U.S. patent application number 16/992446 was filed with the patent office on 2020-12-03 for method for making turbine wheel of hydrokinetic torque converter.
This patent application is currently assigned to VALEO KAPEC CO., LTD.. The applicant listed for this patent is VALEO KAPEC CO., LTD.. Invention is credited to Jean-Francois BISSON, Alexandre DEPRAETE, Subramanian JEYABALAN, Adrien PEDUZZI, David SALVADORI.
Application Number | 20200378487 16/992446 |
Document ID | / |
Family ID | 1000005019725 |
Filed Date | 2020-12-03 |
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United States Patent
Application |
20200378487 |
Kind Code |
A1 |
JEYABALAN; Subramanian ; et
al. |
December 3, 2020 |
METHOD FOR MAKING TURBINE WHEEL OF HYDROKINETIC TORQUE
CONVERTER
Abstract
A turbine wheel for a hydrokinetic torque converter. The turbine
wheel is rotatable about a rotational axis and comprises a
substantially annular turbine shell member coaxial with the
rotational axis, and a plurality of turbine blade members axially
extending from the turbine shell member. The turbine wheel is a
single-piece component such that the turbine blade members are
unitarily formed with the turbine shell member. The turbine wheel
(22) is made by an additive manufacturing process from a polymeric
material.
Inventors: |
JEYABALAN; Subramanian;
(Troy, MI) ; DEPRAETE; Alexandre; (Atsugi-Shi,
JP) ; BISSON; Jean-Francois; (Creteil, FR) ;
SALVADORI; David; (Amiens Cedex, FR) ; PEDUZZI;
Adrien; (Les Ulis, FR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
VALEO KAPEC CO., LTD. |
Daegu |
|
KR |
|
|
Assignee: |
VALEO KAPEC CO., LTD.
|
Family ID: |
1000005019725 |
Appl. No.: |
16/992446 |
Filed: |
August 13, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
15938878 |
Mar 28, 2018 |
10774909 |
|
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16992446 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F16H 41/28 20130101;
F16H 41/04 20130101; B33Y 10/00 20141201; F16F 15/32 20130101 |
International
Class: |
F16H 41/28 20060101
F16H041/28; F16F 15/32 20060101 F16F015/32; F16H 41/04 20060101
F16H041/04; B33Y 10/00 20060101 B33Y010/00 |
Claims
1. A turbine wheel (22) for a hydrokinetic torque converter (14),
the turbine wheel (22) rotatable about a rotational axis (X) and
comprising: a substantially annular turbine shell member (32)
coaxial with the rotational axis (X); and a plurality of turbine
blade members (36) axially extending from the turbine shell member
(32); the turbine blade members (36) and turbine shell members (32)
are unitary, whereby the turbine wheel (22) is a single-piece
component; the turbine wheel (22) being made of polymeric material,
wherein the turbine wheel (22) includes an annular balance belt
(46) configured for correcting mass imbalance of the turbine wheel
(22), and wherein the balance belt (46) extends outwardly from the
turbine shell member (32) of the turbine wheel (22).
2. The turbine wheel (22) as defined in claim 1, wherein the
balance belt (46) of the turbine wheel (22) has an outer peripheral
surface (48) configured to be machined away in order to correct the
mass imbalance of the turbine wheel (22).
3. The turbine wheel (22) as defined in claim 1, wherein the
balance belt (46) extends radially outwardly from the turbine shell
member (32) of the turbine wheel (22).
4. The turbine wheel (22) as defined in claim 3, wherein the
balance belt (46) of the turbine wheel (22) has a radially outer
peripheral surface (48) configured to be machined away in order to
correct the mass imbalance of the turbine wheel (22).
5. The turbine wheel (22) as defined in claim 1, wherein the
turbine shell member (32) has a variable thickness.
6. The turbine wheel (22) as defined in claim 1, wherein the
turbine shell member (32) includes a substantially annular
semi-toroidal turbine shell portion (38), a radially extending
turbine flange portion (40), and a connecting portion (42)
radically extending between the turbine shell portion (38) and the
turbine flange portion (40).
