Clutch assembly cover, method of making same, and optional heat management

Abstract

A clutch cover for use with virtually any combination of make and model of engine components and method of making the same is disclosed. The clutch cover is made by spin forming a sheet of metal and removing material as needed to coincide with the corresponding engine components. Therefore, the exact design of the cover including attaching holes and apertures related to release levers may be quickly and easily formed in the clutch cover. Furthermore, a heat management system is provided that includes the addition of fins or other apertures through the clutch cover to increase the air flow to reduce the temperature within the clutch cover to cool engine components.

1 . A clutch cover for connecting a clutch assembly to a flywheel of an engine, comprising:
 a bowl-shaped member having an axis, a wide end, a narrow end, and an aperture through the narrow end along the axis, the bowl-shaped member being formed by deforming a spinning sheet of metal;   a flange extending about the wide end of the bowl-shaped member;   a rim formed at the narrow end of the bowl-shaped member adjacent the aperture;   a pattern of holes formed in the flange and the rim, the pattern of holes determined by the type of engine used; and   a plurality of apertures through the bowl-shaped member configured to house release levers.   
     
     
         2 . The clutch cover of  claim 1  further comprising a plurality of fins positioned about the bowl-shaped member. 
     
     
         3 . The clutch cover of  claim 2  wherein the fins are bent segments of the bowl-shaped member. 
     
     
         4 . The clutch cover of  claim 3  wherein the fins are bent away from the axis of the bowl. 
     
     
         5 . The clutch cover of  claim 1  wherein the number of plurality of apertures through the bowl-shaped member includes three to six apertures. 
     
     
         6 . The clutch cover of  claim 1  wherein the flange and the rim are generally parallel to one another. 
     
     
         7 . The clutch cover of  claim 1  wherein the bowl-shaped member comprises a first section having a diameter and a second section having a smaller diameter than the first section. 
     
     
         8 . A method of forming a universal clutch cover for use with a clutch assembly used with virtually any make of vehicle engine, the method comprising:
 determining the make of the vehicle engine;   applying a force normal to a spinning sheet of metal having an aperture therethrough to form a generally bowl-shaped member with a flange at a wide end and a rim at a narrow end of the bowl-shaped member;   machining a pattern of holes in the flange of the bowl-shaped member, the pattern of holes corresponding to the make of the vehicle engine; and   machining a plurality of apertures through the bowl-shaped member between the flange and the rim.   
     
     
         9 . The method of  claim 8  further comprising stamping a pattern of fins in the bowl-shaped member between each of the plurality of apertures. 
     
     
         10 . The method of  claim 9  wherein the fins are bent outwardly from the bowl-shaped member. 
     
     
         11 . The method of  claim 8  further comprising leveling the flange relative to the rim. 
     
     
         12 . The method of  claim 8  wherein the number of the plurality of apertures is between three and six apertures. 
     
     
         13 . The method of  claim 8  wherein a portion of the bowl-shaped member is generally perpendicular to the flange and rim. 
     
     
         14 . The method of  claim 8  further comprising centering the aperture in the sheet of metal before spinning the sheet along an axis of the aperture. 
     
     
         15 . The method of  claim 8  wherein the pattern of holes of the flange is stored in a database. 
     
     
         16 . The method of  claim 15  further comprising selecting the pattern of holes from the database based on the make of vehicle engine prior to machining the pattern in the flange. 
     
     
         17 . A method of forming a clutch cover for a clutch assembly of an engine, comprising:
 forming a hole in a sheet of metal;   spinning the sheet of metal on a spin-casting machine about the central axis of the hole;   applying a force normal to the sheet of metal starting a predetermined distance from the edge of the hole to form a bowl-shaped member having a rim adjacent a narrow end and a flange adjacent a wide end, the rim and flange being generally perpendicular to the axis of the hole;   machining a pattern of flange holes in the flange, the pattern of flange holes configured to operably attach the clutch assembly to the engine; and   cutting a plurality of apertures in the bowl-shaped member, the apertures adapted to house release levers.   
     
     
         18 . The method of  claim 17  further comprising stamping a plurality of fins around the bowl-shaped member. 
     
     
         19 . The method of  claim 17  further comprising machining a pattern of rim holes in the rim, the pattern of rim holes corresponding to the engine. 
     
     
         20 . The method of  claim 17  further comprising leveling the flange relative to the rim.