Power actuator with articulating pulley

Abstract

A power actuator for use in an automotive vehicle comprises a housing which contains a drive gear, a pinion, a drive rack, and a pulley. The pinion is driveably coupled to the drive gear and meshingly engaged with the drive rack. The drive rack is selectively translated between a home position and an actuated position. The pulley is pivotably coupled to the drive rack. The power actuator includes a cable operatively coupled to the pulley and an electric motor having a drive shaft driveably coupled to the drive gear. The electric motor rotates the drive shaft in a first rotational direction which causes the drive rack and the pulley to be translated in a first direction towards the actuated position, which increases tension in the cable. Further, the drive rack and the pulley are selectively translated in a second direction, which decreases the tension in the cable.

Description

POWER ACTUATOR WITH ARTICULATING PULLEYCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application 63 / 542,822, filed on October 6, 2023, the disclosure of which is hereby incorporated by reference in its entirety.FIELD AND BACKGROUND OF THE INVENTION

[0002] The present invention relates to a power actuator for use in an automotive vehicle. More particularly, the invention relates to a power actuator for use in a seat assembly for an automotive vehicle.DESCRIPTION OF RELATED ART

[0003] Automotive vehicles typically include one or more seat assemblies having a seat cushion and a seat back for supporting a passenger above a vehicle floor. It is common for the seat assembly to include a recliner mechanism which provides selective pivotal movement of the seat back relative to the seat cushion. The seat assembly may also include a floor latch which releasably couples the seat assembly to the vehicle floor.

[0004] It is common for the seat assembly to include a power actuator operatively coupled to a Bowden cable which is operatively coupled to a seat component such as the recliner mechanism, floor latch, and the like. Typically, the power actuator is configured to apply tension to the Bowden cable and pull the Bowden cable to actuate the seat component. Further, it is typical for the power actuator to selectively release tension in the Bowden cable, which allows the component to return to an unactuated condition.

[0005] However, current commercially available power actuators are bulky and difficult to package within the seat assembly. Further, known power actuators are limited in the amount of cable stroke delivered by the power actuator for actuation of the seat component.

[0006] It is desirable, therefore, to reduce the overall size of the power actuator in order to package the power actuator in smaller environments within the seat assembly. Further, it is desirable to increase the amount cable stroke delivered by the power actuator for actuation of the seat component.SUMMARY OF THE INVENTION

[0007] According to one embodiment, there is provided a power actuator for use in an automotive vehicle. The power actuator comprises a housing which supports and contains a drive gear, a pinion, a drive rack, and a pulley. The pinion is driveably coupled to the drive gear. The drive rack includes a rack meshingly engaged with the pinion. In addition, the drive rack is selectively translated between a home position and an actuated position relative to the pinion. Further, the pulley is pivotably coupled to the drive rack and translated with the drive rack. The power actuator also includes a cable and an electric motor. The cable is operatively coupled to the pulley and includes a proximal end fixedly coupled to the housing. The electric motor is fixedly coupled to the housing and includes a drive shaft driveably coupled to the drive gear. The electric motor rotates the drive shaft in a first rotational direction which causes the drive rack and the pulley to be translated in a first direction towards the actuated position, which increases tension in the cable. Further, the drive rack and the pulley are selectively translated in a second direction opposing the first direction, which decreases the tension in the cable.

[0008] According to another embodiment, there is provided a power actuator for use in an automotive seat assembly. The power actuator comprises a housing and an electric motor fixedly coupled to the housing. The electric motor includes a drive shaft driveably coupled to a drive gear. In addition, the electric motor is configured to selectively rotate the drive gear in a first rotational direction. The power actuator also includes a face gear meshingly engaged with the drive gear, a spur gear rotationally fixed to the face gear and axially aligned with the face gear, and a pinion gear meshingly engaged with the spur gear. In addition, the power actuator includes a pinion rotationally fixed to the pinion gear and axially aligned with the pinion gear, a drive rack including a rack meshingly engaged with the pinion and selectively translated between a home position and an actuated position, and a pulley pivotably coupled to the drive rack and translated with the drive rack. Further, the power actuator also includes a cable fixedly coupled to the housing and operatively coupled to the pulley. When the drive rack is in the home position and the electric motor rotates the drive gear in the first rotational direction, the drive rack and the pulley are translated in a first direction towards the actuated position, which increases tension in the cable. In addition, the drive rack and the pulley are selectively translated in a second direction opposing the first direction from the actuated position to the home position, which decreases the tension in the cable.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

