Reduced leakage torque converter turbine and impeller

Claim 2

A fluid torque converter located between a vehicle engine and a vehicle transmission, generally toroidally shaped, comprising: a turbine, having a principally semitoroidal turbine core formed of sheet metal and a principally semitoroidal turbine shell formed of sheet metal and a complement of turbine blades formed of sheet metal being disposed between the turbine core and the turbine shell, the turbine blades having first edges complementary to an inner surface of the turbine shell and second edges complementary to an outer surface of the turbine core; an impeller, having a principally semitoroidal impeller core formed of sheet metal and a principally semitoroidal impeller shell formed of sheet metal and a complement of impeller blades formed of sheet metal being disposed between the impeller core and the impeller shell, the impeller blades having first edges complementary to an inner surface of the impeller shell and second edges complementary to an outer surface of the impeller core; a stator having a principally annular stator core and a principally annular stator shell and a complement of stator blades, the stator blades being disposed between the stator core and the stator shell; and one of the turbine and the impeller having at least one of: an elastomeric shell lining over the inner surface of the shell, the first edges of the blades pressing into the elastomeric shell lining, locally deforming the elastomeric shell lining, thereby sealing the first edges of the blades against the shell, and an elastomeric core lining over the outer surface of the core, the second edges of the blades pressing into the elastomeric core lining, locally deforming the elastomeric core lining, thereby sealing the second edges of the blades against the core.

Claim 3

A fluid torque converter as claimed in claim 1, further comprising: the other of the turbine and the impeller having at least one of: an elastomeric shell lining over the inner surface of the shell, the first edges of the blades pressing into the elastomeric shell lining, locally deforming the elastomeric shell lining, thereby sealing the first edges of the blades against the shell, and an elastomeric core lining over the outer surface of the core, the second edges of the blades pressing into the elastomeric core lining, locally deforming the elastomeric core lining, thereby sealing the second edges of the blades against the core.

Claim 4

A fluid torque converter located between a vehicle engine and a vehicle transmission, generally toroidally shaped, comprising: a turbine, having a principally semitoroidal turbine core formed of sheet metal and a principally semitoroidal turbine shell formed of sheet metal and a complement of turbine blades formed of sheet metal disposed between the turbine core and the turbine shell, the turbine blades each having a first edge complementary to an inner surface of the turbine shell and a second edge complementary to an outer surface of the turbine core, the turbine core having a plurality of core tab receptors provided by core perforations, the turbine shell having a plurality of shell tab receptors provided by shell perforations, each of the turbine blades having a first tab on the first edge passing through one of the shell perforations and a second tab on the second edge passing through one of the core perforations, the first and second tabs being bent to retain the turbine core and the turbine shell to the turbine blades; an impeller, having a principally semitoroidal impeller core formed of sheet metal and a principally semitoroidal impeller shell formed of sheet metal and a complement of impeller blades formed of sheet metal being disposed between the impeller core and the impeller shell, the impeller blades each having a first edge complementary to an inner surface of the impeller shell and a second edge complementary to an outer surface of the impeller core, the impeller core having a plurality of core tab receptors provided by core perforations, the impeller shell having a plurality of shell tab receptors provided by shell pockets, each of the impeller blades having a first tab on the first edge disposed in one of the shell pockets, the first tabs being locked in the pockets by stakes wedged between the pocket and the first tabs to retain the impeller blades to the impeller shell, and each of the impeller blades having a second tab on the second edge passing through one of the core perforations, the tabs being bent to retain the impeller blades to the impeller core; a stator having a principally annular stator core and a principally annular stator shell and a complement of stator blades, the stator blades being disposed between the stator core and the stator shell, the stator blades being rigidly fixed to both the stator core and the stator shell; and one of the turbine and the impeller having at least one of: an elastomeric shell lining over the inner surface of the shell, the first edges of the blades pressing into the elastomeric shell lining, locally deforming the elastomeric shell lining, thereby sealing the first edges of the blades against the shell, and an elastomeric core lining over the outer surface of the core, the second edges of the blades pressing into the elastomeric core lining, locally deforming the elastomeric core lining, thereby sealing the second edges of the blades against the core.

