Borgwarner, Inc. v. New Venture Gear, Inc.

237 F. Supp. 2d 919, 2002 U.S. Dist. LEXIS 24736, 2002 WL 31886842
CourtDistrict Court, N.D. Illinois
DecidedDecember 27, 2002
Docket00 C 7470
StatusPublished
Cited by1 cases

This text of 237 F. Supp. 2d 919 (Borgwarner, Inc. v. New Venture Gear, Inc.) is published on Counsel Stack Legal Research, covering District Court, N.D. Illinois primary law. Counsel Stack provides free access to over 12 million legal documents including statutes, case law, regulations, and constitutions.

Bluebook
Borgwarner, Inc. v. New Venture Gear, Inc., 237 F. Supp. 2d 919, 2002 U.S. Dist. LEXIS 24736, 2002 WL 31886842 (N.D. Ill. 2002).

Opinion

*922 MEMORANDUM ORDER

BOBRICK, United States Magistrate Judge.

Plaintiff BorgWarner charges defendant New Venture Gear with infringing U.S. Patents Nos. 5,407,024 (“patent 024”); *923 5,485,894 (“patent 894”); 6,000,488 (“patent 488”); and 6,062,330 (“patent 330”). This matter was referred to this Magistrate Judge for the purposes of conducting a Markman hearing and construing the disputed claims of the patents-in-suit. See Markman v. Westview Instruments, Inc., 52 F.3d 967, 979 (Fed.Cir.1995). The patents-in-suit deal with four-wheel drive systems employing active-on-demand transfer cases that automatically control the amount of torque transferred to front and rear wheels. A transfer case is an auxiliary transmission designed to permit the drive from the engine of a vehicle to be operatively split to both the front and rear driving axles. The patents-in-suit disclose a transfer case design that is electronically controlled by a microcontroller.

I. TECHNOLOGY

The microcontroller transfer case is the substance of these patents. Four-wheel drive allows vehicles to operate better on slippery road surfaces, or in off-road conditions. Compared to two-wheel drive systems, however, four-wheel drive systems can result in lower gas mileage, and decreased handling and performance in certain situations. Thus, a part-time four-wheel drive system has the advantage of allowing the operator to select the drive system based on the driving conditions at hand. The operator engages the four-wheel drive system by lever or switch and, within the transfer case, a clutch is engaged that locks the front and rear drive shafts together. The speed of the front and rear wheels becomes equal.

In an on-demand four-wheel drive system, the clutch in the transfer case engages and disengages automatically. This can be an advantage over the part-time, operator-initiated system because it is thought that the operator will not always know when driving conditions call for, or do not call for, four-wheel drive. On-demand transfer cases can be active or reactive. A reactive transfer case employs a mechanical system, such as a viscous clutch, which engages, or reacts, when there is a difference is speed between the front and rear drivelines. A viscous coupling is basically a drum filled with a thick fluid that houses several closely fitted, thin steel discs. One set of the discs is connected to the front wheels and the other to the rear. As one axle begins to demand more torque, the fluid ■ heats up and its viscosity changes. This change in viscosity affects the discs and torque is split according to the actual .demands of the axles.

Active on-demand transfer cases employ sensors that monitor traction needs and automatically adjust the delivery of power to the wheel. Sensors may monitor various factors — such as vehicle speed, wheel slip, accelerator pedal angle, or braking— for which a passive system cannot account. The reaction is quicker than in the passive systems, and some handling problems are eliminated as a result. While this can be an advantage, it can also be a disadvantage in some off-road conditions where the shift might be too abrupt. In addition, as it is a more complex system, it can be more costly.

The patents-in-suit describe an active on-demand system. BorgWarner states that its: “transfer cases have primary and secondary output shafts which drive the primary and secondary axles, front and rear output speed sensors, a modulating clutch to transfer torque from the rear output to the front output when necessary, a drive and a driven sprocket, a chain connecting the two sprockets, a planetary reduction gear for high and low range, and a dog clutch for selecting the range.” (.Plaintiffs Markman Brief, at 7). Borg-Warner goes on to explain some of this as follows:

*924 The modulating clutch is a friction plate clutch that includes plates that rotate with the primary output shaft and plates that rotate with the secondary output shaft. The plates are interleaved together so that when the plates are engaged (i.e., pressed together) torque is transferred from the primary output to the secondary output. The amount of torque transferred will vary with the amount of engagement. The patents-in-suit teach that the clutch actuator can be electromagnetic, hydraulic, or pneumatic.
A microcontroller controls the amount of clutch engagement and disengagement, The microcontroller is' programmed with a control strategy that uses information about vehicle and road conditions to determine when to engage and disengage the modulating clutch. More specifically, the microcontroller first determines the amount of slip (i.e. the difference in rotational speeds) between the front and rear drivelines in determining whether to engage the clutch. A certain amount of slip is acceptable, and in fact, in cornering situations is required. However, when the slip exceeds a certain amount, vehicle handling and performance are affected adversely. The microcontroller determines when the amount of slip is too much. Specifically, the microcontroller receives signals from sensors that are indicative of the rotational speed of the front and rear drivelines. These sensors can be located in the transfer case or at the wheels. From these signals, the microcontroller is able to determine the slip or the speed difference between the front and the rear drivelines.
Once the amount of slip has been determined, the microcontroller uses that information to determine whether the modulating clutch should be engaged or disengaged. Specifically, the amount of slip is compared to a predetermined amount of allowed slip. If the actual slip is greater than the predetermined amount, the microcontroller generates a signal that causes the modulating clutch to be engaged a discrete amount. The microcontroller then repeats its analysis. If the slip is still above the predetermined amount, the amount of engagement of the modulating clutch is increased again. However, if the slip is below the predetermined of threshold amount, the modulating clutch is disengaged by a discrete amount. Thus, the torque is increased and decreased in a stepwise manner. This incremental engagement and disengagement control is a closed loop control strategy that is repeated over and over again as long as the vehicle is in the on demand mode. The constant monitoring and stepwise clutch engagement and disengagement result in an on demand four-wheel drive system that operates without any driver input. In fact, the driver is unaware of this constant monitoring and engagement/disengagement process.
The patents-in-suit disclose that one technique for applying the incremental control strategy is to use pulse width modulation (“PWM”) to control the amount of engagement applied by an electrical clutch actuator. In PWM, the voltage is pulsed to the electrical device to control the amount of power applied. For example, applying five volts to an electrical device will impart about one-half the power that ten volts will provide.

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Cite This Page — Counsel Stack

Bluebook (online)
237 F. Supp. 2d 919, 2002 U.S. Dist. LEXIS 24736, 2002 WL 31886842, Counsel Stack Legal Research, https://law.counselstack.com/opinion/borgwarner-inc-v-new-venture-gear-inc-ilnd-2002.