Hybrid module with sequential clutch

Abstract

A hybrid power module includes a torque converter, an electric motor, a cover plate, a connecting pin, a piston, and a pressure plate. The torque converter includes a turbine and an impeller, the turbine and impeller being arranged together to form a hydrodynamic annulus. The electric motor includes a rotor having a rotor carrier drivingly engaged with the impeller. The cover plate is fixed to the rotor carrier and is located radially inwardly of the rotor carrier, and the cover plate includes a tubular portion having an orifice. The connecting pin is sealed to the tubular portion and extends through the orifice. The piston is disposed on a first axial side of the cover plate, fixed to the connecting pin, and arranged to engage a torque converter clutch, and the pressure plate is disposed on a second axial side of the cover plate opposite the first axial side, fixed to the connecting pin, and arranged to engage a K0 clutch.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. non-provisional application No. 16 / 875,325, filed on May 15, 2020, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present disclosure relates generally to hybrid modules and, more particularly, to a hybrid module having a sequential clutch. Background Art

[0004] Commonly assigned US Patent No. 8,607,948 describes a starting device having a clutch that is engaged by a first pressure and a second clutch that is engaged by a second pressure that is greater than the first pressure. Summary of the Invention

[0005] An exemplary aspect broadly includes a hybrid module comprising a torque converter, an electric motor, a cover plate, a connecting pin, a piston, and a pressure plate. The torque converter includes a turbine and an impeller, the turbine being arranged to be connected to an input shaft of a multi-speed transmission, the impeller being arranged to form a hydrodynamic annulus with the turbine. The electric motor includes a rotor having a rotor carrier drivingly engaged with the impeller. The cover plate is secured to the rotor carrier and positioned radially inwardly of the rotor carrier, and includes a tubular portion having an aperture. The connecting pin is sealed to the tubular portion and extends through the aperture. The piston is disposed on a first axial side of the cover plate, secured to the connecting pin, and configured to engage a torque converter clutch, and the pressure plate is disposed on a second axial side of the cover plate opposite the first axial side, secured to the connecting pin, and configured to engage a K0 clutch.

[0006] In an exemplary embodiment, a first displacement of the piston in a first axial direction toward the impeller engages the K0 clutch, and a second displacement of the pressure plate in the first axial direction engages the torque converter clutch. In an exemplary embodiment, the torque converter clutch includes a first clutch plate drivingly engaged with the rotor carrier and a second clutch plate drivingly engaged with the turbine, and the K0 clutch includes a third clutch plate drivingly engaged with the rotor carrier and a fourth clutch plate arranged for driving engagement with the crankshaft of the internal combustion engine. In an exemplary embodiment, the K0 clutch is necessarily engaged when the torque converter clutch is engaged.

[0007] In some example embodiments, the hybrid module includes a leaf spring or diaphragm spring disposed on the second axial side of the cover plate, axially between the fourth clutch plate and the cover plate. In example embodiments, the leaf spring is compressed when the torque converter clutch is engaged. In example embodiments, the K0 clutch is configured to engage via a first pressure acting on the piston, and the torque converter clutch is configured to engage via a second pressure acting on the piston that is greater than the first pressure. In example embodiments, the hybrid module includes a release spring disposed axially between the pressure plate and the cover plate and configured to disengage the K0 clutch and the torque converter clutch.

[0008] In an exemplary embodiment, the connecting pin includes a first axial end portion, a second axial end portion, and a central portion. The first axial end portion is secured to one of the piston or the pressure plate by deforming the first axial end portion, the second axial end portion is secured to the other of the piston or the pressure plate by a retaining ring disposed in a first groove of the connecting pin, the central portion is axially located between the first and second axial ends, and the central portion is sealed to the tubular portion by a connecting pin seal disposed in the second groove of the connecting pin. In an exemplary embodiment, the hybrid module includes a K0 shaft having a bore, and the cover plate includes a guide disposed in the bore. In an exemplary embodiment, the hybrid module includes a bearing disposed in the bore so as to be radially located between the K0 shaft and the guide.

[0009] Other example aspects broadly include a hybrid module comprising a K0 shaft, a torque converter, an electric motor, and a clutch system. The K0 shaft is configured for driving connection to an internal combustion engine. The torque converter includes a turbine configured for driving connection to a multi-speed transmission. The electric motor includes a rotor. The clutch system includes a first clutch configured to selectively engage the rotor with the turbine, and a second clutch configured to selectively engage the rotor with the K0 shaft. The first clutch is configured to engage sequentially after the second clutch is engaged.

