Stator Assembly

Abstract

A stator assembly for a torque converter includes a body and a washer. The body is rotatable about an axis and has a cavity defined by an axial wall radially spaced from the axis and a radial wall extending radially inward from the axial wall. The washer is disposed in the cavity and configured to be compressed against the radial wall. The washer includes a base and a plurality of tabs circumferentially spaced from one another and extending radially outward from the base. The plurality of tabs are configured to non-rotatably connect to the axial wall.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Non-Provisional Patent Application No. 17 / 974,819, filed October 27, 2022, the disclosure of which is incorporated herein by reference in its entirety.

[0002] Technical Field The present disclosure relates generally to a stator assembly for a torque converter, and more particularly to a stator assembly including a thrust washer non-rotatably connected to a stator body, and a torque converter including the stator assembly. [Background technology]

[0003] Many vehicles include a launch device between the engine and the transmission. A torque converter is one type of launch device commonly used in vehicles with automatic transmissions. A typical torque converter includes an impeller fixed to the engine's crankshaft and a turbine fixed to a turbine shaft, which is the input to the transmission. To improve fuel economy, the torque converter may include a stator assembly disposed axially between the turbine assembly and the impeller assembly, which redirects fluid flowing from the turbine assembly before the fluid reaches the impeller assembly. During operation of the torque converter, drag forces act on the stator assembly, which can cause relative rotation between the stator assembly components and undesirable wear on the stator assembly components. Summary of the Invention [Means for solving the problem]

[0004] An embodiment of the present disclosure provides a stator assembly for a torque converter. The stator assembly includes a body and a washer. The body is rotatable about an axis and has a cavity defined by an axial wall radially spaced from the axis and a radial wall extending radially inward from the axial wall. The washer is disposed in the cavity and configured to be compressed against the radial wall. The washer includes a base and a plurality of tabs circumferentially spaced from one another and extending radially outward from the base. The plurality of tabs are configured to non-rotatably connect to the axial wall.

[0005] In embodiments, in the uncompressed state, the tabs may extend at an angle relative to the axis. In the compressed state, the tabs may extend perpendicular to the axis. In embodiments, in the uncompressed state, the tabs may be radially inward of the axial wall. In the compressed state, the tabs may engage the axial wall. Each tab may include an end spaced apart from the base. In the compressed state, the end may be radially outward of the axial wall. The tabs may be configured to deform the axial wall from the uncompressed state to the compressed state during compression.

[0006] In embodiments, the plurality of tabs may include a plurality of first tabs that, in the uncompressed state, extend in a first axial direction away from the base in the uncompressed state, and a plurality of second tabs that, in the uncompressed state, extend in a second, opposite axial direction away from the base. The plurality of first tabs and the plurality of second tabs may be arranged in an alternating manner about the axis.

[0007] In embodiments, at least some of the tabs may include a plurality of teeth configured to deform the axial wall from an uncompressed state to a compressed state during compression, hi embodiments, the plurality of tabs may be configured to expand outward when the washer is compressed against the radial wall.

[0008] An embodiment of the present disclosure further provides a torque converter including a front cover, an impeller, a turbine, and a stator assembly. The front cover is arranged to receive torque. The impeller has an impeller shell non-rotatably connected to the cover. The turbine is in fluid communication with the impeller and includes a turbine shell. The stator assembly is axially disposed between the impeller shell and the turbine shell. The stator assembly includes a body and a washer. The body is rotatable about an axis and has a cavity defined by an axial wall radially spaced from the axis and a radial wall extending radially inward from the axial wall. The washer is disposed in the cavity and configured to be compressed against the radial wall. The washer includes a base and a plurality of tabs circumferentially spaced from one another and extending radially outward from the base. The plurality of tabs are configured to be non-rotatably connected to the axial wall.

