A bearing housing of a rotor shaft support assembly of a turbocharger core mounts to and closes a forward end of a cavity that both receives and discharges exhaust gases of an internal combustion engine. A turbine rotor operatively coupled to a rotor shaft and a compressor rotor of an associated tur
A bearing housing of a rotor shaft support assembly of a turbocharger core mounts to and closes a forward end of a cavity that both receives and discharges exhaust gases of an internal combustion engine. A turbine rotor operatively coupled to a rotor shaft and a compressor rotor of an associated turbocharger rotor assembly rotates within a turbine rotor shroud portion of an associated turbine nozzle cartridge assembly, wherein the rotor shaft is rotationally supported by at least one bearing within the bearing housing. The turbine nozzle cartridge assembly provides for directing exhaust gases from the cavity through a peripheral inlet leading to a plurality of vanes between forward and aft walls, through the turbine rotor shroud portion, and then through a nozzle exhaust portion incorporating an external sealing surface on an aft portion thereof that cooperates with a sealing element where the exhaust gases are discharged from the cavity.
대표청구항▼
1. A turbocharger core adapted to cooperate with a cavity that provides for both receiving and discharging exhaust gases of an internal combustion engine, comprising: a. a turbocharger rotor assembly comprising: i. a turbine rotor;ii. a compressor rotor; andiii. a rotor shaft operatively coupling sa
1. A turbocharger core adapted to cooperate with a cavity that provides for both receiving and discharging exhaust gases of an internal combustion engine, comprising: a. a turbocharger rotor assembly comprising: i. a turbine rotor;ii. a compressor rotor; andiii. a rotor shaft operatively coupling said turbine rotor to said compressor rotor, wherein said turbine rotor, said compressor rotor and said rotor shaft are operative about a common axis of rotation of said turbocharger rotor assembly;b. a rotor shaft support assembly comprising: i. a bearing housing; andii. at least one bearing within said bearing housing, wherein said rotor shaft is rotationally supported by said at least one bearing along said rotor shaft, and said bearing housing is configured to mount to a forward end of said cavity so as to provide for closing said forward end of said cavity;c. a turbine nozzle cartridge assembly comprising: i. a forward nozzle wall, wherein said forward nozzle wall comprises a first surface, and said forward nozzle wall cooperates with a first aft portion of said bearing housing so as to provide for extending aftwardly therefrom;ii. an aft nozzle wall, wherein said aft nozzle wall comprises a second surface spaced apart aftwardly from said first surface;iii. a peripheral inlet of said turbine nozzle cartridge assembly located in a resulting gap between radially-peripheral portions of a forward portion of said forward nozzle wall and said aft nozzle wall;iv. a plurality of vanes between said forward and aft nozzle walls;v. a turbine rotor shroud portion aftwardly connected to or extending from said aft nozzle wall, wherein a region between said plurality of vanes and said forward and aft nozzle walls provides for fluid communication between said peripheral inlet and said turbine rotor shroud portion, said turbine rotor is located within said turbine nozzle cartridge assembly, said turbine nozzle cartridge assembly is located aft of said bearing housing;vi. a nozzle exhaust portion aftwardly connected to or extending from said turbine rotor shroud portion; andvii. an external sealing surface on an outside of an aft portion of said nozzle exhaust portion; andd. wherein said bearing housing incorporates a cylindrical step extending aftwardly from said bearing housing, said forward nozzle wall of said turbine nozzle cartridge assembly incoporates a cylindrical lip configured to cooperate with said cylindrical step, an inside diameter of said cylindrical lip and a corresponding outside diameter of said cylindrical step are configured so as to provide for an interference fit at room temperature, while also providing for thermally induced expansion of said cylindrical lip relative to said cylindrical step, further comprising a plurality of radial pins through a corresponding plurality of radial holes in said cylindrical lip of said forward nozzle wall and into said cylindrical step for retaining and substantially centering said turbine nozzle cartridge assembly concentric relative to said bearing housing and relative to said common axis of rotation of said turbocharger rotor assembly. 2. A turbocharger core as recited in claim 1, wherein said turbine rotor comprises an axial-flow turbine rotor located aft of said forward nozzle wall and aft of said plurality of vanes and operative within said turbine rotor shroud portion of said turbine nozzle cartridge assembly. 3. A turbocharger core as recited in claim 1, wherein said turbine rotor comprises a radial-flow turbine rotor located radially inboard of said forward nozzle wall and radially inboard of said plurality of vanes and operative within said turbine rotor shroud portion of said turbine nozzle cartridge assembly. 4. A turbocharger core as recited in claim 1, wherein said turbine rotor comprises a mixed-flow turbine rotor located aft and radially inboard of said forward nozzle wall and aft and radially inboard of said plurality of vanes and operative within said turbine rotor shroud portion of said turbine nozzle cartridge assembly. 5. A turbocharger core as recited in claim 1, wherein said compressor rotor comprises a radial flow compressor rotor. 6. A turbocharger core as recited in claim 1, wherein said compressor rotor comprises a boreless hub compressor rotor comprising an aftwardly extending internally threaded boss that cooperates with a threaded portion of a forward end of said rotor shaft. 