary drive mechanism causes controlled pivotal movement of the passenger door 12 relative to the vehicle body 14. According to this preferred configuration, the power operated actuator mechanism 22 is pivotally coupled to the closing surface of the door 12 between the

hinges

16, 18 and in close proximity to the closing surface of the door 12, while the rotary drive mechanism is pivotally coupled to the vehicle body 14. However, those skilled in the art will recognize that alternative packaging configurations for the powered closure member actuation system 20 may be used to accommodate the available packaging space. One such alternative packaging configuration may include mounting the power operated actuator mechanism 22 to the vehicle body 14 and drivingly interconnecting the rotary drive mechanism to the door 12.

Each of the upper and lower door hinges 16, 18 includes a door mounting hinge member and a body mounting hinge member pivotally interconnected by a hinge pin or post. The door mounting hinge part is hereinafter referred to as a door hinge belt, and the body mounting hinge part is hereinafter referred to as a body hinge belt. Although the powered closure member actuation system 20 is shown only as being associated with the front passenger door 12, one skilled in the art will recognize that the powered closure member actuation system 20 may also be associated with any other closure member (e.g., a door or lift gate) of the vehicle 10, such as, for example, the rear passenger door 17 and the trunk lid 19.

The powered closure member actuation system 20 is generally shown in fig. 2 and, as mentioned, the powered closure member actuation system 20 is operable for controllably pivoting the door 12 relative to the body 14 between the open and closed positions. As shown in fig. 2, the lower hinge 18 of the powered closure member actuation system 20 includes a door hinge strap 28 connected to the vehicle door 12 and a body hinge strap 30 connected to the vehicle body 14. Door hinge straps 28 and body hinge straps 30 of lower door hinge 18 are interconnected via hinge pins 32 along generally vertically aligned pivot axes a to establish pivotable interconnection between door hinge straps 28 and body hinge straps 30. However, any other mechanism or device may be used to establish the pivotable interconnection between the door-hinge strap 28 and the body-hinge strap 30 without departing from the scope of the present disclosure.

As best shown in fig. 2, the powered closure member actuation system 20 includes a power operated actuator mechanism 22, the power operated actuator mechanism 22 having a motor and gear train assembly 34 that can be rigidly connected to the vehicle door 12. Illustratively, the powered closure member actuation system 20 is pivotally connected to a closing surface 162 of the door 12. The motor and gear train assembly 34 is configured to generate a rotational force about the pivot axis a. In a preferred embodiment, the motor and gear train assembly 34 includes an electric motor 36 operatively coupled to a speed/torque up assembly 38, the speed/torque up assembly 38 acting as a gearbox having one or more stages with a gear ratio that allows the motor 36 and gear train assembly 34 to generate a rotational force with a high torque output through a very low rotational speed of the electric motor 36. However, any other arrangement of the motor and gear train assembly 34 may be used to establish the required rotational force without departing from the scope of the present disclosure. The electric motor 36 is controlled by electronics, illustratively shown as box 50 in fig. 2, which may include a microprocessor 110 and power electronics 92, such as, for example, an H-bridge FET, controlled by the microprocessor 110. The controller 50 is electrically connected to a command source such as a door opening or closing switch 53, or to another controller 66 such as a vehicle body control module or an authentication controller such as a PKE controller, for example.

The motor and gear train assembly 34 includes a mounting bracket 40 for establishing a connectable relationship with the vehicle door 12 and the power operated actuator mechanism 22. The connectable relationship of the power operated actuator mechanism 22 with the vehicle door 12 via the mounting bracket 40 is illustrated as a pivotal connection to allow the power operated actuator mechanism 22 to pivot about a pivot axis B, such as the rotation indicated as PA in fig. 2. The mounting bracket 40 is configured to be connectable to the vehicle door 12 between the upper hinge 16 and the lower hinge 18 and, for example, to the closure panel 162. The closure face 162 includes a port or aperture for allowing the drive shaft 42 to pass through the closure face 162, wherein such a port may be generally associated for allowing passage of a door stop link. As also shown in fig. 2, such mounting of the motor assembly 34 in a manner as will be described herein places the power operated actuator mechanism 22 of the powered closure member actuation system 20 in close proximity to the pivot axis B. The mounting of the motor and gear train assembly 34 adjacent to the pivot axis B of the vehicle door 12 minimizes the effect that the powered closure member actuation system 20 may have on the mass moment of inertia of the vehicle door 12 (i.e., pivot axis a), thereby improving or facilitating movement of the vehicle door 12 between its open and closed positions. Reducing the mass of the actuator and moving the mass of the actuator 22 closer to the pivot axis a reduces the mass of the door 14 and shifts the center of mass closer to the pivot axis C, allowing the motor 36 to be reduced in power and/or size. Additionally, as also shown in FIG. 2, the mounting of the motor and gear train assembly 34 closer to the pivot axis A of the door 12 allows the powered closure member actuation system 20 to be packaged forward of the A-pillar glass travel channel and other interior door components and sheet metal panels associated with the door 12, and thus avoids any interference with the glazing function of the door 12. In other words, the powered closure member actuation system 20 may be packaged in an unused portion of the interior door cavity 39 within the vehicle door 12, and thus reduce or eliminate impact to existing hardware/mechanisms within the vehicle door 12. Although the powered closure member actuation system 20 is illustrated as being mounted between the upper and lower hinges 16, 18 of the vehicle door 12, the powered closure member actuation system 20 may alternatively be mounted elsewhere within the vehicle door 12 or even on the vehicle body 14 without departing from the scope of the present disclosure.

