Clutch Pack and Piston Layout for Higher Torque With Less Slippage
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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 limitations of the clutch pack, which results in reduced longevity and efficiency.
Innovation Solution
A kit and method for adjusting clutch apply forces by increasing the fluid pressure apply surface area through a replacement annular clutch piston and adapter sleeve, enhancing the clutch pack configuration with double-sided friction clutch plates and a more rigid pressure plate design to improve torque transfer capacity, reduce distortion, and enhance heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the clutch pack torque capacity is increased to transfer more torque, then the torque transfer capacity is improved, but the clutch plates experience excessive slippage leading to performance degradation and premature wear
Solution Approach 1:
The patent changes the physical parameters of the clutch assembly by increasing the fluid pressure apply surface area of the clutch piston and modifying the clutch pack configuration. These parameter changes enable the clutch to transfer higher torque without excessive slippage, resolving the contradiction between torque capacity and reliability.
Solution Approach 2:
The patent employs a composite clutch pack design with double-sided friction clutch plates interleaved with steel plates. This composite structure optimizes the balance between friction material for torque transfer and steel plates for structural integrity and heat dissipation, improving both torque capacity and plate durability.
2Productivity
If the clutch apply forces are increased to reduce slippage, then the torque transfer efficiency is improved, but the clutch pack distortion increases leading to premature failure
Solution Approach 1:
The patent modifies the clutch piston design to increase the fluid pressure apply surface area, which distributes the apply forces more evenly across the clutch pack. This parameter change allows for increased torque transfer efficiency while reducing localized stress and distortion, maintaining clutch pack stability.
3Power
If the clutch assembly is designed to handle higher torque loads, then the power transmission capability is improved, but the heat generation increases leading to premature clutch failure
Solution Approach 1:
The patent uses a composite clutch pack with alternating friction plates and steel plates. The steel plates serve as heat sinks and conduct heat away from the friction interfaces more effectively, enabling the clutch to handle higher power loads while controlling operating temperatures and preventing thermal failure.
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 solution increases clutch apply forces by approximately 10-30%, reduces clutch pack/plate distortion, and improves heat dissipation, leading to enhanced performance and longevity of the clutch assembly without requiring modifications to the existing transmission components or housing.
Implementation Method 1
increasing the fluid pressure apply surface area through a replacement annular clutch piston
Implementation Method 2
Interleaved stacks of clutch plates can transfer torque from a drive shaft to a driven shaft via friction at the mating faces
Implementation Method 3
improves heat dissipation, leading to enhanced performance and longevity of the clutch assembly
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.