Torque converter with a laser-welded sealing disc with an extruded projection

Abstract

Torque converter (100), which includes: a rotational axis (AR); a cover (104) for receiving a torque; a wheel (106) that contains: a wheel housing (108) which is non-rotatably connected to the cover (104); and at least one attached to the impeller housing (108) Wheel blade (110); a turbine (112) comprising a turbine casing (114) and at least one turbine blade (116) attached to the turbine casing (114); a hub (118); a sealing washer (102); and a weld (120) that firmly connects the hub (118) and the sealing disc (102), wherein a line perpendicular to the axis of rotation (AR) successively passes through the hub (118), the weld (120), the sealing disc (102) and the hub (118); and a seal (150) that seals against the sealing disc (102) and a piston plate (144).

Description

TECHNICAL AREA

[0001] The present disclosure relates to a four-way torque converter with a sealing disc having an extruded projection to provide a long and strong weld seam. BACKGROUND OF THE INVENTION

[0002] Fig. Figure 5 is a partial cross-sectional view of a four-way torque converter 200 according to the prior art. The torque converter 200 comprises a cover 202 for receiving torque, an impeller 204 with an impeller housing 206, a turbine 208 with a turbine housing 210, a hub 212, and a lock-up clutch 214 with a piston plate 216. The torque converter 200 includes pressure chambers 218 and 220. Chamber 218 is enclosed by the hub 212, the piston plate 216, and the sealing disc 222. Chamber 220 is enclosed by the cover 202, the hub 212, and the piston plate 216. To close the coupling 214 (to connect the cover 202 to the piston plate 216 in a rotationally fixed manner), the fluid pressure in the chamber 218 is increased and the fluid pressure in the chamber 220 is decreased in order to move the piston plate 216 in the axial direction AD1.To open the coupling 214, the fluid pressure in chamber 220 is increased and the fluid pressure in chamber 218 is decreased in order to move the piston plate 216 in the axial direction AD2.

[0003] One end E of the sealing disc 222 is butt-welded to the hub 212 by a weld 224. The weld 226 projection is a weld area 224 that is very easily damaged by the pressure exerted on the sealing disc 222 when the clutch 214 is closed. Simulations have shown, for example, that at a fluid pressure of 9.5 bar in the chamber 218, the load (stress) at projection 226 increases significantly. The axial extension of the weld 224 is adapted to the thickness 228 of the disc 222. For example, the weld 224 does not extend further in the direction AD1 than the sealing disc 222.

[0004] Further torque converters with a lock-up clutch are known from the publications DE 102 42 856 A1, US 2006 / 0 021 220 A1, DE 11 2007 002 007 T5 and DE 11 2006 002 111 T5.

[0005] The object of the present invention is to further improve torque converters from the prior art with regard to durability and sealing. SUMMARY

[0006] According to the aspects illustrated herein, a torque converter is provided, comprising: a rotating axis; a cover for receiving torque; an impeller comprising an impeller housing non-rotatably connected to the cover and at least one impeller blade attached to the impeller housing; a turbine comprising a turbine housing and at least one turbine blade attached to the turbine housing; a hub; a sealing washer; and a weld that rigidly joins the hub and the sealing washer together. A line perpendicular to the rotating axis passes successively through the hub, the weld, the sealing washer, and the hub.

[0007] According to the aspects illustrated herein, a torque converter is provided, comprising: a rotating axis; a cover for receiving torque; an impeller comprising an impeller housing non-rotatably connected to the cover; a turbine comprising a turbine housing; a sealing disc with a first surface; a hub comprising a first surface; a weld located between the first surface of the hub and the first surface of the sealing disc, and fixedly connected to the first surface of the hub and the first surface of the sealing disc; and a first pressure chamber, at least partially enclosed by the hub and the sealing disc. A line perpendicular to the rotating axis passes successively through the hub, the weld, the sealing disc, and the hub.

