Fabricated Turbine Housing

Abstract

A turbine housing is provided. The turbine housing includes a tongue diverter to manage the interaction between exhaust gases entering the inlet of the housing and gasses flowing within the housing. The tongue member may also be arranged to produce a constant ratio throughout the turbine housing between the cross-sectional area of fluid passages and the distance between the centroid of that area and the axis of rotation of the turbine. The housing may comprise a pair of half shells that each form a portion of the tongue diverter.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims benefit from U.S. Provisional Patent Application No. 61/192,758, entitled “Fabricated Turbine Housing Tongue Diverter,” filed on Sep. 22, 2008, U.S. Provisional Patent Application No. 61/192,759, entitled “Fabricated Turbine Housing Volute,” filed on Sep. 22, 2008, and U.S. Provisional Patent Application No. 61/206,559, entitled “Fabricated Turbine Housing,” filed on Jan. 30, 2009, which are hereby incorporated by reference in their entirety.

FIELD OF INVENTION

The present invention relates generally to turbine housings, and more particularly, to methods and apparatus for fabricating turbine housings.

BACKGROUND

As is known in the art, turbochargers are often used with combustion engines to increase the power output of the engine. Turbochargers increase power by increasing the amount of air used to facilitate combustion in the engine. Increasing the amount to air provided to the cylinders of the engine allows for a proportional increase in the amount to fuel that may be burned in the engine. This increased fuel amount leads to increased power output.

Turbochargers utilize the engine's exhaust to spin a turbine, which in turn spins an air pump to compress air. The compressed air is pumped into the cylinders during combustion. The turbine is typically positioned within a housing that includes an inlet for the engine's exhaust. The housing has a generally volute shape so that exhaust channeled into the housing creates rotational flow as to spin the turbine located in the housing.

Traditional turbine housings suffer from several deficiencies. For example, as explained in further detail below, cross-flow of exhaust within the volute housing can cause a decrease in turbine power. Additionally, the turbocharger system may experience power losses due to exhaust gas leaks at slip joints on the housing. Further, altering the size and geometry of the turbine to maximize output often requires replacing the housing and other housing components to fit the new turbine. Accordingly, there is a need in the art for an improved turbine housing.

SUMMARY OF THE PRESENT INVENTION

A turbine housing apparatus is provided. The turbine housing may be volute shaped and includes a tongue diverter disposed therein. In an embodiment, the turbine housing is assembled by joining two half-shells. A portion of a tongue diverter is formed in each of the half-shells. When the shells are assembled, the formed portions align to form the tongue diverter. The tongue diverter is arranged to manage the interaction between exhaust gases entering the inlet and exhaust gasses flowing within the housing. The tongue member may also be arranged to produce a constant ratio throughout the turbine housing between the cross-sectional area of fluid passages and the distance between the centroid of that area and the axis of rotation of the turbine. The turbine housing further includes one or more mesh rings disposed along the housing to reduce exhaust gas leaks. Additionally, a formed tube interconnects the inner housing shell and the downpipe to allow for easy changes to the size and geometry of the turbine.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Objects and advantages together with the operation of the invention may be better understood by reference to the detailed description taken in connection with the following illustrations, wherein:

FIG. 1 is a schematic view of a turbine housing;

FIG. 2 is a perspective view of a turbine housing having a virtual plane extending therethrough;

FIG. 3 is a cross-sectional view of the turbine housing of FIG. 2 taken along the virtual plane;

FIG. 4 is a detailed view of a tongue member;

FIG. 5 is a perspective view of a turbine housing;

FIG. 6 is a detailed view of the tongue member of FIG. 5;

FIG. 7 is a perspective view of a turbine housing;

FIG. 8 is a detailed view of the tongue member of FIG. 7;

FIG. 9 is a perspective view of a turbine housing having a virtual plane extending therethrough;

FIG. 10 is a cross-sectional view of the turbine housing of FIG. 9 taken along the virtual plane;

FIG. 11 is a first detailed view of a mesh ring of FIG. 10;

FIG. 12 is a second detailed view of a mesh ring of FIG. 10;

FIG. 13 is a perspective view of a turbine housing having a virtual plane extending therethrough;

FIG. 14 is a cross-sectional view of the turbine housing of FIG. 13 taken along the virtual plane;

FIG. 15 is a detailed view of the adapter tube of FIG. 14.

DETAILED DESCRIPTION

Reference will now be made in detail to exemplary embodiments of the present invention, examples of which are illustrated in the accompanying drawings. It is to be understood that other embodiments may be utilized and structural and functional changes may be made without departing from the respective scope of the present invention.

