Torque Converter Rebuild With a Splined Backing Ring

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Original equipment (OE) torque converters are difficult to rebuild due to complex construction and the need for specialized equipment, leading to reluctance among aftermarket rebuilders, especially when components like the backing ring and spline ring are challenging to reattach and repair accurately.

Innovation Solution

A splined backing ring is introduced to replace the OE backing ring, which includes a spline ring configured to engage a clutch plate of a modified lock-up clutch assembly, allowing for easier installation and welding without requiring specialized fixtures, and eliminating the need for costly and labor-intensive repairs of the OE spline ring.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If OE torque converters use complex construction optimized for high production, then manufacturing efficiency is improved, but ease of repair deteriorates

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidease of repair

Core Design Contradiction:

ProductivityVSEase of repair

Solution Approach 1:

The backing ring is segmented into modular components including a splined backing ring and a separate spline ring. This segmentation allows the spline ring to be independently replaced without replacing the entire backing ring assembly, significantly improving repairability while maintaining the integrated construction benefits for manufacturing efficiency.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The spline ring is extracted as a separate replaceable component from the backing ring assembly. This extraction allows the spline ring to be removed and replaced independently when worn or damaged, eliminating the need to replace the entire backing ring and reducing repair complexity and costs.

Inventive Principle:

Principle #2Taking out (Extraction)

2Strength

If OE torque converters use welded backing ring construction, then structural strength is improved, but ease of repair deteriorates due to difficulty in reattachment

Engineering Contradiction:

Improvestructural strengthVSAvoidease of repair

Core Design Contradiction:

StrengthVSEase of repair

Solution Approach 1:

The backing ring assembly is segmented into the splined backing ring and separate spline ring components. This segmentation maintains the welded construction for structural strength while enabling independent replacement of the spline ring without requiring complex reattachment procedures.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The splined backing ring includes pre-formed splines and mounting features that facilitate straightforward installation and welding of the spline ring. This preliminary preparation of the backing ring structure simplifies the repair process while maintaining strong welded connections.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If OE torque converters use loose fit between spline ring and clutch plates, then ease of manufacture is improved, but reliability deteriorates due to vibration and wear

Engineering Contradiction:

Improveease of manufactureVSAvoidreliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The spline ring and splined backing ring are designed with enhanced local quality features including precise spline profiles, increased spline engagement depth, and optimized surface finishes. These local quality improvements create a tighter, more reliable fit that reduces vibration and wear while remaining compatible with standard manufacturing processes.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The spline ring and splined backing ring are constructed from composite or composite-like structures with optimized material properties. This includes using materials with appropriate hardness, wear resistance, and dimensional stability to achieve a tighter fit and reduced vibration without requiring complex manufacturing procedures.

Inventive Principle:

Principle #40Composite materials

4Adaptability or versatility

If OE torque converters include leaf springs to accommodate loose fit, then adaptability is improved, but reliability deteriorates due to failure-prone components

Engineering Contradiction:

ImproveadaptabilityVSAvoidreliability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The leaf springs are completely removed from the design by extracting this compliance mechanism. Instead, adaptability is achieved through the flexible splined connection between the splined backing ring and spline ring, which provides necessary movement and accommodation without the failure-prone leaf spring components.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The mechanical leaf spring system is replaced with a splined mechanical connection system. The splines provide both the structural connection and the necessary flexibility through their engagement geometry, eliminating the need for separate leaf spring components and their associated failure modes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11009125B1Torque converters and methods and devices for rebuilding torque converters

Publication Date: 2021.05.18 SONNAX TRANSMISSION CO

AI summary

Methods of repairing a torque converter that enable the continued use of a torque converter and result in a repaired torque converter with a higher-strength and more durable construction. In some examples, a backing ring can be replaced with a replacement backing ring that includes a spline ring for replacing the function of a cover spline ring. In some examples, a method of repairing a torque converter can be improved by providing a replacement backing ring with a radial protrusion for locating the backing ring on the cover, and a method of determining an axial location of the radial protrusion.