Turbocharger

Claim 2

A turbocharger comprising: a turbine having a turbine wheel carried within a turbine housing and rotatably driven by exhaust gases from an internal combustion engine; a compressor having a compressor wheel carried within a compressor housing and rotatably driven by said turbine for supplying charge air to the internal combustion engine; a common shaft connected between said turbine wheel and said compressor wheel; a center housing connected between said turbine housing and said compressor housing around said common shaft and including bearing means to rotatably support said common shaft; said turbine housing having an open volute and a generally disk-shaped heat shield to close the open volute and also including a plurality of bolt openings therein; and said compressor housing having an open volute and a thrust-diffuser plate closing the open volute; an annular ring disposed around said compressor housing and including a plurality of bolt openings therein aligned with the bolt openings in said turbine housing; and a plurality of bolts extending between said turbine housing and said annular ring in the openings therein.

Claim 3

The turbocharger of claim 1 wherein said center housing is generally cup-shaped with its closed end positioning the heat shield of said turbine housing.

Claim 4

The turbocharger of claim 2, wherein said center housing includes a plurality of radially outwardly extending cooling fins.

Claim 5

The turbocharger of claim 3, wherein said cooling fins are generally symmetrically arranged about a vertical plane through said shaft.

Claim 6

The turbocharger of claim 1, wherein said compressor housing is rotatably positionable about its axis.

Claim 7

The turbocharger according to claim 1 further including an actuator housing comprising: an actuator cover integral with the annular ring disposed around the compressor housing, said actuator cover having at least one bore therein; and a generally cup shaped actuator cap having its open end secured within said at least one bore.

Claim 8

The turbocharger according to claim 6 wherein said actuator cover has a first bore and a concentric enlarged bore therein with an annular transition section therebetween.

Claim 9

The turbocharger according to claim 7 wherein said transition section has a groove therein.

Claim 10

The turbocharger according to claim 8 wherein said transition section is S-shaped.

Claim 11

The turbocharger according to claim 9 wherein said actuator cap has an outwardly rolled edge.

Claim 12

The turbocharger according to claim 1 further including a means forming a bypass flow path for bypass passage of exhaust gases around the turbine, a control actuator comprising a housing with a pressure chamber therein, said housing operably associated with the compressor, and means, internal of said compressor and said housing, for transporting a control pressure from said compressor to said actuator pressure chamber.

Claim 13

The turbocharger according to claim 1 wherein said compressor includes a compressor housing defining an inlet and an outlet.

Claim 14

The turbocharger according to claim 12 wherein said annular ring includes an integral actuator cover.

Claim 15

The turbocharger according to claim 13 further including means forming a bypass flow path for bypass passage of exhaust gases around the turbine, a control actuator having a pressure chamber therein, means for opening and closing the bypass flow path, and means for transporting a control pressure from said compressor outlet to said actuator pressure chamber.

Claim 16

The turbocharger according to claim 14 wherein said means for transporting includes a compressor housing passage internal of said compresor housing and flow connected to said compressor outlet, an annular circumferential passage formed by and internal of said compressor housing and said annular ring member flow connected to said compressor housing passage and an actuator cover passage internal of said actuator cover and flow connected to said annular passage and said actuator pressure chamber.

Claim 17

The turbocharger of claim 1 further including: a lubricating fluid passage in said center housing; a journal bearing sleeve disposed in said center housing in free floating arrangement relative thereto between said center housing and said shaft for rotatably supporting said shaft, said journal bearing sleeve having passages therein for receiving lubricating fluid from said lubricating fluid passage for developing a hydrodynamic fluid bearing film for rotatably supporting said shaft, said sleeve arranged to rotate at a speed slower than said shaft under the urgings of rotation of the shaft acting through said hydrodynamic fluid bearing film, said bearing sleeve having lubricating feed grooves in a transversely extending end surface thereof; and a turbine end bearing plate operably secured to said center housing to be constrained against rotation relative thereto and located with a transverse surface closely adjacent in said end surface of said bearing sleeve, said lubricating feed grooves configured and arranged to develop a hydrodynamic fluid film between said end surface of the bearing sleeve and said transverse surface of the turbine end bearing plate for providing support for axial thrust loads imposed upon said bearing sleeve in a direction toward said plate.

