Patent ID: 12241532

DETAILED DESCRIPTION

Embodiments of the present disclosure are described herein. It should be appreciated that like drawing numbers appearing in different drawing views identify identical, or functionally similar, structural elements. Also, it is to be understood that the disclosed embodiments are merely examples and other embodiments can take various and alternative forms. The figures are not necessarily to scale; some features could be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the embodiments. As those of ordinary skill in the art will understand, various features illustrated and described with reference to any one of the figures can be combined with features illustrated in one or more other figures to produce embodiments that are not explicitly illustrated or described. The combinations of features illustrated provide representative embodiments for typical applications. Various combinations and modifications of the features consistent with the teachings of this disclosure, however, could be desired for particular applications or implementations.

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. Although any methods, devices or materials similar or equivalent to those described herein can be used in the practice or testing of the disclosure, the following example methods, devices, and materials are now described.

Referring toFIGS.1-2a portion of a hybrid module100is illustrated according to an exemplary embodiment of the present disclosure. At least some portions of the hybrid module100are rotatable about an axis of rotation AR. While only a portion of the hybrid module100above the axis of rotation AR is shown inFIG.1, it should be understood that the hybrid module100can appear substantially similar below the axis of rotation AR with many components extending about the axis of rotation AR. Words such as “axial,” “radial,” “circumferential,” “outward,” etc. as used herein are intended to be with respect to the axis of rotation AR.

The hybrid module100includes a rotor assembly102and a stator assembly104forming an e-motor assembly. The rotor assembly102includes a rotor carrier106, a rotor segment108, and an end ring110. The rotor carrier106includes an axially extending portion112, a radially extending portion114, and a rotor flange116. The rotor flange116is fixed to the axially extending portion112of the rotor carrier106and extends radially outward away from the axis of rotation AR. The radially extending portion1114extends radially inward towards the axis of rotation AR from an end of the axially extending portion112. The radially extending portion114is radially spaced from a transmission input shaft118. The rotor flange116is disposed axially between the rotor segment108and the radially extending portion114.

The rotor segment108is installed and arranged on an outer surface of the axially extending portion112of the rotor carrier106. In one embodiment, the rotor segment108may be comprised of a stack of segments. The end ring110is fixed to the outer surface of the axially extending portion112of the rotor carrier106. The rotor assembly102may include a spring end plate (not shown) arranged on an axial side of the rotor segment108. In this way, the spring end plate may be disposed axially between the end ring110and the rotor segment108. Additionally, or alternatively, the rotor assembly102may include a further spring end plate (not shown) arranged on an opposite axial side of the rotor segment108. In this way, the further spring end plate may be disposed axially between the rotor segment108and the rotor flange116. The end ring110is configured to clamp and/or secure the rotor segment108to the rotor carrier106, e.g., via compressing the spring end plate(s), for frictional torque transmission therebetween. Once the desired compression force is achieved, the end ring110is fixed to the rotor carrier106, e.g., by welding.

The stator assembly104is disposed radially outside of the rotor assembly102and is fixed relative to the rotor assembly102. The stator assembly104includes a stator carrier120and a stator segment122. In one embodiment, the stator segment122may be a stack of stator segments. The stator segment122is installed and arranged on an inner surface of the stator carrier120. In one embodiment, the stator segment122may be installed on the stator carrier120via a shrink fit arrangement. That is, the stator carrier120is heated to expand the inner surface, the stator segment122is installed on the stator carrier120, and the inner surface shrink fits to the stator segment122after the stator carrier120cools.

The hybrid module100further includes a torque converter assembly124and a K0 clutch126each fully disposed radially inside the rotor assembly102. The K0 clutch126is arranged to drivingly connect the rotor assembly102to a K0 shaft128. In other words, the K0 clutch126selectively connects and disconnects the rotor assembly102and the K0 shaft128. The K0 shaft128is arranged for driving connection with a crankshaft (not numbered) of an internal combustion engine (not shown). In other words, the K0 shaft128is arranged to receive torque from the engine and/or transmit torque to the engine when installed and operated in a vehicle powered at least in part by the engine.

