Torque Converter Thrust Assembly Axial Load Transmission
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Solution Overview
Problem
Existing torque converters with axially movable turbines face challenges in effectively transmitting thrust loads between the stator and impeller, leading to inefficiencies and potential misalignment issues during engagement and disengagement of the lockup clutch.
Innovation Solution
A torque converter design that incorporates a thrust assembly with a wear-resistant thrust washer and centering plate, which is snap-fit connected to both the stator and impeller, ensuring secure axial contact and preventing misalignment by using radially extending connectors and protrusions to maintain proper positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a friction material ring is attached to the stator for transmitting thrust load, then the thrust load transmission is enabled, but misalignment issues occur during engagement and disengagement of the lockup clutch
Solution Approach 1:
A thrust assembly comprising a thrust washer and centering plate is introduced as an intermediary component between the stator and impeller. The thrust washer with its thrust surface axially contacts the impeller, while the centering plate with radially extending connectors maintains precise alignment. This intermediary structure enables reliable thrust load transmission through the friction material ring while simultaneously preventing misalignment during lockup clutch engagement and disengagement.
Solution Approach 2:
The thrust assembly is segmented into distinct functional components: a thrust washer for axial thrust transmission, a centering plate for alignment maintenance, and radially extending connectors for structural integration. This segmentation allows each component to perform its specific function optimally - the thrust washer handles load transmission while the centering plate ensures alignment precision, resolving the contradiction between reliability and manufacturing precision.
2Adaptability or versatility
If the turbine is made axially movable for lockup clutch operation, then the lockup clutch functionality is achieved, but thrust load transmission efficiency decreases
Solution Approach 1:
The thrust assembly acts as a mediator that maintains optimal thrust transmission pathways even when the turbine moves axially for lockup clutch operation. The centering plate with radially extending connectors ensures that the stator and impeller remain properly aligned during turbine movement, while the thrust washer continuously maintains axial contact. This allows the turbine to achieve full lockup clutch functionality without sacrificing thrust load transmission efficiency.
3Device complexity
If a simple friction material ring is used for thrust transmission, then the structure is simple, but wear resistance and alignment stability are insufficient
Solution Approach 1:
The thrust assembly employs composite structural design combining a thrust washer made of wear-resistant material with a centering plate structure. This composite approach integrates multiple material properties and structural functions into a single assembly - the thrust washer provides superior wear resistance while the centering plate maintains alignment stability. The friction material ring is integrated with this composite structure, achieving enhanced reliability without excessive complexity.
Solution Approach 2:
Rather than using a simple monolithic friction material ring, the structure is segmented into a thrust washer for wear resistance and a centering plate for alignment stability. Each segment is optimized for its specific function, with the thrust washer handling wear through its specialized material and the centering plate handling alignment through its radially extending connectors. This segmentation achieves superior reliability while maintaining reasonable structural simplicity.
Data Source
AI summary
A torque converter is provided. The torque converter includes an impeller and a stator. The stator includes a thrust assembly connected to both the stator and the impeller. The thrust assembly includes an axial thrust surface for axially contacting an axial surface of a radially extending wall of the impeller. A method of forming a torque converter is also provided. The method includes connecting a thrust assembly to a stator and connecting an impeller to the thrust assembly.