Torque Converter Clutch Seal Plate for Two-Pass Flow Control
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Solution Overview
Problem
Existing torque converter designs with complex clutch systems, such as three or four-pass designs, are costly and increase complexity, while simpler designs like two-pass torque converters face challenges in maintaining clutch controllability and managing fluid flow effectively.
Innovation Solution
A torque converter design featuring a cover, impeller shell, piston, and seal plate with a reed valve that controls fluid flow through radially offset orifices, allowing the piston to displace axially to engage or disengage the clutch based on pressure differences, eliminating the need for traditional hubs and reducing complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional cross-flow hubs are used to provide flow paths for clutch apply and release pressure chambers, then clutch controllability is maintained, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the functions of multiple separate flow passages and cross-flow hubs into a single integrated seal plate structure. The seal plate contains multiple orifices (first apply orifice, second apply orifice, release orifice) that collectively provide all necessary fluid flow paths for clutch engagement and disengagement, eliminating the need for separate cross-flow hubs and reducing overall component complexity while maintaining full clutch controllability
Solution Approach 2:
The seal plate serves multiple functions simultaneously: it acts as a sealing surface between the piston and cover, provides structural support, and contains all fluid flow control orifices for both clutch apply and release operations. This multi-functional integration replaces what would traditionally require multiple separate components including cross-flow hubs, thereby reducing device complexity without sacrificing clutch controllability
2Reliability
If multiple separate components are used for fluid flow management, then clutch controllability is maintained, but manufacturing cost increases
Solution Approach 1:
The patent merges multiple separate components (cross-flow hubs, multiple seal plates, flow passages) into a single integrated seal plate structure that contains all necessary orifices and sealing surfaces. This consolidation reduces the number of parts that need to be manufactured, assembled, and quality-checked, thereby reducing manufacturing cost while maintaining full clutch controllability through the integrated orifice system
3Device complexity
If a simpler two-pass torque converter design is used, then device complexity is reduced, but clutch controllability and fluid flow management become challenging
Solution Approach 1:
The patent segments the fluid flow control into distinct, well-defined orifices within the seal plate (first apply orifice, second apply orifice, release orifice), each with specific functions. This segmentation allows the simple two-pass design to achieve precise clutch controllability by controlling fluid flow through specific orifices at specific times, demonstrating that simplicity and controllability can coexist when the fluid path is properly segmented and defined
Solution Approach 2:
The seal plate acts as an intermediary component that mediates between the piston movements and the fluid flow requirements. By positioning the seal plate between the piston and cover with precisely located orifices, it translates simple piston displacement into controlled fluid flow patterns that achieve reliable clutch engagement and disengagement in the simplified two-pass design
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 enhances clutch controllability, reduces dynamic pressure differences, and simplifies the torque converter structure while maintaining efficiency and NVH improvements, achieving cost-effective and less complex fluid flow management.
Implementation Method 1
In response to an increase of pressurized fluid in the first chamber relative to the second chamber, the piston is configured to axially displace to open the clutch and the portion of the valve opens such that fluid flow passes through the first orifice from the first chamber. And, in response to an increase of pressurized fluid in the second chamber relative to the first chamber, fluid passes from the second chamber, through grooved surfaces of the clutch and then into the first chamber via the second orifice of the seal plate
Implementation Method 2
the piston is configured to axially displace to selectively engage a clutch... In response to an increase of pressurized fluid in the first chamber relative to the second chamber, the piston is configured to axially displace to open the clutch; and, in response to an increase of pressurized fluid in the second chamber relative to the first chamber, the piston is configured to axially displace to close the clutch
Implementation Method 3
A portion of the valve is configured to seal the first orifice to restrict fluid flow to one direction
Data Source
AI summary
A torque converter comprises a cover configured to receive an input torque and an impeller having an impeller shell non-rotatably connected to the cover. A piston is disposed axially between the cover and the impeller. The piston is configured to axially displace to selectively engage a clutch and a seal plate is disposed axially between the piston and the cover. The seal plate is sealed to the cover. A first chamber is formed at least in part by the cover, the seal plate, and the piston. A second chamber is formed at least in part by the piston and the impeller shell.