[0010] Figure 1 is a perspective view of a power actuator, according to one embodiment of the present invention;

[0011] Figure 2 is a cut-away bottom view of the power actuator of Figure 1;

[0012] Figure 3 is an exploded view of the power actuator of Figure 1;

[0013] Figure 4 is a bottom perspective view of the housing of Figure 3;

[0014] Figure 5 is a perspective view of the drive rack of Figure 3;

[0015] Figure 6 is a cut-away right side view of the power actuator of Figure 1, with the drive rack in a home position;

[0016] Figure 7 is a cut-away left side view of the power actuator of Figure 1. with the drive rack in the home position;

[0017] Figure 8 is a cut-away right side view of the power actuator of Figure 1, with the drive rack in an actuated position.

[0018] Figure 9 is a cross-sectional view of the power actuator taken along line 9-9 of Figure 2;

[0019] Figure 10 is a cross-sectional view of the power actuator taken along line 10-10 of Figure 2;

[0020] Figure 11 is a cross-sectional view of the power actuator taken along line 11-11 of Figure 1; and

[0021] Figure 12 is a cross-sectional view of the power actuator taken along line 12-12 of Figure 2.DETAILED DESCRIPTION OF THE INVENTION

[0022] Figures 1-12 illustrate a power actuator 10 for use in an automotive seat assembly according to embodiments described herein. Directional references employed or shown in the description, figures, or claims, such as top, bottom, upper, lower, upward, downward, lengthwise, widthwise, left, right, and the like, are relative terms employed for ease of description and are not intended to limit the scope of the invention in any respect. Referring to the Figures, like numerals indicate like or corresponding parts throughout the several views.

[0023] Figures 1 and 2 depict a power actuator 10 operatively coupled to a Bowden cable 12, which in turn is operatively coupled to a component (not shown) of a seat assembly (not shown). Exemplary components include a floor latch, a recliner, and the like as non-limiting examples. The pow er actuator 10 selectively applies tension to the Bowden cable 12 in order to actuate the component. The power actuator 10 also selectively removes tension from the Bowden cable 12 which allows the component to return to an unactuated condition.

[0024] Referring to Figures 1-7, the pow er actuator 10 comprises an electric motor 14, a drive shaft 16, and a drive gear 18. The electric motor 14 is operatively coupled to the drive shaft 16, which defines a motor axis 20. The drive shaft 16 is fixedly coupled to the drive gear 18. The drive gear 18 includes a plurality of drive teeth 22 extending around an outer circumferential surface thereof. Further, the electric motor 14 is configured to selectively rotate the drive shaft 16 and the drive gear 18 about the motor axis 20 in a first rotational direction 24 and a second rotational direction 26 opposite the first rotational direction 24.

[0025] Referring to Figures 3 and 4, the power actuator 10 also comprises a housing 28 which includes a housing wall 30, an upper compartment 32, a low er compartment 34, an upper rim 36, a lower rim 38. an intermediary wall 40, a face bore 42. a pinion bore 44, a motor bracket 46. and a drive opening 48. The housing wall 30 extends circumferentially around the upper compartment 32 and the lower compartment 34 and between the upper rim 36 and the lower rim 38. The intermediary' wall 40 is spaced between the upper and lower compartments 32, 34. The face bore 42 and the pinion bore 44 extend vertically through the intermediary' wall 40 between the upper and lower compartments 32, 34 and are longitudinally spaced apart. The motor bracket 46 projects longitudinally away from the housing wall 30 adjacent the upper compartment 32. In addition, the motor bracket 46 supports and retains the electric motor 14. The drive opening 48 extends through the housing w all 30 between the upper compartment 32and the motor bracket 46. Referring to Figure 9, the drive shaft 16 extends axially through the drive opening 48 in the housing wall 30 with the drive gear 18 positioned within the upper compartment 32.