[0010] In some example embodiments, the first clutch includes a piston operated by hydraulic pressure, and the second clutch includes a pressure plate fixed to the piston. In example embodiments, the second clutch includes a leaf spring arranged to be compressed when the first clutch is engaged. In example embodiments, the first and second clutches include respective plurality of clutch plates. In example embodiments, a first displacement of the piston engages the second clutch, and a second displacement of the piston, which is greater than the first displacement, engages the first clutch. In example embodiments, the hybrid module includes a release spring arranged to displace the pressure plate to disengage the first and second clutches. In example embodiments, the hybrid module includes a damper arranged in the torque path between the K0 shaft and the internal combustion engine. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The single figure illustrates a cross-sectional view of an upper half of a hybrid module having a sequential clutch according to an example embodiment. DETAILED DESCRIPTION

[0012] Various embodiments of the present disclosure are described herein. It should be appreciated that the same reference numerals appearing in different figures identify identical or functionally similar structural elements. It should also be understood that the disclosed embodiments are merely examples, and that other embodiments may take various forms and alternative forms. These figures are not necessarily drawn to scale; some features may be magnified or minimized to illustrate the details of particular components. Therefore, the specific structural and functional details disclosed herein should not be interpreted as restrictive, but rather as a representative basis for teaching those skilled in the art to adopt the various embodiments in various ways. As will be understood by those of ordinary skill in the art, the various features illustrated and described with reference to any of the figures may be combined with the features illustrated in one or more other figures to produce embodiments that are not explicitly illustrated or described. The combination of the illustrated features provides representative embodiments for typical applications. However, for specific applications or implementations, various combinations and modifications of features consistent with the teachings of the present disclosure may be desired.

[0013] The terms used herein are for the purpose of describing specific aspects only and are not intended to limit the scope of the present disclosure. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as that generally understood by one of ordinary skill in the art to which the present disclosure pertains. Although any method, device or material similar to or equivalent to those described herein may be used in the practice or testing of the present disclosure, the following example methods, devices and materials are now described.

[0014] The following description refers to a single figure. The single figure illustrates a cross-sectional view of the upper half of a hybrid module 100 having a sequential clutch 102 according to an exemplary embodiment. Hybrid module 100 includes a torque converter 102, an electric motor 104, a cover plate 106, a connecting pin 108, a piston 110, and a pressure plate 112 secured to piston 110. Hybrid module 100 may include a plurality of connecting pins 108 distributed circumferentially about axis 101. The torque converter includes a turbine 114 and an impeller 120. The turbine is arranged to be connected to an input shaft 116 of a multi-speed transmission (partially shown at 118). The impeller is arranged to form a hydrodynamic annulus 122 with the turbine. Specifically, the turbine is arranged for driving connection to the multi-speed transmission. The torque converter 102 may also include a stator 124, which is arranged to be connected to a stator shaft 126 via a one-way clutch 128. The impeller 120 may include an impeller hub 130 secured to the impeller to drive a pump 132 of the multi-speed transmission.

[0015] The electric motor includes a rotor 134 having a rotor carrier 136 that is drivingly engaged with the impeller. A cover plate is secured to the rotor carrier and is located radially inwardly of the rotor carrier. The cover plate includes a tubular portion 138 having an orifice 140. In the embodiment shown in the figures, the tubular portion 138 is extruded from the same piece of material as the cover plate 106 to form an inner cylindrical surface. In other embodiments (not shown), the tubular portion may be an additional component secured in the orifice of the cover plate. For example, a connecting pin is sealed to the tubular portion by a connecting pin seal 142 and extends through the orifice. That is, a portion of the pin 108 extends through the orifice beyond the opposite axial side of the cover plate, allowing it to be axially displaced relative to the cover plate.

[0016] A piston is disposed on an axial side 144 of the cover plate, secured to a connecting pin, and arranged to engage a torque converter clutch 146. Torque converter clutch 146 includes a piston 110. Clutch 146 is arranged to selectively engage the rotor with the turbine. In other words, piston 110 is arranged to compress a clutch plate of the torque converter clutch to rotationally connect the turbine with the cover plate in response to hydraulic pressure, as described in more detail below. A pressure plate is disposed on an axial side 148 of the cover plate opposite axial side 144, secured to a connecting pin, and arranged to engage a K0 clutch 150 in a manner similar to the engagement of torque converter clutch 146. K0 clutch 150 includes a pressure plate. The K0 clutch is arranged to rotationally connect the cover plate 106 to a K0 shaft 152, selectively engaging the rotor with the K0 shaft. The K0 shaft is arranged for driving connection to an internal combustion engine, as described in more detail below.

