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 
       [0001]    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 
       [0002]    The present invention relates generally to turbine housings, and more particularly, to methods and apparatus for fabricating turbine housings. 
       BACKGROUND 
       [0003]    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. 
         [0004]    Turbochargers utilize the engine&#39;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&#39;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. 
         [0005]    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 
       [0006]    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 
         [0007]    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: 
           [0008]      FIG. 1  is a schematic view of a turbine housing; 
           [0009]      FIG. 2  is a perspective view of a turbine housing having a virtual plane extending therethrough; 
           [0010]      FIG. 3  is a cross-sectional view of the turbine housing of  FIG. 2  taken along the virtual plane; 
           [0011]      FIG. 4  is a detailed view of a tongue member; 
           [0012]      FIG. 5  is a perspective view of a turbine housing; 
           [0013]      FIG. 6  is a detailed view of the tongue member of  FIG. 5 ; 
           [0014]      FIG. 7  is a perspective view of a turbine housing; 
           [0015]      FIG. 8  is a detailed view of the tongue member of  FIG. 7 ; 
           [0016]      FIG. 9  is a perspective view of a turbine housing having a virtual plane extending therethrough; 
           [0017]      FIG. 10  is a cross-sectional view of the turbine housing of  FIG. 9  taken along the virtual plane; 
           [0018]      FIG. 11  is a first detailed view of a mesh ring of  FIG. 10 ; 
           [0019]      FIG. 12  is a second detailed view of a mesh ring of  FIG. 10 ; 
           [0020]      FIG. 13  is a perspective view of a turbine housing having a virtual plane extending therethrough; 
           [0021]      FIG. 14  is a cross-sectional view of the turbine housing of  FIG. 13  taken along the virtual plane; 
           [0022]      FIG. 15  is a detailed view of the adapter tube of  FIG. 14 . 
       
    
    
     DETAILED DESCRIPTION 
       [0023]    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. 
         [0024]    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&#39;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 . 
         [0025]    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. 
         [0026]    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 . 
         [0027]    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 . 
         [0028]    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 . 
         [0029]    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. 
         [0030]    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. 
         [0031]    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. 
         [0032]    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. 
         [0033]    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. 
         [0034]    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.