[0026] Referring to Figure 4, the lower compartment 34 includes a medial wall 50, an end wall 52, a first guide slot 54, a second guide slot 56, and a connector slot 58. The medial wall 50 and the end wall 52 extend downward from the intermediary wall 40 and are spaced longitudinally apart. The first and second guide slots 54, 56 extend vertically along the medial wall 50 and the end wall 52, respectively, between intermediary’ wall 40 and the lower rim 38. The connector slot 58 is formed in the end wall 52 and extends to lower compartment 34. The connector slot 58 is configured to fixedly retain a Bowden cable connector 60 which is fixedly coupled to a proximal end of the Bowden cable 12. Further, the pinion bore 44 extends into the lower compartment 34.

[0027] Referring to Figures 1. 3, and 9. the power actuator 10 also includes a gear cover 62 configured to enclose the upper compartment 32 in the housing 28. Depicted in Figure 9, the gear cover 62 includes a cover wall 64, a cover flange 66, a shaft cavity 68, and a shaft recess 70. The cover flange 66 projects outwardly from the cover wall 64 and matingly engages with the upper rim 36 of the upper compartment 32. In addition, the shaft cavity 68 and the shaft recess 70 are formed in the cover wall 64 and axially align with the face bore 42 and the pinion bore 44, respectively, in the housing 28.

[0028] Depicted in Figures 3 and 9, the power actuator 10 also includes a face shaft 72 and a pinion shaft 74. The face shaft 72 is an elongated cylindrical rod having an upper end 76 fixedly coupled to the shaft cavity 68 in the gear cover 62 and a lower end 78 extending axially through the face bore 42 in the housing 28. The pinion shaft 74 is an elongated cylindrical rod having a top end 80 fixedly coupled to the shaft recess 70 in the gear cover 62 and a bottom end 82 extending axially through the pinion bore 44 in the housing 28.

[0029] Referring to Figures 3, 6, 7, and 9, the power actuator 10 also includes a face gear 84 rotationally fixed to a spur gear 86 and configured to rotate about a common axis. The face gear 84 includes a plurality of face teeth 88 extending in a radial direction and spaced circumferentially around the face gear 84. In addition, the spur gear 86 includes a plurality' of spur teeth 90 extending in the axial direction and spaced apart around the circumference of the spur gear 86. Further, a shaft bore 92 extends axially through the face gear 84 and the spur gear86. Depicted in Figure 9, the face shaft 72 extends axially through the shaft bore 92 with the spur gear 86 adjacent the intermediate wall 40 and the face gear 84 adjacent the gear cover 62 in the upper compartment 32. The face gear 84 is positioned along the face shaft 72 such that the plurality of face teeth 88 on the face gear 84 are meshingly engaged with the drive gear teeth 22 on the drive gear 18. It will be appreciated that power actuator 10 optionally includes one or more components, such as bushings, bearings, circlips, pins, washers, and the like as non-limiting examples, configured to maintain the axial position of the face gear 84 along the face shaft 72 and maintain engagement between the face gear 84 and the drive gear 18.

[0030] Referring to Figures 3, 6, 7, and 9, the power actuator 10 also includes a pinion gear 94 rotationally fixed to a pinion 96 and configured to rotate about a common axis. The pinion gear 94 includes a plurality of input teeth 98 extending in an axial direction and spaced apart circumferentially around pinion gear 94. The pinion 96 includes a plurality of pinion teeth 100 extending in the axial direction and spaced circumferentially around the pinion 96. Further, a shaft aperture 102 extends axially through the pinion gear 94 and the pinion 96. Depicted in Figures 9 and 10, the pinion shaft 74 extends through the shaft aperture 102 in the pinion gear 94 and the pinion 96. The pinion gear 94 is spaced axially along the pinion shaft 74 within the upper compartment 32. Further, the pinion 96 extends through the pinion bore 44 in the intermediary wall 40 and into the lower compartment 34. Referring to Figures 6 and 7, the plurality of input teeth 98 on the pinion gear 94 are meshingly engaged with the plurality of spur teeth 90 on the spur gear 86. It will be appreciated that power actuator 10 optionally includes one or more components, such as bushings, bearings, circlips, pins, washers, and the like as non-limiting examples, configured to maintain the axial position of the pinion gear 94 along the pinion shaft 74 and maintain engagement between the pinion gear 94 and the spur gear 86.

