阅读说明：本技术 所有叶片都能自由旋转的可变节距定子结构以及变矩器 (Variable pitch stator structure with all blades capable of freely rotating and torque converter ) 是由 约翰·爱德华·布雷维克 基思·A·德弗罗 于 2019-08-19 设计创作，主要内容包括：本公开提供了“所有叶片都能自由旋转的可变节距定子结构以及变矩器”。一种变矩器定子,包括：毂；外环；多个叶片；以及多个辐条。所述毂围绕轴线设置。所述叶片沿径向设置在所述外环与所述毂之间。所有所述叶片都可相对于所述毂和所述外环枢转。所述辐条与所述叶片间隔开并且固定到所述毂和所述外环以相对于所述毂支撑所述外环。(The present disclosure provides a "variable pitch stator structure and torque converter with all blades freely rotatable". A torque converter stator comprising: a hub; an outer ring; a plurality of blades; and a plurality of spokes. The hub is disposed about an axis. The blades are radially disposed between the outer ring and the hub. All of the blades are pivotable relative to the hub and the outer ring. The spokes are spaced apart from the blades and fixed to the hub and the outer ring to support the outer ring relative to the hub.)

1. A torque converter stator, comprising:

a hub disposed about an axis;

an outer ring;

a plurality of blades radially disposed between the outer ring and the hub, all of the blades being pivotable relative to the hub and the outer ring; and

a plurality of spokes spaced apart from the blades and fixed to the hub and the outer ring to support the outer ring relative to the hub.

2. The torque converter stator of claim 1, wherein the torque converter stator has a different number of spokes than blades.

3. The torque converter stator of claim 1, further comprising:

a plurality of pivoting members, each pivoting member extending from a first side of a corresponding one of the blades;

a plurality of actuating members, each actuating member extending from a second side of a corresponding one of the blades, the second side being opposite the first side, the pivoting member and the actuating members supporting the blades for rotation relative to the hub and the outer ring;

an actuator coupled to the actuation member and configured to move the actuation member to pivot the blade.

4. The torque converter stator of claim 3, wherein the spokes are thinner than the pivot member and the spokes are thinner than the actuating member.

5. The torque converter stator of claim 3, wherein the actuator is disposed within the hub.

6. The torque converter stator of claim 5, further comprising a one-way clutch disposed within the hub.

7. The torque converter stator as in claim 5 wherein the outer ring comprises first and second housing rings having opposing surfaces that cooperate to form radially extending outer pivot slots, each of the pivot members being rotatably received in a corresponding one of the outer pivot slots.

8. The torque converter stator of claim 7, wherein the hub includes a housing body and a housing cover having opposing surfaces that cooperate to form radially extending inner pivot slots, each of the actuator members being rotatably received in a corresponding one of the inner pivot slots.

9. The torque converter stator of claim 8, wherein the spokes comprise: a first set of spokes extending from the housing body to the first housing ring; and a second set of spokes extending from the housing cover to the second housing ring.

10. The torque converter stator of claim 8, wherein the spokes are directly connected to the first housing ring but not directly connected to the second housing ring.

11. The torque converter stator of claim 3, wherein the actuator includes an annular piston slidably disposed within a cylinder defined by the hub.

12. The torque converter stator of claim 11, wherein each of the actuator members forms a crank coupled to the piston.

13. The torque converter stator of claim 3, wherein each pivot member is integrally formed with a corresponding one of the actuator members to define a shaft extending through a corresponding vane.

14. The torque converter stator of claim 3, wherein each pivot member is integrally formed with a corresponding one of the actuator members and the corresponding vane.

15. The torque converter stator of claim 1, wherein the spokes extend at an angle from the hub to the outer ring.

Technical Field

The present disclosure relates to a variable pitch stator structure in which all blades can freely rotate and a torque converter having a variable pitch stator.

Background

The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.

Automatic transmission vehicles typically include a torque converter between the engine and the transmission. A typical torque converter includes a pump, a turbine, and a stator, with stator blades positioned at a fixed pitch within the torque converter. The pitch of the stator vanes is typically selected to optimize performance, such as fuel economy, over all operating speed ranges; power; noise, vibration, and harshness (NVH). Such optimization over the entire range will generally result in less than optimal performance for any particular speed.

Attempts have been made in the past to create variable pitch stators, but these attempts have generally required handling one blade at a time and assembling one blade. A typical stator may include about twenty to thirty stator blades. The labor intensive processes required to produce the variable pitch torque converter have resulted in unacceptable costs for those earlier variable pitch stators when used at high throughput and also in greater scrap rates due to greater opportunities for assembly errors.

These and other limitations of conventional torque converter stators are addressed by the present disclosure.

Disclosure of Invention

In one form, a torque converter stator includes a hub, an outer ring, a plurality of blades, and a plurality of spokes. The hub is disposed about an axis. The blades are radially disposed between the outer ring and the hub. All the blades are pivotable with respect to the hub and the outer ring. The spokes are spaced apart from the blades and fixed to the hub and the outer ring to support the outer ring relative to the hub.

