Torque Converter Clutch Assembly

Abstract

The torque converter includes a front cover disposed to receive torque and a lock-up clutch engaged with the front cover. The torque converter further includes a damper assembly engageable with the lock-up clutch. The damper assembly includes an inner spring assembly, an outer spring assembly disposed radially outward of the inner spring assembly, and a lower cover plate supporting the inner spring assembly. The lower cover plate includes a chamfer configured to retain the outer spring assembly within the spring window.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Patent Application No. 63 / 240,347, filed September 2, 2021, which claims the benefit of U.S. Non-Provisional Patent Application No. 17 / 870,922, filed July 22, 2022, the disclosure of which is incorporated herein by reference in its entirety.

[0002] The present disclosure relates to a torque converter for a vehicle. In particular, the present disclosure relates to a damper assembly for a torque converter. [Background technology]

[0003] Many vehicles include a transmission between the engine and the transmission. A torque converter is a type of transmission 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 or lock-up clutch that mechanically couples the turbine shaft to the torque converter cover and bypasses the fluid coupling. Due to limited space within the torque converter envelope, it is desirable to have alternative designs and configurations for fitting all necessary components within the torque converter, including the damper assembly. Furthermore, as the envelope space and packaging become more restricted, challenges can arise with manufacturing various components to meet their reduced tolerances. Summary of the Invention [Means for solving the problem]

[0004] In one embodiment, the torque converter includes a front cover positioned to receive torque. The torque converter further includes an impeller having an impeller shell non-rotatably connected to the front cover. The torque converter further includes a turbine in fluid communication with the impeller, the turbine shell including a lock-up clutch including a piston and a clutch plate. The torque converter further includes a damper assembly axially disposed between the front cover and the turbine shell and engageable with the clutch plate. The damper assembly includes an inner spring assembly, an outer spring assembly disposed radially outward of the inner spring assembly, and a lower cover plate supporting the inner spring assembly. The lower cover plate includes a chamfer configured to retain the outer spring assembly within a spring window.

[0005] In embodiments, the torque converter may include an upper cover plate supporting an outer spring assembly. The lower cover plate may include a flat area configured to radially retain the upper cover plate. The flat area may be located on an outer diameter of the lower cover plate. The chamfer may extend radially inward from the flat area. In embodiments, the torque converter may include an additional upper cover plate axially disposed between the piston and the upper cover plate. The additional upper cover plate may support the outer spring assembly. The additional upper cover plate may be connected to the upper cover plate. The additional upper cover plate may be connected to the clutch plate. The upper cover plate and the additional upper cover plate may define a spring window. In embodiments, the torque converter may include an intermediate flange axially disposed between the upper cover plate and the additional upper cover plate. The intermediate flange may be connected to the upper cover plate and the additional upper cover plate. The intermediate flange may be configured to transmit torque to the inner spring assembly based on the torque exceeding a first threshold. In embodiments, the torque converter may include an additional lower cover plate axially disposed between the front cover and the lower cover plate. The additional lower cover plate may support the inner spring assembly. The additional lower cover plate may be connected to the lower cover plate. The additional lower cover plate may be configured to transfer torque to the lower cover plate based on the torque exceeding a second threshold. The additional lower cover plate may be connected to the intermediate flange.

[0006] In embodiments, the lower cover plate may be connected to the turbine shell. The lower cover plate may be arranged to non-rotatably connect to the transmission input shaft. The chamfer may extend from an axial side of the lower cover plate toward an outer diameter of the lower cover plate.

[0007] In another embodiment, a damper assembly for a torque converter includes an inner spring assembly, an outer spring assembly disposed radially outward of the inner spring assembly, and a lower cover plate supporting the inner spring assembly, the lower cover plate including a chamfer configured to retain the outer spring assembly within a spring window.

