Abstract: Components for an automatic motor vehicle transmission including a band brake drum, a clutch housing or hub having a seal surface or a clutch housing or hub utilized in a friction clutch assembly having a spline set. All of these components are fabricated of aluminum and the outer surface of the band brake drum, the housing or hub sealing surface and the area of the spline set includes a thin coating of a thermally sprayed steel material. The thermally sprayed steel material may be a low carbon steel such as SAE 1008 or 1010, a similar alloy, iron or other metal. The resulting components thus exhibit the weight saving of aluminum while providing excellent service life due to the enhanced strength and wear resistance provided by the thermally sprayed steel coating.

Abstract: A weld includes a first component and a second component. The first component includes a fay surface with one or more grooves. The second component includes a surface that is configured to mate with the fay surface of the first component. The fay surface of the first component and the surface of the second component form a friction weld when the two surfaces are mated together and relative motion between the first component and the second component generates heat through mechanical friction between the two components.

Abstract: Components for an automatic motor vehicle transmission including a band brake drum, a clutch housing or hub having a seal surface or a clutch housing or hub utilized in a friction clutch assembly having a spline set. All of these components are fabricated of aluminum and the outer surface of the band brake drum, the housing or hub sealing surface and the area of the spline set includes a thin coating of a thermally sprayed steel material. The thermally sprayed steel material may be a low carbon steel such as SAE 1008 or 1010, a similar alloy, iron or other metal. The resulting components thus exhibit the weight saving of aluminum while providing excellent service life due to the enhanced strength and wear resistance provided by the thermally sprayed steel coating.

Abstract: The present invention provides a stamped steel friction clutch hubs or housings for use in automatic motor vehicle transmissions having a sprayed on hard steel or ceramic coating on wear surfaces. The clutch hub or housing is fabricated of steel which is stamped and of unitary construction. The clutch hub or housing is complexly configured and includes a center through opening having an inner surface which is contacted by a pair of resilient, axially spaced apart seals. The housing also includes a larger diameter portion having female splines which engage male splines on the periphery of a portion of the clutch plates. The inner surface which is contacted by the resilient seals includes a thin layer of sprayed steel or ceramic material that is machined after application to a desired diameter and surface finish.

Abstract: Components for an automatic motor vehicle transmission including a band brake drum, a clutch housing or hub having a seal surface or a clutch housing or hub utilized in a friction clutch assembly having a spline set. All of these components are fabricated of aluminum and the outer surface of the band brake drum, the housing or hub sealing surface and the area of the spline set includes a thin coating of a thermally sprayed steel material. The thermally sprayed steel material may be a low carbon steel such as SAE 1008 or 1010, a similar alloy, iron or other metal. The resulting components thus exhibit the weight saving of aluminum while providing excellent service life due to the enhanced strength and wear resistance provided by the thermally sprayed steel coating.

Abstract: A selectable one way clutch includes a reverse strut pocket plate having a first plurality of struts or pawls, a reverse notch and forward strut pocket plate having a second plurality of struts or pawls, a selector plate disposed between the plates controlled by a selector plate actuator and a forward notch plate. The reverse notch and forward strut pocket plate includes a plurality of ratchet teeth disposed about its periphery which cooperate with a pin or pushrod of a linear actuator. When the reverse notch plate and forward strut pocket plate is stationary but the one way clutch is still carrying torque, the linear actuator may be actuated to rotate the reverse notch plate and forward strut pocket plate to unlock or release the torque carrying struts which would otherwise remain in their locked torque transmitting positions until all or substantially all torque across the clutch was removed.

Abstract: A selectable one way clutch includes a reverse strut pocket plate having a first plurality of struts or pawls, a reverse notch and forward strut pocket plate having a second plurality of struts or pawls, a selector plate disposed between the plates controlled by a selector plate actuator and a forward notch plate. The reverse notch and forward strut pocket plate includes a plurality of ratchet teeth disposed about its periphery which cooperate with a pin or pushrod of a linear actuator. When the reverse notch plate and forward strut pocket plate is stationary but the one way clutch is still carrying torque, the linear actuator may be actuated to rotate the reverse notch plate and forward strut pocket plate to unlock or release the torque carrying struts which would otherwise remain in their locked torque transmitting positions until all or substantially all torque across the clutch was removed.