The efficiency of the power generated by a turbocharged engine may depend on the efficiency in which a turbine housing manages and channels the flow of the engine's exhaust through the turbine housing. FIG. 1 is a schematic illustration of a turbine housing 8. The turbine housing 8 includes a generally volute-shaped inner housing 10 and an inlet 12 at the opening of the inner housing 10. The volute shape and the position of the inlet 12 promote rotational flow within the inner housing 10. Such rotational flow spins a turbine 14 positioned generally in the center of the inner housing 10. As will be understood, as exhaust gases flow along the perimeter of the inner housing 10, such flowing gases may make more than one revolution around the perimeter before exiting the inner housing 10. As the gases flow around the perimeter, the gases may interact with new exhaust gases entering the inner housing 10 through the inlet 12. Failure to manage the interaction between the exhaust gases flowing through the inner housing 10 and the exhaust gases newly introduced into the inner housing 10 may prevent the power output of the engine from realizing optimizal efficiency. As will be described in detail below, a tongue diverter may be positioned proximate to the inlet 12 to manage the interaction between the gases flowing through the inner housing 10 and the gases entering the inner housing 10 through the inlet 12.

One method of optimizing power output for a turbocharged engine is to maintain certain geometric ratios within the inner housing 10. For example as shown in FIG. 1, the cross-sectional area A of the flow path at any point along the flow path may be measured or otherwise determined, and the radial distance R of the centroid of that area A to the rotational axis 16 of the turbine 14 may be measured or otherwise determined. Designing the inner housings 10 to yield a constant value for the ratio of the cross-sectional area to the radius A/R enhances, and potentially optimizes, the power output of the engine.

With reference to FIGS. 2-8, a turbine housing 8 includes an outer body 22 substantially surrounding an inner housing 10. The inner housing 10 may be formed by a first shell 18 and a second shell 20. The shells 18, 20 may be generally mirror images of each other, however, the second shell 20 may include an extrude portion 24 for allowing exhaust to exit the inner housing 10. The shells 18, 20 may be connected together. For example, the shells 18, 20 may be welded, crimped, bonded, or connected by any other method known in the art. In an embodiment, one of the shells 18 may be slightly larger than the other shell 20 to provide an overlap section to aid in welding or otherwise attaching the shells 18, 20.

A tongue diverter 26 may be positioned within the inner housing 10 proximate to a tight turn in the inner housing 10 where the inlet 12 terminates into the flow cavity. The tongue diverter 26 may be arranged to manage or reduce the interaction between the incoming exhaust flow and the rotational or spiral flow of exhaust gases already flowing within the inner housing 10. The tongue diverter 26 may also be arranged and configured such that the A/R ratio is constant throughout the housing 10.

The tongue diverter 26 may be integrally formed with the shells 18, 20. For example, as illustrated in FIGS. 3-8, the first shell 18 may include a recessed portion 28 near the inlet 12. The second shell 20 may also include a recessed portion 30 near the inlet 12. When the shells 18, 20 are assembled to form the housing 10, the recessed portions 28, 30 align to form the tongue diverter 26. The aligned recessed portions 28, 30 act as a barrier between the flow cavity near the inlet 12 and the inner flow cavity. In an embodiment shown in FIGS. 3 and 4, similarly sized and shaped recessed portions 28, 30 in the first and second shells 18, 20 abut one another to form the tongue diverter 26. However, it will be appreciated that the tongue diverter 26 may be formed by a single recessed portion in either the first or second shell 18, 20. It will be further appreciated that each recessed portion 28, 30 may be sized and shaped independent of the other, so as to form the tongue diverter 26.

In an embodiment, the tongue diverter 26 may include a wall (not shown) positioned proximate to the inlet 12. The wall may be integrally formed with either of the shells 18, 20 or may be a unitary piece attached at the inlet 12. The wall may be formed by two or more subcomponents. The two subcomponents may be connected to form a barrier between the flow cavity near the inlet 12 and the inner flow cavity.

With reference to FIGS. 9-12, the turbine housing 8 may further include one or more mesh rings 32 disposed along the inner housing 10. The mesh rings 32 may be positioned to effectively seal the inner housing 10 to prevent exhaust gas leaks. For example, mesh rings 32 may be positioned at slip joints along the inner housing 10. In an embodiment shown in FIG. 11, a mesh ring 32 is disposed near the inlet 12, between outer wall of the inner housing 10 and the inner wall of the outer body 22. The mesh ring 32 is positioned to reduce exhaust leaks at the inlet joint.