[0008] According to the aspects illustrated herein, a torque converter is provided which includes: a pivot axis; a cover for receiving torque; an impeller comprising an impeller housing non-rotatably connected to the cover and at least one impeller blade attached to the impeller housing; a turbine comprising a turbine housing and at least one turbine blade attached to the turbine housing; a hub; a sealing washer comprising a radially innermost surface and a projection that includes at least a portion of the radially innermost surface of the sealing washer and extends in a first axial direction; and a weld that rigidly joins the hub and the sealing washer together and extends beyond the projection in the first axial direction. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Various embodiments are disclosed by way of example only with reference to the accompanying schematic drawings, in which certain reference numerals denote corresponding parts, wherein: Fig. 1 a perspective view of a cylindrical coordinate system illustrating the spatial concepts used in the present application; Fig. 2 is a partial cross-sectional view of a four-way torque converter with a welded sealing disc with an extruded projection; Fig. 3 a detail of area 3 / 4 in Fig. 2 is; Fig. 4 a detail of area 3 / 4 in Fig. 2 is; and Fig. Figure 5 shows a partial cross-sectional view of a state-of-the-art four-way torque converter. DETAILED DESCRIPTION

[0010] It should be obvious from the outset that identical drawing numbers in different drawing views denote identical or functionally similar structural elements of the disclosure. It should be clear that the claimed disclosure is not limited to the disclosed aspects.

[0011] Furthermore, it is clear that this disclosure is not limited to the individual processes, materials, and modifications described and may therefore naturally vary. It is also clear that the terms used herein serve only to describe individual aspects and are not intended to limit the scope of protection afforded by this disclosure.

[0012] Unless otherwise defined, all technical and scientific terms used herein have the same meanings as they would be understood by a person skilled in the art to whom this disclosure is addressed. It should be clear that any methods, units, or materials similar to or equivalent to those described herein may be used to implement or test the disclosure.

[0013] Fig. Figure 1 is a perspective view of a cylindrical coordinate system 10, illustrating the spatial concepts used in the present application. The present application is described, at least in part, in connection with a cylindrical coordinate system. The system 10 includes an axis of rotation or longitudinal axis 11, which serves as a reference for the following spatial and directional concepts. Opposing directions AD1 and AD2 are parallel to the axis 11. A radial direction RD1 is perpendicular to and directed towards the axis 11. A radial direction RD2 is perpendicular to and directed away from the axis 11. Opposing directions CD1 and CD2 are defined by an endpoint of a specific radius R (perpendicular to the axis 11), which is rotated about the axis 11, for example, clockwise and counterclockwise, respectively.

[0014] Objects 12, 13, and 14 serve to illustrate the spatial concepts. For example, an axial surface, such as surface 15A of object 12, is formed by a plane coplanar with axis 11. However, any planar surface parallel to axis 11 is an axial surface. For example, surface 15B, which is parallel to axis 11, is also an axial surface. An axial edge is formed by an edge parallel to axis 11, such as edge 15C. A radial surface, such as surface 16A of object 13, is formed by a plane that is perpendicular to axis 11 and coplanar with a radius, such as radius 17A. A radial edge is collinear with a radius of axis 11. For example, edge 16B is collinear with radius 17B. Surface 18 of object 14 forms a cylindrical or circumferential surface. For example, the perimeter 19, defined by the radius 20, passes through the area 18.

[0015] An axial movement occurs in the axial direction AD1 or AD2. A radial movement occurs in the radial direction RD1 or RD2. A circumferential or rotational movement occurs in the circumferential direction CD1 or CD2. The terms "axial," "radial," and "circumferential" refer to a movement or orientation parallel to axis 11, perpendicular to axis 11, or around axis 11, respectively. For example, an axially arranged surface or edge extends in the direction AD1, a radially arranged surface or edge extends in the direction RD1, and a circumferentially arranged surface or edge extends in the direction CD1.

[0016] Fig. Figure 2 is a partial cross-sectional view of a four-way torque converter 100 with a welded sealing disc 102 with an extruded projection.

[0017] Fig. 3 is a detail of area 3 / 4 in Fig. 2.

[0018] Fig. 4 is a detail of area 3 / 4 in Fig. 2. The following description is in connection with the Fig. Figures 2 to 4 show the following. The torque converter 100 comprises: a rotary axis AR; a sealing disc 102; a cover 104 for receiving torque; an impeller 106, which includes an impeller housing 108 non-rotatably connected to the cover 104 and at least one impeller blade 110 attached to the impeller housing 108; a turbine 112, which includes a turbine housing 114 and at least one turbine blade 116 attached to the turbine housing 114; a hub 118; and a weld 120, which firmly connects the hub 118 and the sealing disc 102. The weld 120 is formed by fusing corresponding sections of the disc 102 and the hub 118, for example, by a laser welding unit. A line L1 perpendicular to the axis of rotation AR passes successively through the hub 118, the weld 120, the sealing washer 102 and the hub 118.

