TURBINE-PISTON FOR HYDROKINETIC TORQUE CONVERTER AND METHOD OF OPERATION

Abstract

A hydrokinetic torque converter including a secondary piston for purposes of enhancing operation of the lock-up feature, and the method of operating such a converter. The secondary piston moves axially behind the turbine-piston to urge respective lock-up clutch friction surfaces into phased engagement. In an initial phase of engagement, friction surfaces between the secondary piston and turbine-piston engage to begin the reduction of relative rotary motion between the converter impeller and turbine-piston. This initial phase of slowing relative movement between the impeller and turbine-piston reduces pressure within the torus and the associated fluid forces separating the friction surfaces of the lock-up clutch. The secondary piston also slows and eliminates fluid flow from within the torus past the lock-up clutch and further reduces engagement resistance of the lock-up clutch owing to the lessening fluid pressure and flow. A more consistent lock-up clutch engagement, with higher torque capacity, is provided in both driven and coasting lock-up operation.

Claims

1. A torque converter, including a lock-up mechanism, adapted to rotate about an axis, comprising: a torus having an interior torus chamber and comprising an impeller having an impeller perimeter friction surface portion, a stator, and a turbine comprising a reactive turbine-piston having opposite first and second turbine-piston perimeter friction surface portions, said turbine being drivable in a rotary direction around said axis by hydrokinetic energy supplied from said impeller; a casing associated with said torus and providing a casing chamber in variable fluid communication with said torus chamber and axially juxtaposed to said torus chamber on an opposite side of said turbine-piston relative to said torus chamber; and a lock-up clutch mechanism comprising a secondary piston having a secondary-piston perimeter friction surface portion, sealed about a perimeter thereof to said casing, fixed in rotation with respect to said casing, located axially adjacent said turbine piston in said casing chamber, wherein said secondary piston is configured to axially move, in response to an effective fluid pressure increase in said casing chamber relative to said torus chamber, to engage said secondary-piston perimeter friction surface portion with said first turbine-piston perimeter friction surface portion, and further configured to thereafter urge said second turbine-piston perimeter friction surface portion into engagement with said impeller perimeter friction surface portion, thereby eliminating relative rotary motion between said turbine-piston and said impeller.

2. A torque converter as in claim 1, wherein: said secondary piston is fixed in rotation to said casing via splines.

3. A torque converter as in claim 1, wherein: said secondary piston is fixed in rotation to said casing via tabs.

4. A torque converter as in claim 1, wherein: said impeller and turbine-piston perimeter friction surfaces extend in a radial direction.

5. A torque converter as in claim 1, wherein: said first turbine-piston perimeter friction surface portion faces toward said secondary piston, and said second turbine-piston perimeter friction surface faces toward said impeller.

6. A torque converter as in claim 5, wherein: said first and second turbine-piston perimeter friction surfaces are clamped between said secondary piston and said impeller perimeter friction surface portion when said lock-up mechanism is engaged.

7. A torque converter as in claim 1, wherein: said impeller perimeter friction surface portion, said first and second turbine-piston perimeter friction surface portions, and said secondary-piston perimeter friction surface portion are radially outward of said torus chamber.

8. A method of operating a torque converter, said method comprising the steps of: providing a torus having an interior torus chamber and comprising an impeller having an impeller perimeter friction surface portion, a stator, and a turbine comprising a reactive turbine-piston having opposite first and second turbine-piston perimeter friction surface portions, said turbine being drivable in a rotary direction around said axis by hydrokinetic energy supplied from said impeller; providing a casing associated with said torus and providing a casing chamber in variable fluid communication with said torus chamber and axially juxtaposed to said torus chamber on an opposite side of said turbine-piston relative to said torus chamber; providing a lock-up clutch mechanism comprising a secondary piston having a secondary-piston perimeter friction surface portion, sealed about a perimeter thereof to said casing, fixed in rotation with respect to said casing, and located axially adjacent said turbine-piston in said casing chamber; increasing fluid pressure in said casing chamber relative to said torus chamber to urge said secondary piston toward said turbine-piston and engage the secondary-piston perimeter friction surface portion with said first turbine-piston perimeter friction surface portion; equalizing a rotary speed differential between said secondary piston and said turbine-piston; reducing hydrodynamic pressure within said torus; and further increasing pressure in said casing chamber relative to said torus chamber so as to urge said second turbine-piston perimeter friction surface portion axially, via movement of said secondary piston, toward and into engagement with said impeller perimeter friction surface portion to eliminate relative rotary motion between said turbine-piston and said impeller.