Claim 18

A turbocharger as set forth in claim 16, further including a thrust washer of larger diameter than said shaft secured for rotation with said shaft, said thrust washer located closely adjacent an opposite transversely extending end surface of said bearing sleeve, said opposite end surface of the bearing sleeve also having lubricating feed grooves therein for developing a hydrodynamic fluid film between said washer and said opposite end surface for also providing support for axial thrust loads in said direction.

Claim 19

A turbocharger as set forth in claim 17, wherein said shaft has a stepped diameter presenting a transverse shoulder engaged by said thrust washer.

Claim 20

A turbocharger as set forth in claim 16, wherein said turbine end bearing plate is disposed between said turbine and said bearing sleeve for supporting thrust loads directed toward said turbine.

Claim 21

A turbocharger as set forth in claim 19, further including a thrust washer of larger diameter than said shaft secured for rotation with said shaft, said thrust washer located closely adjacent an opposite transversely extending end surface of said bearing sleeve, said opposite end surface of the bearing sleeve also having lubricating feed grooves therein for developing a hydrodynamic fluid film between said washer and said opposite end surface for also providing support for axial thrust loads directed toward said turbine.

Claim 22

A turbocharger as set forth in claim 20, further including a thrust spacer sleeve surrounding said shaft, and extending between said compressor and said thrust washer and securely clamped therebetween for causing said thrust spacer sleeve to rotate with said shaft and for transmitting axial thrust loads from said compressor through said spacer sleeve to said thrust washer.

Claim 23

A turbocharger as set forth in claim 21, further including a thrust plate operably secured against rotation relative to said housing and located between said compressor and said thrust washer, said thrust plate configured to develop a hydrodynamic fluid film between said thrust plate and a face of said thrust washer opposite the face thereof adjacent said bearing sleeve for providing support for axial thrust loads imposed on said thrust washer in an opposite direction toward said compressor.

Claim 24

A turbocharger as set forth in claim 22, wherein said thrust plate has a depression therein for directing lubricating flow from said lubricating fluid passage in the center housing to both of said faces of said thrust washer.

Claim 25

A turbocharger as set forth in claim 23, wherein said turbocharger includes wastegate valve means for controlling motive fluid flow to rotate said turbine, whereby the thrust load on said turbocharger directed toward said aturbine is greater than the opposite thrust load in the overall duty cycle of said turbocharger.

Claim 26

A turbocharger comprising: a turbine wheel rotatably driven by exhaust gases from an internal combustion engine; a compressor wheel mounted on a shaft common with said turbine wheel and rotatably driven thereby; a turbine housing disposed around said turbine wheel to direct the exhaust gases through said turbine wheel, said turbine housing including a plurality of bolt openings therein; a compressor housing disposed around said compressor wheel to direct ambient air through said wheel whereby said air is compressed for supplying to the internal combustion engine; a center housing disposed between said turbine housing and said compressor housing and including bearing means to rotatably support the shaft common to said turbine wheel and said compressor wheel; an annular ring disposed around said compressor housing and including a plurality of bolt openings therein aligned with the bolt openings in said turbine housing; and a plurality of bolts extending between said annular ring and said turbine housing in the openings therein.

Claim 27

A turbocharger comprising: a turbine wheel rotatably driven by exhaust gases from an internal combustion engine; a compressor wheel mounted on a shaft common with said turbine wheel and rotatably driven thereby; a turbine housing disposed around said turbine wheel to direct the exhaust gases through said turbine wheel, said turbine housing including a plurality of bolt openings therein; a compressor housing disposed around said compressor wheel to direct ambient air through said wheel whereby said air is compressed for supplying to the internal combustion engine; a center housing disposed between said turbine housing and said compressor housing and including bearing means to rotatably support the shaft common to said turbine wheel and said compressor wheel; an annular ring disposed around said compressor housing and including a plurality of bolt openings therein aligned with the bolt openings in said turbine housing; and a plurality of bolts extending between said annular ring and said turbine housing in the openings therein.

Claim 28

The turbocharger of claim 25, wherein said turbine housing is an open volute closed with a heat shield.

Claim 29

The turbocharger of claim 25, wherein said center housing includes a plurality of radially outwardly extending cooling fins.

