Cast turbocharger turbine housing having guide vanes

Patent metadata

Field	Value
Publication number	US-10240469-B2
Application number	US-201515122652-A
Country	US
Kind code	B2
Filing date	Mar 2, 2015
Priority date	Mar 4, 2014
Publication date	Mar 26, 2019
Grant date	Mar 26, 2019

Abstract

A turbocharger (1) includes a compressor section and a cast turbine section. The turbine section includes a turbine wheel (4), and a turbine housing (11) that defines a gas inlet (13), a gas outlet (10), a volute (9) disposed between the gas inlet (13) and the gas outlet (10). The turbine housing (11) also includes vanes (20) that protrude integrally from, and have a fixed orientation relative to, an inner surface of the turbine housing (11). The turbine wheel (4) is disposed in the turbine housing (11) between the volute (9) and the gas outlet (10), and the vanes (20) are disposed in the turbine housing (11) between the turbine wheel (4) and the volute (9). A method of casting the turbine housing (11) and the vanes (20) together as a single piece is described.

First claim

What is claimed:

1. A turbocharger ( 1 ) including a compressor section ( 3 ) and a cast turbine section ( 2 ), the turbine section ( 2 ) comprising
a turbine wheel ( 4 ), and a turbine housing ( 11 ) that defines a gas inlet ( 13 ), a gas outlet ( 10 ), a volute ( 9 ) disposed between the gas inlet ( 13 ) and the gas outlet ( 10 ), and vanes ( 20 ) arranged in a plane that protrude integrally from, and have a fixed orientation relative to, two opposed inner surfaces of the turbine housing ( 11 ),
wherein the turbine wheel ( 4 ) is disposed in the turbine housing ( 11 ) between the volute ( 9 ) and the gas outlet ( 10 ), and the vanes ( 20 ) are disposed in the turbine housing ( 11 ) between the turbine wheel ( 4 ) and the volute ( 9 ), and at least one vane of the vanes ( 20 ) has a cross-sectional shape that is different than the cross-sectional shape of at least a different one of the vanes ( 20 ).

2. The turbocharger ( 1 ) according to claim 1 , wherein the vanes ( 20 ) are configured to redirect a flow of exhaust gas within the turbine housing ( 11 ) from a first flow direction to a second flow direction that is at an angle (θ) relative to the first flow direction.

3. The turbocharger ( 1 ) according to claim 2 , wherein the angle (θ) is the same for each of the vanes ( 20 ).

4. The turbocharger ( 1 ) according to claim 2 , wherein the angle (θ) for at least one vane ( 20 b ) of the vanes is different than the angle (θ) for at least a different one of the vanes ( 20 a ).

5. The turbocharger ( 1 ) according to claim 2 , wherein the angle (θ) between the first flow direction and the second flow direction is in a range of 100 degrees and 170 degrees.

6. The turbocharger ( 1 ) according to claim 1 , wherein each of the remaining vanes ( 20 ) has the same cross-sectional shape.

7. The turbocharger ( 1 ) according to claim 1 , wherein each vane ( 20 ) is oriented so as to provide gas flow redirection from a first flow direction that is circumferential relative to the turbine wheel ( 4 ) to a second flow direction that is more radially oriented than the first flow direction.

8. The turbocharger ( 1 ) according to claim 1 , wherein at least one vane ( 20 a ) of the vanes provides more exhaust gas redirection than at least a different one of the vanes ( 20 b ).

9. The turbocharger ( 1 ) according to claim 1 , further comprising a bypass passage ( 19 ) that extends between the gas inlet ( 13 ) and the gas outlet ( 10 ) and bypasses the turbine wheel ( 4 ), and a wastegate valve ( 17 ) disposed in the bypass passage ( 19 ).

10. A method of forming a cast, single-piece turbine housing including integral, fixed vanes ( 20 ), wherein the method comprises the following steps:
making a pattern of the turbine housing ( 11 );
dipping the pattern into a slurry of fine refractory material containing a binder;
coating the dipped pattern with coarse ceramic particles;
allowing the dipped, coated pattern to harden, forming a hardened mold; pouring molten metal into the hardened mold to form the turbine housing ( 11 ) including integral, fixed vanes ( 20 ); and
removing the turbine housing ( 11 ) including integral, fixed vanes ( 20 ) from the hardened mold.

11. The method of claim 10 , wherein the pattern is formed of foam.

12. The method of claim 10 , wherein the pattern provides the turbine housing ( 11 ) with a gas inlet ( 13 ), a gas outlet ( 10 ), and a volute ( 9 ) disposed between the gas inlet ( 13 ) and the gas outlet ( 10 ), and the vanes ( 20 ) protrude integrally from an inner surface of the turbine housing ( 11 ) at a location that is adjacent to the volute ( 9 ).

Assignees

• Borgwarner Inc

Inventors

• Rylance Sean
• Mcardle Nathan

Classifications

• F01D9/045 Primary

  for radial flow machines or engines · CPC title

• F01D9/026

  Scrolls for radial machines or engines · CPC title

• Y02T10/144

  Cross-Sectional Technologies · mapped topic

• F02B37/24

  by using pumps or turbines with adjustable guide vanes · CPC title

• F05D2230/21

  by casting · CPC title