The powered closure member actuation system 20 also includes a rotary drive mechanism that is rotationally driven by a power-operated actuator mechanism 22. As shown in fig. 2, the rotary drive mechanism includes a drive shaft 42, the drive shaft 42 being interconnected to an output member of the gear box 38 of the motor and gear train assembly 34 and extending and retracting from both sides of the gear box 38. Additionally, as an alternative configuration, although not explicitly shown, a clutch, such as a mechanical or electrical clutch, may be disposed between the rotational output of the gearbox 38 and the first end 44 of the drive shaft 42. The clutch may be engaged and disengaged using any suitable type of clutching mechanism, such as, for example, a set of struts (sprag), balls, wrap springs, friction plates, or any other suitable mechanism. The clutch may be configured to allow a user to manually move the door 12 relative to the body 14 between an open position of the door 12 and a closed position of the door 12. Such a clutch may also be located, for example, between the output of the electric motor 36 and the input of the gearbox 38. The location of the selectable clutch may be based on, among other things, whether the gearbox 38 includes a back-drivable gear. In another possible configuration, the powered closure member actuation system 20 may not be provided with a clutch, which thereby reduces the mass of the powered closure member actuation system 20 and the door 14. It is possible that the gear box 38 may include a "back-drivable" gear to allow a user to manually move the door 14, whereby the gear of the gear box 38 will be induced to rotate. It is possible that the gearbox 38 could alternatively include a non-back drivable gear to prevent a user from manually moving the door 14, whereby the gear of the gearbox 38 cannot be induced to rotate by the movement of the door 14, but rather only activation of the motor 22 would cause the gear of the gearbox 38 to rotate and thereby move the door 14. A braking mechanism that prevents any of rotation of the motor 22, rotation of the gear box 36, or movement of the drive shaft 42 may also be provided without the powered closure member actuation system 20 to additionally further reduce the mass of the powered closure member actuation system 20 and the door 14.

To accommodate angular movement due to swinging movement of the door 12 relative to the body 14, the powered closure member actuation system 20 further includes a pivotal connection 45 disposed between the body 14 and the first end 44 of the drive shaft 42. A second end 46 of drive shaft 42 is configured to reciprocate into and out of cavity 39 as drive shaft 42 is driven by gearbox 38 in response to actuation of motor 36. Illustratively, the link 45 is a pin and socket (socket) type link that allows the drive shaft 42 to rotate about an axis C that extends parallel or substantially parallel to the pivot axis a of the door 14 and the pivot axis B of the power operated actuator mechanism 22. Translation of drive shaft 42 via operation of motor and gear train assembly 34 serves to: the door 12 is pushed away from the body 14 as the drive shaft 42 is retracted from the cavity 39 and the door 12 is pulled toward the body 14 as the drive shaft 42 translates into the cavity 39. Thus, in the illustrated example of fig. 2, the powered closure member actuation system 20 is capable of effecting movement of the door 12 between its open and closed positions by "directly" transmitting a rotational force to the body 14 via linear translation of the driven drive shaft 42. With the motor and gear train assembly 34 connected to the vehicle door 12 adjacent the closure surface 162, the second end 46 of the drive shaft 42 may reciprocate and oscillate within the cavity 39 as the driven shaft 42 reciprocates R within the gear box 38. Based on the available space within the door cavity 39, the second end 46 of the drive shaft 42 may avoid colliding with the internal components within the cavity 49 when the power operated actuator mechanism 22 swings about the axis B, for example, as the drive shaft 42 retracts from the cavity 39 when the door 12 is opened.

Fig. 3A-3B illustrate a second powered actuator 122 according to aspects of the present disclosure. Specifically, fig. 3B illustrates the electric motor 36, the electric motor 36 being configured to rotate the driven shaft 166 for turning the worm gear 168. The driven shaft 166 is supported by a proximal bearing 170 and a distal bearing 172. The shaft may extend parallel or substantially parallel to the Y-axis when in a mounted relationship with the door 12. The proximal bearing 170 is supported within a motor bracket 174, the motor bracket 174 being attached to an axial end of the electric motor 36 for connecting the motor to the gearbox 140. The proximal bearing 170 is shown as a ball bearing and the distal bearing 172 is shown as a sliding bearing or bushing. However, either of the

bearings

170, 172 may be a different type of bearing, such as a sliding bearing, a ball bearing, a roller bearing, or a needle bearing. FIG. 3B also shows internal components of the high resolution position sensor 144, including a magnetic wheel 180, the magnetic wheel 180 being coupled for rotation with the driven shaft 166 and including a plurality of permanent magnets. The magnet wheel 180 shown in fig. 3B has six permanent magnets, but the magnet wheel 180 may include any number of magnets. The high resolution position sensor 144 also includes a hall effect sensor 182, the hall effect sensor 182 configured to detect movement of the permanent magnet in the magnet wheel 180 in response to rotational movement of the magnet wheel 180 and thereby generate an electrical signal. The high resolution position sensor 144 also includes a sensor housing 184, the sensor housing 184 enclosing all or a portion of the magnet wheel 180 and the hall effect sensor 182.

Fig. 4 illustrates a partial cross-sectional view of the second powered actuator 122, in accordance with aspects of the present disclosure. Fig. 4 shows the general arrangement of the gearbox 140, and the gearbox 38 described herein above will have a similar configuration, the gearbox 140 including a gearbox housing 141, the gearbox housing 141 extending between an adaptor 142 for fixedly connecting the gearbox 140 to the closure surface 162 in a non-pivoting manner, and a cover 148 for enclosing and sealing the second end 46 of the drive shaft 42. The electric motor 36 is attached to the gearbox housing 141 at a location below the gearbox 140, for example via a motor bracket 174, such that the motor shaft 166 is disposed perpendicular to the extendable member 134, with the extendable member 134 being an example of the drive shaft 42 described herein above. The adaptor 142 is shown in fig. 3A and 4 as being fixed from rotation with the housing 141, however, the adaptor 142 may be modified to be rotatably coupled by being pivotally connected to the housing 141 about a pivot axis B as described herein with reference to the pivotal connection 45 of the powered actuator 22. The housing 141 is illustratively formed from a strong load-bearing structure that can be formed by casting, the load-bearing structure being formed from a material such as metal. Thus, the first and second

powered actuators

22, 122 are similar in structure, but differ in the connection of the housing 141 to the vehicle door 12.

