Stamped Backing Plate With Perpendicular Strength Section
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Solution Overview
Problem
Existing friction clutch pack assemblies in automatic transmissions face challenges in achieving the required axial stiffness while minimizing mass and cost, as traditional backing plates often bend and fail to provide sufficient stiffness despite being thick.
Innovation Solution
A two-part backing plate configuration is introduced, comprising a stamped main body backing plate with a reaction section and a strength section, where the strength section is perpendicular to the reaction section and formed with a curved corner, providing increased axial stiffness and reduced mass, and can be piloted or splined to transmission components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the backing plate is made thick to provide axial stiffness, then the axial stiffness is improved, but the mass increases
Solution Approach 1:
The backing plate is divided into two distinct sections: a reaction section that contacts the clutch plates and a strength section that provides structural support. This segmentation allows each section to be optimized for its specific function, with the strength section providing the necessary axial stiffness through its perpendicular orientation and extended length rather than through increased thickness throughout the entire plate.
Solution Approach 2:
The strength section extends perpendicular to the reaction section, utilizing a different spatial dimension to provide structural support. Instead of increasing thickness in the axial direction, the strength is achieved by extending the plate in a radial direction, creating an L-shaped cross-section that provides leverage and stiffness without adding mass through thickness.
2Reliability
If the backing plate is made thick to prevent bending, then the reliability is improved, but the manufacturing cost increases
Solution Approach 1:
The backing plate is segmented into a reaction section and a strength section, allowing the strength section to be optimized for bending resistance through its perpendicular orientation and extended length, while the reaction section maintains the necessary thickness for clutch plate contact. This segmentation enables cost-effective manufacturing by using a single stamped piece of metal rather than requiring expensive multi-part assemblies or thick uniform plates.
Solution Approach 2:
The geometric parameters of the backing plate are changed by introducing the perpendicular strength section with extended length rather than uniform thickness. This parameter change allows the plate to achieve the required bending resistance through its L-shaped cross-section geometry, which can be manufactured cost-effectively by stamping from a single piece of metal.
3Stability of the object's composition
If a single thick backing plate is used, then the structural integrity is improved, but the device complexity increases
Solution Approach 1:
The backing plate is segmented into functional sections (reaction section and strength section) that are integrated into a single stamped component. This segmentation provides structural integrity through the perpendicular strength section while maintaining manufacturing simplicity through single-piece construction, avoiding the complexity of multi-part assemblies.
Solution Approach 2:
The reaction section and strength section are merged into a single stamped backing plate component. This merging maintains structural integrity by providing continuous material support while simplifying manufacturing and assembly compared to separate components, as the entire L-shaped cross-section is formed in a single stamping operation.
Data Source
AI summary
A backing plate configuration and a friction clutch assembly for an automotive transmission are provided. The backing plate configuration includes a main body having a reaction section connected to a perpendicularly disposed strength section. The thickness of the strength section may be less than or equal to the thickness of the reaction section. The friction clutch assembly includes interleaved first and second clutch plates. The main body (of the backing plate) is disposed adjacent to an end second clutch plate. The main body is piloted by and/or splined to the same transmission member as the end second clutch plate. In an engaged position, the end second clutch plate is compressed directly against and into contact with the main body. A method of forming the backing plate configuration is included, which includes stamping of the main body.