The present invention relates to a continuously variable transmission apparatus.

One object of this invention is to provide a variable torque converter transmission means utilizing a combination of interacting planetary gear means and operable through a hydrodynamic fluid torque converter means to achieve a fuel saving, efficient and effective continuously variable power output.

In preferred embodiments of this invention, a continuously variable transmission apparatus includes two embodiments being 1) a torque converter transmission means; and 2) a variable output transmission means, each mounted within a stationary housing member and interconnected between an input shaft and an output shaft to achieve a continuously variable output.

In the drawings:

Figure 1 is a schematic cross-sectional view of a transmission housing and operating assembly utilizing a continuously variable transmission apparatus being a torque converter transmission means and the first embodiment of this invention; and

Figure 2 is a schematic cross-sectional view of a transmission housing and operating assembly utilizing a second embodiment of this invention being a variable output transmission means.

Referring to the drawings in detail, and in particular to Figure 1, a continuously variable transmission apparatus being a torque converter transmission assembly or means as a first embodiment, indicated generally at 12, is utilized with a stationary transmission housing member 14 to continuously regulate and control power output from an input shaft 16 to an output shaft 18.

The torque converter transmission means 12 includes 1) an overdrive clutch means or assembly 20; 2) a hydro-torque or hydrodynamic converter and splitter means

or assembly 22 connected to the clutch overdrive means 20; and 3) a planetary torque and clutch assembly or means 24 connected to the hydro-torque or hydrodynamic converter and splitter means 22 and, in turn, connected to the output shaft 18.

The overdrive clutch means 20 includes a stationary clutch member 28 connected to the transmission housing member 14 and engagable with and connected to a sun carrier assembly 30.

The sun carrier assembly 30 includes 1) a rotatable clutch member 32 selectively operable to engage the stationary clutch member 28 and, in turn, connected by a sun gear support member 33 to a hollow sun gear 34.

The hydro-torque converter and splitter means 22 includes 1) a power splitter assembly or means 35 connected to the overdrive clutch means 20 through the hollow sun gear 34; 2) a torque converter variable clutch assembly 38 connected to the power splitter means 35; and 3) a torque converter assembly 40 connectable to the torque converter variable clutch assembly 38 and, in turn, connected to the planetary torque and clutch means 24.

The power splitter means 35 includes a planet carrier assembly 36 having a first planet gear member 42 connected by a planet gear support member 45 to second planet gear members 44 and to an input ring gear member 46.

The torque converter variable clutch assembly 38 includes 1) first clutch plates 48 connected to the torque converter assembly 40: and 2) second clutch plates 50 interconnected through a ring gear clutch support shaft 51 to the input ring gear member 46; and 3) a clutch actuator assembly 52 in order to selectively and operably engage the first clutch plates 48 and the second clutch plates 50 with varying degrees of engagement.

The torque converter assembly 40 includes 1) a turbine member 54 connected to the first clutch plates 48 and, in turn, to the planetary torque and clutch means 24;

2) an impeller member 56 connected through an impeller support member 57 and the ring gear clutch support shaft to the input ring gear member 46; and 3) a stationary reactor member 58 connected to the stationary housing member 14 by a housing connector member 59.

The planetary torque and clutch means 24 includes 1) a one-way clutch assembly 64 which can be operably connected between the input shaft 16 and the output shaft 18; 2) a planetary torque output assembly 65 to control connection between the hydro-torque converter and splitter means 22, the input shaft 16, and the output shaft 18; 3) a variable ratio clutch assembly 66 selectively connectable between the planetary torque output assembly 65 and the output shaft 18; and 4) an output one-way clutch assembly 72 connectable to the planetary torque output assembly 65, stationary transmission housing member 14, and the variable ratio clutch assembly 66.

The one-way clutch assembly 64 includes clutch members 68 connectable by a clutch sun gear support member 67 to an output sun gear member 69 and to the input shaft 16 through the planet carrier assembly 36.