Fig. 4 also shows internal details of the gearbox 140, including a lead nut 190 disposed about the extendable member 134 in threaded engagement with the extendable member 134 formed as a lead screw. The lead screw and lead nut configuration shown in fig. 4 may provide a relatively small amount of clearance, thereby improving the correlation between the position of the closure member detected by the high resolution position sensor 144 and the actual position of the closure member. Such high accuracy sensing may improve servo control of the

powered actuators

22, 122. The extendable member 134 is driven by rotation of the nut 190 such that the nut 190 is held in position relative to the gearbox 140, while when the nut 190 is rotated, the extendable member 134 is linearly translated and thus moved relative to the gearbox 140. The gearbox 140 may be sealed in the manner described in international patent application No. ca2020051473.

The guide nut 190 is secured within a torque tube 192 having a tubular shape. Specifically, the guide nut 190 includes a flange end 194, the flange end 194 projecting radially outward and engaging an axial end of the torque tube 192 at an end adjacent the adaptor 142. The torque tube 192 is retained within the gearbox housing 141 by a pair of tube supports 196, wherein each of the tube supports 196 is disposed about the torque tube 192 at or near a corresponding axial end of the torque tube 192. One or both of the tube supports 196 may include a bearing, such as a ball bearing or a roller bearing. A worm gear 198 is disposed about the torque tube 192 between the tube supports 196 and is fixed for rotation with the torque tube 192. The worm gear 198 is in meshing engagement with the worm gear 168 (shown in fig. 3B), thereby causing the torque tube 192 and the lead nut 190 to rotate in response to the electric motor 36 driving the worm gear 168. The tube support 196 helps support the torque tube 192 against loads applied by the

extendable members

42, 134 during operation of the

powered actuators

22, 122 attempting to pivot the torque tube 198 relative to the housing 141, and as such pivoting of the

powered actuators

22, 122 is limited to pivoting about axis B while pivoting of the gears of the

gearboxes

38, 140 is limited to movement of the gears relative to the gearbox housing 141 about a fixed axis of rotation to actuate the

extendable members

42, 134 and not allow adjustment of the angular change of the

extendable members

42, 134 to avoid binding of the

extendable members

42, 134 with the gears of the

gearboxes

38, 140 during opening and closing of the door 12.

The first powered actuator 122 shown in fig. 4 also includes a travel limiter 200, the travel limiter 200 being disposed on an axial end of the extendable member 134 opposite the linkage 130 (i.e., furthest from the linkage 130). The travel limiter 200 is configured to engage a portion of the gearbox 140, such as the torque tube 192, for limiting the axial extension of the extendable member 134. Specifically, the stroke limiter 200 includes a bumper 202 made of an elastic material such as rubber, the bumper 202 having a tubular shape extending around the extendable member 134 adjacent to an axial end of the extendable member 134. A retainer clip 204 holds the bumper 202 in place on an axial end of the extendable member 134. The retainer clip 204 may include any suitable hardware including, for example, a washer, nut, cotter pin, E-clip, or C-clip such as snap ring.

Fig. 5 illustrates a cross-sectional view of the second powered actuator 122, in accordance with aspects of the present disclosure. Specifically, the plane of the cross-sectional view shown in fig. 5 extends through the driven shaft 166 and through the plane of the worm gear 198. As shown in fig. 5, the driven shaft 166 includes a gearbox input shaft 224, the gearbox input shaft 224 being coupled to a motor shaft 226 of the electric motor 36 via a coupling 228. The coupling 228 may be a fixed coupling, such as a spline connection, such that the gearbox input shaft 224 rotates with the motor shaft 226. According to the illustrated embodiment, no clutch is provided for disengaging the motor 36 from the gears of the gearbox 140. Similarly, no clutch may be provided between the gearbox 140 and the extendable member 134. A set of input bearings 230 hold the gearbox input shaft 224 on either side of the worm gear 168. Either or both of the input bearings 230 may be any type of bearing, such as a ball bearing, a roller bearing, or the like.

In some embodiments, and as shown in fig. 5, the torque tube 192 and the worm gear 198 are formed as an integral unit, with the gear teeth formed on the outer periphery, and with the guide nut 190 formed on the inner bore. In some embodiments, the torque tube 192 and the worm gear 198 are formed as an integral unit, and the guide nut 190 is a separate component that is fixed for rotation with the integral unit.

Referring now additionally to fig. 6A-6B, fig. 6A-6B illustrate a powered actuator 122' according to aspects of the present disclosure. The powered actuator 122 'is shown in a non-limiting embodiment, wherein it is understood that any of the

powered actuator embodiments

22, 122 discussed above may be modified to include a mounting arrangement 300, as discussed below, illustratively associated with the powered actuator 122', and a contamination-resistant cover (dust, fluid, etc.) referred to below as cover 302. The mounting arrangement 300 and the cover 302 work together to allow the electric motor 36 of the powered actuator 112' to be mounted in close proximity or proximity to the closure face 162, thereby reducing the load on the closure panel 12 material, such as the closure face 162, at the point of mounting of the mounting arrangement 300 and around, and reducing the moment of inertia of the closure panel 12, and other benefits as will become apparent in view of the discussion below.