[0008] In embodiments, the damper assembly may include an upper cover plate supporting the outer spring assembly. The lower cover plate may include a flat region configured to radially retain the upper cover plate. The flat region may be located on an outer diameter of the lower cover plate. In embodiments, the damper assembly may include an additional upper cover plate connected to the upper cover plate. The additional upper cover plate may support the outer spring assembly. The upper cover plate and the additional upper cover plate may define a spring window. In embodiments, the damper assembly may include an intermediate flange axially disposed between the upper cover plate and the additional upper cover plate. The intermediate flange may be connected to the upper cover plate and the additional upper cover plate. The intermediate flange may be configured to transmit torque to the inner spring assembly based on the torque exceeding a first threshold. The damper assembly may include a lower cover plate and an additional lower cover plate connected to the intermediate flange. The additional lower cover plate may support the inner spring assembly and may be configured to transmit torque to the lower cover plate based on the torque exceeding a second threshold.

[0009] The embodiments described herein include advantageous configurations that include moving an inner spring assembly retention feature for the upper or outer spring assembly of the damper to a lower cover plate associated with the lower or inner spring assembly of the damper to allow the damper assembly to be packaged within a smaller envelope. [Brief explanation of the drawings]

[0010] [Figure 1] 1 is a cross-sectional view of a torque converter having a damper assembly according to the present disclosure; DETAILED DESCRIPTION OF THE INVENTION

[0011] Embodiments of the present disclosure are described herein. However, it should 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 those skilled in the art will understand, various features illustrated and described with reference to any one of the figures can be combined with features illustrated in one or more other figures to produce embodiments not explicitly illustrated or described. The combination of illustrated features provides a representative embodiment for a typical application. However, various combinations and modifications of features consistent with the teachings of the present disclosure may be desired for a particular application or implementation.

[0012] 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 102. While only a portion of the torque converter 100 above the central axis 102 is shown in FIG. 1 , it should be understood that the torque converter 100 may appear substantially similar below the central axis 102 with many components extending about the central axis 102. As used herein, the words "axial," "radial," "circumferential," "outwardly," and the like are intended to be relative to the central axis 102.

[0013] The torque converter 100 includes a torque-receiving front cover 104, an impeller 106, a turbine 108, a lock-up clutch 110, and a damper assembly 112. The impeller 106 includes an impeller shell 114 non-rotatably connected to the front cover 104 such that rotation of the front cover 104 causes rotation of the impeller 106, at least one impeller blade 116 attached to the inner surface of the impeller shell 114, and an impeller hub 118 attached to the radially inward end of the impeller shell 114. The turbine 108 includes a turbine shell 120 non-rotatably connected to a transmission input shaft 122 and at least one turbine blade 124 attached to the turbine shell 120. "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 components that are non-rotatably connected relative to one another is possible, but not required.

[0014] Torque converter 100 may include a stator 126 disposed axially between impeller 106 and turbine 108 to redirect fluid flowing from turbine blades 124 before the fluid reaches impeller 106, increasing the efficiency of torque converter 100. For example, as impeller blades 116 rotate about central axis 102, they push fluid outward. The fluid pushes against turbine 108 of torque converter 100, causing turbine 108 to rotate about central axis 102. Stator 126 functions to return fluid from turbine 108 to impeller 106 with minimal or no power loss. Drive is transmitted from turbine 108 to transmission input shaft 122. Torque converter 100 may further include, for example, a one-way clutch 128 disposed within stator 126, a thrust bearing 130 axially disposed between stator 126 and impeller shell 114, and a side plate 132 configured to retain one-way clutch 128 within stator 126.

[0015] Power from a vehicle engine (not shown) may be transferred to a transmission (not shown) via a fluid and through torque converter 100. In particular, power may be transferred initially to a front cover 104 of torque converter 100. Lock-up clutch 110 is configured to selectively transfer torque from front cover 104 to a transmission input shaft 122. Lock-up clutch 110 includes a piston 134, a clutch plate 136, and a reaction plate 138.

[0016] The piston 134 may be connected to the front cover 104 via a leaf spring connection and sealed at its outer diameter to the front cover 104. The reaction plate 138 may be fixed to the front cover 104 via welding, for example. The clutch plate 136 may be disposed between the piston 134 and the reaction plate 138.