7. A turbocharger core as recited in claim 1, further comprising a compressor housing surrounding said compressor rotor, wherein said compressor housing comprises: a. a central inlet forward of said compressor rotor; andb. a volute diffuser radially outboard of said compressor rotor. 8. A turbocharger core as recited in claim 1, wherein said plurality of radial holes are symmetrically located around said cylindrical step. 9. A turbocharger core as recited in claims 1, further comprising an adapter bushing located between said bearing housing and said forward sealing surface at said forward end of said cavity, wherein said adapter bushing surrounds said cylindrical lip of said forward nozzle wall with sufficient clearance so as to provide for uninhibited thermally-induced radial expansion of said cylindrical lip during operation of the turbocharger core within the cavity responsive to the exhaust gases of the internal combustion engine, and said adapter bushing provides for capturing said plurality of radial pins within a corresponding plurality of radial holes in said cylindrical step. 10. A turbocharger core as recited in claim 9, wherein an aft surface of said adapter bushing is located and fillet-shaped so as to provide for a substantially continuous transition from an interior wall of said cavity to said forward nozzle wall of said turbine nozzle cartridge assembly. 11. A turbocharger core as recited in claim 1, wherein said at least one bearing comprises: a. a forward rolling element bearing within a forward portion of said bearing housing; andb. an aft journal bearing within a second aft portion of said bearing housing. 12. A turbocharger core as recited in claim 11, further comprising a lubrication system within said bearing housing comprising: a. an oil inlet port;b. at least one oil distribution passage in fluid communication with said oil inlet port, wherein said at least one oil distribution passage provides for distributing oil from said oil inlet port to both said forward rolling element bearing and to said aft journal bearing;c. an oil scavenge cavity that provides for receiving said oil distributed by said at least one oil distribution passage to said forward rolling element bearing and to said aft journal bearing; andd. an oil scavenge port configured to return said oil from said oil scavenge cavity to an external oil supply. 13. A turbocharger core as recited in claim 1, further comprising a cooling subsystem within said bearing housing comprising: a. a cooling jacket;b. a cooling inlet port on said bearing housing in fluid communication with said cooling jacket; andc. a cooling outlet port on said bearing housing in fluid communication with said cooling jacket, wherein said cooling jacket provides for cooling said at least one bearing responsive to a flow of coolant from said cooling inlet port into said cooling jacket and out of said cooling outlet port. 14. A turbocharger core as recited in claim 1, wherein said turbocharger core is incorporated in a turbocharger assembly further comprising: a. said cavity, wherein said cavity is integral with at least one exhaust conduit portion of said internal combustion engine;b. a first exhaust port extending through a side wall of said cavity, wherein a centerline of said first exhaust port is located radially outwards of an axis of rotation of said turbocharger rotor assembly when assembled in said cavity relative to said common axis of rotation;c. a second exhaust port extending through an aft end wall of said cavity, wherein said second exhaust port provides for in fluid communication with an exhaust system of the internal combustion engine, and an outlet of said nozzle exhaust portion is in fluid communication with said second exhaust port through said aft end wall of said cavity; andd. a sealing element within or proximate to an aft portion of said cavity, wherein said sealing element cooperates with said external sealing surface of said turbine nozzle cartridge assembly so as to provide for maintaining an at least partially sealed condition therebetween that is substantially unaffected by thermally-induced expansion or contraction of said turbine nozzle cartridge assembly during operation of said turbocharger assembly, wherein said sealed condition provides for substantially inhibiting direct fluid communication from said cavity to said second exhaust port without first passing through said turbine rotor shroud portion of said turbine nozzle cartridge assembly. 15. A turbocharger core incorporated in a turbocharger as recited in claim 14, wherein said at least one exhaust conduit portion of the internal combustion engine comprises an exhaust manifold portion of the internal combustion engine, and said first exhaust port is directly coupled to an outlet of said exhaust manifold portion of the internal combustion engine. 16. A turbocharger core incorporated in a turbocharger as recited in claim 15, wherein said exhaust manifold portion of the internal combustion engine is integral with a corresponding cylinder head portion of the internal combustion engine. 17. A turbocharger core incorporated in a turbocharger as recited in claim 16, wherein said cavity is in heat transfer relationship with at least one cooling water passage of the internal combustion engine. 18. A turbocharger core incorporated in a turbocharger as recited in claim 17, further comprising a heat shield liner within at least a substantial portion of said cavity. 19. A turbocharger core incorporated in a turbocharger as recited in claim 18, wherein said heat shield liner is constructed of sheet metal comprising a plurality of standoff dimples that provide for separating a substantial portion of said heat shield liner from an internal surface of said cavity. 20. A turbocharger core incorporated in a turbocharger as recited in claim 15, wherein said exhaust manifold portion of the internal combustion engine is separate from and attachable to a corresponding cylinder head portion of the internal combustion engine. 