Power drive unit for opening and closing vehicle door

Abstract

A power drive unit for opening and closing a vehicle door is described herein and includes a vehicle body bracket, a door bracket, a transmission assembly, an output linkage assembly, and a first drive motor. A transmission assembly is coupled to one of the door bracket and the body bracket. The output linkage assembly is coupled to the other of the door bracket and the vehicle body bracket via an output arm and to the transmission assembly. The link arm is coupled to the output arm and to the other of the body bracket and the door bracket. The first drive motor is coupled to the transmission assembly via the output shaft, and the first drive motor is electrically connected to a vehicle power source. The first energy storage member applies an axial preload to the output shaft. The output linkage assembly moves the door bracket between a door open position and a door closed position based on a direction of the first drive motor.

Description

Technical Field

[0001] This disclosure relates to a door opening system for a motor vehicle, and more specifically to a power drive unit for a vehicle door. Background Technology

[0002] Vehicle doors are typically opened or closed manually by pushing or pulling them, without the aid of a power drive unit. Door checks are usually used to hold the door in the open position. To assist in opening and closing doors, vehicles are increasingly incorporating power drive units for the doors, allowing them to move between the open and closed positions. However, conventional power drive units are quite complex and often take up too much space (and add weight), especially when used in conjunction with door checks.

[0003] Providing a power drive unit that helps overcome such problems would be very helpful. Utility Model Content

[0004] According to some embodiments, a power drive unit for opening and closing a vehicle door is provided. The power drive unit includes a body bracket, a door bracket, a transmission assembly, an output linkage assembly, and a first drive motor. The body bracket is configured to be connected to a vehicle body, and the door bracket is configured to be connected to a vehicle door. The transmission assembly is operatively connected to one of the door bracket and the body bracket. The output linkage assembly is operatively connected to the other of the body bracket and the door bracket, and is also operatively connected to the transmission assembly. The output linkage assembly includes an output arm and a connecting arm. The output arm is connected to the transmission assembly at a first output end and to the connecting arm at a second output end. The connecting arm is connected to the second output end and to the other of the body bracket and the door bracket. The first drive motor is operatively connected to the transmission assembly via an output shaft, and the first drive motor is configured to be electrically connected to a vehicle power source. The output shaft is connected to a first energy storage member configured to apply an axial preload to the output shaft. The output linkage assembly is configured to move the door bracket between a door open position and a door closed position in response to operation of the transmission assembly. When the first drive motor is driven in a first direction, the output linkage assembly moves the door bracket to the door open position. When the first drive motor is driven in a second direction, the output linkage assembly moves the door bracket to the door closed position.

[0005] According to some embodiments, the first energy storage component includes a wave spring or an elastomeric spring.

[0006] According to some implementations, the power drive unit also includes a braking subsystem that is operatively coupled to the transmission assembly.

[0007] According to some embodiments, the braking subsystem includes a brake gear assembly, a second drive motor, and a braking energy storage member. The brake gear assembly is operatively coupled to a drive gear of a transmission assembly via a brake band, wherein the brake gear assembly includes a cam surface configured to move between a braking position and a brake release position. The second drive motor is operatively coupled to the brake gear assembly and configured to be driven in a braking direction and a non-braking direction, wherein when the second drive motor is driven in the braking direction, the cam surface moves to the braking position, and when the second drive motor is driven in the non-braking direction, the cam surface moves to the brake release position. The braking energy storage member is operatively coupled to the brake band and configured to: apply tension to the brake band when releasing energy, and release the tension in the brake band when biased to store energy. When the cam surface is in the brake release position, the cam surface engages with the braking energy storage member to bias the braking energy storage member. When the cam surface is in the braking position, the cam surface moves to disengage from the braking energy storage member, thereby releasing the stored energy.

[0008] According to some implementations, the first drive motor and the second drive motor are positioned parallel to each other.

[0009] According to some embodiments, the power drive unit further includes an electronic control unit configured to actuate the first drive motor. According to some embodiments, the electronic control unit is also configured to actuate a second drive motor.

[0010] According to some embodiments, the power drive unit further includes a motor housing having at least one overmolded electrical connector located within the motor housing. According to some embodiments, the first drive motor includes at least one inlet window configured to align the at least one overmolded electrical connector with a corresponding electrical connector of the first drive motor.

