Bidirectional Hydrodynamic Thrust Washer for Torque Converters
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Solution Overview
Problem
Existing torque converters face limitations in bidirectional operation and axial space constraints, particularly in applications where rotation can occur in both clockwise and counter-clockwise directions and where axial space is limited.
Innovation Solution
A bidirectional hydrodynamic thrust washer with tapered segments and alternating arcuate sections and grooves, allowing for rotation in both directions and a narrow axial profile, is designed to be used between components like stator and impeller, stator and turbine, or flange and cover, maintaining a hydrodynamic film to prevent direct contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional thrust washer design is used, then the structure is simple, but it cannot operate efficiently in bidirectional rotation and requires more axial space
Solution Approach 1:
The thrust washer is divided into multiple arcuate sections (first, second, third, and fourth arcuate sections) with grooves between them. Each arcuate section has tapered surfaces oriented to handle thrust in specific directions, allowing the washer to accommodate bidirectional rotation while maintaining a compact axial profile through the segmented configuration.
Solution Approach 2:
The thrust washer employs asymmetric tapered surfaces on different arcuate sections, where the first and second arcuate sections have tapers oriented for one direction of rotation, while the third and fourth arcuate sections have tapers oriented for the opposite direction. This asymmetric design enables bidirectional operation within a limited axial space.
2Length of moving object
If the thrust washer has a narrow axial profile, then axial space is saved, but it becomes difficult to maintain a hydrodynamic film
Solution Approach 1:
The thrust washer incorporates arcuate (curved) sections instead of flat surfaces, with each arcuate section having a specific radius of curvature. These curved surfaces work in conjunction with the tapered geometry to generate and maintain the hydrodynamic film necessary for reliable operation, even within a narrow axial profile.
Solution Approach 2:
The thrust washer utilizes changes in surface geometry parameters, specifically the tapered surfaces on each arcuate section, to control fluid pressure distribution. The tapers are oriented to direct fluid flow and pressure in directions that maintain the hydrodynamic film during bidirectional rotation, achieving reliable operation with compact axial dimensions.
3Adaptability or versatility
If the thrust washer is designed for bidirectional operation, then versatility is improved, but the structure becomes more complex
Solution Approach 1:
The thrust washer is designed as a single component that performs multiple functions: it supports thrust loads in both clockwise and counter-clockwise rotation directions, maintains hydrodynamic films during bidirectional operation, and provides a compact axial profile. The unified structure with multiple arcuate sections and grooves achieves bidirectional capability without requiring separate components for different rotation directions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The bidirectional thrust washer enables efficient operation in limited axial space, ensuring smooth rotation in both directions and maintaining a hydrodynamic film, thus reducing wear and enhancing torque converter performance.
Implementation Method 1
maintaining a hydrodynamic film to prevent direct contact
Data Source
AI summary
A thrust washer for a torque converter is provided. The thrust washer includes an inner circumferential surface, an outer circumferential surface and a first axial surface extending from the inner circumferential surface to the outer circumferential surface. The axial surface includes a plurality of arcuate sections and a plurality of grooves circumferentially between the arcuate sections. Each of the arcuate sections includes an arcuate axial surface including a first section, a second section and a third section. The first and third sections extend circumferentially away from the second section in opposite directions and extend axially inward from the second section. A torque converter and a method for forming at least one torque converter are also provided.