Torque converter with multiple flow paths

Abstract

The torque converter includes a front cover, an impeller assembly, a turbine assembly, a lock-up clutch, a backing plate, and a flow plate. The front cover is positioned to receive torque. The impeller assembly has an impeller shell non-rotatably connected to the front cover. The turbine assembly is in fluid communication with the impeller assembly and includes a turbine shell. The lock-up clutch includes a piston and a seal plate axially disposed between the piston and the turbine shell. The backing plate is non-rotatably connected to the seal plate and sealed to the piston. The flow plate is axially disposed between the backing plate and the front cover. The flow plate is non-rotatably connected to the backing plate and the front cover. A through bore extends axially through the backing plate and the flow plate. A first chamber is at least partially bounded by the piston, the seal plate, and the backing plate, and a second chamber is at least partially bounded by the front cover, the piston, the backing plate, and the flow plate.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Non-provisional Application No. 17 / 954,418, filed September 28, 2022, the entire disclosure of which is incorporated herein by reference.

[0002] Technical Field The present disclosure relates generally to torque converters, and more particularly to torque converters having multiple flow passages for supplying fluid to a pressure chamber. [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 assembly fixed to the engine crankshaft and a turbine assembly fixed to a turbine shaft, which is the input to the transmission. To improve fuel economy, most torque converters include a bypass or lock-up clutch that mechanically couples the turbine shaft to the torque converter case, bypassing the fluid coupling. Torque converters may have multiple fluid paths for clutch apply and release. It is known to use cross-flow hubs to provide fluid paths for pressure chambers for clutch apply and release. However, these cross-flow hubs can be expensive and add complexity to the torque converter design. Therefore, it is desirable to provide an alternative method for providing fluid paths to the pressurized chambers of a torque converter. Summary of the Invention [Means for solving the problem]

[0004] An embodiment of the present disclosure provides a torque converter including a front cover, an impeller assembly, a turbine assembly, a lock-up clutch, a backing plate, and a flow plate. The front cover is positioned to receive torque. The impeller assembly has an impeller shell non-rotatably connected to the front cover. The turbine assembly is in fluid communication with the impeller assembly and includes a turbine shell. The lock-up clutch includes a piston and a seal plate axially disposed between the piston and the turbine shell. The backing plate is non-rotatably connected to the seal plate and sealed to the piston. The flow plate is axially disposed between the backing plate and the front cover. The flow plate is non-rotatably connected to the backing plate and the front cover. A through bore extends axially through the backing plate and the flow plate. A first chamber is at least partially bounded by the piston, the seal plate, and the backing plate, and a second chamber is at least partially bounded by the front cover, the piston, the backing plate, and the flow plate.

[0005] In embodiments, at least one of the flow plate or the backing plate may be arranged to non-rotatably connect to the transmission input shaft. In embodiments, the seal plate may be non-rotatably connected to the backing plate at an inner diameter of the seal plate, and the seal plate may seal to the piston at an outer diameter of the seal plate. In embodiments, the front cover may include an axial portion and a radial portion extending radially inward from the axial portion. The flow plate may be non-rotatably connected to the front cover radially inward of the radial portion. In embodiments, the flow plate may be non-rotatably connected to the radial portion of the front cover. In embodiments, the outer diameter of the seal plate may be radially offset relative to the outer diameter of the flow plate.

[0006] In embodiments, the torque converter may include a first flow path configured to supply fluid to a first chamber. The first flow path may pass through the through bore and may include a portion bounded in part by the front cover and a flow plate. A second flow path may be configured to provide fluid to a second chamber. The second flow path may include a portion bounded in part by the flow plate and a backing plate. The first flow path may be sealed from the second flow path. In a lock-up mode, a piston is non-rotatably connected to the front cover, and pressurized fluid may be arranged to flow through the first flow path, through the through bore, and into the first chamber to axially displace the piston toward the front cover. In a torque converter mode, pressurized fluid is arranged to flow through the second flow path and into the second chamber to axially displace the piston away from the front cover, disconnecting the piston from the front cover.

[0007] In embodiments, the flow plate may be non-rotatably connected to the front cover at an outer diameter of the flow plate. In embodiments, the flow plate may be non-rotatably connected to the front cover radially outward of the through bore. In embodiments, a rivet may connect the backing plate to the flow plate, and the through bore may be defined within the rivet.