[0011] According to some embodiments, the power drive unit further includes a transmission housing connected to one of the door bracket and the body bracket, the transmission housing comprising at least three mounting positions, wherein at least one of the three mounting positions is not on the same plane as the other three mounting positions.

[0012] According to some embodiments, the connecting arm includes a stop feature configured to engage directly or indirectly with one of the door bracket and the body bracket when the door bracket is in the open position. According to some embodiments, the power drive unit also includes a stop pad connected to one of the door bracket and the body bracket, and configured to abut against the stop feature when the door bracket is in the open position.

[0013] According to some embodiments, the transmission assembly includes a helical gear, a second pulley, an annular transmission member, and a tension pulley. The helical gear (also referred to herein as a drive gear) is configured to be operatively coupled to the output shaft of a first drive motor via a worm gear. The helical gear has a first pulley. The second pulley has a planetary gear set. The annular transmission member is configured to operatively couple the first pulley to the second pulley. The tension pulley is configured to apply tension to the annular transmission member. A first output end of the output arm is operatively coupled to the planetary gear set.

[0014] Other aspects of the subject matter for which protection is sought will become apparent from the following description and explanation. Attached Figure Description

[0015] To better understand the various implementations described herein and to more clearly illustrate how to put these implementations into practice, reference will now be made only to the accompanying drawings, in which:

[0016] Figures 1A-1C A power drive unit according to a non-limiting embodiment is shown;

[0017] Figure 2 It shows Figures 1A-1C A perspective view of the power drive unit, in which a portion of the housing has been removed;

[0018] Figure 3 A non-limiting embodiment is shown. Figures 1A-1C A front view of the transmission assembly of the power drive unit;

[0019] Figure 4 It shows Figure 3 An enlarged rear view of the transmission device assembly;

[0020] Figure 5 It shows Figures 1A-1C An enlarged rear view of the transmission components and braking subsystem of the power drive unit;

[0021] Figure 6 A partial view of a braking subsystem according to a non-limiting embodiment is shown;

[0022] Figure 7A andFigure 7B It shows Figure 6 The brake is in the released position. Figure 7A ) and braking position ( Figure 7B A partial view of the braking subsystem;

[0023] Figure 8 A partial view of a parallel first drive motor and a second drive motor according to a non-limiting embodiment is shown.

[0024] Figure 9 A non-limiting embodiment is shown. Figures 1A-1C A front view plan of the power drive unit, in which one or more housing components have been removed and a schematic diagram of the electronic control unit is shown;

[0025] Figures 10A-10E Components of a motor subassembly according to a non-limiting embodiment are shown;

[0026] Figure 11A It shows Figures 1A-1C A rear-view perspective view of the power drive unit;

[0027] Figure 11B It shows Figures 1A-1C Side view of the power drive unit;

[0028] Figure 11C It shows Figures 1A-1C A top view of the power drive unit; and

[0029] Figure 12A and Figure 12B The stop feature and stop pad of the power drive unit according to a non-limiting embodiment are shown.

[0030] The embodiments, examples, and alternatives described in the preceding paragraphs, claims, or the following description and drawings, including any aspect or feature of their respective aspects or corresponding features, may be employed independently or in any combination. Features described with respect to one embodiment are applicable to all embodiments unless those features are incompatible. Detailed Implementation

[0031] This document describes a power drive unit for opening and closing vehicle doors. Each power drive unit includes at least one component that, when actuated, provides power-assisted movement, and, according to at least some embodiments, causes the vehicle's swing door to open and close fully automatically when actuated. According to some embodiments, at least some of the components are mounted within at least one housing. The housing may be secured to a mounting bracket that is attached to the door or to the vehicle body.

[0032] According to some embodiments, the described power drive unit is installed within the door in an area similar to and with a similar mounting configuration (and instead of the standard door restriction mechanism). The connecting arm can be secured to a body pillar via a U-shaped bracket or other suitable type of bracket. The main drive motor drives the door to open and close, and a second brake motor can be used to engage and disengage the brake, thereby holding the door in a stationary position. According to some embodiments, the described power drive unit is controlled by a separate electronic control unit or other suitable controller located within the door, which can adjust the speed of the drive motor to achieve the desired door movement.