7. The turbine wheel (22) as defined in claim 6, wherein the
connecting portion (42) of the turbine shell member (32) has a
variable thickness.
8. The turbine wheel (22) as defined in claim 1, further comprising
a substantially annular turbine core ring member (34) coaxial with
the turbine shell member (32), wherein the turbine blade members
(36) are unitarily formed with both the turbine shell member (32)
and the turbine core ring member (34).
9. The turbine wheel (22) as defined in claim 8, wherein at least
one of the turbine shell member (32) and the turbine core ring
member (34) has a variable thickness.
10. A hydrokinetic torque converter (14), comprising: an impeller
wheel (20) rotatable about a rotational axis (X), the impeller
wheel (20) including a impeller shell (21) and a plurality of
impeller blades (26) outwardly extending from the impeller shell;
and a turbine wheel (22) rotatable about the rotational axis (X)
and disposed axially opposite to the impeller wheel (20), the
turbine wheel (22) coaxially aligned with and hydro-dynamically
drivable by the impeller wheel (20), the turbine wheel (22)
comprising: a substantially annular turbine shell member (32)
coaxial with the rotational axis (X); and a plurality of turbine
blade members (36) axially extending from the turbine shell member
(32); the turbine blade members (36) are unitarily formed with the
turbine shell member (32), whereby the turbine wheel (22) is a
single-piece component, wherein the turbine wheel (22) being made
of polymeric material, wherein the turbine wheel (22) includes a
substantially annular balance belt (46) configured for correcting
mass imbalance of the turbine wheel (22), and wherein the balance
belt (46) extends outwardly from the turbine shell member (32) of
the turbine wheel (22).
11. The hydrokinetic torque converter (14) as defined in claim 10,
wherein the substantially annular balance belt (46) is configured
for correcting a mass imbalance of the turbine wheel (22) by
removing a portion of material of the turbine wheel (22) from the
balance belt (46).
12. The hydrokinetic torque converter (14) as defined in claim 10,
wherein the balance belt (46) of the turbine wheel (22) has an
outer peripheral surface (48) configured to be machined away in
order to correct the mass imbalance of the turbine wheel (22).
13. The hydrokinetic torque converter (14) as defined in claim 10,
wherein the balance belt extends radially outwardly from the
turbine shell member (32) of the turbine wheel (22).
14. The hydrokinetic torque converter (14) as defined in claim 10,
wherein the turbine shell member (32) has a variable thickness.
16. The hydrokinetic torque converter (14) as defined in claim 10,
wherein the turbine shell member (32) includes a substantially
annular semi-toroidal turbine shell portion (38), a radially
extending turbine flange portion (40), and a connecting portion
(42) radically extending between the turbine shell portion (38) and
the turbine flange portion (40).
17. The hydrokinetic torque converter (14) as defined in claim 10,
further comprising a substantially annular turbine core ring member
(34) coaxial with the turbine shell member (32), wherein the
turbine blade members (36) are unitarily formed with both the
turbine shell member (32) and the turbine core ring member (34).
Description
CROSS-REFERENCE TO RELATED APPLICATIONS AND CLAIM TO PRIORITY
[0001] This application is a division of U.S. patent application
Ser. No. 15/938,878 filed Mar. 28, 2018, the disclosure of which is
incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0002] The present invention generally relates to fluid coupling
devices, and more particularly to a turbine wheel for hydrokinetic
torque converters, and a method for making the same.
2. Background of the Invention
[0003] Typically, a hydrokinetic torque converter includes an
impeller assembly, a turbine assembly, a stator (or reactor) fixed
to a casing of the torque converter, and a one-way clutch for
restricting rotational direction of the stator to one direction.
The turbine assembly is integrally or operatively connected with a
hub linked in rotation to a driven shaft, which is itself linked
typically to an input shaft of a transmission of a vehicle. The
casing of the torque converter generally includes a front cover and
an impeller shell which together define a fluid filled chamber.
Impeller blades are fixed to an impeller shell within the fluid
filled chamber to define the impeller assembly. The turbine
assembly and the stator are also disposed within the chamber, with
both the turbine assembly and the stator being relatively rotatable
with respect to the front cover and the impeller shell. The turbine
assembly includes a turbine shell with a plurality of turbine
blades fixed to one side of the turbine shell facing the impeller
blades of the impeller.
