Torque Converter Core Ring Wrapped Outer Diameter

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Solution Overview

Problem

Conventional core rings in torque converters have weak points due to undercuts, which can lead to stress risers and potential failure under high pressure, and they require thicker, stronger materials to maintain strength.

Innovation Solution

A core ring design with a wrapped outer diameter and an outwardly extending lip provides additional stiffness, allowing for the use of thinner materials while eliminating undercuts and stress risers, and is formed using an onion ring cut for efficient material flow during manufacturing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If undercuts are provided in radially extending edge for manufacturing purposes, then material flow during forming is enabled, but stress risers and weak points are created that can lead to failure under high pressure

Engineering Contradiction:

Improvematerial flow during formingVSAvoidstrength under high pressure

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent removes the undercuts from the radially extending edge that were previously necessary for manufacturing. By eliminating these stress-raising features, the design achieves both manufacturing capability through alternative means (onion ring cut) and improved structural reliability by removing the weak points that caused failure under high pressure.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of providing undercuts to enable material flow during forming, the invention inverts the approach by using an onion ring cut method that eliminates the need for undercuts. This reversal of the conventional manufacturing approach resolves the contradiction by achieving material flow without creating stress risers.

Inventive Principle:

Principle #13The other way round (Inversion)

2Reliability

If thicker and stronger materials are used to maintain strength under high pressure, then reliability is improved, but device complexity and manufacturing difficulty increase

Engineering Contradiction:

Improvestrength under high pressureVSAvoidmaterial thickness requirements

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The invention removes the undercuts that created stress risers, thereby eliminating the need to compensate for these weak points with thicker or stronger materials. This extraction of the harmful feature allows the use of thinner, simpler materials while maintaining or improving reliability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

By changing the geometric parameters of the core ring - specifically eliminating undercuts and adding a wrapped outer diameter with lip - the invention improves stress distribution and structural integrity. This allows reduction in material thickness while maintaining strength under high pressure, thereby reducing device complexity.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If conventional core ring design with undercuts is used, then manufacturing is simplified, but stiffness and strength are compromised requiring thicker materials

Engineering Contradiction:

Improvemanufacturing processVSAvoidstiffness and strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The invention inverts the conventional manufacturing approach by eliminating undercuts and using an onion ring cut method. This reversal achieves both manufacturing ease and improved strength/stiffness by removing stress risers while maintaining material flow capability during forming.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The wrapped outer diameter with lip creates a curved, continuous structure that eliminates the sharp corners and undercuts of conventional designs. This curvature distributes stress more evenly and provides the necessary stiffness and strength without requiring thicker materials, while still enabling manufacturing through the onion ring cut process.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Data Source

PatentUS10465781B2Torque converter core ring including wrapped outer diameter

Publication Date: 2019.11.05 SCHAEFFLER TECHNOLOGIES AG & CO KG

AI summary

A core ring for an impeller or turbine of a torque converter is provided. The core ring includes an annular base portion including a convex blade side surface portion and a concave stator side surface portion and a wrapped outer diameter portion including an outwardly extending lip protruding radially outward from the annular base portion. A method of forming a torque core ring for an impeller or turbine of a torque converter is also provided. The method includes forming a wrapped outer diameter portion including an outwardly extending protrusion protruding radially outward from an annular base portion including a convex blade side surface portion and a concave stator side surface portion. A torque converter including the core ring is also provided.