[0009] In embodiments, the plurality of tabs may be configured to expand radially outward when the washer is compressed against the radial wall. In embodiments, in an uncompressed state, the plurality of tabs may extend at an angle relative to the axis. In embodiments, at least some of the tabs include a plurality of teeth configured to deform the axial wall. In embodiments, each tab includes an end portion spaced apart from the base. In an uncompressed state, the plurality of tabs may be radially inward of the axial wall. In a compressed state, the end portion may be radially outward of the axial wall.

[0010] The embodiments disclosed herein provide the advantageous benefit of non-rotatably connecting the thrust washer to the stator body, which prevents relative rotation between the thrust washer and the stator body during operation of the torque converter, thereby reducing wear on the stator body. Additionally, the embodiments disclosed herein provide design advantages by non-rotatably connecting the thrust washer to the stator body without additional fasteners and / or costly drilling operations. [Brief explanation of the drawings]

[0011] [Figure 1] 1 illustrates a cross-sectional view of a torque converter having a stator assembly according to an embodiment of the present disclosure. [Figure 2A] 2 illustrates an enlarged view of the area of ​​the torque converter shown in FIG. 1 showing one embodiment of a thrust washer of the stator assembly in an uncompressed state. [Figure 2B] 2B illustrates the embodiment of the thrust washer shown in FIG. 2A in a compressed state. [Figure 2C] 2B illustrates an enlarged view of the area of ​​the torque converter shown in FIG. 2A. [Figure 3] 2B illustrates a perspective view of the thrust washer shown in FIG. 2A. [Figure 4] FIG. 1 illustrates a perspective view of another embodiment of a thrust washer of the present disclosure. [Figure 5] FIG. 1 illustrates a perspective view of another embodiment of a thrust washer of the present disclosure. [Figure 6] FIG. 1 illustrates a perspective view of another embodiment of a thrust washer of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0012] Embodiments of the present disclosure are described herein. It should be understood that like drawing numbers appearing in different drawings 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 alternative forms. The figures are not necessarily to scale, and some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein should not be construed as limiting, but merely as representative references to teach those skilled in the art various uses of the embodiments. As one skilled in the art will understand, various features illustrated and described with reference to any one of the drawings can be combined with features illustrated in one or more other drawings to create embodiments not explicitly illustrated or described. The illustrated combinations of features provide representative embodiments for typical applications. However, various combinations and modifications of features consistent with the teachings of the present disclosure may be desired for particular applications or implementations.

[0013] The terms used herein are for the purpose of describing particular embodiments only and are not intended to limit the scope of the present disclosure. Unless otherwise defined, 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 disclosure belongs. Although any methods, devices, or materials similar or equivalent to those described herein can be used in the practice or testing of the present disclosure, the following exemplary methods, devices, and materials are described herein.

[0014] 1-2C, a portion of a torque converter 100 according to one embodiment of the present disclosure is illustrated. At least some portions of the torque converter 100 are rotatable about a central axis A. While only a portion of the torque converter 100 above the central axis A is shown in FIG. 1, it should be understood that the torque converter 100 below the central axis A may appear substantially similar with many components extending about the central axis A. As used herein, terms such as "axial," "radial," "circumferential," and "outward" are intended to be relative to the central axis A.

[0015] The torque converter 100 includes a front cover 102 arranged to receive torque, an impeller assembly 104, a turbine assembly 106, and a stator assembly 108. The impeller assembly 104 includes an impeller shell 110 non-rotatably connected to the front cover 102, at least one impeller blade 112 attached to the inner surface of the impeller shell 110, and an impeller hub 114 fixed to the radially inner end of the impeller shell 110. The turbine assembly 106 includes a turbine shell 116 and at least one turbine blade 118 attached to the turbine shell 116. "Non-rotatably connected" components means that the components are connected such that all components rotate whenever one of the components rotates, and that relative rotation between the components is not possible. Radial and / or axial movement of non-rotatably connected components relative to each other is possible, but is not required.

[0016] In the exemplary embodiment, torque converter 100 includes a damper assembly 120. Damper assembly 120 is axially positioned between front cover 102 and turbine assembly 106 and is configured to transfer torque from front cover 102 to a transmission input shaft 122.

