Compact Torque Converter Layout for Axially Constrained Hybrid Modules
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Solution Overview
Problem
Hybrid modules face challenges in packaging all necessary components such as an e-motor, crank damper, torque converter, torque converter clutch, K0 clutch, and resolver due to axial constraints within limited space.
Innovation Solution
A compact torque converter assembly is designed with a rotor carrier having both axially and radially extending portions, where the torque converter assembly is arranged radially inside the axially extending portion, including an impeller, a turbine, and a lock-up clutch with a clutch plate carrier non-rotatably connected to the turbine shell.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional torque converter designs are used, then the apply pressure chamber requires additional bounding components, but this increases device complexity and axial space requirements
Solution Approach 1:
The turbine shell is merged with the apply pressure chamber bounding structure, where the turbine shell itself forms part of the chamber boundary. This eliminates the need for separate bounding components, reducing device complexity while maintaining the required pressure containment function.
Solution Approach 2:
The turbine shell serves dual functions: it contains the turbine blades for fluid power transmission and simultaneously bounds the apply pressure chamber. This multi-functionality reduces the total number of components needed in the torque converter assembly.
2Volume of moving object
If compact packaging is implemented to fit all components within hybrid module envelope, then axial spacing is reduced, but this may compromise durability and performance requirements
Solution Approach 1:
The torque converter assembly is nested within the hybrid module envelope with the turbine shell forming an inner boundary structure. This nesting arrangement maximizes space utilization while maintaining adequate spacing for durability and performance through the integrated chamber design.
Solution Approach 2:
The design transitions from traditional axial stacking to a more three-dimensional integrated arrangement where the turbine shell creates radial and axial boundaries simultaneously. This dimensional optimization allows compact packaging while preserving functional requirements through the multi-functional chamber structure.
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 design allows for a compact torque converter assembly that fits within hybrid modules with limited space, reducing the need for additional components typically required for bounding the apply pressure chamber, thus lowering costs and complexity while maintaining durability and performance.
Implementation Method 1
An apply chamber is bounded in part by the turbine shell, the piston, and the clutch plater carrier
Implementation Method 2
a turbine in fluid communication with the impeller
Data Source
AI summary
A hybrid module includes a rotor carrier having an axially extending portion and a radially extending portion; and a torque converter assembly arranged radially inside of the axially extending portion. The torque converter assembly includes: an impeller having an impeller shell non-rotatably connected to the axially extending portion; a turbine in fluid communication with the impeller and having a turbine shell arranged axially between the impeller and the radially extending portion; and a lock-up clutch. The lock-up clutch includes a plurality of clutch plates, a clutch plate carrier connected to at least some of the plurality of clutch plates, and a piston axially slidable along the clutch plate carrier to engage the plurality of clutch plates. The clutch plate carrier is non-rotatably connected to the turbine shell. An apply chamber is bounded in part by the turbine shell, the piston, and the clutch plater carrier.