According to another form, the torque converter stator has spokes different from the number of blades.

In another form, the torque converter stator further includes a plurality of pivoting members, a plurality of actuating members, and an actuator. Each pivot member extends from a first side of a corresponding one of the blades. Each actuating member extends from the second side of a corresponding one of the vanes. The second side is opposite the first side. The pivot member and the actuating member support the blades for rotation relative to the hub and the outer ring. An actuator is coupled to the actuating member and configured to move the actuating member to pivot the blade.

In another variation, the spokes are thinner than the pivoting member and the spokes are thinner than the actuating member.

According to a further form, the first side is radially outward of the second side.

In another form, the actuator is disposed within the hub.

In another form, the torque converter stator further includes a one-way clutch disposed within the hub.

According to a further form, the outer ring includes a first housing ring and a second housing ring. The first housing ring and the second housing ring have opposing surfaces that cooperate to form a radially extending outer pivot slot. Each of the pivot members is rotatably received in a corresponding one of the outer pivot slots.

In another variation, the hub includes a housing body and a housing cover. The housing body and the housing cover have opposing surfaces that cooperate to form a radially extending inner pivot slot. Each of the actuator members is rotatably received in a corresponding one of the inner pivot slots.

In another form, the spoke includes: a first set of spokes extending from the housing body to the first housing ring; and a second set of spokes extending from the housing cover to the second housing ring.

According to a further form, the actuator includes an annular piston slidably disposed within a cylinder defined by the hub.

In another form, the actuator includes a spring configured to bias the piston in one axial direction.

In another variation, each of the actuator members forms a crank coupled to the piston.

In another variation, each pivoting member is integrally formed with a corresponding one of the actuator members to define a shaft extending through the corresponding vane.

According to a further form, each pivoting member is integrally formed with a respective one of the actuator members and a respective vane.

According to a further variant, the spokes extend at an angle from the hub to the outer ring.

In another form, a torque converter stator includes a first body, a second body, a first ring, a second ring, a plurality of blades, and a plurality of spokes. The first body and the second body are coupled together to form a hub. The first ring and the second ring are coupled together to form an outer ring. The blades are radially disposed between the hub and the outer ring. All the blades are pivotable with respect to the hub and the outer ring. Each spoke has a first end fixed to the hub and a second end fixed to the outer ring.

According to a further form, the plurality of spokes includes a first set of spokes and a second set of spokes. The first ends of the first set of spokes are fixedly attached to the first body. The second ends of the first set of spokes are fixedly attached to the first ring. The first ends of the second set of spokes are fixedly attached to the second body. The second ends of the second set of spokes are fixedly attached to the second ring.

In another form, the torque converter stator further includes an actuator disposed within the hub and coupled to the blades. The actuator is configured to rotate the blades relative to the hub and the outer ring.

In another variation, the actuator includes a piston and a plurality of crank members. The piston is slidably disposed within the hub. Each crank member has: a first end non-rotatably coupled to a corresponding one of the blades; and a second end rotatably coupled to the piston. The crank member is configured to rotate the blades as the piston moves axially relative to the hub.

Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

Drawings

In order that the disclosure may be well understood, the various forms described herein will now be given by way of example with reference to the accompanying drawings, in which:

FIG. 1 is a schematic cross-sectional view of a torque converter according to the teachings of the present disclosure;

FIG. 2 is a perspective view of a stator of the torque converter of FIG. 1;

FIG. 3 is a partially exploded perspective view of the stator of FIG. 2;

FIG. 4 is a cross-sectional view of a portion of the stator of FIG. 2;

FIG. 5 is a flow chart of a method of manufacturing the stator of FIG. 2 according to the teachings of the present disclosure;

FIG. 6 is a perspective view of a frame for use in the method of FIG. 5 according to the teachings of the present disclosure;

FIG. 7 is a side view of the frame of FIG. 6;

FIG. 8 is a perspective view of a portion of the stator of FIG. 2 illustrated at one step in the method of FIG. 5;

FIG. 9 is a perspective view of the stator of FIG. 2 illustrated at another step of the method of FIG. 5;

FIG. 10 is a flow chart of a method of manufacturing the frame of FIG. 6 according to the teachings of the present disclosure;

FIG. 11 is a perspective view of a portion of the frame of FIG. 6 illustrated at one step of the method of FIG. 10;

FIG. 12 is a perspective view of a portion of the frame of FIG. 6 illustrated at another step of the method of FIG. 10; and is

Fig. 13 is a perspective view of the frame of fig. 6 illustrated with multiple molds at another step of the method of fig. 10 in accordance with the teachings of the present disclosure.

The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

Detailed Description

The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.

