Splined Backing Ring for Easier Torque Converter Rebuilds

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Solution Overview

Problem

Original equipment (OE) torque converters are difficult to rebuild due to complex construction and the need for specialized equipment, leading to reluctance from aftermarket rebuilders, especially when components like the backing ring and spline ring are challenging to reattach and repair accurately.

Innovation Solution

A splined backing ring is introduced to replace the OE backing ring, which includes a spline ring configured to engage a clutch plate of a modified lock-up clutch assembly, allowing for easier installation and welding without requiring specialized fixtures, and eliminating the need for costly and labor-intensive repairs of the OE spline ring.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of repair

If OE torque converters are rebuilt using original construction methods, then manufacturing precision is maintained, but ease of repair deteriorates due to complex construction and specialized equipment requirements

Engineering Contradiction:

Improveease of repairVSAvoidconstruction complexity

Core Design Contradiction:

Ease of repairVSDevice complexity

Solution Approach 1:

The OE torque converter is divided into separable components: the cover assembly and the backing ring assembly. The backing ring is designed to be removable and replaceable, allowing rebuilders to access and service internal components without specialized equipment. This segmentation enables independent replacement of worn parts while maintaining the integrity of the overall converter.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The spline ring function is extracted from the cover and integrated into the backing ring. This allows the spline engagement features to be accessed and serviced by simply removing the backing ring, eliminating the need for specialized fixtures to access internal components. The extraction simplifies the repair process while maintaining proper spline engagement.

Inventive Principle:

Principle #2Taking out (Extraction)

2Manufacturing precision

If OE backing ring and spline ring are reattached using traditional methods, then original design is preserved, but manufacturing precision deteriorates due to difficulty in achieving accurate alignment and weld quality

Engineering Contradiction:

Improvealignment precisionVSAvoidrepair difficulty

Core Design Contradiction:

Manufacturing precisionVSEase of repair

Solution Approach 1:

The backing ring is pre-equipped with integral spline features and positioning elements before installation. This preliminary configuration ensures proper alignment with the cover spline ring without requiring complex alignment procedures during reattachment. The pre-formed features guide accurate positioning and reduce welding complexity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The spline ring features are merged with the backing ring into a single integral component. This eliminates the need for separate spline ring installation and alignment procedures, reducing the number of precision-critical steps. The combined structure maintains proper spline engagement while simplifying the reattachment process to a single welding operation.

Inventive Principle:

Principle #5Merging (Combining)

3Loss of time

If OE spline ring is repaired, then original components are retained, but loss of time increases due to costly and labor-intensive repair processes

Engineering Contradiction:

Improverepair timeVSAvoidmaterial cost

Core Design Contradiction:

Loss of timeVSLoss of substance

Solution Approach 1:

The design enables the backing ring with integrated spline features to be replaced as a single serviceable component. When wear or damage occurs, the entire backing ring assembly can be removed and replaced without attempting to repair the spline features. This approach recovers the time that would be spent on complex spline ring repairs by allowing direct replacement of the integrated assembly.

Inventive Principle:

Principle #34Discarding and recovering

Solution Approach 2:

The backing ring is designed as an economical, replaceable component rather than a permanent, repair-critical part. The integral spline features are built into a component that can be affordably replaced rather than expensive to repair. This reduces both the time and material costs associated with spline ring maintenance while ensuring proper fit and function.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Data Source

PatentUS11506281B2Torque converters and methods and devices for rebuilding torque converters

Publication Date: 2022.11.22 SONNAX TRANSMISSION CO

AI summary

Methods of repairing a torque converter that enable the continued use of a torque converter and result in a repaired torque converter with a higher-strength and more durable construction. In some examples, a backing ring can be replaced with a replacement backing ring that includes a spline ring for replacing the function of a cover spline ring. In some examples, a method of repairing a torque converter can be improved by providing a replacement backing ring with a radial protrusion for locating the backing ring on the cover, and a method of determining an axial location of the radial protrusion.