The powered actuator 122' includes the features discussed above, including the electric motor 36 and the gear box 140 drivingly coupled to the electric motor 36, wherein, as described above, the gear box 140 is configured to drive the extendable member 134 between a retracted position corresponding to the closed position of the closure panel 12 and an extended position corresponding to the open position of the closure panel 12. As noted above, the Electromagnetic (EM) brake associated with the powered actuator is optional and not shown, however, configuring the motor 36 and gear train of the powered actuator 22, 122 'for braking movement of the extendable member 134, such as braking movement of the extendable member 134 when the motor 36 is not powered, provides for elimination of the EM brake or other braking device, thereby reducing the mass of the powered actuator 22, 122'. A cover 302 is attached to the gearbox 140 and is configured to enclose the extendable member 134 to prevent contaminants from within the internal cavity 39 from reaching the extendable member 134. As discussed above with respect to the cover 148, the cover 302 may help prevent dust or dirt from fouling the extendable member 134 and/or protect the extendable member 134 from contacting other components within the closure panel 12, such as the inner panel 95 and/or the outer panel 97 and/or the window 99. The cap 302 is formed as a hollow and telescoping (extendable and retractable along the central longitudinal axis a of the extendable member 134 and the cap 302) tubular member, such as having a cylindrical geometry or other geometry, as described below. The cover 302 is illustratively a lightweight, non-load bearing structure for supporting the weight of the gearbox 140 and motor 36, and in other words, the cover 302 does not support the weight of the motor 36 and/or gearbox 140. The cover 302 may be made of rubber or plastic, for example.

The cover 302 is shown having a plurality of cover portions, shown in a non-limiting embodiment as four

cover portions

302a, 302b, 302c, 302D, that are movable relative to each other along axis D. Axis D is illustratively shown as being perpendicular to axis B. It should be understood that two or more sections may be used depending on the application requirements. The

cover portions

302a, 302b, 302c, 302d are configured in a telescoping relationship with each other, wherein the cover portion 302a is secured to the gearbox 140. The cover portion 302b is directly coupled to the cover portion 302a for telescoping movement at least partially or fully inside the cover portion 302 a. Cover portion 302c is directly coupled to cover portion 302b for telescoping movement at least partially or entirely inside of

cover portions

302b and 302 a. Cover portion 302d is directly coupled to cover portion 302c for telescoping movement at least partially or entirely inside of

cover portions

302c, 302b, and 302 a. Thus, the

cover portions

302a, 302B, 302c, 302d are axially nestable with one another such that when fully nested (axially retracted), corresponding to the open position of the closure panel 12, the overall length is the length of the cover portion 302a (fig. 6B and 9) or slightly greater, such as where the end portions of the

cover portions

302B, 302c, 302d extend slightly outwardly from the cover portion 302a, although this is not required. The extendable member 134 has a proximal end 316 that is secured to an end region of the contamination-prevention cap 302, such as to an end region of the end cap portion 302 d. As such, when the closure panel 12 is moved from the closed position toward the open position and ultimately to the open position, the proximal end 316 pulls on the cover portion 302d, which causes the cover portion 302d to cascade axially retract into the cover portion 302c, then axially retract the cover portion 302c into the cover portion 302B, then axially retract the cover portion 302B into the cover portion 302a (fig. 6B and 9), whereby the closure panel 12 is in the fully open position. When the closure panel 12 is in its fully open position, the extendable member 134 is extendable along an axis D' that is inclined relative to the axis D such that the extendable member 134 pivots in an inclined relationship relative to the plane P of the mounting bracket 304.

Thus, when the extendable member 134 is retracted from the cavity 39, the cover 302 will adopt a telescoping configuration such that neither the cover 302 nor the extendable member 134 collides with internal components within the cavity 39 during pivoting of the powered actuator 122' about the pivot axis B. For example, the cover portion 302d may be attached to the second end 46 such that the cover 302 collapses or expands in response to movement of the extendable member 134.

