Abstract: A torque-transfer clutch includes a clutch reaction plate including an annular-shaped reaction element fixedly attached to a rigid plate element. The annular-shaped reaction element includes a preformed spring steel element and a plurality of undulations projecting orthogonal to a planar surface of the rigid plate element.

Abstract: An apparatus and method for finishing the mating surfaces of a gear set or gear train includes at least a first and a second rotatably connected gear element in dynamic, lubricated contact and rotating at different cycle rates. A hardness differential is employed between mating gear surfaces to balance surface damage imparted by friction and plastic deformation. The mating surfaces are of a hardness of at least approximately 70 on the Rockwell superficial hardness scale (70HR-30N), and are subjected to a polishing process, such as isotropic chemical finishing, to shape the surface asperity profile, thereby reducing accumulative damage due to friction and plastic deformation.

Abstract: The invention is a device for controlling the temperature and thus the viscosity of the lubricating fluid in a rear axle or differential. A first embodiment of the device comprehends a curved bi-metal strip or plate disposed proximate the ring gear and closely conforming to it. The strip extends about the periphery of the ring gear in the direction of rotation of the gear when the vehicle is moving forward. As the temperature of the lubricating fluid increases or decreases, the bi-metal strip or plate moves to direct a larger or smaller flow of the lubricating fluid toward the housing through which heat is transferred to the atmosphere. In another embodiment, a bi-metal baffle disposed adjacent the ring gear includes a plurality of flaps which open upon a rise in lubricating fluid temperature and direct more fluid to the housing to assist heat dissipation.

Abstract: A multi-layer coating for a smooth contact surface of a clutch plate and a method for manufacturing the same have been developed. This coating can help reduce the prevalence of clutch shudder, noise, and plate wear that is often encountered in a friction-disc clutch mechanism found in a motor vehicle's powertrain. The multi-layer coating may comprise a relatively soft base layer and one or more relatively hard particle layers overlying the base layer. This combination of layers can help provide stable friction characteristics and thermal properties between clutch plate surfaces. One or more optional bonding layers may also be provided between any two adjacent layers to improve the adherent bonding therebetween. At least some of the layers of the multi-layer coating may be applied by a HVO/AF thermal spray procedure.

Abstract: The present invention provides a vane pump having variable displacement and high efficiency. The variable displacement vane pump includes a plurality of elongate, axially extending inserts disposed in the rotor. One of the inserts is disposed between every adjacent vane pair. The inserts are received within axially extending pockets in the rotor and are coupled to the rotor by springs. At lower rotational speeds, the inserts are retracted and the displacement of the pump chambers is at maximum. At higher rotational speeds, the inserts are advanced into the pump chambers, effectively reducing their displacement. Thus, the variable displacement pump compensates for the varying drive speed and achieves improved uniformity of fluid flow by providing maximum displacement at low speeds and reduced displacement at higher speeds.

Abstract: A clutch assembly is provided including a controller, a plurality of vibration sensors, a clutch housing containing a lubricated clutch pack having a friction interface, a clutch piston responsive to a current command from the controller and operable for applying a compression force on the clutch pack, and a high-frequency (HF) oscillation source configured to generate at least one HF oscillation, and to direct the HF oscillation to the friction interface, wherein the controller is operable to detect clutch shudder and activate the source in response thereto to minimize the clutch shudder. The source includes HF hardware, and generates different HF oscillations applied directly to the clutch housing or to the clutch-apply current command. A method of reducing clutch shudder includes setting a threshold clutch shudder amplitude, detecting clutch shudder, and applying a HF oscillation to a friction interface to minimize clutch shudder when the detected shudder exceeds the threshold.

Abstract: The clutch of the present invention has a reaction plate, a friction plate, a friction layer, and at least one non-compressible member. The friction plate is disposed adjacent the reaction plate for frictionally engaging the reaction plate to transfer a driving torque between the reaction plate and the friction plate when the compression force is applied. The friction layer has at least one groove. The at least one non-compressible member is disposed in the at least one groove for preventing further compression of the friction layer by the reaction plate. The at least one non-compressible member is adhered to the friction plate or press fit within the friction layer.