[0017] Piston 134 engages or closes lock-up clutch 110 in response to pressurization of a medium (e.g., a fluid such as oil) in a piston apply chamber 140 defined between front cover 104 and piston 134. During axial movement of piston 134, piston 134 slides along a sealing plate 142, which is non-rotatably fixed to front cover 104 via welding, for example, and sealed at its inner diameter to the transmission input shaft. Piston 134 is sealed at its outer diameter to front cover 104 via seal 144 and at its inner diameter to sealing plate 142 via seal 146. Seals 144, 146 maintain fluid separation between piston apply chamber 140 and the remainder of torque converter 100. Piston apply chamber 140 is further defined by or bounded between front cover 104, seal 144, piston 134, seal 146, and seal plate 142. "Partially bounded" means that a portion of the referenced chamber, flow passage, or other structure is bounded or formed by the referenced element.

[0018] Damper assembly 112 is axially positioned between front cover 104 and turbine 108. Damper assembly 112 may be configured to hydraulically transfer torque through torque converter 100. For example, damper assembly 112 may be configured to transfer torque from front cover 104 to transmission input shaft 122. Damper assembly 112 includes an outer spring assembly 148, an inner spring assembly 150 radially inward of outer spring assembly 148, cover plates 152, 154 supporting outer spring assembly 148, an intermediate flange 156, and cover plates 158, 160 supporting inner spring assembly 150. Cover plate 152 is disposed between front cover 104 and intermediate flange 156 and is connected to clutch plate 136 via, for example, a tab connection, to transfer torque from lock-up clutch 110 to damper assembly 112. The cover plate 154 is disposed between the intermediate flange 156 and the turbine shell 120 .

[0019] The cover plate 160 includes chamfers 162 constructed and arranged to maintain or retain the outer spring assemblies 148 in their respective spring windows 172, i.e., predetermined operating regions of the outer spring assemblies 148. The spring windows 172 are defined, i.e., bounded, by the cover plates 152, 154. The chamfers 162 may be referred to as "spinning eyebrows," i.e., the chamfers 162 may rotate independently of, i.e., relative to, the outer spring assemblies 148. The chamfers 162 may be formed at an angle corresponding to the desired positioning of the outer spring assemblies 148 and may be formed into the outer diameter of the cover plate 160. The chamfers 162 may be coined or machined chamfers.

[0020] Cover plate 160 includes a flat region 164 adjacent chamfer 162. Flat region 164 is configured and arranged to provide radial retention of cover plate 154. The inner diameter of cover plate 160 may be further configured and arranged to mate with transmission input shaft 122, for example, via a bubble feature having a broached plug-in tooth that mates with transmission input shaft 122. Torque converter 100 may further include a thrust washer (not numbered) disposed between cover plate 158 and sealing plate 142 and retained by cover plate 152.

[0021] Torque converter 100 further includes a torque path described as follows: when lock-up clutch 110 is engaged (or piston 134 is closed pressing clutch plate 136 against reaction plate 138), torque is transmitted from front cover 104 to cover plate 152, e.g., via a tab connection with clutch plate 136. The torque is then distributed by connector 166 (e.g., a sheet metal rivet connection) to outer spring assembly 148, cover plate 154, and any torque exceeding the spring capacity of outer spring assembly 148 is transmitted through connector 166 to intermediate flange 156. Torque from intermediate flange 156 is then input to inner spring assembly 150, and any torque exceeding the spring capacity of inner spring assembly 150 is transmitted to tab feature 168 on cover plate 158. The torque received by the cover plate 160 comes from a connector (eg, a sheet metal rivet connection) 170 to the cover plate 158 and from the inner spring assembly 150 , which interfaces with the transmission input shaft 122 .

[0022] While exemplary embodiments have been described above, these embodiments are not intended to describe every possible embodiment encompassed by the scope of 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 noted above, features of various embodiments can be combined to form further embodiments of the present invention 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 particular application and implementation. These attributes may include, but are not limited to, cost, strength, durability, life cycle cost, marketability, appearance, implementation, 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]

[0023] 100 torque converter 102 Center axis 104 Front cover 106 Impeller 108 Turbine 110 Lock-up clutch 112 Damper Assembly 114 Impeller shell 116 Impeller Blade 118 Impeller hub 120 Turbine shell 122 Transmission input shaft 124 Turbine Blade 126 Stator 128 One-way clutch 130 Thrust bearing 132 Side Plate 134 Piston 136 Clutch plate 138 Reaction Plate 140 Piston apply chamber 142 Sealing plate 144 Sealing part 146 Sealing part 148 Outer Spring Assembly 150 Inner spring assembly 152 Cover Plate 154 Cover Plate 156 Intermediate flange 158 Cover Plate 160 cover plate 162 Chamfered part 164 flat area 166 Connector 168 Tab Features 170 Connector 172 Spring Window

