Torque Converter Damper Assembly

Abstract

The damper assembly for torque conversion includes a first cover plate, a second cover plate, a first spring, a second spring, an intermediate flange, and a hub flange. The first cover plate is arranged to receive torque. The second cover plate is non-rotatably connected to the first cover plate. The first cover plate and the second cover plate define a spring window. The first spring and the second spring are each disposed within the spring window and are circumferentially spaced apart from each other. The hub flange is axially disposed between the first cover plate and the second cover plate. The hub flange is directly engaged with the first and second springs and includes a first travel stopper. The intermediate flange is axially disposed between the hub flange and the first cover plate. The intermediate flange is directly engaged with the first and second springs and includes a second travel stopper having a tab extending axially toward the first cover plate. The tab is engageable with the first travel stop.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Application No. 17 / 983,726, filed November 9, 2022, the entire disclosure of which is incorporated herein by reference.

[0002] Technical Field The present disclosure relates generally to a damper assembly for a torque converter, and more particularly to a damper assembly including an interlocking travel stop and a torque converter including the damper 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 crankshaft and a turbine fixed to a turbine shaft, which is the input to the transmission. To improve fuel economy, most torque converters include a bypass clutch or lock-up clutch that mechanically couples the turbine shaft to the torque converter cover, bypassing the fluid coupling. In some torque converter configurations, the torque converter may include a damper assembly having a spring arranged in series and configured to transmit torque in drive mode and coast mode. In such configurations, the damper assembly's capacity in coast mode may be limited due to the geometry of the components required to meet the capacity in drive mode and / or limited space within the torque converter envelope. It is desirable to have alternative designs and configurations for fitting all necessary components within a torque converter while still meeting durability and performance requirements. Summary of the Invention [Means for solving the problem]

[0004] An embodiment of the present disclosure provides a damper assembly for a torque converter, the damper assembly including a first cover plate, a second cover plate, a first spring, a second spring, an intermediate flange, and a hub flange. The first cover plate is arranged to receive torque. The second cover plate is non-rotatably connected to the first cover plate. The first cover plate and the second cover plate define a spring window. The first spring and the second spring are each disposed within the spring window and are circumferentially spaced apart from each other. The hub flange is axially disposed between the first cover plate and the second cover plate. The hub flange is directly engaged with the first and second springs and includes a first travel stop. The intermediate flange is axially disposed between the hub flange and the first cover plate. The intermediate flange is directly engaged with the first and second springs and includes a second travel stop having a tab extending axially toward the first cover plate. The tab is engageable with the first travel stop.

[0005] In embodiments, the intermediate flange may be configured to rotate relative to the hub flange to transmit drive torque, and in embodiments, the tabs may be configured to prevent relative rotation between the intermediate flange and the hub flange to transmit coasting torque.

[0006] In embodiments, the second travel stopper may include an extension that is axially offset relative to the first travel stopper. The tab may be circumferentially spaced from the extension. In embodiments, the tab may axially overlap the first travel stopper. In embodiments, the tab may be configured to engage one circumferential side of the first travel stopper. In embodiments, the second travel stopper may be configured to prevent relative rotation between the intermediate flange and the first and second cover plates. In embodiments, the first travel stopper may be configured to prevent relative rotation between the hub flange and the first and second cover plates.

[0007] In embodiments, the damper assembly may include a fastener non-rotatably connecting the first cover plate and the second cover plate. The tab may be configured to contact the fastener to transmit coasting torque. In embodiments, the tab may be circumferentially disposed between the fastener and the first travel stop.

