Abstract: A device and method for imparting a negative pre-whirl to an airstream entering a compressor wheel of a turbocharger. Using a plurality of radially positioned vanes through which the airstream to the compressor wheel communicates, a negative pre-whirl is imparted to the airstream entering the compressor wheel from an intake passage. This pre-whirl is imparted by positioning the vanes radially within an engageable ring and curving the vanes in a direction opposite the direction of rotation of the compressor wheel. Performance is further enhanced by a hub centrally positioned with the vanes where the hub includes a cavity sized to encapsulate a compressor nut and eliminate air turbulence therefrom.

Abstract: A bearing system for a turbocharger rotor assembly that includes an elongated bearing carrier with anti-friction bearings on each end carried in a stationary housing. The elongated bearing carrier is supported within the housing by axially spaced elastomeric bands in grooves in the outside diameter of the bearing carrier that cooperate with grooves in the bore of the stationary housing within which the elastomeric bands are seated to carry the axial thrust of the rotor assembly in both axial directions.

Abstract: A device and method for imparting a negative pre-whirl to an airstream entering a compressor wheel of a turbocharger. Using a plurality of radially positioned vanes through which the airstream to the compressor wheel communicates, a negative pre-whirl is imparted to the airstream entering the compressor wheel from an intake passage. This pre-whirl is imparted by positioning the vanes radially within an engageable ring and curving the vanes in a direction opposite the direction of rotation of the compressor wheel. Performance is further enhanced by a hub centrally positioned with the vanes where the hub includes a cavity sized to encapsulate a compressor nut and eliminate air turbulence therefrom.

Abstract: A variable boost pressure control system for turbocharged internal engine systems comprising an adjustable charge air vent valve connectable with the charge air input to an internal combustion engine to provide selection and adjustment of the charge air pressure to the internal combustion engine, either at the site of the charge air vent valve or at a location remote from the charge air vent valve and to provide, if desirable, a flow of cool charge air to a turbocharger cooling jacket.

Abstract: A bearing system for a turbocharger rotor assembly that includes an elongated bearing carrier with anti-friction bearings on each end carried in a stationary housing. The elongated bearing carrier is supported within the housing by axially spaced elastomeric bands in grooves in the outside diameter of the bearing carrier that cooperate with grooves in the bore of the stationary housing within which the elastomeric bands are seated to carry the axial thrust of the rotor assembly in both axial directions.

Abstract: A bearing system for a turbocharger shaft comprising a rotatable elongated cylinder with axially spaced journal bearing surfaces on the inside diameter and a thrust face on each end. A sleeve on the shaft incorporates a flange on one end that transmits thrust force to one thrust face on the elongated cylinder. A flanged collar on the opposite end of the shaft transmits thrust force to the thrust face on the opposite end of the elongated cylinder. A radially extending flange on one end of the elongated cylinder transmits thrust forces to stationary housings.

Abstract: A cooling system for a turbocharger that has a cooling jacket in the bearing housing wherein air is bled from the area behind the compressor wheel and introduced into the cooling jacket, through which it circulates and then exits into the atmosphere. In addition, a pressure relief valve located behind the compressor wheel is set to open at a predetermined charge air pressure level to introduce additional cooling air into the cooling jacket and also acts to limit the maximum rotational speed of the turbocharger over the high-speed range of the engine on which the turbocharger is mounted. In an alternate embodiment of the invention, cooling air can be taken from the intake manifold system of a turbocharged engine downstream of an air-to-air aftercooler and ducted to the cooling jacket in the turbocharger bearing housing.

Abstract: A variable boost pressure control system for turbocharged internal engine systems comprising an adjustable charge air vent valve connectable with the charge air input to an internal combustion engine to provide selection and adjustment of the charge air pressure to the internal combustion engine, either at the site of the charge air vent valve or at a location remote from the charge air vent valve and to provide, if desirable, a flow of cool charge air to a turbocharger cooling jacket.

Abstract: A bearing system for a turbocharger shaft comprising a rotatable elongated cylinder with axially spaced journal bearing surfaces on the inside diameter and a thrust face on each end. A sleeve on the shaft incorporates a flange on one end that transmits thrust force to one thrust face on the elongated cylinder. A flanged collar on the opposite end of the shaft transmits thrust force to the thrust face on the opposite end of the elongated cylinder. A radially extending flange on one end of the elongated cylinder transmits thrust forces to stationary housings.

Abstract: A cooling system for a turbocharger that has a cooling jacket in the bearing housing wherein air is bled from the area behind the compressor wheel and introduced into the cooling jacket, through which it circulates and then exits into the atmosphere. In addition, a pressure relief valve located behind the compressor wheel is set to open at a predetermined charge air pressure level to introduce additional cooling air into the cooling jacket and also acts to limit the maximum rotational speed of the turbocharger over the high-speed range of the engine on which the turbocharger is mounted. In an alternate embodiment of the invention, cooling air can be taken from the intake manifold system of a turbocharged engine downstream of an air-to-air aftercooler and ducted to the cooling jacket in the turbocharger bearing housing.

Abstract: Bearing systems for high speed rotating shafts, such as turbocharger shafts, include a first ball bearing in one end of an elongated cylinder capable of carrying axial thrust in both directions and a second ball bearing in the opposite end of the elongated cylinder with its outer race slideably mounted in the cylinder against the biasing force of a preload spring. The second ball bearing is free to move axially with the shaft upon axial expansion of the shaft when exposed to high temperature. The inner races of the ball bearings are clamped to and rotate with the shaft as part of the rotating assembly.

