Borgwarner Inc.

Michael Bucking

Augustine Cavagnaro

Paul Diemer

Daniel N Ward

Timothy Mark House

Paul K Anschel

Rajmohan Chandramohanan

Aaron Date

Raj Chandramohanan

Kurtis Henderson

Robert C Lancaster

Mike Harris

A method for enclosing a rotating assembly of a turbocharger including providing at least two bearing housing segments which together form a bearing housing including a bearing bore and an insert bore. The method can include machining complementary mating faces of the segments, machining features as required for alignment and fastening of the segments to each other, machining the bearing bore and the insert bore, and machining oil feed passages and oil drain features into at least one segment. The at least one oil feed bore is drilled from the radially inner surface of the corresponding bearing housing segment. The method can further include balancing a rotating assembly, installing the rotating assembly into one of the bearing housing segments, and joining the segments together to enclose the rotating assembly.

Multi-segment turbocharger bearing housing and methods therefor

A ball stud () with a relatively short grip length, adapted for use with a turbocharger, having a flexible flange () extending from a center of the ball stud (). The flexible flange () is between a ball section () and a first shaft portion () adjacent to the flexible flange () and preferably a narrower threaded shaft portion () extending further from the ball section (). The first shaft portion () may be tapered to fit in a complementary aperture () of a plate (). The flexible flange () preferably includes a narrow circumference () adjacent to a center of the ball stud () with a circumferential lip () adapted to engage a plate (). The flexible flange () allows subtle flex for thermal expansion and essentially changes a spring rate of the ball stud () to emulate a longer fastener.

Vibration resistant flex flange ball stud

A turbocharger () having a rotatable shaft () passing through a bearing housing () with a turbine-end bearing support () with a support bar (). A turbine-end bearing support () may include the support bar () with radial supports () and () connected to each opposite side () and () of cavity () of the bearing housing () wherein oil can flow in recesses () and () above the radial supports () and (). Each radial support () and () of the support bar () is preferably integrated in the corresponding side () and (). A turbine-end bearing support () may also include the support bar () with a rod portion () forming a bottom tie support bar () that supports the bottoms of both bearing supports () and (), which are top-supported by the bearing housing (). Each support bar () is preferably integral with the bearing support ().

Turbine-end bearing support and cooling system

A turbocharger () having a bearing housing () between a turbine housing and a compressor housing with a shaped core () forming an internal oil drain cavity () adjacent to a spacer () shaped to induce swirling for oil defoaming. A depression () in an internal core wall of the bearing housing () forms the oil drain cavity () with each end () of the depression () corresponding to a distal end () of the spacer (). The spacer () is preferably substantially tubular with a row of oil-flow apertures () aligned on each outer span () of a recessed center portion () to induce swirling.

Swirl inducing bearing housing spacer and core

An electrically assisted turbocharger () includes an air cooling system for cooling an electric motor () housed within a motor chamber () in a bearing housing (). An inlet volute () is formed in the bearing housing () on a first side of the electric motor () and an outlet volute () is formed in the bearing housing () on a second side of the electric motor () opposite from the inlet volute (). The inlet volute () accelerates cooling air that is fed into the inlet volute () and directs the cooling air into the motor chamber (). The cooling air travels in an axial direction through the motor chamber () from the inlet volute () to the outlet volute (), thereby cooling the electric motor (). The outlet volute () decelerates the cooling air and directs the cooling air out of the motor chamber ().

Supplemental air cooling system and air pressure oil sealing system for electrical turbocompound machine

A system and method is provided in which a turbocharger includes a heat shield wall that is formed together with the bearing housing as a unitary structure. The wall can extend from a main body portion of the bearing housing in a generally radially outward direction. The wall can be spaced from the main body and attached by a plurality of ribs such that chambers are defined therebetween. A circumferential passage can extend through the bearing housing to permit fluid communication between the chambers and outside of the bearing housing. In this way, a fluid outlet from the chambers is provided. As a result of such an arrangement, the need for a separate heat shield is eliminated, which can facilitate the assembly process and special attachment methods associated with a separate heat shield.

Turbocharger bearing housing with integrated heat shield

A product that may include a first linked element that may have an opening that may have a coaxial counter bore. A collar may be included and may have a parti-spherical section and may have a countersunk section that may extend into the counter bore. A stud may have a sphere-like section and may be engaged with the parti-spherical section. The stud may include a shank extending from the sphere-like section and through the collar and the opening. A fastener may be engaged with the shank, and the collar and the first linked element may be compressed between the sphere-like section and the fastener. A second linked element may be included and may have a race within which the sphere-like section may be engaged.

Preload loss prevention system for a clamping ball stud

A number of variations may include a product that may be usable with a turbocharger system and may include a housing that may define a lubrication bore. A bearing assembly may be positioned in the housing. A shaft may extend through, and may be supported by, the bearing assembly. A turbine wheel may be connected to the shaft. An end cap may be connected between the housing and the turbine wheel. The end cap may define a cooling chamber. A spray head may provide an opening between the lubrication bore and the cooling chamber.

Bearing housing

To solve both axial and rotational constraint problems in turbochargers with rolling element bearings (REBs), a REB sleeve or outer race is mounted to the bearing housing in a way that is not axially and radially rigid, thus allowing for oil damping films both radially and axially. At the same time, the REB sleeve or outer race is held so that the REB sleeve or outer race does not rotate relative to the bearing housing. This dual purpose is achieved using an anti-rotation ring and a damping ring. The anti-rotation ring includes at least one anti-rotation feature for engaging the bearing housing and at least one anti-rotation feature for engaging the REB cartridge, preventing rotation of the REB cartridge sleeve or outer race. The damping ring axially locates the REB cartridge and dampens axial movement and cushions axial thrust.

Rolling element bearing cartridge with axial thrust damping and anti-rotation assemblies

An electrically assisted turbocharger () comprising a housing () and an electric motor stator () disposed in the housing (). The stator () includes a pair of o-rings, or other circumferential seals (), disposed therearound. The o-rings () are operative to seal against an interior of the housing () to form an annular chamber () around at least a portion of the stator () and a pair of end cavities () at the axial ends of the stator (). The annular chamber () is adapted to allow the circulation of a cooling fluid around the stator (). A pair of bearings () may be disposed in the housing (), one on each side of the stator (). A shaft () is supported in the housing () by the bearings (). The shaft () in turn supports a turbine wheel () and a compressor wheel. An electric motor rotor () is disposed on the shaft () between the bearings () and inside the stator ().

Electrically assisted turbocharger

A product for use with a turbocharger is disclosed. According to a number of variations, the product may include a bearing housing with a bearing assembly positioned in the bearing housing. A shaft may extend through the bearing assembly for rotation. A turbine wheel may be exposed to high temperature exhaust gases and may be connected to the shaft. The product may include a number of features to manage heat transfer and protect the bearing assembly from excessive temperatures that may otherwise result from exposure to the exhaust gases.

High efficiency and durable ball bearing system with reduced turbine end heat transfer

A restraint system () for a vaned diffuser () of a turbocharger () or other fluid boosting device is provided that can reduce or eliminate losses. The system () uses a structure to provide both a pressure load on the vaned diffuser () and a seal for the vaned diffuser (). The structure can be a fluoroelastomer O-ring (). The O-ring () can be positioned at least partially in a channel () formed in at least one of the diffuser ring ('), the compressor housing () and the center housing ().

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Asheville, NC, United States of America

Michael Bucking