The planetary torque output assembly 65 includes planetary gear members 71 mounted on a planet gear support member 73, a ring gear clutch support member 70 connected to the variable ratio clutch assembly 66, and a torque sun carrier assembly 60 which is connected to a torque sun gear member 62 and a support member to the turbine member 54.

The ring gear clutch support member 70 is connected to a clutch ring gear member 76 which is engagable with the planetary gear members 71.

The variable ratio clutch assembly 66 includes ring gear clutch plates 78 connected through a ring gear support member 79 to the clutch ring gear member 76 of the ring gear clutch assembly 70.

The variable ratio clutch assembly 66 is of a viscous fluid clutch type and includes a planetary clutch actuator 74 which is operable to engage the ring gear clutch plate 78 with output clutch plates 77 which, in turn, are secured to the output shaft 18.

The second embodiment of this invention, as shown in Figure 2, is the variable output transmission assembly or means 80 mounted within the stationary housing member 14 and operable to interconnect the power input shaft 16 to the output shaft 18.

The variable output transmission means 80 includes 1) an overdrive clutch assembly or means 20 having a portion thereof connected to the transmission housing member 14; 2) a torque converter and splitter assembly,or means 82 connected to the overdrive clutch means 20; and 3) a planetary torque assembly or means 84 connected to the torque converter and splitter means 82 and, in turn, to the output shaft 18.

The overdrive clutch means 20 includes 1) the stationary clutch member 28 connected to the stationary housing member 14; and 2) the sun carrier assembly 30 operable to be selectively engagable with the stationary clutch member 28.

The sun carrier assembly 30 includes the rotatable clutch member 32 which is connected by the sun gear support member 33 to the sun gear clutch member 34.

The torque converter and splitter means 82 includes the power splitter assembly or means 35 connected through a torque converter clutch assembly 86 to the planetary torque means 84.

The power splitter means 35 includes the planet carrier assembly 36 connected to the overdrive clutch means 20 and through a torque converter clutch assembly 86 to the planetary torque means 84.

The planet carrier assembly 36 includes first planet gear members 42 interconnected to second planet

gear members 44 through a planet gear support member 45 which, in turn, is connected to the input shaft 16.

The planet carrier assembly 36 further includes the clutch input ring gear member 46 which is connectable by the ring gear clutch support shaft 51 to the torque converter clutch assembly 86.

The torque converter clutch assembly 86 includes

1) input clutch plates 88 connected by the ring gear clutch support shaft 51 to the input ring gear member 46;

2) output clutch plates 90 connected to an output ring gear support member 91; 3) a low range clutch actuator 92 operable to actuate input clutch plates 88 with a portion of the planetary torque means 84; and 4) a high range clutch actuator 94 operable to operably engage the input clutch plates 88 with the output clutch plates 90.

The planetary torque means 84 includes 1) a sprag clutch assembly 64 connectable between the output shaft 18 and the planet carrier assembly 36; 2) a planet gear output assembly 96 connected to the output shaft 18 and the torque converter clutch assembly 86; 3) an output clutch assembly 98 connected to the torque converter clutch assembly 86, the stationary housing member 14, and the planet gear output assembly 96; and 4) a torque sun carrier assembly 99 connected to the torque converter clutch assembly 86 and the planet gear output assembly 96.

The one-way clutch assembly 64 includes clutch members 68 for connection from the input shaft 16, the planet carrier assembly 36, and through an output sun gear member 69 to the output shaft 18 as will be explained.

The torque sun carrier assembly 99 includes a torque sun gear member 62 connected by a sun gear support member 61 to sun clutch plates 63 to the torque converter clutch assembly means 86.

The planet gear output assembly 96 includes output planet gear members 102 which are engagable with the torque sun gear member 62 and an output ring gear

member 91 which is connected to the output clutch assembly 98 and the torque connector clutch assembly 86.

The output clutch assembly 98 includes an output clutch 104 which is connectable to the transmission housing member 14, the torque converter clutch 86 through the output ring gear member 91, and through the planetary torque assembly 84 to the output shaft 18.