[0031] Referring to Figures 3, 5, 7, 10. and 11. the power actuator 10 also includes a drive rack 104 positioned within the lower compartment 34 in the housing 28 and meshingly engaged with the pinion 96. In more detail, the drive rack 104 includes a top wall 106 opposing a bottom wall 108, a first end wall 110 opposing a second end wall 1 12, and a side wall 114 opposing a rack wall 116. The drive rack 104 also includes a recessed cavity 118 in the top wall 106 and a pivot hole 120 extending vertically between the recessed cavity 118 and the bottom wall 108. The drive rack 104 also includes a plurality of rack teeth 122 spaced apart in a longitudinal direction along the rack wall 1 1 . Depicted in Figure 11 , the plurality' of rack teeth 122 on thedrive rack 104 are meshingly engaged with the plurality of pinion teeth 100 on the pinion 96. Depicted in Figure 5, the drive rack 104 also includes a guide hole 124 and a spring hole 126. The guide hole 124 extends through the second end wall 1 12 and to the recessed cavity 118. Further, the spring hole 126 extends through the first end wall 110 to the recessed cavity 118 and is axially aligned with the guide hole 124.

[0032] Depicted in Figures 3 and 11, the power actuator 10 also includes a return spring 128 and a spring guide 130 which are operatively coupled to the drive rack 104 and positioned in the lower compartment 34. The return spring 128 is a coiled compression spring which defines a spring passageway 132 extending longitudinally therethrough. Further, the spring guide 130 is a generally cylindrical-shaped rod extending in a longitudinal direction between a first rod end 134 and opposing a second rod end 136. The spring guide 130 extends through the spring passageway 132, the guide hole 124, and the spring hole 126 with the first and second rod ends 134, 136 inserted into the first and second guide slots 54, 56, respectively. The first and second guide slots 54. 56 include guided interference fit features which guide the spring guide 130 towards the intermediary wall 40 and retains the spring guide 130 in frictional engagement with the respective first and second guide slots 54, 56. The return spring 128 extends through the spring hole 126 and into the recessed cavity' 118. However, the return spring 128 is sized and shaped such that the return spring 128 is prevented from entering the guide hole 124. The return spring 128 applies a biasing force (in the direction of arrow 138) onto the drive rack 104.

[0033] Depicted in Figure 3, the power actuator 10 also includes a pulley pivot 140 and a pulley 142 within the lower compartment 34. The pulley pivot 140 has a generally cylindrical shape extending between a rack end 144 and a pulley end 146 and defining a pulley axis 148. In addition, the pulley pivot 140 includes a spacer flange 150 extending circumferentially around the pulley pivot 140. The rack end 144 is pivotably coupled with the pivot hole 120 in the drive rack 104. The pulley 142 is generally cylindrically-shaped and includes a cable groove 152 extending circumferentially therearound and a pulley bore 154 extending axially therethrough. The pulley end 146 of the pulley pivot 140 is pivotably coupled with the pulley bore 154 and extends axially through the pulley bore 154. In addition, the cable groove 152 is sized and shaped to support and receive at least a portion of the Bowden cable 12.

[0034] Depicted in Figures 3 and 10-12. the power actuator 10 also includes a pulley cover 156 which encloses the lower compartment 34 in the housing 28. The pulley cover 156 includes a base wall 158, a base flange 160, a cable slot 162, a connector recess 164, and a pulley track166. The base flange 160 projects from the base wall 158 and extends circumferentially around an outer perimeter of the base wall 158. Further, the base flange 160 is matingly engaged with the lower rim 38 of the housing 28. The cable slot 162 extends longitudinally through the base flange 160. The connector recess 164 is a cylindrically-shaped recess in the base wall 158 which retains a portion of the Bowden cable connector 60. The Bowden cable connector 60 is fixedly coupled to the connector recess 164 in the pulley cover 156 and the connector slot 58 in the housing 28. In addition, the Bowden cable 12 extends around the cable groove 152 in the pulley 142 and extends through the cable slot 1 2 in the pulley cover 156. The pulley track 166 extends longitudinally along the base wall 158 between opposing first and second track ends 168, 170. In addition, the pulley end 146 of the pulley pivot 140 is slidably coupled to the pulley track 166.