[0019] The sealing washer 102 comprises: a surface 122 extending in a radial direction RD perpendicular to the axis of rotation; a radially innermost surface 124 extending from surface 122 in the axial direction AD1 away from the turbine housing 114; and a projection 126 extending in the axial direction AD1 and comprising a radially innermost surface 124. It should be noted that surface 124 also extends radially inward. A line L1 passes successively through the hub 118, the weld 120, the projection 126, surface 124, and hub 118.

[0020] The hub 118 includes a recess 128 extending into the hub 118 in the axial direction AD1. The projection 126 is located in the recess 128 and includes a section 124A of the surface 124. The section 120A of the weld 120 is located in the recess 128. According to an exemplary embodiment, the projection 130, which forms the section of the weld 120 furthest in the direction AD1, extends beyond the projection 126 in the direction AD1. The hub 118 includes a surface 132. The surface 132 forms a section of the recess 128. The weld 120 is in contact with the surfaces 124 and 132 and is located radially between them. The line L1 passes successively through the surface 132, the weld 120, and the surface 124.

[0021] The torque converter 100 contains pressure chambers 134, 136, and 138. Chamber 134 is at least partially enclosed by the disk 102 and the hub 118. According to an exemplary embodiment: chamber 136 is at least partially enclosed by the cover 104 and the hub 118; and chamber 138 is at least partially enclosed by the sealing disk 102 and the turbine housing 114.

[0022] The torque converter 100 includes a lock-up clutch 142, which contains an axially displaceable piston plate 144. The chambers 134 and 136 are at least partially enclosed by the piston plate 144. In response to pressure in the pressure chamber 134 (by increasing the fluid pressure in the chamber 134), the piston plate 144 is displaceable in the axial direction AD1 to close the clutch 142 and connect the piston plate 144 to the cover 104 in a rotationally fixed manner. In response to pressure in the pressure chamber 136 (by increasing the fluid pressure in the chamber 136), the piston plate 144 is displaceable in the axial direction AD2, which is opposite to the axial direction AD1, to open the clutch 142 so that the piston plate 144 can rotate with respect to the cover 104.The term "components rigidly connected to one another" means that: whenever one of the components rotates at a specific speed, all components rotate at that specific speed; and relative rotation between the components is not possible. Axial or radial displacement of the components relative to each other is possible.

[0023] The torque converter 100 comprises: a seal 146 that seals against the hub 118 and the piston plate 144; a seal 148 that seals against the piston plate 144 and the cover 104; and a seal 150 that seals against the sealing washer 102 and the piston plate 144. According to an exemplary embodiment, the hub 118 comprises at least one channel 152 extending from the radially innermost surface 154 of the hub 118 to the chamber 134. The chamber 134 is sealed against the remainder of the torque converter 100, for example, against the chambers 136 and 138, with the exception of the channels 152. This means that the only way in which the liquid enters or leaves chamber 134 is through the channels 152. For example, seals 146 and 148 seal chamber 134 against chamber 136, and seal 150 seals chamber 134 against chamber 138.

[0024] The sealing disc 102 comprises surfaces 158 and 160. Surface 158 extends radially outward from surface 124. Surface 160 extends axially from surface 158 in the direction AD2 toward the turbine housing. According to an exemplary embodiment, one or both surfaces 158 and 160 are in contact with the hub 118. The sealing disc 102 comprises a surface 162 that extends radially outward from surface 160. The chamber 134 is at least partially enclosed by surface 162. According to an exemplary embodiment, at least a portion of surface 162 is in contact with the hub 118. Thus, the projection 126 is shaped like an inverted "L" extending from surfaces 122 and 162. That is, the projection 128 is formed by section 124A of surface 124, surface 158 and surface 160. The chamber 138 is partially enclosed by surface 122.

[0025] The hub 118 comprises surfaces 164 and 166. Surface 164 extends radially outward from surface 132. Surface 166 extends from surface 164 in the direction AD2. The recess 128 is formed by surfaces 132, 164, and 166 of the hub 118. Surfaces 132 and 166 are separated from each other in the radial direction RD. Surface 164 directly connects surfaces 132 and 166. In one exemplary embodiment, surface 164 is in contact with surface 158, or surface 166 is in contact with surface 160. In another exemplary embodiment, surface 164 is in contact with surface 158 and surface 166 is in contact with surface 160.

