Torque converters and methods and devices for rebuilding torque converters

• US 10,458,540 B1
• Filed: 01/03/2018
• Issued: 10/29/2019
• Est. Priority Date: 01/03/2017
• Status: Active Grant

• Current Assignee: Sonnax Transmission Co (Berkshire Hathaway Incorporated)
• Original Assignee: Sonnax Transmission Co (Berkshire Hathaway Incorporated)
• Inventors: Morin, Michael G.
• Primary Examiner(s): Dang, Tinh T
• Application Number:
  US15/860,954
• Time in Patent Office: 664 Days
• CPC Class Codes: F16D 13/58 Details tools for assembling or disassembling clutches B25B27/0064
• CPC Class Codes: F16D 2300/12 Mounting or assembling
• CPC Class Codes: F16D 25/0635 with flat friction surfaces, e.g. discs
• CPC Class Codes: F16D 25/126 adjustment for wear or play
• CPC Class Codes: F16H 2045/0294 Single disk type lock-up clutch, i.e. using a single disc engaged between friction members
• CPC Class Codes: F16H 2057/0068 Repairing of transmissions by using repair kits for gear wheels F16H2055/175
• CPC Class Codes: F16H 2061/6609 Control of clutches or brakes in torque split transmissions
• CPC Class Codes: F16H 3/663 with conveying rotary motion between axially spaced orbital gears, e.g. RAVIGNEAUX
• CPC Class Codes: F16H 41/24 Details
• CPC Class Codes: F16H 45/02 with mechanical clutches for bridging a fluid gearing of the hydrokinetic type control of torque converter lock-up clutches F16H61/14
• CPC Class Codes: F16H 55/0806 Involute profile
• CPC Class Codes: F16H 57/00 General details of gearing of screw-and-nut gearing F16H25/00; of fluid gearing F16H39/00 - F16H43/00
• CPC Class Codes: F16H 61/143 using electric control means
• CPC Class Codes: F16H 61/62 involving use of a speed-changing gearing or of a clutch in the connection between runners F16H61/60 takes precedence; combinations of fluid gearings for conveying rotary motion with mechanical clutches for bridging a fluid gearing of the hydrokinetic type F16H45/02
• CPC Class Codes: F16H 63/3026 comprising friction clutches or brakes band brake actuating mechanisms F16H63/3003
• CPC Class Codes: Y10T 29/49716 Converting

Abstract

Methods of repairing a torque converter that enable the continued use of a torque converter and result in a repaired torque converter with a higher-strength and more durable construction. In some examples, a backing ring can be replaced with a replacement backing ring that includes a spline ring for replacing the function of a cover spline ring. In some examples, a method of repairing a torque converter can be improved by providing a replacement backing ring with a radial protrusion for locating the backing ring on the cover, and a method of determining an axial location of the radial protrusion.

Claims

1. A kit for repairing an original equipment (“

OE”

) torque converter, the OE torque converter including a backing ring and a cover, the cover including a spline ring that engages an OE clutch plate of a lock-up clutch assembly, the kit comprising;

a splined backing ring for replacing the OE backing ring, the splined backing ring including;

an outer surface configured and dimensioned to be fixed to the cover; and

a spline ring configured to engage a clutch plate of a modified lock-up clutch assembly.

2. The kit of claim 1, further comprising the clutch plate of the modified lock-up clutch assembly, wherein the clutch plate of the modified lock-up clutch assembly is a replacement metal clutch plate for replacing the OE clutch plate, the replacement metal clutch plate having a plurality of teeth configured and dimensioned to engage the splined backing ring spline ring.

3. The kit of claim 2, wherein the replacement metal clutch plate has an outer diameter that is less than an outer diameter of the OE clutch plate.

4. The kit of claim 2, further comprising a plurality of compression springs configured and dimensioned to be located between the splined backing ring spline ring and the replacement metal clutch plate for facilitating disengagement of the replacement metal clutch plate.

5. The kit of claim 4, wherein the replacement metal clutch plate includes a plurality of spring guides for guiding the compression springs.

6. The kit of claim 1, wherein the splined backing ring includes a reaction surface for engaging a friction surface of a friction clutch plate of the modified lock-up clutch assembly.

7. A method of modifying an original equipment (“

OE”

) torque converter, the OE torque converter including a cover, a backing ring welded to the cover, and a lock-up clutch assembly that includes a plurality of metal clutch plates, the cover including a spline ring that engages the plurality of metal clutch plates, the method comprising;

cutting the cover to remove the backing ring; and

installing a splined backing ring on the cover, the splined backing ring including a spline ring configured and dimensioned to engage a metal clutch plate of a modified lock-up clutch assembly.

8. The method of claim 7, wherein the installing includes:

measuring a distance from a cut end of the cover formed during the cutting step to a rearward-most clutch plate of the modified lock-up clutch assembly;

determining, based on the measuring step, a location on an outer surface of the splined backing ring for creating a radially-extending step, the radially-extending step configured to rest on the cut end of the cover when the splined backing ring is installed thereon; and

machining the radially-extending step in the outer surface of the splined backing ring.

9. The method of claim 7, further comprising replacing the plurality of metal clutch plates with at least one replacement metal clutch plate, wherein the at least one replacement metal clutch plate has a smaller outside diameter than the plurality of metal clutch plates.

10. A splined backing ring for replacing an original equipment (“

OE”

) torque converter backing ring, the OE torque converter including a cover that includes a spline ring that engages an OE clutch plate of a lock-up clutch assembly, the splined backing ring comprising;

an outer surface configured and dimensioned to be fixed to the cover of the OE torque converter; and

a spline ring configured to engage a clutch plate of a modified lock-up clutch assembly.

11. The splined backing ring of claim 10, wherein the splined backing ring spline ring has an outer diameter that is less than an inner diameter of the cover spline ring.

12. The splined backing ring of claim 10, wherein the splined backing ring spline ring is configured and dimensioned to be located radially-inward and fit within the cover spline ring and replace the function of the cover spline ring.

13. The splined backing ring of claim 10, wherein the splined backing ring is configured to drive the clutch plate of the modified lock-up clutch assembly.

14. The splined backing ring of claim 10, further comprising a reaction surface for engaging a friction surface of a friction clutch plate of the modified lock-up clutch assembly.

15. The splined backing ring of claim 10, further comprising a radially-extending step on the outer surface, the radially-extending step located for abutting an end of the cover for precisely locating the splined backing ring on the cover.

16. The splined backing ring of claim 10, wherein the OE torque converter is a torque converter for Ford'"'"'s model number 6R140 transmission.