[0004] The turbine assembly works together with the impeller
assembly, which is linked in rotation to the casing that is linked
in rotation to a driving shaft driven by an internal combustion
engine. The stator is interposed axially between the turbine
assembly and the impeller assembly, and is mounted so as to rotate
on the driven shaft with the interposition of the one-way
clutch.
[0005] Conventionally, the turbine shell and the turbine blades are
typically formed separately by stamping from steel blanks. The
turbine shell is typically slotted to receive, through the slots,
tabs formed on the turbine blades. After the turbine blades are
located within the turbine shell, the tabs are bent or rolled over
to form a mechanical attachment on the turbine shell that holds the
turbine blades fixed in position.
[0006] Current hydrokinetic torque converters and methods for
assembly thereof are quite complex, cumbersome and expensive.
Therefore, while conventional hydrokinetic torque converters,
including but not limited to those discussed above, have proven to
be acceptable for vehicular driveline applications and conditions,
improvements that may enhance their performance and cost are
possible.
BRIEF SUMMARY OF THE INVENTION
[0007] According to a first aspect of the invention, there is
provided a turbine wheel for a hydrokinetic torque converter. The
turbine wheel is rotatable about a rotational axis and comprises a
substantially annular turbine shell member coaxial with the
rotational axis, and a plurality of turbine blade members axially
extending from the turbine shell member. The turbine wheel is a
single-piece component such that the turbine blade members are
unitarily formed with the turbine shell member. The turbine wheel
is made of polymeric material.
[0008] According to a second aspect of the present invention, there
is provided a hydrokinetic torque converter, comprising an impeller
wheel rotatable about a rotational axis, and a turbine wheel
rotatable about the rotational axis and disposed axially opposite
to the impeller wheel. The impeller wheel includes an impeller
shell and a plurality of impeller blades outwardly extending from
the impeller shell. The turbine wheel is coaxially aligned with and
hydro-dynamically drivable by the impeller wheel. The turbine wheel
comprises a substantially annular turbine shell member coaxial with
the rotational axis, and a plurality of turbine blade members
axially extending from the turbine shell member. The turbine wheel
is a single-piece component, and the turbine blade members are
unitarily formed with the turbine shell member. The turbine wheel
is made of polymeric material.
[0009] According to a third aspect of the present invention, there
is provided a method for manufacturing a turbine wheel of a
hydrokinetic torque converter. The method comprises the step of
forming the turbine wheel by an additive manufacturing process as a
single-piece component from a polymeric material. The turbine wheel
comprises a substantially annular turbine shell member, and a
plurality of turbine blade members unitarily formed with the
turbine shell member and axially extending from the turbine shell
member.
[0010] Other aspects of the invention, including apparatus,
devices, systems, converters, processes, and the like which
constitute part of the invention, will become more apparent upon
reading the following detailed description of the exemplary
embodiments.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0011] The accompanying drawings are incorporated in and constitute
a part of the specification. The drawings, together with the
general description given above and the detailed description of the
exemplary embodiments and methods given below, serve to explain the
principles of the invention. The objects and advantages of the
invention will become apparent from a study of the following
specification when viewed in light of the accompanying drawings, in
which like elements are given the same or analogous reference
numerals and wherein:
[0012] FIG. 1 is a fragmented half-view in axial section of a
hydrokinetic torque-coupling device with a turbine wheel in
accordance with an exemplary embodiment of the present
invention;
[0013] FIG. 2 is a sectional view of a turbine hub secured to the
turbine wheel in accordance with the exemplary embodiment of the
present invention; and
[0014] FIG. 3 is a sectional view of the turbine wheel in
accordance with the exemplary embodiment of the present
invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENT(S) AND EMBODIED
METHOD(S) OF THE INVENTION
[0015] Reference will now be made in detail to exemplary
embodiments and methods of the invention as illustrated in the
accompanying drawings, in which like reference characters designate
like or corresponding parts throughout the drawings. It should be
noted, however, that the invention in its broader aspects is not
limited to the specific details, representative devices and
methods, and illustrative examples shown and described in
connection with the exemplary embodiments and methods.