[0033] It is understood that numerous specific details have been set forth in order to provide a full understanding of the exemplary aspects of this application as described herein. However, it will be understood by those skilled in the art that the exemplary aspects described herein can be implemented without these specific details. In other instances, well-known methods, processes, and components have not been described in detail so as not to obscure the exemplary aspects described herein. Furthermore, this description should not be construed as limiting the scope of the exemplary aspects described herein. Any system, method step, method block, component, or portion of a component described herein in the singular should be construed as also including such systems, method steps or tasks, components, or portions of a component described in the plural, and vice versa. Other aspects of the present invention will become apparent from the accompanying figures and descriptions. As will be apparent to those skilled in the art, the specific arrangement of the elements described herein can be modified.

[0034] Reference Figures 1A-4 , Figures 1A-4 An exemplary power drive unit 100 for opening and closing a vehicle door (not shown) according to a non-limiting embodiment is illustrated. The power drive unit 100 includes a body bracket 102 and a door bracket 104, the body bracket 102 being configured to be coupled to a vehicle body (not shown), and the door bracket 104 being configured to be coupled to a vehicle door. According to some embodiments, the body bracket 102 is a U-shaped bracket. However, any suitable bracket and device for coupling the body bracket to the vehicle body is contemplated. For example, according to some embodiments, the body bracket 102 is coupled to a pillar of the vehicle body. The door bracket 104 includes any suitable bracket and device for coupling the door bracket 104 to the vehicle door. For example, according to some embodiments, the door bracket 104 is coupled to or forms part of a device housing, such as a transmission housing 105. Figures 1A-1C ).

[0035] The power drive unit 100 also includes a transmission assembly 106 (see, for example, see...). Figure 3and Figure 4 The transmission assembly 106 is operatively coupled to one of the door bracket 104 and the body bracket 102. For example, according to some embodiments, the transmission assembly 106 is operatively coupled to a pillar of the vehicle body. However, according to some embodiments, as shown in the figures, the transmission assembly 106 is operatively coupled to the door bracket 104 via an output linkage assembly 108. According to some embodiments, the transmission assembly 106 includes at least one gear and an annular transmission member operatively coupled to the at least one gear. For example, as shown, the transmission assembly 106 includes a helical gear 110 having a first pulley 118 and a planetary gear set 122 (…). Figure 3 The second pulley 120 ( Figure 4 The second pulley 120 is operatively coupled to the sun gear 112 of the planetary gear set 122. Power from the helical gear 110 is transmitted to the planetary gear set 122 via a belt 114 coupled to the first pulley 118 and the second pulley 120 (i.e., the helical gear 110 is the drive gear). The belt 114 comprises any annular transmission member suitable for transmitting power between the helical gear 110 and the planetary gear set 122. For example, according to some embodiments, the belt 114 may comprise a toothed rubber belt. According to some embodiments, the belt 114 is configured to help isolate noise and vibration originating from the first drive motor 124 (discussed further below) and to help prevent noise and vibration from being transmitted to the vehicle via the helical gear 110, the planetary gear set 122, and the connecting arm (discussed further below). Furthermore, the use of a belt-driven powertrain allows for a narrower powertrain across the vehicle compared to a larger conventional powertrain. This is particularly useful because vehicle side doors tend to be narrower in the direction across the vehicle, and according to some embodiments, the power drive unit 100 is intended to be fitted into the door area where the window falls. According to some embodiments, the drive assembly 106 also includes at least one tension pulley, such as tension pulley 116.

[0036] The power drive unit 100 also includes an output linkage assembly 108, which is operatively coupled to another of the body bracket 102 and the door bracket 104, and is also operatively coupled to the transmission assembly 106. The output linkage assembly 108 includes an output arm 126, which is coupled to the transmission assembly 106 at a first output end 128 and to a connecting arm 130 at a second output end 132. Figure 2 , Figure 3The connecting arm 130 is connected to the second output end 132 and to another of the body bracket 102 and door bracket 104 (e.g., connected to the body bracket 102 shown in the exemplary power drive unit 100 as illustrated in the figures).

[0037] As described above, the power drive unit 100 includes at least one drive motor, such as a first drive motor 124. The first drive motor 124 is operatively coupled to the transmission assembly 106 via an output shaft 134. For example, according to some embodiments, the output shaft 134 includes a worm gear 136 configured to mesh with the teeth of a helical gear 110. The first drive motor 124 is configured to be electrically connected to a vehicle power source (e.g., via...). Figure 10E The electrical connector 138 shown is also mentioned. Furthermore, the output shaft 134 is connected to a first energy storage member 140, which is configured to apply an axial preload 142 to the output shaft 134. Figure 3 This typically helps prevent clicking noise from the power drive unit 100 during load reversal, such as when the door stops. Applying axial preload 142 also helps reduce the effects of axial free play in the first drive motor 124.

