Torque converter assembly including thrust washer

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.

FIELD OF INVENTION

The present disclosure relates to a torque converter assembly, and more particularly relates to a thrust washer for a torque converter assembly.

BACKGROUND

Torque converter assemblies are well known. One known type of torque converter is a three-pass torque converter which includes three ports. The first two ports can generally be used for a charging function for the torque converter which requires fluid to be constantly flowing into the torus. This flow is also used for cooling friction facings which are in operation during steady state points while the vehicle is in motion to improve efficiency. A third port can be provided to actuate a piston with an isolated static pressure chamber to actuate the piston, which forces friction facings to compress and transmit torque and bypass the torus. In one aspect, this configuration requires higher pressure than the charge region or chamber but allows the area of the torque converter receiving charge pressure to operate at a lower pressure.

In certain conditions, the torus will exert a thrust load because of the fluid dynamics. Generally, conventional thrust washers or thrust bearings are used for supporting the load.

FIG.1illustrates one type of arrangement for a known torque converter design that includes a machined or forged component5that defines flow paths to keep the apply pressure separated from the charge pressure. Component5can function as a flow diverter, and can be arranged generally between a cover1, pressure plate2, and seal plate3. Component5can be expensive to manufacture due to its geometry and specific design requirement.

It would be desirable to provide an improved configuration for a multi-pass (i.e. at least three-pass) torque converter that is inexpensive, durable, provides a reliable separation between different fluid chambers, and serve the purpose of supporting thrust loads coming from the turbine-damper assembly.

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 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.

A seal plate hub is configured to engage a radially outer surface of the thrust washer. The seal plate hub defines a first passage configured to receive fluid from the second flow path of the thrust washer and a second passage configured to receive fluid from the third flow path of the thrust washer.

The thrust washer is formed from plastic, in one aspect. One of ordinary skill in the art would understand that other materials and manufacturing methods could be used. The thrust washer does not require machining or forging processing steps, in one aspect.

The second flow path and the third flow path can overlap each other in a circumferential direction, in one aspect. The second and third flow paths can be slanted or oriented in an angled configuration such that the inlet and outlets of each flow paths are axially offset from each other. In this way, the flow paths can be provided in a single component (i.e. the thrust washer), and can be circumferentially offset from each other. Multiple flow paths of each of the second and third flow paths can be provided.

The seal plate hub can be configured to axially retain the thrust washer. This retention can be provided via at least one retainer configured to axially retain the thrust washer. The retainer can be formed as a bent over tab or staking tab. This aspect provides a simplified way to axially secure the thrust washer.

Various other secondary components for the torque converter assembly can be provided, and various interfaces or connections between these components can be provided. For example, the thrust washer can be configured to have an interference fit with the drive shaft. The thrust washer can also be configured to have an interference fit with the seal plate hub. The cover can be fixed to the seal plate hub, such as via welding or other connection arrangement. The thrust washer can be configured to provide a seal against the drive shaft and the cover. In one aspect, each side or face of the thrust washer provides a seal interface except for the side or face adjacent to the damper flange.

In one aspect, a seal plate can be attached to the seal plate hub. The seal plate can be attached to the seal plate hub via welding.

The first flow path and the third flow path can be configured to receive fluid from a first source, and the second flow path can be configured to receive fluid from a second source that is different than the first source.

A method of assembling a torque converter assembly is also provided herein.

Additional embodiments are disclosed herein.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Certain terminology is used in the following description for convenience only and is not limiting. “Axially” refers to a direction along an axis (X) of an assembly. “Radially” refers to a direction inward and outward from the axis (X) of the assembly. “Circumferentially” refers to a direction extending along a curve or circumference of a respective element relative to the axis (X) of the assembly. A reference to a list of items that are cited as “at least one of a, b, or c” (where a, b, and c represent the items being listed) means any single one of the items a, b, or c, or combinations thereof. The terminology includes the words specifically noted above, derivatives thereof and words of similar import.

As shown inFIG.2, a torque converter assembly10is disclosed herein. The torque converter assembly10generally can include a thrust washer20, a seal plate hub30, a seal plate35, a damper flange40, a drive shaft45, and a cover50. Additional features for the torque converter assembly10can be included. Additionally, the term torque converter assembly10can refer to fewer elements than generally disclosed herein.

In one aspect, the thrust washer20provides flow paths for fluid to respective chambers and passages, as well as provides a bearing feature. The thrust washer20is shown in more detail inFIG.4. In one aspect, the bearing feature, i.e. the thrust washer20, is generally arranged between the cover50and the damper flange40. The thrust washer20can generally provide at least two flow paths or passages. The thrust washer20can be configured to provide at least three flow paths, in one aspect.

The thrust washer20comprises a radially inner surface22configured to engage against the drive shaft45. The thrust washer20can be secured to the drive shaft45via an interference fit, in one aspect. The thrust washer20can directly contact the drive shaft45, and can provide a seal interface with the drive shaft45, such that chambers on either axial side of the thrust washer20are separated and sealed from each other.

The thrust washer20includes a first axial surface23aconfigured to contact the cover50. In one aspect, the thrust washer20also provides a seal interface or surface with the cover50. Additional details regarding this engagement and interface are provided herein.

The thrust washer20includes a second axial surface23bconfigured to contact the damper flange40and support high axial loads. As shown inFIG.3, a first flow path21ais provided between the thrust washer20and the damper flange40. In one aspect, the thrust washer20can include a groove or recess25that is configured to define the first flow path21a. Alternatively, a plurality of protrusions can be provided on the second axial surface23bthat engage with the damper flange40, and the first flow path21acan be defined in circumferential regions between the protrusions. The first flow path21acan have a boundary or perimeter defined partially by the damper flange40and partially by the thrust washer20.

