Turbocharger containment assembly

A turbine assembly and turbocharger containing the same are disclosed. Such an assembly can include a turbine housing for a turbocharger having an inlet portion, a central portion, and a hollow cylindrical portion defining a hollow passageway and an outlet. The inlet portion, central portion, and hollow cylindrical portion are in fluid connection with one another which allows a fluid to enter and pass through the inlet portion to the central portion, pass through the central portion to the hollow passageway, and pass through the hollow passageway to exit the turbine housing through the outlet. The assembly also includes a containment assembly at least partially disposed in the hollow passageway of the hollow cylindrical portion.

BACKGROUND

Turbochargers are typically used with an engine to improve the engine's volumetric efficiency. Turbochargers include a turbine wheel within a turbine housing. The turbine wheel is a rotating component that is used to extract energy from exhaust gases that pass through the turbine housing. Unfortunately, turbocharger turbines can catastrophically fail resulting in fragmentation of the turbine blades and hub. This type of failure is referred to as a burst and can have many root causes such as material contaminants, improper heat treat, inadequate attachment to the shaft, excessive temperature, and excessive rotational speed. Given the high rotation speeds of the turbine wheel, a burst failure can cause fragments of the turbine wheel to become dangerous projectiles.

Up until now, turbine housings were only designed to contain fragments of the turbine wheel that traveled in a radial direction from the turbine wheel. However, the fragments of the turbine wheel created by a burst failure do not always travel in a radial direction. In fact, the fragments could exit the turbine housing outlet and cause a great deal of damage to systems nearby, such as engine parts. There have been attempts to create an exhaust pipe, which attaches to the turbine housing to carry away exhaust gases, with cross bars for slowing down fragments of the turbine wheel that travel through the exhaust pipe. However, such exhaust pipe designs still permit fragments of the turbine wheel to break through the walls of the exhaust pipe, including those portions of the exhaust pipe between the cross bars and the turbine housing.

Accordingly, there exists a need for a turbine assembly that can contain flying fragments of turbine wheel in order to prevent them from escaping and harming other systems nearby.

SUMMARY

The present disclosure discloses a turbine assembly and a turbocharger including the turbine assembly. Such a turbine assembly includes a turbine housing for a turbocharger having an inlet portion, a central portion, and a hollow cylindrical portion defining a hollow passageway and an outlet. The inlet portion, central portion, and hollow cylindrical portion are in fluid connection allowing a fluid to enter and pass through the inlet portion to the central portion, pass through the central portion to the hollow passageway, and pass through the hollow passageway to exit the turbine housing through the outlet. The turbine assembly also includes a containment assembly at least partially disposed in the hollow passageway of the hollow cylindrical portion.

In at least one embodiment of a turbine assembly of the present disclosure, the turbine assembly includes a turbine housing and a containment assembly. The turbine housing includes a hollow central portion having a central opening and a turbine wheel adjacent to the central opening and a hollow cylindrical inlet portion having a first inlet end and a second inlet end. The first inlet end defines an inlet opening and the second inlet end is connected to the central portion. The turbine housing also includes a hollow cylindrical outlet portion having a first outlet end and a second outlet end. The first outlet end is connected to the hollow central portion about the central opening and the second outlet end defines an outlet opening. The hollow cylindrical inlet portion, hollow central portion, and hollow cylindrical outlet portion are fluidly connected such that a fluid can enter the first inlet end, pass through the hollow cylindrical inlet portion to the second inlet end, enter and pass through the hollow central portion, and exit through the outlet. The containment assembly is at least partially disposed in the hollow cylindrical outlet portion and configured to obstruct the movement of portions of the turbine wheel through the hollow cylindrical outlet portion.

In at least one embodiment of a turbocharger of the present disclosure, the turbocharger includes the turbine assembly and a turbine wheel that is disposed within the central portion of the turbine assembly adjacent to the hollow cylindrical portion of the turbine assembly. The containment assembly of the turbine assembly is configured to obstruct the movement of portions of the turbine wheel through the hollow passageway leading to the outlet of the turbine housing.

DETAILED DESCRIPTION

FIG. 1shows a perspective view of an exemplary embodiment of a turbocharger50having a turbine assembly100according to the present disclosure.FIG. 2ashows a perspective view of the turbine assembly100according to the present disclosure. As shown inFIG. 2a, the turbine assembly100includes a turbine housing200, a turbine wheel250disposed within the turbine housing200, and a containment assembly300. As discussed further below, the containment assembly300is configured to obstruct the passageway between the turbine wheel250and the outlet237of the turbine housing200such that when the turbine wheel250experiences a burst failure or otherwise fails, the containment assembly300is able to slow down or block the movement of fragments of the turbine wheel250traveling through the outlet portion230towards the outlet237of the turbine housing200. By resisting or blocking the movement of fragments of the turbine wheel250in such a manner, the turbine assembly100effectively contains the failure of the turbine wheel250thereby protecting systems located nearby to the assembly100.