Claim 5

A fluid torque converter located between a vehicle engine and a vehicle transmission, generally toroidally shaped, comprising: a turbine, having a principally semitoroidal turbine core formed of sheet metal and a principally semitoroidal turbine shell formed of sheet metal and a complement of turbine blades formed of sheet metal disposed between the turbine core and the turbine shell, the turbine blades each having a first edge complementary to an inner surface of the turbine shell and a second edge complementary to an outer surface of the turbine core, the turbine core having a plurality of core tab receptors provided by core perforations, the turbine shell having a plurality of shell tab receptors provided by shell perforations, each of the turbine blades having a first tab on the first edge passing through one of the shell perforations and a second tab on the second edge passing through one of the core perforations, the first and second tabs being bent to retain the turbine core and the turbine shell to the turbine blades; an impeller, having a principally semitoroidal impeller core formed of sheet metal and a principally semitoroidal impeller shell formed of sheet metal and a complement of impeller blades formed of sheet metal being disposed between the impeller core and the impeller shell, the impeller blades each having a first edge complementary to an inner surface of the impeller shell and a second edge complementary to an outer surface of the impeller core, the impeller core having a plurality of core tab receptors provided by core perforations, the impeller shell having a plurality of shell tab receptors provided by shell pockets, each of the impeller blades having a first tab on the first edge disposed in one of the shell pockets, the first tabs being locked in the pockets by stakes wedged between the pocket and the first tabs to retain the impeller blades to the impeller shell, and each of the impeller blades having a second tab on the second edge passing through one of the core perforations, the tabs being bent to retain the impeller blades to the impeller core; a stator having a principally annular stator core and a principally annular stator shell and a complement of stator blades, the stator blades being disposed between the stator core and the stator shell, the stator blades being rigidly fixed to both the stator core and the stator shell; and one of the turbine and the impeller having at least one of: an elastomeric shell lining over the inner surface of the shell, the first edges of the blades pressing into the elastomeric shell lining, locally deforming the elastomeric shell lining, thereby sealing the first edges of the blades against the shell, and an elastomeric core lining over the outer surface of the core, the second edges of the blades pressing into the elastomeric core lining, locally deforming the elastomeric core lining, thereby sealing the second edges of the blades against the core.

Claim 6

A fluid torque converter as claimed in claim 3, further comprising: the other of the turbine and the impeller having both: an elastomeric shell lining over the inner surface of the shell, the first edges of the blades pressing into the elastomeric shell lining, locally deforming the elastomeric shell lining, thereby sealing the first edges of the blades against the shell; and an elastomeric core lining over the outer surface of the core, the second edges of the blades pressing into the elastomeric core lining, locally deforming the elastomeric core lining, thereby sealing the second edges of the blades against the core.

Claim 7

A torque converter as claimed in claim 3, further comprising: the elastomeric shell lining covering the shell tab receptors prior to the first tabs of the blades being passed into the tab receptors; and the elastomeric core lining covering the turbine core tab receptors prior to the second tabs of the blades being passed into the tab receptors.

Claim 8

A torque converter as claimed in claim 4, further comprising: the elastomeric shell lining covering the shell tab receptors prior to the first tabs of the blades being passed into the tab receptors; and the elastomeric core lining covering the turbine core tab receptors prior to the second tabs of the blades being passed into the tab receptors.

Claim 11

A method of forming either of a torque converter turbine and a torque converter impeller as claimed in claim 7, further comprising: providing a plurality of tab receptors in the shell in stamping the shell; providing a plurality of tab receptors in the core in stamping the shell; providing tabs on the first edges and on the second edges of blades in stamping the blades; passing the tabs of the blades into tab receptors in the shell and the core; and fixing the tabs within the tab receptors.

Claim 12

A method of forming a torque converter turbine as claimed in claim 8, further comprising: providing a plurality of perforations to serve as the tab receptors in the shell in stamping the shell; providing a shell die which provides an inner surface cavity between the shell die and an inner surface of the shell; placing the shell in the shell die; forcing an uncured elastomeric material into the inner surface cavity, thereby forming a shell lining of elastomeric material on the inner surface of the shell; curing the elastomeric material; providing a plurality of perforations to serve as the tab receptors in the core in stamping the core; providing a core die which provides an outer surface cavity between the core die and an outer surface of the core; placing the core in the core die; forcing an uncured elastomeric material into the outer surface cavity, thereby forming a core lining on the outer surface of the core; curing the elastomeric material; passing the tabs of the blades into and through the perforations in the shell and the core; and bending over the tabs to fix the blades to the shell and to the core after pressing the shell and core toward each other.

Claim 13

A method of forming a turbine as claimed in claim 9, further comprising: covering the perforations of the core and the shell with uncured elastomeric material while the core and the shell are in their dies prior to the curing of the elastomeric material; and piercing the cured elastomeric material covering the perforations by passing the tabs through the perforations.

Claim 14

A method of forming an impeller as claimed in claim 10, further comprising: providing a plurality of pockets to serve as the tab receptors in the shell in the stamping of the shell; providing a plurality of perforations to serve as the tab receptors in the core in the stamping of the core; passing the tabs on the first edges of the blades into the pockets in the shell; wedging stakes between the turbine blade tabs and the pockets, thereby fixing the blades to the shell; passing the tabs on the second edges of the blades into and through the perforations in the core; and bending over the tabs after pressing the shell and the core toward each other.

Claim 15

A method of forming a turbine as claimed in claim 11, further comprising: covering the perforations of the core and covering the pockets of the shell with elastomeric material; and piercing the elastomeric material covering the tab receptors by the passing of the tabs into the receptors.