Torque Converter Stator Washer Retention Without a Side Plate
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Solution Overview
Problem
Existing stator assembly designs for torque converters face challenges in preventing relative motion between the thrust washer and the stator body while maintaining efficiency and reducing complexity, often requiring additional components like side plates for retention.
Innovation Solution
A stator assembly design that includes a rotatable body with a cavity, a one-way clutch, and a thrust washer with an axial retention element, where the axial retention element engages with the body's channel to non-rotatably connect the thrust washer directly to the stator body, eliminating the need for a side plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a side plate is used to retain the one-way clutch and connect the thrust washer, then the thrust washer is prevented from rotating relative to the stator body, but the device complexity increases due to the additional side plate component
Solution Approach 1:
The patent combines the functions of the side plate and the thrust washer into a single integrated component. The thrust washer is designed with an axial retention feature that directly engages with the stator body, eliminating the need for a separate side plate to retain the one-way clutch and prevent relative motion. This merging of components reduces the overall device complexity while maintaining the reliability of preventing relative rotation between the thrust washer and stator body.
2Reliability
If a side plate is used to retain the one-way clutch, then the one-way clutch is securely retained within the stator body, but the manufacturing cost increases due to additional components and assembly steps
Solution Approach 1:
The patent integrates the one-way clutch retention function directly into the thrust washer component. The axial retention feature of the thrust washer engages with the stator body to secure the one-way clutch, eliminating the need for a separate side plate. This reduces the number of parts to manufacture and assemble, thereby lowering manufacturing costs and simplifying the assembly process while maintaining secure retention of the one-way clutch.
Solution Approach 2:
The thrust washer is designed to perform multiple functions: it provides axial thrust support, retains the one-way clutch, and prevents relative rotation between itself and the stator body. By making the thrust washer a multi-functional component, the patent eliminates the need for the separate side plate component, reducing manufacturing complexity and cost while maintaining reliable retention of the one-way clutch.
Data Source
AI summary
A stator assembly for a torque converter includes a body, a one-way clutch, and a washer. The body is rotatable about an axis and has a cavity defined by an axial wall radially spaced from the axis and a radial wall extending radially inward from the axial wall. The one-way clutch is disposed in the cavity. The washer includes a thrust surface, a supporting surface, and an axial retention feature. The thrust surface faces away from the cavity. The supporting surface directly contacts the one-way clutch. The axial retention element is configured to connect to the axial wall of the body.