Patent Publication Number: US-2023151873-A1

Title: Vibration damper with intermediate flange travel stop and torque converter with vibration damper having intermediate flange travel stop

Description:
TECHNICAL HELD 
     The present disclosure relates to a vibration damper using an intermediate damper as a travel stop and a torque converter including the vibration damper using an intermediate damper as a travel stop 
     BACKGROUND 
     Known vibration dampers use a rivet, connecting cover plates of the vibration damper, as a travel stop. 
     SUMMARY 
     According to aspects illustrated herein, there is provided a vibration damper for a torque converter, including: a first cover plate arranged to receive, from a lock-up clutch, a first rotational torque in a first rotational direction; a second cover plate non-rotatably connected to the first cover plate and including a plurality of radially outwardly extending protrusions defining a first plurality of indentations; an intermediate flange axially disposed between the first cover plate and the second cover plate and including a plurality of axially extending protrusions disposed in the first plurality of indentations; and at least one spring directly engaged with the first cover plate, the second cover plate, and the intermediate flange. 
     According to aspects illustrated herein, there is provided a vibration damper for a torque converter, including: a first cover plate; a second cover plate non-rotatably connected to the first cover plate; an intermediate flange axially disposed between the first cover plate and the second cover plate; at least one spring directly engaged with the first cover plate, the second cover plate, and the intermediate flange; and a resilient element directly engaged with the first cover plate and the intermediate flange and urging the intermediate flange in a first axial direction, parallel to an axis of rotation of the torque converter, away from the first cover plate and into contact with the second cover plate. 
     According to aspects illustrated herein, there is provided a torque converter, including: a cover arranged to receive a first rotational torque in a first rotational direction; an impeller including an impeller shell connected to the cover and at least one impeller blade; a turbine in fluid communication with the impeller and including a turbine shell and at least one turbine blade; stator including at least one stator blade axially disposed between the turbine and the impeller; and a vibration damper including a first cover plate, a second cover plate non-rotatably connected to the first cover plate, an intermediate flange axially disposed between the first cover plate and the second cover plate, at least one spring directly engaged with the first cover plate, the second cover plate, and the intermediate flange, and a resilient element directly engaged with the first cover plate and the intermediate flange and urging the intermediate flange in a first axial direction, parallel to an axis of rotation of the torque converter, away from the first cover plate and into contact with the second cover plate. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Various embodiments are disclosed, by way of example only, with reference to the accompanying schematic drawings in which corresponding reference symbols indicate corresponding parts, in which: 
         FIG.  1    is a partial cross-sectional view of an example torque converter with a vibration damper having an intermediate flange travel stop; 
         FIG.  2    is a back isometric view of the vibration damper shown  FIG.  1   ; 
         FIG.  3    is a front view of a cover plate shown in  FIG.  1   ; 
         FIG.  4    is a back isometric view of an intermediate flange shown in  FIG.  1   ; 
         FIG.  5    is a detail of area  6  in  FIG.  1   ; 
         FIG.  6    is a back view of an output flange shown in  FIG.  1   ; 
         FIG.  7    is an isometric view of the vibration damper shown in  FIG.  1    with a cover plate removed; 
         FIG.  8    is a partial back view of the vibration damper shown in  FIG.  1    in a drive mode, with the intermediate flange and cover plate in contact; 
         FIG.  9    is a partial back view of the vibration damper shown in  FIG.  1    in a coast mode, with the intermediate flange and cover plate in contact; and, 
         FIG.  10    is a partial back view of the vibration damper shown in  FIG.  1    in the drive mode or in the coast mode, with the intermediate flange and cover plate not in contact. 
     
    
    
     DETAILED DESCRIPTION 
     At the outset, it should be appreciated that like drawing numbers on different drawing views identify identical, or functionally similar, structural elements of the disclosure. It is to be understood that the disclosure as claimed is not limited to the disclosed aspects. 
     Furthermore, it is understood that this disclosure is not limited to the particular methodology, materials and modifications described 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 disclosure. 
     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 disclosure belongs. It should be understood that any methods, devices, or materials similar or equivalent to those described herein can be used in the practice or testing of the disclosure. 
       FIG.  1    is a partial cross-sectional view of example torque converter  100  with vibration damper  102  having intermediate flange travel stop. 
