Borgwarner Inc.

Martin P Keating

James Ronald Papania

Michael Wagner

Michael Roche

David L Podbielski

Christopher Sullivan

Kenneth C Yuergens

Richard Vogele

Dirk Neubauer

Yosuke Kimpara

Keith Honkala

A rotatable inner race is disclosed. The inner race may include a plurality of arcuate segments each having a first end with a first end geometry and a second end with a second end geometry. The first and second end geometries may be complimentary to each other to join adjacent arcuate segments at an interlocking joint. The rotatable inner race may further include a plurality of race engagement notches extending radially from an outer circumferential surface of each arcuate segment and the plurality of arcuate segments are joined together at the interlocking joints to form a race ring and the plurality of race engagement notches of each arcuate segment align with one another to define an array of race engagement notches around an outer circumference of the race ring.

Segmented and laminated one-way clutch components

Methods and apparatus for manufacturing a circular laminated component are disclosed herein. In one embodiment, a method comprises stamping an inlet stock of material to form a line of arc segments, the line of arc segments having: a plurality of notches along a first edge; a first longitudinal end; and a second longitudinal end opposite the first longitudinal end; wrapping the line of arc segments to form a circular segment having the first edge along an inner-circumferential diameter of the circular segment; joining the first longitudinal end to the second longitudinal end to form a circular laminate layer; and stacking a plurality of circular laminate layers to form a laminate disc.

Laminated mechanical components

A race for a mechanical clutch assembly may be formed from multiple race layers that assembled from pluralities of stamped arcuate segments. First and second race layers may have the same shape when their arcuate segments are assembled are assembled. The arcuate segments of the first race layer may be identical to each other, and the arcuate segments of the second race layer may be identical to each other, but the first layer arcuate segments are not identical to the second layer arcuate segments. Interlocking joints between the first layer arcuate segments are not aligned with interlocking joints between the second layer arcuate segments when the race layers are joined together and aligned for use in the mechanical clutch assembly.

Segment and laminated mechanical clutch race for permanently engaged starter one way clutch

A transfer case for a vehicle having a selective four wheel drive mode of operation is provided. The transfer case includes a front shell boltably connected with a rear shell, a front axle output shaft and sprocket, and a main input shaft torsionally connected with a transmission and rear axle of the vehicle. A main sprocket is provided, rotatably mounted on the main input shaft. The sprocket has an axial extension. A chain torsionally connects the main sprocket with the front axle output sprocket. A clutch housing having a splined opening is torsionally connected with the main sprocket extension. A hub is spline connected on the main input shaft. A clutch pack is selectively torsionally connected with the clutch housing and with the hub. A pressure plate is provided to actuate the clutch pack. An electrically powered ball ramp mechanism is provided for axially displacing the pressure plate to torsionally join the main input shaft to the front axle input shaft causing the main sprocket extension to contact the hub.

Transfer case

Segmented and laminated steel core plates (') having at least one groove or channel formed at the interface of the core plates for either double sided or single sided wet clutch friction plates or separator plates and a process for making the same are disclosed.

Segmented and laminated core steel plate for single and/or double sided wet clutch friction plates or separator plates

One embodiment includes a friction plate and method of manufacture thereof wherein the friction plate is fabricated from a thixomolded magnesium or titanium material or alloy thereof, which is lighter than comparable steel friction plates.

Thixomolded core plates

An automotive clutch housing and a method of manufacture thereof is provided. The clutch housing has a cylindrical body that is formed from a form folded strip metal sheet that is later formed into a cylindrical body. The cylindrical body is then joined to a hub to form a clutch housing.

Corrugated strip for splined clutch housing and hub

A clutch has an outer aluminum housing and an inner housing arranged coaxially with respect to one another to support a plurality of first and second alternating, interiorly arranged, radially extending, friction members for axial movement between engaged and disengaged positions. The outer aluminum housing can have a cylindrical side wall and a radially inwardly extending end wall. A plurality of spline teeth can be formed at angularly spaced locations along the cylindrical side wall. Each spline tooth can have radial wall portions extending inwardly and longitudinally terminating at a circumferential wall portion extending between the radial wall portions to define the spline teeth. A sheet metal liner can be wrapped around to form a continuous, generally cylindrical, corrugated ring with inwardly extending spline teeth covers connected to a collar.

Aluminum clutch housing for a friction clutch with a piston pocket and a spline liner

A parking brake () for a transmission () of a motorized vehicle (). An anchor () is located to support an actuator () interposed between the anchor () and a parking pawl () when the parking pawl () is in the engaged position with a toothed parking gear (). The anchor () is defined by a plurality of stacked laminas (). Each of the plurality of stacked laminas () is rigid and has at least one peripherally extending surface (), wherein the at least one peripherally extending surface () of at least two of the plurality of stacked laminas cooperate to define at least one load-bearing surface (), and wherein the plurality of stacked laminas () are secured together to prevent relative movement of any one of the plurality of stacked laminas () with respect to another of the plurality of stacked laminas () when a load is transmitted through the parking pawl () from the at least one load-bearing surface ().

Stamped laminated stacks for parking pawl, parking gear and parking anchor

Segmented steel core plates for either double sided or single sided wet clutch friction plates or separator plates and a process for making the same are disclosed.

Segmented core plate and friction disc

A core plate is provided including a plurality of stamped metal semi-trapezoidal members formed from a linear portion of planar stock material. Each member has teeth along a common edge and is connected to an adjoining member by an integral cord. The members are wound into a closed ring.

Growing community of inventors

Plainfield, IL, United States of America

Martin P Keating