Abstract: Bearing systems for high speed rotating shafts, such as turbocharger shafts, include a first ball bearing in one end of an elongated cylinder capable of carrying axial thrust in both directions and a second ball bearing in the opposite end of the elongated cylinder with its outer race slideably mounted in the cylinder against the biasing force of a preload spring. The second ball bearing is free to move axial with the shaft upon axially expansion of the shaft when exposed to high temperature. The inner races of the ball bearings are clamped to and rotate with the shaft as part of the rotating assembly.

Abstract: A bearing system for a turbocharger shaft includes an elongated bearing carrier with two anti-friction ball bearings mounted in its ends and with a radially extending flange at one end that cooperates with stationary housing portions and carries thrust loads of the rotor in both directions. The elongated bearing carrier is supported within the housing by axially spaced elastic supports which permit the rotating assembly to rotate about its mass center and provide a shock and vibration cushion. The elongated bearing carrier and housing cooperate to provide a coolant cavity which communicates with the outside periphery of the elongated bearing carrier between the axially spaced elastic supports, which also act as coolant seals between the elongated bearing cavity and the bearing housing.

Abstract: A bearing system for a turbocharger shaft includes an elongated bearing carrier with two anti-friction ball bearings mounted in its ends and with a radially extending flange at one end that cooperates with stationary housing portions and carries thrust loads of the rotor in both directions. The elongated bearing carrier is supported within the housing by axially spaced elastic supports which permit the rotating assembly to rotate about its mass center and provide a shock and vibration cushion. The elongated bearing carrier and housing cooperate to provide a coolant cavity which communicates with the outside periphery of the elongated bearing carrier between the axially spaced elastic supports, which also act as coolant seals between the elongated bearing cavity and the bearing housing. The coolant cavity protects the bearing system and anti-friction ball bearings from heat conducted from the exhaust gas-driven turbine and also cools the housing.

Abstract: A turbocharger comprising two closely spaced ball bearings that does not require lubricating oil from an engine. The bearing housing forms a cooling jacket with two bearing engagement surfaces engaged with the outer races of the ball bearings through an intermediate radial spring. Closely spacing the ball bearings provides a rotor shaft of minimal length. In addition, an external motor-generator may be by mounted on the turbocharger, with the motor rotor solidly connected to the turbocharger rotor. In such an assembly, an electronic control is energizes the motor from battery power during acceleration up to approximately torque peak speed; thereafter, the control changes to a generator mode when there is excess energy in the engine exhaust gas.

Abstract: The use of anti-friction ball bearings in a unique arrangement does not require the use of lubricating oil from the internal combustion engine lubricating system and permits close coupling of the bearings and a compact turbocharger. A turbocharger bearing housing forms a coolant jacket with an inner bearing engaging portion that has two bearing engagement surfaces engaged with the outer races of two anti-friction bearings whose inner races carry rotating shaft, turbine and compressor of the turbocharger. The anti-friction bearings are, preferably, angular contact ball bearings, and the two bearing engagement surfaces of the bearing housing are closely spaced, providing a turbocharger shaft of minimal length and substantially reducing the thermal expansion of the shaft. The coolant jacket protects the anti-friction bearings from exposure to the extreme heat of the exhaust gas driven turbine, notwithstanding their increased proximity due to the shortened turbocharger shaft.

Abstract: A bearing system for a turbocharger shaft includes two angular contact ball bearings mounted in the opposite ends of a lubricated rotatable elongated cylinder, which includes a radially extending flange at one end that cooperates with stationary housing portions and carries the thrust load of the rotor in both directions. The angular contact ball bearing on the turbine end (hot end) of the machine is provided with a radial spring between the outside of its outer race and the elongated cylinder, which prevents rotation of the outer race, but still allows axial movement of the outer race in the elongated cylinder due to axial expansion of the shaft when exposed to high temperature. The inner races of the ball bearings are separated by a spacer, which is clamped in place between the bearings when the rotor assembly lock nut is tightened. Thus, the inner race of the bearings and spacer rotate with the shaft as part of the rotating assembly.

Abstract: A bearing system for a turbocharger shaft includes two angular contact ball bearings mounted in the opposite ends of a lubricated rotatable elongated cylinder, which includes a radially extending flange at one end that cooperates with stationary housing portions and carries the thrust load of the rotor in both directions. The angular contact ball bearing on the turbine end (hot end) of the machine is provided with a radial spring between the outside of its outer race and the elongated cylinder, which prevents rotation of the outer race, but still allows axial movement of the outer race in the elongated cylinder due to axial expansion of the shaft when exposed to high temperature. The inner races of the ball bearings are separated by a spacer, which is clamped in place between the bearings when the rotor assembly lock nut is tightened. Thus, the inner race of the bearings and spacer rotate with the shaft as part of the rotating assembly.

Abstract: The motor-assisted variable geometry turbocharging system has a motor to add power to the turbocharger rotating assembly, especially at low exhaust gas volume. Additionally, the system includes a control over compressor air inlet direction, and/or control of exhaust gas to a two-volute expander. These are individually controlled, or controlled in combination, to enhance turbocharged engine performance. In a preferred embodiment, the system comprises an electric motor, mounted directly within the turbocharger main housing, variable pre-whirl vanes mounted upstream of the turbocharger compressor, and a diverter valve in the exhaust piping upstream of a divided turbine volute.

Abstract: Charge air systems may include a small electric motor-driven compressor for supplying charge air to four-cycle internal combustion engines, including systems with turbocharger charge air compressors in series and parallel connection. The disclosed charge air systems can provide an effective charge air flow path to the internal combustion engine and avoids air flow restrictions at high engine operating speeds.