Torque converter assembly including thrust washer

Abstract

Disclosed herein is a torque converter assembly. The torque converter assembly includes a thrust washer having a radially inner surface configured to engage a drive shaft. A first axial surface of the thrust washer is configured to contact the cover. A second axial surface of the thrust washer is configured to contact the damper flange. The second axial surface of the thrust washer partially defines a first flow passage. The thrust washer further includes a second flow passage configured to direct fluid in a first direction and a third flow passage configured to direct fluid in a second direction. The thrust washers disclosed herein both provide an axial thrust bearing function as well as provide three distinct flow passages or passages.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Non-provisional Application No. 17 / 667,982, filed February 9, 2022, the entire disclosure of which is incorporated herein by reference.

[0002] Technical Field The present disclosure relates to torque converter assemblies, and more particularly to thrust washers for torque converter assemblies. [Background technology]

[0003] Torque converter assemblies are well known. One type of known torque converter is the three-pass torque converter, which includes three ports. The first two ports are generally used for the charging function of the torque converter, which requires constant fluid flow to the torus. This flow is also used for cooling the friction facings, which operate at a steady-state point while the vehicle is moving to improve efficiency. A third port can be provided to actuate a piston with an isolated hydrostatic chamber, which forces the friction facings to compress, transmitting torque and bypassing the torus. In one aspect, this configuration requires a higher pressure than the charging region or chamber, but allows the region of the torque converter that receives the charging pressure to operate at a lower pressure.

[0004] Under certain conditions, the torus generates a thrust load due to hydrodynamics, and conventional thrust washers or thrust bearings are generally used to support the load.

[0005] 1 illustrates one type of configuration for known torque converter designs that includes a machined or forged component 5 that defines a flow path to keep the applied pressure separated from the charge pressure. The component 5 may function as a flow divider and may be located generally between the cover 1, the pressure plate 2, and the seal plate 3. The component 5 may be expensive to manufacture due to its geometry and specific design requirements.

[0006] It would be desirable to provide an improved configuration of a multi-pass (i.e., at least three-pass) torque converter that is inexpensive, durable, provides reliable isolation between different fluid chambers, and serves the purpose of supporting thrust loads coming from a turbine damper assembly. Summary of the Invention [Means for solving the problem]

[0007] The torque converter assembly includes a thrust washer having a radially inner surface configured to engage a drive shaft. A first axial surface of the thrust washer is configured to contact the cover. A second axial surface of the thrust washer is configured to contact the damper flange. The second axial surface of the thrust washer defines a first flow path. The thrust washer further includes a second flow path configured to direct fluid in a first direction and a third flow path configured to direct fluid in a second direction. The thrust washers disclosed herein both provide axial thrust bearing functionality and provide three distinct flow paths or passages.

[0008] The seal plate hub is configured to engage a radially outer surface of the thrust washer and defines a first passage configured to receive fluid from the second passage of the thrust washer and a second passage configured to receive fluid from the third passage of the thrust washer.

[0009] The thrust washer, in one aspect, is formed from plastic. One skilled in the art will appreciate that other materials and manufacturing methods may be used. The thrust washer, in one aspect, does not require machining or forging processes.

[0010] In one embodiment, the second and third flow paths can overlap one another in the circumferential direction. The second and third flow paths can be oriented in a tilted or angled configuration so that the inlets and outlets of each flow path are axially offset from one another. In this manner, the flow paths can be provided within a single component (i.e., a thrust washer) and can be circumferentially offset from one another. Multiple flow paths of each of the second and third flow paths can be provided.

[0011] The seal plate hub can be configured to axially retain the thrust washer. This retention can be achieved via at least one retainer configured to axially retain the thrust washer. The retainer can be formed as a bent tab or a staking tab. This embodiment provides a simplified method for axially securing the thrust washer.

[0012] Various other secondary components for the torque converter assembly may be provided, and various interfaces or connections between these components may be provided. For example, the thrust washer may be configured to have an interference fit with the drive shaft. The thrust washer may also be configured to have an interference fit with the seal plate hub. The cover may be secured to the seal plate hub, such as via welding or other connection configuration. The thrust washer may be configured to provide a seal with the drive shaft and the cover. In one aspect, each side or face of the thrust washer provides a sealing interface, except for the side or face adjacent the damper flange.

[0013] In one aspect, the seal plate can be attached to a seal plate hub. The seal plate can be attached to the seal plate hub by welding.