Claim 30

The turbocharger of claim 25, wherein said compressor housing includes an open volute closed with a thrust-diffuser plate.

Claim 31

The turbocharger of claim 28, wherein said bolts are operable to intersecure said compressor and turbine housings and to rigidly clamp said center housing therebetween, said thrust-diffuser plate arranged with a peripheral section thereof retained by said compressor housing, said thrust-diffuser plate having a central boss contacting said bearing means whereby the bearing means are held within said center housing by the clamping force of said bolts as transmitted through said central boss.

Claim 32

The turbocharger of claim 29, wherein said compressor housing includes a radial, transversely flat diffuser section, said thrust-diffuser plate having an outer, flat, annular section closing said open volute and extending radially inwardly sufficiently to define a radial diffuser space between said thrust-diffuser plate and said compressor housing.

Claim 33

The turbocharger of claim 30, wherein said thrust-diffuser plate includes a flat, disk-shaped section extending radially inwardly from said flat outer section at an angle relative thereto in backing relationship to said compressor wheel.

Claim 34

The turbocharger of claim 28, wherein said open volute of the compressor housing comprises an annular, semi-circularly curved section whose maximum cross-sectional area smoothly varies circumferentially, said open volute having an open side located substantially at the point of said maximum cross-sectional area at substantially all circumferential locations of said volute.

Claim 35

The turbocharger of claim 29, wherein said peripheral section of the thrust-diffuser plate is clamped between said compressor housing and said center housing, with the remainder of said thrust-diffuser plate located inside said compressor housing and center housing.

Claim 36

The turbocharger of claim 26, wherein the heat shield has an annular bend therein.

Claim 37

The turbocharger according to claim 25, further including an actuator housing comprising: an actuator cover integral with the annular ring disposed around the compressor housing, said actuator cover having at least one bore therein; and a generally cup shaped actuator cap having its open end secured within said at least one bore.

Claim 38

The turbocharger according to claim 35 wherein said actuator cover has a first bore and a concentric enlarged bore therein with an annular transition section therebetween.

Claim 39

The turbocharge according to claim 36 wherein said transition section has a groove therein.

Claim 40

The turbocharger according to claim 37 wherein said transition section is S-shaped.

Claim 41

The turbocharger according to claim 38 wherein said actuator cap has an outwardly rolled edge.

Claim 42

The turbocharger according to claim 25 further including a means forming a bypass flow path for bypass passage of exhaust gases around the turbine wheel, a control actuator comprising a housing with a pressure chamber therein, said housing operably associated with the compressor, and means, internal of said compressor and said housing, for transporting a control pressure from said compressor to said actuator pressure chamber.

Claim 43

The turbocharger according to claim 25 wherein said compressor housing includes an inlet and an outlet.

Claim 44

The turbocharger according to claim 41 wherein said annular ring includes an integral actuator cover.

Claim 45

The turbocharger according to claim 42 further including means forming a bypass flow path for bypass passage of exhaust gases around the turbine wheel, a control actuator having a pressure chamber therein, means for opening and closing the bypass flow path, and means for transporting a control pressure from said compressor outlet to said actuator pressure chamber.

Claim 46

The turbocharger according to claim 43 wherein said means for transporting includes a compressor housing passage internal of said compressor housing and flow connected to said compressor outlet, an annular circumferential passage formed by and internal of said compressor housing and said annular ring member flow connected to said compressor housing passage and an actuator cover passage internal of said actuator cover and flow connected to said annular passage and said actuator pressure chamber.

Claim 47

Apparatus for delivering compressed airflow to the intake manifold of an internal combustion engine comprising: a housing arrangement having a compressor volute open at one side, a bearing cavity, a portion of said bearing cavity defining a reservoir for lubricating fluid, and lubricating fluid inlet and outlet passages communicating with said bearing cavity; a compressor rotatably carried in said housing arrangement for compressing airflow to be delivered to said engine; a shaft operably connected to drive said compressor and extending into said bearing cavity; bearing means in said cavity for rotatably supporting said shaft and for providing support for axial thrust loads developed by said apparatus, said bearing means including a thrust plate operably secured to said housing arrangement; a diffuser plate operably secured to said housing and disposed between said thrust plate and said compressor for closing said open side of the compressor volute, said diffuser plate and thrust plate relatively positioned to define an open space therebetween, both said diffuser and thrust plates having central openings therein through which said shaft extends, said thrust plate having an opening therein communicating said open space with said reservoir; and a pair of sealing members disposed between said shaft and said central openings in said thrust and diffuser plates respectively, said sealing members defining an annularly shaped, axially extending space therebetween communicating with said open space between said thrust and diffuser plates, said diffuser plate having axially extending spacer spokes adjacent said central opening therein for contacting said diffuser plate to relatively position said thrust and diffuser plates, said spacer spokes defining radial openings therebetween communicating said annularly shaped, axially extending space with said open space between said thrust and diffuser plates.

