FIELD

[0001] The invention relates generally to a cover hub assembly for a torque converter.

BACKGROUND

[0002] U.S. Patent Publication No. 2009/0266665, hereby incorporated by reference herein, describes a hub staked to a cover. Centering or positioning posts are not disclosed.

[0003] U.S. Patent No. 7,841 ,174, hereby incorporated by reference herein, describes an attachment between a cover and a pilot boss.

BRIEF SUMMARY

[0004] Example aspects broadly comprise a cover hub assembly for a torque converter comprising: an axis of rotation; a cover including: an outer surface; an inner surface; and, at least two extruded pins protruding from inner surface and symmetrical about the axis of rotation; and, a cover hub including: a cylindrical wall having: a thickness; an inner cylindrical surface, symmetrical about the axis of rotation, forming an opening; and, an outer cylindrical surface symmetrical about the axis of rotation; a cover mounting portion including at least two mating holes for receiving said extruded pins; and, at least one flow groove extending from the outer cylindrical surface to the inner cylindrical surface.

[0005] In an example aspect, the at least one extruded pin of the cover hub assembly includes a head having a first diameter and sidewalls having a first depth. In an example aspect, the mating hole includes a bottom portion having a second diameter and side portions having a second depth. In an example aspect, the first diameter is at most equal to the second diameter and the first depth is at most equal to the second depth. In an example aspect, the flow grooves are circumferentially offset from the mating holes. In an example aspect, the hub is matingly engaged with the extruded pin by a compressive force. In an example aspect, the cover hub assembly further comprises at least one weld portion connecting the cover and the hub. In an example aspect, the at least one weld portion is circumferentially aligned with respect to the mating holes and circumferentially offset with respect to the flow grooves. In an example aspect, the cover hub assembly further includes at least one recess portion extending from outer surface axially toward inner surface and symmetrical about the axis of rotation. In an example aspect, the extruded pin is generally cylindrical or frustum shaped.

[0006] Other example aspects broadly comprise a cover hub assembly for a torque converter comprising: an axis of rotation; a cover including: an outer surface; and, an inner surface provided with one or more centering protrusions, each protrusion having a first depth; a cover hub including: a cylindrical wall having a thickness and including an outer cylindrical surface and an inner cylindrical surface; and, a cover mounting portion provided with one or more centering recesses for receiving said centering protrusion, each recess having a second depth, where the second depth is greater than the first depth to provide a gap in an axial direction arranged to form one or more recess channels for radial fluid flow. In an example aspect, the one or more recess channels extend from the outer cylindrical surface to the inner cylindrical surface. In an example aspect, the recess channels are aligned with the centering protrusions. In an example aspect, the cover hub assembly further comprises at least one weld connecting the cover to the cover hub, where the recess channels and centering protrusions are offset with respect to the weld. In an example aspect, the centering protrusion of the cover is generally a cross shaped protrusion symmetrical about the axis of rotation. In an example aspect, the cover hub includes four centering recesses symmetrical about the axis of rotation and arranged for aligned engagement with the cross shaped protrusion.

[0007] Other example aspects broadly comprise a torque converter comprising: the cover hub assembly as described previously, namely comprising: an axis of rotation; a cover including: an outer surface; an inner surface; and, at least two extruded pins protruding from inner surface and symmetrical about the axis of rotation; and, a cover hub including: a cylindrical wall having: a thickness; an inner cylindrical surface, symmetrical about the axis of rotation, forming an opening; and, an outer cylindrical surface symmetrical about the axis of rotation; a cover mounting portion including at least two mating holes for receiving said extruded pins; and, at least one flow groove extending from the outer cylindrical surface to the inner cylindrical surface; further comprising a seal; a piston including a recess for the seal and arranged for sealing engagement with the cover hub assembly; and, at least one weld, located offset from the at least one flow groove, connecting the hub to the cover.

[0008] Other example aspects broadly comprise a torque converter comprising: the cover hub as described previously, namely comprising: an axis of rotation; a cover including: an outer surface; and, an inner surface provided with one or more centering protrusions, each protrusion having a first depth; a cover hub including: a cylindrical wall having a thickness and including an outer cylindrical surface and an inner cylindrical surface; and, a cover mounting portion provided with one or more centering recesses for receiving said centering protrusion, each recess having a second depth, where the second depth is greater than the first depth to provide a gap in an axial direction arranged to form one or more recess channels for radial fluid flow; further comprising a seal; a piston including a recess for the seal and arranged for sealing engagement with the cover hub assembly; and at least one weld, located offset from the one or more recess channels, connecting the hub to the cover.