[0035] The power actuator 10 can selectively apply tension to the Bowden cable 12 and cause a distal end 12a of the Bowden cable 12 to be repositioned a predetermined cable stroke distance towards the power actuator 10 in order to actuate, or unlatch, a component operatively coupled to the Bowden cable 12. Typically, the Bowden cable 12 is operatively coupled to a component of a seat assembly, such as a latch release mechanism, a recliner mechanism, and the like as non-limiting examples. Further, the component is ty pically actuated, or unlatched, when tension is applied to the Bow den cable 12 and the distal end 12a of the Bow den cable 12 is repositioned towards the power actuator 10. In addition, the component is typically spring- biased towards a latched condition such that the component will automatically relatch when tension is removed from the Bowden cable 12.

[0036] Referring to Figures 11 and 12. the power actuator 10 is configured to translate the drive rack 104, the pulley 142, and the pulley pivot 140 between a home position (shown as the drive rack 104, the pulley 142, the pulley pivot 140, and the pulley axis 148) and an actuated position (shown as the drive rack 104', the pulley 142', the pulley pivot 140', and an actuated pulley axis 148'). The longitudinal distance between the pulley axis 148 and the actuated pulley axis 148' in Figure 12 generally corresponds to an internal stroke length 172 of the power actuator 10. An exemplary power actuator 10 has an internal stroke length 172 of about 40 mm. However, the power actuator 10 applies a cable stroke distance of twice the internal stroke length 172 onto the Bowden cable 12 because the Bowden cable 12 is operatively coupled to the pulley 142 which is pivotably coupled to the drive rack 104. The pulley 142 effectively doubles the cable stroke distance applied by the powder actuator 1 . As such, the exemplarypower actuator 10 delivers a cable stroke distance of about 80 mm on the Bowden cable 12, or two times the internal stroke length 172 of 40 mm. Further, the power actuator 10 of the present invention has an overall length less than known power actuators. In addition, the power actuator 10 of the present invention delivers a greater cable stroke distance and a similar force than known power actuators having a similar overall length. It will be appreciated that the power actuator 10 optionally can be configured to deliver a different cable stroke distance greater or less than described above without altering the scope of the present invention.

[0037] Referring to Figures 6, 7, 8, 11, and 12, the power actuator 10 is initially in an unactuated condition with the electric motor 14 de-energized, the drive gear 18 meshingly engaged with the face teeth 88 on the face gear 84, the input teeth 98 on the pulley gear 94 meshingly engaged with the spur teeth 90 on the spur gear 86, and the pinion teeth 100 on the pinion 96 meshingly engaged with the rack teeth 122 on the drive rack 104. In addition, the spur gear 86 and the pinion 96 are rotationally fixed to the face gear 84 and pinion gear 94, respectively. The drive rack 104 and the pulley 142 are initially in the home position in the lower compartment 34. The home position is defined by the relative position of the pulley axis 148 shown in Figure 12. Further, the drive rack 104 is slidably coupled to the spring guide 130, which in turn is fixedly coupled to the first and second guide slots 54, 56 in the housing 28. The drive rack 104 is spring-biased (in the direction of arrow 138) by the return spring 128 along the spring guide 130 towards the home position. The pulley 142 is pivotably coupled to the drive rack 104 by the pulley pivot 140. In addition, the pulley pivot 140 is slidably coupled to the pulley track 166 in the pulley cover 156. Initially, the pulley 142 and the pulley pivot 140 are positioned adjacent the second track end 170 corresponding to the home position. In addition, the Bowden cable connector 60 is fixedly coupled to the proximal end of the Bowden cable 12 and is fixedly coupled to the housing 28. The Bowden cable 12 extends at least partially around the cable groove 152 in the pulley 142 and extends through a cable slot 162 in the pulley cover 156. The Bow den cable 12 includes a distal cable end 12a spaced apart from the power actuator 10 and connected to the seat component for actuation. Also, the electric motor 14, the face gear 84, the pinion gear 94. the drive rack 104, and other optional gears within the power actuator 10 are readily back-drivable when the electric motor 14 is deenergized.

