Transfer Case Plate Clutch Torque Transfer
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Solution Overview
Problem
Current transfer cases do not effectively couple the primary output shaft to the secondary output shaft for torque transfer in four-wheel drive modes, leading to inefficiencies in power distribution.
Innovation Solution
A transfer case design that includes a plate clutch with interleaved plates and an apply plate, which can form both positive and friction couplings between the primary and secondary output shafts, allowing for selective torque transfer through axial movement of the apply plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plate clutch with interleaved plates is used for selective torque transfer, then torque transfer capability is improved, but device complexity increases due to multiple coupling mechanisms
Solution Approach 1:
The patent combines positive coupling elements (locking ring with splines) and friction coupling elements (interleaved plates) into a single integrated plate clutch assembly. The apply plate serves dual functionality by既能 engage the locking ring for positive coupling又能 compress the interleaved plates for friction coupling, eliminating the need for separate mechanisms and reducing overall device complexity while maintaining reliable torque transfer capability
Solution Approach 2:
The apply plate is designed as a multi-functional component that can perform both positive coupling (through splined engagement with the locking ring) and friction coupling (through compression of interleaved plates). This universal component approach allows a single element to provide multiple coupling modes, reducing the number of parts needed and simplifying the overall clutch mechanism structure
2Adaptability or versatility
If multiple coupling configurations are implemented, then operational versatility is improved, but ease of operation deteriorates due to multiple axial positions required
Solution Approach 1:
The clutch mechanism employs dynamic positioning of the apply plate along the axial direction, where a single actuation movement automatically transitions the system through different coupling states. The apply plate can be positioned at a first axial position for positive coupling, a second axial position for friction coupling, or an intermediate position for disengagement, allowing the system to adapt to different operational requirements through one continuous actuation motion rather than requiring separate control mechanisms for each coupling mode
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
Enables efficient torque transfer between the primary and secondary output shafts, improving power distribution and operational efficiency in four-wheel drive modes by forming a positive coupling and friction coupling as needed.
Implementation Method 1
the apply plate compresses the interleaved plates to form a friction coupling between the primary output shaft and the housing to transfer torque therebetween
Implementation Method 2
the apply plate forms a splined coupling with the locking ring
Data Source
AI summary
A transfer case comprises a primary output shaft, and a secondary output shaft selectively coupleable to the primary output shaft with a plate clutch to transfer torque therebetween. The plate clutch includes a housing, a plurality of interleaved plates that are engaged alternatingly with the primary output shaft and the housing to rotate therewith, and an apply plate non-selectively coupled to the primary output shaft to rotate therewith. The apply plate is moveable axially along the primary output shaft into a first configuration in which the apply plate is positively coupled to the housing to rotate therewith, a second configuration in which the apply plate rotates independent of the housing, and a third configuration in which the apply plate compresses the interleaved plates to form a friction coupling between the primary output shaft and the housing.