[0009] Other example aspects broadly comprise a torque converter comprising: an axis of rotation; a cover including: an outer surface; and, an inner surface provided with one or more centering protrusions, each protrusion having a first depth; a cover hub including: a cylindrical wall having a thickness and including an outer cylindrical surface and an inner cylindrical surface; and, a cover mounting portion provided with one or more centering recesses for receiving said centering protrusions, each recess having a second depth, where the second depth is greater than the first depth; a first seal; a piston including a recess for the seal and arranged for sealing engagement with the outer circumferential surface of the cover hub; a second seal; a turbine hub arranged for sealing engagement with the inner circumferential surface of the cover hub; and, at least one weld, located offset from the one or more centering recesses, connecting the hub to the cover. In an example aspect, the torque converter further comprises a recess channel for radial fluid flow, wherein the recess channel is formed axially by a gap between the protrusion and the centering recess. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The nature and mode of operation of the present invention will now be more fully described in the following detailed description of the invention taken with the accompanying drawing figures, in which:

[0011] Figure 1 illustrates a cross sectional side view of a torque converter including a cover hub assembly according to an example aspect.

[0012] Figure 2 illustrates a partial side view of a cover including an extruded pin according to an example aspect.

[0013] Figure 3 illustrates a front view of a hub including mating holes and flow grooves according to an example aspect.

[0014] Figure 4A illustrates a partial cross sectional side view of a torque converter including a cover hub assembly according to an example aspect.

[0015] Figure 4B illustrates a partial cross sectional side view of a torque converter including a cover hub assembly according to another example aspect.

[0016] Figure 5 illustrates a back view of a hub including weld pattern according to an example aspect.

[0017] Figure 6 illustrates a partial back view of cover inner surface according to an example aspect.

[0018] Figure 7 illustrates a partial back view of cover inner surface according to another example aspect.

DETAILED DESCRIPTION

[0019] At the outset, it should be appreciated that like drawing numbers appearing in different drawing views identify identical, or functionally similar, structural elements. Furthermore, it is understood that this invention is not limited only to the particular embodiments, methodology, materials and modifications described herein, and as such may, of course, vary. It is also understood that the terminology used herein is for the purpose of describing particular aspects only, and is not intended to limit the scope of the present invention, which is limited only by the appended claims.

[0020] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this invention belongs. Although any methods, devices or materials similar or equivalent to those described herein can be used in the practice or testing of the invention, the following example methods, devices, and materials are now described.

[0021] Centering posts, formed integrally in a cover for a torque converter by known methods, in an example aspect, are referred to interchangeably herein as extruded simply posts, pins, or protrusions. A cover hub is referred to as simply a hub, interchangeably herein. In an example aspect, a cover hub assembly, including a cover and a cover hub, is disclosed where the hub is pre-machined to include a sealing surface for a piston and a sealing surface for a turbine hub. In an example aspect, the cover hub includes an inner cylindrical surface machined to receive a bearing and/or a bushing. In an example aspect, the cover includes centering posts or extruded pins for positioning with the hub, which includes corresponding mating holes. Mating holes in the hub provide radial centering and circumferential positions to ensure stitch welded fixing components do not overlap with flow grooves. In an example aspect and as determined by the positioning the hub, stitch welding is controlled so that flow grooves, located offset from the mating holes, are not contaminated with weld material.

[0022] The following description is made with reference to Figures 1-5. Figure 1 illustrates a cross sectional side view of a torque converter rotatable about axis A and including a cover hub assembly according to an example aspect. Torque converter 10 includes front cover 12 for connecting to a crankshaft of an internal combustion engine via stud/lug 1 1 and rear cover 16, also referred to as impeller shell interchangeably herein, for an impeller 18. Impellers are also referred to in the art interchangeably as 'pump' . Torque converter 10 also includes turbine 20, turbine shell 22, stator 32 between turbine 20 and impeller 18, and one-way clutch 30 supporting stator 32. Side plate 36 holds one-way clutch 30 in place within stator 32. [0023] Torque converter 10 includes piston 14, leaf springs 58, seal 45, clutch plate 38, clutch backing plate 34, and drive plate 42. Leaf springs 58 connect front cover 12 and piston 14. Torque converter 10 further includes damper assembly 40 including springs 44, radially outward springs 46, flange 48, and rivets 47, 49. Damper assembly 40 is connected to and drivable by turbine 20, and is positioned between turbine 20 and front cover 12. Cover 12 includes recess portion 13 and extruded portion or extruded pin 25. Extruded pin 25 may also be interchangeably referred to as post, protrusion, or pin. Extruded pin 25 is arranged for mating engagement with mating hole 54.

