Hybrid Conversion Module Engine Decoupling Torque Converter

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Solution Overview

Problem

Light hybrid vehicles face inefficiencies in power transmission and fuel economy due to the lack of a seamless disconnect mechanism between the engine and electric motor/generator, leading to suboptimal energy utilization and increased emissions.

Innovation Solution

A hybrid conversion module with an electro-magnetic clutch and electric motor/generator that selectively decouples the engine from the torque converter, allowing efficient power transmission and energy storage, and includes a battery to facilitate electric-only operation, with the motor/generator attached directly to the torque converter for cooling and to drive the transmission pump.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If a disconnect mechanism is added to selectively decouple the engine from the torque converter, then fuel efficiency and emissions are improved, but device complexity increases

Engineering Contradiction:

Improvefuel efficiencyVSAvoiddevice complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The patent combines the disconnect clutch with the existing torque converter assembly, merging the new hybrid functionality into the conventional powertrain architecture. The clutch is integrated between the engine flywheel and torque converter, allowing selective engagement/disengagement without requiring separate disconnect mechanisms, thus improving fuel efficiency while limiting complexity increases.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The disconnect clutch serves multiple functions: it enables engine disconnection during electric-only operation, facilitates energy recovery during deceleration, and maintains conventional power transmission when engaged. This multi-functionality allows a single component to address multiple operational requirements, improving overall system efficiency without proportionally increasing complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Temperature

If the electric motor/generator is attached directly to the torque converter for cooling, then thermal management is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvethermal managementVSAvoidmanufacturing complexity

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The torque converter's existing coolant flow system serves a dual purpose: it cools the transmission and now also cools the electric motor/generator through direct thermal contact at the attachment interface. The motor/generator housing acts as a heat sink that utilizes the already-present coolant circulation, allowing the system to self-regulate thermal loads without requiring separate cooling infrastructure.

Inventive Principle:

Principle #25Self-service

3Use of energy by moving object

If a clutch is added to enable selective decoupling, then energy utilization is improved, but ease of operation increases complexity

Engineering Contradiction:

Improveenergy utilizationVSAvoidease of operation

Core Design Contradiction:

Use of energy by moving objectVSEase of operation

Solution Approach 1:

The patent replaces manual or mechanical clutch control with electronic control of an electro-magnetic clutch. The clutch engagement and disengagement are managed by an electronic control unit that monitors vehicle operating conditions and automatically actuates the clutch as needed, eliminating the need for manual intervention while optimizing energy utilization during hybrid operation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Enhances fuel efficiency, reduces emissions, and improves vehicle performance by enabling efficient electric-only operation and energy recovery during deceleration, while maintaining consistent propulsion characteristics through speed control.

Implementation Method 1

A clutch is configured to selectively decouple the light hybrid vehicle's engine from the torque converter

Methodology Applied

Scientific EffectElectromagnetic clutch: Electromagnet

Implementation Method 2

The electric motor/generator may be attached directly to the torque converter such that the torque converter can be implemented to cool the electric motor/generator by transmitting engine heat through the torque converter housing where it is absorbed by working fluid within the torque converter

Methodology Applied

Scientific EffectHeat transfer: Heat Exchanger

Data Source

PatentUS7810592B2Light hybrid vehicle configuration

Publication Date: 2010.10.12 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

The present invention provides a hybrid conversion module configured to easily attach to existing powertrain components in order to produce a light hybrid vehicle. The hybrid conversion module includes an electric motor/generator operable to transmit power to a torque converter and thereby drive the light hybrid vehicle. A storage device such as a battery is operatively connected to the electric motor/generator and is configured to transmit energy to or receive energy from the electric motor/generator. A clutch is configured to selectively decouple the light hybrid vehicle's engine from the torque converter such that the vehicle can be powered by the electric motor/generator in an efficient manner. The apparatus of the present invention also includes a light hybrid vehicle having such a hybrid conversion module attached in the manner described to a conventional powertrain.