The K0 clutch126may include a hub130supported on and sealed to the transmission input shaft118. The hub130may include an apply channel (not numbered) for providing a hydraulic pressure to the K0 clutch126and a balancing channel (not numbered) for providing a balancing oil to the K0 clutch126.

The K0 clutch126includes a housing136fixed, at an outer diameter thereof, to the radially extending portion114, e.g., via a welded connection. The housing136may be fixed, at an inner diameter thereof, to the hub130, e.g., via a welded connection. The housing136includes an outer axially extending portion138radially spaced from the hub130. The outer axially extending portion160, e.g., an outer surface thereof, is connected to the radially extending portion114. The housing136further includes an inner axially extending portion140disposed radially between the hub130and the outer axially extending portion138.

The K0 clutch126further includes a piston142, a plurality of clutch plates144, a reaction plate146, and a support flange148. The reaction plate146may, e.g., be fixed to the axially extending portion138, e.g., an inner surface thereof, of the housing136. As another example, the reaction plate146may be fixed to the support flange148. The support flange148is connected, e.g., via a welded connection, to a radially extending outer portion of the K0 shaft128. The clutch plates144are disposed axially between the reaction plate146and the piston142. At least some of the clutch plates144may be connected to the support flange148. At least some of the clutch plates144may be connected to the axially extending portion138, e.g., the inner surface thereof, of the housing136.

The piston142is disposed axially between the reaction plate146and the torque converter assembly124. The piston142may be configured to be sealed to the hub130at an inner diameter of the piston142via a seal (not numbered) and configured to be sealed to the inner axially extending portion140, e.g., an inner surface thereof, via a seal (not numbered). The seals maintain a fluid separation between a piston apply chamber (not numbered) and the rest of the K0 clutch126. The piston apply chamber is defined, or bounded, in part between the housing136, the hub130, and the piston142. By “bounded in part,” we mean that a portion of the cited chamber, flow path, or other structure is bounded, or formed, by the cited element.

The K0 clutch126may include a balance dam (not numbered) disposed axially between the piston142and the support flange148. The balance dam may be fixed to the hub130, e.g., via staking. In such an example, the balance dam may be sealed to the hub130at the staking. The balance dam is sealed to the piston142at an outer diameter thereof via a seal (not numbered). The seal maintains a fluid separation between a balance chamber (not numbered) and the rest of the K0 clutch126. The balance chamber is defined by, or bounded between, the hub130, the piston142, and the balance dam.

The K0 clutch126may include a resilient element (not numbered) disposed axially between the piston142and the balance dam, i.e., in the balance chamber, urging the piston142away from the balance dam. In the example embodiment shown, the resilient element160includes coil springs. Although coil springs are shown, other resilient elements are possible, e.g., a Belleville washer or a rubber puck.

The piston142closes the K0 clutch126in response to pressurization of a medium (e.g., fluid such as oil) in the apply chamber. That is, when K0 clutch126engagement is desired, pressure is introduced through the apply channel to the apply chamber. Once pressure in the apply chamber reaches a closing pressure, i.e., applies sufficient force on the piston142, the piston142slides along the hub130and the inner axially extending portion140of the housing136engaging and compressing the clutch plates144against the reaction plate146. Meanwhile, flow from the balancing channel flows into a balancing chamber of the K0 clutch126.

The torque converter assembly124includes: an impeller150having an impeller shell154with at least one blade attached thereto, a turbine152having a turbine shell156with at least one blade attached thereto; a stator158having at least one blade attached thereto; and a lock-up clutch170. The impeller shell154may be fixed to the rotor carrier106, e.g., via a welded connection. The impeller shell154and the rotor carrier106together form a housing for the torque converter assembly124. The lock-up clutch170and the stator158are disposed within the housing formed by the impeller shell154and the rotor carrier106.

The lock-up clutch170includes: a clutch plate carrier172non-rotatably connected to the turbine shell156; a piston174disposed axially between the radially extending portion114and the turbine134; a reaction plate176fixed relative to the turbine134; and a plurality of clutch plates178disposed axially between the piston174and the reaction plate176. The reaction plate176may, for example, be fixed to the clutch plate carrier172, e.g., an inner surface thereof. As another example, the reaction plate176may be fixed to the outer axially extending portion138, e.g., an outer surface thereof, of the housing136. At least some of the clutch plates178may be connected to the clutch plate carrier172, e.g., the inner surface thereof. At least some of the clutch plates178may be connected to the outer axially extending portion138, e.g., the outer surface thereof, of the housing136.