In the use and operation of the torque converter transmission means 12 of this invention as noted in Figure 1, a hydro-torque converter and splitter means 22 are used to receive input from a power source driving the input shaft 16 which operates to be engaged and rotate the power splitter means 15 and the torque converter assembly 40.

The output shaft 18 is held stationary by a brake or load condition. At a low RPM of the input shaft 16, the turbine member 54 would not be driven by a rotating impeller member 56. This is in an idle mode which operates similar to the viscous torque converter clutch assembly 86 in the second embodiment being the variable output transmission means 80.

In a torque multiplication mode of the torque converter transmission means 12, the torque converter clutch assembly 38 operates to reduce and control the input-output ratio of the torque converter assembly 40. This control and increased RPM of the input shaft 16 causes the torque converter assembly 40 to rotate the operating fluid therein and engage rotation of the turbine member 54. This reduces the RPM difference between the input shaft 16 and the output shaft 18.

In reaction to this rotational force, the output shaft 18 is driven at maximum torque. Then, controlled actuation of the variable ratio clutch assembly 66 reduces torque towards direct drive as the one-way clutch assembly 72 allows forward rotation of the clutch ring gear member 76.

In a direct drive mode of the torque converter transmission assembly 12, the operating control fluid

within the torque converter assembly 40 interacts between the turbine member 54 and the impeller member 56 and the action of the torque converter clutch assembly 38 causes them to turn at the same RPM. In this condition, the input shaft 16, the sun gear member 69 and the output shaft 18 rotate in unity due to the one-way clutch 64 being engaged.

Next, application of the variable ratio clutch assembly 66 causes the clutch ring gear member 76 to rotate conjointly therewithin in the direct drive mode.

In an overdrive mode of the torque converter transmission means 12, the overdrive clutch means 20 is placed in a fully engaged position. In this condition, it is noted that the output sun gear clutch member 34 is locked to the transmission housing member 14 so it will not rotate.

As the planet carrier assembly 36 rotates due to input from the input shaft 16, it is noted that the first and second planet gear members 42, 44 are caused to rotate forwardly due to the stationary sun gear clutch member 34.

The first and second planet gear members 42, 44 then drive the interconnected input ring gear member 46 at a higher RPM than the input from the input shaft 16 and the planet carrier assembly 36. The one-way sprag clutch assembly 64 allows output to exceed input which, therefore, achieves the overdrive mode condition.

It is noted that use of the torque converter clutch assembly 38 in the torque converter transmission assembly 12 instead of the viscous torque converter clutch assembly 86 of the second embodiment achieves characteristics of a torque converter assembly 40 which balances a torque requirement versus the torque available. This achieves a smooth adjustment from maximum torque mode multiplication at start-up to a one-to-one ratio or an overdrive mode condition under ideal conditions.

The four operational modes of the torque converter transmission means 12 are set forth by the respective modes indicated as follows:

I - Idle

TM - Torque multiplication

D - Direct

OD - Overdrive

The status and/or rotation of the major elements of the torque converter transmission assembly 12 are indicated as follows:

+ - Forward motion

0 - Off

P - Partial

F - Full

Reverse rotation

Z - Zero rotation

CHART

MODES

ELEMENTS I TM D OD

Torque Converter Assembly 40 0 P F F

Variable Ratio Clutch Assembly 66 0 O/P F F

Planet Carrier Assembly 36 + + + +

Planet Gear Members 71 0 - Z Z

Torque Sun Gear 62 0 + + +

Output Shaft 18 0 + + +

Overdrive Clutch Means 20 0 0 0 F

The rotational relationship or speed in terms of revolutions per minute (RPM) of the major elements of the torque converter transmission means 12 having the torque converter clutch assembly 38 expressed by the following relationships:

