Core ring for a torque converter for positioning the stator and torque converter with this core ring

Abstract

Core ring (50, 150, 250, 350) for a torque converter (10), wherein the core ring (50, 150, 250, 350) comprises: a ring-shaped body section that has: an inner concave surface (70, 170, 270, 370); an outer convex surface (172, 272, 372); an inner circumferential margin (174, 274, 374); and an outer circumferential margin (176, 276, 376); a plurality of blade tongue slots (54, 154, 254) for receiving a plurality of blades (24); and several positioning elements (52, 152, 252, 352), each comprising a material that projects axially inwards from the inner concave surface (70, 170, 270, 370) to form tips of the positioning elements (52, 152, 252, 352) for aligning a stator (40), each positioning element (52, 152, 252, 352) being completely confined and arranged circumferentially between two adjacent blade tongue slots (54, 154, 254).

Description

FIELD OF THE INVENTION

[0001] The invention relates generally to a core ring in a torque converter and, more particularly, to a core ring having positioning elements, which may be cut and / or pierced features, for positioning the stator during assembly. BACKGROUND OF THE INVENTION

[0002] In US patent application 2004 / 0172936, which is hereby incorporated by reference, a torque converter is described and shows a core ring with blades attached thereto.

[0003] U.S. Patent No. 5,065,509, which is hereby incorporated by reference, describes a method for attaching a vane for a torque converter. A plurality of vanes are attached, spaced apart, to the surface of a concave shell and a core ring along the circumferential direction of the shell. Tongues are integrally formed on the convex and concave edges of the vanes, respectively, and fit through slots in the shell and core ring. Furthermore, ribs are formed on the ends of the convex and concave edges of the vanes. Both the convex and concave edges are welded to the shell and core ring, respectively.

[0004] US Patent No. 8,056,330 discloses a core ring containing at least two segments. Other torque converters with core rings are known from publications DE 18 14 667 A, DE 10 2008 030 469 A1, US Patent No. 5,282,362 A, and DE 10 2009 029 496 A1.

[0005] It is well known that when installing a torque converter into a transmission, a transmission input shaft, stator shaft, and impeller are aligned with and then mated to a torque converter turbine hub, stator hub, or impeller hub, respectively. This process can be difficult and time-consuming due to the large number of shafts and hubs that must be correctly aligned. If the input shaft, stator shaft, or impeller and the turbine hub, stator hub, or impeller hub are not correctly aligned, the one or more misaligned components are notoriously twisted relative to each other in an attempt to mate the input shaft, stator shaft, impeller, turbine hub, stator hub, and impeller hub. Therefore, component alignment features must be included in the design to enable rapid assembly.Previously, the outer diameter of the stator was centered using a rim on the core ring. SUMMARY

[0006] Example aspects generally include a core ring for a torque converter comprising: an annular body portion having an inner concave surface, outer convex surface, an inner peripheral edge, and an outer peripheral edge; a plurality of blade tongue slots for receiving a plurality of blades; and at least one locating element including a material extending axially inwardly from the inner concave surface to form a tip of the locating element for aligning a stator.

[0007] Other exemplary aspects generally include a core ring wherein the at least one positioning element for aligning the stator is disposed entirely between the blade tongue slots.

[0008] Other exemplary aspects generally include a core ring, wherein the core ring extends circumferentially about an axis.

[0009] Other exemplary aspects generally include a core ring wherein the at least one positioning element is an incised feature.

[0010] Other exemplary aspects generally include a core ring wherein the inner peripheral edge is discontinuous.

[0011] Other exemplary aspects generally include a core ring wherein the inner peripheral edge is divided into a plurality of regions equal in number to the number of incised features.

[0012] Other exemplary aspects generally include a core ring wherein the at least one positioning element is a pierced feature.

[0013] Other exemplary aspects generally include a core ring wherein the inner peripheral edge is continuous.

[0014] Other exemplary aspects generally include a core ring, wherein the core ring is made of stamped low carbon steel.

[0015] Other exemplary aspects generally include a torque converter comprising: a stator, a core ring (described in paragraph 6) having at least one locating element disposed entirely between the blade tab slots; and a plurality of blades having corresponding blade tabs disposed in the blade tab slots of the core ring.

[0016] Other exemplary aspects generally include a torque converter wherein the core ring extends circumferentially about an axis.

[0017] Other example aspects generally include a torque converter wherein the at least one positioning element is a cut-in feature.

[0018] Other exemplary aspects generally include a torque converter wherein the inner peripheral edge is discontinuous.

[0019] Other exemplary aspects generally include a torque converter wherein the inner peripheral edge is divided into a plurality of regions equal in number to the number of incised features.

