TURBOCHARGER BOOST ASSIST DEVICE

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional

Application No. 60/870,406, filed December 17, 2006.

TECHNICAL FIELD

[0002] The field to which the disclosure generally relates includes turbocharger boost assist devices.

BACKGROUND

[0003] Turbocharger boost assist devices may be utilized to assist in the delivery of air to a combustion engine. Typically, such turbocharger boost assist devices are utilized in combination with a turbocharger to reduce or eliminate turbocharger lag. These turbocharger boost assist devices include a shaft which may be subject to forces including torsion and bending frequencies.

SUMMARY OF EXEMPLARY EMBODIMENTS OF THE INVENTION [0004] One embodiment of the invention includes a product comprising: a compressor housing constructed and arranged to receive a compressor wheel and a portion of a shaft operatively connected to the compressor wheel to rotate the compressor wheel, the housing including a second bearing support constructed and arranged to receive a portion of the shaft and to facilitate rotational movement of the shaft.

[0005] One embodiment of the invention includes a shaft, a compressor connected to the shaft, a first bearing support and a second bearing support each receiving a respective portion of the shaft to facilitate rotational movement of the shaft, and wherein the first bearing support is positioned on a first side of the compressor and wherein the second bearing support is positioned on a second side of the compressor.

[0006] One embodiment of the invention includes a product comprising: a turbocharger boost assist device comprising a shaft, a compressor, a first bearing support, and a second bearing support, and wherein the shaft includes a first end and a second end, the compressor connected to the shaft between the first end and second end to be driven by the shaft, the first bearing support and second bearing support each receiving a respective portion of the shaft to facilitate rotational movement of the shaft, the first bearing support being positioned on a first side of the compressor and the second bearing support being positioned on a second side of the compressor to prevent the shaft from being damaged by force acting thereon during the operation of the turbocharger boost assist device.

[0007] One embodiment of the invention includes a product comprising a shaft, a turbine housing, a turbine wheel, a compressor wheel, a first bearing support, wherein the shaft includes a first end and a second end, and wherein the turbine wheel is operatively connected to the shaft at or near the first end to drive the shaft, and wherein the compressor is connected to the shaft at a location near the second end of the shaft, and wherein the turbine housing is constructed and arranged to receive the turbine wheel and a portion of the shaft, and wherein the first bearing support is constructed and

arranged to support the shaft for rotational movement and wherein the first bearing support is positioned on a first side of the compressor wheel; a compressor housing constructed and arranged to receive the compressor wheel and a portion of a shaft operatively connected to the compressor wheel to rotate the compressor wheel, the compressor housing comprising a second bearing support constructed and arranged to receive a portion of the shaft and to facilitate rotational movement of the shaft, wherein the second bearing support is positioned on a second side of the compressor wheel and constructed and arranged so that the first bearing support and the second bearing support sufficiently support the shaft to prevent forces from damaging the shaft during operation of the product; and wherein the turbine wheel comprises a plurality of blades and further comprising a nozzle ring surrounding the turbine wheel, and wherein the nozzle ring includes a plurality of nozzle passages constructed and arranged to direct high pressure hydraulic fluid onto the blades of the turbine wheel.

[0008] Other exemplary embodiments of the invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while disclosing exemplary embodiments of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Exemplary embodiments of the present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:

[0010] FIG. 1 is a sectional view of a turbocharger boost assist device according to one embodiment of the invention. [0011] FIG. 2 is a sectional view of a turbocharger boost assist device according to another embodiment. [0012] FIG. 3 is an enlarged, sectional view of a portion of a turbocharger boost assist device according to one embodiment. [0013] FIG. 4 is an enlarged, sectional view of a portion of a turbocharger boost assist device according to one embodiment of the invention. [0014] FIG. 5 is a top view of a compressor housing including a second bearing support according to one embodiment of the invention. [0015] FIG. 6 is a sectional view illustrating a nozzle ring, turbine wheel arrangement according to one embodiment of the invention. [0016] FIG. 7 is an illustration of the braking effect on a turbine wheel caused by hydraulic swirl. [0017] FIG. 8 illustrates a piston ring useful in one embodiment of the invention. [0018] FIG. 9 illustrates another type of piston ring combination useful in one embodiment of the invention.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS [0019] The following description of the embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.

[0020] Referring now to FIG. 1 , one embodiment of the invention includes a product 10 which may include one or more of the following components. The product 10 may be, but is not limited to, a turbocharger boost assist device which may include a shaft 12 that is received in a boost assist housing 14 which may include a turbine housing 16 and a compressor housing 18. This shaft 12 may have a first end 20 and an opposite second end 22. A turbine wheel 24 may be connected to the shaft 12 at or near the first end 20 of drive shaft 12. A compressor wheel 26 is operatively connected to the shaft 12 at a location spaced a distance from the first end 22. The turbine wheel 24, shaft 12, and compressor wheel 26 are operatively connected so that a fluid such as air, hydraulic fluid, or other material may be utilized to drive the turbine and consequently the shaft 12 and connected compressor wheel 26. A turbine insert 28 may be received in and carried by the turbine housing 18. The turbine insert 28 is positioned to surround a portion of the shaft 12 near the first end 20. A nozzle ring 30 may be positioned to surround the turbine wheel 24. The nozzle ring 30 may include a plurality of nozzle passages formed therein constructed and arranged to inject hydraulic fluid onto blades of the turbine wheel as will be described in further detail hereafter.