Abstract: The present invention provides a stamped steel friction clutch hubs or housings for use in automatic motor vehicle transmissions having a sprayed on hard steel or ceramic coating on wear surfaces. The clutch hub or housing is fabricated of steel which is stamped and of unitary construction. The clutch hub or housing is complexly configured and includes a center through opening having an inner surface which is contacted by a pair of resilient, axially spaced apart seals. The housing also includes a larger diameter portion having female splines which engage male splines on the periphery of a portion of the clutch plates. The inner surface which is contacted by the resilient seals includes a thin layer of sprayed steel or ceramic material that is machined after application to a desired diameter and surface finish.

Abstract: A clutch housing for an automatic transmission includes an aluminum hub and a drum portion which is laser or friction welded to the hub. Due to the different strength requirements of the hub and drum, the hub is fabricated of 6082-T6 aluminum or a material of similar strength and malleability and is forged or die cast. The hub includes male splines or gear teeth disposed on its periphery. The cylindrical drum is fabricated of 7075-T6 aluminum or a material of similar or greater strength and similar malleability and is roller died or stamped and includes female splines or gear teeth on its inner surface as well as a plurality of radially oriented lubrication openings or slots which facilitate flow of lubricating fluid from the interior to the exterior of the cylindrical drum.

Abstract: A weld includes a first component and a second component. The first component includes a fay surface with one or more grooves. The second component includes a surface that is configured to mate with the fay surface of the first component. The fay surface of the first component and the surface of the second component form a friction weld when the two surfaces are mated together and relative motion between the first component and the second component generates heat through mechanical friction between the two components.

Abstract: Friction clutch reaction plate assemblies include two thin reaction plates which are preferably secured together in spaced relation to form a single reaction plate assembly. At least plate includes through openings which improve fluid flow between and around the plates and both plates include projections which align and define the spacing between the plates. The two plates may be secured together by various means such as spot welding, CD welding, laser welding, riveting or an adhesive. The axial space between the splines or teeth which couple the reaction plate to a clutch component (either a hub or a housing) may be reinforced with material to improve surface area contact. The reaction plate assembly has a thickness substantially equal to a conventional reaction plate in order that it may be readily substituted into current friction clutch assemblies.

Abstract: A transmission and a clutch assembly for a vehicle are disclosed. The clutch assembly includes a housing defining a cavity presenting an interior surface. The interior surface defines a pocket along a longitudinal axis. The clutch assembly further includes a piston disposed in the pocket and movable between an initial position and a final position relative to the pocket along the longitudinal axis. The piston includes a plurality of flanges extending outwardly away from the longitudinal axis. The clutch assembly also includes a biasing member attached to the interior surface of the housing and engaging the piston to continuously bias the piston toward the initial position. The biasing member abuts the flanges of the piston to prevent rotation of the piston about the longitudinal axis as the piston moves between the initial and final positions along the longitudinal axis.

Abstract: A component for a friction clutch assembly utilized in automatic transmissions, such as an outer housing, hub or carrier, exhibits reduced weight and speed sensing capability. An outer clutch housing, a clutch hub or a carrier including integral tone wheel openings are fabricated of aluminum and the tone wheel includes a coating of a thin layer of thermally sprayed steel material. Alternatively, a circumferential area of the housing, hub or carrier lacking tone wheel openings may be masked in an interrupted or discontinuous path and thermally sprayed to provide steel, teeth-like regions or patches. The thermally sprayed steel material may be a low carbon steel such as SAE 1008 or 1010, a similar alloy or iron. The resulting component thus exhibits the weight saving of aluminum and cooperates with a magnetic speed sensor to provide rotational speed sensing capability.