I - is the input speed of input shaft 16

R - is the speed of clutch ring gear member 76

C - is the speed of the output shaft 18

S - is the speed of the torque sun gear member 62

Dl - is the diameter of the torque sun gear member 62

D2 - is the diameter of the clutch ring gear member 76

2.2/1 - is the stall torque of the tongue converter assembly

The rotational relationships are expressed in the following formula:

Dl -l- D2 Dl

R = D2 (C) - D2 (S)

If we assume a 6-inch diameter of the ring gear member 76 and a 1.5 inch diameter of the torque sun gear member 62, a vehicle under acceleration would show the RPM relationships charted as follows:

C S I R Torαue Ratio

RPM RPM RPM

1) 1 5 1000 -0- 7.2/1

2) 500 2000 2500 -0- 4.4/1

3) 1000 2500 2500 500 2.5/1

4) 1500 2500 2500 1200 1.7/1

5) 2000 2500 2500 1800 1.3/1

6) 2500 2500 2500 2500 1/1

It is seen that both embodiments of the continuously variable transmission apparatus utilize a fluid type transmission, whether the viscous fluid torque converter assembly 40 or the torque converter clutch assembly 86. They are similarly operable to achieve a smooth and variable transmission of power to the output shaft receiving input from a divided or split power source being a torque converter and splitter means 22 or 82 operable to change from an idle condition to a variable torque multiplication condition to a direct drive condition and, finally, to an overdrive condition for fuel efficiency.

ith reference to the second embodiment in Figure 2, the variable output transmission means 80 utilizes a viscous torque converter and splitter means 82, the purpose and function of this embodiment is to provide a compact, uncomplicated, fuel-efficient, variable torque transmission with high torque multiplication capabilities. The variable output transmission means 80 needs a rotating power input source, such as on a milling machine or a vehicle, rotating a main drive shaft 16.

In an idle mode operation, the splitter means 35 is operable to be rotated by the input shaft 16 which operates to actuate the planet carrier assembly 36 rotating he first and second planet gear members 42, 44. This moves the first and second planet gear members 42, 44 about the outside of the output sun gear member 69.

In this condition, a brake or load is applied to the milling machine or vehicle and, therefore, the output sun gear member 69 is held stationary by the braking or load condition. This causes the first and second planet gear members 42, 44 which are engagable with the input ring gear member 46 to cause same to rotate and, in turn, will rotate the input clutch plates 88 of the torque converter clutch assembly 86.

However, since the torque converter and clutch assembly 86 is not engaged, this causes free rotation of the input clutch plates 88 and such movement is not transferred to the inner clutch plates 63, thus achieving the idle condition. In this condition, the torque converter clutch assembly 86 is in a released or disengaged condition.

Next, in a start-up mode, the low range clutch actuator 92 of the torque converter clutch assembly 86 is engaged. This causes free rotation of the output clutch plates 90 in the torque converter clutch assembly 86. This operates to engage the viscous clutch with the input clutch plates 88 and the sun clutch plates 63 and achieve

a smooth start-up of the variable output transmission means 80. In this mode, the housing one-way clutch 98 holds the output ring gear member 91 stationary. The transmission thus moves from the idle mode to an output mode to drive the machinery or vehicle.

The torque converter variable clutch assembly 38 and the torque converter clutch assembly 86 are defined as one using viscous fluid which is a fluid of a viscosity of 1,000 center strokes or more measured at 77 degrees Fahrenheit (F) .

In the variable torque mode, the high range clutch actuator 94 is moved in a direction of arrow 108 which causes the output clutch plates 90 to move closer to the input clutch plates 88 thereby engaging the torque converter clutch assembly 86. Then, through connection of the input clutch plates 88 and connection to the output ring gear member 91, this will impart motion to the interconnected output planet gear members 102 to the output shaft 18. The clutch ring gear member 76 is allowed to rotate forwardly by the housing one-way clutch assembly 98.

The amount of movement of the high range clutch actuator 94 regulates the closeness of the input clutch plates 88 and the output clutch plates 90 of the torque converter clutch assembly 86 which achieves a desired variable torque multiplication and output through the output drive shaft 18.