[0038] Any suitable energy storage component can be considered for the first energy storage component 140. For example, according to some embodiments, the first energy storage component 140 includes one or more of a wave spring and an elastomeric spring. Using a wave spring or an elastomeric spring helps to avoid unwanted noise that might occur with the use of a helical spring. The first energy storage component 140 may resonate due to the operating frequency of the first drive motor 124. It has been observed that if a helical spring is used instead of a wave spring or an elastomeric spring, such resonance can cause unwanted whistling noise. Using a wave spring or an elastomeric spring with a significantly higher torsional natural frequency can help prevent such resonance. Furthermore, according to some embodiments, the first energy storage component 140 is coupled to a bushing 144, which is configured to abut against the worm gear 136.

[0039] In operation, the output linkage assembly 108 is configured to cooperate with the operation of the transmission assembly 106 to position the door bracket 104 in the door open position (along direction O). Figure 1B ) and the door closed position (along direction C) ( Figure 1C Movement between ) . For example, such as Figure 3As shown, the output arm 126 rotates in the door opening direction O in response to the driving motion of the planetary gear set 122 in one direction, causing the door bracket 104 to move away from the body bracket 102. Conversely, the output arm rotates in the door closing direction C in response to the driving motion of the planetary gear set 122 in the opposite direction, causing the door bracket 104 to move towards the body bracket 102. Specifically, when the first drive motor 124 is driven in a first direction (also referred to herein as the first motor direction), power is transmitted to the output linkage assembly 108, and the output linkage assembly 108 moves the door bracket 104 to the door open position. When the first drive motor 124 is driven in a second direction opposite to the first direction (also referred to herein as the second motor direction), the output linkage assembly 108 moves the door bracket 104 to the door closed position.

[0040] Reference Figures 5-7B , Figures 5-7B Other exemplary components are shown. For example, according to some embodiments, the power drive unit 100 further includes a braking subsystem 146 operatively coupled to the transmission assembly 106. According to some embodiments, the braking subsystem 146 includes a brake gear assembly 148 and a second drive motor 150. The brake gear assembly 148 is operatively coupled to a drive gear, such as a helical gear 110, of the transmission assembly 106 via a brake band 152. The brake band 152 is, for example, operatively coupled to a secondary pulley 154 of the helical gear 110 (also referred to herein as a brake drum 154). The brake gear assembly 148 includes a sector gear 156 having a cam surface 158 configured to be in the braking position ( Figure 7B ) and brake release position ( Figure 7A They move between ( ).

[0041] The second drive motor 150 is operatively coupled to the brake gear assembly 148. For example, according to some embodiments, the second drive motor 150 includes a worm gear 160 coupled to the second output shaft 162 and configured to mesh with the teeth of a sector gear 156. The second drive motor 150 is configured to be driven in the braking direction and in a non-braking direction opposite to the braking direction. Figure 7A and Figure 7B When the second drive motor 150 is driven in the braking direction, the cam surface 158 moves to the braking position, in which tension is applied to the brake band 152. Figure 7B When the second drive motor is driven in the non-braking direction, the cam surface 158 moves to the brake release position, in which the tension in the brake band 152 is released. Figure 7A ).

[0042] The braking subsystem 146 also includes a braking energy storage member 164, which is operatively coupled to the brake band 152. The braking energy storage member 164 is configured to apply tension to the brake band 152 when releasing energy, and to release tension in the brake band 152 when biased to store energy. When the cam surface 158 is in the brake release position, the cam surface 158 engages with the braking energy storage member 164 to bias the braking energy storage member 164. When the cam surface 158 is in the braking position, the cam surface 158 moves to disengage from the braking energy storage member 164, thereby enabling the release of the stored energy. For example, according to some embodiments, when the cam surface 158 engages with the braking energy storage member 164, the braking energy storage member 164 is compressed (…). Figure 7A This compression releases tension in the brake band 152, allowing the helical gear 110 to be driven by the first drive motor 124. When the cam surface 158 moves to disengage from the brake energy storage member 164, the brake energy storage member 164 decompresses, releasing the energy stored during compression, and the brake energy storage member 164 applies tension to the brake band 152. Figure 7B Applying tension to the brake band 152 restricts the movement of the helical gear 110. The cam surface 158 may engage with the brake energy storage member 164 via an intermediate component, such as a cover 166. According to some embodiments, the brake energy storage member 164 abuts against another component at its end, thereby facilitating the compression and decompression of the brake energy storage member 164. According to some embodiments, the abutting component includes the surface of a housing.