       FIG.  2    is a back isometric view of vibration damper  100  shown  FIG.  1   . The following should be viewed in light of  FIGS.  1  and  2   . Torque converter  100  includes: vibration damper  102 ; cover  104 ; impeller  106 ; turbine  108 ; and stator  110 . Impeller  106  includes impeller shell  112  connected to cover  104 , and at least one impeller blade  114 . Turbine  108  is in fluid communication with impeller  106  and includes turbine shell  116  and at least one turbine blade  118 . Stator  110  includes at least one stator blade  120  axially disposed between turbine  108  and impeller  106 . 
       FIG.  3    is a front view of a cover plate shown in  FIG.  1   . 
       FIG.  4    is a back isometric view of an intermediate flange shown in  FIG.  1   . 
       FIG.  5    is a detail of area  6  in  FIG.  1   . The following should be viewed in light of  FIG.  1  through  5   . Vibration damper  102  includes: cover plate  122 ; cover plate  124 ; intermediate flange  126 ; resilient element  128 ; output flange  130  arranged to non-rotatable connect to transmission input shaft TIS, and springs  131  directly engaged with cover plate  122 , cover plate  124 , intermediate flange  126 , and output flange  130 . Resilient element  128  can be any suitable resilient element known in the art, including but not limited to a Belleview washer or diaphragm spring. Resilient element  128  is directly engaged with cover plate  122  and intermediate flange  126  and urges intermediate flange  126  in axial direction AD 1 , parallel to axis of rotation AR of torque converter  100 , away from cover plate  122  and into contact with plate  124 . 
     By one component “directly engaged with” another component, we mean that the components are in direct contact, or that the components are each in direct contact with one or more ancillary intermediate parts, for example, a cap fixed to an end of a spring, such that the components and the ancillary parts are mechanically solid at the points of contact with the one or more ancillary intermediate parts. For example, a washer or coating could be disposed between the two components. 
     Cover plate  124  is non-rotatably connected to cover plate  122 , for example by fasteners  132 , and includes radially outwardly extending protrusions  134  defining indentations  136 . Protrusions  134  extend radially outwardly in radially outer direction RD 1 , orthogonal to axis of rotation AR of torque converter  100 , from body portion  138  of cover plate  124 . In the example of  FIG.  1   , fasteners  132  are rivets. 
     By “non-rotatably connected” components, we mean that components are connected so that whenever one of the components rotates, all the components rotate; and relative rotation between the components is precluded. Radial and/or axial movement of non-rotatably connected components with respect to each other is possible. Components connected by tabs, gears, teeth, or splines are considered as non-rotatably connected despite possible lash inherent in the connection. The input and output elements of a closed clutch are considered non-rotatably connected despite possible slip in the clutch. The input and output parts of a vibration damper, engaged with springs for the vibration damper, are not considered non-rotatably connected due to the compression and unwinding of the springs. Without a further modifier, the non-rotatable connection between or among components is assumed for rotation in any direction. However, the non-rotatable connection can be limited by use of a modifier. For example, “non-rotatably connected for rotation in circumferential direction CD1,” defines the connection for rotation only in circumferential direction CD1. 
     Intermediate flange  126  is axially disposed between cover plate  122  and cover plate  124 , in particular between cover plate  122  and output flange  130 . Intermediate flange  126  includes axially extending protrusions  140  disposed in indentations  136 . Axially extending protrusions  140  define indentations  142 . Each indentation  142  is bounded in axial direction AD 1  by surface segment  144  of intermediate flange  126 . Each surface segment  144  contacts a radially outwardly extending protrusion  134 , for example surface  146  of protrusion  134  facing in axial direction AD 2 , opposite direction AD 1 . Resilient element  128  urges surfaces  144  into contact with surfaces  146  of protrusions  134 . 
     Intermediate flange  126  is rotatable, via springs  131 , with respect to cover plate  122 , cover plate  124 , and output flange  130 . As further described below: surfaces  144  are rotatable with respect to surfaces  146 ; and protrusions  140  are rotatable within indentations  136 . 