[0020] Other example aspects generally include a torque converter wherein the at least one positioning element is a pierced feature.

[0021] Other exemplary aspects generally include a torque converter wherein the inner peripheral edge is continuous.

[0022] Other exemplary aspects generally include a torque converter wherein the core ring is made of stamped low carbon steel.

[0023] Other exemplary aspects generally include a torque converter wherein the stator is made of cast aluminum.

[0024] Other example aspects generally include a torque converter comprising: a stator and a core ring for supporting a plurality of blades, the core ring having at least one element for centering the stator, each centering element being disposed entirely between the blades.

[0025] Other example aspects generally include a method of assembling a torque converter to a transmission, the method including the steps of: providing an annular body of the core ring comprising a material extending axially inward to provide at least one locating feature for aligning a stator having a stator rim, a stator edge, and a stator hub; supporting a plurality of blades on the core ring, the at least one locating feature being fully disposed between the blades; aligning the stator by translating the stator until the stator edge contacts the at least one locating feature; and fitting a stator shaft into the stator hub. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The nature and operation of the present invention will now be more fully described in the following detailed description of the invention when taken in conjunction with the accompanying drawings, in which: Fig. 1 illustrates a torque converter according to an example aspect. Fig. 2 illustrates a plan view of a core ring according to an example aspect. Fig. 3A illustrates a perspective view of a core ring according to an example aspect. Fig. Figure 3B shows an enlarged view of a section of the core ring of Fig. 3A. Fig. 4A illustrates a perspective view of a core ring according to an example aspect. Fig. Figure 4B shows an enlarged view of a section of the core ring of Fig. 4A. Fig. 5 illustrates a cross-sectional view of a core ring stator assembly according to an example aspect. DETAILED DESCRIPTION

[0027] It should be understood at the outset that like drawing numbers in different drawing views indicate identical or functionally similar structural elements. Furthermore, it is understood that this invention is not limited solely to the individual embodiments, methods of procedure, materials, and modifications described herein and, of course, may vary accordingly. It is also understood that the terms used herein are used only to describe particular aspects and are not intended to limit the scope of the present invention, which is limited only by the appended claims.

[0028] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. While any methods, units, or materials similar or equivalent to those described herein may be used to practice or test the invention, the following methods, units, and materials are now described.

[0029] The following description refers to the Fig. 1 to 5. Fig. 1 shows the cross-section of a torque converter 10 having a core ring 50 and a plurality of blades 24. The torque converter 10 includes an impeller 20 and a turbine 30. According to another exemplary aspect, a core ring 50' is alternatively shown, wherein the core ring is suitable for supporting turbine blades and / or impeller blades. The blades 24 have tabs 22 that extend through slots in the core ring 50. After insertion, the blades are crimped to the core ring 50 and secured thereto by brazing or welding or other methods known to those skilled in the art. The core ring 50 extends circumferentially about an axis 80. Known core rings typically have continuous annular bodies around the circumference. Alternatively, the blade portions themselves form an inner boundary.In the present example, the core ring 50 holding the blades 24 has an element for centering and positioning a stator 40.

[0030] The stator 40 can be manufactured by any method known in the art; according to one or more embodiments, the stator is made of cast aluminum. Alternatively, a phenolic resin stator is used. The stator includes a stator body, a plurality of blades, a stator rim 42, and a stator rim 44. The stator rim 42 typically represents the upper portion of a stator, and the stator rim 44 represents the horizontal area directly below the rim. The stator rim 42 is aligned by one or more locating elements 52 of the core ring. The stator includes a stator hub 60, typically having an inner tooth profile, which is mateably mated with a stator shaft 65, having an outer tooth profile, during assembly.An exemplary method for attaching a torque converter to a transmission includes the steps of: providing a core ring 50 having an annular body including an axially inwardly extending material to provide at least one locating feature for aligning a stator 40 having a stator rim 42, a stator rim 44, and a stator hub 60; supporting a plurality of blades on the core ring 50 with the at least one locating feature 52 disposed entirely between the blades; aligning the stator 40 by translating the stator 40 until the stator rim 44 contacts the at least one locating feature 52; and fitting a stator shaft 65 into the stator hub 60.

[0031] The at least one element for centering or positioning a stator is referred to interchangeably herein as a centering element or a positioning element. The positioning element 52 does not interfere with the working functions of the torque converter.

[0032] Positioning elements 52 can be used on core rings that hold impeller blades and / or turbine blades. The at least one positioning element 52 aligns the stator 40 during assembly by centering the stator relative to the impeller and / or the turbine. The impeller is also referred to as a pump by those skilled in the art; accordingly, the terms impeller and pump may be used interchangeably herein.

