Multi-Stage Clutch Housing Segmented Splines and Separator

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Solution Overview

Problem

Multi-stage automatic transmission housings face challenges in independently activating and supporting multiple clutch stages without interference, as existing designs rely on internal splines that can lead to contact between reaction plates when stages are activated.

Innovation Solution

A housing design with a separator that transfers the load of the first clutch pack to the housing, featuring distinct splines for each stage support portion, including a shoulder for the backing plate to prevent interference and allow independent activation of clutch stages.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If internal splines are used to support multiple clutch stages in the same housing, then the housing can support multiple stages of reaction plates, but the reaction plates may contact each other when stages are activated

Engineering Contradiction:

Improvehousing support capabilityVSAvoidclutch stage independence

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The housing is segmented into distinct support portions: a first stage support portion with first stage splines and a second stage support portion with second stage splines. This segmentation allows each clutch stage to be independently supported and activated without interference from other stages, resolving the contradiction between multi-stage support capability and stage independence.

Inventive Principle:

Principle #1Segmentation

2Device complexity

If reaction plates are positioned on the same splines for multiple stages, then the housing structure is simplified, but interference between stages occurs when either stage is activated

Engineering Contradiction:

Improvehousing structureVSAvoidclutch stage activation

Core Design Contradiction:

Device complexityVSEase of operation

Solution Approach 1:

The housing is divided into separate support portions with distinct splines for each stage. The first stage support portion includes first stage splines, and the second stage support portion includes second stage splines. This segmentation maintains structural simplicity while enabling independent activation of each clutch stage without interference.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A separator is introduced as an intermediary component positioned between the first and second clutch packs. The separator transfers the load of the first clutch pack to the housing and prevents contact between reaction plates of different stages, allowing independent stage activation while maintaining a simplified housing structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If a single spline structure is used for multiple clutch stages, then manufacturing is simplified, but load transfer between stages causes interference

Engineering Contradiction:

Improvehousing manufacturingVSAvoidload transfer capability

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The housing includes a first stage support portion with first stage splines and a second stage support portion with second stage splines, segmented to handle loads independently. This segmentation maintains manufacturing simplicity while ensuring proper load transfer capability for each stage without interference.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The separator acts as an intermediary that transfers the load of the first clutch pack directly to the housing, preventing load transfer between stages that would cause interference. This maintains the strength and load transfer capability needed for each stage while avoiding stage interference.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS8448768B2Clutch tooth index and step for multiple cast clutches in one housing

Publication Date: 2013.05.28 ALLISON TRANSMISSION INC

AI summary

A housing for a multi-stage clutch assembly is formed to include a shoulder upon which a backing plate of a first stage clutch pack may be positioned to transfer a load from the first stage clutch pack to the housing.