[0008] An embodiment of the present disclosure further provides a torque converter including a front cover, an impeller, a turbine, and a damper 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 damper assembly is axially disposed between the front cover and the turbine shell. The damper assembly includes a first cover plate, a second cover plate, a first spring, a second spring, an intermediate flange, and a hub flange. The first cover plate is arranged to receive torque from the front cover. The second cover plate is non-rotatably connected to the first cover plate. The first cover plate and the second cover plate define spring windows. The first spring and the second spring are each disposed within the spring window and are circumferentially spaced apart from each other. The hub flange is axially disposed between the first cover plate and the second cover plate. The hub flange is directly engaged with the first and second springs and includes a first travel stop. The intermediate flange is axially disposed between the hub flange and the first cover plate. The intermediate flange is directly engaged with the first and second springs and includes a second travel stop having a tab extending axially toward the first cover plate. The tab is engageable with the first travel stop.

[0009] In embodiments, the first and second travel stops may be configured to allow the intermediate flange to rotate relative to the hub flange to transmit drive torque. In embodiments, the tab and the first travel stop may be configured to non-rotatably connect the intermediate flange to the hub flange to transmit coasting torque. In embodiments, the tab may axially overlap the first travel stop. In embodiments, the damper assembly may include a fastener that non-rotatably connects the first and second cover plates. The tab may be configured to contact the fastener to transmit coasting torque. In embodiments, the tab may be circumferentially disposed between the fastener and the first travel stop.

[0010] An embodiment of the present disclosure further provides a method for operating a damper assembly. The damper assembly includes a first cover plate, a second cover plate non-rotatably connected to the first cover plate, first and second springs each disposed within a spring window defined by the first and second cover plates, a hub flange axially disposed between the first and second cover plates and directly engaged with the first and second springs, an intermediate flange axially disposed between the hub flange and the first cover plate and directly engaged with the first and second springs, a first travel stop on the hub, and a second travel stop on the intermediate flange having a tab extending axially toward the first cover plate and engageable with the first travel stop. The method includes applying a coast torque to the first cover plate. The method further includes compressing the first spring against the intermediate flange via the first cover plate. The method further includes rotating the intermediate flange via transmission of coast torque through the first spring. The method further includes rotating the hub flange relative to the first and second cover plates via an interface between the tab and the first travel stop.

[0011] In an embodiment, the intermediate flange may rotate with the hub flange.

[0012] In embodiments, the method may further include providing a driving torque to the first cover plate. The method may further include compressing a second spring against the intermediate flange via the first cover plate. The method may further include rotating the intermediate flange relative to the first and second cover plates via transmission of the driving torque through the second spring. The method may further include compressing the first spring against the hub flange via the intermediate flange. The method may further include rotating the hub flange relative to the first and second cover plates via transmission of the driving torque through the first spring.

[0013] In embodiments, the intermediate flange may rotate relative to the hub flange. In embodiments, the method may further include contacting the tab with a fastener positioned to non-rotatably connect the first and second cover plates. The method may further include preventing further rotation of the intermediate flange relative to the first and second cover plates with the tab.

[0014] Embodiments of the present disclosure provide advantageous benefits such as increased coast torque transmission capacity for a damper assembly having a spring in series with an additional spring having a higher spring rate than the spring, for example, by means of an interlocking travel stop on the mid-flange and a hub flange to limit or prevent compression of the spring to transmit coast torque. Additionally, embodiments disclosed herein provide design advantages that can reduce the cost and complexity of the damper assembly by selectively compressing the spring and the additional spring for drive mode or coast mode, while meeting durability, performance, and packaging requirements for torque converters with limited space. [Brief explanation of the drawings]

[0015] [Figure 1] 1 illustrates a cross-sectional view of a torque converter according to the present disclosure. [Figure 2A] 1 illustrates a perspective view of a damper assembly according to the present disclosure. [Figure 2B] 2B illustrates a perspective view of the damper assembly shown in FIG. 2A with the cover plate omitted. [Figure 3A] 1 illustrates a side view of a region of a damper assembly when the damper assembly is not subjected to torque. [Figure 3B] 1 illustrates a side view of an area of ​​a damper assembly when the damper assembly is subjected to a driving torque. [Figure 3C] 1 illustrates a side view of an area of ​​a damper assembly when the damper assembly is subjected to a driving torque. [Figure 3D] 1 illustrates a side view of an area of ​​a damper assembly when the damper assembly is subjected to a coasting torque. [Figure 3E] 1 illustrates a side view of an area of ​​a damper assembly when the damper assembly is subjected to a coasting torque. DETAILED DESCRIPTION OF THE INVENTION

[0016] 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.