[0014] The first flow path and the third flow path can be configured to receive fluid from a first source, and the second flow path can be configured to receive fluid from a second source different from the first source.

[0015] Also provided herein is a method for assembling a torque converter assembly.

[0016] Further embodiments are disclosed herein.

[0017] The foregoing summary, as well as the following detailed description, will be better understood when read in conjunction with the accompanying drawings illustrating preferred embodiments of the present disclosure. [Brief explanation of the drawings]

[0018] [Figure 1] 1 is a cross-sectional view of a torque converter configuration according to the prior art. [Figure 2] FIG. 2 is a cross-sectional view of a torque converter assembly including a thrust washer. [Figure 3] FIG. 3 is an enlarged view of region "III" in FIG. 2. [Figure 4] FIG. 4 is a perspective view of the thrust washer of FIGS. 2 and 3. DETAILED DESCRIPTION OF THE INVENTION

[0019] In the following description, certain terminology is used for convenience only and is not limiting. "Axially" refers to a direction along the axis (X) of the assembly. "Radially" refers to a direction inward and outward from the axis (X) of the assembly. "Circumferentially" refers to a direction extending along the curvature or circumference of the respective element relative to the axis (X) of the assembly. Reference to a list of items recited as "at least one of a, b, or c" (where a, b, and c represent the listed items) means any one of items a, b, or c, or any combination thereof. Terms include those specifically mentioned above, derivatives thereof, and words of similar import.

[0020] As shown in Figure 2, a torque converter assembly 10 is disclosed herein. Torque converter assembly 10 may generally include a thrust washer 20, a seal plate hub 30, a seal plate 35, a damper flange 40, a drive shaft 45, and a cover 50. Additional features for torque converter assembly 10 may be included. Additionally, the term torque converter assembly 10 may refer to fewer elements than those generally disclosed herein.

[0021] In one embodiment, the thrust washer 20 provides a flow path for fluid to the respective chambers and passages, and also provides a bearing function. The thrust washer 20 is shown in more detail in FIG. 4. In one embodiment, the bearing function, i.e., the thrust washer 20, is generally disposed between the cover 50 and the damper flange 40. The thrust washer 20 generally can provide at least two flow paths or passages. In one embodiment, the thrust washer 20 can be configured to provide at least three flow paths.

[0022] The thrust washer 20 includes a radially inner surface 22 configured to engage the drive shaft 45. The thrust washer 20, in one aspect, may be secured to the drive shaft 45 via an interference fit. The thrust washer 20 may directly contact the drive shaft 45 and provide a sealing interface with the drive shaft 45 such that the chambers on either axial side of the thrust washer 20 are sealed apart from one another.

[0023] Thrust washer 20 includes a first axial surface 23a configured to contact cover 50. In one aspect, thrust washer 20 also provides a sealing interface or surface with cover 50. Further details regarding this engagement and interface are provided herein.

[0024] The thrust washer 20 includes a second axial surface 23b configured to contact the damper flange 40 and support high axial loads. As shown in FIG. 3 , a first flow passage 21a is defined between the thrust washer 20 and the damper flange 40. In one embodiment, the thrust washer 20 can include a groove or recess 25 configured to define the first flow passage 21a. Alternatively, the second axial surface 23b can include multiple protrusions that engage with the damper flange 40, and the first flow passage 21a can be defined in a circumferential region between the protrusions. The first flow passage 21a can have a boundary or periphery that is partially defined by the damper flange 40 and partially defined by the thrust washer 20.

[0025] The thrust washer 20, in one embodiment, can be formed as a plastic part. The thrust washer 20 can be formed as a polymer part. The thrust washer 20, in one embodiment, can be formed by injection molding. The thrust washer 20, in one embodiment, does not require forging or other machining forming methods or processes.

[0026] The thrust washer 20 further includes a second flow passage 21b configured to direct fluid in a first direction and a third flow passage 21c configured to direct fluid in a second direction. In one embodiment, the second flow passage 21b and the third flow passage 21c overlap one another in the circumferential direction. The second flow passage 21b and the third flow passage 21c can each be inclined in the axial direction. The second flow passage 21b and the third flow passage 21c can each extend generally radially through the thrust washer 20. In one embodiment, the second flow passage 21b and the third flow passage 21c can have generally the same size or diameter. In one embodiment, the second flow passage 21b and the third flow passage 21c can have various shapes, sizes, geometries, etc.