[0016] This description of exemplary embodiments is intended to be
read in connection with the accompanying drawings, which are to be
considered part of the entire written description. In the
description, relative terms such as "horizontal," "vertical," "up,"
"down," "upper", "lower", "right", "left", "top" and "bottom" as
well as derivatives thereof (e.g., "horizontally," "downwardly,"
"upwardly," etc.) should be construed to refer to the orientation
as then described or as shown in the drawing figure under
discussion. These relative terms are for convenience of description
and normally are not intended to require a particular orientation.
Terms concerning attachments, coupling and the like, such as
"connected" and "interconnected," refer to a relationship wherein
structures are secured or attached to one another either directly
or indirectly through intervening structures, as well as both
movable or rigid attachments or relationships, unless expressly
described otherwise. The term "operatively connected" is such an
attachment, coupling or connection that allows the pertinent
structures to operate as intended by virtue of that relationship.
The term "integral" (or "unitary") relates to a part made as a
single part, or a part made of separate components fixedly (i.e.,
non-moveably) connected together. Additionally, the word "a" and
"an" as used in the claims means "at least one" and the word "two"
as used in the claims means "at least two".
[0017] An exemplary embodiment of a hydrokinetic torque-coupling
device is generally represented in FIG. 1 by reference numeral 10.
The hydrokinetic torque-coupling device 10 is intended to couple
driving and driven shafts, for example in a motor vehicle. In this
case, the driving shaft is an output shaft of an internal
combustion engine (not shown) of the motor vehicle and the driven
shaft is connected to an automatic transmission (not shown) of the
motor vehicle.
[0018] The hydrokinetic torque-coupling device 10 comprises a
sealed casing 12 filled with a fluid, such as oil or transmission
fluid, and rotatable about a rotational axis X of rotation, and a
hydrokinetic torque converter 14 disposed in the casing 12. The
sealed casing 12 and the torque converter 14 are both rotatable
about the rotational axis X. The drawings discussed herein show
half-views, that is, a cross-section of the portion or fragment of
the hydrokinetic torque-coupling device 10 above rotational axis X.
As is known in the art, the torque-coupling device 10 is
symmetrical about the rotational axis X. Hereinafter the axial and
radial orientations are considered with respect to the rotational
axis X of the torque-coupling device 10. The relative terms such as
"axially," "radially," and "circumferentially" are with respect to
orientations parallel to, perpendicular to, and circularly around
the rotational axis X, respectively.
[0019] The sealed casing 12 according to the exemplary embodiment
as illustrated in FIG. 1 includes a first casing shell 17, and a
second casing shell 18 disposed coaxially with and axially opposite
to the first casing shell 17. The first and second casing shells
17, 18 are non-movably (i.e., fixedly) interconnected and sealed
together about their outer peripheries, such as by welding or bolts
19 or other mechanical fasteners. The second casing shell 18 is
non-movably (i.e., fixedly) connected to the driving shaft, more
typically to a flywheel (not shown) that is non-rotatably fixed to
the driving shaft, so that the casing 12 turns at the same speed at
which the engine operates for transmitting torque. Specifically, in
the illustrated embodiment of FIG. 1 the casing 12 is rotatably
driven by the internal combustion engine and is non-rotatably
coupled to the flywheel thereof, such as with studs 13. As shown in
FIG. 1, the studs 13 are fixedly secured, such as by welding, to
the first casing shell 17. Each of the first and second casing
shells 17, 18 are integral or one-piece and may be made, for
example, by press-forming one-piece metal sheets.