[0043] Any suitable energy storage component can be considered for use in the braking energy storage component 164. For example, according to some embodiments, the braking energy storage component 164 includes a helical spring or an elastomeric spring.

[0044] In operation, the braking subsystem 146 has two positions: ON and OFF (i.e., the braking position and the brake release position corresponding to the cam surface 158). Power is typically required to change from one position to the other, but no power is required to maintain either position. When needed, at least according to some embodiments, the braking subsystem 146 can be engaged to hold the door in any open position. Because no power is required to keep the braking subsystem 146 engaged, the door can typically remain open for extended periods without the braking subsystem 146 drawing current from the vehicle's power source (e.g., a vehicle battery, not shown). According to some embodiments, the braking subsystem 146 can be disengaged when a user interacts with the door to close it.

[0045] According to some embodiments, the first drive motor 124 and the second drive motor 150 are positioned parallel to each other. Figure 8 According to some embodiments, the first drive motor 124 and the second drive motor 150 are mounted as sub-assemblies connected to each other via a motor housing 168. According to some embodiments, the motor housing 168 includes at least one overmolded electrical connector, such as an overmolded electrical connector 170. Figure 10B ).

[0046] To facilitate alignment of the overmolded electrical connector with the corresponding electrical connector of the respective drive motor (e.g., the corresponding electrical connector 172, also referred to herein as the corresponding electrical receiver 172), one or more of the first drive motor 124 and the second drive motor 150 include at least one inlet window 173. Figure 10C and Figure 10D As described above, according to some embodiments, the power drive unit 100 includes a transmission housing 105 connected to one of a door bracket 104 and a body bracket 102. The transmission housing 105 includes at least three mounting positions, such as mounting position 174 (separate mounting positions 174A, 174B, and 174C). Figures 11A-11C At least one of the mounting positions 174, such as mounting position 174A, is not on the same plane as the other mounting positions 174, such as mounting positions 174B and 174C. For example, as Figure 11B As shown, mounting position 174A is located on a first plane 176 on the transmission housing 105, while mounting positions 174B and 174C are located on a second plane 178 on the door bracket 104, spaced apart from the first plane 176. Positioning mounting position 174A on the transmission housing 105 on a different plane than mounting positions 174B and 174C on the door bracket 104 helps to provide at least some torsional stiffness to the door panel and helps to reduce the deflection of the power drive unit 100 during operation. The applicant has found that power drive units for vehicle doors typically apply loads to the door panel more significantly compared to conventional door restraint mechanisms. Placing the mounting positions on different planes helps to reduce the need for additional reinforcement of the power drive unit 100.

[0047] The power drive unit 100 may include additional features to improve the feel of opening and closing the doors. For example, according to some embodiments, the connecting arm 130 includes a stop feature 180 configured to, when the door bracket 104 is in the open position, directly or indirectly engage with one of the door bracket 104 and the body bracket 102 (e.g., as shown in the image). Figure 12A and Figure 12BThe door bracket 104 shown in the diagram is engaged with it. According to some embodiments, the power drive unit 100 also includes a stop pad 182, which is coupled to one of the door bracket 104 and the body bracket 102 (e.g., as shown in the diagram). Figure 12A and Figure 12B The door bracket 104 is shown. The stop pad 182 is configured to abut against the stop feature 180 when the door bracket 104 is in the open position. These features help to provide a premium feel to the door and prevent clicking noise when the door reaches the fully open position. Figure 12A and Figure 12B ).

[0048] According to some embodiments, the power drive unit 100 includes an electronic control unit 184 configured to actuate the first drive motor 124. Figure 9 According to some embodiments, the electronic control unit 184 is also configured to actuate the second drive motor 150. For example, the electronic control unit 184 may send a command to the braking subsystem 146 to hold the door in the open position. When a user interacts with the door (e.g., the user presses against the door to close it), the electronic control unit 184 may also send a command to the braking subsystem 146 to disengage the braking subsystem 146.