[0017] During operation of the hybrid module, a first displacement of the piston in an axial direction 154 toward the impeller engages the K0 clutch, and a second displacement of the pressure plate in an axial direction 154 engages the torque converter clutch. The torque converter clutch is arranged to engage sequentially after the K0 clutch engages. In other words, when the torque converter clutch engages, the K0 clutch necessarily engages. The torque converter clutch and the K0 clutch include respective multiple clutch plates. The torque converter clutch 146 includes clutch plates 156 drivingly engaged with the rotor carrier and clutch plates 158 drivingly engaged with the turbine. The K0 clutch includes clutch plates 160 drivingly engaged with the rotor carrier and clutch plates 162 arranged for driving engagement with the crankshaft of the internal combustion engine (e.g., via the K0 shaft 152 and damper 164).

[0018] Hybrid module 100 includes a leaf spring 166 disposed on axial side 148 of the cover plate, axially located between clutch plate 162 and the cover plate. K0 clutch 150 includes leaf spring 166. When the torque converter clutch is engaged, the leaf spring 166 is compressed. The K0 clutch is configured to engage via a first pressure acting on the piston, and the torque converter clutch is configured to engage via a second pressure acting on the piston that is greater than the first pressure. In other words, the pressure acting on the piston pulls the pressure plate via the connecting pin, engaging the K0 clutch.

[0019] The force from the leaf spring allows the K0 clutch to engage without additional piston displacement. As pressure increases, the force from the piston pulling on the pressure plate exceeds the leaf spring force, and the piston shifts to engage the torque converter clutch. Thus, a first displacement of the piston engages the K0 clutch, and a second displacement of the piston, greater than the first, engages the torque converter clutch. Specifically, the leaf spring is arranged to be compressed when the torque converter clutch is engaged.

[0020] The piston, cover plate, connecting pin, connecting pin seal, and piston seals 168 and 170 form an apply chamber 172, allowing pressurized oil introduced through input shaft bore 174 to act on or operate on the piston to sequentially engage clutches 146 and 150. A release spring 176 is axially disposed between the pressure plate and the cover plate. The release spring is arranged to displace the pressure plate to disengage the K0 clutch and the torque converter clutch. In other words, when the pressure in chamber 172 decreases, the force from the release spring acting between the pressure plate and the cover plate pushes the pressure plate in an axial direction 178 opposite to axial direction 154. When the pressure in chamber 172 is low, the force from the release spring 176 reacts against the housing wall 183 via bearing 177, an external clutch carrier 179 fixed to K0 shaft 152, and bearing 181.

[0021] The connecting pin 108 includes an axial end 180 fixed to the pressure plate by deforming the axial end 180 and an axial end 182 fixed to the piston by a snap ring 184 disposed in a groove 186 of the connecting pin. The connecting pin 108 also includes a central portion 188 axially located between the axial end 180 and the axial end 182. The central portion is sealed to the tubular portion by a seal 142 disposed in a groove 190 of the connecting pin.

[0022] Hybrid module 100 also includes a K0 shaft 152 and a bearing 192. The K0 shaft includes a hole 194, and cover plate 106 includes a guide 196 disposed in the hole. Bearing 192 is disposed in the hole so as to be radially located between the K0 shaft and the guide. Damper 164 is arranged in the torque path between the K0 shaft and the internal combustion engine.

[0023] Although exemplary embodiments have been described above, these embodiments are not intended to describe all possible forms covered by the claims. The words used in the specification are descriptive and not restrictive, and it should be understood that various changes can be made without departing from the spirit and scope of the present disclosure. As previously described, the features of the various embodiments can be combined to form additional embodiments of the present disclosure that may not be explicitly described or illustrated. Although various embodiments can be described as providing advantages or being superior to other embodiments or prior art implementations with respect to one or more desired characteristics, it is appreciated by those skilled in the art that one or more features or characteristics can be compromised to achieve the desired overall system properties depending on the specific application and implementation. These properties may include, but are not limited to, cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, applicability, weight, manufacturability, ease of assembly, etc. Therefore, to the extent that any embodiment is described as being less ideal than other embodiments or prior art implementations with respect to one or more characteristics, these embodiments do not depart from the scope of the present disclosure and may be desirable for a particular application.