[0017] 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.

[0018] Referring to FIG. 1 , 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.

[0019] The torque converter 100 includes a front cover 102 arranged to receive torque, an impeller assembly 104, a turbine assembly 106, a damper assembly 110, and a lock-up clutch assembly 112. The impeller assembly 104 includes an impeller shell 114 non-rotatably connected to the front cover 102, at least one impeller blade 116 attached to the inner surface of the impeller shell 114, and an impeller hub 118 fixed to the radially inner end of the impeller shell 114. The turbine assembly 106 includes a turbine shell 120 and at least one turbine blade 122 attached to the turbine shell 120. "Non-rotatably connected" components mean 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 the non-rotatably connected components relative to each other is possible, but is not required.

[0020] Torque converter 100 may include a stator 124 axially disposed between impeller assembly 104 and turbine assembly 106 to redirect fluid flowing from turbine blades 122 before the fluid reaches impeller assembly 104, increasing the efficiency of torque converter 100. For example, impeller blades 116 push fluid outward as they rotate about central axis A. The fluid is forced against turbine assembly 106 of torque converter 100, causing turbine assembly 106 to rotate about central axis A. Stator 124 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 a transmission input shaft 126. Torque converter 100 may further include, for example, a one-way clutch 128 disposed within stator 124, a thrust bearing 130 axially disposed between stator 124 and impeller shell 114, and a side plate 132 configured to retain one-way clutch 128 within stator 124.

[0021] Lock-up clutch assembly 112 is configured to selectively transfer torque from front cover 102 to transmission input shaft 126. Lock-up clutch assembly 112 includes a piston 134, a clutch plate 140, and a reaction plate 138. Reaction plate 138 may be secured to front cover 102 via, for example, a weld.

[0022] Clutch plate 140 is disposed between reaction plate 138 and piston 134 and is connected to damper assembly 110 via, for example, a tab connection. Lock-up clutch assembly 112 may include one or more clutch plates 140. In the embodiment shown in FIG. 1 , lock-up clutch assembly 112 includes clutch plate 140A, clutch plate 140B, and clutch plate 140C, where clutch plates 140A and 140C are connected to damper assembly 110 via, for example, tab connections, and clutch plate 140B is connected to reaction plate 138 via, for example, a tab connection. In the discussion above and below, capital letters are used to represent specific components from a group of components, and are otherwise indicated by a three-digit number, for example, clutch plate 140A is one specific example from among clutch plates 140.

[0023] The piston 134 is axially slidable to press the clutch plates 140 against the reaction plates 138. The piston 134 may be axially disposed between the front cover 102 and the clutch plates 140 and may be configured to be sealed at its outer end to the front cover 102 via a seal 146 and at its inner end to the hub 148 via a seal 150. The piston 134 may further be connected to the front cover 102 via a leaf spring connection that allows axial displacement of the piston 134 in a first axial direction AD1 and a second axial direction AD2 for selective engagement of the lock-up clutch assembly 112.

[0024] Piston 134 slides along hub 148 during axial movement of piston 134. Piston 134 closes lock-up clutch assembly 112 in response to pressurization of a medium (e.g., a fluid such as oil) in a piston apply chamber 152 defined between front cover 102 and piston 134. Seals 146, 150 maintain fluid separation between piston apply chamber 152 and the remainder of torque converter 100. Piston apply chamber 152 is further defined by or bounded by front cover 102, hub 148, seal 146, piston 134, and seal 150. "Partially bounded" means that a portion of the referenced chamber, flow passage, or other structure is bounded or formed by the referenced element.

