Polymeric Torque Converter Turbine Assembly Without Brazing
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Solution Overview
Problem
Current hydrokinetic torque converters and their assembly methods are complex, cumbersome, and expensive, limiting their performance and cost-effectiveness in vehicular driveline applications.
Innovation Solution
The use of polymeric turbine shell elements and blades connected via welding and/or adhesive bonding to form a coaxial turbine assembly, eliminating the need for costly brazing processes and simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional stamping and brazing processes are used to form the turbine shell and secure turbine blades, then the turbine assembly achieves structural integrity, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent combines the turbine shell and turbine blades into a single integrally formed polymeric component, eliminating the need for separate brazing operations to attach blades to the shell. This merging of components reduces manufacturing steps while maintaining structural integrity through the monolithic polymer structure.
Solution Approach 2:
The invention changes the material parameter from metallic components requiring brazing to polymeric materials that can be integrally formed through molding processes. This parameter change in material selection fundamentally alters the manufacturing approach, replacing complex thermal joining processes with simpler molding and welding operations.
2Strength
If multiple separate turbine components are assembled using fasteners and brazing, then the turbine assembly achieves mechanical attachment, but the assembly time and production cost increase
Solution Approach 1:
The patent merges multiple turbine components (shell and blades) into a single integrally formed polymeric component, eliminating the need for mechanical fastening operations. This integration dramatically reduces assembly time and increases productivity by removing multiple attachment steps from the manufacturing process.
3Ease of manufacture
If polymeric materials are used for turbine shell elements, then the manufacturing cost and complexity are reduced, but the structural strength must be maintained
Solution Approach 1:
The invention changes the material parameter to polymeric substances with appropriate mechanical properties, enabling easier manufacturing through molding processes while maintaining sufficient structural strength for turbine application. The polymeric material parameters are selected to balance manufacturability with structural requirements.
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 approach reduces production complexity and costs while enhancing the performance of hydrokinetic torque converters by providing a robust and efficient turbine assembly that is hydro-dynamically drivable and torsionally vibration-damped.
Implementation Method 1
The connecting involves welding and/or adhesive bonding the first turbine shell element to the second turbine shell element
Implementation Method 2
The connecting involves welding and/or adhesive bonding the first turbine shell element to the second turbine shell element
Implementation Method 3
enhancing the performance of hydrokinetic torque converters by providing a robust and efficient turbine assembly that is hydro-dynamically drivable and torsionally vibration-damped
Data Source
AI summary
A method of making a turbine assembly for a hydrokinetic torque converter includes providing a first turbine component including a polymeric first turbine shell element and first turbine blades connected to the first turbine shell element, providing a second turbine component including a second turbine shell element and second turbine blades connected to the second turbine shell element, and connecting the first turbine shell element to the second turbine shell element to collectively provide a turbine shell of the turbine assembly and fixedly secure the first and second turbine components to one another in a coaxial relationship about the rotational axis. The connecting involves welding and/or adhesive bonding the first turbine shell element to the second turbine shell element. A turbine assembly, a hydrokinetic torque converter, and a method of making a hydrokinetic torque converter are also provided.