Referring now additionally to fig. 7 and 8, the mounting arrangement 300 includes a door adapter bracket, also referred to as a mounting bracket 304, the mounting bracket 304 being configured to pivotally attach to the gearbox 140 and fixedly attach to the closure panel 12, thereby allowing the mounting bracket 304 and gearbox 140 and all components operatively attached to the gearbox 140, including the motor 36, to pivot relative to one another. Illustratively, the mounting bracket 304 is configured for direct pivotal attachment to the gearbox 140 to allow only pivotal movement of the gearbox 140 about axis B. Illustratively, the mounting bracket 304 is configured for pivotal attachment to the outer peripheral edge of the gearbox. Thus, the mounting bracket 304 allows a single axis about which the gearbox 140 pivots. The mounting bracket 304 is shown having a plurality (by way of example and not limitation, a pair) of fastener openings 305, the fastener openings 305 being sized to receive a fastener, such as a threaded bolt (not shown), to facilitate fixedly attaching the mounting bracket 304 to the closure panel 12, such as to the closure panel 162. It should be appreciated that the reverse arrangement is contemplated herein such that the mounting bracket 304 may be configured to fixedly attach to the gearbox 140 and pivotally attach to the closure panel 12, thereby allowing the mounting bracket 304, gearbox 140, and all components operatively attached to the gearbox 140 to pivot relative to the closure panel 12. Mounting arrangement 300 is an illustrative example of pivot connection 45. The mounting arrangement 300 may be configured to allow the powered actuator 122' to pivot about a single axis of rotation, such as about a pivot axis B. The pivot axis B is illustratively parallel to the Y axis, which is aligned with the downward directed pulling force due to gravity. Illustratively, only a single axis of rotation is provided between the power actuator 122' and the door 12. Illustratively, the mounting bracket 304 is configured as a U-shaped bracket. As shown in fig. 7, to facilitate pivotal attachment, the mounting bracket 304 has a pair of yokes, also referred to as lugs or flanges 306, the lugs or flanges 306 having axially aligned through openings configured for receiving trunnions (trunnions), such as may be provided by pins 308, therein. The pin 308 may be disposed to be received in an axially aligned receiving boss 310 extending from the gearbox 140 (e.g., extending parallel to axis B), but it is contemplated that the pin may be formed as a unitary piece of material with the gearbox 140, as desired. The pin 308 provides for pivotal movement of the gearbox 140 relative to the mounting bracket 304. The flange 306 supports against movement of the gearbox 140 in the Y direction. For example, the lower boss 310 may be supported by the bottom flange 306 and thereby support the weight of the powered actuator 122'. The upper flange 306 may support an upper boss 310, for example, by connection with a pin 308. Thus, the weight of the powered actuator 122', including the weight of the gearbox 140 and motor 36, is transferred to the bracket 304, but not to the extendable member 134, as would be the case if the boss 310 and pin 308 were to be rotated ninety degrees such that the pin 308 extends along the Z-axis. Distributing the weight of the powered actuator 122 'to the bracket 304 reduces the force between the gears of the gearbox 140 and the extendable member 134 that would tend to increase binding, increase friction between the nut tube and the teeth of the extendable member 134, and possibly cause flexing of the extendable member 134, which may require increasing the motor size to compensate for such force, as compared to when the weight of the powered actuator 122', such as the weight from the gearbox 140 and/or the motor 36, is supported by the extendable member 134. To allow unrestricted pivotal movement of the gearbox 140 relative to the mounting bracket 304, the mounting bracket 304 has a clearance opening 312 through the mounting bracket 304. The gap opening 312 is provided for receiving the extendable member 134 through the gap opening 312, and the gap opening 312 is sized to allow free, unimpeded pivotal movement in the gap opening 312 as the closure panel 12 moves between the closed position of the closure panel 12 and the open position of the closure panel 12. The gap opening 312 is shown as extending much in the Z-axis direction than in the Y-axis direction. Thus, the extendable member 134 ensures that a clearance relationship is maintained with the mounting bracket 304 as the closure panel 12 moves between the closed and open positions and as the extendable member 134 translates through the clearance opening 312 and pivots relative to the mounting bracket 304. Due to the single pivot axis B, the extendable member 134 is restricted to swing only in the Z-direction.

The link 130 connected to the first end 42 shown in fig. 3A is not required due to the ability of the extendable member 134 to pivot about the pivot axis B relative to the clearance opening 312 of the mounting bracket 304 and within the clearance opening 312. As such, similar to the first end 42, the distal end 314 of the extendable member 134 may be directly pivotally secured to the body 14, wherein the distal end 314 has the attachment through opening 136. Accordingly, the gear box 140 and the components attached to the gear box 140, including the electric motor 36, may move proximate to the closure face 162, providing reduced moment variation and enhanced haptic/servo control response, particularly because the moment arm does not change as the closure panel 12 moves between the closed and open positions. Furthermore, by eliminating additional pivot axes associated with the pivotal connection between the power actuator 122 ' and the closure surface 162, such as a rotational axis extending in the Z-direction, and providing only a single rotational axis, such as rotational axis B, additional complex pivotal coupling configurations may be avoided, which further eliminates distance-producing components between the closure surface 162 and the gear box 140, reduces the mass of the power actuator 122 ' and allows the mass of the power actuator 122 ' to be closer to the door pivot axis C. Accordingly, the size of the motor 36 may be reduced and the braking capability and response time of the motor 36 may be improved due to less mass producing inertia away from the pivot axis C. Furthermore, providing the gearbox 140 as a structural support for other components reduces the binding of the extendable member 134 to the gears of the gearbox 140 and other loads on the gears of the gearbox 140, since all of the gears are supported by load bearing bearings as described herein.

Referring now to fig. 10 and 11, a comparative configuration of a powered actuator for moving the vehicle door 12 is illustrated. Fig. 10 shows the power actuator in region 1, also referred to as Z1, with components positioned between the closing surface 162 and the motor 36 and gear train, such as multiple pivot linkages (e.g., more than one pivot point allowing the motor 36 to pivot at least about the Z and Y axes), overlapping tubes, where one of the tubes serves as an extendable member, while the other support tube overlaps the extension tube to both support and guide it and support the weight of any other drive components, such as the weight of clutches, motors, gear trains, brakes, etc., connected via the support tube connected to the closing surface 162. The known device has a motor, clutch, brake, lead screw connection in region 2, also referred to as Z2. These components are supported by support members such as tubes or fixed non-pivoting brackets provided in the region 1, which themselves need to have structural strength tending to increase the mass of the actuator. Accordingly, such heavier components are positioned at a distance D1 from the closing surface 162, thereby offsetting the center of mass of the door 12 from the closing surface 162. Fig. 11 illustrates a configuration of an actuator 22, 122 'according to aspects of the present disclosure, the actuator 22, 122' having a zone 3 also referred to as Z3, zone 3 having a single pivot connection or link without additional multi-pivot components or any other support brackets or support tubes. The gear box 140 of the actuator 22, 122' is directly coupled to the single pivot connection, allowing any other intermediate components to be lightened to allow the gear box 140 to be moved further toward the closing surface 162. Illustratively, therefore, distance D2 is less than distance D1. Illustratively, the motor 36 is also disposed in alignment with the gearbox 140, or extending adjacent in the Z-direction, such that the weight associated with the motor 36 does not extend beyond a distance greater than D2, for example. In addition, the actuator 22, 122 'is not provided with a clutch or brake in either zone 3 or zone 4 or zone 5, thereby further minimizing any shift of the center of mass of the actuator 22, 122' away from the closing surface 162. Furthermore, when the extendable member 134 leaves or almost leaves the zone 5(Z5), the extendable member 134 moves across the closure surface 162, thereby further moving the mass of the actuator 22, 122' towards the closure surface 162. Illustratively, distance D2 is less than distance D1.