[0025] The damper assembly 110 is axially positioned between the front cover 102 and the turbine assembly 106 and is configured to transfer torque from the front cover 102 to the transmission input shaft 126. The damper assembly 110 includes a first spring 154, a second spring 156, cover plates 158, 160, an intermediate flange 162, and a hub flange 164. The first spring 154 has a different spring constant than the second spring 156. For example, the spring constant of the first spring 154 may be greater than the spring constant of the second spring 156.

[0026] The cover plate 158 may support the inner spring 156 on one axial side. The cover plate 160 may support the springs 154, 156 on another, opposite axial side. The cover plates 158, 160 may be connected to one another, for example, via a plurality of rivets 166 extending radially outward of the springs 154, 156. The cover plate 158 may be connected to the clutch plates 140A, 140C, for example, via a tab connection, and the cover plate 160 may be connected to the turbine shell 120, for example, via a rivet connection. That is, the cover plates 158, 160 are positioned to act as inputs to the damper assembly 110.

[0027] 2A , the cover plates 158, 160 may define a spring window 168 that extends partially circumferentially about the central axis A. The spring window 168 may be configured to receive the first spring 154 and the second spring 156. The first spring 154 and the second spring 156 may be circumferentially spaced apart from one another within the spring window 168.

[0028] Intermediate flange 162 is axially disposed between cover plates 158, 160, specifically between hub flange 164 and cover plate 158. Hub flange 164 is axially disposed between intermediate flange 162 and cover plate 160. Hub flange 164 is connected to transmission input shaft 126 to transmit torque therebetween.

[0029] 2B , as discussed further below, hub flange 164 and intermediate flange 162 are engaged with first spring 154 and second spring 156, respectively, to transmit torque through damper assembly 110. Intermediate flange 162 and hub flange 164 may each define a plurality of slots (not numbered) circumferentially spaced from one another. The slots in intermediate flange 162 may be circumferentially offset relative to the slots in hub flange 164 such that one slot in intermediate flange 162 defines a first opening (not numbered) with one slot in hub flange 164 and a second opening (not numbered) with another slot in hub flange 164. The first opening may be configured to receive first spring 154, and the second opening may be configured to receive second spring 156. The intermediate flange 162 and the hub flange 164 may be configured to rotate relative to one another such that the first spring 154 and / or the second spring 156 are compressed within their respective openings to transmit torque through the damper assembly 110.

[0030] The hub flange 164 includes a first travel stop 170 disposed on the outer diameter of the hub flange 164. The first travel stop 170 extends radially outward from and circumferentially along the outer diameter of the hub flange 164. The first travel stop 170 is configured to engage the rivet 166A. The first travel stop 170 may be positioned such that the first travel stop 170 contacts the rivet 166A when the first spring 154 is compressed to its full length (as shown in FIG. 3C ). Upon engaging the rivet 166A, the first travel stop 170 prevents rotation of the hub flange 164 relative to the cover plates 158, 160. That is, the interface between the first travel stop 170 and the rivet 166A non-rotatably connects the hub flange 164 to the cover plates 158, 160.

[0031] The intermediate flange 162 includes a second travel stop 172 disposed on the outer diameter of the intermediate flange 162. The second travel stop 172 includes an extension 174 and a tab 176. The extension 174 extends radially outward from the outer diameter of the intermediate flange 162 and circumferentially along the outer diameter of the intermediate flange 162. The extension 174 is circumferentially disposed between the tab 176 and the rivet 166A and is configured to engage the rivet 166A. The extension 174 may be positioned such that it contacts the rivet 166A when the second spring 156 is compressed to its full length (as shown in FIG. 3C ). Once the extension 174 engages the rivet 166A, it prevents rotation of the intermediate flange 162 relative to the cover plates 158, 160. That is, the interface between extension 174 and rivet 166A non-rotatably connects intermediate flange 162 to cover plates 158,160.

