Torque Converter Unified Components for Simpler Clutch-Damper Assembly
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Solution Overview
Problem
Existing torque converters require numerous individual components for lock-up clutches, turbines, vibration dampers, and vibration absorbers, leading to complexity and inefficiency in design and assembly.
Innovation Solution
A torque converter design featuring a combination component with a single unified structure that integrates multiple functions, such as a pilot hub, seal plate, turbine shell, and vibration damper components, reducing the parts count and simplifying assembly through non-rotatably connected sections and direct engagement of springs with flanges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple individual components are used for lock-up clutches, turbines, vibration dampers, and vibration absorbers, then each component can be optimized for its specific function, but the overall device complexity and assembly difficulty increase significantly
Solution Approach 1:
The patent combines multiple previously separate components (turbine, vibration damper, vibration absorber, lock-up clutch elements) into a single integrated torque converter assembly. The turbine shell forms the vibration damper housing, the damper plate is integrated within the turbine assembly, and the lock-up clutch piston and seal plate are combined with the turbine structure. This merging reduces the total number of discrete parts while maintaining all necessary functions through carefully designed integrated components.
Solution Approach 2:
The integrated torque converter assembly performs multiple functions simultaneously: the turbine shell serves as both the turbine housing and vibration damper containment structure, the damper plate provides both vibration damping and structural support for the lock-up clutch, and the seal plate integrates sealing functions with the lock-up clutch mechanism. Each component is designed to fulfill multiple roles that previously required separate parts.
2Adaptability or versatility
If numerous individual components are assembled together, then functional flexibility is maintained, but assembly time and manufacturing cost increase
Solution Approach 1:
The patent merges multiple assembly steps into fewer operations by providing pre-integrated components. The turbine and vibration damper are manufactured as a single unified assembly, eliminating the need to separately assemble these two components. Similarly, the lock-up clutch elements (piston, seal plate, springs) are integrated with the turbine structure, reducing the number of assembly operations required and simplifying the manufacturing process.
3Ease of repair
If multiple separate components are used, then ease of repair and replacement is improved, but overall system weight and cost increase
Solution Approach 1:
The patent combines multiple components into integrated assemblies that reduce total weight by eliminating redundant structures, fasteners, and sealing elements that would be required between separate parts. The unified turbine-vibration damper-lockup clutch assembly weighs less than the sum of its separately manufactured counterparts due to shared material and consolidated manufacturing processes.
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 the complexity of torque converter assembly, enhances structural flexibility, and optimizes weight and cost by combining multiple components into a single unified structure, while maintaining effective torque transmission and vibration management.
Implementation Method 1
at least one spring directly engaged with the third section and the output flange
Implementation Method 2
a turbine in fluid communication with the impeller
Data Source
AI summary
A torque converter including: a cover arranged to receive torque; an impeller; a turbine in fluid communication with the impeller; a stator assembly; a lock-up clutch including an axially displaceable piston plate; a vibration damper including an output flange, a retainer plate, and a spring directly engaged with the output flange and retainer plate; a first combination component having a first single unified structure including a first section forming a pilot hub located radially inward of the cover and non-rotatably connected to the cover, and a second section forming a seal plate of the lock-up clutch; and a second combination component having a second single unified structure including a third section forming a shell of the turbine, and a fourth section forming a cover plate of the vibration damper, the fourth section directly engaged with the spring and non-rotatably connected to the retainer plate.