Hybrid Module Rotor Connector Layout for Torque Converter Sealing

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Traditional rivets used in hybrid modules require pre-cut holes, leading to potential leakage issues due to contact impacts during sealing.

Innovation Solution

A hybrid module design featuring a connector formed as a single piece with the torque converter's front cover, received in the rotor carrier, eliminating contact between the piston and the connector, and utilizing a tapered or inclined hole to ensure sealing without protrusion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional rivets are used to connect the rotor carrier to the torque converter, then the connection is achieved, but leakage occurs due to contact impact on the sealing surface

Engineering Contradiction:

Improveconnection strengthVSAvoidsealing reliability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The harmful element (protruding connector portion) is completely removed from the system. The connector is designed to be received within the rotor carrier housing without protruding toward the piston, eliminating the source of sealing interference while maintaining connection functionality

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of having the connector protrude outward to make the connection (traditional approach), the connector is inverted to be received inward within the rotor carrier housing. This reverses the traditional configuration and eliminates the sealing interference problem

Inventive Principle:

Principle #13The other way round (Inversion)

2Ease of manufacture

If pre-cut holes are used for traditional rivets, then the connection is formed, but sealing is compromised due to contact during rivet formation

Engineering Contradiction:

Improvemanufacturing easeVSAvoidsealing reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The connector is pre-formed as an integrated part of the torque converter housing before assembly. The receiving hole is pre-formed in the rotor carrier, allowing the connector to be inserted and secured without requiring post-assembly sealing operations that could compromise the sealing surface

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The connector and torque converter housing are merged into a single integrated component. This eliminates the separate sealing interface between the connector and housing, removing the leakage path that plagues traditional rivet connections

Inventive Principle:

Principle #5Merging (Combining)

3Strength

If the connector protrudes toward the piston, then the connection is achieved, but the piston and connector contact causing leakage

Engineering Contradiction:

Improveconnection strengthVSAvoidleakage

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The harmful protruding portion is completely extracted from the system. The connector is designed with a recessed configuration where it is received within the rotor carrier housing, removing the element that causes harmful contact with the piston

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The potential harm of connector protrusion is converted into a benefit by using the rotor carrier housing as a protective enclosure. The housing that could potentially be a source of leakage becomes a protective feature that contains the connector and prevents it from contacting the piston

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Data Source

PatentUS20250119023A1Hybrid module including motor rotor connector for connecting to a torque converter

Publication Date: 2025.04.10 SCHAEFFLER TECHNOLOGIES AG & CO KG

AI summary

A hybrid module is configured for arrangement in a torque path upstream from a transmission and downstream from an internal combustion engine. The hybrid module includes a hybrid drive unit including an electric motor including a rotor. The rotor includes a rotor carrier carrying magnets. The hybrid module also includes a torque converter including a clutch assembly formed by a front cover, a friction material and a piston. The piston is operable to selectively force the friction material into the front cover. The hybrid module also includes a connector non-rotatably fixing the rotor to the torque converter. The connector is formed as a single piece with the front cover and being received in the rotor carrier such that no portion of the connector protrudes from the front cover toward the piston.