Flexible Torque Converter Clutch Plate Without a Hub
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Solution Overview
Problem
Existing torque converters with integrated lock-up clutches face challenges in reducing complexity and cost, particularly in three-pass designs, and require machining of the turbine shell before clutch facings can be bonded.
Innovation Solution
The torque converter design integrates a lock-up clutch with a clutch plate connected to the turbine shell and a piston actuation system, allowing for radial placement adjustments and material removal slots, which reduces axial stiffness and eliminates the need for a hub, thereby simplifying the manufacturing process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a hub is used in traditional torque converter designs to direct flow to apply and cooling circuits, then the torque converter can achieve proper fluid flow distribution, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent removes the hub component entirely from the torque converter design. The clutch plate is directly connected to the turbine shell without requiring a hub, thereby eliminating the complexity associated with hub-based fluid flow distribution while maintaining functional integrity through alternative sealing and actuation mechanisms
Solution Approach 2:
The clutch plate serves multiple functions: it acts as both the clutch engagement surface and the structural element that directs fluid flow to the apply and cooling circuits. This multi-functional design eliminates the need for a separate hub component while maintaining proper fluid distribution
2Ease of manufacture
If the turbine shell is machined before clutch facings are bonded, then proper bonding surface preparation is achieved, but the manufacturing process complexity and cost increase
Solution Approach 1:
The clutch plate is designed with pre-formed bonding surfaces that require no additional machining before clutch facings are bonded. The bonding surfaces are prepared during the clutch plate manufacturing process itself, eliminating the need for separate machining operations while ensuring adequate surface preparation for bonding
3Ease of manufacture
If the clutch plate is made with high axial stiffness, then the clutch engagement is more precise, but the radial placement flexibility and manufacturing simplicity are reduced
Solution Approach 1:
The clutch plate is designed with non-uniform thickness distribution, featuring thicker regions at the outer diameter and thinner regions toward the center. This local variation in thickness provides adequate axial stiffness at the clutch engagement interface while maintaining manufacturing flexibility and allowing for optimized radial placement
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 reduces the complexity and cost of torque converters by eliminating the need for a hub and allowing for design flexibility, while also simplifying the manufacturing process and improving the radial placement of the clutch plate, leading to enhanced torque transmission efficiency.
Implementation Method 1
the piston is configured to actuate the piston actuation plate to close the lock-up clutch to connect the turbine shell to the impeller shell
Implementation Method 2
a first friction facing is affixed to one of the piston actuation plate and the second end of the clutch plate; and a second friction facing is affixed to one of the second end of the clutch plate and the impeller shell
Data Source
AI summary
A torque converter comprising a front cover, an impeller having an impeller shell connected to the front cover, a turbine having a turbine shell and at least one blade attached thereto, and a lock-up clutch configured to selectively couple the turbine shell to the impeller shell for torque transmission therebetween is provided. In embodiments, the lock-up clutch comprises a clutch plate connected to the turbine shell and extending radially outward therefrom. The clutch plate may include a first end, a second end, and a slot defined between the first and the second ends. The lock-up clutch further may include a piston connected to the front cover, and a piston actuation plate connected to the piston, wherein the piston is configured to actuate the piston actuation plate to close the lock-up clutch to connect the turbine shell to the impeller shell.