[0049] It should be understood that, in addition to Figures 1A-12B In addition to the configuration shown, alternative configurations of the power drive unit 100 can be considered. Specifically, the power drive unit 100 can be configured such that multiple components are mounted to the vehicle body rather than the doors. For example, according to some embodiments, the configuration of the power drive unit 100 can be reversed such that the transmission assembly 106 is connected to the vehicle body bracket 102 (instead of...). Figures 1A-12B As shown, it is connected to the door bracket 104), and the connecting arm 130 is connected to the door bracket 104 (instead of as shown). Figures 1A-12B As shown in the figures, it is connected to the body bracket 102. According to some embodiments, the first drive motor 124, the second drive motor 150, and the braking subsystem 146, as well as accompanying components, are also (e.g., via body pillars) connected to the body bracket 102, instead of being connected to the door bracket 104 as shown in the figures.

[0050] It should also be understood that, for the purposes of this application, the language expression “at least one of X, Y and Z” or “one or more of X, Y and Z” can be interpreted as only X, only Y, only Z, or any combination of two or more items X, Y and Z (e.g., XYZ, XYY, YZ, ZZ, XX, XY).

[0051] In this application, a component may be described as being "constructed" or "capable" of performing one or more functions. Generally, it should be understood that a component constructed or capable of performing a function is constructed or capable of performing that function, or is adapted to perform that function, or is operable to perform that function, or is capable of performing that function in other ways.

[0052] Furthermore, components in this application may be described as "operationally connected to," "operationally coupled to," or other similar terms. It should be understood that these components are connected or coupled to each other in some way to perform a specific function. It should also be understood that the terms "connection," "coupling," etc., used in this application include both direct and indirect connections between components.

[0053] References to "an embodiment," "implementation," "form of implementation," "variation," etc., in this application indicate that the described embodiment, form of implementation, or variation may include a particular aspect, feature, structure, or characteristic, but not every embodiment, form of implementation, or variation must include that aspect, feature, structure, or characteristic. Furthermore, such terms may, but do not necessarily, refer to the same embodiment mentioned in other parts of the specification. Moreover, when a particular aspect, feature, structure, or characteristic is described in connection with an embodiment, it means, to the extent that a person skilled in the art, influences such a module, aspect, feature, structure, or characteristic, or connects such a module, aspect, feature, structure, or characteristic to other embodiments, whether explicitly described or not. In other words, unless there is an obvious or inherent incompatibility or it is explicitly excluded, any module, element, or feature can be combined with any other element or feature in different embodiments.

[0054] It should also be noted that the claims can be drafted to exclude any optional elements. Therefore, this statement is intended to serve as a prerequisite for the use of exclusive terms such as "only," "merely," etc., in relation to the description of claim elements or the use of "negative" limitations. The terms "preferred," "ideally," "preferred," "optionally," "may," and similar terms are used to indicate that the mentioned item, condition, or step is an optional (non-essential) feature of the present invention.

[0055] Unless the context clearly indicates otherwise, the singular forms “a,” “an,” and “the” include plural referents. The term “and / or” means any one of the items associated with the term, any combination of these items, or all of these items. Those skilled in the art will readily understand the term “one or more,” especially when read in the context in which the term is used.

[0056] The term "about" can refer to a variation of ±5%, ±10%, ±20%, or ±25% of a specified value. For example, in some embodiments, "about 50%" can have a variation from 45% to 55%. For integer ranges, the term "about" can include one or two integers that are greater than and / or less than the integers at both ends of the range. Unless otherwise stated herein, the term "about" is intended to include values ​​and ranges that are close to the range and are functionally equivalent in the composition or embodiment.

[0057] Those skilled in the art will understand that, for any and all purposes, particularly in providing a written description, all ranges described herein also encompass any and all possible subranges and combinations thereof, as well as the individual values, particularly integer values, that constitute the range. The ranges include every specific value, integer, decimal, or identity within the range. Any listed range can be readily considered sufficiently descriptive and capable of being decomposed into at least equal halves, thirds, quarters, fifths, or tenths. As a non-limiting example, each range discussed herein can be readily decomposed into a lower third, a middle third, and an upper third, etc.

[0058] Those skilled in the art will also understand that all linguistic expressions such as “reach,” “at least,” “greater than,” “less than,” “more than,” and “or more” include the listed numbers, and these terms refer to ranges that can subsequently be divided into subranges as described above. In the same manner, all ratios listed herein also include all sub-ratios falling within a wider range.