Referring to FIG. 1, an example of a torque converter 10 constructed in accordance with the teachings of the present disclosure is schematically illustrated. The torque converter 10 includes an input member 14, an output member 18, a pump 22, a turbine 26, and a stator 30. In the example provided, the torque converter 10 also includes a one-way clutch 34, which is also referred to as an overrunning clutch. The torque converter is generally disposed about the central axis 38.

The input member 14 is supported for rotation about an axis 38 and is configured to receive input torque from a prime mover (not shown; e.g., an electric motor or an internal combustion engine). For example, the input member 14 may be drivingly coupled to an internal combustion engine (not shown) via a flywheel (not shown). The output member 18 is supported for rotation about an axis 38 and is configured to output torque to a set of drive wheels (not shown). For example, the output member 18 may be drivingly coupled to drive wheels (not shown) through a transmission (not shown). The input member 14 and the output member 18 are generally supported for rotation relative to each other about an axis 38. The pump 22, turbine 26, and stator 30 are generally disposed about an axis 38 and are configured to cooperate to transfer torque from the input member 14 to the output member 18, and may function to multiply the input torque such that increased torque is output by the output member 18. Although described with respect to powering the drive wheels of a vehicle, the torque converter 10 may be used in torque transmitting applications other than vehicles.

In the example provided, the input member 14 includes a main housing 42. The pump 22 may be configured in a manner common to torque converter pumps, but the pump 22 typically includes a plurality of pump or impeller blades (not shown) that are circumferentially spaced about the axis 38 and coupled to the main housing 42 for common rotation about the axis 38. The turbine 26 may be configured in a manner common to torque converter turbines, but the turbine 26 typically includes a plurality of turbine blades (not shown) disposed within the main housing 42. Turbine blades (not shown) are circumferentially spaced about the axis 38 and are coupled to the output member 18 for common rotation about the axis 38.

The stator 30 is described in more detail below, but is generally configured to direct transmission oil flow from the turbine 26 to the pump 22. The stator 30 is typically coupled to a rotationally fixed component 46 (e.g., a transmission case of the transmission) that does not rotate about the axis 38. In the example provided, the one-way clutch 34 is disposed between the stator 30 and the rotationally fixed component 46 and is configured to permit the stator 30 to rotate about the axis 38 in one rotational direction relative to the fixed component 46, but not in an opposite rotational direction.

Referring additionally to fig. 2-4, the stator 30 is shown in greater detail. Stator 30 includes a stator housing 210, a plurality of stator vanes 214, a plurality of pivoting members 218, a plurality of actuating members 222, and an actuator 226.

Stator housing 210 includes a housing body 230, a housing cover 234, a first housing ring 238, a second housing ring 242, a plurality of first supports 246, and a plurality of second supports 250. The housing body 230 is a generally annular shaped body having a central bore 254 coaxial with the axis 38. In the example provided, the housing body 230 defines a clutch recess 258 and an annular recess that defines a portion of the annular actuator chamber 262. The clutch recess 258 is disposed radially inward of the actuator chamber 262 and opens through a first side 266 of the housing body 230 and opens through the housing body 230 in a radially inward direction toward the axis 38. The portion of the actuator chamber 262 defined by the housing body 230 opens through the first side 266 of the housing body 230.

In the example provided, the first side 266 of the housing body 230 also includes a plurality of inner pivot slots 270, the plurality of inner pivot slots 270 being disposed radially outward of the actuator chamber 262 and equally spaced in a circumferential direction around the housing body 230. Inner pivot slot 270 opens through a radially outward surface of housing body 230 and extends longitudinally along an axis that intersects axis 38. The number of inner pivot slots 270 corresponds to the number of stator vanes 214 and pivot members 218. Each inner pivot slot 270 is a semi-cylindrical shaped slot configured to cradle (cradle) a portion of one of the pivot members 218 as described below. In the example provided, the housing body 230 may optionally define a seal groove that perpendicularly intersects each inner pivot groove 270 and permits a seal (e.g., an o-ring 274) to form a seal between the pivot member 218 and the stator housing 210 while still permitting the pivot member 218 to rotate relative to the stator housing 210.

The first housing ring 238 is an annular shaped body coaxial with the axis 38 and disposed radially outside of the housing body 230. The first housing ring 238 defines a plurality of outer pivot slots 278, the number of the plurality of outer pivot slots 278 corresponding to the number of inner pivot slots 270 of the housing body 230. The outer pivot slot 278 opens through the first side 282 of the first housing ring 238 and opens through a radially inward surface of the first housing ring 238. Outer pivot slot 278 is aligned with inner pivot slot 270 such that it extends longitudinally along the same axis as inner pivot slot 270. Each outer pivot slot 278 is a semi-cylindrical shaped slot configured to cradle a portion of one of the pivot members 218 as described below. In the example provided, the outer pivot slot 278 extends radially outward to also open through the radially outward surface of the first housing ring 238.