[0021] In one embodiment, the turbine wheel 24 may be secured to the shaft 12 by a turbine screw 32. The turbine housing 16 may have a central bore 33 there through constructed and arranged to allow hydraulic fluid to flow out of the turbine housing 16 after the hydraulic fluid has struck the blades 94 of the turbine wheel 24. In one embodiment of the invention, a swirl stopper 34 may be received in the bore 33 in the turbine housing 16 and positioned to

stop hydraulic fluid from swirling in an opposite direction of rotation of the turbine wheel 24 as will be described in greater detail hereafter. In one embodiment, the stopper 34 may include a wall positioned near an interior location of the turbine wheel 24 to at least impede the swirling action of the hydraulic fluid. The stopper 34 may include a hole 36 formed there through to allow the passage of hydraulic fluid. In one embodiment of the invention, a turbine housing lid 38 is connected to a first face 40 of the turbine housing 16, for example, by a screw 88 or other means. The turbine housing lid 38 includes a central bore 42 and may be constructed and arranged to receive and support a portion of the stopper 34. As shown in FIG. 2, in one embodiment of the invention, a stopper 34 without a hole is provided to prevent hydraulic fluid swirl adjacent the turbine wheel 24.

[0022] In one embodiment of the invention, a first bearing support 44 is provided and is constructed and arranged to support the shaft 12 and allow for rotational movement thereof. The first bearing support 44 receives the shaft and is located at a position spaced a distance from the first end 20 of the shaft 12 and is positioned on a first side of the compressor wheel 26. In one embodiment, the first bearing support 44 includes a bearing housing 46 which may be a part of or may be carried by the turbine housing 16. A plurality of ball bearings 48 may be received in the bearing housing 46 for rotational movement therein. A sealed bushing 50 may be positioned adjacent the ball bearings 48.

[0023] The compressor housing 18 may include an inlet opening 52 constructed and arranged to allow air to enter the compressor housing 18 and be compressed by the compressor wheel 26 and to exit through an outlet

opening 54 formed in the compressor housing 18. The inlet opening 52 may be provided in a tubular projection 62 of the compressor housing 18. The outlet opening 54 may be provided in a second tubular projection 63 of the compressor housing 18.

[0024] In one embodiment, a second bearing support 56 is provided to support the shaft 12 and allow for rotational movement of the shaft 12. The second bearing support 56 is positioned along the shaft 12 at a location at or near the second end 22 and on a second side of the compressor wheel 26. In one embodiment, the second bearing support 56 is a part of the compressor housing 18.

[0025] In one embodiment, best seen in FIGS. 3 and 5, the second bearing support 56 includes a tubular portion received in the throat of a tubular projection 62 of the compressor housing 18 and is supported in position by wings 60 extending from an inner wall 64 of the tubular projection 62. The second bearing support 56 carries a plurality of ball bearings 66 to facilitate rotational movement of a shaft 12. Providing a first bearing support 44 positioned on a first side of the compressor wheel 26 and providing a second bearing support 56 positioned on a second side of the compressor wheel 26 prevents the shaft 12 from being bent and destroyed due to forces acting thereon (including torsion and bending frequencies) during the operation of the device 10. Although ball bearings 48 and 66 are utilized in the above described embodiments for the first bearing support 44 and the second bearing support 56, other bearing members may be utilized including, but not limited to, bearing rollers, bearing journals and the like.

[0026] Referring again to FIG. 1 , the compressor wheel 26 may be held in position by a compressor wheel nut 68 which may be threaded onto a shaft 12. A spring 70 such as a wave washer spring may be interposed between the compressor wheel 26 and a portion of the bearing housing 58 holding the ball bearings 66. The ball bearings 66 may have an associated spacer 72. A plurality of o-rings 74, 76, 78, 79, 80, 82 and 84 may be provided at a plurality of locations. Also, a plurality of piston rings 86 may be provided about the shaft 12. Various components of the product 10 may be held together by a plurality of bolts or screws 88 and nuts 90.

[0027] As shown in FIG. 8, in one embodiment, the piston ring 86 includes a first end 88 and a second end 90 in overlapping positions with a space between to allow for the flow of hydraulic fluid. As shown in FIG. 9, in another embodiment of the invention, a set of stacked piston rings 86 with each ring 86 including a first end 88 spaced from a second end 90 to provide a passage for hydraulic fluid.

[0028] Referring again to FIG. 3, an end cap 92 for the compressor housing 18 may be provided and may be threaded to the wings 60. A spacer 72 may be provided between the end cap 92 and the second bearing support 56.

[0029] Referring to FIG. 4, in one embodiment of the invention, a nozzle ring 96 having a plurality of nozzle passages 98 therein (best seen in FIG. 6) may be provided for directing hydraulic fluid onto the blades 94 of the turbine wheel 24.

[0030] Referring now to FIG. 7, high pressure hydraulic fluid, for example from an accumulator, may be directed onto blades 94 of the turbine

wheel 24 for example, along a direction of line A causing the turbine wheel 24 to rotate causing the position of the blade 94 to move in a direction indicated by line B. However, the hydraulic fluid is reflected off of the blade 94 in a direction indicated by line C and begins to swirl in a direction by line D. This produces a breaking action on the turbine wheel 24. To prevent or substantially reduce the swirling action of the hydraulic fluid, stoppers 34 may be provided.

[0031] In one embodiment of the invention, the product 10 is a turbocharger boost assist device that may be positioned in the air intake side of a combustion engine breathing system at a location upstream or down stream of a turbocharger.

[0032] The above description of embodiments of the invention is merely exemplary in nature and, thus, variations thereof are not to be regarded as a departure from the spirit and scope of the invention.