Hybrid module including motor rotor connector for connecting to a torque converter
A hybrid module is configured for arrangement in a torque path upstream from a transmission and downstream from an internal combustion engine. The hybrid module includes a hybrid drive unit including an electric motor including a rotor. The rotor includes a rotor carrier carrying magnets. The hybrid module also includes a torque converter including a clutch assembly formed by a front cover, a friction material and a piston. The piston is operable to selectively force the friction material into the front cover. The hybrid module also includes a connector non-rotatably fixing the rotor to the torque converter. The connector is formed as a single piece with the front cover and being received in the rotor carrier such that no portion of the connector protrudes from the front cover toward the piston.
1 . A hybrid module configured for arrangement in a torque path upstream from a transmission and downstream from an internal combustion engine, the hybrid module comprising:
a hybrid drive unit including an electric motor including a rotor, the rotor including a rotor carrier carrying magnets;
a torque converter including a clutch assembly formed by a front cover, a friction material and a piston, the piston being operable to selectively force the friction material into the front cover; and
a connector non-rotatably fixing the rotor to the torque converter, the connector being formed as a single piece with the front cover and being received in the rotor carrier such that no portion of the connector protrudes from the front cover toward the piston,
wherein the connector is extruded from the front cover and extends axially into a hole formed in a radially extending surface of the rotor carrier, the connector only extending partially axially through the hole.
2 . The hybrid module as recited in claim 1 , wherein the connector is positioned such that any contact between the piston and the front cover does not contact the connector.
3 . The hybrid module as recited in claim 1 , wherein the rotor carrier includes a cylindrical axially extending section supporting the magnets and a disc shaped radially extending section protruding radially outward from an end of axially extending section, the connector being received in the disc shaped radially extending section.
4 . The hybrid module as recited in claim 3 , wherein the disc shaped radially extending section includes a hole formed therein.
5 . The hybrid module as recited in claim 4 , wherein the hole is a tapered hole and an axis of the tapered hole passes through the front cover and a center of the tapered hole, the tapered hole being defined by a tapered surface inclined with respect to the axis of the tapered hole and extending through the disc shaped radially extending section from a first radially extending surface axially facing the front cover to a second radially extending surface axially facing the magnets.
6 . The hybrid module as recited in claim 5 , wherein the tapered hole has a frustoconical shape.
7 . The hybrid module as recited in claim 5 , wherein the tapered surface is tapered at an angle of between 3 and 10 degrees with respect to the axis of the tapered hole.
8 . The hybrid module as recited in claim 4 , wherein an axis of the hole extends parallel to a center axis of the hybrid module, the axis of the hole passing through the front cover and the hole, the disc shaped radially extending section including a first radially extending surface axially facing the front cover, the hole including an annular surface intersecting the first radially extending surface and being inclined with respect to the axis of the connector.
9 . The hybrid module as recited in claim 8 , wherein the annular surface has a cylindrical shape.
10 . The hybrid module as recited in claim 9 , wherein the hole is a blind hole including a second surface at the end of the annular surface, the second surface intersecting the axis of the hole at a non-perpendicular angle.
11 . The hybrid module as recited in claim 1 , wherein the rotor carrier is formed of a cast metal and the front cover is formed of steel.
12 . A method of manufacturing the hybrid module as recited in claim 1 , the method comprising:
non-rotatably fixing together the hybrid drive unit and the torque converter via the connector, the connector being formed as a single piece with the front cover of the torque converter,
the non-rotatably fixing including inserting the connector into hole in the rotor carrier, and performing a punching operation to join the connector to the rotor carrier.
13 . The method as recited in claim 12 , further comprising casting the rotor carrier to include the hole, and extruding the front cover to form the connector.
14 . The method as recited in claim 12 , wherein the rotor carrier includes a cylindrical axially extending section supporting magnets of the rotor and a disc shaped radially extending section protruding radially outward from an end of axially extending section.
15 . A hybrid module configured for arrangement in a torque path upstream from a transmission and downstream from an internal combustion engine, the hybrid module comprising:
a hybrid drive unit including an electric motor including a rotor, the rotor including a rotor carrier carrying magnets;
a torque converter including a clutch assembly formed by a front cover, a friction material and a piston, the piston being operable to selectively force the friction material into the front cover; and
a connector non-rotatably fixing the rotor to the torque converter, the connector being formed as a single piece with the front cover and being received in the rotor carrier such that no portion of the connector protrudes from the front cover toward the piston,
wherein the rotor carrier includes a cylindrical axially extending section supporting the magnets and a disc shaped radially extending section protruding radially outward from an end of axially extending section, the connector being received in the disc shaped radially extending section.
16 . The hybrid module as recited in claim 15 , wherein the disc shaped radially extending section includes a hole formed therein.
17 . The hybrid module as recited in claim 16 , wherein the hole is a tapered hole and an axis of the tapered hole passes through the front cover and a center of the tapered hole, the tapered hole being defined by a tapered surface inclined with respect to the axis of the tapered hole and extending through the disc shaped radially extending section from a first radially extending surface axially facing the front cover to a second radially extending surface axially facing the magnets.
18 . The hybrid module as recited in claim 17 , wherein the tapered hole has a frustoconical shape.
19 . The hybrid module as recited in claim 17 , wherein the tapered surface is tapered at an angle of between 3 and 10 degrees with respect to the axis of the tapered hole.
20 . The hybrid module as recited in claim 16 , wherein an axis of the hole extends parallel to a center axis of the hybrid module, the axis of the hole passing through the front cover and the hole, the disc shaped radially extending section including a first radially extending surface axially facing the front cover, the hole including an annular surface intersecting the first radially extending surface and being inclined with respect to the axis of the connector,
wherein the annular surface has a cylindrical shape,
wherein the hole is a blind hole including a second surface at the end of the annular surface, the second surface intersecting the axis of the hole at a non-perpendicular angle.