In accordance with another aspect of the present disclosure, fig. 12 provides a method 1000 of configuring a powered actuator 122h for moving a closure panel 12 of a motor vehicle 10 between a closed position and an open position. The method 1000 includes a step 1100 of configuring the electric motor 36 to drive the driven shaft 166 and coupling the gearbox 140 to the driven shaft 166. Step 1200 provides the extendable member 134 through the gearbox 140, wherein the extendable member 134 extends to the proximal end 316 on one side of the gearbox 140 and to the distal end 314 on an opposite side of the gearbox 140 and provides the proximal end 316 configured to be pivotably coupled to one of the body 14 or the closure member 12. Further, step 1300 configures the extendable member 134 to move between a retracted position (fig. 8) corresponding to the closed position of the closure panel 12 and an extended position (fig. 9) corresponding to the open position of the closure panel 12 in response to rotation of the driven shaft 166. Further, step 1400 covers at least a portion of the extendable member 134 extending between the gear box 140 and the distal end 314 with the contamination prevention cover 302. Also, step 1500 configures the anti-contamination cover 302 to move between an axially extended state (fig. 8) having a first length L1 when the extendable member 134 is in the retracted position and an axially retracted state (fig. 9) having a second length L2 when the extendable member 134 is in the extended position, wherein the first length L1 is greater than the second length L2.

According to another aspect, method 1000 may include step 1600: a contamination-prevention cap 302 is provided having a plurality of

cap portions

302a, 302b, 302c, 302d, the plurality of

cap portions

302a, 302b, 302c, 302d being configured to move telescopically relative to one another when the contamination-prevention cap is moved between an axially-extended state and an axially-retracted state.

According to another aspect, the method 1000 may include the step 1650: the extendable member 134 is configured to attach to one of the body 14 and the closure member 12 without incorporating an intermediate linkage between the extendable member 134 and the one of the body 14 and the closure member 12.

According to another aspect, method 1000 may include step 1700: the mounting bracket 304 is pivotally attached to the gearbox 140 to provide pivotal movement of the gearbox 140 relative to the mounting bracket 304, wherein the mounting bracket 304 is configured to be directly attached to one of the closure member 12 and the body 14.

According to another aspect, method 1000 may include step 1750: a mounting bracket 304 having a clearance opening 312 is provided and the extendable member 134 extends through the clearance opening 312, wherein the extendable member 134 may be configured to pivot within the clearance opening 312 as the extendable member 134 moves between the extended and retracted positions.

According to another aspect, method 1000 may include step 1800: the mounting bracket 304 is pivotally attached to one side of the gearbox 140, one of the cover portions 302a is secured directly to the opposite side of the gearbox 140, and the other cover portion 302d is secured to the distal end 314 of the extendable member 134.

Referring now to fig. 13 and 14 in addition to fig. 1-12, illustrated is the operation of the powered actuator 20, 122' to move the door 12 from the closed position of fig. 13 to the open position of fig. 14. In fig. 13, the extendable member 134 extends substantially within the door interior 39 and extends substantially parallel to the inner and

outer panels

95, 97 of the door 12 in an orientation that does not interfere with adjacent interior components, such as, for example, the window glass 99 or glass travel channel. In fig. 14, the extendable member 134 extends substantially out of the door interior cavity 39 due to actuation of the motor 36 to open the door 12, such that changes in the angle of the extendable member 134 due to rotation of the gearbox housing 141 about the axis B and retraction of the extendable member 134 from the cavity 39 do not cause interference of the powered actuator 20, 122' with any component of the door 12, such as the interior panel 95 or the window 99. Furthermore, since the shroud or cover 302 has telescoped in response to retraction of the extendable member 134 from the cavity 29, the cover 302 will also not collide with any internal door hardware or panels during the swinging motion PA of the powered actuator 20, 122'. Additionally, because the gearbox housing 141 is positioned closer to the closing surface 162, the length of the extendable member 134 may be shortened, further reducing the mass of the powered actuator 20, 122 'and further offsetting the center of mass of the door 12 toward the pivot axis a, and the gearbox housing 141 and powered actuator 20, 122' may generally pivot within the internal cavity without interfering with other internal door components. In other words, the footprint of the powered actuator 20, 122 ' within the door cavity 39 is reduced when the door 12 is moved from the closed position to the open position allowing for greater angular variation of the extendable member 134, compared to the case where the footprint of the extendable member's housing or cover is not configured to telescope because the length of the shroud 134 remains constant within the door cavity 29, and therefore, greater door opening angle results and/or improved door leverage and/or reduction in the cross-sectional width of the closure panel 12 are possible because the angular rotation of the powered actuator 20, 122 ' is not limited by contact with adjacent door components. In addition, providing a pivotal coupling between the vehicle closure panel 12 and the gearbox housing 141, for example a direct coupling with the structural housing of the gearbox 140, without an intermediate tubular housing configured for supporting the reciprocating movement of the extendable actuation member as in known devices, eliminates components that tend to increase the distance D2 from the closure face 162 closer to the distance D1. By this direct coupling of the pivotal connection with the gearbox housing 141, the powered actuator 20, 122 ' is supported at a location closer to the closing face 162 without the need for a tubular housing that is strong enough to resist bending loads due to the electric motor being positioned at the opposite end from the coupling with the closing face 162, thereby reducing component and component weight, for example due to increased thickness of the tubular housing and tubular housing for strength, reducing vertical loads on the coupling 45 and closing face 162, and bringing the weight of the vehicle door 12 closer to the hinge line (e.g., about pivot axis a), which is beneficial for improving the performance of the powered actuator 20, 122 ' because the weight of the door 12 away from the

hinge

16, 28 that must be moved or stopped by the powered actuator 20, 122 ' is less. Additionally, a single structural component in the form of the gearbox housing 141 may be designed to support both the load from the weight of the electric motor 36 and the weight of the gears enclosed within the gearbox housing 141 supported thereby, as well as the side loads of the extendable member 134 acting on the nut 192 during opening and closing of the door 12.