[0017] In the exemplary embodiment, torque converter 100 includes a lock-up clutch 124. Lock-up clutch 124 is configured to selectively transfer torque from front cover 102 to transmission input shaft 122.

[0018] Stator assembly 108 is axially disposed between turbine assembly 106 and impeller assembly 104 to redirect fluid flowing from turbine blades 118 before the fluid reaches impeller assembly 104 to increase the efficiency of torque converter 100. For example, impeller blades 112 push fluid outward as they rotate about central axis A. The fluid pushes against turbine assembly 106, causing turbine assembly 106 to rotate about central axis A. Stator assembly 108 functions to return fluid from turbine assembly 106 to impeller assembly 104 with minimal or no power loss.

[0019] The stator assembly 108 includes a stator body 126 and at least one stator blade 128 attached thereto. The stator body 126 includes an axial wall 130 radially spaced from a central axis A and a radial wall 132 extending radially inward from the axial wall 130. The axial wall 130 extends along the central axis A. The axial wall 130 and the radial wall 132 define a cavity 134.

[0020] Stator assembly 108 further includes a one-way clutch 136 engaged with stator body 126 and disposed within cavity 134. For example, one-way clutch 136 may include an outer race (not numbered) connected to axial wall 130, an inner race (not numbered) connected to an inner diameter of radial wall 132, and rollers (not numbered) disposed between the inner and outer races.

[0021] The stator assembly 108 further includes a side plate 138 in contact with the one-way clutch 136. The side plate 138 is provided axially between the stator assembly 108 and the turbine assembly 106 and is configured to retain the one-way clutch 136 within the cavity 134. An axial thrust bearing 140 may also be provided axially between the radially extending inner portion of the turbine shell 116 and the side plate 138 and / or axially between the stator body 126 and the impeller assembly 104.

[0022] The stator assembly 108 further includes an axial thrust washer 142 axially disposed between the one-way clutch 136 and the radial wall 132. The axial thrust washer 142 includes a base 144 and a plurality of tabs 146 extending from the base 144. The plurality of tabs 146 are disposed on the outer diameter of the base 144 and extend radially outward from the outer diameter of the base 144. The plurality of tabs 146 are circumferentially spaced apart from one another about the central axis A.

[0023] The plurality of tabs 146 includes a first end 148 pivotally connected to the base 144 and a second end 150 spaced apart from the first end 148. The plurality of tabs 146 may be integrally formed with the base 144. For example, the base 144 and the plurality of tabs 146 may be formed by stamping. The plurality of tabs 146 may be configured as bendable tabs. That is, after forming the plurality of tabs 146, the plurality of tabs 146 may be bent relative to the base 144, for example, via an overbending process.

[0024] The axial thrust washer 142 is configured to be compressed against the radial wall 132. For example, the axial thrust washer 142 may be compressible by the one-way clutch 136 between an uncompressed state, as shown in FIG. 2A , and a compressed state, as shown in FIG. 2B . In such an embodiment, during assembly of the stator assembly 108, the axial thrust washer 142 may be inserted into the cavity 134 before the one-way clutch 136. In this situation, the axial thrust washer 142 is in an uncompressed state. In the uncompressed state, the second ends 150 of the multiple tabs 146 are positioned radially inward of the axial wall 130. Positioning the second ends 150 radially inward of the axial wall 130 facilitates assembly of the axial thrust washer 142 into the cavity 134. That is, in the uncompressed state, the axial thrust washer 142 is movable relative to the stator body 126. The base 144 may be axially spaced from the radial wall 132 in an uncompressed state.