The first supports 246 are thin, rigid spokes that extend in a radial direction between the first housing ring 238 and the housing body 230 to support the first housing ring 238 coaxially with respect to the housing body 230. In the example provided, there are fewer first supports 246 than stator vanes 214, and the first supports 246 are thinner than the pivot members 218, although other configurations may be used. The first supports 246 may be equally spaced in a circumferential direction about the axis 38. An inboard end of each first support 246 is rigidly coupled (e.g., welded) to the housing body 230, and an outboard end of each first support 246 is rigidly coupled (e.g., welded) to the first housing ring 238. In the example provided, the inboard end of the first support 246 is at a position axially offset from the first housing ring 238 such that the first support 246 extends at an angle from the housing body 230 to the first housing ring 238.

The housing cover 234 is a generally annular shaped body having a central bore 286 coaxial with the axis 38. The housing cover 234 has a first side 290 that faces the first side 266 of the housing body 230 and may abut the first side 266. The housing cover 234 is configured to be fixedly (i.e., rigidly or non-movably) coupled to the housing body 230 to cover the first side 266 of the housing body 230. Although not specifically shown, additional seals may be used to form a seal between the first side 266 of the housing body 230 and the first side 290 of the housing cover 234. In the example provided, the housing cover 234 is fixedly coupled to the housing body 230 by a plurality of bolts (not expressly shown) that are received through holes 294 in the housing cover 234 and threadingly engage with threaded holes 298 in the housing body 230, although other configurations (e.g., rivets or welding) may be used. In the example provided, the housing cover 234 has an annular recess that opens through a first side 290 of the housing cover 234 to define the remainder of the actuator chamber 262.

In the example provided, the housing cover 234 includes a plurality of inner pivot slots 310, the plurality of inner pivot slots 310 corresponding to and opposing the inner pivot slots 270 of the housing body 230. The inner pivot slots 310 are equally spaced in the circumferential direction around the housing cover 234. Inner pivot slot 310 opens through a radially outward surface of housing cover 234 and extends longitudinally along an axis that intersects axis 38 (e.g., the same axis as inner pivot slot 270). The number of inner pivot slots 310 corresponds to the number of stator vanes 214 and pivot members 218. Each inner pivot slot 310 is a semi-cylindrical shaped slot configured to cradle a portion of one of the pivot members 218 as described below. In the example provided, the housing cover 234 may optionally define a seal groove that perpendicularly intersects each inner pivot groove 310 and permits a seal (e.g., an o-ring 274) to form a seal between the pivot member 218 and the stator housing 210 while still permitting the pivot member 218 to rotate relative to the stator housing 210.

The second housing ring 242 corresponds to the first housing ring 238, and is an annular-shaped body that is coaxial with the axis 38 and disposed radially outside the housing cover 234. The second housing ring 242 defines a plurality of outer pivot slots 314, the plurality of outer pivot slots 314 corresponding to and opposing the outer pivot slots 278 of the first housing ring 238. The outer pivot slots 314 correspond to the inner pivot slots 310 of the housing cover 234. The outer pivot slot 314 opens through a first side 318 of the second housing ring 242 opposite the first side 282 of the first housing ring 238, and the outer pivot slot 314 opens through a radially inward surface of the second housing ring 242. Outer pivot slot 314 is aligned with inner pivot slot 310 such that it extends longitudinally along the same axis as inner pivot slot 310. Each outer pivot slot 314 is a semi-cylindrical shaped slot configured to cradle a portion of one of the pivot members 218 as described below. In the example provided, the outer pivot slot 314 extends radially outward to also open through a radially outward surface of the second housing ring 242.

The first side 318 of the second housing ring 242 faces the first side 282 of the first housing ring 238 and may abut the first side 282. The second housing ring 242 is configured to be fixedly coupled to the first housing ring 238 to cover the first side 282 of the first housing ring 238. In the example provided, the second housing ring 242 is fixedly coupled to the first housing ring 238 by a plurality of bolts (not expressly shown) that are received through holes 322 in the second housing ring 242 and threadably engage threaded holes 326 in the first housing ring 238, although other configurations (e.g., rivets or welds) may be used.

The second supports 250 are thin, rigid spokes that extend in a radial direction between the second housing ring 242 and the housing cover 234 to support the second housing ring 242 coaxially with respect to the housing cover 234. In the example provided, there are fewer second supports 250 than stator blades 214, there are the same number of second supports 250 as first supports 246, and the first and second supports are not directly aligned with each other in the circumferential direction, although other configurations may be used. In the example provided, the second support 250 is thinner than the pivot member 218 and may be substantially the same thickness as the first support 246, although other configurations may be used. The second supports 250 may be equally spaced in the circumferential direction about the axis 38. An inboard end of each second support 250 is rigidly coupled (e.g., welded) to the housing cover 234, and an outboard end of each second support 250 is rigidly coupled (e.g., welded) to the second housing ring 242. In the example provided, the inboard end of the second support 250 is at a position axially offset from the second housing ring 242 such that the second support 250 extends at an angle from the housing cover 234 to the second housing ring 242. In the example provided, the inboard ends of the first and second supports 246, 250 are spaced further apart in the axial direction than their corresponding outboard ends.

