Driveline component having lightweight ball-ramp mechanism

1. A vehicle driveline component comprising:

a ball-ramp mechanism having a first ball-ramp ring, a second ball-ramp ring and a plurality of balls, the first and second ball-ramp rings being disposed concentrically about an actuation axis, each of the first and second ball-ramp rings having a backing structure and a plurality of ball supports that are fixedly coupled to the backing structure, the backing structure defining a rear surface, the ball supports being spaced circumferentially about actuation axis and extending forwardly of the backing structure, the ball supports cooperating to define a front face, each of the ball supports defining a ball track, each ball track having a first circumferential end, which is disposed below the front face by a first dimension, and a second circumferential end that is disposed below the front face by a second dimension that is less than the first dimension, each of the ball tracks having a radial width that tapers between the first circumferential end and the second circumferential end, each of the balls being received in an associated one of the ball tracks and being movable between the first and second circumferential ends of the associated one of the ball tracks;

wherein each of the ball supports has a first radial width at a first location where the first circumferential end intersects the front face and a second radial width at a second location where the second circumferential end intersects the front face, the first radial width being taken along a first line passing through the actuation axis and a center of an associated one of the balls as positioned in the first circumferential end, the second width being taken along a second line passing through the actuation axis and the center of the associated one of the balls as positioned in the second circumferential end; and

wherein the first radial width is greater than the second radial width;

wherein an outer radial surface of each of the ball supports tapers radially outwardly from the front face toward the backing structure.

2. The vehicle driveline component of claim 1 , wherein each of the first and second ball-ramp rings further comprises a plurality of transition structures, each of the transition structures being fixedly coupled to the backing structure and disposed circumferentially between a pair of the ball supports.

3. The vehicle driveline component of claim 1 , wherein the first ball-ramp ring further comprises a gear element fixedly coupled to the backing structure of the first ball-ramp ring.

4. The vehicle driveline component of claim 3 , wherein the gear element is a sector gear.

5. The vehicle driveline component of claim 1 , further comprising a clutch having a clutch input member, a clutch output member, and wherein the clutch is selectively operable in a first mode, in which the clutch input member is rotationally decoupled from the clutch output member, and a second mode in which the clutch output member is coupled to the clutch input member for rotation therewith, and wherein an operational mode of the clutch changes between the first and second modes in response to relative rotational movement between the first and second ball-ramp rings.

6. The vehicle driveline component of claim 5 , wherein the clutch is a friction clutch.

7. The vehicle driveline component of claim 6 , further comprising a differential assembly and an output shaft, wherein the differential assembly includes a differential input and first and second differential outputs, wherein the output shaft is coupled to one of the first and second differential outputs for rotation therewith, wherein the clutch input member is coupled to the differential input for rotation therewith, and wherein the clutch output member is coupled to the output shaft for rotation therewith.

8. The vehicle driveline component of claim 6 , further comprising a power take-off input member and a power take-off output member, the power take-off input member being disposed for rotation about the actuation axis, the power take-off output member being disposed for rotation about a power take-off output axis that is transverse to the actuation axis, and wherein the clutch is disposed in a torque transmission path between the power take-off input member and the power take-off output member.

9. A vehicle driveline component comprising:

a ball-ramp mechanism having a first ball-ramp ring, a second ball-ramp ring and a plurality of balls, the first and second ball-ramp rings being disposed concentrically about an actuation axis, each of the first and second ball-ramp rings having a backing structure and a plurality of ball supports that are fixedly coupled to the backing structure, the backing structure defining a rear surface, the ball supports being spaced circumferentially about actuation axis and extending forwardly of the backing structure, the ball supports cooperating to define a front face, each of the ball supports defining a ball track, each ball track having a first circumferential end, which is disposed below the front face by a first dimension, and a second circumferential end that is disposed below the front face by a second dimension that is less than the first dimension, each of the ball tracks having a radial width that tapers between the first circumferential end and the second circumferential end, each of the balls being received in an associated one of the ball tracks and being movable between the first and second circumferential ends of the associated one of the ball tracks;

wherein each of the ball supports has a first radial width at a first location where the first circumferential end intersects the front face and a second radial width at a second location where the second circumferential end intersects the front face, the first radial width being taken along a first line passing through the actuation axis and a center of an associated one of the balls as positioned in the first circumferential end, the second width being taken along a second line passing through the actuation axis and the center of the associated one of the balls as positioned in the second circumferential end; and

wherein the first radial width is greater than the second radial width;

wherein an inner radial surface of each of the ball supports tapers radially inwardly from the front face toward the backing structure.

10. The vehicle driveline component of claim 9 , wherein each of the first and second ball-ramp rings further comprises a plurality of transition structures, each of the transition structures being fixedly coupled to the backing structure and disposed circumferentially between a pair of the ball supports.

11. The vehicle driveline component of claim 9 , wherein the first ball-ramp ring further comprises a gear element fixedly coupled to the backing structure of the first ball-ramp ring.

