Clutch Intermediate Plate Contact Lug Design
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Solution Overview
Problem
Current multi-plate clutches are unsuitable for vehicle applications due to overheating and improper release without lubrication, limiting their ability to transmit high torque effectively in dry conditions.
Innovation Solution
An intermediate plate with an annular body and contact lug, formed by plastic deformation, increases friction surfaces and reduces the mass moment of inertia, allowing for higher torque transmission with reduced actuation force and improved heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multi-plate clutches are used to increase friction surfaces for high torque transmission, then torque transmission capability is improved, but the plates overheat quickly due to insufficient heat capacity
Solution Approach 1:
The clutch assembly is segmented into multiple friction plates (first friction plate, second friction plate) and steel plates arranged in alternating sequence. This segmentation increases the number of friction surfaces for higher torque transmission while distributing heat generation across multiple contact points, preventing localized overheating.
Solution Approach 2:
The friction plates and steel plates are nested between pressure plates and counter-plates in a compact arrangement. The intermediate plate with contact lugs is nested within the clutch assembly, allowing multiple friction surfaces to be contained within a limited space while maintaining adequate heat dissipation pathways.
2Power
If multi-plate clutches are used to increase friction surfaces, then torque transmission is improved, but the clutch does not release properly without oil lubrication
Solution Approach 1:
The intermediate plate with contact lugs acts as an intermediary mechanism between the pressure plate and friction plates. The contact lugs engage with slots in the friction plates, providing a mechanical linkage that ensures proper release motion is transmitted to all friction surfaces even without oil lubrication, solving the sticking problem.
Solution Approach 2:
The pressure plates are designed to be displaceable axially between engaged and released positions. This dynamic movement, combined with the intermediate plate's contact lugs, ensures that all friction surfaces are uniformly pressed during engagement and uniformly released during disengagement, maintaining proper operation in dry conditions.
3Power
If the number of friction surfaces is increased to transmit higher torque, then torque capacity is improved, but the mass moment of inertia increases
Solution Approach 1:
The intermediate plate features contact lugs with specific geometries (protruding contact bodies) that are locally optimized for engagement with the friction plates. This localized structural optimization allows the intermediate plate to provide necessary mechanical linkage functions with minimal mass, increasing torque capacity without proportionally increasing moment of inertia.
Solution Approach 2:
The contact lugs extend in the axial direction with protruding contact bodies, utilizing the axial dimension for engagement rather than requiring additional radial or circumferential mass. This dimensional approach allows multiple friction surfaces to be engaged through axial displacement rather than requiring heavier components.
4Weight of moving object
If the outer radius of plates is reduced to decrease mass moment of inertia, then space and inertia are improved, but the torque transmission capability decreases
Solution Approach 1:
The intermediate plate with its contact lugs is pre-configured to engage with the friction plates before full axial compression occurs. This preliminary engagement ensures that all friction surfaces are effectively utilized across the available radius, maximizing torque transmission capability within the constrained outer radius without requiring heavier plates.
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
Enables efficient torque transmission with reduced actuation force and improved heat dissipation, making it suitable for sporty and dynamic driving behaviors while minimizing fuel consumption.
Implementation Method 1
the contact body being formed by plastic deformation of part of the contact lug for axial abutment with a subsequent plate in the axial direction to the intermediate plate
Data Source
Figure 1
Figure 2~3b
Figure 4a~6
AI summary
The invention relates to an intermediate plate (34) for a multi-disk clutch (20), in particular a two-disk clutch, for coupling a drive shaft (12) of a motor-vehicle motor to at least one transmission input shaft (16, 18) of a motor-vehicle transmission, in particular for a dual clutch (10), comprising: an annular body (48) for pressing, in a friction-closed manner, between a counterplate (22) that can be coupled to the drive shaft (12) and a pressure plate (26) that can be axially displaced in relation to the counterplate (22); and a contact tab (46), in particular formed integrally with the annular body (48), for displacably coupling the annular body (48) to the pressure plate (26), wherein the contact tab (46) has a contact body (42), which is formed by plastically deforming part of the contact tab (46) and which protrudes in the axial direction, for axially stopping against a restoring spring (38), which is connected to a pressure plate (26) or further intermediate plate following the intermediate plate (34) in the axial direction and which is designed in particular as a leaf spring. By means of the contact body (42) formed by plastically deforming the contact tab (46), transmission of an especially high torque by means of a friction clutch (20) in the case of different structural forms of a drive train of a motor vehicle is enabled by means of the additional friction surfaces provided by the annular body (48).