Torque Converter Clutch Assembly With Integrated Fluid Diversion
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Solution Overview
Problem
Existing torque converters with lock-up clutches require complex designs and assembly processes, leading to high production costs due to the need for multiple processing steps and complex components like riveting and welding.
Innovation Solution
A simplified torque converter design that integrates a lock-up clutch with a dam plate, piston plate, and fluid diversion plate connected via a single connector, eliminating the need for welding by using rivets to transmit torque and guide fluid flow, and incorporating a balance chamber for fluid dynamic balancing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional torque converters use large hubs with drilled passages and multiple processing steps including riveting and welding, then the lock-up clutch can function properly, but the production costs increase significantly and the design complexity increases
Solution Approach 1:
The patent combines multiple separate components (hub, fluid diversion plate, and connector) into an integrated structure where the connector is formed as part of the hub itself. This merging eliminates the need for separate riveting and welding operations while maintaining the lock-up clutch functionality, thus reducing design and assembly complexity without compromising reliability.
Solution Approach 2:
The hub structure is designed to perform multiple functions simultaneously: it provides structural support, guides fluid flow through integrated passages, and connects the fluid diversion plate. This multi-functionality eliminates the need for separate components for each function, reducing overall device complexity while maintaining proper lock-up clutch operation.
2Ease of manufacture
If traditional torque converters require multiple processing steps including stamping, machining, riveting, and welding, then the components can be assembled, but the processing costs increase significantly
Solution Approach 1:
The patent integrates the connector as a formed portion of the hub, eliminating the need for separate riveting and welding operations. This reduces the number of processing steps from four (stamping, machining, riveting, welding) to primarily stamping and machining, significantly reducing processing costs while maintaining component assembly capability.
Solution Approach 2:
The patent extracts and eliminates the need for separate riveting and welding processes by integrating the connection function directly into the hub structure. This removal of unnecessary processing steps reduces both cost and complexity while preserving the essential assembly capability.
3Adaptability or versatility
If traditional torque converters use separate components for torque transmission and fluid guidance, then the components can be manufactured independently, but the overall complexity and cost increase
Solution Approach 1:
The patent merges the torque transmission function and fluid guidance function into a single integrated hub structure. The hub simultaneously transmits torque from the impeller and guides fluid to the lock-up clutch through integrated passages, reducing the number of components while maintaining the adaptability to manufacture the hub as a single piece.
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 complexity and costs by eliminating welding operations and integrating existing connectors for both torque transmission and fluid guidance, while maintaining the functionality of a four-pass torque converter.
Implementation Method 1
an apply chamber bounded at least in part by the cover and the piston plate and arranged to receive a first fluid to axially displace the piston plate to close the lock-up clutch
Implementation Method 2
a balance chamber is bounded at least in part by the piston and the dam plate and arranged to receive a second fluid to balance the first fluid in the apply chamber
Data Source
AI summary
A torque converter comprises a cover arranged to receive torque, an impeller including an impeller shell fixed to the cover, and a turbine fluidly coupled to the impeller. A lock-up clutch is provided that includes a dam plate non-rotatably connected to the cover, and a piston plate disposed, at least partially, between the cover and the dam plate. A fluid diversion plate is disposed between the dam plate and the turbine, wherein the dam plate is connected to the piston plate on a first axial side and connected to the fluid diversion plate on a second axial side, opposite the first axial side.