[0024] Torque converter 10 includes cover hub 50, turbine hub 60, and seals 70, 80. Cover hub 50 is positioned or centered by aligning and inserting extruded pins 25 into mating holes 54 of cover hub 50. Cover hub or interchangeably 'hub' 50 is sealingly engaged with piston 14 by seal 70. Hub 50 is sealingly engaged with turbine hub 60 by seal 80. Seal 80, which is a dynamic seal, is a teflon seal in an example aspect. Seals 45 and 70 are o-rings in a non- limiting example aspect. Hub 50 is fixed to cover 12 by weld 59; wherein the weld pattern is arranged about axis A so that weld locations are misaligned with flow grooves of cover hub 50, which will be described in detail as relates to Figure 5. Torque converter 10 further includes bushing 62, bearings 84, 86, inner race 88, roller 92 for one-way clutch 30, outer race 94, welds 96, and cover pilot 90.

[0025] Figure 2 illustrates a partial side view of a cover including an extruded pin according to an example aspect. Cover 12 includes inner surface 26 and outer surface 28. Cover 12 includes extruded pin or extruded portion 25 protruding out from inner surface 26 and corresponding recess portion 13 at outer surface. Extruded pin 25, having diameter dl , includes head 23 and cylindrical sidewall 24, having length si . The shape of head 23 is not critical, and may be flat, rounded, pointed, or other such shape as will be accommodated by mating hole to be described below.

[0026] Figure 3 illustrates a front view of a hub including flow grooves according to an example aspect. Cover hub 50 includes cover hub cylindrical wall 51 having thickness tl , inner cylindrical surface 52, outer cylindrical surface 53, mating holes 54, mating hole bottom portion 55a, flow grooves 56, and opening 57. Flow grooves are also referred to as centering recesses, interchangeably herein. Mating holes 54 have diameter d2. Flow grooves 56 are channels including inner portion 56a having width wl at inner cylindrical surface 52 and outer portion 56b having width w2 at outer cylindrical surface 53. In an example aspect, width wl of flow groove inner portion 56a is at least equal to width w2 of outer portion 56b. In another example aspect, width wl of inner portion 56a is greater than width w2 of outer potion 56b.

[0027] Mating holes 54, having diameter d2 and bottom portion 55, are arranged to mate with extruded pins 25 of cover 12. In an example embodiment, mating holes 54 are circumferentially offset from flow grooves 56. In other words, as shown in Figure 3, mating hole 54 is aligned with line B-B', while flow groove 56 is aligned with line B-C. While Figure 3 illustrates four mating holes and four flow grooves, one skilled in the art would recognize that the number of mating holes and/or flow grooves is not limited and may be any number one or greater. Flow grooves 56, having a depth, allow for fluid flow between hub 50 and cover 12.

[0028] Figure 4A illustrates a partial cross sectional side view of a torque converter including a cover hub assembly according to an example aspect. In an example aspect, cover hub assembly 15 comprises: (i) axis of rotation A; (ii) cover 12 including: outer surface 28; inner surface 26; and, at least two extruded pins 25 protruding from inner surface 26 and symmetrical about axis of rotation A; and, (iii) cover hub 50 including: cylindrical wall 51 having: thickness tl ; inner cylindrical surface 52, aligned with or concentric about axis of rotation A; and, outer cylindrical surface symmetrical 53 about axis of rotation A; cover mounting portion 63 including at least two mating holes 54 for receiving extruded pins 25; and, at least one flow groove 56 extending from outer cylindrical surface 53 to inner cylindrical surface 52. Flow groove 56 is not shown in Figure 4A as is circumferentially offset from mating holes 54 as shown in Figure 3. In an example aspect the cover hub assembly is useful in a torque converter comprising: cover hub assembly 15; seal 70; piston 14 including a recess for seal 70 and arranged for sealing engagement with cover hub assembly 15; and, at least one weld 59, referring to Figure 3, located offset from the at least one flow groove, connecting hub 50 to cover 12. [0029] Referring again to Figure 4A, in an example aspect, cover hub assembly 15 includes hub 50 attached to cover 12 including inner surface 26, outer surface 28, and recess portion 13 having diameter d3. Cover 12 further includes extruded pin 25 having diameter dl and including including head 23 and sidewalls 24, having a depth si . In a example aspect, cover hub assembly 15 is centered by positioning extruded pins 25 of cover 12 and inserting into and matingly engaging with mating holes 54 of hub 50. In an example aspect, cover 12 further includes at least one recess portion 13 extending from outer surface 28 axially toward inner surface 26 and symmetrical about axis of rotation A. In an example aspect, extruded pin 25 is generally cylindrical, cuboid, or frustum shaped.