[0008] In an embodiment, the lock-up clutch may include a clutch plate and a friction facing axially disposed between the front cover and the piston. The third chamber may be at least partially bounded by the front cover and the turbine shell. The torque converter may include a flow passage configured to provide circulating fluid to the friction facing. The turbine shell may include an opening extending axially therethrough. The flow passage may pass through the opening and enter the third chamber, and may include a portion bounded in part by the turbine shell and the seal plate. The piston may include an opening radially outward of the opening in the turbine shell. The flow passage may flow through the opening in the piston and may be routed through the friction facing. The turbine shell may be axially spaced from the impeller shell. The flow passage may pass between the turbine shell and the impeller shell to return circulating fluid to the transmission input shaft. The flow passage may be sealed from the first chamber and the second chamber.

[0009] In embodiments, the first chamber may be sealed from the second chamber.

[0010] The embodiments disclosed herein provide advantageous advantages of reducing the cost and complexity of multi-pass torque converters, for example, by eliminating flow plates typically used to direct flow to the appropriate apply and compensation chambers. Additionally, the embodiments disclosed herein provide design advantages by creating a cross-flow configuration without forging or costly cross-drilling operations. [Brief explanation of the drawings]

[0011] [Figure 1] 1 illustrates a cross-sectional view of a torque converter configured for cross-flow to a pressure chamber in accordance with an embodiment of the present disclosure. [Figure 2] 2 illustrates a cross-sectional view of the torque converter shown in FIG. 1 showing cross-flow into the pressure chambers. [Figure 3]10 illustrates a cross-sectional view of a torque converter configured for cross-flow to a pressure chamber according to another embodiment of the present disclosure. [Figure 4] 4 illustrates a cross-sectional view of the torque converter shown in FIG. 3 showing cross-flow to the pressure chambers. 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] 1-4, 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 appears substantially similar due to the 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, a lock-up clutch 108, and a damper assembly 110. The impeller assembly 104 includes an impeller shell 112 non-rotatably connected to the front cover 102 such that the impeller assembly 104 rotates with the rotation of the front cover 102, at least one impeller blade 114 attached to the inner surface of the impeller shell 112, and an impeller hub 116 attached to the radially inner end of the impeller shell 112. The turbine assembly 106 includes a turbine shell 118 and at least one turbine blade 120 attached to the turbine shell 118. "Non-rotatably coupled" components means that the components are coupled 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 coupled components relative to each other is possible, but is not required.

[0016] The front cover 102 includes an axial portion 122 extending radially away from the central axis A. The front cover 102 includes a transition portion 124 disposed radially inward from the axial portion 122. The transition portion 124 may extend obliquely relative to the central axis A. The front cover 102 includes a radial portion 126 extending radially inward from the axial portion 122 toward the transition portion 124. The radial portion 126 extends transversely relative to the axial portion 122 and the transition portion 124. The front cover 102 further includes an inner radial portion 128 extending radially inward from the transition portion 124 and an outer radial portion 130 extending radially outward from the axial portion 122.

[0017] The turbine shell 118 is axially spaced from the impeller shell 112. The turbine shell 118 includes an opening 132 extending axially through a radially extending inner portion 134 thereof. That is, the opening 132 is disposed radially inward of the turbine blades 120. The radially extending inner portion 134 may be disposed to non-rotatably connect to a transmission input shaft 136. As one example, the radially extending inner portion 134 may be fixed to a hub 137 via, for example, a rivet connection and non-rotatably connected to the transmission input shaft 136 via, for example, a spline connection. As another example, the radially extending inner portion 134 may be sealed to the transmission input shaft 136 at its inner diameter.

[0018] Torque converter 100 may include a stator 138 that is axially disposed between impeller assembly 104 and turbine assembly 106 and redirects fluid flowing from turbine blades 120 before the fluid reaches impeller assembly 104 to increase the efficiency of torque converter 100. For example, as impeller blades 114 rotate about central axis A, they push fluid outward. The fluid is forced against turbine assembly 106 of torque converter 100, causing turbine assembly 106 to rotate about central axis A. Stator 138 functions to return fluid from turbine assembly 106 to impeller assembly 104 with minimal or no power loss. Drive is transmitted from turbine assembly 106 to transmission input shaft 136. The torque converter 100 may further include, for example, a one-way clutch 140 disposed within the stator 138, a thrust bearing 142 axially disposed between the stator 138 and the radially extending inner portion 134 of the turbine shell 118, a side plate 144 configured to hold the one-way clutch 140 within the stator 138, and a thrust bearing 146 provided axially between the impeller hub 116 and the side plate 144.

