Torque Converter Flow Plate Layout Without Cross-Flow Hub
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Solution Overview
Problem
Existing torque converters with cross-flow hubs are expensive and add complexity due to the need for costly forgings and cross-drilling operations, making them undesirable for efficient fluid flow to pressure chambers.
Innovation Solution
A torque converter design that eliminates the hub by using a flow plate and backing plate with a through-bore, where the flow plate is welded to the backing plate, creating separate fluid flow paths for clutch apply and release without the need for cross-flow hubs, allowing for a cross-flow configuration without forgings or costly drilling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cross-flow hubs are used to provide fluid flow paths for clutch apply and release, then fluid flow paths are provided, but cost and device complexity increase due to expensive forgings and cross-drilling operations
Solution Approach 1:
The hub is divided into a first hub portion and a second hub portion that are separately formed and then assembled together. This segmentation eliminates the need for expensive cross-drilling operations through a single monolithic hub, as each portion can be manufactured independently using standard drilling processes, then joined through conventional assembly methods.
Solution Approach 2:
The first hub portion and second hub portion are assembled together to form the complete hub structure. This merging of separately manufactured components achieves the same fluid flow path functionality as a single cross-drilled hub, but through a more cost-effective and less complex manufacturing process that avoids expensive forgings and cross-drilling operations.
2Ease of manufacture
If cross-flow hubs with multiple flow passages are used, then fluid flow paths are provided for pressure chambers, but manufacturing complexity increases due to cross-drilling operations
Solution Approach 1:
The hub is segmented into two separately manufactured portions, each with its own flow passages drilled independently. This eliminates the need for complex cross-drilling operations that require high precision to pass through the entire hub, as each portion is drilled separately using simpler, more precise single-sided drilling processes.
Solution Approach 2:
The interface between the first hub portion and second hub portion serves as an intermediary that connects the separately drilled flow passages. This assembly interface allows fluid to flow from one portion to the other, achieving the cross-flow functionality without requiring complex cross-drilling through a single component.
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 reduces costs and complexity by eliminating the hub, providing a cost-effective and simplified cross-flow configuration for fluid flow to pressure chambers, enhancing the efficiency and reliability of torque converters.
Implementation Method 1
The flow plate is welded to the backing plate around the through-bore
Data Source
AI summary
A torque converter includes a front cover arranged to receive a torque; an impeller non-rotatably connected to the front cover; a turbine in fluid communication with the impeller; a lock-up clutch having a piston and a seal plate disposed axially between the piston and the turbine. The torque converter further includes a flow plate non-rotatably connected to the front cover, and a backing plate sealed to the piston and disposed axially between the flow plate and the seal plate. A through-bore extends axially through the backing plate and the flow plate. The flow plate is welded to the backing plate around the through-bore. A first chamber is bounded at least in part by the piston, the seal plate, and the backing plate, and a second chamber is bounded at least in part by the front cover, the piston, the backing plate, and the flow plate.