The turbine housing 8 may also include a wastegate 34. The wastegate 34 may be a valve, configured to control the speed of the turbine 14. Specifically, at a predetermined speed or pressure, the wastegate 34 may open to allow some exhaust entering the inner housing 10 to bypass the turbine 14. A connecting tube 36 may connect the wastegate 34 to the inner housing 10. In an embodiment illustrated in FIG. 12, a mesh ring 32 is located around an outer wall of the connecting tube 36 near the wastegate 34. The mesh ring 32 is positioned to reduce exhaust leaks at the wastegate joint.

The inner housing 10 may be connected to a downpipe 38. Exhaust gas exiting the inner housing 10 may flow through the extrude portion 24 in the inner housing 10 and into the downpipe 38. The turbine 14 may be generally positioned within the extrude portion 24. With reference to FIGS. 13-15, the turbine housing 8 may include an adapter tube 40. The adapter tube 40 may be positioned to interconnect the extrude portion 24 and the downpipe 38. For example, a first end 42 of the adapter tube 40 may be welded to the extrude portion 24, and a second end 44 of the adapter tube 40 may be welded or otherwise connected to the downpipe 38. It will be appreciated, however, that the adapter tube 40 may be connected to the extrude portion 24 and downpipe 38 by any manner known in the art.

The adapter tube 40 may overlap the extrude portion 24 such that the turbine 14 is positioned within the adapter tube 40. The adapter tube 40 may thus be sized and shaped to receive to the turbine 14. By altering the thickness and shape of the adapter tube 40, a single turbine housing 8 may adapt to a variety of turbines 14 of varying size and geometry.

Although the preferred embodiment of the present invention has been illustrated in the accompanying drawings and described in the foregoing detailed description, it is to be understood that the present invention is not to be limited to just the preferred embodiment disclosed, but that the invention described herein is capable of numerous rearrangements, modifications and substitutions without departing from the scope of the claims hereafter.

Claims

1. A turbine housing comprising:

a housing having a top portion and a bottom portion;

a turbine positioned within said housing;

an inlet at an outer end of said housing; and

a tongue diverter positioned adjacent to said inlet, wherein said tongue diverter is formed by an engagement between said top portion and said bottom portion.

2. The turbine housing of claim 1 wherein said tongue diverter is capable of reducing the interaction between gasses entering the inlet and gasses flowing within said housing.

3. The turbine housing of claim 1 further comprising a flow path within said housing, wherein the ratio between a cross-sectional area of said flow path and the distance between the centroid of said cross-sectional area and the center of said turbine remains approximately constant along a length of said flow path.

4. The turbine housing of claim 1 further comprising an outer body at least partially surrounding said housing.

5. The turbine housing of claim 4 further comprising at least one mesh ring disposed between said housing and said outer body.

6. The turbine housing of claim 4 wherein a mesh ring is positioned between said outer body and said housing near said inlet.

7. The turbine housing of claim 1 further comprising a wastegate valve connected to said housing.

8. The turbine housing of claim 7 further comprising a connecting tube disposed between said housing and said wastegate valve.

9. The turbine housing of claim 8 further comprising a mesh ring located attached to a portion of said connecting tube.

10. The turbine housing of claim 1 further comprising an adapter tube positioned about said turbine.

11. The turbine housing of claim 10 further comprising an exhaust pipe connected to said adapter tube.

12. A turbine housing comprising

a first half shell having a recessed portion;

a second half shell connected to said first half shell to form a housing;

an inlet at an outer end of said housing; and

a tongue diverter positioned adjacent to said inlet, wherein said tongue diverter is formed by an engagement between said recessed portion said second half shell.

13. The turbine housing of claim 12 wherein said first half shell overlaps said second half shell.

14. The turbine housing of claim 12 wherein said first half shell is welded to said second half shell.

15. The turbine housing of claim 12 wherein said second half shell includes a recessed portion.

16. The turbine housing of claim 15 wherein said tongue diverter is formed by an engagement between said recessed portion in said first half shell and said recessed portion in said second half shell.

17. The turbine housing of claim 12 further comprising a flow path within said housing, wherein the ratio between a cross-sectional area of said flow path and the distance between the centroid of said cross-sectional area and the center of said housing remains approximately constant along a length of said flow path.

18. The turbine housing of claim 12 further comprising a turbine positioned within said housing.

19. The turbine housing of claim 18 further comprising an adapter tube positioned about said turbine.

20. The turbine housing of claim 19 further comprising an exhaust pipe connected to said adapter tube.