9. A method as in claim 8, wherein: said secondary piston is fixed in rotation to said casing via splines.

10. A method as in claim 8, wherein: said secondary piston is fixed in rotation to said casing via tabs.

11. A method as in claim 8, wherein: said impeller and turbine-piston perimeter friction surfaces extend in a radial direction.

12. A method as in claim 8, wherein: said first turbine-piston perimeter friction surface portion faces toward said secondary piston, and said second turbine-piston perimeter friction surface faces toward said impeller.

13. A method as in claim 12, wherein: said first and second turbine-piston perimeter friction surfaces are clamped between said secondary piston and said impeller perimeter friction surface portion when said lock-up mechanism is engaged.

14. A method as in claim 8, wherein: said impeller perimeter friction surface portion, said first and second turbine-piston perimeter friction surface portions, and said secondary-piston perimeter friction surface portion are radially outward of said torus chamber.

15. A torque converter as in claim 2, wherein: said impeller and turbine-piston perimeter friction surfaces extend in a radial direction.

16. A torque converter as in claim 3, wherein: said impeller and turbine-piston perimeter friction surfaces extend in a radial direction.

17. A torque converter as in claim 2, wherein: said first turbine-piston perimeter friction surface portion faces toward said secondary piston, and said second turbine-piston perimeter friction surface faces toward said impeller.

18. A torque converter as in claim 3, wherein: said first turbine-piston perimeter friction surface portion faces toward said secondary piston, and said second turbine-piston perimeter friction surface faces toward said impeller.

19. A torque converter as in claim 4, wherein: said first turbine-piston perimeter friction surface portion faces toward said secondary piston, and said second turbine-piston perimeter friction surface faces toward said impeller.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

[0009] The accompanying drawings are incorporated in and constitute a part of the specification. The drawings, together with the general description given above and the detailed description of the exemplary embodiments and methods given below, serve to explain the principles of the invention. The objects and advantages of the invention will become apparent from a study of the following specification when viewed in light of the accompanying drawings, in which like elements are given the same or analogous reference numerals and wherein:

[0010] FIG. 1 is a top half cross-sectional view of a hydrokinetic torque converter with a turbine-piston and secondary piston assembly in accordance with an exemplary embodiment of the present invention;

[0011] FIG. 2 is an enlarged radially outer cross-sectional view of the assembly of the hydrokinetic torque converter shown in FIG. 1 in lock-up off operation; and

[0012] FIG. 3 is an enlarged radially outer cross sectional view of the turbine assembly shown in FIG. 1 in a lock-up initiation configuration.

[0013] FIG. 4 is a full sectional view of a full lock-up configuration where the secondary piston and turbine piston have fully engaged the front cover of the torque converter.

[0014] FIG. 5 shows an exploded view of the major components of a torque converter including the secondary piston assembly in accord with the present invention.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENT(S) AND EMBODIED METHOD(S) OF THE INVENTION

[0015] Reference will now be made in detail to exemplary embodiments and methods of the invention as illustrated in the accompanying drawings, FIGS. 1-5, in which like reference characters designate like or corresponding parts throughout the drawings. It should be noted, however, that the invention in its broader aspects is not limited to the specific details, representative devices and methods, and illustrative examples shown and described in connection with the exemplary embodiments and methods.

[0016] A torque converter 100 including a secondary piston 122 for actuation of the lock-up feature 110 between the impeller 102 and turbine 106 is shown in a top half partial section in FIG. 1. The torque converter 100 includes an impeller 102 including vanes 103 located on an inner side of the front surface of the casing of the torque converter 100. A turbine-piston 106 is located in an axially opposed manner to the impeller 102, with a stator 104 equipped with one-way clutch 105 positioned axially therebetween. The torque path through the torque converter is schematically represented by incoming torque arrow 3, i.e., from an internal combustion (IC) engine, into the casing/impeller 102 via arrow 4, to the vaned turbine-piston 106, arrow 5, through the damper 130, and out through the hub of the turbine via arrow 6 to the input shaft (not shown) of a multi-ratio transmission. Rearward casing portion 108 is attached (via welding for example) to the impeller 102 to create, along with the front cover/impeller 102, a fluid tight compartment surrounding the torus elements (i.e., the impeller 102, the stator 104, and the turbine piston 106) as well as the elements making up the lock-up clutch 110, and a vibration damper system 130.

