Clutch Disk Spring Device Using Flat Plates and Spacers
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Solution Overview
Problem
Existing clutch discs with corrugated spring segments face manufacturing accuracy challenges, leading to non-uniform thickness, judder issues, increased costs, and longer development times due to the need for specialized tools and complex design adjustments.
Innovation Solution
A clutch disc design featuring flat spring sheets with partially overlapping recesses and spacers, allowing for even spring force distribution and reduced judder, with the ability to produce the components without specialized tools and minimizing axial extent.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If corrugated spring segments are used, then the spring device can be implemented, but manufacturing accuracy requirements increase and judder occurs due to non-uniform thickness
Solution Approach 1:
The spring device is segmented into multiple flat spring sheets (at least two) arranged in parallel, each contributing to the overall spring force. This segmentation allows for better manufacturing control compared to monolithic corrugated segments, as flat sheets are easier to manufacture with consistent thickness and properties.
Solution Approach 2:
Multiple identical flat spring sheets are used instead of complex corrugated segments. These sheets are copies of each other in terms of geometry and material properties, which simplifies manufacturing and ensures uniformity. The repetitive simple geometry of flat sheets reduces the risk of manufacturing variations.
2Force
If corrugated spring segments are used, then spring force can be generated, but production costs increase due to specialized corrugation tools
Solution Approach 1:
The patent uses simple flat spring sheets that can be manufactured using conventional, inexpensive tools rather than specialized corrugation equipment. These simple components are easier and cheaper to produce, reducing tooling costs and manufacturing complexity while still providing the necessary spring force functionality.
3Adaptability or versatility
If corrugated spring segments are used, then spring characteristics can be tuned, but development time increases due to repeated prototype adjustments
Solution Approach 1:
The spring characteristics are tuned by changing parameters of the flat spring sheets such as thickness, width, length, or material properties, rather than modifying complex corrugation profiles. This approach allows for easier and faster adjustment of spring characteristics during development, as these parameters can be modified directly in the manufacturing process without requiring specialized tooling changes.
4Ease of operation
If the clutch disc is designed with spring device, then torque transmission control is achieved, but axial dimensions increase
Solution Approach 1:
The spring force is generated primarily through bending of flat sheets in the radial and circumferential directions, rather than requiring significant axial thickness. This dimensional approach allows the spring device to provide necessary force characteristics while maintaining a compact axial profile, as the elastic deformation occurs mainly in other dimensions.
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 design achieves a compact, reproducible, and cost-effective clutch disc with reduced judder and even spring force distribution, enabling a progressive spring force characteristic without the need for complex manufacturing processes.
Implementation Method 1
a spring device arranged between them, the friction linings being compressible against the force of the spring device
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to a clutch disk (10) for a clutch device, comprising two friction linings (11) and a spring device (18) that lies between said linings, wherein the friction linings can be pressed together against the force of the spring device. A low grabbing in the axial direction and a low overall height with a high reproducibility of the spring properties are achieved with low production costs with said clutch disk. Recesses (14) that at least partly overlap are provided in the inner faces of both friction linings. The spring device comprises a plurality of flat spring plates (19) that are positioned such that said spring plates cover the corresponding recesses, and spacing elements (20, 33) are positioned between the spring plates in the region of the corresponding recesses.