[0038] Upon actuation of the power actuator 10, power is applied to the electric motor 14 causing the drive shaft 16 and the drive gear 18 to rotate in the first rotational direction 24,which causes the face gear 84, the spur gear 86, the pinion gear 94, and the pinion 96 to rotate, forcing the drive rack 104 to be translated along the spring guide 130 and the pulley pivot 140 to be translated along the pulley track 166 in a first direction 174 towards the actuated position with the pulley 142 and pulley pivot 140 positioned adjacent the first track end 168 (shown as the drive rack 104', the pully 142', and the pulley pivot 140' having an actuated pulley axis 148' in Figures 11 and 12). The movement of the drive rack 104' to the actuated position compresses the return spring 128, causing the return spring 128 to apply a biasing force (arrow 138) onto the drive rack 104' which biases the drive rack 104' towards the home position. As the pulley 142 is translated along the pulley track 166 towards the actuated position, tension is applied onto the Bowden cable 12 and the Bowden cable 12 is pulled towards the power actuator 10, as illustrated by arrow 178. The power actuator 10 applies a cable stroke distance of twice the internal stroke length 172 onto the Bowden cable 12 in response to the pulley 142' translating to the actuated position. The electric motor 14 is de-energized after the drive rack 104' and the pulley 142' are translated to the actuated position. When the power actuator 10 de-energizes the electric motor 14, the drive gear 18, the face gear 84, the spur gear 86, the pinion gear 94, and the pinion 96 are free to rotate since the power actuator 10 is readily back-drivable.

[0039] When the electric motor 14 is de-energized and the drive rack 104' is in the actuated position, the biasing force (arrow 138) in the return spring 128 causes the drive rack 104 to be translated along the spring guide 130 in a second direction 176 to the home position, wherein the second direction 176 is opposite the first direction 174. In addition, the biasing force (arrow 138) also causes the pulley 142 and the pulley pivot 140 to be translated in the second direction 176 along the pulley track 166 towards the second track end 170 to the home position, which releases the tension in the Bowden cable 12. as illustrated by arrow 180. The distal end 12a of the Bowden cable returns to an unactuated position when tension is released from the Bowden cable 12. In addition, the translation of the drive rack 104 to the home position causes the pinion 96, the pinion gear 94, the spur gear 86, the face gear 84, and the drive gear 18 to rotate in the second rotational direction 26, which returns the power actuator 10 to the unactuated condition.

[0040] When the power actuator 10 is not readily back-drivable by the return spring 128 and the drive rack 104' is in the actuated position, power is provided to the electric motor 14 causing the drive shaft 16 to rotate in the second rotational direction 26, which causes the face gear 84, the spur gear 86. the pinion gear 94, and the pinion 96 to rotate, which causes the drive rack 104 and the pulley 142 to be translated in the second direction 176 along the spring guide 130and the pulley track 166, respectively. Tension is released from the Bowden cable 12 as the pulley 142 is translated towards the home position, which causes the distal end 12a of the Bowden cable 12 to be repositioned away from the power actuator 10. The electric motor 14 is de-energized when the drive rack 104 and the pulley 142 return to the home position.

[0041] The invention has been described in an illustrative manner, and it is to be understood that the terminology, which has been used, is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced other than as specifically described.

Claims

What is claimed is:

1. A power actuator for use in an automotive vehicle, the power actuator comprising: a housing supporting a drive gear, a pinion, a drive rack, and a pulley, wherein the pinion is driveably coupled to the drive gear, the drive rack includes a rack meshingly engaged with the pinion, the drive rack is selectively translated between a home position and an actuated position relative to the pinion, and the pulley is pivotably coupled to the drive rack and translated with the drive rack; a cable operatively coupled to the pulley and including a proximal end fixedly coupled to the housing; and an electric motor fixedly coupled to the housing and including a drive shaft driveably coupled to the drive gear; wherein the electric motor rotates the drive shaft in a first rotational direction to cause the drive rack and the pulley to be translated in a first direction towards the actuated position which increases tension in the cable; and wherein the drive rack and the pulley are selectively translated in a second direction opposite the first direction towards the home position which decreases the tension in the cable.