[0059] Those skilled in the art will understand that many other alternative implementations and modifications may exist, and the examples above are merely illustrative of one or more implementations. Therefore, the scope is limited only by the appended claims.

Claims

1. A power drive unit for opening and closing a vehicle door, characterized by, The power drive unit includes: a body bracket configured to be coupled to a vehicle body; a door bracket configured to be coupled to the vehicle door; a transmission assembly operatively coupled to one of the door bracket and the body bracket; an output linkage assembly operatively coupled to the other of the door bracket and the body bracket and operatively coupled to the transmission assembly, wherein the output linkage assembly includes: an output arm coupled at a first output end to the transmission assembly and coupled at a second output end to a link arm, the link arm coupled to the second output end and coupled to the other of the door bracket and the body bracket; a first drive motor operatively coupled to the transmission assembly via an output shaft, and the first drive motor is configured to be electrically coupled to a vehicle power source, wherein the output shaft is coupled to a first energy storage member configured to apply an axial preload to the output shaft; wherein, the output linkage assembly is configured to cooperatively move the door bracket between a door open position and a door closed position in response to operation of the transmission assembly; the output linkage assembly moves the door bracket to the door open position when the first drive motor is driven in a first direction; and the output linkage assembly moves the door bracket to the door closed position when the first drive motor is driven in a second direction.

2. The power drive unit of claim 1, wherein, The power drive unit further includes: a brake subsystem operatively coupled to the transmission assembly.

3. The power drive unit of claim 2, wherein, The brake subsystem includes: a brake gear assembly operatively coupled to a drive gear of the transmission assembly via a brake band, wherein the brake gear assembly includes a cam surface configured to move between a brake position and a brake release position; a second drive motor operatively coupled to the brake gear assembly, and the second drive motor is configured to be driven in a brake direction and a non-brake direction, wherein the cam surface moves to the brake position when the second drive motor is driven in the brake direction, and the cam surface moves to the brake release position when the second drive motor is driven in the non-brake direction; a brake energy storage member operatively coupled to the brake band, and the brake energy storage member is configured to apply tension to the brake band when releasing energy, and release tension in the brake band when biased to store energy; wherein, the cam surface engages the brake energy storage member to bias the brake energy storage member when the cam surface is in the brake release position; When the cam surface is in the braking position, the cam surface moves out of engagement with the brake energy storage member, thereby enabling the stored energy to be released.

4. The power drive unit of claim 3, wherein, The first drive motor and the second drive motor are positioned parallel to one another.

5. The power drive unit of claim 1 or 2, wherein, The power drive unit further includes an electronic control unit configured to actuate the first drive motor.

6. The power drive unit of claim 3 or 4, wherein, The power drive unit further includes an electronic control unit configured to actuate the first drive motor.

7. The power drive unit of claim 6, wherein, The electronic control unit is further configured to actuate the second drive motor.

8. The power drive unit of any one of claims 1 to 4, wherein, The power drive unit further includes a motor housing having at least one overmolded electrical connector located in the motor housing.

9. The power drive unit of claim 8, wherein, The first drive motor includes at least one lead-in window configured to align the at least one overmolded electrical connector with a corresponding electrical connector of the first drive motor.

10. The power drive unit of any one of claims 1 to 4, wherein, The power drive unit further includes a transmission housing coupled to the one of the door bracket and the vehicle body bracket, the transmission housing including at least three mounting locations in total, wherein at least one of the at least three mounting locations is not in the same plane as the remaining mounting locations of the at least three mounting locations.

11. The power drive unit of any of claims 1 to 4, wherein, The link arm includes a stop feature configured to directly or indirectly engage the one of the door bracket and the vehicle body bracket when the door bracket is in the door open position.

12. The power drive unit of claim 11, wherein, The power drive unit further includes a stop pad coupled to the one of the door bracket and the vehicle body bracket, and the stop pad is configured to abut the stop feature when the door bracket is in the door open position.

13. The power drive unit of any one of claims 1 to 4, wherein, The first energy storage member includes a wave spring or an elastomeric spring.

14. The power drive unit of any one of claims 1 to 4, wherein, The transmission assembly includes: a helical gear configured to be operatively coupled to the output shaft of the first drive motor via a worm gear, the helical gear having a first pulley; a second pulley having a planetary gear set; an endless drive member configured to operatively couple the first pulley to the second pulley; and a tensioning pulley configured to apply tension to the endless drive member; wherein the first output end of the output arm is operatively coupled to the planetary gear set.

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