Torque Converter Lock-Up Clutch Rivet Assembly Without Weld Splatter
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing torque converters use welds to connect plates, leading to splatter residue that degrades durability and increases fabrication complexity and cost, as well as requiring channel formation between welds for fluid transfer.
Innovation Solution
A torque converter design utilizing a rivet to non-rotatably connect plates, eliminating the need for welds and allowing for simplified plate fabrication by creating a gap for fluid flow, with the rivet being either distinct from or integral to the plates, and defining pressure chambers to control fluid flow and clutch operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welds are used to connect plates forming pressure chambers, then the plates are non-rotatably connected, but splatter residue is generated that degrades durability and service life
Solution Approach 1:
The patent removes the welding process entirely from the plate connection method. Instead of welding plates together, the invention uses a rivet passing through both plates to achieve non-rotatable connection, thereby eliminating splatter residue generation and its harmful effects on durability and service life.
Solution Approach 2:
The patent replaces the welding mechanical system with a rivet-based mechanical fastening system. The rivet passes through both plates and is deformed to create a secure non-rotatable connection, substituting the thermal welding process with a mechanical fastening approach that avoids splatter contamination.
2Strength
If welds are used to connect plates, then the plates are securely joined, but the fabrication cost and complexity increase
Solution Approach 1:
The patent eliminates the welding operation from the fabrication process. By using a rivet to connect the plates instead of welding, the manufacturing process becomes simpler and less costly, while still achieving the required non-rotatable connection strength between plates.
Solution Approach 2:
The patent employs a rivet, which is a simple, inexpensive fastening component compared to the welding process. The rivet provides adequate connection strength for the application while being more cost-effective and easier to manufacture than welded joints.
3Strength
If welds are used to connect plates, then the plates are joined, but channels must be shaped between welds for fluid transfer
Solution Approach 1:
The patent removes the welding process and the associated channel shaping requirements. By using a rivet connection, the plates do not require complex shaping to create fluid channels between welds, as the rivet connection method allows for simpler plate geometries while maintaining fluid transfer capability.
4Ease of manufacture
If a rivet is used to connect plates with a gap for fluid flow, then fabrication complexity is reduced, but the connection must prevent rotation
Solution Approach 1:
The patent uses a rivet that passes through both plates, creating a segmented connection where the rivet acts as a separate component between the plates. This segmentation allows the rivet to specifically prevent rotation while the plates maintain their structural integrity and fluid flow pathways.
Solution Approach 2:
The rivet serves as an intermediary component between the two plates. It provides the anti-rotation function while allowing the plates to remain relatively simple in shape, facilitating easier manufacturing. The rivet mediates between the conflicting requirements of simplicity and rotational constraint.
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 rivet connection enhances durability, reduces fabrication complexity and cost, and improves the operational efficiency of the torque converter by eliminating splatter contamination and channel formation, while maintaining effective fluid flow and clutch functionality.
Implementation Method 1
a rivet non-rotatably connecting the first plate to the second plate
Implementation Method 2
The first pressure chamber and the second pressure chamber are arranged to receive and expel a fluid to axially displace the piston plate to open and close the lock-up clutch
Implementation Method 3
flowing a second pressurized fluid into a second pressure chamber at least partly defined by the cover and the piston plate
Data Source
AI summary
A torque converter, including: a cover arranged to receive torque; an impeller; a turbine; a stator; and a lock-up clutch including a piston plate, a first plate, a second plate axially disposed between the cover and the first plate, and a rivet non-rotatably connecting the first plate to the second plate, the rivet being a component distinct from the first plate and the second plate. The cover and the piston plate define at least a portion of a first pressure chamber. The first plate and the second plate define at least a portion of a second pressure chamber. The first pressure chamber and the second pressure chamber are arranged to receive and expel a fluid to axially displace the piston plate to open and close the lock-up clutch.