The thrust washer20can be formed as a plastic component, in one aspect. The thrust washer20can be formed as a polymeric component. The thrust washer20can be formed via injection molding, in one aspect. The thrust washer20does not require forging or other machining formation techniques or steps, in one aspect.

The thrust washer20further comprises a second flow path21bconfigured to direct fluid in a first direction and a third flow path21cconfigured to direct fluid in a second direction. In one aspect, the second flow path21band the third flow path21coverlap with each other in a circumferential direction. The second flow path21band the third flow path21ccan each be slanted in an axial direction. The second flow path21band the third flow path21ccan each extend in a generally radial direction through the thrust washer20. In one aspect, the second flow path21band the third flow path21ccan generally have the same size or diameter. In one aspect, the second flow path21band the third flow path21ccan have varying shapes, sizes, geometries, etc.

The first flow path21acan be configured to receive fluid provided via an inlet in the drive shaft45. For example, an inlet in the drive shaft45can provide fluid through an opening in the damper flange40. The third flow path21ccan also be configured to receive fluid from the same source as the first flow path21a, i.e. via an inlet formed in the drive shaft45.

The seal plate hub30is configured to engage a radially outer surface24of the thrust washer20. The seal plate hub30defines a first passage31aconfigured to receive fluid from the second flow path21bof the thrust washer20and a second passage31bconfigured to receive fluid from the third flow path21cof the thrust washer20. The first and second passages31a,31bcan be oriented in a radial direction, in one aspect. Other orientations, shapes, sizes, etc. can be provided for the first and second passages31a,31b.

In one aspect, the seal plate hub30is configured to axially retain the thrust washer20. This retention can be configured to be achieved in a variety of ways, as one of ordinary skill in the art would appreciate from this disclosure. In one aspect, the seal plate hub30includes at least one retainer32configured to axially retain the thrust washer20. The at least one retainer32can be formed as at least one staking tab that is bent over and engages the thrust washer20. Multiple retainers32can be provided that are circumferentially spaced from each other. Alternatively, the at least one retainer32can include a tab that extends for 360 degrees.

The thrust washer20is configured to have an interference fit with the drive shaft45, in one aspect. The thrust washer20is configured to have an interference fit with the seal plate hub30, in one aspect. In this configuration, the thrust washer20provides sealing surfaces on respective radially inner and outer surfaces22,24. The thrust washer20further provides a sealing interface against the cover50on the surface23a. The thrust washer20is configured to provide a seal against the seal plate hub30, the drive shaft45and the cover50, in one aspect.

The cover50can be fixed to the seal plate hub30, in one aspect. The cover50can be fixed to the seal plate hub30via welding in one aspect. One of ordinary skill in the art would understand that various types of connections or fixation arrangements could be provided between these components.

A seal plate35can be connected or attached to the seal plate hub30. The seal plate35can be attached to the seal plate hub30in a variety of ways. For example, the seal plate35can be welded to the seal plate hub30. In one aspect, the seal plate hub30can include a shoulder33ain which the seal plate35is arranged. The seal plate hub30can further include a groove33bon a radially outer surface configured to receive a seal34. The seal34can be configured to engage against a piston36.

As shown inFIG.3, the first flow path21aand the third flow path21care configured to receive fluid from a first source, and the second flow path21bis configured to receive fluid from a second source that is different than the first source. One of ordinary skill in the art would understand based on this disclosure that various configurations for the flow paths21a,21b,21ccan be provided.

A method of assembling a torque converter assembly10is also provided herein. The method includes attaching the seal plate35to the seal plate hub30. This attachment can be achieved in a variety of ways, such as via welding or other permanent fixation arrangement. The method also includes attaching the cover50to the seal plate hub30. This step can include welding the cover50to the seal plate hub30. The method includes installing a thrust washer20inside of the seal plate hub30, and axially securing the thrust washer20relative to the seal plate hub30via at least one retainer32provided on the seal plate hub30such that the cover50engages a first axial surface23aof the thrust washer20. The method further includes arranging a damper flange40against a second axial surface23bof the thrust washer20. The thrust washer20defines a first flow path21aadjacent to the damper flange40, a second flow path21bconfigured to direct fluid in a first direction, and a third flow path21cconfigured to direct fluid in a second direction. According to this method, multiple interfaces and connections between the components can be provided. For example, the thrust washer20can be configured to have an interference fit with the drive shaft45, the thrust washer20can be configured to have an interference fit with the seal plate hub30, and the thrust washer20can be configured to provide a seal against the drive shaft45and the cover50. One of ordinary skill in the art would understand that various other types of connections and interfaces between adjacent components is possible.

Having thus described the present disclosure in detail, it is to be appreciated and will be apparent to those skilled in the art that many physical changes, only a few of which are exemplified in the detailed description of the invention, could be made without altering the inventive concepts and principles embodied therein.

It is also to be appreciated that numerous embodiments incorporating only part of the preferred embodiment are possible which do not alter, with respect to those parts, the inventive concepts and principles embodied therein.

The present embodiment and optional configurations are therefore to be considered in all respects as exemplary and/or illustrative and not restrictive, the scope of the embodiments being indicated by the appended claims rather than by the foregoing description, and all alternate embodiments and changes to this embodiment which come within the meaning and range of equivalency of said claims are therefore to be embraced therein.