Abstract: A method of forming a friction plate is provided. The method includes force fitting a friction material onto a base to form a mechanical connection between the friction material and the base. A friction plate is also provided. The friction plate includes a base and a friction material force fit onto the base such that a mechanical connection is formed by a shape of the friction material and a shape of the base.

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 and damper assembly for a torque converter includes a clutch piston with a piston friction surface for engaging the clutch and an outer sealing diameter, and a damper. The piston friction surface is disposed radially inward of the damper and the outer sealing diameter is disposed radially outward of the damper. In an example embodiment, the clutch piston includes an inner sealing diameter disposed radially inward of the piston friction surface. In some example embodiments, the damper includes a resilient element and a drive plate. The drive plate is drivingly engaged with the resilient element and frictionally engageable with the clutch piston.

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 clutch assembly for a torque converter, including: a cover; a piston plate including a hole; and a rivet in the hole. The rivet includes a rivet head. Prior to applying pressure to the rivet to fix the rivet to the piston plate, the rivet head is clamped between the piston plate and the cover. A clutch assembly for a torque converter, including: a cover; a piston plate with a hole; a leaf spring with a first end fixedly attached to the cover and a second end; and a rivet connecting the second end of the leaf spring to the piston plate. The rivet includes: a head disposed between the leaf spring second end and the cover; and a shaft in the piston plate hole. The piston plate or the cover is deflectable to clamp the rivet head between the cover and the piston plate before the shaft is expanded.

Abstract: A torque converter includes an impeller with a plurality of impeller blades and a shell with a radial wall disposed radially outside of the blades. The converter also includes a cover fixed to the impeller shell to form a housing, and a turbine. The turbine includes a plurality of turbine blades and a shell with a radial wall disposed radially outside of the turbine blades. The turbine radial wall is arranged to frictionally engage the impeller shell radial wall. In some example embodiments, the turbine shell includes indented slots and the turbine blades include tabs disposed in the slots. In an example embodiment, the turbine blades are fixed to the turbine shell by brazing.

Abstract: A flat blade for a transmission input shaft includes a substantially rectangular body portion for insertion in a center bore of the input shaft and at least one radial blade segment extending from the body portion. The radial blade segment is arranged for assembly proximate a distal end of the input shaft and for extending radially beyond the center bore. In an example embodiment, the radial blade segment is substantially rectangular in shape. In an example embodiment, the radial blade segment is a pair of radial blade segments extending in opposing directions. In an example embodiment, the body portion is arranged for press-fitting into the center bore.

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 torsion damper including: a plurality of springs; a first plate with a central axis; and a second plate with a central axis. The plurality of springs displaces the first and second plates so that the central axis for the first plate is radially offset from the central axis for the second plate. In one embodiment, the radial offset between the central axis for the first plate and the central axis for the second plate is fixed. In another embodiment, the first plate comprises a central bore and the second plate comprises an extruded cylinder; and the fixed alignment is maintained by contact between the central bore and the extruded cylinder.

Abstract: A clutch and damper assembly for a torque converter includes a clutch piston with a piston friction surface for engaging the clutch and an outer sealing diameter, and a damper. The piston friction surface is disposed radially inward of the damper and the outer sealing diameter is disposed radially outward of the damper. In an example embodiment, the clutch piston includes an inner sealing diameter disposed radially inward of the piston friction surface. In some example embodiments, the damper includes a resilient element and a drive plate. The drive plate is drivingly engaged with the resilient element and frictionally engageable with the clutch piston.

Abstract: A torque converter having a first damper stage, a second damper stage, a floating flange torsionally connecting the first and second damper stages, an inertia element, and a tuned torsion damper. The torsion damper connects the inertia element and the flange. In a preferred embodiment, the inertia element is a turbine. In one embodiment, the first damper stage is a radially outer damper stage and the second damper stage is a radially inner damper stage. In another embodiment, the torsion damper generates a friction torque when rotated.

