Abstract: A torque converter includes an impeller shell and a backing plate defining at least a portion of a first hydraulic chamber, a cover and a piston plate defining at least a portion of a second hydraulic chamber, and a third hydraulic chamber. The third chamber is sealed from the first and second hydraulic chambers such that a hydraulic flow between the third chamber and the other chambers is at least restricted. In some example embodiments, the torque converter includes a turbine, a stator, and an impeller disposed within the first hydraulic chamber, and a lockup clutch including a piston plate. The first chamber is for being pressurized to prevent cavitation in the turbine, stator, or impeller, the second or third chamber is for being pressurized to engage the lockup clutch, and the other of the second or third chamber is for being de-pressurized to reduce a back pressure on the lockup clutch piston plate.

Abstract: A torque converter includes a cover arranged for driving engagement with a crankshaft and a connecting sleeve with an internal thread arranged for engaging an external thread of the cover or the crankshaft to directly connect the cover to the crankshaft. In some example embodiments, the connecting sleeve includes a cylindrical portion including the internal thread and a first radial wall disposed at a distal end of the cylindrical portion. In an example embodiment, the cover includes a hub portion with a pilot arranged for insertion into a recess of the crankshaft. In some example embodiments, the cover includes a face spline for engaging a crankshaft face spline or a conical surface for engaging a crankshaft conical surface.

Abstract: A torque converter includes an impeller shell and a backing plate defining at least a portion of a first hydraulic chamber, a cover and a piston plate defining at least a portion of a second hydraulic chamber, and a third hydraulic chamber. The third chamber is sealed from the first and second hydraulic chambers such that a hydraulic flow between the third chamber and the other chambers is at least restricted. In some example embodiments, the torque converter includes a turbine, a stator, and an impeller disposed within the first hydraulic chamber, and a lockup clutch including a piston plate. The first chamber is for being pressurized to prevent cavitation in the turbine, stator, or impeller, the second or third chamber is for being pressurized to engage the lockup clutch, and the other of the second or third chamber is for being de-pressurized to reduce a back pressure on the lockup clutch piston plate.

Abstract: A torque converter includes a housing, a turbine shell, and a spring. The housing includes an impeller shell and a cover. The turbine shell includes a clutch portion. The spring is disposed axially between the cover and the turbine shell, and is arranged for urging the turbine clutch portion into driving engagement with the impeller shell. In an example embodiment, the spring is a diaphragm spring. In an example embodiment, the turbine shell is arranged for sealing to and driving engagement with a transmission input shaft. In some example embodiments, the torque converter includes a bearing disposed axially between the cover and the turbine shell, and arranged for rotationally disconnecting the spring from the cover. In an example embodiment, the bearing is a ball bearing or a needle roller bearing.

Abstract: A torque converter comprising: first and second cover plates arranged to receive torque; a flange; a turbine shell independently rotatable relative to the flange; at least one resilient element, at least partially disposed axially between the first and second cover plates, for transmitting a torque force between the flange and the first and second cover plates; a first axial gap, disposed between the flange and the first cover plate, having a first width; a second axial gap, disposed between the flange and the second cover plate, having a second width; one of the first cover plate or the second cover plate having at least one ramp protruding in an axial direction toward the flange, the ramp rotatably engageable with the flange for urging the flange axially in a direction toward the cover, and for transmitting an axial force for urging a clutch to engage.

Abstract: A torque converter includes an impeller shell and a backing plate defining at least a portion of a first hydraulic chamber, a cover and a piston plate defining at least a portion of a second hydraulic chamber, and a third hydraulic chamber. The third chamber is sealed from the first and second hydraulic chambers such that a hydraulic flow between the third chamber and the other chambers is at least restricted. In an example embodiment, the first chamber is for being pressurized to prevent cavitation in the turbine, stator, or impeller, the second or third chamber is for being pressurized to engage the lockup clutch, and the other of the second or third chamber is for being de-pressurized to reduce a back pressure on the lockup clutch piston plate.

Abstract: A torque converter includes a torus with an impeller and a turbine having respective shells, a cover shell, and a first damper plate. The impeller shell has a radial wall disposed radially outside of the torus and the turbine shell has a radial wall arranged for frictionally engaging the impeller shell radial wall. The cover shell has a radial wall and the first damper plate has a radial wall for transmitting a turbine shell thrust force to the cover shell radial wall. In an example embodiment, the torque converter includes a friction material ring fixedly attached to the turbine shell radial wall or the impeller shell radial wall. In some example embodiments, the torque converter includes a friction material ring fixedly attached to the cover shell radial wall or the first damper plate radial wall.

Abstract: A friction material part is provided. The friction material part includes a first segment and a second segment, an end of the first segment overlapping an end of the second segment to form a joint that is compressed more than intermediate portions of the first and second segments. A method for manufacturing a friction material part is also provided. The method includes overlapping an end of a first friction material segment and an end of a second friction material segment; and compressing the overlapped ends to form a compressed joint.

Abstract: A clutch assembly comprising: an axis of rotation; first and second spherical centers positioned along the axis of rotation; a first member having a first spherical surface including: a radius defining a first curvature; the first spherical center; and a first frictional surface; a second member having a second spherical surface including: said radius defining a second curvature about same or equal to the first curvature; the second spherical center; and a second frictional surface. A torque converter comprising a spherical clutch assembly is also disclosed.

