Cover plate sealed to stator assembly

1. A torque converter for a motor vehicle drive train comprising:

a damper including a first cover plate and a drive flange; and

a stator assembly, the first cover plate being sealingly rotatable along the stator assembly at a sealed interface, the first cover plate and drive flange forming a fluid flow gap therebetween, fluid flowing through the fluid flow gap during operation of the torque converter, the sealed interface preventing the fluid from flowing therethrough.

2. The torque converter as recited in claim 1 wherein the damper further includes a second cover plate and a plurality of springs, the first cover plate and the second cover plate holding the springs therebetween, the drive flange being between the first cover plate and the second cover plate and driving the springs.

3. The torque converter as recited in claim 1 further comprising a turbine and an impeller, the stator assembly being between the turbine and the impeller.

4. The torque converter as recited in claim 3 further comprising a lock-up clutch, the fluid flowing in a path from between the turbine and the impeller, around the damper, through the lock-up clutch and into the fluid flow gap.

5. The torque converter as recited in claim 1 wherein the first cover plate includes an axially extending flange, an end of the axially extending flange forming the sealed interface with the stator assembly.

6. The torque converter as recited in claim 5 wherein an inner radial surface of the axially extending flange is shaped to define the fluid flow gap with the drive flange.

7. The torque converter as recited in claim 6 wherein the inner radial surface has a varying diameter.

8. The torque converter as recited in claim 7 wherein the inner radial surface includes a plurality of protrusions contacting the drive flange and grooves, each of the grooves being formed between two of the protrusions, the grooves defining channels forming the fluid flow gap.

9. A method of forming a torque converter for a motor vehicle comprising:

forming a first cover plate for a damper, a drive flange for the damper and a stator assembly and coupling the first cover plate, drive flange and stator assembly together in the torque converter such that the first cover plate and the drive flange form a fluid flow gap therebetween and the first cover plate and the stator assembly form a sealed interface preventing the fluid from flowing therethrough.

10. The method as recited in claim 9 wherein the forming the first cover plate includes providing grooves on an inner radial surface of an axial extension of the first cover plate, the grooves defining the fluid flow gap with the drive flange.

11. The method as recited in claim 9 wherein the forming the first cover plate includes providing an outer radial surface of an axial extension of the first cover plate, the outer radial surface having a constant diameter and defining the sealed interface with the stator assembly.

12. The method as recited in claim 9 wherein the coupling the first cover plate, drive flange and stator assembly together in the torque converter includes:

placing the drive flange and a plurality of springs spaced circumferentially within the drive flange between the first cover plate and a second cover plate,

riveting the first cover plate and second cover plate together, and

sliding an inner race of the stator assembly onto an axially extending flange of the first cover plate to form the sealed interface.

13. The method as recited in claim 9 wherein after the coupling the first cover plate, drive flange and stator assembly together in the torque converter, a fluid flow is formed extending from between a turbine and an impeller of the torque converter, around the damper, through a lock-up clutch of the torque converter and into the fluid flow gap.

14. The method as recited in claim 13 wherein the fluid in the fluid flow path comes into contact with the sealed interface after passing through the fluid flow gap.

15. The method as recited in claim 9 wherein the forming the first cover plate includes:

forming the first cover plate to include a radially extending portion and an axially extending portion axially extending from an end of the radially extending portion, the axially extending portion including an inner radial surface having a varying diameter and an outer radial surface having a varying diameter;

machining the outer radial surface having the varying diameter such that the outer radial surface has a constant diameter.

16. The method as recited in claim 15 wherein the outer radial surface having the varying diameter includes a plurality of axially extending grooves and radial protrusions, each of the grooves being between two of the protrusions, the machining removing the grooves and protrusions from the outer radial surface.

17. The method as recited in claim 16 wherein before the machining the axially extending flange has a constant thickness and after the machining the axially extending flange has a varying thickness.

18. A torque converter for a motor vehicle drive train comprising:

a damper including a first cover plate and a drive flange; and

a stator assembly including a one-way clutch, the first cover plate being sealingly rotatable with respect to the stator assembly at a sealed interface formed by the first cover plate and the one-way clutch, the first cover plate and drive flange forming a fluid flow gap therebetween, fluid flowing through the fluid flow gap during operation of the torque converter, the sealed interface preventing the fluid from flowing therethrough.

19. The torque converter as recited in claim 18 wherein the first cover plate includes an axially extending flange having an outer cylindrical surface, the outer cylindrical surface contacting the one-way clutch to form the sealed interface.

20. The torque converter as recited in claim 19 wherein the one-way clutch includes an inner race, the outer cylindrical surface contacting the inner race to form the interface.