Torque Converter Thrust Washer With Integrated Fluid Flow Paths
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional torque converter assemblies face challenges in providing an inexpensive, durable, and reliable configuration that effectively separates fluid chambers and supports thrust loads while maintaining efficiency, particularly in multi-pass designs where high pressure and thrust loads are involved.
Innovation Solution
A torque converter assembly incorporating a thrust washer with radially inner and axial surfaces for engagement with a drive shaft and damper flange, featuring three distinct flow paths and a seal plate hub for fluid management, formed from plastic without the need for machining or forging, and secured via interference fits and retainer tabs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional thrust washers or thrust bearings are used to support thrust loads, then the torque converter can handle high pressure and thrust loads, but the manufacturing cost and complexity increase
Solution Approach 1:
The patent combines the thrust bearing function and fluid flow path function into a single integrated thrust washer component. The thrust washer includes axial surfaces for supporting thrust loads from the turbine-damper assembly while simultaneously defining flow paths for fluid communication between chambers. This integration eliminates the need for separate thrust bearing components and complex machined parts, reducing manufacturing cost while maintaining thrust load support capability.
Solution Approach 2:
The thrust washer serves multiple functions: it acts as a thrust bearing to support axial loads, defines flow paths for fluid communication between different chambers, and provides structural support for the seal plate hub. This multi-functionality reduces the overall component count and simplifies the assembly, addressing the contradiction between strength and ease of manufacture.
2Reliability
If a machined or forged component is used to separate fluid chambers and provide flow paths, then reliable separation between chambers is achieved, but manufacturing cost increases due to geometry and design requirements
Solution Approach 1:
The thrust washer integrates the fluid chamber separation function with the thrust bearing function. The axial surfaces and flow path definitions are incorporated directly into the thrust washer structure, eliminating the need for separate machined or forged components dedicated to fluid chamber separation. This reduces manufacturing cost while maintaining reliable separation between charge pressure and apply pressure chambers.
3Strength
If multiple separate components are used for thrust support and fluid flow paths, then each function can be optimized, but device complexity increases
Solution Approach 1:
The patent merges the thrust bearing component with the fluid flow path component into a single thrust washer. This integration reduces the number of parts and assembly steps while maintaining both thrust load support and fluid flow path functions. The simplified assembly process and reduced component count directly address the device complexity issue.
Data Source
AI summary
A torque converter assembly is disclosed herein. The torque converter assembly includes a thrust washer having a radially inner surface configured to engage against a drive shaft. A first axial surface of the thrust washer is configured to contact a cover. A second axial surface of the thrust washer is configured to contact a damper flange. The second axial surface of the thrust washer partially defines a first flow path. The thrust washer further comprises a second flow path configured to direct fluid in a first direction and a third flow path configured to direct fluid in a second direction. The thrust washer disclosed herein both provides an axial thrust bearing feature, and also provides three distinct flow paths or passages.