Abstract:
A lug for a torque converter includes a first radial segment, a second radial segment, and an axially extending connector segment. The first radial segment has a first aperture and respective first and second circumferential ends. The second radial segment has a second aperture aligned with the first aperture, a third circumferential end fixed to the first circumferential end, and a fourth circumferential end fixed to the second circumferential end. The axially extending connector segment joins the first and second radial segments. In an example embodiment, a pre-formed blank for the lug includes a line of symmetry passing through the connector segment.

Description:
FIELD 
     The invention relates generally to a lug for a torque converter, and more specifically to a stamped sheet metal lug for a torque converter having improved durability. 
     BACKGROUND 
     Torque converter lugs are known. One example is shown in  FIGS. 2-3 .  FIG. 2  is a front view of prior art torque converter  100 .  FIG. 3  is a section view of prior art torque converter  100  of  FIG. 2  taken generally along line  3 - 3  in  FIG. 2 . Converter  100  includes impeller  102 , stator  104 , and turbine  106 . Cover  108  is fixed to the impeller by welding, for example, to form a housing for the torque converter. Prior art lugs  110  are fixed to the cover by welding. Lugs  110  may be made by machining or forging, for example. Also, an example sheet metal drive plate is shown and described in commonly-assigned U.S. Pat. No. 6,561,330. 
     BRIEF SUMMARY 
     Example aspects broadly comprise a lug for a torque converter including a first radial segment, a second radial segment, and an axially extending connector segment. The first radial segment has a first aperture and respective first and second circumferential ends. The second radial segment has a second aperture aligned with the first aperture, a third circumferential end fixed to the first circumferential end, and a fourth circumferential end fixed to the second circumferential end. The axially extending connector segment joins the first and second radial segments. In an example embodiment, a pre-formed blank for the lug includes a line of symmetry passing through the connector segment. 
     In an example embodiment, the first and second radial segments are in contact. In an example embodiment, the first and third circumferential ends are fixed together by welding, and the second and fourth circumferential ends are fixed together by welding. In an example embodiment, the first and second apertures include a continuous thread arranged for receiving a fastener. In an example embodiment, the first circumferential end is aligned with the third circumferential end or the second circumferential end is aligned with the fourth circumferential end. In an example embodiment, a circumferential length of the first or second radial segment is greater than a circumferential length of the connector segment. In an example embodiment, the lug is manufactured from sheet metal. 
     Other example embodiments broadly comprise a cover assembly for a torque converter including a cover shell, at least one sheet metal lug, and first and second welds. The sheet metal lug includes a radially outer axial connector portion and first and second radial portions. The radial portions are fixed together at the radially outer axial connector portion. Each radial portion includes a first and a second circumferential end. The first weld fixes the respective first circumferential ends together and to the cover shell. The second weld fixes the respective second circumferential ends together and to the cover shell. In an example embodiment, the respective first circumferential ends or the respective second circumferential ends are aligned. 
     In an example embodiment, the first or second radial portion includes an aperture for receiving a fastener for connecting the cover assembly to an engine flexplate. In an example embodiment, the respective first circumferential ends or the respective second circumferential ends include a radial length, and the first or second weld extends along the entire radial length. In an example embodiment, at least a portion of the first or second weld extends circumferentially from the respective first or second circumferential end. In an example embodiment, the cover shell includes a radial surface and the at least one sheet metal lug is fixed to the radial surface. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The nature and mode of operation of the present invention will now be more fully described in the following detailed description taken with the accompanying drawing figures, in which: 
         FIG. 1A  is a perspective view of a cylindrical coordinate system demonstrating spatial terminology used in the present application; 
         FIG. 1B  is a perspective view of an object in the cylindrical coordinate system of  FIG. 1A  demonstrating spatial terminology used in the present application; 
         FIG. 2  is a front view of a prior art torque converter; 
         FIG. 3  is a section view of the prior art torque converter of  FIG. 2  taken generally along line  3 - 3  in  FIG. 2 ; 
         FIG. 4  is a pre-form blank of a lug according to an example aspect; and, 
         FIG. 5  is a partial cover assembly showing the lug of  FIG. 4  in a formed state. 
     
    
    