[0019] The damper assembly 110 is axially positioned between the front cover 102 and the impeller shell 112 and is configured to transfer torque from the front cover 102 to the transmission input shaft 136. The damper assembly 110 includes a spring 148 and a spring retainer 150. The spring 148 may be drivingly engaged with the lock-up clutch 108. The spring retainer 150 supports the spring 148 and is secured to the turbine shell 118.

[0020] Power from a vehicle engine may be fluidly transferred through torque converter 100 to a transmission (not shown). In particular, the power may be transferred to a front cover 102. Lock-up clutch 108 is configured to selectively transfer torque from front cover 102 to a transmission input shaft 136. Lock-up clutch 108 includes a piston 152, a clutch plate 154, a seal plate 156, and a backing plate 158.

[0021] A clutch plate 154 is disposed between the front cover 102, e.g., the outer radial portion 130, and the piston 152. The clutch plate 154 may be configured to engage the spring 148. That is, the clutch plate 154 may transmit torque from the front cover 102 to the damper assembly 110. A friction material or facing 160 may be disposed between and affixed to one of the front cover 102 or the clutch plates 154, and a friction material or facing 162 may be disposed on and affixed to one of the clutch plates 154 or the piston 152. The friction materials 160, 162 may include grooves or slots for passing cooling flow.

[0022] The backing plate 158 is positioned to non-rotatably connect to the transmission input shaft 136. As one example, the backing plate 158 may be sealed, for example, at its inner diameter to the hub 137, which is non-rotatably connected to the transmission input shaft 136 via, for example, a splined connection, as shown in FIG. 1. As another example, as shown in FIG. 3, the backing plate 158 may be sealed to the transmission input shaft 136 at its inner diameter. The backing plate 158 is sealed to the piston 152 via a seal 164. The backing plate 158 may be sealed to the piston 152 at its outer diameter.

[0023] The piston 152 may be sealed at its inner diameter to the backing plate 158 via a seal 164. Additionally, the piston 152 is sealed to the axial portion 122 of the front cover 102 via a seal 166. The piston 152 may be further connected to the seal plate 156 via a leaf spring connection, allowing axial displacement of the piston 152 in the first axial direction AD1 and the second axial direction AD2 for selective engagement of the lock-up clutch 108. The piston 152 may further include an opening 170 extending axially therethrough. The opening 170 may be located radially outward of the seal 166. The opening 170 may be located radially inward of the friction materials 160, 162.

[0024] The seal plate 156 is sealed at its outer diameter to the piston 152 via a seal 168. The seal plate 156 may be secured at its inner diameter to the backing plate 158, for example, via stacking. The seal plate 156 may be sealed to the backing plate 158 at the stacking, for example.

[0025] Flow plate 172 is axially disposed between backing plate 158 and front cover 102. Flow plate 172 is positioned to non-rotatably connect to transmission input shaft 136. As one example, flow plate 172 may be sealed, for example, at its inner diameter, to hub 137, which is non-rotatably connected to transmission input shaft 136 via, for example, a splined connection, as shown in FIG. 1. As another example, flow plate 172 may be sealed, for example, at its inner diameter, to transmission input shaft 136, as shown in FIG. 3.

[0026] Flow plate 172 is secured at its outer diameter to front cover 102, for example, via welding. Flow plate 172 may be secured to inner radial portion 128 of front cover 102, for example, as shown in FIG. 1 . As another example, flow plate 172 may be secured to radial portion 126 of front cover 102, as shown in FIG. 3 . The outer diameter of flow plate 172 may be radially offset relative to the outer diameter of backing plate 158. That is, one of flow plate 172 or backing plate 158 may extend radially outward of the other of flow plate 172 or backing plate 158.

[0027] Flow plate 172 includes a through bore 174 bounded by flow plate 172 in opposite radial directions RD1 and RD2 perpendicular to central axis A. Through bore 174 is further defined by and is also bounded in opposite radial directions RD1 and RD2 by backing plate 158. In the exemplary embodiment, torque converter 100 includes a rivet 176 connecting flow plate 172 and backing plate 158, with through bore 174 passing through or defined within rivet 176.

