Bidirectional Clutch Piston Locking Against Residual Pressure Drift

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Solution Overview

Problem

Existing clutches for motor vehicles face issues with unwanted axial movements of the switching piston due to residual pressures in hydraulic systems, leading to functional and safety concerns, such as breakage of toothing and uncontrolled vehicle driving, and are complex and costly to control with additional valves.

Innovation Solution

A clutch design featuring a piston actuated in two directions within a housing with variable pressure spaces and engaging elements, including a baffle plate and pressure space sleeve, to prevent unusual axial movements and ensure robust control of the shift sleeve and switching piston positions, using hydraulic actuation for improved disconnect units in electric axles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If hydraulic actuation is used to control the switching piston, then the clutch can be actuated bidirectionally with improved control, but residual pressures cause unwanted axial movements leading to functional safety issues

Engineering Contradiction:
Improveclutch actuation controlVSAvoidfunctional safety
Core Design Contradiction:
Ease of operationVSReliability

Solution Approach 1:

The patent applies preliminary anti-action by introducing a return spring that pre-exerts a counteracting force on the switching piston to compensate for residual hydraulic pressures. The spring is pre-loaded to generate a force that opposes the unwanted axial movements caused by residual pressure, thereby preventing functional safety issues before they occur.

Inventive Principle:
Principle #9Preliminary anti-action

Solution Approach 2:

The return spring acts as an intermediary element between the hydraulic actuation system and the switching piston. It mediates the interaction by providing a mechanical counterforce that balances the residual hydraulic pressure, allowing the piston to remain stable in its positioned state without direct intervention from additional valves or complex control mechanisms.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Reliability

If additional valves are used to control residual pressures, then functional safety can be maintained, but device complexity and cost increase

Engineering Contradiction:
Improvefunctional safetyVSAvoidvalve system complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The return spring enables the clutch system to self-regulate residual pressures without requiring additional valves or complex control systems. The spring automatically generates the necessary counterforce based on the piston's position and the residual pressure conditions, allowing the system to maintain functional safety through its own internal mechanisms rather than external additions.

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The patent extracts the complex valve system from the solution by replacing it with a simple return spring mechanism. Instead of adding sophisticated pressure control valves to manage residual pressures, the invention removes the need for such complex components by using the spring's elastic properties to naturally counterbalance the residual pressures.

Inventive Principle:
Principle #2Taking out (Extraction)

3Device complexity

If the switching piston is freely movable in pressure chambers, then hydraulic actuation is simple, but unwanted axial movements cause noise and friction

Engineering Contradiction:
Improvehydraulic actuation simplicityVSAvoidnoise and friction
Core Design Contradiction:
Device complexityVSObject-generated harmful factors

Solution Approach 1:

The return spring provides preliminary anti-action by pre-loading the switching piston with a counterforce that prevents unwanted axial movements. This pre-established counterbalance eliminates the piston's tendency to move freely under residual pressure, thereby reducing noise and friction generated during operation.

Inventive Principle:
Principle #9Preliminary anti-action

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 minimizes friction and axial play, reduces noise, and simplifies assembly by distributing axial forces through engaging elements, ensuring precise control and positioning of the shift sleeve and switching piston, thus enhancing functional safety and reducing NVH noise.

Implementation Method 1

A first region of the piston is operatively connected to a first pressure space such that when pressure is applied to the first pressure space, the piston is moved in a first direction parallel to the longitudinal axis L

Methodology Applied
Scientific EffectHydraulic pressure: Pressure Increase

Implementation Method 2

using hydraulic actuation for improved disconnect units in electric axles

Methodology Applied
Scientific EffectHydraulic actuation: Hydraulic Press

Data Source

PatentUS12379003B2Clutch with a piston that can be actuated on both sides and mechanical engaging elements
Publication Date: 2025.08.05 SCHAEFFLER TECHNOLOGIES AG & CO KG
  • US12379003B2 patent drawing
  • US12379003B2 patent drawing
  • US12379003B2 patent drawing

AI summary

A clutch for selectively coupling a motor and a motor vehicle drive train includes a housing having two pressure chambers, a shift sleeve, an actuating cap arranged for moving the shift sleeve, a piston, an idler gear and a mechanical engaging element. The piston is arranged in the housing between the two pressure chambers in a pressure-dependent, axially movable manner and is connected to the actuating cap. The mechanical engaging element is arranged between an axially movable component and an axially fixed component to engage the shift sleeve in two different axial positions. The axially movable component may be the shift sleeve or the piston, and the axially fixed component may be the housing or the idler gear.