Abstract: A clutch including a reaction plate configured to exert a compression force. The clutch further includes a friction plate having a surface opposing the reaction plate. A friction material layer has a first surface attached to the surface of the friction plate, and a second surface opposing the reaction plate. The second surface of the friction material layer has a plurality of dimples formed therein. Further, a lubrication fluid is disposed between the reaction plate and the friction material layer for transferring the compression force and providing a lubrication layer between the reaction plate and the friction plate.

Abstract: An apparatus and method for finishing the mating surfaces of a gear set or gear train including at least a first and second rotatably connected gear element in dynamic, lubricated contact. A hardness differential is employed between mating gear surfaces to balance surface damage imparted by friction and plastic deformation. The invention also includes subjecting the mating surfaces to a polishing process, preferably isotropic chemical finishing, to shape the surface asperity profile, thereby reducing accumulative damage due to friction and plastic deformation.

Abstract: The disclosed clutch includes a reaction plate, a friction plate, a friction layer, at least one non-compressible member and a fluid lubricant. The friction layer has a coefficient of friction that is sufficient to prevent relative rotation of the reaction and friction plates when the friction layer is compressed by the reaction plate. Further, the friction layer has at least one groove. At least one non-compressible member is disposed in the at least one groove to prevent further compression of the friction layer by the reaction plate. The at least one non-compressible member is mechanically fastened to the friction plate.

Abstract: The clutch of the present invention has a reaction plate, a friction plate, a friction layer, at least one non-compressible member, and a fluid lubricant. The friction plate is disposed adjacent the reaction plate for frictionally engaging the reaction plate to transfer a driving torque between the reaction plate and the friction plate when the compression force is applied. The friction layer has at least one groove. The at least one non-compressible member is disposed in the at least one groove for preventing further compression of the friction layer by the reaction plate. The at least one non-compressible member is adhered to the friction plate and a fluid lubricant is disposed between the reaction plate and the friction plate for providing a lubrication layer between the plates.

Abstract: A clutch plate assembly is provided having a friction interface and internal fluid passages for delivering pressurized fluid to the friction interface to cool the interface, and to reduce spin losses through the clutch assembly. The fluid passages comprise a plurality of primary passages extending inward from a clutch plate inner or outer diameter, and a plurality of secondary fluid passages intersecting the primary fluid passages for conducting fluid to the friction interface. Fluid is directed to the friction interface during clutch engagement for cooling thereof when the clutch assembly is engaging, and separates the clutch plates to reduce spin losses when the clutch assembly is disengaged. A method is also provided for controlling fluid flow at the friction interface, including providing fluid directly to the interface for cooling when the clutch plate assembly is engaging, and for reducing spin losses when the clutch plate assembly is substantially disengaged.

Abstract: An apparatus and method for increasing the operating life of a rotating gear element including a plurality of outwardly-projecting gear teeth each having an involute profile, with each gear tooth having a pair of flanks and a pair of generally semi-circular root portions. A ring tool having a plurality of hardened, inwardly-projecting burnishing teeth is employed to plastically deform only the root portions of the gear element being formed, while avoiding contact with the flanks as the gear element is passed through the ring tool. The ring tool also includes a plurality of broaching surfaces or cutting edges for removing excess stock material from the surfaces of the root portions. The ring tool increases the compressive residual stresses in the root portion of the gear element being formed, thereby creating an optimal residual stress profile and greater bending strength within the root portion of the gear element.