[0020] The torque converter 14 comprises an impeller wheel
(sometimes referred to as the pump or impeller assembly) 20, a
turbine wheel (sometimes referred to as the turbine assembly) 22,
and a stator (sometimes referred to as the reactor) 24 interposed
axially between the impeller wheel 20 and the turbine wheel 22. The
impeller wheel 20, the turbine wheel 22, and the stator 24 are
coaxially aligned with one another and the rotational axis X. The
impeller wheel 20, the turbine wheel 22, and the stator 24 are all
rotatable about the rotational axis X. The impeller wheel 20, the
turbine wheel 22, and the stator 24 collectively form a torus. The
impeller wheel 20 and the turbine wheel 22 may be fluidly coupled
to one another in operation as known in the art. The
torque-coupling device 10 also includes a substantially annular
turbine (or output) hub 28 (as best shown in FIG. 1) rotatable
about the rotational axis X, which is arranged to non-rotatably
couple together the driven shaft and the turbine wheel 22.
[0021] The turbine hub 28 has internal splines 29, as best shown in
FIG. 2, and is non-rotatably coupled to the driven shaft, such as
an input shaft of the automatic transmission of the motor vehicle,
which is provided with complementary external splines.
Alternatively, a weld or other connection may be used to fix (i.e.,
non-movably secure) the turbine hub 28 to the driven shaft. The
turbine hub 28 is rotatable about the rotational axis X and is
coaxial with the driven shaft to center the turbine wheel 22 on the
driven shaft. A sealing member 27 (shown in FIGS. 1 and 2), mounted
to a radially inner peripheral surface of the turbine hub 28,
creates a seal at the interface of the transmission input shaft and
the turbine hub 28.
[0022] The impeller wheel 20 includes a substantially annular,
semi-toroidal (or concave) impeller shell 21, a substantially
annular impeller core ring 25, and a plurality of impeller blades
26 fixedly (i.e., non-moveably) attached, such as by brazing, to
the impeller shell 21 and the impeller core ring 25. Thus, a
portion of the second casing shell 18 of the casing 12 also forms
and serves as the impeller shell 21 of the impeller wheel 20.
Accordingly, the impeller shell 21 sometimes is referred to as part
of the casing 12. The impeller wheel 20, including the impeller
shell 21, the impeller core ring 25 and the impeller blades 26, is
non-rotatably secured to the first casing shell 18 and hence to the
drive shaft (or flywheel) of the engine to rotate at the same speed
as the engine output.
[0023] Furthermore, the turbine wheel 22, as best shown in FIG. 2,
comprises a substantially annular turbine shell member 32, a
substantially annular turbine core ring member 34, and a plurality
of turbine blade members 36 axially extending between the turbine
shell member 32 and the turbine core ring member 34. The turbine
blade members 36 extend axially inwardly from the turbine shell
member 32 so as to face the impeller blades 26 of the impeller
wheel 20.
[0024] The turbine core ring member 34 and the turbine blade
members 36 are formed unitary with the turbine shell member 32.
Specifically, according to the exemplary embodiment as best shown
in FIG. 2, the turbine wheel 22 is manufactured as a single-piece
component by an additive manufacturing process. Examples of an
additive manufacturing process include selective laser sintering
(SLS) (technique that uses a laser as the power source to sinter
powdered material (typically nylon/polyamide)), selective laser
melting (SLM) (technique that uses a high power-density laser as
the power source to melt and fuse material), fused deposition
modeling (FDM) (works on an "additive" principle by laying down
material in layers), and stereolithography (SLA; also known as
stereolithography apparatus, optical fabrication,
photo-solidification, or resin printing) which is a form of 3-D
printing technology used for creating models, prototypes, patterns,
and production parts in a layer by layer fashion using
photo-polymerization, a process by which light causes chains of
molecules to fuse together from polymers, etc.
[0025] Typically, a method of additive manufacturing of a
three-dimensional article comprises the steps of sequentially
depositing a plurality of successive layers in a configured pattern
corresponding to the shape of the article, and selectively
sintering or otherwise fusing the deposited material of each layer
prior to deposition of the subsequent layer so as to form the
article. Thus, each layer is formed by dispensing at least one
modeling material to form an uncured layer, and
curing/sintering/fusing the uncured layer. Exemplary additive
manufacturing processes are disclosed in U.S. Pat. Nos. 9,751,260,
9,738,031, 9,688,021, 9,555,475, 9,505,171, 9,597,730, 9,248,611,
9,144,940, 6,042,774, 5,753,274, and U.S. patent application No.