[0033] Before assembly, the components of the torque converter, including the impeller 20 and the turbine 30, are freely movable relative to one another. According to yet another exemplary aspect, the core ring 50, which includes the positioning elements 52, centers the stator 40 relative to the impeller 20, which in turn advantageously centers the turbine 30 relative to the impeller 20.

[0034] Fig. 2 illustrates a plan view of the core ring 50 according to an exemplary aspect, having an inner concave surface 70 and an outer convex surface (not shown). In other words, the inner surface is disposed opposite the outer surface. The core ring 50 further includes a plurality of blade tab slot positions or tab slots 54 for receiving blades or blade tabs. A plurality of blades are held in the tab slot positions by means of the core ring 50. The core ring 50 further includes at least one positioning element 52 for aligning the stator, wherein the at least one positioning element is disposed entirely between the blade slots. In an exemplary assembly including blades and an outer shell, the positioning element is disposed entirely between the blades.The core ring may advantageously be formed from a single piece, for example, by stamping or other methods known in the art; and the core ring may be formed, without limitation, from materials such as low-carbon steel. A suitable material for forming core rings according to an exemplary aspect is 1018 steel. According to an alternative exemplary aspect, the core ring comprises two segments described in U.S. Patent No. 8,056,330, hereby incorporated by reference.

[0035] The positioning elements can be cut-out features that are placed in Fig. 3 are shown in more detail. As used herein, the term "cutout feature" means, but is not limited to, a tongue-like protruding portion of the core ring that projects inwardly to provide additional axial width for positioning a stator. Fig. 3A illustrates a perspective view of a core ring 150 according to an exemplary embodiment. The core ring 150 extends circumferentially about an axis 180 and has an inner concave surface 170 and an (oppositely disposed) outer convex surface 172. The positioning element in the form of a cutout feature 152 projects axially inward from the inner concave surface 170. In other words, the positioning element in the form of the cutout feature is that the material of the core ring projects axially inward to provide additional axial width for positioning the stator. The cutout features 152 are advantageously disposed between the tongue slots 154 (for receiving the blades). By placing cutout features between the blades, it is ensured that the blades are advantageously retained by the core ring.Furthermore, applying the cutout features in this manner avoids performance degradation during operation and ensures that the core rings more accurately conform to the blade profile. The core ring 150 further includes an inner peripheral edge 174 and an outer peripheral edge 176, with the inner peripheral edge 174 being discontinuous at the one or more locations of the at least one cutout feature 152. The inner peripheral edge 174 of the core ring 150 is divided into a plurality of regions equal in number to the number of cutout features. Fig. 3B shows the section of the core ring 150 as an enlarged view of the box 190.

[0036] Fig. Figure 3B illustrates, at box 190, a section of core ring 150 having an inner concave surface 170 and an oppositely disposed outer convex surface, as well as an inner peripheral edge 174 and an outer peripheral edge 176. In one exemplary aspect, a cutout feature 152 is disposed entirely between tongue slots 154. The inner peripheral edge 174 is discontinuous at the location of the cutout feature 152.

[0037] Fig. Figure 4 shows in more detail positioning elements, which may be pierced features. As used herein, the term "pierced feature" includes, but is not limited to, a pierced portion from which the material thickness of the core ring protrudes inward to provide additional axial width for stator positioning. Fig. 4A illustrates a perspective view of a core ring 250 according to an exemplary embodiment of the present invention. The core ring 250 extends circumferentially about an axis 280 and includes an inner concave surface 270 and an outer convex surface 272. A pierced feature 252 projects axially inward from the inner concave surface 270. In other words, the pierced material is the core ring material that projects axially inward to provide additional axial width for stator positioning. The pierced features 252 are advantageously disposed between tongue slots 254 (for receiving blades). Placing the pierced features between the blades ensures that the blades are properly retained by the core ring.Additionally, locating the pierced features between blade positions in this manner avoids performance degradation during operation and ensures that the core rings more accurately conform to the blade profile. The core ring 250 further includes an inner peripheral edge 274 and an outer peripheral edge 276, with the inner peripheral edge 274 also being continuous at the one or more locations of the one or more pierced features 252. The pierced features 252 are formed within the inner concave surface 270, and therefore, the inner peripheral edge 274 is continuous. Fig. Figure 4B shows an enlarged section of the core ring 250 in box 290.

[0038] Fig. Figure 4B illustrates a section of the core ring 250, identified in box 290, including the inner concave surface 270 and the opposite outer convex surface 272, as well as the inner peripheral edge 274 and the outer peripheral edge 276. The pierced feature 252 is entirely disposed between the tongue slots 254. The inner peripheral edge 274 is continuous.