[0026] According to an exemplary embodiment, the hub 118 includes at least one channel 168 extending from the radially inner surface 154 of the hub 118 to the chamber 136. The chamber 136 is sealed against the rest of the torque converter 100, for example, against the chambers 134 and 138, with the exception of the channels 168. That is, the only path through which the fluid enters or leaves the chamber 136 is through the channels 168. For example, the seal 146 seals the chamber 136 against the chamber 134, and the seal 148 seals the chamber 136 against the chamber 138. The torque converter 100 includes a cavity or torus 170 formed by the housings 108 and 114. The chamber 138 includes the cavity 170.

[0027] According to an exemplary embodiment, the clutch 142 comprises a drive disc 172 and a friction material 174, which is arranged axially between the cover 104 and the piston plate 144. According to an exemplary embodiment, the torque converter 100 comprises a torsional vibration damper 176 and an output hub 178. The hub 178 is non-rotatably connected to the turbine housing 114 and serves to non-rotatably connect it to a (not shown) drive shaft of a transmission, for example by means of a tooth profile 180. The damper 176 comprises a spring retaining disc 182 and at least one spring 184. The disc 182 is non-rotatably connected to the turbine housing 114, and at least one spring 184 engages the drive disc 172 and the disc 182.

[0028] The torque converter 100 operates as follows. In converter mode, the clutch 142 is open, allowing the piston plate 144 to rotate relative to the cover 104 and transmitting torque from the cover 104 to the impeller housing 108. Through a hydraulic connection between the impeller 106 and the turbine 112, the torque is transmitted via the stator 186 from the housing 108, through the housing 114, to the output hub 178. To open the clutch 142, the fluid pressure in chamber 136 is increased until it exceeds the fluid pressure in chamber 134. The pressure in chamber 134 can be reduced to create this pressure differential.

[0029] In the lock-up mode of the torque converter 100, the clutch 142 is closed, so that the drive disc 172 and the piston plate 144 are rotationally fixed to the cover 104. The torque is transmitted from the cover 104 via the drive disc 172, the spring(s) 184, the disc 182, and the housing 114 to the output hub 178. To close the clutch 142, the fluid pressure in chamber 134 is increased until it is higher than the fluid pressure in chamber 136. The pressure in chamber 136 can be reduced to create this pressure difference.

[0030] One advantage is that the sealing washer 102, the hub 118, and the weld 120 solve the problem of excessive stress at the weld joint connecting a sealing washer, for example, of a four-way torque converter, to a hub of the four-way torque converter. For example, the fluid pressure in chamber 134 exerts a force F in the direction AD2 on the sealing washer 102. Instead, significant portions of the force F are diverted from the weld joint 130 and transferred to the projection 126. For example, the bending stress between the projection 126 and the rest of the washer 102 absorbs portions of the force F.

[0031] Accordingly, the stress at the end 130 of the weld 120 and at the weld 120 as a whole is reduced. Simulations have shown, for example, that at a fluid pressure of 9.5 bar in chamber 134, the load (stress) at the end 130 is approximately 2.5 times lower than the load at the end 226 described above. By reducing the load at the end 130, the durability of the weld 120 is increased and the service life of the torque converter 100 is extended.

[0032] Furthermore, the axial extension 188 of the weld 120 is not adapted to the thickness 190 of the disc 102, but rather to the axial extension 192 of the projection 126. The extension 192 is greater than the thickness 190, so the weld 120 is axially longer and stronger than the weld 224 described above. Additionally, the axial deflection of the sealing disc 102 in the bridging mode is reduced, thus advantageously improving the volume change of the chamber 134 and the controllability of the clutch 142.

[0033] It is obvious that various features and functions disclosed above, as well as other features and functions or their alternatives, can be desirablely combined to form many other systems or applications. A person skilled in the art may later make various currently unforeseeable or unexpected alternatives, modifications, or improvements to them, which are also intended to be covered by the following claims.