2013/0171434, 2012/0139167, 2010/0047470, 2008/0032083, the
complete disclosures of which are incorporated herein by
reference.
[0026] According to the exemplary embodiment of the present
invention, the turbine wheel 22 is made of polymeric material (or
polymer) including technical plastic, such as polyether ether
ketone (PEEK), thermoplastic polymer (an organic thermoplastic
polymer in the polyaryletherketone (PAEK) family), nylon and carbon
fibers (e.g., Carbon Fiber CFF.TM.), and resins, such as PLASTCure
Rigid, etc. PEEK polymer, for example, provides fatigue and
chemical resistance, can operate at high temperatures and retains
outstanding mechanical properties at continuous-use temperatures of
up to 240.degree. C. (464.degree. F.), allowing it to replace metal
even in the most severe end-use environments of torque converters.
Moreover, the technical plastics and resins have a volumetric mass
density lower than that of steel.
[0027] Accordingly, the additive manufacturing process of making
the turbine wheel 22 allows one to optimize the profile and
thickness of the turbine shell member 32, the turbine core ring
member 34 and/or the turbine blade members 36 for better
performance, including hydraulic performance. In other words, the
turbine wheel 22 made by the additive manufacturing process from
polymeric material can have variations in thickness, and be formed
in very particular forms and shapes, including complex shapes not
possibly by metal stamping. Also, the turbine assembly can have
reinforcing ribs also formed by additive manufacturing. Thus, with
the turbine wheel 22 of the present invention there is a
possibility for mass optimization by putting the thickness where it
is needed for strength and reducing the thickness where it is not
needed, such as where stress and deformation are low.
[0028] The turbine shell member 32, as best shown in FIG. 3,
includes a substantially annular, semi-toroidal (or concave)
turbine shell portion 38, a radially extending turbine flange
portion 40, and a connecting portion 42 radially extending between
the turbine shell portion 38 and the turbine flange portion 40. The
turbine shell member 32 of the turbine wheel 22 is non-movably
(i.e., fixedly) secured to the turbine hub 28 by appropriate means,
such as by threaded fasteners 31 or other mechanical fasteners
extending through openings 41 in the turbine flange portion 40 (as
best shown in FIG. 2), or by welding. The connecting portion 42 of
the turbine shell member 32 has a variable thickness k in the
direction orthogonal to an axially outer peripheral surface 33 of
the turbine shell member 32, as best shown in FIG. 3. Specifically,
according to the exemplary embodiment of the present invention, the
thickness k of the connecting portion 42 is largest adjacent to the
turbine shell portion 38, and smallest adjacent to the turbine
flange portion 40. As can be seen, the thickness k varies between
shell 38 and turbine flange portion 40 and the additive
manufacturing process allows precise control over the thickness
variation. Also, the turbine core ring member 34 has a variable
thickness tin the direction parallel to the rotational axis X, as
best shown in FIG. 3. Specifically, according to the exemplary
embodiment of the present invention, the thickness t of the turbine
core ring member 34 is largest in a radially middle portion of the
turbine core ring member 34, and smallest adjacent to a radially
outer end of the turbine core ring member 34.
[0029] The turbine wheel 22 made by the above-described additive
manufacturing process from polymeric material is usually
imbalanced. In order to resolve this problem, the turbine wheel 22
of the exemplary embodiment of the present invention includes a
substantially annular balance belt 46 extending outwardly (such as
radially outwardly) from an outer peripheral surface 39 of the
turbine shell portion 38 of the turbine shell member 32 of the
turbine wheel 22, as best shown in FIG. 3. The balance belt 46 is
configured for correcting a mass imbalance of the turbine wheel 22.
The balance belt 46 of the turbine wheel 22 has a radially outer
peripheral surface 48. By machining away material on the radially
outer peripheral surface 48 of the balance belt 46, the mass
imbalance of the turbine wheel 22 is corrected. In other words, the
mass imbalance of the turbine wheel 22 is corrected by removing a
portion of the material of the turbine wheel 22 from the balance
belt 46.
