Torque Converter Pressure Regulation to Prevent Housing Ballooning
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Solution Overview
Problem
Conventional torque converters with lockup clutches experience excessive oil pressure leading to ballooning and potential damage due to the inability to effectively regulate internal pressure, particularly when using stronger regulator valve springs to increase line pressure.
Innovation Solution
A new lock up apply regulator valve system that isolates and regulates the pressure acting on the lockup clutch piston, using a check ball and orifice to control oil flow and prevent excessive pressure buildup, along with a modified separator plate to block overdrive feed and restrict oil flow, thereby preventing ballooning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If a stronger regulator valve spring is used to increase line pressure, then the clutch lockup time is reduced, but the torque converter housing experiences excessive ballooning and potential damage
Solution Approach 1:
The patent segments the pressure regulation function into two independent systems: (1) the main line pressure regulation system using the pressure regulator valve and spring, and (2) the torque converter internal pressure regulation system using the new regulator valve with spring. This segmentation allows each system to operate at optimized pressure levels without interfering with the other, preventing housing ballooning while maintaining fast lockup response.
Solution Approach 2:
The new regulator valve acts as an intermediary component between the main line pressure system and the torque converter internal pressure system. It receives high-pressure oil from the main system and regulates it to a lower, controlled pressure level before delivering it to the torque converter clutch chamber, thereby mediating the pressure conflict between fast lockup and housing protection.
2Productivity
If increased line pressure is applied to reduce clutch engagement time, then productivity improves, but the torque converter components suffer from excessive deformation and damage
Solution Approach 1:
The patent applies local quality by creating different pressure zones within the torque converter system. The main line pressure remains high for fast clutch engagement, while the new regulator valve creates a localized lower-pressure zone in the torque converter internal circuit. This allows high productivity in clutch engagement while protecting local components from excessive pressure damage.
3Strength
If the torque converter housing is made more resilient to withstand higher pressure, then pressure tolerance improves, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
Instead of extracting and solving the problem by making the housing stronger, the patent extracts the pressure regulation function and places it in a dedicated regulator valve component. This removes the need to over-engineer the housing for high pressure, allowing the housing to remain simple and easy to manufacture while the valve system handles the pressure control complexity.
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
The system effectively regulates oil pressure within the torque converter, preventing damage from excessive deformation and ensuring safe operation by maintaining pressure within acceptable limits, thus protecting the torque converter and oil pump components.
Implementation Method 1
using a check ball and orifice to control oil flow and prevent excessive pressure buildup
Implementation Method 2
The main pressure regulator valve 1 is mounted on a compression spring 2, so as to hold the valve in a bore of the transmission casting
Data Source
AI summary
A valve body for an automotive transmission includes a pressure regulator valve in the casting for controlling oil pressure within the torque converter. The valve has a bore to provide fluid communication with an exhaust circuitry in the transmission when the valve is moved by oil pressure from a first position to a second position. The regulator valve prevents excessive pressure and damage from ballooning of the torque converter housing. In an alternative non-lockup torque converter, a check ball in a modified separator plate moves to open and close an oil path in the plate to thereby control oil pressure.