In a direct drive mode, the low range clutch actuator 92 and the high range clutch actuator 94 are operable so that the output clutch plates 90 and the input clutch plates 88 of the torque converter clutch assembly 86 substantially move as a single unit. In this condition, the output ring gear support member 91 and the torque sun bear member 62 are rotating at the same speed which causes the output drive shaft 18 to rotate as a single unit at the subject same speed. Therefore, this

would transfer this direct drive on a one-to-one drive ratio to the power splitter means 35 completing the direct drive connection.

In the overdrive mode, the torque converter clutch assembly 36 remains engaged. At this time, the overdrive clutch means 20 is engaged locking the sun gear clutch member 14 to the transmission housing member 14.

As the planet carrier assembly 36 is rotated, it is seen that this will rotate the first planet gear members 42 and the second planet gear members 44 which will engagably rotate about the stationary sun gear clutch member 34. This causes the first planet gear members 42 to rotate forwardly to drive the input ring gear member 46 forwardly at a higher speed than the actual input from the planet carrier assembly 36 to achieve the overdrive condition. The one-way clutch assembly 64 allows the output shaft 18 to over speed the output sun gear member 69.

The following chart summarizes the above described modes of operation for the variable output transmission means 80 utilizing two viscous clutch assemblies and, more specifically, the torque converter clutch assembly 86 of this invention with the respective modes of operation indicated as follows:

I - Idle

S - Start

VT - Variable Torque

D - Direct

OD - Overdrive

The status and/or rotation of the major elements of the variable output transmission means 80 are indicated as follows:

+ - Forward motion

O - Off

P - Partial

F - Full

Reverse rotation Z - Zero

CHART

MODES

ELEMENTS I S VT D OD

Torque Converter Clutch Assembly 86 0 P/F P/F F F

Input Shaft 16 + + + + +

Planet Gear Members 102 0 - - Z Z

Sun Gear Member 62 0 + + + +

Output Shaft Member 18 0 + + + +

Overdrive Clutch Member 28

The rotational relationship or speed in terms of revolutions per minute (RPM) of the major elements of the variable output transmission means 80 are expressed by the following relationships:

R - is the speed of clutch ring gear member 76

C - is he speed of the output shaft member 18

S - is the speed of the torque sun gear member 62

Dl - is the diameter of the torque sun gear member 62

D2 - is the diameter of the clutch ring gear member 76

The rotational relationships are expressed in the following formula:

Dl + D2 Dl R = D2 (C) D2 (S)

If we assume that we are utilizing a 6-inch diameter clutch ring gear member 76 and a 1.5 inch diameter torque sun gear member 62, a vehicle under acceleration would show the RPM relationships charter as follows:

C S R Torque Ratio

RPM RPM RPM

1) 0 0 0 0

2) 100 500 0 5/1

3) 500 2500 0 5/1

4) 1000 2500 625 2.5

5) 1500 2500 1250 1.67

6) 2000 2500 1875 1.25

7) 2500 2500 2500 1/1

The line "1) " indicates the idle mode while line "7)" indicates the direct drive mode with the variable output achieved at the output shaft 18 from a constant input RPM from the power input shaft 16.

It is seen that the torque converter transmission means 12 and the variable output transmission means 80 both utilize a fluid type transmission, whether a viscous fluid, torque converter clutch assembly 86 or the torque converter clutch assembly 38 and the hydro torque converter assembly 40. They operate similarly to achieve a smooth and variable transmission of power to the output shaft having input from a divided power source operable to change from an idle condition to a variable torque multiplication condition to a direct drive condition and, finally, to an overdrive condition for fuel efficiency.

The continuously variable transmission apparatus of this invention provides a transmission means which is relatively economical to manufacture compared to prior art structures; sturdy in construction; reliable in use; operable to provide a variable degree of torque multiplication; and providing various modes of operation as needed from idle, torque mode multiplication, direct drive, and overdrive conditions.