[0030] An exemplary method for assembling the hydrokinetic
torque-coupling device 10 according to the exemplary embodiment
will now be explained. It should be understood that this exemplary
method may be practiced in connection with the other embodiments
described herein. This exemplary method is not the exclusive method
for assembling the hydrokinetic torque coupling devices described
herein. While the method for assembling the hydrokinetic
torque-coupling device 10 may be practiced by sequentially
performing the steps as set forth below, it should be understood
that the methods may involve performing the steps in different
sequences.
[0031] The impeller wheel 20 and the stator 24 of the torque
converter 14 may each be preassembled, as shown in FIG. 1. Next,
the turbine wheel 22 is made as a single-piece component from
polymeric material, such as plastic, resin, etc, by the additive
manufacturing process. The method comprises the steps of
sequentially depositing a plurality of successive layers of the
polymeric material in a configured pattern corresponding to the
shape of the turbine wheel (22) including a substantially annular
turbine shell member (32), and a plurality of turbine blade members
(36) unitarily formed with the turbine shell member (32) and
axially extending from the turbine shell member (32), and
selectively sintering or otherwise fusing the deposited material of
each layer prior to deposition of the subsequent layer so as to
form the turbine wheel (22). The turbine shell member (32) includes
the semi-toroidal turbine shell portion (38), a radially extending
turbine flange portion (40), and a connecting portion 42 radially
extending between the turbine shell portion 38 and the turbine
flange portion 40.
[0032] The polymeric materials used in making the turbine wheel 22
include technical plastic, such as PEEK, nylon and carbon fibers,
and resins, such as PLASTCure Rigid, etc. Moreover, the turbine
wheel 22 is manufactured as a single-piece component by the
additive manufacturing process, such as through use of SLS, SLM,
FDM, SLA, etc. Furthermore, the impeller wheel 20 is unitarily
formed with the substantially annular balance belt 46 extending
outwardly from the outer peripheral surface 39 of the turbine shell
portion 38 of the turbine shell member 32 of the turbine wheel 22,
as best shown in FIG. 3.
[0033] Next, the turbine wheel 22 is balanced using the method
comprising the following steps. First, a magnitude of a mass
imbalance of the turbine wheel 22 is determined (or measured), such
as by rotation of the turbine wheel 22 to a speed at which the
imbalance of the turbine wheel 22 is manifested. Then, material on
the radially outer surface 48 of the balance belt 46 is machined
away or otherwise removed until the mass imbalance of the turbine
wheel 22 is corrected by removing a portion of the material of the
turbine wheel 22 from the balance belt 46.
[0034] Then, the turbine shell member 32 of the turbine wheel 22 is
non-movably (i.e., fixedly) secured to the turbine hub 28 by
appropriate means, such as by screws 31 or other mechanical
fasteners extending through openings 41 in the turbine flange
portion 40 (as best shown in FIG. 2), or by welding.
[0035] Next, the impeller wheel 20, the turbine wheel 22 and the
stator 24 subassemblies are assembled together so as to form the
torque converter 14, as best shown in FIG. 1. After that, the first
casing shell 17 is sealingly fixed to the second casing shell 18 of
the casing 12, such as by welding or threaded fasteners 19 or other
mechanical fasteners, so that the torque converter 14 is sealed
within the casing 12, as best shown in FIG. 1.
[0036] Various modifications, changes, and alterations may be
practiced with the above-described embodiment.
[0037] The foregoing description of the exemplary embodiment(s) of
the present invention has been presented for the purpose of
illustration in accordance with the provisions of the Patent
Statutes. It is not intended to be exhaustive or to limit the
invention to the precise forms disclosed. The embodiments disclosed
hereinabove were chosen in order to best illustrate the principles
of the present invention and its practical application to thereby
enable those of ordinary skill in the art to best utilize the
invention in various embodiments and with various modifications as
suited to the particular use contemplated, as long as the
principles described herein are followed. This application is
therefore intended to cover any variations, uses, or adaptations of
the invention using its general principles. Further, this
application is intended to cover such departures from the present
disclosure as come within known or customary practice in the art to
which this invention pertains. Thus, changes can be made in the
above-described invention without departing from the intent and
scope thereof. It is also intended that the scope of the present
invention be defined by the claims appended thereto.
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