[0025] During assembly of the one-way clutch 136 into the cavity 134, the one-way clutch 136 engages with the axial thrust washer 142 and compresses the axial thrust washer 142 against the radial wall 132. During compression of the axial thrust washer 142, the tabs 146 bend about the first ends 148 toward the base 144 and engage with the axial wall 130. In this state, the tabs 146 expand radially outward, deforming the axial wall 130. In the compressed state, the second ends 150 of the tabs 146 are disposed radially outward from the axial wall 130, as shown in FIG. 2C . The plurality of tabs 146 may extend perpendicular to the central axis A in the compressed state. Deforming the axial wall 130 non-rotatably connects the axial thrust washer 142 to the stator body 126. For example, the tabs 146 may create grooves (not numbered) in the axial wall 130 that circumferentially restrain the tabs 146, e.g., by directing material from the axial wall 130 between the tabs 146, thereby preventing relative rotation between the axial thrust washer 142 and the stator body 126, thereby reducing wear on the stator body 126.

[0026] In the uncompressed state, the plurality of tabs 146 extend at an angle relative to the central axis A. That is, in the uncompressed state, the plurality of tabs 146 may be bent in a first axial direction AD1 and / or a second, opposite axial direction AD2 relative to the central axis A. As one example, each of the tabs 146 may be bent in the first axial direction AD1 as shown in FIGS. 3 and 4. As another example, each of the tabs 146 may be bent in the second axial direction AD2.

[0027] As yet another example, the plurality of tabs 146 may include a plurality of first tabs 146A and a plurality of second tabs 146B. As shown in FIG. 5 , the plurality of first tabs 146A may be bent in a first axial direction AD1, and the plurality of second tabs 146B may be bent in a second axial direction AD2. In such an example, the plurality of first tabs 146A and the plurality of second tabs 146B may be arranged in an alternating manner about the central axis A. That is, circumferentially adjacent tabs 146 may be bent in both axial directions AD1 and AD2. In the discussion above and below, capital letters are used to designate particular components from a group of components otherwise designated by three-digit numbers; for example, tab 146B is a particular example from among tabs 146.

[0028] The axial thrust washer 142 may include any suitable number of tabs 146. The tabs 146 may be uniformly spaced about the central axis A. The plurality of tabs 146 may have any suitable shape, such as, for example, trapezoidal (see FIGS. 3 and 6), rectangular (see FIGS. 4 and 5), triangular, etc.

[0029] At least some of the tabs 146 may include a plurality of teeth 152 disposed on a respective second end 150, as shown in FIG. 6 . The teeth 152 may be configured to engage with and specifically deform the axial wall 130 during compression of the axial thrust washer 142. For example, in a non-compressed state, the teeth 152 may be disposed radially inward of the axial wall 130, and in a compressed state, the teeth 152 may be disposed radially outward of the axial wall 130. During compression of the axial thrust washer 142, the teeth 152 may create grooves in the axial wall 130. In this situation, material from the axial wall 130 may be directed between the teeth 152, which may help circumferentially constrain the teeth 152 and thereby non-rotatably connect the axial thrust washer 142 to the axial wall 130.

[0030] Embodiments according to the present disclosure provide various advantages, including reducing wear on the stator assembly by non-rotatably connecting the thrust washer to the stator body without additional fasteners or costly drilling operations.

[0031] While exemplary embodiments have been described above, these embodiments are not intended to describe all possible forms encompassed by the claims. The terms used herein are terms of description rather than limitation, and it is understood that various changes can be made without departing from the spirit and scope of the present disclosure. As previously described, features of various embodiments can be combined to form further embodiments of the present disclosure that may not be explicitly described or illustrated. While various embodiments have been described as offering advantages or being preferred over other embodiments or prior art implementations with respect to one or more desired characteristics, those skilled in the art will recognize that one or more features or characteristics may be compromised to achieve desired overall system attributes depending on the specific application and implementation. These attributes may include, but are not limited to, cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, maintainability, weight, manufacturability, ease of assembly, etc. Thus, to the extent that any embodiment is described as less desirable than other embodiments or prior art implementations with respect to one or more characteristics, these embodiments are not outside the scope of the present disclosure and may be desirable for particular applications. [Explanation of symbols]