     Intermediate flange  126  defines slots  148 , In the example of  FIG.  1   , slots  148  are bound by continuous edges  150  of flange  126 . Fasteners  132  pass through slots  148 . Surfaces  152  of protrusions  140  define indentations  142  in rotational direction RTD 1  around axis AR. Surfaces  154  of protrusions  140  define indentations  142  in rotational direction RTD 2 , opposite direction RTD 1 . Portions  156  of edges  150  define slots  148  in direction RTD 1 . Portions  158  of edges  150  define slots  148  in direction RTD 2 . 
       FIG.  6    is a front view of output flange  130  shown in  FIG.  1   . 
       FIG.  7    is an isometric view of vibration damper  100  shown in  FIG.  1    with cover plate  124  removed. The following should be viewed in light of  FIGS.  1  through  7   . Intermediate flange  126  defines slots  160  in which springs  131  are disposed, Output flange  130  defines slots  162  in which pairs of springs  131 A and  131 B are disposed. For springs  131 A: ends  164  directly engage surfaces  166  of cover plate  124 , and surfaces  168  defining slots  162  in direction RTD 2 ; and ends  170  directly engage surfaces  172  defining slots  160  in direction RTD 1 . For springs  131 B: ends  174  directly engage surfaces  176  of cover plate  124 , and surfaces  178  defining slots  162  in direction RTD 1 ; and ends  180  directly engage surfaces  182  defining slots  160  in direction RTD 2 . In the discussion above and in the discussion that follows, capital letters are used to designate a specific component from a group of components otherwise designated by a three-digit reference character. For example, springs  131 A and  1316  are specific examples among springs  131 . 
     In the example of  FIG.  1   , torque converter  100  includes lock-up clutch  184  with axially displaceable piston plate  186  and clutch plate  188  non-rotatably connected to cover plate  122 , for example by meshing with radially outwardly extending protrusions  190  of cover plate  122 . Protrusions  134  include surfaces  188  bounding indentations  136  in direction RTD 1 , and surfaces  190  bounding indentations  136  in direction RTD 2 . 
       FIG.  8    is a partial back view of vibration damper  100  shown in  FIG.  1    in a drive mode, with intermediate flange  126  and cover plate  124  in contact. The following should be viewed in light of  FIGS.  1  through  8   . As is known in the art, in the drive mode of torque converter  100 , cover  104  receives rotational torque RT 1 , for example in direction RTD 1 , and cover  104  transmits torque RT 1  to output flange  130  via damper  102 . In a torque converter sub-mode of the drive mode, clutch  184  is open and torque RT 1  is transmitted to damper  102  via turbine shell  116  non-rotatably connected to cover plate  124 , In a lock-up sub-mode of the drive mode, clutch  184  is closed and torque RT 1  is transmitted to damper  102  via clutch  184  and clutch plate  188 . It is understood that torque multiplication occurs in the torque converter mode. However, to simplify the discussion that follows, it is assumed that the magnitude of torque RT 1  received by damper  102  is the same for both sub-modes. 
     In the drive mode, and for a magnitude of rotational torque RT 1  in direction RTD 1  and less than threshold value TV 1 : cover plate  124  transmits torque RT 1  to flange  126  via springs  131 A; and flange  126  transmits torque RT 1  to flange  130  via springs  131 B. Springs  131  can be uncompressed or partially compressed. 
     In the drive mode, and for a magnitude of rotational torque RT 1  greater than or equal to threshold value TV 1 : cover plate  124  rotates, with respect to flange  126 , in direction RTD 1 , and compresses springs  131 A until surfaces  154  of protrusions  140  contact surfaces  192 , defining indentations  136  in direction RTD 2 , preventing further rotation of cover plate  124 , with respect to flange  126 , in direction RTD 1  and further compression of and possible damage to springs  131 A. Cover plate  124  transmits torque RT 1  directly to flange  126 , bypassing springs  131 A. Fasteners  132  do not contact portions  156 , preventing damage to fasteners  132 . 
       FIG.  9    is a partial back view of damper  102  shown in  FIG.  1    in a coast mode with intermediate flange  126  and cover plate  124  in contact. In the coast mode of torque converter  100 , output flange  130  receives rotational torque RT 2 , in direction RTD 2  from shaft TIS. In the coast mode, and for a magnitude of rotational torque RT 2  less than threshold value TV 2 : flange  130  transmits torque RT 2  to flange  126  via springs  131 B; and flange  126  transmits torque RT 2  to cover plate  124  via springs  131 A. Springs  131  can be uncompressed or partially compressed. 