Abstract: A clutch plate includes an annular body and an integral resilient portion connected to the annular body by a first circumferentially extending tab. The annular body has inner and outer diameters and first and second parallel surfaces extending therebetween. The resilient portion has third and fourth parallel surfaces extending at respective acute angles to the first and second parallel surfaces. In some example embodiments, the clutch plate includes a wet friction material affixed to the first and third surfaces. In an example embodiment, the clutch plate has a wet friction material affixed to the second and fourth surfaces. In an example embodiment, the clutch plate has first and second circumferential slots respectively disposed radially inside and outside of the first circumferentially extending tab.

Abstract: A torque converter is provided. The torque converter includes an impeller including an impeller shell, a turbine including a turbine shell and a stator axially between the turbine and the impeller. A first fluid flow is generated between the impeller and the stator and a second fluid flow is generated between the turbine and the stator. The torque converter further includes a thrust bearing axially between the impeller and the stator or axially between the turbine and the stator. The thrust bearing includes a bearing surface arranged for maintaining a hydrodynamic film thereon in a region of the first fluid flow or the second fluid flow during operation of the torque converter. A method of forming a torque converter is also provided.

Abstract: A piloting sleeve for a torque converter comprising: (i) an axis of rotation; (ii) a tubular body portion including a circumferential wall comprising: a first inner circumferential surface having a first inner diameter; a second inner circumferential surface having a second inner diameter; a first outer circumferential surface having a first outer diameter; (iii) an extended portion including at least two castles, each including a tip portion, for attachment to a cover; and (iv) a distal end. A transmission assembly comprising: a transmission input shaft and a torque converter including the piloting sleeve as described.

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: A hub seal assembly includes a hub having a groove with a first radial wall, a first floating seal including a second radial wall, and a resilient element. The first floating seal is axially displaced by the resilient element so that the second radial wall contacts the first radial wall. In an example embodiment, the first floating seal includes polytetrafluoroethylene. In some example embodiments, the resilient element is an o-ring. In an example embodiment, the first floating seal includes a circumferential groove or a notch and the o-ring is at least partially disposed in the groove or the notch.

Abstract: A torque converter is provided. The torque converter includes an impeller; a turbine axially movable toward and away from the impeller; and a damper coupled to the turbine, the damper including an elastic element forcing the turbine against the impeller in a no pressure condition. A method of forming a torque converter is also provided. The method includes forming a damper to include an elastic element; providing the damper inside a front cover so the damper contacts the front cover; and providing axially movable turbine between the damper and an impeller such that the elastic element forces the turbine to engage an impeller in a no pressure condition.

Abstract: A piston plate assembly for a torque converter comprising: an aperture including a chamfer portion; and, a bushing installed in the aperture and including a radius portion proximate the chamfer portion, wherein the bushing is arranged to seal the piston directly to a transmission input shaft and the radius portion is arranged to ease assembly of the bushing onto the input shaft.

Abstract: A clutch plate includes an annular body and an integral resilient portion connected to the annular body by a first circumferentially extending tab. The annular body has inner and outer diameters and first and second parallel surfaces extending therebetween. The resilient portion has third and fourth parallel surfaces extending at respective acute angles to the first and second parallel surfaces. In some example embodiments, the clutch plate includes a wet friction material affixed to the first and third surfaces. In an example embodiment, the clutch plate has a wet friction material affixed to the second and fourth surfaces. In an example embodiment, the clutch plate has first and second circumferential slots respectively disposed radially inside and outside of the first circumferentially extending tab.

Abstract: A damper assembly for a torque converter includes a drive side elastic element arranged for transmitting torque to a turbine for the torque converter in a first direction and a coast side elastic element, separate from the drive side elastic element, arranged for transmitting torque to the turbine in a second direction opposite the first direction. In an example embodiment, a slope of a torque curve for the damper remains constant in a transition region between transmitting torque to the turbine in the first direction and transmitting torque to the turbine in the second direction. In an example embodiment, the damper assembly includes an input damper and an output damper. The elastic elements are disposed in a torque path between the input damper and the output damper. In an example embodiment, the input damper is selectively engaged with a cover for the torque converter and the output damper is drivingly engaged with an output hub for the torque converter.

Abstract: A thrust washer is provided. The thrust washer includes a wet friction material and a phenolic resin layer coating an outer surface of the wet friction material. A torque converter comprising the thrust washer is also provided. A method of forming a thrust washer is further provided. The method includes providing a layer of phenolic resin on an outer surface of a wet friction material.

Abstract: A torque converter having a housing with an impeller wall section, and pump vanes brazed to the impeller wall section. The housing is connected to an output of an engine for rotation about a longitudinal axis. A turbine having turbine vanes that are connected to a hub is located about the longitudinal axis within the housing and is connected to an input shaft of a transmission. A stator is located between the pump vanes and the turbine vanes. In order to allow for a thinner housing wall, particularly an area of the impeller wall section, an annular retainer plate is brazed to the impeller wall section about the longitudinal axis and forms a reinforcement. A rolling bearing is located between the retainer plate and the stator, and is used in supporting the housing. An assembly method is also provided.