Each stator blade 214 has a shape generally configured to direct fluid flow into the torque converter 10. Each stator blade 214 is radially disposed in the space between the housing body 230 and the first housing ring 238, also radially between the housing cover 234 and the second housing ring 242. In the example provided, the pivot member 218 is a generally thin cylindrical but rigid straight line. In the example provided, the pivot member 218 has a cross-sectional thickness (e.g., diameter) that is less than or equal to the thickness of the stator vane 214. In the example provided, the diameter of the pivot member 218 is about 2 millimeters, but other configurations may be used. Each pivot member 218 is fixedly coupled to a corresponding one of the stator vanes 214 and extends radially outward from a radially outward side of the corresponding stator vane 214. Each pivot member 218 is received in a corresponding outer pivot slot 278, 314 such that the pivot member 218 can rotate about its axis relative to the housing rings 238, 242.

In the example provided, the actuation member 222 is a generally thin cylindrical but rigid wire having a double bend to form the first leg 330, the second leg 334, and the third leg 338. In the example provided, the actuation member 222 has a cross-sectional thickness (e.g., diameter) that is less than or equal to a thickness of the stator vanes 214. In the example provided, the actuation member 222 is about 2 millimeters in diameter, but other configurations may be used. In the example provided, the first leg 330 is fixedly coupled to a corresponding one of the stator blades 214 and extends radially inward from a radially inward side of the stator blade 214. The first leg 330 is coaxial with the corresponding pivot member 218. Each first leg 330 is received in a corresponding inner pivot slot 270, 310 such that the first leg 330 can rotate about its axis relative to the housing body 230 and the housing cover 234. In the example provided, the first leg 330 extends radially inward into the actuator chamber 262. In the example provided, the second leg 334 extends substantially perpendicularly between the housing body 230 and the housing cover 234 from a radially inward end of the first leg 330 in the actuator chamber 262. In the example provided, the third leg 338 extends substantially perpendicularly from the second leg 334 in a radially inward direction toward the axis 38 while remaining within the actuator chamber 262.

In the example provided, each pivoting member 218 and its corresponding actuating member 222 are integrally formed wires that include an intermediate portion 342 (shown in fig. 11 and 12) that connects the pivoting member 218 to the first leg 330 by extending longitudinally through an aperture in the corresponding stator vane 214. In the example provided, the intermediate portion 342 of the integrally formed wire (shown in fig. 11 and 12) has a predetermined shape, such as a splined shape (shown in fig. 11 and 12), a flattened shape, or other suitable shape, and the bore of the stator vane 214 has a mating predetermined shape such that the stator vane 214 cannot rotate relative to the intermediate portion 342 of the wire. In an alternative configuration, not specifically shown, pivoting member 218 and actuating member 222 may be separate components fixedly attached to stator vane 214. In another alternative configuration, not specifically shown, pivoting member 218, stator vanes 214, and actuating member 222 may be a single integrally formed component.

Returning to the example provided, actuator 226 is generally configured to displace third leg 338 of actuation member 222 to rotate stator blade 214 relative to stator housing 210. In the example provided, the actuator 226 is a hydraulically operated piston-cylinder type linear actuator, although other types of linear actuators (e.g., solenoid actuators) may be used. In the example provided, the actuator 226 includes an actuator chamber 262, a piston 346, a plurality of return springs 350, a fluid reservoir 354, and a pump 358. In the example provided, the actuator 226 may also include a bleed valve 362.

Piston 346 is a generally annular shaped body that is axially slidable within actuator chamber 262. In the example provided, the piston 346 includes a piston head and a plurality of spring seats. The piston head is an annular body coaxial with the axis 38. In the example provided, a seal ring may form a seal between the outer cylindrical surface of the piston head and the housing body 230, and another seal ring may form a seal between the inner cylindrical surface of the piston head and the housing body 230. The piston head also defines a circumferential groove 366, the circumferential groove 366 extending circumferentially around the piston head and opening through a radially outward surface of the piston head. The distal end of third leg 338 of actuation member 222 is disposed within circumferential slot 366. Thus, as the piston 346 moves axially in the actuator chamber 262, the third leg 338 moves axially with the piston 346, thereby rotating the stator vanes 214 relative to the stator housing 210.

The spring seats are spaced in a circumferential direction about the axis 38 and extend in a direction axially away from the housing cover 234. In the example provided, the return spring 350 is a coil spring spaced in a circumferential direction about the axis 38 within the portion of the actuator chamber 262 defined by the housing body 230. Each return spring 350 may be disposed around a corresponding one of the spring seats to maintain a spacing thereof. The return spring 350 may bias the piston 346 in a direction axially toward the housing cover 234. Although separate spaced apart coil springs are shown, other types of springs may be used. For example, in an alternative configuration not shown, an annular wave spring may be coaxial with the axis in place of the plurality of return springs 350 and spring seats.