     DETAILED DESCRIPTION 
     At the outset, it should be appreciated that like drawing numbers appearing in different drawing views identify identical, or functionally similar, structural elements. Furthermore, it is understood that this invention is not limited only to the particular embodiments, methodology, materials and modifications described herein, and as such may, of course, vary. It is also understood that the terminology used herein is for the purpose of describing particular aspects only, and is not intended to limit the scope of the present invention, which is limited only by the appended claims. 
     Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this invention belongs. Although any methods, devices or materials similar or equivalent to those described herein can be used in the practice or testing of the invention, the following example methods, devices, and materials are now described. 
       FIG. 1A  is a perspective view of cylindrical coordinate system  80  demonstrating spatial terminology used in the present application. The present invention is at least partially described within the context of a cylindrical coordinate system. System  80  has a longitudinal axis  81 , used as the reference for the directional and spatial terms that follow. The adjectives “axial,” “radial,” and “circumferential” are with respect to an orientation parallel to axis  81 , radius  82  (which is orthogonal to axis  81 ), and circumference  83 , respectively. The adjectives “axial,” “radial” and “circumferential” also are regarding orientation parallel to respective planes. To clarify the disposition of the various planes, objects  84 ,  85 , and  86  are used. Surface  87  of object  84  forms an axial plane. That is, axis  81  forms a line along the surface. Surface  88  of object  85  forms a radial plane. That is, radius  82  forms a line along the surface. Surface  89  of object  86  forms a circumferential plane. That is, circumference  83  forms a line along the surface. As a further example, axial movement or disposition is parallel to axis  81 , radial movement or disposition is parallel to radius  82 , and circumferential movement or disposition is parallel to circumference  83 . Rotation is with respect to axis  81 . 
     The adverbs “axially,” “radially,” and “circumferentially” are with respect to an orientation parallel to axis  81 , radius  82 , or circumference  83 , respectively. The adverbs “axially,” “radially,” and “circumferentially” also are regarding orientation parallel to respective planes. 
       FIG. 1B  is a perspective view of object  90  in cylindrical coordinate system  80  of  FIG. 1A  demonstrating spatial terminology used in the present application. Cylindrical object  90  is representative of a cylindrical object in a cylindrical coordinate system and is not intended to limit the present invention in any manner. Object  90  includes axial surface  91 , radial surface  92 , and circumferential surface  93 . Surface  91  is part of an axial plane, surface  92  is part of a radial plane, and surface  93  is part of a circumferential plane. 
     The following description is made with reference to  FIGS. 4-5 .  FIG. 4  is a pre-form blank of lug  200  according to an example aspect.  FIG. 5  is a partial cover assembly showing sheet metal lug  200  of  FIG. 4  in a formed state. Lug  200  includes radial segments  202  and  204 , and connector segment  206 . Segment  202  includes aperture  208  and circumferential ends, or surfaces,  210  and  212 . Segment  204  includes aperture  214  and circumferential ends, or surfaces,  216  and  218 . Apertures  208  and  214  are shown as dashed lines in  FIG. 4  because some embodiments may include apertures in the blank while others may include apertures that are pierced after the lug is formed. In the formed state shown in  FIG. 5 , apertures  208  and  214  are aligned. In an example embodiment, the apertures form a hole extending continuously through segments  202  and  204 . In an example embodiment, the apertures include a continuous thread  219  arranged for receiving a fastener. 
     In the cover assembly shown in  FIG. 5 , end  216  is fixed to end  210 , and end  218  is fixed to end  212 . In an example embodiment, ends  210  and  216  are aligned, and ends  212  and  218  are aligned. In an example embodiment, radial segments  202  and  204  are in contact and the respective pairs of circumferential ends are fixed by respective welds  220  and  222 . Other embodiments (not shown) may include radial segments  202  and  204  connected together by spot welds, for example. In the formed condition shown in  FIG. 5 , connector segment  206  extends axially to connect or join segments  202  and  204 . 
     As shown in  FIG. 4 , an example pre-formed blank for lug  200  includes line of symmetry  224  passing through connector segment  206 . Circumferential length  226  of radial segment  202  is greater than circumferential length  228  of connector segment  206 . Similarly, circumferential length  230  of radial segment  204  is greater than circumferential length  228  of connector segment  206 . In an example embodiment, lug  200  is manufactured from sheet metal. Although lug  200  is shown as symmetric about line of symmetry  224 , other embodiments may exist. For example, in a formed state, ends  210  and  216 , and ends  212  and  218 , may be aligned with respective radial lines passing through a rotational axis of cover assembly  232  as indicated by dashed lines  210 A and  216 A in  FIG. 4 . 
     Cover assembly  232  includes cover shell  234  and sheet metal lug  200 . Lug  200  may be one of a plurality of lugs fixed to shell  234 . Lug  200  includes radial portions  202  and  204  fixed together at radially outer axial connector portion  206 . Ends  210  and  216  are circumferentially aligned and fixed together and to radial surface  235  of cover shell  234  by weld  220 . Ends  212  and  218  are circumferentially aligned and fixed together and to cover shell  234  by weld  222 . In an example embodiment, portions  202  and  204  include respective apertures  208  and  214  for receiving a fastener for connecting cover assembly  232  to an engine flexplate (not shown). In an example embodiment, the apertures are threaded and the fastener is a bolt. Ends  210  and  212  include respective radial lengths  236  and  238 , and welds  220  and  222  extend respectively along the entire radial lengths. Respective portions  240  and  242  of welds  220  and  222  extend circumferentially from respective ends  210  and  212 . 
     Of course, changes and modifications to the above examples of the invention should be readily apparent to those having ordinary skill in the art, without departing from the spirit or scope of the invention as claimed. Although the invention is described by reference to specific preferred and/or example embodiments, it is clear that variations can be made without departing from the scope or spirit of the invention as claimed.