[0027] The first flow path 21a can be configured to receive fluid provided via an inlet in the drive shaft 45. For example, the inlet in the drive shaft 45 can provide fluid through an opening in the damper flange 40. Additionally, the third flow path 21c can be configured to receive fluid from the same source as the first flow path 21a, i.e., via an inlet formed in the drive shaft 45.

[0028] The seal plate hub 30 is configured to engage the radially outer surface 24 of the thrust washer 20. The seal plate hub 30 defines a first passage 31a configured to receive fluid from the second flow passage 21b of the thrust washer 20 and a second passage 31b configured to receive fluid from the third flow passage 21c of the thrust washer 20. The first passage 31a and the second passage 31b may be radially oriented in one aspect. Other orientations, shapes, sizes, etc. may be provided for the first passage 31a and the second passage 31b.

[0029] In one aspect, the seal plate hub 30 is configured to axially retain the thrust washer 20. This retention can be configured to be achieved in a variety of ways, as one of ordinary skill in the art will understand from this disclosure. In one aspect, the seal plate hub 30 includes at least one retainer 32 configured to axially retain the thrust washer 20. The at least one retainer 32 can be formed as at least one staking tab that is bent and engages the thrust washer 20. Multiple retainers 32 can be provided circumferentially spaced apart from one another. Alternatively, the at least one retainer 32 can include a tab that extends 360 degrees.

[0030] In one aspect, thrust washer 20 is configured to have an interference fit with drive shaft 45. In one aspect, thrust washer 20 is configured to have an interference fit with seal plate hub 30. In this configuration, thrust washer 20 provides a sealing surface on each of radially inner surface 22 and radially outer surface 24. Thrust washer 20 further provides a sealing interface against cover 50 on surface 23 a. In one aspect, thrust washer 20 is configured to provide a seal against seal plate hub 30, drive shaft 45, and cover 50.

[0031] In one aspect, the cover 50 can be secured to the seal plate hub 30. In one aspect, the cover 50 can be secured to the seal plate hub 30 by welding. Those skilled in the art will appreciate that various types of connections or securing configurations can be provided between these components.

[0032] The seal plate 35 may be connected to or attached to the seal plate hub 30. The seal plate 35 may be attached to the seal plate hub 30 in a variety of ways. For example, the seal plate 35 may be welded to the seal plate hub 30. In one aspect, the seal plate hub 30 may include a shoulder 33a on which the seal plate 35 is positioned. The seal plate hub 30 may further include a groove 33b on its radially outer surface configured to receive the seal 34. The seal 34 may be configured to engage the piston 36.

[0033] 3, first flow path 21a and third flow path 21c are configured to receive fluid from a first source, and second flow path 21b is configured to receive fluid from a second source different from the first source. One skilled in the art will understand based on this disclosure that flow paths 21a, 21b, and 21c can be provided in various configurations.

[0034] A method of assembling the torque converter assembly 10 is also provided herein. The method includes attaching a seal plate 35 to the seal plate hub 30. This attachment can be accomplished in a variety of ways, such as via welding or other permanent fastening arrangements. The method also includes attaching a cover 50 to the seal plate hub 30. This step can include welding the cover 50 to the seal plate hub 30. The method includes placing a thrust washer 20 inside the seal plate hub 30 and axially securing the thrust washer 20 to the seal plate hub 30 via at least one retainer 32 on the seal plate hub 30, whereby the cover 50 engages the first axial surface 23 a of the thrust washer 20. The method further includes positioning a damper flange 40 against the second axial surface 23 b of the thrust washer 20. The thrust washer 20 defines a first flow passage 21a adjacent the damper flange 40, a second flow passage 21b configured to direct fluid in a first direction, and a third flow passage 21c configured to direct fluid in a second direction. Multiple interfaces and connections between components can be established in accordance with the present method. For example, the thrust washer 20 can be configured to have an interference fit with the drive shaft 45, the thrust washer 20 can be configured to have an interference fit with the seal plate hub 30, and the thrust washer 20 can be configured to provide a seal against the drive shaft 45 and the cover 50. One skilled in the art will recognize that various other types of connections and interfaces between adjacent components are possible.

[0035] Having thus described the present disclosure in detail, it will be understood, and will be apparent to those skilled in the art, that many physical changes, only some of which are illustrated in the detailed description of the invention, can be made without altering the concepts and principles of the invention embodied in the embodiments.