Claims

1. A torque converter, a front cover arranged to receive torque; an impeller having an impeller shell non-rotatably connected to the front cover; a turbine in fluid communication with the impeller and including a turbine shell; a lock-up clutch including a piston and a clutch plate; a damper assembly axially disposed between the front cover and the turbine shell and engageable with the clutch plate, an inner spring assembly; and an outer spring assembly disposed radially outward of the inner spring assembly; a lower cover plate supporting the inner spring assembly, the lower cover plate including a chamfer configured to retain the outer spring assembly within a spring window; and Equipped with 10. A torque converter, further comprising an upper cover plate supporting the outer spring assembly, the lower cover plate including a flat area configured to radially retain the upper cover plate.

2. 2. The torque converter of claim 1, wherein said flat area is located on an outer diameter of said lower cover plate.

3. The torque converter of claim 1 , wherein said chamfer extends radially inward from said flat region.

4. 2. The torque converter of claim 1, further comprising an additional upper cover plate axially disposed between said piston and said upper cover plate, said additional upper cover plate supporting said outer spring assembly, said additional upper cover plate connected to said upper cover plate.

5. The torque converter of claim 4 , wherein the additional upper cover plate is connected to the clutch plate.

6. 5. The torque converter of claim 4, further comprising an intermediate flange axially disposed between the upper cover plate and the further upper cover plate, the intermediate flange connected to the upper cover plate and the further upper cover plate, the intermediate flange configured to transfer the torque to the inner spring assembly based on the torque exceeding a first threshold value.

7. 7. The torque converter of claim 6, further comprising an additional lower cover plate axially disposed between said front cover and said lower cover plate, said additional lower cover plate supporting said inner spring assembly, said additional lower cover plate connected to said lower cover plate.

8. The torque converter of claim 7 , wherein the further lower cover plate is configured to transfer the torque to the lower cover plate through a connector based on the torque exceeding a second threshold.

9. The torque converter of claim 7 , wherein the additional lower cover plate is coupled to the intermediate flange.

10. The torque converter of claim 4 , wherein said upper cover plate and said further upper cover plate define said spring window.

11. The torque converter of claim 1 , wherein the lower cover plate is connected to the turbine shell.

12. 2. The torque converter of claim 1, wherein said lower cover plate is positioned to non-rotatably connect to a transmission input shaft.

13. 2. The torque converter of claim 1, wherein said chamfer extends from an axial side of said lower cover plate toward an outer diameter of said lower cover plate.

14. 1. A damper assembly for a torque converter, comprising: an inner spring assembly; and an outer spring assembly disposed radially outward of the inner spring assembly; a lower cover plate supporting the inner spring assembly, the lower cover plate including a chamfer configured to retain the outer spring assembly within a spring window; Equipped with 10. The damper assembly of claim 9, further comprising an upper cover plate supporting the outer spring assembly, the lower cover plate including a flat area configured to radially retain the upper cover plate, the flat area located on an outer diameter of the lower cover plate.

15. The damper assembly of claim 14 further comprising an additional upper cover plate connected to said upper cover plate, said additional upper cover plate supporting said outer spring assembly.

16. 16. The damper assembly of claim 15, further comprising an intermediate flange axially disposed between the top cover plate and the further top cover plate, the intermediate flange connected to the top cover plate and the further top cover plate, the intermediate flange configured to transfer torque to the inner spring assembly based on the torque exceeding a first threshold value.

17. 17. The damper assembly of claim 16, further comprising an additional lower cover plate connected to the lower cover plate and the intermediate flange, the additional lower cover plate supporting the inner spring assembly configured to transfer the torque to the lower cover plate based on the torque exceeding a second threshold.

18. The damper assembly of claim 15, wherein the upper cover plate and the further upper cover plate define the spring window.

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