Reduced cost viscous coupling by-pass element for a torque converter

A viscous coupling for transmitting torque between an outer housing (H) and an input-output shaft (S);

• said viscous coupling being of the type including an annular housing assembly including means adapted for operable engagement with the outer housing (H), said annular housing assembly having axially-spaced, radially-extending first and second annular side wall members defining an annular viscous chamber therebetween adapted to contain viscous fluid;
• an annular clutch assembly disposed within said viscous chamber and including an annular, radially-extending clutch portion adapted for viscous clutching co-action with one of said first and second side wall members, and an axially-extending clutch hub portion adapted to be drivingly associated with the input-output shaft (S), characterized by:
• (a) said annular clutch portion of said clutch assembly including a plurality N+1 of annular, radially-extending clutch plates, each of said clutch plates disposed adjacent, and adapted for viscous clutching co-action with at least one adjacent surface of said annular housing assembly;
• (b) each of said plurality of clutch plates being drivingly associated with said axially-extending clutch hub portion, whereby rotation of said clutch plates results in rotation of said clutch hub portion;
• (c) said annular housing assembly further comprising N annular radially-extending housing plates, each of said housing plates being disposed axially between a pair of adjacent ones of said plurality N+1 of clutch plates, and adapted for viscous clutching co-action therewith;
• and
• (d) a first housing plate including a first plurality of portions in operable engagement with said first annular side wall member;
• and an Nth housing plate including a second plurality of portions in operable engagement with said second annular side wall member, said first and second pluralities of portions being disposed within said annular viscous chamber.

A method of assembling and filling a viscous fluid coupling including first and second annular side wall members, said first side wall member having a reservoir-defining portion and said second side wall member having a radially outer peripheral portion;

• an annular clutch assembly including an axially-extending clutch hub portion and first and second clutch plates drivingly associated with said clutch hub portion;
• said viscous fluid coupling further including an annular radially-extending housing plate disposed axially between said first and second clutch plates for viscous clutching co-action therewith in response to the presence of viscous fluid, said housing plate including a first plurality of portions and a second plurality of portions, the method comprising:
• (a) positioning said first side wall member with said reservoir-defining portion oriented downwardly;
• (b) locating said clutch hub portion in sealing engagement with said reservoir-defining portion of said first side wall member;
• (c) positioning said first clutch plate onto said first side wall member, and in driving engagement with said clutch hub portion;
• (d) positioning said housing plate above said first clutch plate with said first plurality of portions in engagement with said first side wall member;
• (e) positioning said second clutch plate onto said housing plate, and in driving engagement with said clutch hub portion;
• (f) subsequent to step (b), introducing a predetermined volume of viscous fluid into said reservoir-defining portion of said first side wall member;
• (g) positioning said second side wall member above said second clutch plate, in sealing engagement with said clutch hub portion, in engagement with said second plurality of portions, and with said outer peripheral portion of said second side wall member in engagement with said first side wall member.

A viscous coupling for use as a bypass element in a torque converter assembly (T) including a torque converter housing (H) and an output shaft (S);

• said viscous coupling being of the type including an annular housing assembly adapted to be positioned within the torque converter housing, and having axially spaced, radially-extending first and second annular side wall members defining an annular viscous chamber therebetween adapted to contain viscous fluid;
• said annular housing assembly defining a radially-extending annular clutching surface adapted for clutching co-action with a confronting surface of the torque converter housing (H);
• an annular clutch assembly disposed within said viscous chamber and including an annular, radially-extending clutch portion adapted for viscous clutching co-action with one of said first and second side wall members, and an axially-extending clutch hub portion adapted to be drivingly associated with the output shaft (S) of the torque converter assembly;
• characterized by:
• (a) said annular clutch portion of said clutch assembly including first and second annular, radially-extending clutch plates disposed adjacent, and adapted for viscous clutching co-action with adjacent surfaces of said housing assembly;
• (b) said first and second clutch plates being drivingly associated with said axially-extending clutch hub portion, whereby rotation of said clutch plates results in rotation of said clutch hub portion;
• (c) said coupling further including an annular, radially-extending housing plate disposed axially between said first and second clutch plates, and adapted for viscous clutching co-action with both of said first and second clutch plates;
• and
• (d) at least one of said housing assembly and said housing plate including a plurality of axially-extending portions, disposed in said viscous chamber, and in operable engagement the other of said housing assembly and said housing plate, whereby said housing plate is fixed to rotate with said housing assembly.