Torque Converter Clutch Assembly With Single-Rivet Fluid Routing
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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 such as stamping, machining, 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 rivet, eliminating the need for welding by using existing connectors to guide fluid flow and reduce complexity, while maintaining functionality through separate fluid channels and chambers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional torque converter design with separate components is used, then functional reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the centering flange and dam plate into a single integrated component. The centering flange is formed as an integral part of the dam plate, eliminating the need for separate welding operations while maintaining the structural integrity and functional reliability of the torque converter clutch assembly.
Solution Approach 2:
The connector serves multiple functions: it connects the dam plate to the piston plate, transmits clutch torque, and guides fluid flow through integrated flow passages. This multi-functionality reduces the number of separate components needed while maintaining reliable operation.
2Manufacturing precision
If multiple processing steps (stamping, machining, riveting, welding) are used, then manufacturing precision is improved, but productivity decreases and manufacturing cost increases
Solution Approach 1:
The patent extracts and eliminates the welding operation from the manufacturing process by using mechanical connectors with integrated flow passages. This removes a complex, time-consuming, and costly process step while maintaining adequate assembly precision through precision machining of the connector interfaces.
Solution Approach 2:
The centering flange and dam plate are merged into a single piece, eliminating the welding step required to join them. This integration reduces the total number of processing steps (stamping, machining, riveting) while maintaining the necessary assembly precision through direct mechanical connection.
3Strength
If welding operations are used to connect components, then structural strength is improved, but manufacturing cost and production time increase
Solution Approach 1:
The patent removes welding operations from the manufacturing process by using mechanical connectors (rivets or bolts) to join the dam plate to the piston plate. The integrated centering flange design eliminates the need for welding between the centering flange and dam plate, simplifying manufacturing while maintaining adequate structural strength for torque transmission.
Solution Approach 2:
The patent uses conventional mechanical fasteners (rivets or bolts) instead of permanent welding joints. These connectors are simpler, cheaper to manufacture and install, and sufficient for the application requirements, reducing overall manufacturing cost and production time.
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 design complexity and costs by eliminating the welding operation, integrating the centering flange with the dam plate, and using rivets for both clutch torque transmission and guiding fluid flow, resulting in a more efficient and cost-effective assembly process.
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
Implementation Method 3
A first channel connected to the apply chamber and bounded at least in part by the cover and the dam plate and arranged to route the first fluid from a first fluid circuit to the apply chamber
Implementation Method 4
A second channel may be connected to the balance chamber and bounded at least in part by the dam plate and the fluid diversion plate and arranged to route the second fluid from a second fluid circuit to the balance 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, via a single connector.