[0030] In an example aspect, mating hole 54, having a diameter d2, includes bottom portion 55a and side portions 55b, having depth s2. In an example aspect, diameter dl is at most equal to diameter d2 and depth si is at most equal to depth s2. In an example aspect, hub 50 is matingly engaged with extruded pin 25 by a compressive force. In an example aspect, weld portion 59 connects cover 12 and hub 50. In an example aspect, weld portion 59 is circumferentially aligned with respect to mating holes 54 (refer to Figure 4A) and circumferentially offset with respect to flow grooves 56. In an example aspect, flow grooves 56 are circumferentially offset from mating holes 54 (refer to Figure 3).

[0031] In an example aspect, inner diameter of hub 50 includes a base portion 61 , which may include chamfered edges, with thickness t2, where thickness tl is greater than thickness t2, to accommodate bushing 62 (shown in Figure 1). Extruded pins 25, having diameter dl , generally slip fit or are otherwise engaged with mating holes 54. In an example aspect, diameter d2 of mating hole 54 is at least equal to diameter dl of pin 25. In another example aspect, diameter d2 is greater than diameter dl . In an example embodiment, depth s2 of mating hole 54 is at least equal to length si of pin 25. In another example aspect, depth s2 is greater than length si . After positioning of the cover to the cover hub, attachment is secured or fixed by weld 59. In an example aspect, welds 59 are arranged in circumferential alignment with mating holes 54 while being offset from flow grooves 56. [0032] Figure 5 illustrates a back view of a hub including weld pattern according to an example aspect. Weld 59 attaches cover 12 to hub 50. The weld pattern of Figure 5 is applicable to a cover hub assembly as is shown in Figure 4A. Although in the embodiments shown in Figures 3-5, extruded pins 25 and mating holes 54 are generally cylindrical in shape, one of ordinary skill in the art will recognize that other shapes are also possible, e.g., square parallelepiped, cuboid, frustum, cone and paraboloid, and such shapes are within the spirit and scope of the claimed invention.

[0033] Figure 4B illustrates a partial cross sectional side view of a torque converter including a cover hub assembly according to an alternative embodiment. In an example aspect, deeper cover hub flow grooves, or centering recesses, are installed on radially extending cover protrusions. In an example aspect, cover hub assembly 1 15 for a torque converter comprises: (i) axis of rotation A; (ii) cover 1 12 including: outer surface 128; and, inner surface 126 provided with one or more centering protrusions 125, each protrusion having depth s3; and, (iii) cover hub 150 including: cylindrical wall 151 having thickness t3 and including outer cylindrical surface 153 and inner cylindrical surface 152; and, cover mounting portion 163 provided with one or more centering recesses 154 for receiving said centering protrusion 125, each recess having depth s4, where depth s4 is greater than depth s3 to provide gap 158 in an axial direction arranged to form one or more recess channels 155 for radial fluid flow 157. In an example aspect the cover hub assembly is useful in a torque converter comprising: cover hub assembly 1 15 further comprising a seal; a piston including a recess for the seal and arranged for sealing engagement with the cover hub assembly; and at least one weld, located offset from the one or more recess channels, connecting the hub to the cover. Cover 1 12 includes recess portion 1 13. Cover hub 150 includes cover hub cylindrical wall 151 having thickness t3, cover mounting portion 163 and base portion 161 , having thickness t4.

[0034] Referring again to Figure 4B, in an example aspect recess channels 155 extend from outer cylindrical surface 153 to inner cylindrical surface 152. In an example aspect, recess channels 155 are aligned with centering protrusions 125. In an example aspect, cover hub assembly 1 15 further comprises at least one weld (not shown in Figure 4B because offset) connecting cover 1 12 to cover hub 150, where recess channels 155 and centering protrusions 125 are offset with respect to the weld. In an example aspect, centering protrusion 125 protruding from inner surface 126 of cover 1 12 is generally a cross shaped protrusion 125 (see also Figure 6) symmetrical about axis of rotation A. Alternatively, as shown in Figure 7, cover 212 includes centering protrusions 225 protruding from inner surface 226. Any complementary configuration of protrusions and centering recesses may be employed and are not limited to the example herein. In an example aspect, the cover hub to complement cover 1 12 of Figure 6 includes four centering recesses symmetrical about the axis of rotation and arranged for aligned engagement with cross shaped protrusion 125. Similarly, in an example aspect, the cover hub to complement cover 212 of Figure 7 also includes four centering recesses symmetrical about the axis of rotation and arranged for aligned engagement with protrusion 225. In a cross shaped protrusion such as shown in the cover of Figure 7, the extensions or 'arms' need to correspond in number and be symmetrical about axis A in complementary fashion with the centering recesses of the cover hub. It is possible, however, to have more hub recesses than cover arms for increased fluid flow.