[0032] 100 torque converter 102 Front cover 104 Impeller 106 Turbine 108 Stator Assembly 110 Impeller shell 112 Impeller blade 114 Impeller hub 116 Turbine shell 118 Turbine Blade 120 Damper Assembly 122 Transmission input shaft 124 Lock-up clutch 126 Stator body 128 stator blades 130 Axial wall 132 Radial Wall 134 Cavity 136 One-way clutch 138 Side Plate 140 Axial thrust bearing 142 Axial thrust washer 144 base 146 tabs 148 End 150 End 152 teeth A center axis AD1 Axial direction AD2 axial direction

Claims

1. 1. A stator assembly for a torque converter, comprising: a body rotatable about an axis and having a cavity defined by an axial wall radially spaced from the axis and a radial wall extending radially inward from the axial wall; a washer disposed within the cavity and configured to be compressed against the radial wall, the washer comprising: With the base, a plurality of tabs circumferentially spaced from one another and extending radially outward from the base, the plurality of tabs configured to non-rotatably connect to the axial wall; Stator assembly.

2. The stator assembly of claim 1 , wherein in an uncompressed state, said plurality of tabs extend at an angle relative to said axis.

3. The stator assembly of claim 2 wherein, in a compressed state, said plurality of tabs extend perpendicular to said axis.

4. 3. The stator assembly of claim 2, wherein the plurality of tabs includes a plurality of first tabs that extend in a first axial direction away from the base in the uncompressed state, and a plurality of second tabs that extend in a second, opposite axial direction away from the base in the uncompressed state.

5. The stator assembly of claim 4 , wherein said plurality of first tabs and said plurality of second tabs are arranged in an alternating manner about said axis.

6. The stator assembly of claim 2 , wherein in said uncompressed state, said plurality of tabs are radially inward of said axial wall.

7. The stator assembly of claim 2 , wherein in a compressed state, said plurality of tabs engage said axial wall.

8. The stator assembly of claim 7 , wherein the plurality of tabs are configured to deform the axial wall from the uncompressed state to the compressed state during compression.

9. The stator assembly of claim 7 , wherein each of the tabs includes a plurality of teeth configured to deform the axial wall from the uncompressed state to the compressed state during compression.

10. The stator assembly of claim 1 , wherein in an uncompressed state, said plurality of tabs are radially inward of said axial wall.

11. The stator assembly of claim 10 , wherein each tab includes an end spaced from the base, and in a compressed state, the end is radially outward of the axial wall.

12. The stator assembly of claim 10 , wherein the plurality of tabs are configured to deform the axial wall from the uncompressed state to the compressed state during compression.

13. The stator assembly of claim 10 , wherein each of the tabs includes a plurality of teeth configured to deform the axial wall from the uncompressed state to the compressed state during compression.

14. The stator assembly of claim 1 , wherein at least some of the tabs include a plurality of teeth configured to deform the axial wall.

15. The stator assembly of claim 1 , wherein the plurality of tabs are configured to expand radially outward when the washer is compressed against the radial wall.

16. A torque converter, a front cover arranged to receive torque; an impeller having an impeller shell non-rotatably connected to the cover; a turbine in fluid communication with the impeller and including a turbine shell; a stator assembly disposed axially between the impeller shell and the turbine shell, the stator assembly comprising: a body rotatable about an axis and having a cavity defined by an axial wall radially spaced from the axis and a radial wall extending radially inward from the axial wall; a washer disposed within the cavity and configured to be compressed against the radial wall, the washer comprising: With the base, a plurality of tabs circumferentially spaced from one another and extending radially outward from the base, the plurality of tabs configured to non-rotatably connect to the axial wall; Torque converter.

17. 17. The torque converter of claim 16, wherein the plurality of tabs are configured to expand radially outward when the washer is compressed against the radial wall.

18. 17. The torque converter of claim 16, wherein in an uncompressed state, said plurality of tabs extend obliquely relative to said axis.

19. The torque converter of claim 16 , wherein at least some of the tabs include a plurality of teeth configured to deform the axial wall.

20. 17. The torque converter of claim 16, wherein each tab includes an end spaced from the base, and wherein in an uncompressed state the plurality of tabs are radially inward of the axial wall, and in a compressed state the ends are radially outward of the axial wall.

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