Hybrid drive module with optimized electric motor attachment

Patent metadata

Field	Value
Publication number	US-2016109010-A1
Application number	US-201514861337-A
Country	US
Kind code	A1
Filing date	Sep 22, 2015
Priority date	Oct 16, 2014
Publication date	Apr 21, 2016
Grant date	—

Abstract

A hybrid drive module with a torque converter and a rotor carrier. The torque converter includes a cover made of a piece of material, an impeller and a turbine. The rotor carrier is made of a piece of aluminum different from the piece of material, is arranged to non-rotatably connect to a rotor for an electric motor, and includes a connection element. The connection element: is formed from the piece of aluminum and includes at least one rivet non-rotatably connecting the cover and the rotor carrier; or is made of a piece of non-aluminum material, partially embedded in the piece of aluminum, and non-rotatably connected to the cover.

First claim

What is claimed is:

1 . A hybrid drive module, comprising:
a torque converter including:
a cover formed of a first piece of material;
an impeller; and,
a turbine; and,
a rotor carrier:
made of a second piece of material different from the first piece of material;
arranged to non-rotatably connect to a rotor for an electric motor; and,
including a connection element:
formed from the second piece of material and including at least one first rivet non-rotatably connecting the cover and the rotor carrier; or,
made of a third piece of material partially embedded in the second piece of material and non-rotatably connected to the cover.

2 . The hybrid drive module of claim 1 , wherein:
the connection element is formed from the second piece of material; the rotor carrier includes a shoulder portion with a surface; the at least one first rivet extends from the surface in an axial direction; and, at least a portion of the surface is engaged with the cover.

3 . The hybrid drive module of claim 2 , wherein the rotor carrier is non-rotatably connected to the cover solely by the at least one first rivet.

4 . The hybrid drive module of claim 1 , wherein the connection element:
is made of the third piece of material; and, includes at least one second rivet non-rotatably connecting the rotor carrier and the cover.

5 . The hybrid drive module of claim 4 , wherein:
the connection element includes a shoulder portion with a surface; the at least one second rivet extends from the surface in an axial direction; and, at least a portion of the surface is engaged with the cover.

6 . The hybrid drive module of claim 4 , wherein the rotor carrier is non-rotatably connected to the cover solely by the at least one second rivet.

7 . The hybrid drive module of claim 1 , wherein the connection element:
is made of the third piece of material in a form of a plate; includes a surface in contact with the cover; and, is non-rotatably connected to the cover by at least one weld.

8 . The hybrid drive module of claim 7 , wherein the rotor carrier is non-rotatably connected to the cover solely by the at least one weld.

9 . The hybrid drive module of claim 1 , further comprising:
an input part arranged to receive torque; and, a disconnect clutch including:
at least one first clutch plate non-rotatably connected to the rotor carrier;
an inner carrier non-rotatably connected to the input part;
at least one second clutch plate non-rotatably connected to the inner carrier; and,
a piston plate axially displaceable to open and close the clutch.

10 . A method of assembling a hybrid drive module including a rotor carrier made of a first piece of material and including at least one rivet, comprising:
inserting the at least one rivet through at least one respective opening in a cover for a torque converter, the cover made of a second piece of material different from the first piece of material; deforming the at least one rivet to fixedly secure the rotor to the cover; fixing an impeller for the torque converter to the cover; and, installing a turbine and stator for the torque converter.

11 . The method of claim 10 , wherein the at least one rivet is formed from the first piece of material.

12 . The method of claim 10 , wherein the at least one rivet is formed of a third piece of material, different from the first piece of material and fixed to the first piece of material.

13 . The method of claim 10 , further comprising:
non-rotatably connecting at least one first clutch plate for a disconnect clutch to the rotor carrier; non-rotatably connecting an inner carrier for a disconnect clutch to an input part arranged to receive torque for the hybrid drive module; non-rotatably connecting at least one second clutch plate for the disconnect clutch to the inner carrier; and, installing a piston plate axially displaceable to open and close the disconnect clutch.

14 . A hybrid drive module, comprising:
a torque converter including:
a cover formed of a piece of material;
an impeller; and,
a turbine; and,
a rotor carrier:
formed of a piece of aluminum different from the piece of material;
arranged to non-rotatably connect to a rotor for an electric motor; and,
including a connection element:
formed of a piece of non-aluminum material different from the piece of material;
partially embedded in the piece of aluminum; and,
non-rotatably connected to the rotor carrier and the cover.

15 . The hybrid drive module of claim 14 , wherein the connection element includes at least one rivet passing through the material forming the cover and non-rotatably connected to the cover.

16 . The hybrid drive module of claim 15 , wherein:
the connection element includes a shoulder portion with a surface; the at least one rivet extends from the surface in an axial direction; and, at least a portion of the surface is engaged with the cover.

17 . The hybrid drive module of claim 15 , wherein the rotor carrier is non-rotatably connected to the cover solely by the at least one rivet.

18 . The hybrid drive module of claim 14 , wherein the connection element:
is an annular plate; includes a surface in contact with the cover; and, is non-rotatably connected to the cover by at least one weld.

19 . The hybrid drive module of claim 18 , wherein the rotor carrier is non-rotatably connected to the cover solely by the at least one weld.

20 . The hybrid drive module of claim 14 , further comprising:
an input part arranged to receive torque; and, a disconnect clutch including:
at least one first clutch plate non-rotatably connected to the rotor carrier;
an inner carrier non-rotatably connected to the input part;
at least one second clutch plate non-rotatably connected to the inner carrier; and,
a piston plate axially displaceable to open and close the clutch.

Assignees

• Schaeffler Technologies Ag

Inventors

• Lindemann Patrick M
• Schrader Scott

Classifications

• B60K6/36

  characterised by the transmission gearings · CPC title

• F16H45/02

  with mechanical clutches for bridging a fluid gearing of the hydrokinetic type (control of torque converter lock-up clutches F16H61/14) · CPC title

• B23P2700/50

  Other automobile vehicle parts, i.e. manufactured in assembly lines · CPC title

• F16H41/28 Primary

  with respect to manufacture, e.g. blade attachment · CPC title

• F16H2045/0278

  comprising only two co-acting friction surfaces · CPC title