12. The vehicle driveline component of claim 11 , wherein the gear element is a sector gear.

13. The vehicle driveline component of claim 9 , further comprising a clutch having a clutch input member, a clutch output member, and wherein the clutch is selectively operable in a first mode, in which the clutch input member is rotationally decoupled from the clutch output member, and a second mode in which the clutch output member is coupled to the clutch input member for rotation therewith, and wherein an operational mode of the clutch changes between the first and second modes in response to relative rotational movement between the first and second ball-ramp rings.

14. The vehicle driveline component of claim 13 , wherein the clutch is a friction clutch.

15. The vehicle driveline component of claim 14 , further comprising a differential assembly and an output shaft, wherein the differential assembly includes a differential input and first and second differential outputs, wherein the output shaft is coupled to one of the first and second differential outputs for rotation therewith, wherein the clutch input member is coupled to the differential input for rotation therewith, and wherein the clutch output member is coupled to the output shaft for rotation therewith.

16. The vehicle driveline component of claim 14 , further comprising a power take-off input member and a power take-off output member, the power take-off input member being disposed for rotation about the actuation axis, the power take-off output member being disposed for rotation about a power take-off output axis that is transverse to the actuation axis, and wherein the clutch is disposed in a torque transmission path between the power take-off input member and the power take-off output member.

17. A vehicle driveline component comprising:

a ball-ramp mechanism having a first ball-ramp ring, a second ball-ramp ring and a plurality of balls, the first and second ball-ramp rings being disposed concentrically about an actuation axis, each of the first and second ball-ramp rings having a backing structure and a plurality of ball supports that are fixedly coupled to the backing structure, the backing structure defining a rear surface, the ball supports being spaced circumferentially about actuation axis and extending forwardly of the backing structure, the ball supports cooperating to define a front face, each of the ball supports defining a ball track, each ball track having a first circumferential end, which is disposed below the front face by a first dimension, and a second circumferential end that is disposed below the front face by a second dimension that is less than the first dimension, each of the ball tracks having a radial width that tapers between the first circumferential end and the second circumferential end, each of the balls being received in an associated one of the ball tracks and being movable between the first and second circumferential ends of the associated one of the ball tracks;

wherein each of the ball supports has a first radial width at a first location where the first circumferential end intersects the front face and a second radial width at a second location where the second circumferential end intersects the front face, the first radial width being taken along a first line passing through the actuation axis and a center of an associated one of the balls as positioned in the first circumferential end, the second width being taken along a second line passing through the actuation axis and the center of the associated one of the balls as positioned in the second circumferential end; and

wherein the first radial width is greater than the second radial width;

wherein each transition structure has a first transition portion, which is fixedly coupled to the first circumferential end of a first one of the pair of ball supports, a second transition portion, which is fixedly coupled to the second circumferential end of a second one of the pair of the ball supports, and an intermediate transition portion that fixedly couples the first and second transition portions to one another, wherein a radial width of the first transition portion narrows with decreasing distance toward the second transition portion and wherein a radial width of the second transition portion narrows with decreasing distance toward the first transition portion; and

wherein an outer radial surface of at least one of the first transition portion and the second transition portion on each of the transition structures tapers radially outwardly from the front face toward the backing structure.

18. A vehicle driveline component comprising:

a ball-ramp mechanism having a first ball-ramp ring, a second ball-ramp ring and a plurality of balls, the first and second ball-ramp rings being disposed concentrically about an actuation axis, each of the first and second ball-ramp rings having a backing structure and a plurality of ball supports that are fixedly coupled to the backing structure, the backing structure defining a rear surface, the ball supports being spaced circumferentially about actuation axis and extending forwardly of the backing structure, the ball supports cooperating to define a front face, each of the ball supports defining a ball track, each ball track having a first circumferential end, which is disposed below the front face by a first dimension, and a second circumferential end that is disposed below the front face by a second dimension that is less than the first dimension, each of the ball tracks having a radial width that tapers between the first circumferential end and the second circumferential end, each of the balls being received in an associated one of the ball tracks and being movable between the first and second circumferential ends of the associated one of the ball tracks;

wherein each of the ball supports has a first radial width at a first location where the first circumferential end intersects the front face and a second radial width at a second location where the second circumferential end intersects the front face, the first radial width being taken along a first line passing through the actuation axis and a center of an associated one of the balls as positioned in the first circumferential end, the second width being taken along a second line passing through the actuation axis and the center of the associated one of the balls as positioned in the second circumferential end; and

wherein the first radial width is greater than the second radial width;

wherein each transition structure has a first transition portion, which is fixedly coupled to the first circumferential end of a first one of the pair of ball supports, a second transition portion, which is fixedly coupled to the second circumferential end of a second one of the pair of the ball supports, and an intermediate transition portion that fixedly couples the first and second transition portions to one another, wherein a radial width of the first transition portion narrows with decreasing distance toward the second transition portion and wherein a radial width of the second transition portion narrows with decreasing distance toward the first transition portion; and

wherein an inner radial surface of at least one of the first transition portion and the second transition portion on each of the transition structures tapers radially inwardly from the front face toward the backing structure.