     In the coast mode, and for a magnitude of rotational torque RT 2  greater than or equal to threshold value TV 2 : intermediate flange  126  rotates, with respect to cover plate  124 , in direction RTD 2 , and compresses springs  131 A until surfaces  152  of protrusions  140  contact surfaces  192 , defining indentations  136  in direction RTD 1 , preventing further rotation of flange  126 , with respect to cover plate  124 , in direction RTD 2  and further compression of and possible damage to springs  131 A. Flange  126  transmits torque RT 2  directly to cover plate  124 , bypassing springs  131 A. Fasteners  132  do not contact portions  158 , preventing damage to fasteners  132 . 
       FIG.  10    is a partial back view of vibration damper  100  shown in  FIG.  1    in either the drive mode or the coast mode with intermediate flange  126  and cover plate  124  free of contact. In the drive mode and for a magnitude of torque RT 1  below threshold value TV 1 : some or all of springs  131  may be partially compressed, causing relative rotation among cover plate  124 , flange  126  and/or flange  130 , or springs  131  may be uncompressed by torque RT 1 ; protrusions  140  are free of contact with protrusions  134 ; and fasteners  132  are free of contact with portions  156 . 
     In the coast mode and for a magnitude of torque RT 2  below threshold value TV 2 : some or all of springs  131  may be partially compressed, causing relative rotation among cover plate  124 , flange  126  and/or flange  130 , or springs  131  may be uncompressed by torque RT 1 ; protrusions  140  are free of contact with protrusions  134 ; and fasteners  132  are free of contact with portions  158 . 
     Protrusions  140  include surfaces  196  facing in radially inward direction RD 1 , and cover plate  124  includes surface segments  198  defining indentations  136  in radially outer direction RD 1 . The interface of surfaces  196  with segments  198  radially centers flange  126  to cover plate  124 . 
     The following should be viewed in light of  FIGS.  1  through  10   . The following describes a method of operating a torque converter in a drive mode, the torque converter including a cover, an impeller, a turbine in fluid communication with the impeller, a stator including at least one stator blade axially disposed between the turbine and the impeller, a lock-up clutch, and a vibration damper including a first cover plate, a second cover plate non-rotatably connected to the first cover plate with a fastener and including a plurality of radially outwardly extending protrusions defining a first plurality of indentations, an intermediate flange axially disposed between the first cover plate and the second cover plate and including a plurality of axially extending protrusions disposed in the first plurality of indentations and defining a second plurality of indentations, an output flange, and pairs of springs engaged with the first cover plate, the second cover plate, the intermediate flange, and the output flange, the intermediate flange further including a slot through which the fastener passes. 
     A first step rotates, in a rotational direction and with a rotational torque having a magnitude less than a threshold value, the cover, the first cover plate, and the second cover plate. A second step transmits, via the springs, the torque from the second cover plate to the intermediate flange. A third step increases the magnitude of the rotational torque to be greater than or equal to the threshold value. A fourth step compresses one spring of each pair of springs between the second cover plate and the intermediate flange. A fifth step rotates the second cover plate, with respect to the intermediate flange, in the rotational direction. A sixth step contacts, with the plurality of axially extending protrusions, the plurality of radially outwardly extending protrusions. A seventh step blocks further compression of the one spring. An eighth step transmits the rotational torque directly from the second cover plate to the intermediate flange, bypassing the one spring. A ninth step displaces, in the rotational direction, the fastener through a slot in the intermediate flange without contacting a portion of the intermediate flange defining the slot in the rotational direction. 
     The following should be viewed in light of  FIGS.  1  through  10   . The following describes a method of operating a torque converter in a coast mode, the torque converter including a cover, an impeller, a turbine in fluid communication with the impeller, a stator including at least one stator blade axially disposed between the turbine and the impeller, a lock-up clutch, and a vibration damper including a first cover plate, a second cover plate non-rotatably connected to the first cover plate with a fastener and including a plurality of radially outwardly extending protrusions defining a first plurality of indentations, an intermediate flange axially disposed between the first cover plate and the second cover plate and including a plurality of axially extending protrusions disposed in the first plurality of indentations and defining a second plurality of indentations, an output flange, and pairs of springs engaged with the first cover plate, the second cover plate, the intermediate flange, and the output flange, the intermediate flange further including a slot through which the fastener passes. 