[0032] The extension 174 may be configured to engage the rivet 166A before the first travel stop 170 engages the rivet 166A. For example, at least a portion of the extension 174 may be axially offset relative to the first travel stop 170, i.e., may be circumferentially disposed between the rivet 166A and the first travel stop 170. That is, a line extending parallel to the central axis A and passing through the extension 174 may not pass through the first travel stop 170.

[0033] Tab 176 may be, for example, circumferentially spaced from extension 174. Alternatively, tab 176 may be located on a circumferential side of extension 174. Tab 176 is circumferentially disposed between first travel stop 170 and rivet 166B, which is circumferentially spaced from rivet 166A. Tab 176 is configured to engage rivet 166B (as shown in FIG. 3E ). Upon engaging rivet 166B, tab 176 prevents rotation of intermediate flange 162 relative to cover plates 158, 160. That is, the interface between tab 176 and rivet 166B non-rotatably connects intermediate flange 162 to cover plates 158, 160.

[0034] The tab 176 is configured to selectively engage the first travel stop 170. That is, the tab 176 is configured to engage, i.e., contact, the first travel stop 170 during the transmission of the coast torque CT, and is configured to not engage, i.e., not contact, the first travel stop 170 during the transmission of the drive torque DT. The tab 176 extends axially from the intermediate flange 162 toward the cover plate 158 (as shown in FIG. 2B ). Specifically, the tab 176 axially overlaps the first travel stop 170. That is, the tab 176 may intersect an arc defined by a rotational path of the first travel stop 170 about the central axis A.

[0035] The tab 176 and the first travel stopper 170 are configured to prevent relative rotation between the intermediate flange 162 and the hub flange 164 during the transmission of coasting torque CT. The tab 176 rotates about the central axis A toward the first travel stopper 170 during the transmission of coasting torque CT. Specifically, the tab 176 contacts the first travel stopper 170 and drives the hub flange 164 during the transmission of coasting torque CT (as shown in FIG. 3D ). The first travel stopper 170 and the second travel stopper 172 are configured to allow relative rotation between the intermediate flange 162 and the hub flange 164 during the transmission of driving torque DT. That is, the first travel stopper 170 rotates about the central axis A away from the tab 176 during the transmission of driving torque DT.

[0036] For the transmission of drive torque DT, intermediate flange 162 and hub flange 164 are configured to compress first spring 154 and second spring 156. Tab 176 may be positioned to allow or prevent compression of second spring 156 during the transmission of coast torque CT. For example, tab 176 may be circumferentially spaced from first travel stop 170 when damper assembly 110 is not receiving torque (as shown in FIG. 3A). In one such example, tab 176 may allow compression of second spring 156 during the transmission of coast torque CT (as shown in FIG. 3D). As another example, tab 176 may contact first travel stop 170 when damper assembly 110 is not receiving torque (as shown in FIGS. 2A-2B). In one such example, tab 176 may prevent compression of second spring 156 during the transmission of coast torque CT.

[0037] The following should be considered in light of FIGS. 1-3E. The following describes an exemplary method for operating the damper assembly 110 in drive mode, i.e., to transmit a drive torque DT. However, it should be understood that the method may include fewer steps and / or the steps may be performed in a different order. The first step provides the drive torque DT to the cover plate 158. The second step compresses the second spring 156 between the cover plate 158 and the intermediate flange 162. The third step transmits the drive torque DT from the cover plate 158 to the intermediate flange 162 via the second spring 156. The fourth step rotates the intermediate flange 162 toward the rivet 166A. In this situation, the intermediate flange 162 may rotate relative to the hub flange 164 due to, for example, the different spring constants of the first spring 154 and the second spring 156. The fifth step compresses the first spring 154 between the intermediate flange 162 and the hub flange 164. The sixth step transmits the drive torque DT from the intermediate flange 162 to the hub flange 164 via the first spring 154. The seventh step rotates the hub flange 164 toward the rivet 166A. The eighth step contacts the second travel stop 172, specifically the extension 174, with the rivet 166A, preventing further compression of the second spring 156. In this situation, the intermediate flange 162 rotates relative to the hub flange 164 together with the cover plates 158, 160. The ninth step contacts the first travel stop 170 with the rivet 166A (as shown in FIG. 3C ), preventing further compression of the first spring 154. In this situation, the hub flange 164, the intermediate flange 162, and the cover plates 158, 160 rotate together to transmit the drive torque DT.