[0035] In an example aspect, the extruded portion of cover 1 12 is mated with extended flow grooves or centering recesses 154 of cover hub 150. In other words, cover 1 12 is centered, positioned, or otherwise aligned with hub 150 via extruded portions being fitted into centering recesses or deepened flow grooves. In an example aspect, cover 1 12 further includes at least one recess portion 1 13 extending from outer surface 128 axially toward inner surface 126 and symmetrical about axis of rotation A.

[0036] In other example aspects, torque converter 10 comprises: (i) axis of rotation A;

(ii) cover 12, 1 12 including: outer surface 28, 128; and, inner surface 26, 126 provided with one or more centering protrusions 25, 125, each protrusion having a first depth dl , d3; (iii) cover hub 50, 150 including: cylindrical wall 51 , 151 having a thickness tl , t3 and including outer cylindrical surface 53, 153 and inner cylindrical surface 52, 152; and, cover mounting portion 63, 163 provided with one or more centering recesses 54, 154 for receiving said centering protrusions 25, 125 each recess 54, 154 having a second depth, s2, s4 where the second depth is greater than the first depth si , s3; (iv) first seal 70; (v) piston 14 including a recess for the seal and arranged for sealing engagement with outer circumferential surface 53, 153 of cover hub 50, 150; second seal 80; (vi) turbine hub 60 arranged for sealing engagement with inner circumferential surface 52, 152 of cover hub 50,150; and, (vii) at least one weld 59, located offset from the one or more centering recesses 54,154, connecting hub 50, 150 to cover 12, 1 12. In another example aspect, the torque converter further comprises recess channel 155 for radial fluid flow 157, wherein recess channel 155 is formed axially by gap 158 between protrusion 125 and centering recess 154.

[0037] Of course, changes and modifications to the above examples of the invention should be readily apparent to those having ordinary skill in the art, without departing from the spirit or scope of the invention as claimed. Although the invention is described by reference to specific preferred and/or example embodiments, it is clear that variations can be made without departing from the scope or spirit of the invention as claimed.

Listing of Elements

A axis

10 torque converter

1 1 stud/lug

12 front cover

13 recess portion, diameter = d3

14 piston

15 cover hub assembly

16 rear cover

18 impeller

20 turbine

22 turbine shell

23 extruded pin head

24 sidewalls, length = si

25 extruded pin / protruded portion, diameter = dl 26 inner surface of cover

28 outer surface of cover

30 one-way clutch

32 stator

34 clutch backing plate

36 side plate

38 clutch plate

40 damper assembly

42 drive plate

44 springs

45 seal

46 radially outward springs

47 rivet

48 flange

49 rivet

50 cover hub

51 cover hub cylindrical wall, thickness = t

52 cover hub inner cylindrical surface

53 cover hub outer cylindrical surface

54 mating hole, diameter = d2

55a mating hole bottom portion

55b mating hole side portion, depth = s2

56 flow groove

56a flow groove inner portion, width = wl

56b flow groove outer portion, width = w2

57 opening

58 leaf springs

59 weld 60 turbine hub

61 base portion of cover hub cylindrical wall, thickness = t2

62 bushing

63 cover mounting portion of cover hub

70 seal

80 seal

84 bearing

86 bearing

88 inner race

90 cover pilot

92 roller

94 outer race

96 weld

112 cover

1 13 recess portion

115 cover hub assembly

125 centering protrusion, depth = s3

126 inner surface of cover

128 outer surface of cover

150 cover hub

151 cover hub cylindrical wall, thickness = t3

152 cover hub inner cylindrical surface

153 cover hub outer cylindrical surface

154 centering recess, depth = s4

155 recess channel

157 radial fluid flow

158 gap

161 base portion of cover hub cylindrical wall, thickness = t4 163 cover mounting portion of cover hub

212 cover

225 centering protrusion

226 inner surface of cover