Shaftless turbocharger

Patent metadata

Field	Value
Publication number	US-2016245115-A1
Application number	US-201514630152-A
Country	US
Kind code	A1
Filing date	Feb 24, 2015
Priority date	Feb 24, 2015
Publication date	Aug 25, 2016
Grant date	—

Abstract

A product for use with a turbocharger is disclosed. The product may include a housing with an opening extending through at least part of the housing. An outer bearing race may be positioned in the opening. An inner bearing race may be rotatably positioned in the outer bearing race. A turbine wheel may be fixed to one end of the inner bearing race. A compressor wheel may be fixed to another end of the inner bearing race. The inner bearing race may be comprised of one, two, or more race sections. The turbine wheel may be connected to the compressor wheel only through the inner bearing race or race sections.

First claim

1 . A product for use with a turbocharger system comprising:
a housing with an opening extending through at least part of the housing; an outer bearing race positioned in the opening, and fixed relative to the housing; a first inner bearing race rotatably positioned in the outer bearing race; a turbine wheel fixed to the first inner bearing race; a second inner bearing race rotatably positioned in the outer bearing race; and a compressor wheel fixed to the second inner bearing race; the first and second inner bearing races mating at a junction; wherein the turbine wheel is connected to the compressor wheel only through the first and second inner bearing races.

2 . The product according to claim 1 wherein the inner bearing race includes a first inner bearing race section connected to the compressor wheel and a second inner bearing race section connected to the turbine wheel and further comprising an inner race section connected between the first inner bearing race section and the second inner bearing race section, wherein the inner race section is secured to the first and second inner bearing race sections so that the inner race section and the first and second inner bearing race sections rotate together as a unit.

3 . The product according to claim 1 wherein the turbine wheel includes a first stub pressed into the first inner bearing race and wherein the compressor wheel includes a second stub pressed into the second inner bearing race, and wherein the first stub does not directly contact the second stub so that an open space is defined within the first and second inner bearing races between the first stub and the second stub.

4 . The product according to claim 1 wherein the housing has a bottom below the outer bearing race that defines a second opening wherein the first inner bearing race section is connected to the compressor wheel and the second inner bearing race section is connected to the turbine wheel wherein the first inner bearing race section overlaps the second inner bearing race section at the junction when the first and second inner bearing race sections are positioned in the outer bearing race, wherein the outer bearing race has a side that defines a third opening that is aligned with the second opening.

5 . The product according to claim 4 wherein the turbine and compressor wheels rotate about a central axis and wherein a radial direction is defined perpendicular to the central axis and further comprising a pin connecting the first and second inner bearing races at the junction, the pin elongated in the radial direction and aligned with the second and third openings.

6 . The product according to claim 2 further comprising a pin, wherein the first and second inner bearing race sections are connected by the pin.

7 . The product according to claim 2 wherein the first inner bearing race section has a first notched end and wherein the second inner bearing race section has a second notched end that mates with the first notched end.

8 . A product for use with a turbocharger system comprising:
a turbine wheel that has a first extending stub, the turbine wheel configured to rotate in response to a flow of exhaust gas; a compressor wheel that has a second extending stub, the compressor wheel configured to compress gas; a bearing assembly rotatably supporting the turbine wheel and the compressor wheel to rotate about a central axis, the bearing assembly connecting the turbine wheel with the compressor wheel and defining an open shaft that extends along the central axis with a first end and a second end, wherein the first extending stub extends into the open shaft through the first end and the second extending stub extends into the open shaft through the second end and the first extending stub does not directly contact the second extending stub so that the open shaft remains open across the central axis.

9 . The product according to claim 8 wherein the bearing assembly includes a first inner bearing race and a separate second inner bearing race, both supported in a single outer bearing race, wherein the first and second inner bearing races define the open shaft.

10 . The product according to claim 9 wherein the bearing assembly further comprises an inner race section connected between the first and second inner bearing races, the inner race section comprising a ceramic material that resists heat transfer.

11 . A method of constructing a product according to claim 21 comprising:
providing the housing;
providing an outer bearing race wherein the outer bearing race has a first end, a second end opposite the first end, and an opening between the first and second ends;
providing the inner race with a first inner bearing race that has a first inner edge;
providing the inner race with a second inner bearing race that has a second inner edge;
positioning the first inner bearing race inside the outer bearing race through the first end so that the first edge faces inside the outer bearing race;
positioning the second inner bearing race inside the outer bearing race through the second end so that the second inner edge abuts the first inner edge;
attaching the first inner edge to the second inner edge;
positioning the outer bearing race in the housing;
attaching a turbine wheel to the first inner bearing race; and
attaching a compressor wheel to the second inner bearing race.

12 . The method according to claim 11 including the steps of:
extending a joining process tool through the opening to access the first and second inner bearing races, and joining the first inner edge to the second inner edge.

13 . The method according to claim 11 including the step of providing a splined connection between the first inner bearing race and the second inner bearing race.

14 . The method according to claim 11 including the steps of:
casting the turbine wheel with an integral first stub;
casting the compressor wheel with an integral second stub;
pressing the first stub into the first inner bearing race; and
pressing the second stub into the second inner bearing race.

15 . The method according to claim 11 including the step of providing an open air gap in the first and second inner bearing races between the turbine wheel and the compressor wheel.

16 . The method according to claim 11 further comprising cutting a notch in each of the first and second inner edges.

17 . The method according to claim 11 further comprising forming a slant in each of the first and second inner edges.

18 . The method according to claim 11 further comprising cutting castellation notches in each of the first and second inner edges.

19 . The method according to claim 11 further comprising
forming an inward facing splined section at the first inner edge;
forming an outward facing splined section at the second inner edge; and
inserting the second inner edge into the first inner edge.

20 . The method according to claim 11 further comprising positioning a heat transfer resistant section between the first and second inner edges.

21 . A product comprising a turbocharger with a turbine wheel, a compressor wheel connected to rotate together with the turbine wheel, a housing positioned between the turbine wheel and the compressor wheel, the housing containing a bearing that has an inner race supported to rotate relative to the housing, the inner race being a sole element that rotatably connects the turbine wheel and the compressor wheel, so that the product does not include a sep

Assignees

• Borgwarner Inc

Inventors

• Norton John David

Classifications

• F01D25/16 Primary

  Arrangement of bearings; Supporting or mounting bearings in casings (bearings per se F16C) · CPC title

• F05D2220/40

  in turbochargers · CPC title

• F04D25/04 Primary

  the pump being fluid-driven {(pumps driven by exhaust gases F02B37/00, F02B39/00; turbochargers F02C6/12)} · CPC title

• F16C2360/24

  Turbochargers · CPC title

• F16C2226/36

  by welding · CPC title