[0038] The following should be considered in light of FIGS. 1-3E. The following describes an exemplary method for operating the damper assembly 110 in coast mode, i.e., to transmit coast torque CT. However, it should be understood that the method may include fewer steps and / or the steps may be performed in a different order. The first step is to provide coast torque CT to the cover plate 158. The second step is to compress the first spring 154 between the intermediate flange 162 and the cover plate 158. The third step is to transmit coast torque CT from the cover plate 158 to the intermediate flange 162 via the first spring 154. The fourth step is to compress the second spring 156 between the intermediate flange 162 and the hub flange 164. The fifth step is to rotate the intermediate flange 162 relative to the hub flange 164 until the tab 176 contacts the first travel stop 170 (as shown in FIG. 3D). The fourth step 508 and the fifth step 510 may be omitted in instances where the tab 176 contacts the first travel stop 170 when the damper assembly 110 is subjected to torque.

[0039] The sixth step rotates the hub flange 164 and intermediate flange 162 together relative to the cover plates 158, 160 via the interface between the first travel stop 170 and the tab 176. Driving the hub flange 164 via the tab 176 can limit or prevent compression of the second spring 156 during transmission of coast torque CT, which can increase the ability of the damper assembly 110 to transmit coast torque CT within the envelope of the damper assembly 110. The seventh step brings the tab 176 into contact with the rivet 166B (as shown in FIG. 3E ), preventing further compression of the first spring 154. In this situation, the hub flange 164, intermediate flange 162, and cover plates 158, 160 rotate together to transmit coast torque CT.

[0040] Embodiments according to the present disclosure provide various advantages, including limiting or preventing compression of one spring in a series damper to transmit coasting torque, which can increase the damper assembly's ability to transmit coasting torque while reducing the complexity of the damper assembly.

[0041] 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]

[0042] 100 torque converter 102 Front cover 104 Impeller Assembly 106 Turbine Assembly 110 Damper Assembly 112 Lock-up clutch assembly 114 Impeller shell 116 Impeller Blade 118 Impeller hub 120 Turbine shell 122 Turbine Blade 124 Stator 126 Transmission input shaft 128 One-way clutch 130 Thrust bearing 132 Side Plate 134 Piston 138 Reaction Plate 140 clutch plate 146 Seal part 148 Hub 150 Seal part 152 Apply Chamber 154 Spring 156 Spring 158 Cover Plate 160 cover plate 162 Intermediate flange 164 Hub flange 166 Rivets 168 Spring window 170 First moving stopper 172 Second moving stopper 174 Extension 176 tabs A center axis AD1 Axial direction AD2 axial direction CT Coast Torque DT driving torque

Claims

1. 1. A damper assembly for a torque converter, comprising: a first cover plate arranged to receive a torque; a second cover plate non-rotatably connected to the first cover plate, the first cover plate and the second cover plate defining a spring window; a first spring and a second spring, each disposed within the spring window and circumferentially spaced apart from one another; a hub flange axially disposed between the first cover plate and the second cover plate, the hub flange directly engaging the first and second springs and including a first travel stop; an intermediate flange axially disposed between the hub flange and the first cover plate, the intermediate flange directly engaging the first and second springs and including a second travel stop having a tab extending axially toward the first cover plate; The damper assembly, wherein the tab is engageable with the first travel stop.

2. The damper assembly of claim 1 , wherein the intermediate flange is configured to rotate relative to the hub flange to transmit drive torque.

