Powder metal net shape alignment feature
AssigneeToyota Motor Engineering & Manufacturing North America, Inc.
InventorsShail N. Shah, Nicholas S. Vernon, Sean I. Hayes
Life of this patent
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Abstract
A powder metal component for a transmission includes a body portion defining a substantially planar major surface, and at least three radially spaced-apart retention features formed in the body portion in a green state, prior to sintering. Each retention feature may include a bore having a shaped geometry extending between an upper region adjacent the major surface of the body portion, and a lower region defining a radius of curvature. Each bore may be defined by two opposing, substantially parallel sidewalls and a substantially U-shaped bottom portion. The U-shaped bottom portion may include a center region defining the radius of curvature connecting two angled bottom walls.
Claims20
A powder metal component for a transmission, the powder metal component comprising:
- a body portion defining a substantially planar major surface;
- and
- at least three radially spaced-apart retention features formed in the body portion in a green state, prior to sintering,
- wherein each retention feature comprises a bore having a shaped geometry extending between an upper region adjacent the major surface of the body portion, and a lower region defining a radius of curvature.
A planetary carrier sub-assembly for aligning rotational components of an automatic transmission, the carrier sub-assembly comprising:
- a radial member comprising a plurality of claws;
- and
- a powder metal component having a body portion defining:
- a substantially planar major surface;
- and
- at least three radially spaced-apart retention features formed in the body portion in a green state, prior to sintering, configured for receiving the claws from the radial member for co-rotational movement with the radial member,
- wherein each retention feature comprises a bore having a shaped geometry defined by two opposing, substantially parallel sidewalls and a substantially U-shaped bottom portion.
A method for forming a powder metal component with a plurality of net-shaped retention features therein, the method comprising:
- filling a die mold with a powder metal mixture;
- applying a pressure to the powder metal mixture to shape a green compact including at least three spaced-apart retention features defined in a major surface of the green compact, each retention feature comprising a bore defined by two opposing, substantially parallel sidewalls and a substantially U-shaped bottom portion;
- opening the die mold and allowing the green compact to expand in a radial direction aligned with a longitudinal axis of each retention feature, thereby minimizing interference between the green compact and protrusions extending from the die mold;
- and
- sintering the green compact to form the powder metal component.
Dependencies are inferred from the claim text.