Claim 48

Apparatus for delivering compressed airflow to the intake manifold of an internal combustion engine comprising: a housing arrangement having a compressor volute open at one side, a bearing cavity, a portion of said bearing cavity defining a reservoir for lubricating fluid, and lubricating fluid inlet and outlet passages communicating with said bearing cavity; a compressor rotatably carried in said housing arrangement for compressing airflow to be delivered to said engine; a shaft operably connected to drive said compressor and extending into said bearing cavity; bearing means in said cavity for rotatably supporting said shaft and for providing support for axial thrust loads developed by said apparatus, said bearing means including a thrust plate operably secured to said housing arrangement; a diffuser plate operably secured to said housing and disposed between said thrust plate and said compressor for closing said open side of the compressor volute, said diffuser plate and thrust plate relatively positioned to define an open space therebetween, both said diffuser and thrust plates having central openings therein through which said shaft extends, said thrust plate having an opening therein communicating said open space with said reservoir; and a pair of sealing members disposed between said shaft and said central openings in said thrust and diffuser plates respectively, said sealing members defining an annularly shaped, axially extending space therebetween communicating with said open space between said thrust and diffuser plates, said diffuser plate having axially extending spacer spokes adjacent said central opening therein for contacting said diffuser plate to relatively position said thrust and diffuser plates, said spacer spokes defining radial openings therebetween communicating said annularly shaped, axially extending space with said open space between said thrust and diffuser plates.

Claim 49

Apparatus as set forth in claim 45, further including a spacer collar extending through said central openings in said thrust and diffuser plates, said collar carrying said pair of sealing members and arranged to rotate with said shaft.

Claim 50

Apparatus as set forth in claim 46, wherein said pair of sealing members are piston rings disposed in grooves in said spacer collar and respectively rotating against said central openings in said thrust and diffuser plates in sealing engagement therewith.

Claim 51

Apparatus as set forth in claim 45, said thrust plate having an oil deflector section thereof extending into said reservoir for directing lubricating fluid flow expelled from said bearing means toward said fluid outlet passage.

Claim 52

Apparatus as set forth in claim 48, wherein said oil deflector section comprises an integral bent tang of said thrust plate extending at an angle from the major planes of said thrust plate to define said opening in the thrust plate communicating said reservoir with said open space between said thrust and diffuser plates.

Claim 53

The apparatus of claim 45 wherein said bearing means comprises: a journal bearing sleeve disposed in said housing in free floating arrangement relative thereto between said housing and said shaft for rotatably supporting said shaft, said journal bearing sleeve having passages therein for receiving lubricating fluid from said lubricating fluid passage for developing a hydrodynamic fluid bearing film for rotatably supporting said shaft, said sleeve arranged to rotate at a speed slower than said shaft under the urgings of rotation of the shaft acting through said hydrodynamic fluid bearing film, said bearing sleeve having lubricating feed grooves in a transversely extending end surface thereof; and a turbine end bearing plate operably secured to said housing to be constrained against rotation relative thereto and located with a transverse surface closely adjacent in said end surface of said bearing sleeve, said lubricating feed grooves configured and arranged to develop a hydrodynamic fluid film between said end surface of the bearing sleeve and said transverse surface of the turbine end bearing plate for providing support for axial thrust loads imposed upon said bearing sleeve in a direction toward said plate.

Claim 54

An apparatus as set forth in claim 50, further including a thrust washer of larger diameter than said shaft secured for rotation with said shaft, said thrust washer located closely adjacent an opposite transversely extending end surface of said bearing sleeve, said opposite end surface of the bearing sleeve also having lubricating feed surface of the bearing sleeve also having lubricating feed grooves therein for developing a hydrodynamic fluid film between said washer and said opposite end surface for also providing support for axial thrust loads in said direction.