Referring now additionally to fig. 15 and 16, fig. 15 and 16 illustrate a powered actuator 122 "in accordance with aspects of the present disclosure. The power actuator 122 "is shown in a non-limiting embodiment, wherein it is understood that any of the power actuator embodiments 22, 122' discussed above may be modified to include two contamination-resistant covers (dust, fluid, etc.) referred to hereinafter as an inner cover 302" and an outer cover 303 "and illustratively associated with the power actuator 122" as discussed below. The covers 302 ", 303" work together to completely enclose the extendable member 134 "to prevent the ingress of debris, dust, dirt, contaminants, etc. into contact with the threads of the extendable member 134", wherein the extendable member 134 "is driven to reciprocate within the gearbox 140", for example in the manner described herein above with reference to the extendable member 134. The inner cover 302 "is shown attached to one side of the housing 141", for example by press-fit engagement with the housing 141 "(see fig. 17), and the inner cover 302" is illustratively configured as a collapsible bellows, and the inner cover 302 "is shown in fig. 15 in a collapsed state corresponding to a door open position when the extendable member 134" is extended from the closure face 162, and the inner cover 302 "is shown in fig. 16 in a deployed state corresponding to a door closed position when the extendable member 134" is extended into the cavity 39. The housing 141 "also has a motor 36" attached to the housing 141 ", the motor 36" being similar to the motor 36 described herein above, but now extending upwardly from the housing 141 ". A proximal end of the extendable element 134 "similar to the proximal end 316 of the extendable element 134 described herein above may be coupled to the inner cap 302". The outer cover 303 "is shown attached to the other, opposite side of the housing 141", and the outer cover 303 "is illustratively configured as a collapsible bellows, and the outer cover 303" is shown in a deployed state corresponding to a door open position when the extendable member 134 "is extended from the closing face 162 in fig. 15, and the outer cover 303" is shown in a collapsed state corresponding to a door closed position when the extendable member 134 "is extended into the chamber 39 in fig. 16. A distal end 314 "of the extendable member 134" similar to the proximal end 314 of the extendable member 134 described herein above may be coupled to the inner cap 302 "such that the outer cap 303" changes state in response to movement of the extendable member 134 ". The outer cover 303 "is shown attached to one side of the housing 141" using a sleeve (boot)143 ", the sleeve 143" having an internal bore to receive the outer cover 303 ", and the sleeve 143" is further configured to connect with the housing 141 ", such as by a snap-fit engagement or by a threaded engagement (see fig. 17), to secure the outer cover 303" to the housing 141 ". The outer cover 303 "completely encloses the extendable member 134" to prevent debris, dust, dirt, contaminants, etc. originating from the external environment outside the cavity 39 from entering into contact with the threads of the extendable member 134 "as the extendable member 134" is extended and retracted relative to the gearbox 140 ". The covers 302 ", 303" may be formed of a resilient material, such as a flexible plastic or a flexible rubber, as non-limiting examples.

Referring additionally now to fig. 17, a cross-sectional view of the powered actuator 122 "is shown illustrating a support arrangement for a torque tube 192" similar to the nut tube 192 described herein above. The support arrangement for the torque tube 192 "includes a bushing 196 a" at one end of the torque tube 192 "for supporting rotation of the torque tube 192" relative to the housing 141 "as a nut support, and includes a bearing 192 b" at an opposite end of the torque tube 192 "for supporting rotation of the torque tube 192" relative to the housing 141 ". The bearing 192b "is shown to include a ball bearing disposed between an inner race 199" coupled to the torque tube 192 "and an outer race 197" coupled to the housing 141 ". The prevention of axial movement of the bearing 192b "is achieved by: a first nut 193 "is provided that is threaded to an inner surface of the housing 141" for positioning against or adjacent to the outer ring 197 "to prevent axial movement of the outer ring 197", and a second nut 195 "is provided that is threaded to an outer surface of the torque tube 192" for positioning against or adjacent to the inner ring 195 "to prevent axial movement of the outer ring 195". The back drive capability of the power actuator 122 "is improved because the axial movement of the bearing 192 b" is limited during back driving of the torque tube 192 "due to movement of the extendable member 134" caused by manual movement of the door.

It will be apparent, however, that changes may be made to what is described and illustrated herein without departing from the scope as defined by the appended claims. The foregoing description of embodiments has been presented for purposes of illustration and description. The foregoing description of embodiments is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The various elements or features of a particular embodiment may also be varied in a number of ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

The foregoing description of embodiments has been presented for purposes of illustration and description. The foregoing description of embodiments is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The various elements or features of a particular embodiment may also be varied in a number of ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Embodiments of the present disclosure may be understood with reference to the following numbered paragraphs:

1. a powered actuator 22, 122' for moving a closure panel 12 of a motor vehicle 10 between a closed position and an open position, the powered actuator comprising:

an electric motor 36 configured to rotate the driven shaft 166;

a gearbox 140 coupled to the driven shaft 166;

a gearbox housing 141 enclosing the gearbox;

an extendable member 134 extending through the gear box and having a proximal end 316 configured to be pivotably coupled to one of the body 14 or the closure panel 12, the extendable member 134 configured to move between a retracted position corresponding to the closed position of the closure panel 12 and an extended position corresponding to the open position of the closure panel 12 in response to rotation of the driven shaft 166; and

a coupling configured to couple the gearbox housing to the closure panel.