The reservoir 354 is configured to hold a volume of hydraulic fluid or oil. The pump 358 is configured to draw fluid from the reservoir 354 and pump the fluid to the actuator chamber 262. In the example provided, the reservoir 354 and the pump 358 are remote from the torque converter 10 and are coupled to the stator 30 by conduits. In the example provided, the pump 358 is coupled to communicate fluid to the side of the actuator chamber 262 defined by the annular recess in the housing cover 234. In the example provided, the pump 358 is a one-way pump, and the bleed valve 362 is in fluid communication with the reservoir 354 and the actuator chamber 262 on the same side of the piston 346 as the pump 358. Then, when the pump 358 is deactivated, the return spring 350 may move the piston 346 to return fluid to the reservoir 354 via the bleed valve 362. In an alternative configuration, not specifically shown, pump 358 may be a bi-directional pump that returns fluid to reservoir 354.

In the example provided, the one-way clutch 34 includes a plurality of clutch members 370 and a clutch wheel 374 disposed within the clutch recess 258. The clutch members 370 may be biased radially inward by a spring (not shown). The clutch wheel 374 includes a plurality of ramps disposed about its outer circumference that are configured to lockingly engage the clutch member 370 in a manner that prevents the clutch wheel 374 from rotating relative to the housing body 230 in one rotational direction while slidably engaging the ramps to permit the clutch wheel 374 to rotate relative to the housing body 230 in an opposite rotational direction. In the example provided, the clutch wheel 374 is non-rotatably coupled to the stationary component 46 (FIG. 1; e.g., a transmission housing).

In operation, the torque converter 10 may operate as a typical torque converter, except that when different torque multiplier increments are required, the actuator 226 may be activated to move the piston 346 and rotate the stator blades 214 to different pitches relative to the stator housing 210.

With additional reference to fig. 5-9, a method 510 of manufacturing the stator 30 is provided and illustrated in fig. 5 with steps generally shown in flow chart form. At step 514, a frame 610 (fig. 6 and 7) is formed. With particular reference to fig. 6 and 7, frame 610 includes an outer ring 614, pivot members 218 ', actuating members 222', and stator vanes 214. In the example provided, the frame 610 (fig. 6 and 7) also includes an inner ring 618. The pivot member 218 ' is similar to the pivot member 218 (fig. 3), except that the pivot member 218 ' is in the form of a preform, wherein the pivot member 218 ' extends further radially outward from the stator vane 214 than the finished pivot member 218 (fig. 3). Actuating member 222 'is similar to actuating member 222 (fig. 3), except that actuating member 222' is in the form of a preform, wherein third leg 338 'of actuating member 222' extends further radially inward from stator vane 214 than finished actuating member 222 (fig. 3). Accordingly, elements identified by primed reference numerals are similar to elements identified above by unprimed reference numerals, except as otherwise shown or described herein.

The outer ring 614 has an inner diameter that is greater than the outermost diameter of the first and second housing rings 238, 242 (fig. 2-4). Outer ring 614 is a relatively thin, rigid, annular body disposed about axis 622. In the example provided, the outer ring 614 has a thickness in the axial direction that is approximately equal to the diameter of the pivot member 218', although other configurations may be used. In the example provided, the outer ring 614 is formed from a round wire having a diameter of about 2 millimeters, although other configurations may be used. The radially outermost end of each pivot member 218' is fixedly coupled to the inner diameter of the outer ring 614. Pivoting members 218 ' are circumferentially spaced about axis 622 to correspond to the spacing of outer pivoting slots 278, 314 (fig. 3), and first legs 330 ' of actuating members 222 ' are positioned to correspond to the spacing of inner pivoting slots 270, 310 (fig. 3). As best shown in fig. 7, the inner ring 618 is coaxial with the outer ring 614, but is offset from the outer ring 614 in the axial direction. The radially innermost end of third leg 338 'of actuating member 222' is fixedly coupled to the outer diameter of inner ring 618. Inner ring 618 is a relatively thin, rigid, annular body disposed about axis 622. In the example provided, the inner ring 618 has a thickness in the axial direction that is approximately equal to the diameter of the actuation member 222', although other configurations may be used. In the example provided, inner ring 618 is formed from a round wire having a diameter of about 2 millimeters, although other configurations may be used. The steps in forming the frame 610 are described in more detail below.

After the frame 610 is formed, the frame 610 may be easily transported, packaged, or handled without disturbing the positioning of the stator blades 214. When the remainder of the stator 30 is ready for assembly, the inner ring 618 may be cut from the actuating member 222 'and may be cut so that the actuating member 222' is its finished length. Accordingly, the actuating means at this stage in the method is now referred to with reference numeral 222. In an alternative configuration, not specifically shown, inner ring 618 may be omitted and not attached to actuation member 222, and actuation member 222 may already be its finished length.