[0036] It should also be understood that many embodiments are possible that incorporate only portions of the preferred embodiment, and that, with respect to those portions, do not change the concepts and principles of the present invention embodied therein.

[0037] The present embodiments and optional configurations are therefore to be considered in all respects as illustrative and / or explanatory and not restrictive, the scope of the embodiments being indicated by the appended claims rather than the foregoing description, and all alternative embodiments and modifications to the present embodiments that come within the meaning and range of equivalents of the claims are therefore intended to be embraced therein. [Explanation of symbols]

[0038] 1 cover 2 pressure plates 3 Seal Plate 5 parts 10 Torque converter assembly 20 Thrust washer 21a First flow path 21b Second flow path 21c Third Stream 22 Radial inner surface 23a first axial surface 23b second axial surface 24 Radial outer surface 25 Groove or recess 30 Seal plate hub 31a First Passage 31b Second Passage 32 Retainer 33a Shoulder 33b Groove 34 Seal 35 Seal plate 36 Piston 40 Damper flange 45 drive shaft 50 Cover

Claims

1. 1. A torque converter assembly comprising: a thrust washer having a radially inner surface configured to engage a drive shaft, a first axial surface configured to contact a cover, and a second axial surface configured to contact a damper flange, the second axial surface partially defining a first flow passage, the thrust washer further including a second flow passage configured to direct fluid in a first direction and a third flow passage configured to direct fluid in a second direction; a seal plate hub configured to engage a radially outer surface of the thrust washer, the seal plate hub defining a first passage configured to receive fluid from the second flow passage of the thrust washer and a second passage configured to receive fluid from the third flow passage of the thrust washer; A torque converter assembly comprising:

2. The assembly of claim 1 , wherein the thrust washer is formed from plastic.

3. The assembly of claim 1 , wherein the second flow passage and the third flow passage overlap each other in a circumferential direction.

4. The assembly of claim 1 , wherein the seal plate hub is configured to axially retain the thrust washer.

5. The assembly of claim 4 , wherein the seal plate hub includes at least one retainer configured to axially retain the thrust washer.

6. The assembly of claim 5 , wherein the at least one retainer is bent to engage the thrust washer.

7. The assembly of claim 1 , wherein the thrust washer is configured to interface directly with a drive shaft to isolate different pressure zones.

8. The assembly of claim 1 , wherein the thrust washer is configured to have an interference fit with the seal plate hub.

9. The assembly of claim 1 , further comprising the cover, the cover being secured to the seal plate hub.

10. The assembly of claim 9 , wherein the cover is welded to the seal plate hub.

11. The assembly of claim 1 , wherein the thrust washer is configured to provide a seal against the drive shaft and the cover.

12. The assembly of claim 1 further comprising a seal plate attached to the seal plate hub.

13. The assembly of claim 12 , wherein the seal plate is attached to the seal plate hub by welding.

14. 2. The assembly of claim 1, wherein the first flow path and the third flow path are configured to receive fluid from a first source, and the second flow path is configured to receive fluid from a second source different from the first source.

15. 1. A method of assembling a torque converter assembly, the method comprising: attaching a seal plate to a seal plate hub; attaching a cover to the seal plate hub; placing a thrust washer inside the seal plate hub; axially fixing the thrust washer to the seal plate hub via at least one retainer provided on the seal plate hub, whereby the cover engages a first axial surface of the thrust washer; and positioning a damper flange against the second axial surface of the thrust washer; the thrust washer defines a first flow passage adjacent the damper flange, a second flow passage configured to direct fluid in a first direction, and a third flow passage configured to direct fluid in a second direction.

16. The method of claim 15 , wherein the second flow path and the third flow path circumferentially overlap one another.

17. The method of claim 15, wherein the thrust washer is formed from plastic.

18. 16. The method of claim 15, wherein the thrust washer is configured to have an interference fit with a drive shaft, the thrust washer is configured to have an interference fit with the seal plate hub, and the thrust washer is configured to provide a seal against the drive shaft and the cover.

19. The method of claim 15 , wherein the at least one retainer is bent to engage the thrust washer.

20. 16. The method of claim 15, wherein the seal plate hub defines a first passage configured to receive fluid from the second flow path of the thrust washer and a second passage configured to receive fluid from the third flow path of the thrust washer.

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