Abstract: Components for an automatic motor vehicle transmission including a band brake drum, a clutch housing or hub having a seal surface or a clutch housing or hub utilized in a friction clutch assembly having a spline set. All of these components are fabricated of aluminum and the outer surface of the band brake drum, the housing or hub sealing surface and the area of the spline set includes a thin coating of a thermally sprayed steel material. The thermally sprayed steel material may be a low carbon steel such as SAE 1008 or 1010, a similar alloy, iron or other metal. The resulting components thus exhibit the weight saving of aluminum while providing excellent service life due to the enhanced strength and wear resistance provided by the thermally sprayed steel coating.

Abstract: A torque transmitting mechanism includes a drum attached to one of a first member and a second member, and a shell attached to another of the first member and the second member. The drum and the shell are concentrically disposed about a longitudinal axis, with the shell concentrically disposed about the drum. An electric motor includes a stator, and a first rotor rotatable about the longitudinal axis relative to the stator. A band is coupled to the shell, wrapped around the drum between four and twelve complete revolutions, and includes a first end attached to the first rotor for rotation with the first rotor. The band includes a second end attached to a reaction member. Rotation of the first rotor tightens the band against the drum to bias the drum against the shell, to transmit torque between the first member and the second member.

Abstract: A torque transmitting mechanism includes a drum attached to one of a first member and a second member, and a shell attached to another of the first member and the second member. The drum and the shell are concentrically disposed about a longitudinal axis, with the shell concentrically disposed about the drum. An electric motor includes a stator, and a first rotor rotatable about the longitudinal axis relative to the stator. A band is coupled to the shell, wrapped around the drum between four and twelve complete revolutions, and includes a first end attached to the first rotor for rotation with the first rotor. The band includes a second end attached to a reaction member. Rotation of the first rotor tightens the band against the drum to bias the drum against the shell, to transmit torque between the first member and the second member.

Abstract: A composite, i.e., two element, two material clutch hub includes an inner sleeve of a heavy, high strength material to and about which is cast an outer element of a lighter, lower strength material. The sleeve typically includes a splined opening that is received on one or two complementarily splined shafts and a plurality of radially oriented pins or lugs or a discontinuous flange about which the outer element is cast. The outer element is splined to the friction plate of a clutch or other component. The high strength material is preferably, though not necessarily, steel and the lighter material is preferably, though not necessarily, an aluminum alloy. Alternatively, the sleeve may be a high strength aluminum alloy such as a metal matrix composite (MMC) and the outer element may be a lower strength, different aluminum alloy.

Abstract: A transmission and a clutch assembly for a vehicle are disclosed. The clutch assembly includes a housing defining a cavity presenting an interior surface. The interior surface defines a pocket along a longitudinal axis. The clutch assembly further includes a piston disposed in the pocket and movable between an initial position and a final position relative to the pocket along the longitudinal axis. The piston includes a plurality of flanges extending outwardly away from the longitudinal axis. The clutch assembly also includes a biasing member attached to the interior surface of the housing and engaging the piston to continuously bias the piston toward the initial position. The biasing member abuts the flanges of the piston to prevent rotation of the piston about the longitudinal axis as the piston moves between the initial and final positions along the longitudinal axis.

Abstract: A hybrid powertrain includes a plurality of torque generative devices, a transmission input shaft, and a planetary gear set connecting the torque generative devices to the transmission input shaft. A method to control the powertrain includes monitoring a desired configuration of the powertrain and selectively grounding a gear of the planetary gear set with a selectable one way clutch based upon the desired configuration of the powertrain.

Abstract: A method of cooling a dual clutch transmission is provided. The transmission has first and second input clutches alternately engagable to transfer torque to an output member along first and second input shafts, respectively, at various speed ratios dependent upon engagement of synchronizers. The method includes determining a currently established speed ratio by determining which of the input clutches and synchronizers are currently engaged and which of the input clutches and synchronizers are currently open. One of the open synchronizers is then engaged during the currently established speed ratio to cause the open input clutch to rotate at a speed greater than the speed of rotation of the engaged input clutch, thereby creating a fan cooling effect.