Claim 55

An apparatus as set forth in claim 51, wherein said shaft has a stepped diameter presenting a transverse shoulder engaged by said thrust washer.

Claim 56

An apparatus as set forth in claim 50, wherein said turbine end bearing is disposed between said turbine and said bearing sleeve for supporting thrust loads directed toward said turbine.

Claim 57

An apparatus as set forth in claim 53, further including a thrust washer of larger diameter than said shaft secured for rotation with said shaft, said thrust washer located closely adjacent an opposite transversely extending end surface of said bearing sleeve, said opposite end surface of the bearing sleeve also having lubricating feed grooves therein for developing a hydrodynamic fluid film between said washer and said opposite end surface for also providing support for axial thrust loads directed toward said turbine.

Claim 58

An apparatus as set forth in claim 54, further including a thrust spacer sleeve surrounding said shaft, and extending between said compressor and said thrust washer and securely clamped therebetween for causing said thrust spacer sleeve to rotate with said shaft and for transmitting axial thrust loads from said compressor through said spacer sleeve to said thrust washer.

Claim 59

The apparatus of claim 55 further including a thrust plate operably secured against rotation relative to said housing and located between said compressor and said thrust washer, said thrust plate configured to develop a hydrodynamic fluid film between said thrust plate and a face of said thrust washer opposite the face thereof adjacent said bearing sleeve for providing support for axial thrust loads imposed on said thrust washer in an opposite direction toward said compressor.

Claim 60

An apparatus as set forth in claim 56, wherein said thrust plate has a depression therein for directing lubricating flow from said lubricating flow passage in the housing to both of said faces of said thrust washer.

Claim 61

A turbocharger as set forth in claim 57, wherein said turbocharger includes wastegate valve means for controlling motive fluid flow to rotate said turbine, whereby the thrust load on said turbocharger directed toward said turbine is greater than the opposite thrust load in the overall duty cycle of said turbocharger.

Claim 62

Apparatus for delivering compressed, pressurized airflow to an internal combustion engine, comprising: a front compressor housing having a volute with an open side; a rear housing having a plurality of bolt holes therein; an annular ring disposed around said compressor housing and having a plurality of bolt openings therein aligned with said bolt holes in the rear housing; a center housing disposed between said compressor housing and said rear housing; a compressor wheel rotatably carried in said compressor housing for compressing air flow to be delivered to the engine; a shaft drivingly engaging said compressor wheel and extending into said center housing; bearing means disposed in said center housing for rotatably supporting said shaft to said center housing; a thrust-diffuser plate having a peripheral section retained by said compressor housing, a radially extending section closing said open side of the volute, and a central boss contacting said bearing means; and a plurality of bolts extending between said annular ring and said rear housing for axially clamping said annular ring, compressor housing, central housing, and rear housing, and for axially clamping said bearing means within said center housing through said central boss.

Claim 63

Apparatus for delivering compressed, pressurized airflow to an internal combustion engine, comprising: a front compressor housing having a volute with an open side; a rear housing having a plurality of bolt holes therein; an annular ring disposed around said compressor housing and having a plurality of bolt openings therein aligned with said bolt holes in the rear housing; a center housing disposed between said compressor housing and said rear housing; a compressor wheel rotatably carried in said compressor housing for compressing air flow to be delivered to the engine; a shaft drivingly engaging said compressor wheel and extending into said center housing; bearing means disposed in said center housing for rotatably supporting said shaft to said center housing; a thrust-diffuser plate having a peripheral section retained by said compressor housing, a radially extending section closing said open side of the volute, and a central boss contacting said bearing means; and a plurality of bolts extending between said annular ring and said rear housing for axially clamping said annular ring, compressor housing, central housing, and rear housing, and for axially clamping said bearing means within said center housing through said central boss.

Claim 66

A method as set forth in claim 60, further including the steps of: interengaging the first-mentioned thrust plate and the housing to prevent relative rotation therebetween, interengaging the bearing carrier and the first-mentioned thrust plate; and interengaging the second thrust plate and the bearing carrier.