[0017] The lock-up clutch 110 system includes a secondary piston 122, sealed around its perimeter to the surrounding casing 108 via seal 124, which may be an o-ring or equivalent. The secondary piston 122 can move toward and away with respect to the outer casing 108 and is fixed in rotation with respect to the outer casing 108, for example via splines or tabs 120. See FIG. 5. The secondary piston 122 includes a forwardly facing secondary-piston perimeter friction surface portion 113 oriented to engage a (rearwardly oriented) first turbine-piston perimeter friction surface portion 112a of the turbine-piston 106. The opposite side of the turbine-piston 106 includes a (forwardly oriented) second perimeter friction surface portion 112b which faces an impeller perimeter friction surface portion 114 of the impeller 102, as best shown in FIG. 3.

[0018] In operation, when the lock-up clutch system 110 is disengaged, as best shown in FIG. 2, the impeller vanes act on the fluid contained in a torus chamber 1 and, through this action, provide torque to the opposed turbine-piston 106, thereafter the fluid passes though the vanes of stator 104 and begins the cycle again. Fluid also flows from the torus chamber 1 as shown by arrow 7 around and through the lock-up clutch system 110 and into a casing chamber 2 behind the turbine-piston 106. The pressure/force of the fluid pushes turbine-piston 106 in the direction of arrows A and B, as best shown in FIG. 2.

[0019] When fluid pressure is increased on the rearward side of the turbine piston 106, i.e., from right to left in FIGS. 1-3, to engage the lock-up clutch system 110, fluid is now reversed and is directed from casing chamber 2 to the torus chamber 1. As a result, the secondary piston 122 is urged toward the turbine-piston 106, in the direction of arrow C, and causes the first of two perimeter friction surface portions 112 on the turbine-piston 106 to begin to engage with a perimeter friction surface portion 113 on the forward side of the secondary piston 122 as best shown in FIG. 3. Inasmuch as the secondary piston 122 rotates at the same speed as the casing 108 and impeller 102, the speed difference between the turbine-piston 106 and impeller 102 begins to equalize, thus reducing the hydrodynamic forces inside the torus. The hydrodynamic forces, in coast mode, tend to push the turbine-piston 106 away from the impeller 102. In addition, as the gap between the friction surface portions 112a and 113 decreases, fluid flow around the perimeter of the lock-up clutch 110 is substantially reduced. Pressure continues to build in the casing chamber 2 and reduce in the torus chamber 1 and the lock-up clutch now engages, in the direction of arrow D in FIG. 3. In the lock-up phase, as best shown in FIG. 4, the impeller friction surface portion 114 on the impeller (inside of casing 108), and the second turbine-piston friction surface portion 112b on the forward side of the turbine-piston 106 are now forced together. The lock-up configuration is now fully and rapidly engaged. Relative rotational motion between the impeller 102 and turbine-piston 106 ceases.

[0020] The phased method of lock-up enabled by the use of a secondary piston 122 allows for a predictable phased engagement of the lock-up feature regardless of the operational demand being placed on the torque converter 100 through the control input. Upshifting and downshifting through the multi-ratio gearbox can be accompanied by a satisfying feel of rapid and certain engagement of the lock-up feature. In addition, owing to the reduction in relative rotational speeds of the impeller 102 and turbine-piston 106 prior to full engagement, one or more of the following advantages can be realized. First, more positive clutch engagement feel; second, less wear and attendant heat build-up on the friction surfaces and in the working fluid; third, lower activation pressures of the lock-up feature and thus less parasitic pumping losses to create such pressures; and/or, fourth, a smoother less jarring lock-up torque bump owing to the initial speed equalization between the impeller and turbine-piston.

[0021] The various components and features of the above-described exemplary embodiments may be substituted into one another in any combination. It is within the scope of the invention to make the modifications necessary or desirable to incorporate one or more components and features of any one embodiment into any other embodiment. In addition, although the exemplary embodiments discuss steps performed in a particular order for purposes of illustration and discussion, the methods discussed herein are not limited to any particular order or arrangement. One skilled in the art, using the disclosures provided herein, will appreciate that various steps of the methods can be omitted, rearranged, combined, and/or adapted in various ways.

[0022] Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains. Thus, changes can be made in the above-described invention without departing from the intent and scope thereof. It is also intended that the scope of the present invention be defined by the claims appended thereto.