Torque Converter Damper Assembly With Pulling Bias Spring
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Solution Overview
Problem
Existing torque converters face challenges in fitting all necessary components within the limited envelope while maintaining durability and performance, particularly due to the increased size caused by bias springs that create friction between damper components, which affect noise, vibration, and harshness (NVH) performance.
Innovation Solution
A torque converter design incorporating a pulling bias spring that pulls damper assembly components into contact, reducing the stack path and install height variation, thereby ensuring consistent hysteresis, loads, and stresses, while adhering to packaging constraints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a bias spring is used to push damper components into contact to create friction, then NVH performance is improved, but the size of the damper assembly increases due to the required stack path
Solution Approach 1:
Instead of using a bias spring to push components into contact (conventional approach), the patent inverts the approach by using a pulling bias spring that draws components together. The bias spring is attached to the intermediate flange and pulls it toward the front cover, creating friction between the intermediate flange and front cover while reducing the axial stack path required.
Solution Approach 2:
The patent repositions the bias spring operation from a conventional pushing mechanism requiring significant axial space to a pulling mechanism that operates with reduced axial clearance. By changing the direction of force application (from push to pull) and utilizing the radial attachment points on the intermediate flange, the design achieves the same friction generation function with reduced dimensional requirements in the axial direction.
2Volume of moving object
If a pulling bias spring is used to reduce stack path, then packaging space is improved, but installation height variation may increase
Solution Approach 1:
The patent modifies the bias spring configuration parameters, specifically using a pulling rather than pushing arrangement, and positions the spring to engage with the intermediate flange at optimized locations. This changes the force application parameters to achieve consistent component contact while minimizing axial space requirements.
Solution Approach 2:
The intermediate flange serves as a mediator between the bias spring and the front cover. The bias spring attaches to the intermediate flange, which then transmits the pulling force to create friction with the front cover. This intermediary structure helps distribute and stabilize the forces, reducing variation in installation height while maintaining compact packaging.
3Length of stationary object
If damper components are arranged with limited axial clearance, then torque converter envelope is reduced, but friction contact consistency becomes difficult to maintain
Solution Approach 1:
The patent inverts the conventional pushing bias spring approach to a pulling approach. By attaching the bias spring to pull the intermediate flange toward the front cover rather than pushing from behind, the design achieves reliable friction contact consistency even with limited axial clearance in the torque converter envelope.
Solution Approach 2:
The pulling bias spring is pre-configured to apply the necessary pulling force to maintain consistent contact between the intermediate flange and front cover. This preliminary action ensures that friction contact consistency is maintained throughout operation, even within the constrained axial space of the torque converter envelope.
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 design reduces the stack path for friction creation between components, leading to more consistent hysteresis, loads, and stresses, thus improving NVH performance and satisfying packaging requirements.
Implementation Method 1
a bias spring used to push other damper components into contact with each other to create friction
Implementation Method 2
a bias spring engaged with the intermediate flange and the second cover plate. The bias spring is configured to pull the second cover plate into contact with the intermediate flange
Implementation Method 3
an arc spring supported by the first cover plate and the second cover plate
Data Source
AI summary
A torque converter includes: a front cover arranged to receive torque; an impeller having an impeller shell non-rotatably connected to the front cover; a turbine in fluid communication with the impeller and including a turbine shell; and a damper assembly disposed axially between the front cover and the turbine shell. The damper assembly includes a first cover plate non-rotatably connected to the turbine shell. The damper assembly further includes a second cover plate non-rotatably connected to the first cover plate and disposed axially between the front cover and the first cover plate. The damper assembly further includes an intermediate flange disposed axially between the first cover plate and the second cover plate. The damper assembly further includes a bias spring engaged with the intermediate flange and the second cover plate. The bias spring is configured to pull the second cover plate into contact with the intermediate flange.