2. The powered actuator of paragraph 1 wherein the link is a pivotal link configured for pivotal movement in response to the closure panel moving between the open and closed positions.

3. The powered actuator of paragraph 2 wherein the pivot coupling is a bracket configured for fixed attachment to an inner closure panel extending between outer and inner panels of the closure panel and for pivotal attachment to the gearbox housing.

4. The power actuator of paragraph 3 wherein the pivotal attachment to the gearbox housing is at an outer periphery of the gearbox housing.

5. The powered actuator of paragraph 3 wherein the bracket includes a plate for abutting the closure face, the plate including an aperture for receiving the extendable member, wherein the aperture is aligned with a port provided in the closure face for receiving the extendable member.

6. The powered actuator of paragraph 5, wherein the port is a door check port for receiving an extendable member of a door check, wherein the closure panel is not provided with a door check.

7. A powered actuator according to paragraph 1, wherein the extendable member and motor shaft are aligned substantially perpendicular to each other.

8. The powered actuator of paragraph 1 wherein the electric motor is attached to the gearbox housing.

9. The powered actuator of paragraph 1 wherein, when the coupling is attached to a closure face, the electric motors are arranged in parallel along the closure face and extend in close proximity.

10. The powered actuator of paragraph 9 wherein the close proximity does not substantially change during opening and closing of the closure panel.

11. The powered actuator of paragraph 1, wherein the gearbox housing is directly coupled to the coupling.

12. The powered actuator of paragraph 11 wherein the direct coupling does not include a tube interconnecting the gearbox housing to the coupling.

13. The powered actuator of paragraph 1, wherein the gearbox is configured to rotatably support a nut operable to drive the motor shaft, wherein the extendable member is operably coupled to the nut and extends through the nut to extend and retract in response to rotation of the nut by the electric motor.

14. The powered actuator of paragraph 13 wherein the nut is rotatably supported within the gearbox housing by at least one bushing.

15. The powered actuator of paragraph 14, wherein the nut is configured as an elongated nut tube, wherein more than one bushing is disposed between the nut tube and the gearbox housing.

16. The powered actuator of paragraph 1 wherein a majority of the extendable member extends outside of the internal cavity of the closure panel when the extendable member is in the extended position.

17. The powered actuator of paragraph 1 further comprising at least one extendable/retractable guard coupled to a distal side or a proximal side of the gearbox housing for receiving the extendable member therein in an extended state.

18. The powered actuator of paragraph 1, further comprising a seal disposed between the gearbox housing and the extendable member for sealing the gearbox.

19. The powered actuator of paragraph 1 wherein the powered actuator is not provided with at least one of a clutch mechanism or a brake mechanism.

20. The powered actuator of paragraph 1, wherein the coupling is configured to allow the gearbox housing to pivot about only a single axis.

Claims

1. A powered actuator (22, 122') for moving a closure panel (12) of a motor vehicle (10) between a closed position and an open position, the powered actuator comprising:

an electric motor (36) configured to rotate a driven shaft (166);

a gearbox (140) coupled to the driven shaft (166);

a gearbox housing (141) enclosing the gearbox;

an extendable member (134) extending through the gearbox and having a proximal end (316) configured to be pivotably coupled to one of a vehicle body (14) or the closure panel (12), the extendable member (134) configured to move between a retracted position corresponding to the closed position of the closure panel (12) and an extended position corresponding to the open position of the closure panel (12) in response to rotation of the driven shaft (166); and

a coupling configured to couple the gearbox housing to the closure panel.

2. The power actuator according to claim 1, wherein said link is a pivotal link configured for pivotal movement in response to movement of said closure panel between said open and closed positions.

3. A powered actuator according to claim 2, wherein the pivotal coupling is a bracket configured for fixed attachment to an inner closure face panel extending between outer and inner panels of the closure panel and for pivotal attachment to the gearbox housing.

4. A powered actuator according to claim 3, wherein the pivotal attachment to the gearbox housing is at an outer periphery of the gearbox housing.

5. A powered actuator according to claim 3 or 4 wherein the bracket comprises a plate for abutment with the closure face, the plate comprising an aperture for receiving the extendable member, wherein the aperture is aligned with a port provided in the closure face for receiving the extendable member.

6. The powered actuator of claim 5, wherein the port is a door check port for receiving an extendable member of a door check, wherein the closure panel is not provided with a door check.

7. A powered actuator according to any of claims 1 to 6, wherein the electric motor is attached to the gearbox housing.

8. A powered actuator according to any of claims 1 to 8, wherein the gearbox housing is coupled directly to the coupling.

9. The powered actuator of claim 1, wherein the gearbox is configured to rotatably support a nut operatively driving a motor shaft, wherein the extendable member is operatively coupled to the nut and extends through the nut to extend and retract in response to rotation of the nut by the electric motor.

10. The power actuator according to claim 9, wherein said nut is rotatably supported within said gearbox housing by at least one bushing.

11. The power actuator according to claim 10, wherein said nut is configured as an elongated nut tube, wherein more than one bushing is disposed between said nut tube and said gearbox housing.

12. The powered actuator according to any one of claims 1 to 11, wherein the powered actuator is not provided with at least one of a clutch mechanism or a brake mechanism.

13. A powered actuator according to any of claims 1 to 11, wherein the coupling is configured to allow the gearbox housing to pivot about only a single axis.