[0024] Reference Signs List

[0025] 100 Hybrid Module

[0026] 101 Axis

[0027] 102 Torque Converter

[0028] 104 electric motor

[0029] 106 cover

[0030] 108 connecting pin

[0031] 110 piston

[0032] 112 Pressure Plate

[0033] 114 turbines

[0034] 116 Input shaft

[0035] 118 Multi-speed transmission (part)

[0036] 120 impeller

[0037] 122 Hydrodynamic Torus

[0038] 124 stator

[0039] 126 stator shaft

[0040] 128 One-way clutch

[0041] 130 impeller hub

[0042] 132 Pump (Multi-speed Transmission)

[0043] 134 rotor

[0044] 136 rotor carrier

[0045] 138 tubular part

[0046] 140 Orifice

[0047] 142 Connecting pin seal

[0048] 144 Axial side (first)

[0049] 146 Torque Converter Clutch

[0050] 148 Axial side (second)

[0051] 150 K0 clutch

[0052] 152 K0 axis

[0053] 154 Axial direction (first)

[0054] 156 Clutch plate (first)

[0055] 158 Clutch plate (second)

[0056] 160 Clutch plate (third)

[0057] 162 Clutch plate (fourth)

[0058] 164 Damper

[0059] 166 leaf spring

[0060] 168 Piston seal (ID)

[0061] 170 Piston seal (OD)

[0062] 172 Application Room

[0063] 174 Input shaft hole

[0064] 176 Release Spring

[0065] 177 bearings

[0066] 178 Axial direction (second)

[0067] 179 External clutch carrier

[0068] 180 Axial end (first)

[0069] 181 bearings

[0070] 182 Axial end (second)

[0071] 183 Shell wall

[0072] 184 clasp

[0073] 186 Groove (First)

[0074] 188 Central part

[0075] 190 groove (second)

[0076] 192 bearings

[0077] 194 holes

[0078] 196 Director.

Claims

1. A hybrid power module comprising: A torque converter, the torque converter comprising: a turbine arranged to be connected to an input shaft of a multi-speed transmission; and an impeller arranged to form a hydrodynamic annulus with the turbine; an electric motor including a rotor having a rotor carrier in driving engagement with the impeller; a cover plate fixed to the rotor carrier and located radially inward of the rotor carrier, the cover plate including a tubular portion having an aperture; a connecting pin sealed to the tubular portion and extending through the aperture; a piston disposed on a first axial side of the cover plate, secured to the connecting pin, and arranged to engage a torque converter clutch; and A pressure plate is provided on a second axial side of the cover plate opposite the first axial side, is fixed to the connecting pin, and is arranged to engage the K0 clutch.

2. The hybrid power module according to claim 1, wherein: A first displacement of the piston in a first axial direction toward the impeller engages the K0 clutch; and A second displacement of the pressure plate in the first axial direction engages the torque converter clutch.

3. The hybrid power module according to claim 1, wherein: the torque converter clutch including a first clutch plate drivingly engaged with the rotor carrier and a second clutch plate drivingly engaged with the turbine; and The K0 clutch comprises a third clutch plate drivingly engaged with the rotor carrier and a fourth clutch plate arranged for driving engagement with a crankshaft of an internal combustion engine.

4. The hybrid module according to claim 1, wherein: When the torque converter is engaged, the K0 clutch is necessarily engaged.

5. The hybrid module according to claim 1, further comprising a leaf spring, wherein The K0 clutch includes a clutch plate, and the leaf spring is provided on the second axial side of the cover plate so as to be axially located between the clutch plate and the cover plate.

6. The hybrid power module according to claim 5, wherein: When the torque converter is engaged, the leaf spring is compressed.

7. The hybrid power module according to claim 1, wherein: said K0 clutch being arranged to be engaged by a first pressure acting on said piston; and The torque converter clutch is arranged to be engaged by a second pressure acting on the piston that is greater than the first pressure. 8 . The hybrid module of claim 1 , further comprising a release spring disposed axially between the pressure plate and the cover plate and arranged to disengage the K0 clutch and the torque converter clutch.

9. The hybrid power module according to claim 1, wherein: The connecting pin comprises: a first axial end portion secured to one of the piston or the pressure plate by deforming the first axial end portion; a second axial end portion secured to the other of the piston or the pressure plate by a snap ring disposed in the first groove of the connecting pin; and A central portion is axially located between the first axial end and the second axial end, the central portion being sealed to the tubular portion by a connecting pin seal disposed in the second groove of the connecting pin.

10. The hybrid module of claim 1 , further comprising a K0 shaft having a hole, wherein The cover plate includes a guide disposed in the hole. 11 . The hybrid module according to claim 10 , further comprising a bearing provided in the hole so as to be located radially between the K0 shaft and the guide.

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