Stamped Flexplate Assembly for Simpler Torque Transfer
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Solution Overview
Problem
Existing flexplates in motor vehicle drivetrains are complex and costly to produce and assemble, often requiring rivets and threaded holes which can lead to inefficiencies in torque transfer and assembly processes.
Innovation Solution
A fully stamped flexplate design with separate components (drive plate, carry plate, backing plate, clinch nuts, and dowel pins) that are attached via direct contact methods such as press fitting and welding, eliminating the need for rivets and threaded holes, and utilizing clinch nuts for fixing to a damper assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional flexplate design with rivets and threaded holes is used, then assembly is possible, but production complexity and cost increase
Solution Approach 1:
The patent merges the drive plate and carry plate into a single integrated flexplate component, eliminating the need for separate rivets and threaded holes. This integration reduces production complexity and assembly steps while maintaining structural integrity through direct metal-to-metal contact between the merged components.
Solution Approach 2:
The flexplate is segmented into functional zones within a single component: the drive plate section with damping elements, the carry plate section with mounting holes, and the flexing section connecting them. This segmentation allows each zone to perform its specific function while maintaining overall structural simplicity.
2Reliability
If rivets and threaded holes are used for attachment, then components can be joined, but torque transfer efficiency decreases
Solution Approach 1:
By merging the drive plate and carry plate into one continuous metal component, the patent eliminates intermediate fasteners (rivets and threaded holes) that create stress concentration points and reduce torque transfer efficiency. The direct metal-to-metal contact across the entire interface provides superior torque transmission while reducing assembly complexity.
3Ease of manufacture
If separate drive plate and carry plate components are used, then assembly flexibility is possible, but production cost increases
Solution Approach 1:
The patent combines separate drive plate and carry plate components into a single stamped flexplate, eliminating the need for additional fastening operations and reducing production costs. The single-component design maintains sufficient assembly flexibility through integrated mounting features and flexing capabilities.
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 solution simplifies production and assembly, reduces costs, and enhances torque transfer efficiency by using direct contact attachment methods, resulting in a more cost-effective and efficient flexplate design.
Implementation Method 1
The clinch nuts may be press fit onto an output side surface of the drive plate
Implementation Method 2
The clinch nuts may be press fit onto an output side surface of the drive plate
Implementation Method 3
The flexplate may further include dowel pins fixed in holes in the drive plate and protruding axially at an output side of the drive plate
Implementation Method 4
The ring gear may be welded to the carry plate
Implementation Method 5
The drive plate may be press fit onto an output side surface of the carry plate
Implementation Method 6
The drive plate may be press fit onto an output side surface of the carry plate
Data Source
AI summary
A flexplate for a motor vehicle drivetrain includes a carry plate configured for being connected to an engine crankshaft and a drive plate. The drive plate and the carry plate are separate components attached directly via contact. The drive plate is configured for transferring torque input into the carry plate to a downstream component. A method of constructing a flexplate for a motor vehicle drivetrain includes stamping a carry plate configured for being connected to an engine crankshaft; stamping a drive plate separate from the carry plate; and attaching the drive plate and the carry plate directly together via contact. The drive plate is configured for transferring torque input into the carry plate to a downstream component.