A torque converter is provided. The torque converter includes a front cover. The front cover includes a radially extending section and an axially extending section extending axially from an outer radial end of the radially extending section. The torque converter also includes a rear cover. The rear cover includes a rear radially extending section and a rear axially extending section extending axially from an outer radial end of the rear radially extending section. The torque converter also includes a plurality of baffles connected to the front cover. Each of the baffles includes a first tab connected to the axially extending section of the front cover. A method of forming a torque converter is also provided.

A stator assembly of a hydrokinetic torque converter includes a stator rotatable about an axis and having a radially outer stator belt, an annular stator hub disposed radially within the radially outer stator belt, at least one fixed post extending radially outwardly between the stator hub and the stator belt and fixed thereto so as to non-moveably secure the stator belt to the stator hub, and a plurality of pivotable stator blades extending radially outwardly between the stator hub and the stator belt and configured to pivot relative to both the stator hub and the stator belt in the direction orthogonal to the rotational axis.

A stator of a hydrokinetic torque converter comprises a stator hub having an axis, a stator belt coaxial to the axis and a plurality of stator blades extending radially outwardly between the stator hub and the stator belt. Each of the stator blades has radially inner and outer mounting pins. The stator hub has hub slots, and the stator belt has belt slots. The radially inner mounting pin of one of the stator blades is disposed in one of the hub slots of the stator hub and the radially outer mounting pin of one of the stator blades is disposed in one of the belt slots of the stator belt.

A stator of a torque converter is divided into a first stator on an upstream side and a second stator on a downstream side, and the first and second stators are supported on a fixed part via first and second one-way clutches, respectively. Since, with regard to a blade of the first stator, when viewed in the axis direction, the blade tip part is inclined relative to the blade base part in the disengagement direction of the first one-way clutch, it is possible to ensure the blade area without increasing the dimension in the radial direction and the dimension in the axis direction of the blade of the first stator, and it is possible, by smoothly guiding oil along the blade of the first stator to thus suppress the occurrence of a vortex, to reduce energy loss in a low speed ratio region where the vortex easily occurs.

A method of forming a stator for a torque converter is provided. The method includes casting a stator casting to include a body and blades on an outer circumferential surface of the body. The body includes excess material at an axial surface thereof. The method also includes machining the excess material to balance the stator casting. A torque converter is also provided. The torque converter includes a turbine, an impeller and a stator axially between the turbine and the impeller. The stator includes a stator casting including a body and blades on an outer circumferential surface of the body. The body includes a material segment at an axial surface thereof.

A modular stator for a torque converter includes a stator hub, an outer ring, and a plurality of blades extending radially between the stator hub and the outer ring. Each blade is releasably securable to the stator hub in at least two different orientations. A blade angle of the plurality of blades can be predetermined by selecting one of the at least two orientations. A lock member secures each blade at the selected orientation.

A method of fabricating a torque converter, including: forming a turbine shell including a first annular portion with a first surface having a first roughness and forming a radially outermost portion of the turbine shell; fixing a first plurality of blades to the turbine shell; forming an impeller shell including a second annular portion with a second surface having a second roughness; fixing a second plurality of blades to the impeller shell; removing at least a portion the first or second surface without the use of particulate matter or a liquid; increasing the first or second roughness of the first or second surface from which the at least a portion is removed; applying an adhesive to the first or second surface from which the at least a portion is removed; and bonding, with the adhesive, friction material to the first or second surface.

A hydrokinetic torque converter comprises an impeller rotatable about a rotational axis, a coaxial turbine, and a stator disposed between the impeller and the turbine. The stator includes an annular stator hub, an annular radially outer stator rim, a plurality of stator blades radially outwardly extending between the stator hub and the stator rim, and an annular outer stator flange extending radially outwardly from the stator rim thereof and disposed between an impeller core ring and a turbine core ring. The stator further includes a plurality of hydraulic pressure grooves provided on at least one of axially opposite impeller and turbine side surfaces of the stator flange. The hydraulic pressure grooves face at least one of the impeller and turbine core rings so as to create a hydrodynamic lift between the stator and at least one of the impeller and turbine core rings in the axial direction.

A transmission includes a torque converter stator with controllable blade angle. The blade angle is adjusted by adjusting the rotational position of a control ring with respect to a stator hub. The stator blades are supported by the stator hob, a locking ring, and an outer ring. The stator blades have teeth that mesh with teeth on the control ring to determine blade angle. A controller adjust the blades by commanding fluid pressures in hydraulic circuits routed to the stator hub. Various circumstances in which the controller would adjust the blade angle are discussed.

A method of forming a stator for a torque converter is provided. The method includes casting a stator casting to include a body and blades on an outer circumferential surface of the body. The body includes excess material at an axial surface thereof. The method also includes machining the excess material to balance the stator casting. A torque converter is also provided. The torque converter includes a turbine, an impeller and a stator axially between the turbine and the impeller. The stator includes a stator casting including a body and blades on an outer circumferential surface of the body. The body includes a material segment at an axial surface thereof.