     A first step rotates, in a rotational direction and with a rotational torque having a magnitude less than a threshold value, the output flange. A second step transmits, via the springs, the torque from the output flange to the intermediate flange. A third step transmits, via the springs, the torque from the intermediate flange to the second cover plate. A fourth step increases the magnitude of the rotational torque to be greater than or equal to the threshold value. A fifth step compresses one spring of each pair of springs between the intermediate flange and the second cover plate. A sixth step rotates the intermediate flange, with respect to the second cover plate, in the rotational direction. A seventh step contacts, with the plurality of axially extending protrusions, the plurality of radially outwardly extending protrusions. An eighth step blocks further compression of the one spring. A ninth step transmits the rotational torque directly from the intermediate flange to second cover plate, bypassing the one spring. A tenth step displaces, in the rotational direction, the intermediate flange such that the fastener does not contact a portion of the intermediate flange defining the slot in the rotational direction. 
     The following should be viewed in light of  FIGS.  1  through  10   . The following describes a method of operating a torque converter including a cover, an impeller, a turbine in fluid communication with the impeller, a stator including at least one stator blade axially disposed between the turbine and the impeller, and a vibration damper including a first cover plate, a second cover plate non-rotatably connected to the first cover plate with a fastener and including radially outwardly extending protrusions, an intermediate flange axially disposed between the first cover plate and the second cover plate and including a axially extending protrusions, an output flange, a resilient element directly engaged with the first cover plate and the intermediate flange, and springs directly engaged with the first cover plate, the second cover plate, the intermediate flange, and the output flange. 
     A first step urges, with the resilient element, the axially extending protrusions into contact with the radially outwardly extending protrusions. A second step rotates, with a rotational torque, the cover, the first cover plate, and the second cover plate in a first rotational direction. A third step compresses one spring of each pair of springs between the second cover plate and the intermediate flange. A fourth step rotates, in the first rotational direction, the second cover plate with respect to the intermediate flange. A fifth step drags, in the first rotational direction, the axially extending protrusions across the radially extending protrusions, while maintaining contact between the axially extending protrusions and the radially extending protrusions. 
     A sixth step rotates, with a rotational torque, the output flange, the intermediate flange, the first cover plate, and the second cover plate in a second rotational direction, opposite the first rotational direction. A seventh step compresses one spring of each pair of springs between the intermediate flange and second cover plate. An eighth step rotates, in the second rotational direction, the intermediate flange with respect to second cover plate. A ninth step drags, in the second rotational direction, the radially extending protrusions across the axially extending protrusion, while maintaining contact between the axially extending protrusions and the radially extending protrusions. 
     It will be appreciated that various of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims. 
     List of Reference Characters:
     AD 1  axial direction   AD 2  axial direction   AR axis of rotation   RD 1  radially outer direction   RD 2  radially inner direction   RTD 1  rotational direction   RTD 2  rotational direction   RT 1  rotational torque   RT 2  rotational torque   TIS transmission input shaft   TV 1  threshold value   TV 2  threshold value     100  torque converter     102  vibration damper     104  cover     106  impeller     108  turbine     110  stator     112  impeller shell     114  impeller blade     116  turbine shell     118  turbine blade     120  stator blade     122  cover plate     124  cover plate     126  intermediate flange     128  resilient element     130  output flange     131  spring     131 A spring     131 B spring     132  fastener     134  radially outwardly extending protrusion     136  indentation     138  body portion, plate  124       140  axially extending protrusion     142  indentation     144  surface segment, intermediate flange     146  surface, protrusion  134       148  slot     150  edge, slot  148       152  surface, axial protrusion     154  surface, axial protrusion     156  portion, edge  150       158  portion, edge  150       160  slot, intermediate flange     162  slot, output flange     164  end, spring     166  surface, cover plate     168  surface, output flange     170  end, spring     172  surface, intermediate flange     174  end, spring     176  surface, cover plate     178  surface, output flange     180  end, spring     182  surface, intermediate flange     184  lock-up clutch     186  piston plate     188  clutch plate     190  protrusion, cover plate  122       192  surface, radial protrusion     194  surface, radial protrusion     196  surface, protrusion  140       198  surface segment, cover plate