Clutch Pack and Piston Structure for Higher Torque Transfer
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Solution Overview
Problem
Traditional clutch assemblies in automotive transmissions are limited by the torque they can transfer due to excessive slippage, leading to performance degradation and premature wear, primarily because of the torque limits of the clutch pack, which results in reduced longevity and efficiency.
Innovation Solution
The introduction of an annular clutch retainer adapter sleeve and a replacement clutch piston with an enlarged effective piston reaction area, along with a more rigid clutch pressure plate configuration and an improved clutch pack design featuring double-sided friction clutch plates, increases the torque transfer capacity, reduces slippage, and enhances heat dissipation within the clutch assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If traditional clutch pack design is used, then the clutch assembly can be manufactured with standard components, but the torque transfer capacity is limited and excessive slippage occurs
Solution Approach 1:
The patent changes the physical parameters of the clutch pack by introducing double-sided friction clutch plates with friction material on both faces, increasing the effective friction surface area. This parameter change allows the clutch pack to transfer higher torque without excessive slippage, directly resolving the contradiction between power transfer capacity and performance reliability
Solution Approach 2:
The patent uses composite construction for the clutch plates, combining steel core plates with friction material bonded to both faces. This composite material approach increases the torque transfer capacity while maintaining structural integrity, preventing the slippage that would otherwise occur with single-sided friction plates
2Power
If clutch pack operates at higher torque limits, then power transfer capacity increases, but excessive slippage causes performance degradation and premature wear
Solution Approach 1:
By doubling the friction surface area through double-sided clutch plates, the patent changes the operational parameters to allow higher torque transfer without exceeding the slippage threshold. This extends the service life of clutch plates by preventing the excessive slippage that causes premature wear, while simultaneously increasing power transfer capacity
Solution Approach 2:
The double-sided friction plate design provides a built-in cushioning effect by distributing the frictional heat and stress across both faces of each clutch plate. This prevents localized overheating and stress concentration that would otherwise lead to premature failure, allowing sustained high-torque operation
3Power
If single-sided clutch plates are used, then the clutch assembly structure is simpler, but the torque transfer capacity is insufficient
Solution Approach 1:
The patent changes the structural parameter of the clutch plates from single-sided to double-sided friction material configuration. This parameter change doubles the effective friction surface area without significantly increasing overall assembly complexity, as the double-sided plates are stacked alternately with steel plates in a standard clutch pack arrangement
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
This solution increases clutch apply forces by up to 16%, reduces clutch pack distortion, and improves heat dissipation, thereby enhancing the overall performance and longevity of the clutch assembly while maintaining compatibility with existing OEM transmission components.
Implementation Method 1
Interleaved stacks of clutch plates can transfer torque from a drive shaft to a driven shaft via friction at the mating faces
Implementation Method 2
pressurized fluid passes through ports and into the annular piston chamber. This fluid pressure causes clutch piston to translate axially
Data Source
AI summary
Methods and apparatuses can be used to adjust the torque transfer capacity and improve the overall performance and longevity of a clutch assembly. Through the use of various improved clutch components disclosed herein, it is possible to: (1) increase clutch apply forces through an increase in the fluid pressure apply surface area, or piston reaction area, of a clutch piston, thereby increasing frictional forces generated within a clutch pack for transferring input torque from a drive shaft to a driven shaft; (2) improve clutch plate contact conditions through a more rigid clutch pressure plate configuration, thereby reducing clutch pack/plate distortion and supporting structure deformation and/or wear that can otherwise lead to excessive heat generation and overall clutch performance degradation and/or failure; and/or (3) improve the clutch assembly's ability to dissipate and/or tolerate heat generated through clutch plate friction by means of an improved clutch pack configuration.