Torque Converter Stator Side Plate Attachment Without Weakening

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Stator assemblies in torque converters face issues with attachment methods that weaken the stator, leading to cracking under higher torque applications, as existing methods create weakened areas in the stator material.

Innovation Solution

The stator assembly incorporates an annular side plate with circumferentially arranged attachment portions and anti-rotation tabs, which are staked into the hub to prevent rotation and axial displacement, reducing material removal and minimizing the risk of cracking, or uses teeth that cut into the stator to secure the plate without creating weakened areas.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional attachment methods are used to secure the side plate to the stator, then the side plate is firmly attached, but the stator material is weakened and prone to cracking under high torque

Engineering Contradiction:

Improvestator strengthVSAvoidattachment reliability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The attachment system is segmented into discrete attachment portions distributed circumferentially around the stator. Each attachment portion includes spaced anti-rotation tabs that define a receptacle, with material flowing between the tabs during staking to create rotational fixation without compromising overall stator integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The attachment portions are localized to specific circumferential positions on the stator rather than requiring extensive material removal across the entire stator structure. This localized approach concentrates the attachment function at discrete points, preserving the overall strength and structural integrity of the stator while achieving reliable fixation.

Inventive Principle:

Principle #3Local quality

2Ease of manufacture

If material is removed from the stator to attach the side plate, then the plate can be secured, but weakened areas are created that lead to cracking

Engineering Contradiction:

Improveattachment easeVSAvoidstator strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

Instead of removing material from the stator to create attachment features, the invention inverts the approach by having the stator material flow into receptacles defined by tabs on the side plate during the staking process. This eliminates the need for material removal from the stator while achieving secure attachment.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The attachment portions with anti-rotation tabs serve as an intermediary mechanism between the side plate and stator. These tabs define receptacles that receive stator material during staking, creating a mechanical interlock that secures the attachment without requiring material removal from the stator body.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Stability of the object's composition

If the side plate is securely attached to prevent rotation, then relative rotation between stator and plate is prevented, but the attachment method may create stress concentration points

Engineering Contradiction:

Improverotational stabilityVSAvoidstator strength

Core Design Contradiction:

Stability of the object's compositionVSStrength

Solution Approach 1:

The anti-rotation tabs are spaced asymmetrically around the attachment portions, creating a non-uniform distribution of attachment points. This asymmetric arrangement provides effective rotational prevention while distributing stress more evenly compared to symmetric configurations, reducing stress concentration at any single point.

Inventive Principle:

Principle #4Asymmetry

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 provides a robust attachment method that enhances the stator's durability and resistance to failure in high-torque conditions by minimizing material removal and eliminating weakened areas, ensuring reliable operation of the torque converter.

Implementation Method 1

staking the stator at each of the attachment portions such that material of the hub flows between the anti-rotation tabs to rotationally fix the stator and the plate

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Implementation Method 2

teeth formed on the outer surface. The plate is disposed within the inner ring with the teeth penetrating into the inner ring to attach the plate to the stator

Methodology Applied

Scientific EffectMechanical interlocking: Mechanical Fastener

Data Source

PatentUS10895310B2Side plate to stator attachment for torque converter

Publication Date: 2021.01.19 SCHAEFFLER TECHNOLOGIES AG & CO KG

AI summary

A stator assembly of a torque converter includes a stator having circumferentially arranged blades, an inner ring, and projections circumferentially arranged around the inner ring and extending radially inward therefrom. An annular plate is circumscribed by the inner ring and has a plurality of attachment portions circumferentially arranged around an outer surface of the plate. Each of the attachment portions engages with an associated one of the projections and has a pair of spaced anti-rotation tabs that define a receptacle. The receptacle receives the associated one of the projections to prevent relative rotation between the stator and the plate.