21. A turbocharger core incorporated in a turbocharger as recited in claim 14, wherein said first exhaust port is directly coupled within a cylinder head assembly of the internal combustion engine to one or more exhaust runners from a corresponding one or more cylinders of the internal combustion engine. 22. A turbocharger core incorporated in a turbocharger as recited in claim 14, wherein a region within said cavity external of at least one of said turbine rotor shroud portion or said nozzle exhaust portion of said turbine nozzle cartridge assembly comprises a volute shape that is operative from said first exhaust port to said peripheral inlet of said turbine nozzle cartridge assembly. 23. A turbocharger core incorporated in a turbocharger as recited in claim 14, further comprising a counterbore within said cavity proximate to said aft end wall thereof, wherein said sealing element comprises a sealing ring around at least a portion of said external sealing surface on said aft portion of said nozzle exhaust portion, and said sealing ring cooperates with an internal groove within said counterbore. 24. A turbocharger core as recited in claim 1, wherein said first surface of said forward nozzle wall comprises a first curved swept surface and said second surface of said aft nozzle wall comprises a second curved swept surface. 25. A turbocharger core as recited in claim 24, wherein said first curved swept surface comprises a first surface of revolution and said second curved swept surface comprises a second surface of revolution. 26. A turbocharger core as recited in claim 25, wherein said first and second surfaces of revolution are substantially concentric with one another. 27. A turbine nozzle cartridge assembly adapted to cooperate with a turbine rotor of an associated turbocharger core, comprising: a. a forward nozzle wall, wherein said forward nozzle wall comprises: i. a first surface; andii. a cylindrical lip located at a forward end of said first surface, wherein said cylindrical lip is configured to fit over a corresponding cylindrical step extending aftwardly from an associated bearing housing of the turbocharger core, said cylindrical lip incorporates a plurality of radial holes, and said plurality of radial holes are configured to cooperate with a corresponding plurality of radial pins extending radially outward from said cylindrical step, so as to provide for maintaining a concentricity of said turbine nozzle cartridge assembly with respect to said bearing housing when said cylindrical lip is thermally expanded with respect to said cylindrical step;b. an aft nozzle wall, wherein said aft nozzle wall comprises a second surface spaced apart aftwardly from said first surface;c. a peripheral inlet to said turbine nozzle cartridge assembly located in a resulting gap between radially-peripheral portions of a forward portion of said forward nozzle wall and said aft nozzle wall;d. a plurality of vanes between said forward and aft nozzle walls;e. a turbine rotor shroud portion aftwardly connected to or extending from said aft nozzle wall, wherein a region between said plurality of vanes and said forward and aft nozzle walls provides for fluid communication between said peripheral inlet and said turbine rotor shroud portion, said turbine rotor shroud portion provides for receiving therewithin at least a portion of the turbine rotor of the associated turbocharger core;f. a nozzle exhaust portion aftwardly connected to or extending from said turbine rotor shroud portion; andg. an external sealing surface on an outside of an aft portion of said nozzle exhaust portion, wherein said external sealing surface is configured to cooperate with a corresponding sealing element so as to provide for maintaining a sealed condition therebetween that is substantially unaffected by thermally-induced expansion or contraction of said turbine nozzle cartridge assembly during operation thereof. 28. A turbine nozzle cartridge assembly as recited in claim 27, wherein said forward nozzle wall comprises a first curved swept surface, and said forward portion of said aft nozzle wall comprises a second curved swept surface. 29. A turbine nozzle cartridge assembly as recited in claim 27, wherein said turbine nozzle cartridge assembly is formed from sheet metal, and said plurality of vanes are constructed of sheet metal with portions thereof extending through corresponding slots in said forward nozzle wall and said forward portion of said aft nozzle wall. 30. A turbine nozzle cartridge assembly as recited in claim 27, wherein said turbine rotor shroud portion is reinforced with a containment sleeve. 31. A turbine nozzle cartridge assembly as recited in claim 27, wherein said first surface of said forward nozzle wall comprises a first curved swept surface and said second surface of said aft nozzle wall comprises a second curved swept surface. 32. A turbine nozzle cartridge assembly as recited in claim 31, wherein said first curved swept surface comprises a first surface of revolution and said second curved swept surface comprises a second surface of revolution. 33. A turbine nozzle cartridge assembly as recited in claim 32, wherein said first and second surfaces of revolution are substantially concentric with one another.
Deacon Edwin R. (Skelmersdale CA GB2) Swihart William R. (Torrence CA) Heim Jonathan R. (Shelbyville IL), Boreless hub compressor wheel assembly for a turbocharger.
Wyczalek Floyd A. (Birmingham MI) Harned John L. (Grosse Pointe Woods MI) Smith Ora M. (Romeo MI), Internal combustion engine and turbosupercharger therefor with heat pipe for intake mixture heating.
Keelan Thomas M. (Howell MI) Hinkle Stanley J. (Milford MI), Internal combustion engine cylinder heads and similar articles of manufacture and methods of manufacturing same.
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Johnston Andrew E. (16735 Index St. Granada Hills CA 91344) Meyer Jon A. (13273 Bracken St. Arleta CA 91331) Miller Ronald (13920 Old Harbor La. Marina del Rey CA 90272), Turbocharger water-cooled bearing housing.
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