Abstract: A series damper, including: a first damper with a flange and a cover plate; and a second damper with first and second cover plates and a flange. The flange and the cover plate for the first damper are rotationally frictionally engaged and the flange for the second damper rotates free of frictional engagement with the first and second cover plates. The series damper includes a resilient element arranged to cause the frictional engagement of the flange and the cover plate for the first damper. In some aspects, the resilient element is frictionally engaged with the cover plate for the first damper and is arranged to frictionally engage a turbine hub for a torque converter. In some aspects, the resilient element is rotationally connected to the flange for the first damper. In some aspects, the flange for the first damper includes the second cover plate for the second damper.

Abstract: A hub assembly for a torque converter includes a hub with a circumferential groove and a seal arranged to contact an element of the torque converter. The seal is at least partially disposed in the groove. The groove has a first radial wall, a second radial wall axially offset with respect to the first radial wall, and at least one opening in the second radial wall. The seal is axially displaceable to seal against the first wall to block fluid flow between the hub and the element and to seal against the second radial wall and enable fluid flow through the opening.

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: The present invention broadly comprises a method for controlling engine speed, engine torque, and torque converter output including the steps of applying engine torque to a torque converter and modulating the transferring of the torque to a pump for the torque converter. In some aspects, the torque converter further comprises a pump clutch and the method applies torque to the pump clutch and controllably slips the pump clutch. In some aspects, the method supplies engine torque from an engine with a turbocharger and controllably slips the pump clutch to increase speed and torque for the engine during a launch event for the vehicle or determines a parameter regarding operation of the vehicle and controllably slips the pump clutch responsive to the parameter. The present invention also comprises a method for controlling torque converter output by connecting a clutch between an engine and a torque converter and controllably slipping the clutch.

Abstract: A flat blade for a transmission input shaft includes a substantially rectangular body portion for insertion in a center bore of the input shaft and at least one radial blade segment extending from the body portion. The radial blade segment is arranged for assembly proximate a distal end of the input shaft and for extending radially beyond the center bore. In an example embodiment, the radial blade segment is substantially rectangular in shape. In an example embodiment, the radial blade segment is a pair of radial blade segments extending in opposing directions. In an example embodiment, the body portion is arranged for press-fitting into the center bore.

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 piston plate stop for a torque converter including: a flexible connection element with a first end and a second end, the first end arranged to connect to a piston plate for the torque converter, the second end arranged to rotationally connect to a cover for the torque converter and a stop disposed on the flexible connection element. The stop is arranged to restrict axial movement of the piston plate. In some aspects, the flexible connection element is arranged to rotationally connect the cover and the piston plate. A torque converter including a piston plate; a cover; and at least one flexible connection element rotationally connecting the piston plate and the cover. The flexible connection element has a tab that is positioned to limit axial displacement of the piston plate away from the cover.

Abstract: A torque converter including a cover having a central longitudinal axis and an outer surface and a pilot stamped from metal. The pilot includes a disc at least partially radially aligned with the axis for the cover. The pilot and the cover central axis are fixedly secured to each other. In a first embodiment, the disc is flat. In a second embodiment, the disc is annular. In a third embodiment, the pilot includes a machined outer circumferential surface. In a fourth embodiment, the pilot includes first and second portions radially off-set with respect to one another. In a fifth embodiment, the pilot includes a portion axially extending from the portion of the disc at least partially radially aligned with the axis for the cover. In a preferred embodiment, the cover and pilot are fixedly secured by welding.

Abstract: A clutch assembly for a torque converter, including: a cover; a piston plate including a hole; and a rivet in the hole. The rivet includes a rivet head. Prior to applying pressure to the rivet to fix the rivet to the piston plate, the rivet head is clamped between the piston plate and the cover. A clutch assembly for a torque converter, including: a cover; a piston plate with a hole; a leaf spring with a first end fixedly attached to the cover and a second end; and a rivet connecting the second end of the leaf spring to the piston plate. The rivet includes: a head disposed between the leaf spring second end and the cover; and a shaft in the piston plate hole. The piston plate or the cover is deflectable to clamp the rivet head between the cover and the piston plate before the shaft is expanded.