[0039] During assembly and before installing a stator shaft, the internal parts of the torque converter are freely movable. Fig. 5 is a cross-sectional view of a core ring and stator assembly 400 according to an example aspect. The core ring 350 includes an inner concave surface 370 and an outer convex surface 372, as well as an inner peripheral edge 374 and an outer peripheral edge 376. The pierced feature 252 includes a pierced feature tip 356. The stator 340, which includes a stator rim 342 and a stator edge 344, is centered during assembly such that contact with the pierced feature 352 and its rim 365 limits radial displacement of the stator edge 344. The locating feature, or the pierced feature in this non-limiting example, limits stator movement or slippage, which is known to result in misalignment.The at least one or more positioning elements maintain the “centering” or correct alignment for the subsequent insertion of the stator shaft (see . Fig. 1). Therefore, the at least one positioning element or the pierced feature 352 provides a means for preventing decentering of the stator.

[0040] Those skilled in the art will appreciate that the wall thickness 358 of the core ring, in other words the material thickness between and including the inner concave surface 370 and the outer convex surface 372, is advantageously reduced if desired in an exemplary core ring construction. The positioning elements 352, examples of which are not limited to cut features and pierced features, provide an axial width necessary for positioning the stator during assembly of the torque converter to the transmission. In one exemplary aspect, a torque converter includes a stator and a core ring for supporting a plurality of blades. The core ring has at least one element for centering the stator, with each centering element disposed entirely between the blades.

[0041] Of course, changes and modifications to the above examples of the invention will be apparent to those skilled in the art without departing from the spirit or scope of the claimed invention. While the invention is described with reference to specific preferred and / or exemplary embodiments, it is understood that changes may be made thereto without departing from the spirit or scope of the claimed invention.

Claims

[1] Core ring (50, 150, 250, 350) for a torque converter (10), the core ring (50, 150, 250, 350) comprising: an annular body portion comprising: an inner concave surface (70, 170, 270, 370); an outer convex surface (172, 272, 372); an inner peripheral edge (174, 274, 374); and an outer peripheral edge (176, 276, 376); a plurality of blade tongue slots (54, 154, 254) for receiving a plurality of blades (24); and a plurality of positioning elements (52, 152, 252, 352), each comprising a material projecting axially inwardly from the inner concave surface (70, 170, 270, 370) to form tips of the positioning elements (52, 152, 252, 352) for aligning a stator (40), each positioning element (52, 152, 252, 352) being circumferentially defined and arranged entirely between two adjacent blade tongue slots (54, 154, 254). [2] Torque converter (10) comprising: a stator (40); a core ring (50, 150, 250, 350) according to claim 1; and a plurality of blades (24) having corresponding blade tongues disposed in the blade tongue slots (54, 154, 254) of the core ring (50, 150, 250, 350). [3] The core ring (50, 150, 250, 350) of claim 1 or the torque converter (10) of claim 2, wherein the core ring (50, 150, 250, 350) extends circumferentially about an axis (80, 180, 280) and the at least one positioning element (52, 152, 252, 352) is a cut or pierced feature. [4] The core ring (50, 150, 250, 350) of claim 1 or the torque converter (10) of claim 2 or 3, wherein the at least one positioning element (52, 152, 252, 352) is a cut feature and the inner peripheral edge (174, 274, 374) is discontinuous. [5] The core ring (50, 150, 250, 350) of claim 4, wherein the inner peripheral edge (174, 274, 374) is divided into a plurality of regions, the number of which is equal to the number of incised features. [6] The core ring (50, 150, 250, 350) of claim 1 or the torque converter (10) of claim 2 or 3, wherein the at least one positioning element (52, 152, 252, 352) is a pierced feature and the inner peripheral edge (174, 274, 374) is continuous. [7] Core ring (50, 150, 250, 350) according to claim 1 or torque converter (10) according to claims 2 to 6, wherein the core ring (50, 150, 250, 350) is made of stamped low carbon steel. [8] Torque converter (10) according to claims 2 to 7, wherein the stator (40) is made of cast aluminum. [9] A torque converter (10) comprising: a stator (40) and a core ring (50, 150, 250, 350) for supporting a plurality of blades (24), wherein the core ring (50, 150, 250, 350) has a plurality of elements for centering the stator (40), and each centering element is circumferentially completely delimited and arranged between two adjacent blades (24). [10] The torque converter (10) of claim 9, wherein the core ring (50, 150, 250, 350) extends circumferentially about an axis (80, 180, 280) and the at least one centering element is a cut or pierced feature.

Images