[0028] Torque converter 100 includes apply chamber 178, compensation chamber 180, and circulation chamber 182. Apply chamber 178 is bounded at least in part by seal plate 156, backing plate 158, seal 164, piston 152, and seal 168. Compensation chamber 180 is bounded at least in part by front cover 102, flow plate 172, backing plate 158, seal 164, piston 152, and seal 166. Seals 164, 166, and 168 maintain fluid separation between apply chamber 178 and compensation chamber 180. Circulation chamber 182 is bounded at least in part by seal plate 156 and impeller shell 112. "Partially bounded" means that a portion of the referenced chamber, flow passage, or other structure is bounded or formed by the referenced element.

[0029] 2 and 4 , torque converter 100 includes a flow passage 184 and a flow passage 186. Flow passage 186 is sealed from flow passage 184 and includes, or passes through, through bore 174. That is, flow passage 186 includes through bore 174. Flow passage 184 does not pass through through bore 174. Flow passage 186 may be further bounded, at least in part, by front cover 102 and flow plate 172. Flow passage 186 passes through through bore 174 and enters apply chamber 178. That is, pressurized fluid may be supplied from transmission input shaft 136 to flow passage 186, which extends to apply chamber 178. Piston 152 engages or closes lock-up clutch 108 in response to pressurization of a medium (e.g., a fluid such as oil) in apply chamber 178, for example, by axially displacing piston 152 toward front cover 102.

[0030] Flow passage 184 is bounded, at least in part, by flow plate 172 and backing plate 158. That is, flow passage 184 passes or flows between flow plate 172 and backing plate 158. Flow plate 172 and / or backing plate 158 may include grooves (not numbered) for flow therebetween. That is, fluid may pass from transmission input shaft 136 into flow passage 184 extending between flow plate 172 and backing plate 158 and be provided to compensation chamber 180.

[0031] In a lock-up mode of torque converter 100, where piston 152 is non-rotatably connected to front cover 102 and torque is transmitted to transmission input shaft 136 through lock-up clutch 108, pressurized fluid is arranged to pass through passage 186, through through bore 174, and into apply chamber 178 to displace piston 152 in an axial direction AD1, bypassing the hydrodynamic fluid coupling and connecting piston 152 with front cover 102. In a torque converter mode of torque converter 100, where front cover 102 is rotatable relative to piston 152 and torque bypasses lock-up clutch 108, pressurized fluid is arranged to pass through passage 184, including between flow plate 172 and backing plate 158, and into compensation chamber 180 to displace piston 152 in an axial direction AD2 opposite direction AD1 and disconnect piston 152 from front cover 102.

[0032] With continued reference to FIGS. 2 and 4 , the torque converter 100 may include a flow path 188. Pressurized fluid is provided to the circulation chamber 182 via the flow path 188. The flow path 188 extends from the transmission input shaft 136 between the stator 138 and the radially extending inner portion 134 of the turbine shell 118, through an opening 132 in the turbine shell 118, and into the circulation chamber 182. The flow path 188 is further bounded by the piston 152 and the front cover 102. That is, the fluid flows through an opening 170 in the piston 152 and is then routed through the friction facings 160, 162, for example, to cool the friction facings 160, 162. The fluid passes between the turbine shell 118 and the impeller shell 112, and is then routed between the impeller shell 112 and the side plate 144, before being returned to the transmission input shaft 136. The flow passage 188 is sealed from the apply chamber 178 and the compensation chamber 180 .

[0033] Embodiments according to the present disclosure provide various advantages, including cost savings by creating a cross-flow configuration without forging or expensive cross-drilling operations.

[0034] 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 embodiments are 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]

[0035] 100 torque converter 102 Front cover 104 Impeller Assembly 106 Turbine Assembly 108 Lock-up clutch 110 Damper Assembly 112 Impeller shell 114 Impeller Blade 116 Impeller hub 118 Turbine shell 120 Turbine Blade 122 Axial section 124 Transition part 126 Radial section 128 Inner radial section 130 Outer radial section 132 Opening 134 Radial Extending Inner Part 136 Transmission input shaft 137 Hub 138 Stator 140 One-way clutch 142 Thrust bearing 144 Side Plate 146 Thrust bearing 148 Spring 150 spring retainer 152 Piston 154 Clutch plate 156 Seal plate 158 Backing Plate 160 Friction Facing 162 Friction Facing 164 Seal part 166 Seal part 168 Seal part 170 Opening 172 Flow Plate 174 through bore 176 Rivets 178 Apply Chamber 180 Compensation Chamber 182 Circulation Chamber 184 flow path 186 Channel 188 Channel A center axis AD1 Axial direction AD2 axial direction RD1 Radial direction RD2 Radial direction

