Torque Converter Lock-Up Clutch Assembly for Faster Piston Release
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Solution Overview
Problem
Existing lock-up devices in torque converters face challenges with assembly adjustments due to the integration of springs on the piston itself, leading to difficulties in reducing mutual rotation between the lock-up piston and the input side clutch support, which slows down the response speed of the lock-up clutch.
Innovation Solution
A lock-up device design featuring a spring pack as an independent unit, fixed between the lock-up piston and the input side clutch supporter, with a mutual rotation prevention mechanism, including an outer gear and inner gear for axis movement while preventing rotation, and a compact design with bent retainer plates and extrusion rivets for simplified assembly and reduced stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the spring is mounted on the piston itself to accelerate clutch release response, then the response speed is improved, but the assembly adjustment becomes difficult
Solution Approach 1:
The spring is separated from the piston and organized into an independent spring pack unit. This segmentation allows the spring to be pre-assembled and adjusted as a complete module, then installed as a single unit between the piston and clutch support, eliminating complex assembly adjustments while maintaining rapid clutch release response.
2Speed
If the lock-up piston is designed for rapid acceleration to improve response, then the response speed is improved, but mutual rotation between the piston and clutch support occurs
Solution Approach 1:
A mutual rotation prevention mechanism is introduced with asymmetric geometric features: protrusions on the piston perimeter and corresponding recesses on the clutch support, along with a positioning plate having a specific geometric shape. This asymmetric design allows the piston to move rapidly in the axial direction while preventing rotational movement through the interlocking protrusion-recess geometry.
3Ease of manufacture
If the spring pack is composed as an independent unit for easier assembly, then the assembly process is simplified, but additional components (retainer plates, spring supporters) are required
Solution Approach 1:
Multiple components are merged into the spring pack assembly: the spring, first retainer plate, second retainer plate, first spring supporters, and second spring supporters are combined into a single pre-assembled unit. This merging reduces the number of separate assembly operations and simplifies installation, as the entire spring pack is installed as one module between the piston and clutch support.
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 enhances the assembly efficiency, accelerates the response speed of the lock-up piston, prevents mutual rotation, and reduces the complexity of the assembly process, while maintaining a compact size and stable operation of the torque converter.
Implementation Method 1
a spring pack fixed to the lock-up piston, installed between the lock-up piston and the input side clutch supporter, and including an elastic body that presses the lock-up piston in the direction of releasing the clutch
Implementation Method 2
a mutual rotation prevention mechanism that prevents a mutual rotation between the lock-up piston and the input side clutch supporter
Data Source
AI summary
The lock-up device of a torque converter includes an input side clutch supporter fixed to a front cover for transmitting a power from a drive side; a plurality of clutch plates supported by the input side clutch supporter; a lock-up piston to pressurize the clutch plate to make the clutch connected; a piston guide supporting the end portion of the lock-up piston; a spring pack fixed to the lock-up piston, installed between the lock-up piston and the input side clutch supporter and including an elastic body that presses the lock-up piston in the direction of releasing the clutch; and an mutual rotation prevention mechanism that prevents a relative rotation between the lock-up piston and the input side clutch supporter.