Lock-Up Clutch Stacked Plates Using Rivets Instead of Welds
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Solution Overview
Problem
Existing torque converters use welds to connect plates, leading to splatter residue that degrades durability and increases fabrication complexity and cost, as welded plates require shaping for fluid channels.
Innovation Solution
A torque converter design utilizing a rivet to non-rotatably connect plates, eliminating the need for welds and allowing for planar surfaces, thereby reducing contamination and fabrication complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welds are used to connect plates, then the connection strength is improved, but splatter residue is generated that degrades durability and service life
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a mechanical fastening system using a rivet and stacked plates. The rivet passes through aligned bores in multiple plates, securing them together through mechanical interlocking rather than thermal fusion, thereby eliminating splatter residue while maintaining connection integrity
Solution Approach 2:
The patent introduces an intermediary mechanical fastening system (rivet + stacked plates) between the cover and piston plate assembly. This intermediary structure provides the necessary mechanical connection without the harmful byproducts of welding, acting as a mediator that satisfies both connection strength and durability requirements
2Strength
If welds are used to connect plates, then the connection is achieved, but the plates require shaping to create channels between welds for fluid transfer, increasing fabrication complexity and cost
Solution Approach 1:
The patent segments the fluid transfer function from the structural connection function. Instead of creating channels through welded plates, the design uses separate stacked plates with integrated bores that serve both as connection points for the rivet and as fluid passages. This segmentation allows each component to be simpler in shape while achieving both connection and fluid transfer functions
Solution Approach 2:
The rivet and stacked plate structure serves multiple functions simultaneously: it provides mechanical connection between plates, creates fluid transfer channels through its bores, and eliminates the need for additional shaping operations. This multi-functionality reduces fabrication complexity while maintaining connection strength
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 rivet connection enhances durability and reduces manufacturing costs by eliminating splatter contamination and the need for channel formation between welds, improving the overall performance and efficiency of the torque converter.
Implementation Method 1
a rivet non-rotatably connecting the first plate to the second plate
Implementation Method 2
The first pressure chamber and the second pressure chamber are arranged to receive and expel a fluid to axially displace the piston plate
Data Source
AI summary
A torque converter, including: a cover arranged to receive torque; an impeller; a turbine; a stator; and a lock-up clutch including a piston plate, a first plate, a second plate axially disposed between the cover and the first plate, and a rivet non-rotatably connecting the first plate to the second plate, the rivet being a component distinct from the first plate and the second plate. The cover and the piston plate define at least a portion of a first pressure chamber. The first plate and the second plate define at least a portion of a second pressure chamber. The first pressure chamber and the second pressure chamber are arranged to receive and expel a fluid to axially displace the piston plate to open and close the lock-up clutch.