Torque Converter Seal Plate Sealing Without Welds in Hybrid Modules
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Solution Overview
Problem
Hybrid modules face challenges in packaging all necessary components due to axial and radial constraints, making it difficult to fit components like e-motor, crank damper, torque converter, torque converter clutch, and resolver within the limited hybrid module envelope while maintaining durability and performance.
Innovation Solution
A hybrid module design incorporating a torque converter with a seal plate non-rotatably connected to the front cover and piston, creating an apply chamber without welds or bonded seals, which reduces complexity and size, allowing for axial and radial movement of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welds and bonded seals are used to seal the seal plate to the front cover, then sealing reliability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent replaces the mechanical joining methods (welding and bonding) with a purely mechanical sealing approach using a groove and seal lip configuration. The seal plate includes a groove that receives a seal, and the front cover has a seal lip that engages with this groove, creating a mechanical interference fit that provides both sealing and structural attachment without thermal or chemical processes.
Solution Approach 2:
The patent uses a simple, inexpensive seal element (such as an O-ring or lip seal) that can be easily replaced if needed, rather than relying on permanent welds or bonds. This disposable seal component provides reliable sealing while keeping the overall manufacturing process simpler and more cost-effective.
2Adaptability or versatility
If the front cover is bent to create the apply chamber, then design flexibility is improved, but manufacturing precision and durability worsen
Solution Approach 1:
The patent divides the apply chamber creation into separate functional elements: the seal plate with its groove configuration and the front cover with its seal lip. This segmentation allows each component to be manufactured with standard precision using conventional processes, avoiding the need for complex bending operations on the front cover while still achieving the desired chamber geometry through the assembly of these segmented parts.
3Reliability
If the seal plate size is increased to accommodate welds and bends, then sealing capability is improved, but the hybrid module envelope increases
Solution Approach 1:
The patent employs a thin seal lip on the front cover that flexibly engages with the groove in the seal plate. This flexible seal lip configuration provides effective sealing capability while maintaining a compact seal plate size, as the sealing function is achieved through the elastic deformation and contact of the thin seal lip rather than requiring a large rigid sealing surface.
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 costs and complexity by eliminating the need for welds and allows for more compact packaging of the clutch assembly within the hybrid module, enhancing durability and performance by creating an apply chamber with a reduced seal plate size and no bends in the front cover.
Implementation Method 1
The seal is compressed between the seal plate and the front cover
Data Source
AI summary
A hybrid module includes a torque converter and a clutch assembly. The torque converter includes a front cover. The clutch assembly includes a piston axially spaced from the front cover. The piston is axially slidable to engage the clutch assembly. The clutch assembly further includes a seal plate non-rotatably connected to the front cover and sealed to the piston. A seal is compressed between the seal plate and the front cover.