Claims

[1] Torque converter (100) comprising: a rotational axis (AR); a cover (104) for receiving a torque; a wheel (106) that contains: a wheel housing (108) which is non-rotatably connected to the cover (104); and at least one attached to the impeller housing (108) Wheel blade (110); a turbine (112) comprising a turbine casing (114) and at least one turbine blade (116) attached to the turbine casing (114); a hub (118); a sealing washer (102); and a weld (120) that firmly connects the hub (118) and the sealing disc (102), wherein a line perpendicular to the axis of rotation (AR) successively passes through the hub (118), the weld (120), the sealing disc (102) and the hub (118); and a seal (150) that seals against the sealing disc (102) and a piston plate (144). [2] Torque converter (100) according to claim 1, wherein: the sealing disc (102) contains: a first surface (122) which extends in a radial direction (RD) perpendicular to the axis of rotation (AR); a radially innermost surface (124) extending from the first surface (122) in a first axial direction (AD1) away from the turbine housing (114); and a projection (126) extending in the first axial direction (AD1), wherein the projection (126) forms the radially innermost surface (124) contains; and the line (L1) passes successively through the hub (118), the weld (120), the projection (126) and the hub (118). [3] Torque converter (100) according to claim 1, wherein: the hub (118) contains a recess (128) which extends away from the turbine housing (114) in an axial direction (AD1) into the hub (118); the sealing disc (102) contains a projection (126), wherein the projection (126): is arranged in the recess (128); and at least one section (124A) of a radially innermost surface (128) of the Sealing washer (102) contains; and a section (120A) of the weld (120) is arranged in the projection (126). [4] Torque converter (100) comprising: a rotational axis (AR); a cover (104) for receiving a torque; an impeller (106) which includes an impeller housing (108) which is connected to the cover (104) in a rotationally fixed manner; a turbine (112) containing a turbine casing (114); a sealing disc (102) containing a first surface (122); a hub (118) containing a first surface (132); a weld (120) that connects the first surface (132) of the hub (118) and the first surface (124) of the sealing disc (102) and is firmly connected to the first surface (132) of the hub (118) and the first surface (124) of the sealing disc (102); and a first pressure chamber (134) which is at least partially enclosed by the hub (118) and the sealing disc (102), wherein: a line (L1) perpendicular to the axis of rotation (AR) successively through the hub (118), the weld seam (120), the sealing washer (102) and the hub (118) runs; and a seal (150) that seals against the sealing disc (102) and a piston plate (144). [5] Torque converter (100) according to claim 4, further comprising: a second pressure chamber (136) which is at least partially enclosed by the sealing disc (102) and the turbine housing (114); and a third pressure chamber (138) which is at least partially enclosed by the cover (104) and is enclosed by the hub (118). [6] Torque converter (100) according to claim 4, wherein the sealing disc (102) comprises: a second surface extending in a radial direction perpendicular to the axis of rotation (AR); a radially innermost surface (124) which extends from the second surface in a first axial direction (AD2) and contains the first surface of the sealing disc (102); a third surface extending radially outwards from the radially innermost surface; and a fourth surface extending from the third surface in a second axial direction (AD2) opposite to the first axial direction (AD1). [7] Torque converter (100) according to claim 6, wherein: the sealing disc (102) contains a fifth surface which extends radially outwards from the fourth surface of the sealing disc (102); and the first pressure chamber (134) is at least partially enclosed by the fifth surface. [8] Torque converter (100) according to claim 4, wherein: the hub (118) contains a depression (128) formed by the first surface of the hub (118), a second surface of the hub (118) and a third surface of the hub (118); the first and second surfaces of the hub (118) are separated from each other in a radial direction; the third surface is directly connected to the first and second surfaces; and the sealing disc (102) includes a projection (126) arranged in the recess (128), wherein the projection (126) includes at least a section of the first surface of the sealing disc (102). [9] Torque converter (100) according to claim 4, wherein: the hub (118) contains: a radially innermost surface (124); and at least one channel extending from the radially innermost surface (124) to extends to the first pressure chamber (134); and the first pressure chamber (134) is sealed against a remainder of the torque converter (100) with the exception of at least one channel. [10] Torque converter (100) comprising: a pivot axis; a cover (104) for receiving a torque; a wheel (106) that contains: a wheel housing (108) which is connected to the cover (104) in a rotationally fixed manner and at least one attached to the impeller housing (108) Wheel blade (110); a turbine (112) comprising a turbine casing (114) and at least one turbine blade (112) attached to the turbine casing (114); a hub (118); a sealing washer (102) which contains; a radially innermost surface (124); and a projection (126) which includes at least a section of the radially innermost surface (124) of the sealing disc (102) and extends in a first axial direction (AD1); and a weld (120): which firmly connect the hub (118) and the sealing washer (102) connects; and extends beyond the projection (126) in the first axial direction (AD1); and a seal (150) that seals against the sealing disc (102) and a piston plate (144).

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