Clutch design and manufacture

Abstract

There is disclosed a conversion for a clutch of a motor vehicle which uses a conventional Belleville spring to bias a pressure plate and clamp a clutch disc between the pressure plate and the flywheel of the vehicle. In this invention, the frictional linings of the conventional clutch are substituted by frictional linings which are preferably located at optimum geometric spacing, and which have from 30-70 percent less surface area for frictional engagement than that conventionally furnished with the clutch. The invention is particularly applicable to upgraded performance cars, e.g., the new line of SLP cars being introduced by some manufacturers.

What is claimed is:  
     
       1. In an automotive clutch wherein a clutch disc having first and second, organic composite, non-metallic, frictional linings, one each on opposite sides thereof, is carried on a drive shaft and is located between a pressure ring and a flywheel, and including means to apply a compressive clamp load of a predetermined maximum value to clamp said disc between said ring and flywheel; the improvement thereof which comprises at least one of said first and second frictional linings having an organic composite, non-metallic, frictional facing with an area which is limited to no more than 59 percent of the available area of said disc, sufficient to provide a unit pressure, with the predetermined maximum clamp load on said facing, which is at least 35 psi. 
     
     
       2. The clutch improvement of  claim 1  wherein said frictional facing having said limited area provides a unit pressure at said predetermined maximum clamp load, which is from 45 to about 125 pounds per square inch. 
     
     
       3. The clutch improvement of  claim 2  wherein said frictional facing of limited area is located on the side of said clutch disc which faces said flywheel. 
     
     
       4. The clutch improvement of  claim 1  wherein both said first and second frictional linings are organic composite, non-metallic facings of limited area. 
     
     
       5. The clutch improvement of  claim 1  wherein said facing of limited area is located in an outer annular area of said disc. 
     
     
       6. The clutch improvement of  claim 5  wherein said outer annular area is an annular ring adjacent the periphery of said disc. 
     
     
       7. The clutch improvement of  claim 1  wherein said facing of limited area comprises a plurality of raised islands interspaced on the surface of said disc in a geometric pattern and at equal spacings. 
     
     
       8. The clutch improvement of  claim 7  wherein said linings are secured to said clutch disc by a plurality of fasteners at locations and spacings corresponding to predetermined locations and spacings. 
     
     
       9. A frictional lining for a clutch disc which comprises: 
       a. a base ring formed entirely of a fiber-reinforced resin and having a first thickness and an annular area;  
       b. an organic composite, non-metallic frictional facing on the surface of said base ring and formed of a high frictional resin material having a second thickness greater than said first thickness, and a limited area, less than the annular area of said base ring to provide a frictional area which is no more than 59% of said annular area and is limited sufficiently to provide a unit pressure from the maximum clamp load on said facing which is at least 35 psi.  
     
     
       10. The frictional lining of  claim 9  wherein said frictional facing provides an area which is limited sufficiently to provide a unit pressure from the maximum clamp load on said facing which is at least 35 psi. 
     
     
       11. The frictional lining of  claim 10  wherein said frictional facing having said limited area provides a unit pressure at said predetermined maximum clamp load which is from 45 to about 125 pounds per square inch. 
     
     
       12. The frictional lining of  claim 10  wherein said base ring has a plurality of through holes at a preselected pattern and wherein said frictional facing comprises an annular of said high frictional resin having a lesser annular width than said ring. 
     
     
       13. The frictional lining of  claim 9  wherein said frictional facing comprises a plurality of raised islands of limited area and located in a selected geometric pattern across the face of said annular base ring. 
     
     
       14. The frictional lining of  claim 13  wherein said fiber reinforcement in said annular base ring comprises a woven fabric. 
     
     
       15. In an automotive clutch disc assembly comprising first and second clutch linings on annular backing ring surfaces having inner and outer diameters, the linings being on opposite sides of said clutch disc assembly, said clutch disc assembly being carried on a drive shaft and being located between a pressure ring and a flywheel with friction pressure surfaces thereon, including means for applying a compressive clamp load on said disc assembly of a predetermined maximum value to clamp said disc assembly between said pressure ring and said flywheel; 
       
         the improvement thereof which comprises first and second clutch linings wherein at least one of said first and second clutch linings comprises arcuate segments with multiple, angularly-spaced organic, composite, nonmetallic, frictional planar facings offset from its annular backing ring surface to provide frictional clutch torque as the compressive clamp load is applied to the disc assembly, the planar facings having an area that is limited to no more than  59  percent of the annular area between the inner and outer diameters of the one clutch lining thereby providing a unit pressure, with a predetermined maximum clamp load on said planar facings that is at least  35  psi. 
       
     
     
       16. The clutch disc assembly of  claim 15  wherein said frictional facings of limited area provide a unit pressure, at said predetermined maximum clamp load, which is from  45  to about  125  pounds per square inch. 
     
     
       17. The clutch disc assembly of  claim 16  wherein said frictional facings of limited area are located on the side of said clutch disc that faces said flywheel. 
     
     
       18. The clutch disc assembly of  claim 15  wherein both said first and second clutch linings have organic composite, non-metallic facings of limited area. 
     
     
       19. The clutch disc assembly of  claim 15  wherein said facings of limited area are located in a radially outward annular area of said disc assembly. 
     
     
       20. The clutch disc assembly of  claim 19  wherein said radially outward annular area is an annular ring adjacent the outer periphery of said disc assembly. 
     
     
       21. The clutch disc assembly of  claim 15  wherein said facings of limited area comprise a plurality of raised islands angularly spaced on the surface of said facing in a geometric pattern and at equal spacings. 
     
     
       22. The clutch disc assembly of  claim 21  wherein said linings are secured to said backing ring by a plurality of fasteners at locations and spacings corresponding to predetermined locations and spacings.