3. The damper assembly of claim 1 , wherein the tabs are configured to prevent relative rotation between the intermediate flange and the hub flange for transmitting coasting torque.

4. 2. The damper assembly of claim 1, wherein the second travel stop includes an extension that is axially offset relative to the first travel stop, and the tab is circumferentially spaced from the extension.

5. The damper assembly of claim 1 , wherein the tab axially overlaps the first travel stop.

6. The damper assembly of claim 1 , wherein the second travel stop is configured to prevent relative rotation between the intermediate flange and the first and second cover plates.

7. The damper assembly of claim 1 , wherein the first travel stop is configured to prevent relative rotation between the hub flange and the first and second cover plates.

8. 2. The damper assembly of claim 1, further comprising a fastener non-rotatably connecting the first cover plate and the second cover plate, the tab configured to contact the fastener to transmit coast torque.

9. The damper assembly of claim 8 , wherein the tab is circumferentially disposed between the fastener and the first travel stop.

10. 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 damper assembly axially disposed between the front cover and the turbine shell, a first cover plate disposed to receive the torque from the front cover; a second cover plate non-rotatably connected to the first cover plate, the first cover plate and the second cover plate defining a spring window; a first spring and a second spring, each disposed within the spring window and circumferentially spaced apart from one another; a hub flange axially disposed between the first cover plate and the second cover plate, the hub flange directly engaging the first and second springs and including a first travel stop; an intermediate flange axially disposed between the hub flange and the first cover plate, the intermediate flange directly engaging the first and second springs and including a second travel stop having a tab extending axially toward the first cover plate; The tab is engageable with the first travel stop.

11. 11. The torque converter of claim 10, wherein the first travel stop and the second travel stop are configured to allow the intermediate flange to rotate relative to the hub flange for transmitting drive torque.

12. The torque converter of claim 10 , wherein the tab and the first travel stop are configured to non-rotatably connect the intermediate flange to the hub flange for transmitting coasting torque.

13. The torque converter of claim 10 , wherein the tab axially overlaps the first travel stop.

14. 11. The torque converter of claim 10, wherein the damper assembly includes a fastener non-rotatably connecting the first cover plate and the second cover plate, the tab configured to contact the fastener to transmit coast torque.

15. The torque converter of claim 14 , wherein the tab is circumferentially disposed between the fastener and the first travel stop.

16. 1. A method for operating a damper assembly, the damper assembly including: a first cover plate; a second cover plate non-rotatably connected to the first cover plate; first and second springs, each disposed within a spring window defined by the first and second cover plates; a hub flange axially disposed between the first and second cover plates and directly engaged with the first and second springs; an intermediate flange axially disposed between the hub flange and the first cover plate and directly engaged with the first and second springs; a first travel stop on the hub; and a second travel stop on the intermediate flange, the second travel stop extending axially toward the first cover plate and having a tab engageable with the first travel stop; The method comprises: providing a coast torque to the first cover plate; compressing the first spring against the intermediate flange via the first cover plate; rotating the intermediate flange via transmission of the coast torque through the first spring; and rotating the hub flange relative to the first and second cover plates via an interface between the tab and the first travel stop.

17. The method of claim 16 , wherein the intermediate flange rotates with the hub flange.

18. providing a driving torque to the first cover plate; compressing the second spring against the intermediate flange via the first cover plate; rotating the intermediate flange relative to the first and second cover plates via transmission of the driving torque through the second spring; compressing the first spring against the hub flange via the intermediate flange; 17. The method of claim 16, further comprising rotating the hub flange relative to the first and second cover plates via transmission of the driving torque through the first spring.

19. The method of claim 18 , wherein the intermediate flange rotates relative to the hub flange.

20. contacting the tab with a fastener positioned to non-rotatably connect the first and second cover plates; 17. The method of claim 16, further comprising: preventing further rotation of the intermediate flange relative to the first and second cover plates with the tabs.

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