The piston174may be sealed to the clutch plate carrier172, e.g., the inner surface thereof, via a seal (not numbered) and may be sealed, at an inner diameter thereof, to an output hub180via a seal (not numbered). The seals maintain a fluid separation between an apply chamber182and the rest of the torque converter assembly124. The apply chamber182is defined by, or bounded between, the output hub180, the piston174, the clutch plate carrier172, and the turbine152.

The output hub180may be connected to the turbine shell156, e.g., via a riveted connection. The output hub180is connected to the transmission input shaft118for torque transmission therebetween. The output hub180may include an apply channel184for providing a hydraulic pressure to the lock-up clutch170and a balancing channel (not numbered) for providing a balancing oil to the lock-up clutch170. The clutch plate carrier172is non-rotatably connected to the turbine shell156radially outside of the output hub180. That is, a connection between the clutch plate carrier172and the turbine shell156is radially spaced from the output hub180.

The lock-up clutch170may further include a seal plate (not numbered) disposed axially between the piston174and the radially extending portion114. The seal plate may be fixed to the output hub180, e.g., via staking. In such an example, the seal plate may be sealed to the output hub180at the staking. The seal plate is sealed to the piston174at an outer diameter thereof via a seal (not numbered). The seal maintains a fluid separation between a balance chamber (not numbered) and the rest of the torque converter assembly124. The balance chamber is defined by, or bounded between, the output hub180, the piston174, and the seal plate.

The lock-up clutch170may further include a resilient element (not numbered) disposed axially between the piston174and the seal plate, i.e., in the balance chamber, urging the piston174away from the seal plate. In the example embodiment shown, the resilient element includes a diaphragm spring. Although a diaphragm spring is shown, other resilient elements are possible, e.g., a Belleville washer or a rubber puck.

The piston174closes the lock-up clutch170in response to pressurization of a medium (e.g., fluid such as oil) in the apply chamber182. That is, when lock-up clutch170engagement is desired, pressure is introduced through the apply channel184to the apply chamber182. Once pressure in the apply chamber182reaches a closing pressure, i.e., applies sufficient force on the piston174, the piston174slides along the output hub180and the clutch plate carrier172engaging and compressing the clutch plates178against the reaction plate176. Meanwhile, flow from the balancing channel flows into the balancing chamber of the torque converter assembly124.

Connecting the clutch plate carrier to the turbine shell and utilizing the clutch plate carrier and the turbine to partially define the apply chamber for the torque converter assembly reduces an axial envelop of the torque converter assembly, which can assist in satisfying packaging constraints in hybrid modules with limited space.

While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms encompassed by the claims. The words used in the specification are words of description rather than limitation, and it is understood that various changes can be made without departing from the spirit and scope of the disclosure. As previously described, the features of various embodiments can be combined to form further embodiments of the disclosure that may not be explicitly described or illustrated. While various embodiments could have been described as providing advantages or being preferred over other embodiments or prior art implementations with respect to one or more desired characteristics, those of ordinary skill in the art recognize that one or more features or characteristics can be compromised to achieve desired overall system attributes, which depend on the specific application and implementation. These attributes can include, but are not limited to cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, serviceability, weight, manufacturability, ease of assembly, etc. As such, to the extent any embodiments are described as less desirable than other embodiments or prior art implementations with respect to one or more characteristics, these embodiments are not outside the scope of the disclosure and can be desirable for particular applications.

LIST OF REFERENCE NUMBERS

100hybrid module102rotor assembly104stator assembly106rotor carrier108rotor segment110end ring112axially extending portion114radially extending portion116rotor flange118transmission input shaft120stator carrier122stator segment124torque converter assembly126K0 clutch128K0 shaft130hub136housing138outer axially extending portion140inner axially extending portion142piston144clutch plate146reaction plate148support flange150impeller152turbine154impeller shell156turbine shell158stator170lock-up clutch172clutch plate carrier174piston176reaction plate178clutch plates180output hub182apply chamber184apply channelAR axis of rotation