2. The power actuator as set forth in claim 1. further comprising a spring guide fixedly coupled to the housing and slidably coupled to the drive rack; wherein the drive rack is translated along the spring guide between the home position and the actuated position.

3. The power actuator as set forth in claim 2, wherein the drive rack is spring-biased towards the home position.

4. The power actuator as set forth in claim 3, further comprising a return spring operatively coupled between the housing and the drive rack such that the drive rack is biased towards the home position by the return spring.

5. The power actuator as set forth in claim 4, wherein the return spring causes the drive rack to translate to the home position when the electric motor is de-energized.

6. The power actuator as set forth in claim 4, further comprising a face gear and a spur gear;wherein the face gear includes a plurality of face teeth meshingly engaged with the drive gear, the spur gear is rotationally fixed with the face gear and includes a plurality of spur teeth, and the spur gear is driveably coupled to the pinion.

7. The power actuator as set forth in claim 6, further comprising a pinion gear; wherein the pinion gear includes a plurality of input teeth meshingly engaged with the plurality of spur teeth on the spur gear, the pinion is rotationally fixed with the pinion gear and includes a plurality' of pinion teeth, and the rack includes a plurality' of rack teeth meshingly engaged with the plurality' of pinion teeth.

8. The power actuator as set forth in claim 7, wherein the drive rack is translated in the second direction in response to the electric motor rotating the drive shaft in a second rotational direction opposing the first rotational direction.

9. The power actuator as set forth in claim 8. further comprising a cable groove extending circumferentially around the pulley which receives at least a portion of the cable.

10. A power actuator for use in an automotive seat assembly, the power actuator comprising: a housing; an electric motor fixedly coupled to the housing, the electric motor including a drive shaft driveably coupled to a drive gear and configured to selectively rotate the drive gear in a first rotational direction; a face gear meshingly engaged with the drive gear; a spur gear rotationally fixed to the face gear and axially aligned with the face gear; a pinion gear meshingly engaged with the spur gear; a pinion rotationally fixed to the pinion gear and axially aligned with the pinion gear; a drive rack including a rack meshingly engaged with the pinion and wherein the drive rack is selectively translated between a home position and an actuated position; a pulley pivotably coupled to the drive rack and translated with the drive rack; and a cable fixedly coupled to the housing and operatively coupled to the pulley; wherein when the drive rack is in the home position and the electric motor rotates the drive gear in the first rotational direction, the drive rack and the pulley are translated in a first direction towards the actuated position which increases tension in the cable; andwherein the drive rack and the pulley are selectively translated in a second direction opposing the first direction from the actuated position to the home position which decreases the tension in the cable.

11. The power actuator as set forth in claim 10. further comprising a spring guide fixedly coupled to the housing and slidably coupled to the drive rack; wherein the drive rack is translated along the spring guide between the home position and the actuated position.

12. The power actuator as set forth in claim 11, wherein the drive rack is spring-biased towards the home position.

13. The power actuator as set forth in claim 12, further comprising a return spring operatively coupled between the housing and the drive rack such that the drive rack is biased towards the home position by the return spnng.

14. The power actuator as set forth in claim 13, wherein the return spring causes the drive rack to translate to the home position when the electric motor is de-energized.

15. The power actuator as set forth in claim 11, wherein the drive rack is translated in the second direction in response to the electric motor rotating the drive shaft in a second rotational direction opposing the first rotational direction.

16. The power actuator as set forth in claim 15, further comprising a cable groove extending circumferentially around the pulley which receives at least a portion of the cable.

17. The power actuator as set forth in claim 16. wherein the housing contains and supports the drive gear, the face gear, the spur gear, the pinion gear, the pinion, the drive rack, and the pulley.

Images