Claims

1. A torque converter, a front cover arranged to receive torque; an impeller assembly having an impeller shell non-rotatably connected to the front cover; a turbine assembly in fluid communication with the impeller assembly and including a turbine shell; a lock-up clutch including a piston and a seal plate axially disposed between the piston and the turbine shell; a backing plate non-rotatably connected to the seal plate and sealed to the piston; a flow plate axially disposed between the backing plate and the front cover, the flow plate being non-rotatably connected to the backing plate and the front cover; a through bore extending axially through the backing plate and the flow plate, wherein a first chamber is bounded at least in part by the piston, the seal plate, and the backing plate, and a second chamber is bounded at least in part by the front cover, the piston, the backing plate, and the flow plate; and A torque converter comprising:

2. The torque converter of claim 1 , wherein at least one of the flow plate or the backing plate is positioned to non-rotatably connect to a transmission input shaft.

3. 2. The torque converter of claim 1, wherein the seal plate is non-rotatably connected to the backing plate at an inner diameter of the seal plate, and the seal plate is sealed to the piston at an outer diameter of the seal plate.

4. 2. The torque converter of claim 1, wherein the front cover includes an axial portion and a radial portion extending radially inward from the axial portion, and the flow plate is non-rotatably connected to the front cover radially inward of the radial portion.

5. 2. The torque converter of claim 1, wherein the front cover includes an axial portion and a radial portion extending radially inward from the axial portion, and the flow plate is non-rotatably connected to the radial portion of the front cover.

6. The torque converter of claim 1 , wherein an outer diameter of said seal plate is radially offset relative to an outer diameter of said flow plate.

7. a first flow path configured to provide fluid to the first chamber, the first flow path passing through the through bore and including a portion bounded in part by the front cover and the flow plate; a second flow path configured to provide a fluid to the second chamber, the second flow path including a portion bounded in part by the flow plate and the backing plate; The torque converter of claim 1 further comprising:

8. 8. The torque converter of claim 7, wherein said first flow path is sealed from said second flow path.

9. 8. The torque converter of claim 7, wherein in a lock-up mode, the piston is non-rotatably connected to the front cover and pressurized fluid is arranged to flow through the first flow passage, through the through bore, and into the first chamber to axially displace the piston toward the front cover.

10. 8. The torque converter of claim 7, wherein, in a torque converter mode, pressurized fluid flows through said second flow path into said second chamber to axially displace said piston away from said front cover, disconnecting said piston from said front cover.

11. The torque converter of claim 1 , wherein the flow plate is non-rotatably connected to the front cover at an outer diameter of the flow plate.

12. The torque converter of claim 1 , wherein the flow plate is non-rotatably connected to the front cover radially outward of the through bore.

13. The torque converter of claim 1 , wherein a rivet connects the backing plate to the flow plate, the through bore being defined within the rivet.

14. The lock-up clutch is Clutch plate and a friction facing axially disposed between the front cover and the piston, wherein a third chamber is at least partially bounded by the front cover and the turbine shell; and 10. The torque converter of claim 1, comprising:

15. The torque converter of claim 14 further comprising a flow passage configured to provide a circulating fluid to the friction facings.

16. 16. The torque converter of claim 15, wherein the turbine shell includes an opening extending axially therethrough, the flow passage passing through the opening into the third chamber and including a portion bounded in part by the turbine shell and the seal plate.

17. 17. The torque converter of claim 16, wherein the piston includes an opening radially outward of the opening in the turbine shell, and the flow passage is routed through the opening in the piston and through the friction facing.

18. 16. The torque converter of claim 15, wherein the turbine shell is axially spaced from the impeller shell, and the flow passage passes between the turbine shell and the impeller shell to return circulating flow to a transmission input shaft.

19. 16. The torque converter of claim 15, wherein said flow passage is sealed from said first chamber and said second chamber.

20. 2. The torque converter of claim 1, wherein said first chamber is sealed from said second chamber.

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