The method 510 then proceeds to step 518. As shown in fig. 8, at step 518, the frame 610 without the inner ring 618 is positioned relative to the housing body 230, the first housing ring 238, and the piston 346 such that the axes 38, 622 are coaxial. In the example provided, the housing body 230 has been coupled to the first housing ring 238 by a first support 246 (shown in fig. 2). The radially inward end of the third leg 338 of the actuation member 222 is positioned into the circumferential groove 366 of the piston 346. The piston 346 is positioned within an annular recess, shown in fig. 4, of the portion of the housing body 230 that defines the actuator chamber 262. First leg 330 is positioned in inner pivot slot 270 and pivot member 218' is positioned in outer pivot slot 278. At this stage, the outer ring 614 is still attached to the pivot member 218' and the method can proceed to step 522.

Referring specifically to fig. 9, at step 522, the housing cover 234 and the second housing ring 242 may be coaxially aligned with the housing body 230 and the first housing ring 238. In the example provided, the housing cover 234 has been coupled to the second housing ring 242 by a second support 250. The housing cover 234 may be attached to the housing body 230, and the second housing ring 242 may be attached to the first housing ring 238. The method may proceed to step 526.

At step 526, the pivot member 218' may be cut to remove the outer ring 614. The pivoting member 218' may be cut to its finished length, or the pivoting member may be cut and then machined to its finished length. Accordingly, the pivoting member is designated at this stage by reference numeral 218. In the example provided, the radially outward ends of the pivot members 218 are flush with the radially outward surfaces of the first and second housing rings 238, 242, although other configurations may be used. In an alternative configuration not specifically shown, the pivot member 218 'may be cut to remove the outer ring 614 while the pivot member 218' and actuating member 222 rest in the outer and inner pivot slots 278, 270, but before the housing cover 234 and second housing ring 242 are attached to the housing body 230 and first housing ring 238.

With additional reference to fig. 10-13, a method 1010 of forming the frame 610 is provided and illustrated in fig. 10 with steps generally shown in flow chart form. At step 1014, an outer ring 614 is formed. In the example provided, the outer ring 614 is formed from straight wire bent into a circular shape, and the opposing ends are welded together to form the complete annular outer ring 614. In the example provided, the outer ring 614 is a steel material (e.g., mild steel), although other materials may be used. The outer ring 614 may alternatively be formed in other ways, such as being stamped from a single piece of material or casting, for example. In the example provided, the method 1010 then proceeds to step 1018.

With specific reference to fig. 11 and at step 1018, a plurality of linear or straight shafts 1110 are fixedly attached (e.g., welded) to the outer ring 614. In the example provided, the shaft 1110 is a steel material (e.g., mild steel) similar to the outer ring 614, although other materials may be used. The shafts 1110 are attached to the outer ring 614 such that the shafts 1110 are equally spaced in a circumferential direction about the axis 622. The radially outward end of the shaft 1110 is the pivot member 218'. The middle region of the shaft 1110 is the middle portion 342 and extends co-linearly with and radially inward from the pivot member 218'. The radially inward end 1114 of the shaft 1110 extends co-linearly with and radially inward from the intermediate portion 342 and corresponds to the actuating member 222' (fig. 6 and 7), except that the inward end 1114 is straight.

In the example provided, a predetermined shape (e.g., a splined shape, a flattened shape, or other non-concentric shape) is formed (e.g., pressed or stamped) in the intermediate portion 342 prior to attaching the shaft 1110 to the outer ring 614. In an alternative configuration, the predetermined shape may be formed into the shaft 1110 after the shaft 1110 is attached to the outer ring 614, but before step 1022. In the example provided, the method 1010 then proceeds to step 1022.

With specific reference to fig. 12 and at step 1022, inward end 1114 may be bent to form first leg 330 ', second leg 334', and third leg 338 'of actuation member 222'. In the example provided, both bends of the actuation member 222' are formed with a single stamping process. In the example provided, the outer ring 614 having the straight axis 1110 is placed on a first press die (not shown) and a second press die (not shown) presses the inward end 1114 into a double bend shape to form the first leg 330 ', the second leg 334 ', and the third leg 338 '.

In an alternative configuration, not specifically shown, the first and second dies may also form the predetermined shape on the intermediate portion 342 with the same stamping process for the bend. In another alternative configuration, not shown, a separate process may form the predetermined shape on the intermediate portion 342 after forming the double bend.