19. A vehicle driveline component comprising:

a ball-ramp mechanism having a first ball-ramp ring, a second ball-ramp ring and a plurality of balls, the first and second ball-ramp rings being disposed concentrically about an actuation axis, each of the first and second ball-ramp rings having a backing structure and a plurality of ball supports that are fixedly coupled to the backing structure, the backing structure defining a rear surface, the ball supports being spaced circumferentially about actuation axis and extending forwardly of the backing structure, the ball supports cooperating to define a front face, each of the ball supports defining a ball track, each ball track having a first circumferential end, which is disposed below the front face by a first dimension, and a second circumferential end that is disposed below the front face by a second dimension that is less than the first dimension, each of the ball tracks having a radial width that tapers between the first circumferential end and the second circumferential end, each of the balls being received in an associated one of the ball tracks and being movable between the first and second circumferential ends of the associated one of the ball tracks;

wherein each of the ball supports has a first radial width at a first location where the first circumferential end intersects the front face and a second radial width at a second location where the second circumferential end intersects the front face, the first radial width being taken along a first line passing through the actuation axis and a center of an associated one of the balls as positioned in the first circumferential end, the second width being taken along a second line passing through the actuation axis and the center of the associated one of the balls as positioned in the second circumferential end; and

wherein the first radial width is greater than the second radial width;

wherein each transition structure has a first transition portion, which is fixedly coupled to the first circumferential end of a first one of the pair of ball supports, a second transition portion, which is fixedly coupled to the second circumferential end of a second one of the pair of the ball supports, and an intermediate transition portion that fixedly couples the first and second transition portions to one another, wherein a radial width of the first transition portion narrows with decreasing distance toward the second transition portion and wherein a radial width of the second transition portion narrows with decreasing distance toward the first transition portion; and

wherein an outer radial surface of the intermediate transition portion of each of the transition structures tapers radially outwardly from the front face toward the backing structure.

20. A vehicle driveline component comprising:

a ball-ramp mechanism having a first ball-ramp ring, a second ball-ramp ring and a plurality of balls, the first and second ball-ramp rings being disposed concentrically about an actuation axis, each of the first and second ball-ramp rings having a backing structure and a plurality of ball supports that are fixedly coupled to the backing structure, the backing structure defining a rear surface, the ball supports being spaced circumferentially about actuation axis and extending forwardly of the backing structure, the ball supports cooperating to define a front face, each of the ball supports defining a ball track, each ball track having a first circumferential end, which is disposed below the front face by a first dimension, and a second circumferential end that is disposed below the front face by a second dimension that is less than the first dimension, each of the ball tracks having a radial width that tapers between the first circumferential end and the second circumferential end, each of the balls being received in an associated one of the ball tracks and being movable between the first and second circumferential ends of the associated one of the ball tracks;

wherein each of the ball supports has a first radial width at a first location where the first circumferential end intersects the front face and a second radial width at a second location where the second circumferential end intersects the front face, the first radial width being taken along a first line passing through the actuation axis and a center of an associated one of the balls as positioned in the first circumferential end, the second width being taken along a second line passing through the actuation axis and the center of the associated one of the balls as positioned in the second circumferential end; and

wherein the first radial width is greater than the second radial width;

wherein each transition structure has a first transition portion, which is fixedly coupled to the first circumferential end of a first one of the pair of ball supports, a second transition portion, which is fixedly coupled to the second circumferential end of a second one of the pair of the ball supports, and an intermediate transition portion that fixedly couples the first and second transition portions to one another, wherein a radial width of the first transition portion narrows with decreasing distance toward the second transition portion and wherein a radial width of the second transition portion narrows with decreasing distance toward the first transition portion; and

wherein an inner radial surface of the intermediate transition portion of each of the transition structures tapers radially inwardly from the front face toward the backing structure.

21. A vehicle driveline component comprising:

a ball-ramp mechanism having a first ball-ramp ring, a second ball-ramp ring and a plurality of balls, the first and second ball-ramp rings being disposed about an actuation axis, each of the first and second ball-ramp rings defining a plurality of ball tracks, wherein the ball tracks of the first ball-ramp ring are disposed eccentrically about the actuation axis, each of the balls being received into an associated set of ball tracks in the first and second ball-ramp rings, wherein relative rotation between the first and second ball-ramp rings causes eccentric motion of the first ball-ramp ring about the actuation axis.

22. The vehicle driveline component of claim 21 , further comprising an operator selected from a group consisting of sensors, switches, valves, pumps and combinations of two or more thereof, and wherein the operator is operated through eccentric motion of the second ball-ramp ring about the actuation axis.