Abstract: A turbocharger for an internal combustion engine includes a bearing housing and a rotating assembly arranged therein. The rotating assembly includes a shaft with a turbine wheel and a compressor wheel. The turbocharger also includes a thrust bearing assembly operatively connected to the shaft, lubricated by pressurized oil from the engine, and configured to transmit thrust forces developed by the turbine wheel to the bearing housing. The thrust bearing assembly includes a thrust plate having a first thrust face and a thrust washer having a second thrust face. An oil film is generated between the first and second thrust faces, and the first and second thrust faces rotate relative to each other and transmit the thrust forces to the bearing housing. The thrust plate and/or the thrust washer include a circumferential groove configured to trap oil-borne debris and minimize an amount of the debris in the oil film.

Abstract: A turbocharger for an internal combustion engine includes a rotating assembly having a turbine wheel disposed inside a turbine housing and a compressor wheel disposed inside a compressor cover. The turbocharger also includes a waste-gate assembly configured to selectively redirect at least a portion of the engine's post-combustion gases away from the turbine wheel. The waste-gate assembly includes a valve, a rotatable shaft connected to the valve, and a bushing fixed relative to the turbine housing and disposed concentrically around the shaft such that the shaft rotates inside the bushing for opening and closing the valve. The bushing is defined by a length, an outer surface in contact with the turbine housing, and an inner surface in contact with the shaft. The inner surface includes a plurality of longitudinal grooves configured to counteract friction between the bushing and the shaft and avoid seizure of the shaft relative to the bushing.

Abstract: A turbocharger for an internal combustion engine includes a rotating assembly having a turbine wheel disposed inside a turbine housing and a compressor wheel disposed inside a compressor cover. The turbine housing defines a turbine outlet cavity, a turbine housing inlet, and a turbine housing outlet. The turbine housing inlet is configured to channel engine post-combustion gases to the turbine wheel and the turbine housing outlet is configured to exhaust the gases aft of the turbine wheel. A diffuser arranged inside the turbine outlet cavity is configured to channel the post-combustion gases aft of the turbine wheel and out to the turbine housing outlet, without discharging into the turbine outlet cavity.

Abstract: A turbocharger for an internal combustion engine includes a bearing housing and a bearing bore defined by the bearing housing. The bearing bore has an annular bearing groove configured to receive a fluid. A journal bearing is disposed within the bore such that the annular bearing groove encircles the journal bearing and feeds the fluid thereto. The turbocharger also includes a rotating assembly having a shaft with a turbine wheel and a compressor wheel. The shaft has a longitudinal axis and is supported by the journal bearing for rotation within the bore about the axis. The annular bearing groove is characterized by a trapezoidal shape in a cross-sectional view of the bearing bore taken along and through the longitudinal axis. The trapezoidal shape is configured to generate Taylor vortices in the fluid for capturing debris carried by the fluid and keeping the debris from being fed to the journal bearing.

Abstract: A turbocharger for an internal combustion engine includes a rotating assembly having a turbine wheel disposed inside a turbine housing and a compressor wheel disposed inside a compressor cover. The turbocharger also includes a waste-gate assembly configured to selectively redirect at least a portion of the engine's post-combustion gases away from the turbine wheel. The waste-gate assembly includes a valve, a rotatable shaft connected to the valve, and a bushing fixed relative to the turbine housing and disposed concentrically around the shaft such that the shaft rotates inside the bushing to thereby selectively open and close the valve. The shaft is defined by an outer surface in contact with the bushing and the outer surface includes a coating composed of a ceramic-based material. An internal combustion engine employing such a turbocharger is also disclosed.

Abstract: A turbocharger for an internal combustion engine includes a bearing housing with a bearing bore and a thrust wall. The bearing housing includes a journal bearing disposed within the bore. The turbocharger also includes a shaft supported by the journal bearing for rotation about an axis within the bore. The turbocharger also includes a turbine wheel fixed to the shaft and configured to be rotated about the axis by the engine's post-combustion gasses. The turbocharger additionally includes a compressor wheel fixed to the shaft and configured to pressurize an ambient airflow. Furthermore, the turbocharger includes a thrust bearing assembly pressed onto the shaft and configured to transmit thrust forces developed by the turbine wheel to the thrust wall. Pressing the thrust bearing assembly onto the shaft minimizes radial motion between the thrust bearing assembly and the shaft. An internal combustion engine employing such a turbocharger is also disclosed.

Abstract: A turbocharger for an internal combustion engine includes a shaft, a first turbine wheel, a compressor wheel, and a second turbine wheel. The shaft includes a first end and a second end and is supported for rotation about an axis. The first turbine wheel is mounted on the shaft proximate to the first end and configured to be rotated about the axis by post-combustion gasses emitted by the engine. The compressor wheel is mounted on the shaft between the first and second ends and configured to pressurize an airflow being received from the ambient for delivery to the engine. The second turbine wheel is mounted on the shaft proximate to the second end and configured to be rotated about the axis by a pressurized fluid. An internal combustion engine employing such a turbocharger is also disclosed.

Abstract: A turbocharger for an internal combustion engine includes a bearing housing with a bearing bore and a semi-floating bearing disposed within the bore. The turbocharger also includes a shaft having a first end and a second end, wherein the shaft is supported by the bearing for rotation about an axis within the bore. The turbocharger also includes a turbine wheel fixed to the shaft proximate to the first end and configured to be rotated about the axis by post-combustion gasses emitted by the engine. Additionally, the turbocharger includes a compressor wheel fixed to the shaft proximate to the second end and configured to pressurize an airflow being received from the ambient for delivery to the engine. Furthermore, the turbocharger includes a plate secured within the bearing housing and configured to prevent rotation of the bearing about the axis. An internal combustion engine employing such a turbocharger is also disclosed.