Returning to the example provided, the method 1010 may proceed to step 1026, where an inner ring 618 may be formed. In the example provided, the inner ring 618 is formed from a straight wire bent into a circular shape, and the opposing ends are welded together to form the complete annular inner ring 618. In the example provided, inner ring 618 is a steel material (e.g., mild steel) similar to outer ring 614, although other materials may be used. The inner ring 618 may alternatively be formed in other ways, such as being stamped from a single piece of material or casting, for example. At step 1026, the inner ring 618 is then positioned coaxially with, but axially offset from (as best seen in fig. 7) the outer ring 614, and the inner ring 618 is attached (e.g., welded) to the third leg 338 'of the actuation member 222'. In an alternative configuration not shown, the inner ring 618 may be formed and attached to the inward end 1114 (fig. 11), then a bend may be created, followed by attachment of the outer ring 614 to the pivot member 218'.

With particular reference to fig. 13 and at step 1030, the stator vanes 214 may be formed on the intermediate portion 342 (shown in fig. 11 and 12) to complete the formation of the frame 610. In the example provided, the incomplete frame shown in fig. 12 (i.e., without stator blades 214) is placed between two dies 1310, 1314, which dies 1310, 1314 cooperate to form a cavity 1318 having a shape that corresponds to the shape of stator blades 214. Although not specifically shown, the molds 1310, 1314 may have a series of gates and risers. In the example provided, the stator vanes 214 are aluminum, but other materials may be used. In the example provided, the molds 1310, 1314 are closed around the incomplete frame and poured or allowed to flow into the gates (not shown) until the molten aluminum fills the cavities 1318. The molten aluminum is allowed to cool, then the mold is separated and the frame 610 is removed. Trimming work (e.g., shearing, grinding, or machining) may need to be performed on the frame 610 to remove any material remaining from the gates and risers (not shown).

In an alternative configuration, the incomplete frame shown in fig. 12 is metal and the molds 1310, 1314 are injection molding molds. In this configuration, a liquid polymer or composite material may be injected into the molds 1310, 1314 and allowed to cure to form the stator vanes 214. In another alternative configuration, the incomplete frame shown in FIG. 12 is a type of polymer or composite material that is injection molded between molds similar to molds 1310, 1314 except without cavity 1318 for stator blade 214; the incomplete frame is inserted between molds similar to the molds 1310, 1314 and a different polymer or composite material is injected into the molds to overmold the stator vanes 214 onto the remainder of the frame 610.

In another alternative configuration, the entire frame 610 is a polymer or composite material, and the method 1010 is replaced by a single step of: the entire frame 610 (i.e., including outer ring 614, inner ring 618, pivot member 218 'and actuating member 222') is injection molded between two molds similar to molds 1310, 1314. In another alternative configuration, the entire frame 610 is a single type of metallic material, and the method 1010 is replaced by a single step of: the entire frame 610 (i.e., including outer ring 614, inner ring 618, pivot member 218 'and actuating member 222') is cast between two molds similar to molds 1310, 1314.

In another alternative configuration, the straight shaft 1110 (fig. 11) may already have its predetermined shaped middle portion 342 and the stator vanes 214 may be individually formed as holes having their mating predetermined shapes. The stator blades 214 are then slid onto the straight shaft 1110 (FIG. 11) prior to attaching the shaft 1110 to the outer ring 614.

Although the steps of methods 510 and 1010 are shown and described with reference to a particular example order of steps, these example orders are not intended to be construed as the only possible order of steps.

Accordingly, the teachings of the present disclosure provide for a variable pitch torque converter stator and a method that allows for manufacturing a variable pitch stator in a robust, cost effective, and time effective manner. The stator and method of the present disclosure provide a robust and low cost torque converter in which the stator blade pitch can be varied to optimize performance at a particular speed. In addition to optimizing power, fuel efficiency, and NVH, the stator of the present disclosure may also reduce the effects of turbo lag in turbocharged vehicles.

The description of the disclosure is merely exemplary in nature and, thus, variations that do not depart from the gist of the disclosure are intended to be within the scope of the disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the disclosure.

According to the present invention, there is provided a torque converter stator having: a first body and a second body coupled together to form a hub; a first ring and a second ring coupled together to form an outer ring; a plurality of blades radially disposed between the hub and the outer ring, all of the blades being pivotable relative to the hub and the outer ring; and a plurality of spokes, each spoke having a first end fixed to the hub and a second end fixed to the outer ring.

According to one embodiment, the plurality of spokes includes a first set of spokes having a first end fixedly attached to the first body, a second end fixedly attached to the first ring, a first end fixedly attached to the second body, and a second set of spokes having a second end fixedly attached to the second ring.

According to one embodiment, the invention is further characterized by: an actuator disposed within the hub and coupled to the blades, the actuator configured to rotate the blades relative to the hub and the outer ring.

According to one embodiment, the actuator comprises a piston slidably disposed within the hub and a plurality of crank members, each crank member having: a first end non-rotatably coupled to a corresponding one of the blades; and a second end rotatably coupled to the piston, the crank member configured to rotate the blades as the piston moves axially relative to the hub.

According to one embodiment, the first side is radially outward of the second side.

According to one embodiment, the actuator comprises a spring configured to bias the piston in one axial direction.