Abstract: The present invention provides a friction plate with features to provide additional cooling for use within a wet clutch system. The friction plate has a core plate with a friction facing layer affixed to each face of the core plate. The first friction facing layer has a plurality of radially oriented lubrication grooves formed by a plurality of friction pads having porosity. Additionally, the second friction facing layer has a plurality of friction pads formed by radially oriented lubrication grooves whose centerline is coincident with the radial centerline of the friction pads of the first friction facing layer. Each of the lubrication grooves has at least one hole provided therein to introduce fluid to effect cooling of the friction pad opposite the groove. Additionally, the present invention provides a method of enhancing the performance of a wet clutch system.

Abstract: The present invention provides a friction plate with features to provide additional cooling for use within a wet clutch system. The friction plate has a core plate with a friction facing layer affixed to each face of the core plate. The first friction facing layer has a plurality of radially oriented lubrication grooves formed by a plurality of friction pads having porosity. Additionally, the second friction facing layer has a plurality of friction pads formed by radially oriented lubrication grooves whose centerline is coincident with the radial centerline of the friction pads of the first friction facing layer. Each of the lubrication grooves has at least one hole provided therein to introduce fluid to effect cooling of the friction pad opposite the groove. Additionally, the present invention provides a method of enhancing the performance of a wet clutch system.

Abstract: A friction member for engagement in a torque-transmitting mechanism includes an outer layer comprising a first material. The outer layer has a friction surface for sliding contact with an opposing reaction member in the torque-transmitting mechanism. An inner layer is connected to the outer layer opposite the friction surface and comprises a second material. The inner layer is characterized by a first modulus of elasticity and the outer layer is characterized by a second modulus of elasticity greater than the first modulus of elasticity.

Abstract: A friction member for engagement in a torque-transmitting mechanism includes a friction surface for sliding contact with an opposing reaction member in a torque-transmitting mechanism. The sliding contact is characterized by a coefficient of friction and acts to engage the friction member with the reaction member in the torque-transmitting mechanism. The friction member is characterized by a first modulus of elasticity in a first direction, preferably substantially normal to the sliding contact, and a second modulus of elasticity in a second direction, preferably substantially parallel to the sliding contact. The second modulus of elasticity is greater than the first modulus of elasticity and the moduli of elasticity cooperate to at least partially establish the coefficient of friction and control vibrational shudder.

Abstract: A friction member for engagement in a torque-transmitting mechanism includes a first material and a second material. The first and second materials are woven together to provide a friction surface. The friction member is characterized by a first modulus of elasticity in a first direction with respect to the friction surface and a second modulus of elasticity in a second direction with respect to the friction surface. The second modulus of elasticity is greater than the first modulus of elasticity.

Abstract: A reaction member adapted for engagement with a friction member in a torque-transmitting mechanism is provided. The reaction member includes a reaction member base and a coating formed on the reaction member base. The coating is characterized by a coefficient of friction. The coated reaction member base is selectively engageable in sliding contact with the friction member. The sliding contact is at least partially characterized by the coefficient of friction of the coating. When lubricant is disposed between the friction member and the coated reaction member base, the sliding contact is at least partially characterized by an elasto-hydrodynamic (EHD) coefficient of friction of the lubricant. When no lubricant is so-disposed (i.e., during the asperity phase), the sliding contact is characterized by the coefficient of friction of the coating, which is less than the EHD coefficient of friction, thus avoiding a high operating coefficient of friction during the asperity phase.

Abstract: A clutch friction member for engagement in a torque-transmitting mechanism includes a friction surface for sliding contact with an opposing reaction member. The sliding contact is characterized by a coefficient of friction and acts to engage the friction member with the reaction member. The friction member is formed from a plurality of coiled cords, each defining a first channel disposed in a first direction, preferably substantially normal to the sliding contact, and transporting lubricant through the clutch friction member in the first direction, to increase the coefficient of friction. The coiled cords are arranged adjacent to one another to form an annular ring. The friction member has second channels disposed in a second direction, preferably substantially parallel to the sliding contact, for transporting the lubricant through the friction member in the second direction. The second channels thereby decrease vibrational shudder resulting from the sliding contact.