Abstract: An impeller for a torque converter is provided. The impeller includes an impeller shell including an inner circumference, an outer circumference and a radial extension extending radially outward from the inner circumference. The radial extension includes an axially extending groove formed therein. The impeller also includes an impeller hub welded to the impeller shell by a weld. The weld is radially inside of the axially extending groove. A method of forming an impeller for a torque converter is also provided.

Abstract: An impeller for a torque converter is provided. The impeller includes an impeller shell including an inner circumference, an outer circumference and a radial extension extending radially outward from the inner circumference. The radial extension includes an axially extending groove formed therein. The impeller also includes an impeller hub welded to the impeller shell by a weld. The weld is radially inside of the axially extending groove. A method of forming an impeller for a torque converter is also provided.

Abstract: A torque converter, including an axis of rotation, a cover arranged to receive torque, an impeller including an impeller shell non-rotatably connected to the cover and, at least one impeller blade fixedly connected to the impeller shell, a turbine including a turbine shell and at least one turbine blade fixedly connected to the turbine shell, a stator axially disposed between the impeller and turbine shells and including at least one stator blade and a first core ring fixedly secured to the at least one impeller blade and, including at least one first flat annular surface facing the at least one turbine blade or a second core ring fixedly secured to the at least one turbine blade and, including at least one second flat annular surface facing the at least one impeller blade.

Abstract: A torque converter comprising: an axis of rotation; a stator including a side plate having a first radial surface; one of an impeller shell or a turbine shell having a second tapered surface facing the stator side plate first radial surface; a hydrodynamic thrust bearing disposed between the stator side plate and the one of an impeller shell or a turbine shell, and comprising: a thrust surface facing one of the first radial surface or the second tapered surface with a fluid pathway therebetween; a supporting surface opposite the thrust surface and facing the other of the first radial surface or the second tapered surface; and an opening concentric with the axis of rotation; and, a gap between the supporting surface and the other of the first radial surface or the second tapered surface such that the bearing thrust surface is alignable to be parallel with the one of the first radial surface or the second tapered surface.

Abstract: A thrust assembly for a torque converter is provided. The thrust assembly includes a drivable mating component and a thrust washer connected to the drivable mating components. The thrust washer includes a thrust surface on a first axial side thereof and at least two axial contact surfaces on a second axial side thereof opposite the first axial side. The at least two axial contact surfaces include a first axial contact surface at a first axial distance from the thrust surface and a second axial contact surface at a second axial distance from the thrust surface. The first and second axial contact surfaces are configured for alternatively contacting the axial contact surface of the drivable mating component so as to vary an effective height of the thrust surface with respect to the drivable mating component.

Abstract: A torque converter, including an axis of rotation, a cover arranged to receive torque, an impeller including an impeller shell non-rotatably connected to the cover and, at least one impeller blade fixedly connected to the impeller shell, a turbine including a turbine shell and at least one turbine blade fixedly connected to the turbine shell, a stator axially disposed between the impeller and turbine shells and including at least one stator blade and a first core ring fixedly secured to the at least one impeller blade and, including at least one first flat annular surface facing the at least one turbine blade or a second core ring fixedly secured to the at least one turbine blade and, including at least one second flat annular surface facing the at least one impeller blade.

Abstract: A torque converter cover assembly is provided. The torque converter cover assembly includes a front cover for facing an engine crankshaft and a pilot configured for aligning the front cover with the engine crankshaft. The pilot including a base end fixed to the front cover and a tapered section extending from the base end. The tapered section decreasing in size radially as the pilot extends axially away from the front cover. A method of forming a torque converter is also provided.

Abstract: A thrust assembly for a torque converter is provided. The thrust assembly includes a drivable mating component and a thrust washer connected to the drivable mating components. The thrust washer includes a thrust surface on a first axial side thereof and at least two axial contact surfaces on a second axial side thereof opposite the first axial side. The at least two axial contact surfaces are configured for axially contacting an axial contact surface of a first axial side of the drivable mating component. The at least two axial contact surfaces include a first axial contact surface at a first axial distance from the thrust surface and a second axial contact surface at a second axial distance from the thrust surface. The first and second axial contact surfaces are configured for alternatively contacting the axial contact surface of the drivable mating component so as to vary an effective height of the thrust surface with respect to the drivable mating component.

Abstract: A stator assembly for a torque converter includes a housing, a blocking element, an inner race, and a first ring. The housing includes a plurality of stator blades, a central axis, and a pocket. The blocking element is disposed in the pocket and is pivotable about an axis parallel to the central axis. The inner race includes an outer notch for engaging the blocking element, an inner spline for engaging a transmission shaft, and a first outer piloting surface. The first ring is for radially positioning the housing on the inner race first outer piloting surface. In some example embodiments, the housing includes a bore and the first ring is pressed into the housing bore. In some example embodiments, the housing includes a radially extending surface in contact with the first ring. In an example embodiment, the radially extending surface limits axial displacement of the inner race.

Abstract: An impeller for a torque converter is provided. The impeller includes an impeller shell including an inner circumference, an outer circumference and a radial extension extending radially outward from the inner circumference. The radial extension includes an axially extending groove formed therein. The impeller also includes an impeller hub welded to the impeller shell by a weld. The weld is radially inside of the axially extending groove. The axially extending groove is 5 to 10 millimeters from the weld. A method of forming an impeller for a torque converter is also provided.

Abstract: A blade family for torque converters with a first blade having a first shape and flow guiding surface and a second blade having a second shape and flow guiding surface. The first surface is different from the second surface and the first shape is the same as a portion of the second shape, or the second shape is the same as a portion of the second shape. In an example embodiment of the invention, at least one of the first or second blades includes holes or slots. In an example embodiment of the invention, the first blade includes more material than the second blade. The first and second blades may have respective mounting tabs, with the second blade having fewer mounting tabs than the first blade. Other example aspects of the present invention broadly comprise a torque converter with a plurality of first and/or second blades from the blade family.

Abstract: A blade family for torque converters with a first blade having a first shape and flow guiding surface and a second blade having a second shape and flow guiding surface. The first surface is different from the second surface and the first shape is the same as a portion of the second shape, or the second shape is the same as a portion of the second shape. In an example embodiment of the invention, at least one of the first or second blades includes holes or slots. In an example embodiment of the invention, the first blade includes more material than the second blade. The first and second blades may have respective mounting tabs, with the second blade having fewer mounting tabs than the first blade. Other example aspects of the present invention broadly comprise a torque converter with a plurality of first and/or second blades from the blade family.