Abstract: A turbocharger includes a turbine housing defining a turbine chamber and a compressor housing defining a compressor chamber. A turbine wheel is disposed in the turbine chamber and a turbine shaft is connected to the turbine wheel. A compressor wheel is disposed in the compressor chamber and connected to the turbine shaft. A compressor back plate is adjacent to the compressor wheel and a bearing cartridge is sandwiched directly between the compressor back plate and the turbine housing and rotatably supporting the turbine shaft.

Abstract: A turbine wheel and shaft assembly is provided for a turbocharger including a turbine wheel including a body portion supporting a plurality of blades on a first axial face thereof. A hub extends from a body portion on a second axial face. A shaft is welded to the hub at a weld location spaced from the second axial face. The weld location is spaced axially from the second axial face by a distance sufficient to provide a significant reduction in the residual stresses in the welded parts. This design is intended to mitigate turbine wheel imbalance problems.

Abstract: A turbocharger for an internal combustion engine includes a bearing housing with a bearing bore and a thrust wall. The bearing housing includes a journal bearing disposed within the bore. The turbocharger also includes a shaft supported by the journal bearing for rotation about an axis within the bore. The turbocharger also includes a turbine wheel fixed to the shaft and configured to be rotated about the axis by the engine's post-combustion gasses. The turbocharger additionally includes a compressor wheel fixed to the shaft and configured to pressurize an ambient airflow. Furthermore, the turbocharger includes a thrust bearing assembly pressed onto the shaft and configured to transmit thrust forces developed by the turbine wheel to the thrust wall. Pressing the thrust bearing assembly onto the shaft minimizes radial motion between the thrust bearing assembly and the shaft. An internal combustion engine employing such a turbocharger is also disclosed.

Abstract: A turbocharger for an internal combustion engine includes a shaft, a first turbine wheel, a compressor wheel, and a second turbine wheel. The shaft includes a first end and a second end and is supported for rotation about an axis. The first turbine wheel is mounted on the shaft proximate to the first end and configured to be rotated about the axis by post-combustion gasses emitted by the engine. The compressor wheel is mounted on the shaft between the first and second ends and configured to pressurize an airflow being received from the ambient for delivery to the engine. The second turbine wheel is mounted on the shaft proximate to the second end and configured to be rotated about the axis by a pressurized fluid. An internal combustion engine employing such a turbocharger is also disclosed.

Abstract: A turbocharger includes a housing, a first rotor wheel, a second rotor wheel, a driveshaft, a first bearing and a second bearing. The housing defines a first region, a second region, an intake air inlet, an intake air outlet and an exhaust gas inlet. The first rotor wheel is located in the first region and the second rotor wheel is located in the second region. The first bearing is located on a first axial side of the first rotor wheel axially between the first and second rotor wheels and supports the driveshaft for rotation relative to the housing. The second bearing is located on a second axial side of the first rotor wheel and supports the first rotor wheel for rotation relative to the housing.

Abstract: A turbocharger for an internal combustion engine includes a bearing housing with a bearing bore and a semi-floating bearing disposed within the bore. The turbocharger also includes a shaft having a first end and a second end, wherein the shaft is supported by the bearing for rotation about an axis within the bore. The turbocharger also includes a turbine wheel fixed to the shaft proximate to the first end and configured to be rotated about the axis by post-combustion gasses emitted by the engine. Additionally, the turbocharger includes a compressor wheel fixed to the shaft proximate to the second end and configured to pressurize an airflow being received from the ambient for delivery to the engine. Furthermore, the turbocharger includes a plate secured within the bearing housing and configured to prevent rotation of the bearing about the axis. An internal combustion engine employing such a turbocharger is also disclosed.

Abstract: A turbocharger includes a housing, a first rotor wheel, a second rotor wheel, a driveshaft, a first bearing and a second bearing. The housing defines a first region, a second region, an intake air inlet, an intake air outlet and an exhaust gas inlet. The first rotor wheel is located in the first region and the second rotor wheel is located in the second region. The first bearing is located on a first axial side of the first rotor wheel axially between the first and second rotor wheels and supports the driveshaft for rotation relative to the housing. The second bearing is located on a second axial side of the first rotor wheel and supports the first rotor wheel for rotation relative to the housing.

Abstract: Systems are provided for supplying oil from an oil source to a bearing assembly, the bearing assembly including a cage having a forward rail and an aft rail, and at least one bearing disposed therebetween.

Abstract: Systems are provided for supplying oil from an oil source to a bearing assembly, the bearing assembly including a cage having a forward rail and an aft rail, and at least one bearing disposed therebetween.

Abstract: The present invention provides a method and apparatus for retaining bearing balls in a bearing assembly. For example, a cage assembly may comprise an annular cage having a plurality of pockets in which to snap-in bearing balls via openings having a width less than the diameter of the bearing balls. A retainer ring for the cage may have an inner diameter that is equal to the inner diameter of the cage. The cage assembly may comprise a plurality of cage webs, wherein each cage web is located between two adjacent pockets, and each cage web may be tapered (either radially, axially, or both radially and axially). The plurality of cage webs may be tapered such that the cage webs are tapered towards a distal end of each cage web and away from a proximal end of each cage web. An outer land may pilot the bearing assembly.