As shown inFIG. 2a, the turbine housing200includes an inlet portion210, a central portion220, and an outlet portion230. InFIG. 2a, the inlet portion210is a hollow cylinder that includes an inlet203and an intermediate inlet portion207(shown inFIG. 2b). The inlet203is configured to receive exhaust gases from an engine (e.g., internal combustion engine). For example, a hose or other connecting member may connect the exhaust port of an engine to the inlet203. After exhaust gas is received by the turbine housing200at the inlet203, the gas travels through the inlet portion210between the inlet203to the intermediate inlet portion207. The inlet portion210may be various diameters and thicknesses depending upon the application. The gas continues traveling through the turbine housing200by entering the central portion220, which is fluidly connected to the intermediate inlet portion207. The central portion220is a hollow pathway that fluidly connects the inlet portion210and the outlet portion230. While circulating within the central portion220, the exhaust gas interacts with and passes by the turbine wheel250, which is disposed within the central portion220, such that the turbine wheel250begins to rotate. The central portion220and turbine wheel250may be various sizes and thicknesses depending upon the application. After the exhaust gas passes by the turbine wheel250, the exhaust gas exits the central portion220, and enters the outlet portion230through the outlet opening233. The exhaust gas passes through the outlet portion230, around the containment assembly300, and exits the turbine housing200through the outlet237of the outlet portion230. Typically, after exiting the turbine housing200, the exhaust gas enters a hose that empties to the ambient air.

As discussed above, the turbine housing200includes an outlet portion230, which is a hollow cylindrical extension from the central portion220.FIG. 2bshows a side view of the turbocharger ofFIG. 1with a partial section view of the turbine100. As shown inFIG. 2b, the outlet portion230effectively extends the exit opening of the turbine housing200from approximately the position of the turbine wheel250to the outlet237(shown as length EXT). The outlet portion230can be configured to support various types of containment assemblies300, such as those described below. For example, the outlet portion230may include various apertures to receive bolts or other devices. The outlet portion230may have various dimensions and thicknesses depending upon the application.

As shown inFIGS. 2aand 2b, the containment assembly300is shown as two bolts that are secured to the outlet portion230and extend through, and thereby obstruct, the hollow passageway of the outlet portion230in a substantially perpendicular configuration. InFIG. 2a, the containment assembly300is shown located midway between the outlet opening233and the outlet237of the outlet portion230. It should be noted that the containment assembly300may be positioned anywhere within the outlet portion230. For example, the containment assembly300may be positioned adjacent to the outlet237or adjacent to the outlet opening233. Also, it should be noted that the containment assembly300may be two bolts in a different configuration (e.g., parallel to one another) or just one bolt or three or more bolts in various configurations. For example,FIG. 3shows a turbocharger50with a containment assembly300having six bolts with three parallel in one direction and three parallel in a direction perpendicular to the other three bolts. As shown inFIGS. 2aand 2b, the bolts may be staggered along the outlet portion230. Of course, the bolts may not be staggered but form an X-shape as a single part or may pass through one another. The bolts of the containment assembly300may be various sizes and shapes. For example, the bolts may each have a diameter of about 0.953 centimeters (0.375 inches). Also, the containment assembly300may be one or more plates, a mesh, or various other devices that partially obstruct the hollow passageway of the outlet portion230but allow exhaust gases to pass. For example,FIGS. 4 and 5show turbochargers50having containment assemblies300with different mesh patterns.

It shall be understood that smaller and smaller fragments of the turbine wheel250can be blocked or slowed by increasing the cross-section of the containment assembly300. Therefore, the containment assembly300can be manipulated based upon the desired application to have a greater cross-sectional area to block or slow smaller fragments or a smaller cross-sectional area to block or slow larger fragments. One of ordinary skill in the art would appreciate that the greater the interruption of the exhaust gas flow by the containment assembly300, the greater the adverse affect on the overall performance of the turbocharger. Therefore, the containment assembly300is typically arranged and/or configured to minimize flow restrictions through the outlet portion230. By minimizing flow restrictions through the outlet portion230, the containment assembly300is able to provide protection from a burst failure of the turbine wheel250without substantially affecting the performance of the turbocharger50.

While the containment assembly300and turbine housing200may be a single part (discussed below), it should be noted that the containment assembly300may be separate and distinct from the turbine housing200. In some cases, it may be advantageous for the containment assembly300to be removable from the turbine housing200. For example, the containment assembly300will experience significant wear from normal operation of the turbocharger50. Therefore, the ability to replace or repair just the containment assembly300, without having to replace the turbine housing200, would be cost effective. It may also be helpful to have a removable containment assembly300to repair or replace the turbine wheel250.

The turbine housing200may be formed as separate, distinct parts or created as a single part. For example, the inlet portion210, the central portion220, and the outlet portion230may be separate parts that are connected together (e.g., welding, fastening, and the like) to form the turbine housing200. In another example, the turbine housing200may be formed as a single part by using a mold process or other process. Furthermore, while typically the containment assembly300and turbine housing200may be separate, distinct parts, it should be noted that the containment assembly300may also be integrated with the turbine housing200such that the housing200and containment assembly300are created as a single part.

The turbine housing200may be formed of various materials, such as, for example, metals, composites, and the like. It should be noted that the inlet portion210, central portion220, and outlet portion230may each be formed of different materials. In any case, the central portion220and outlet portion230are configured to contain fragments of the turbine wheel250upon the occurrence of a burst failure. For example, the central portion220and outlet portion230may have a particular thickness and be formed of a material that can withstand a turbine wheel250projectile at a particular speed. The containment assembly may also be formed of various materials, such as, for example, high temperature resistant and high ductility materials. For example, the containment assembly may be formed of Inconel®, Incaloy®, or other high nickel, high temperature super alloys.

While this disclosure has been described as having various embodiments, these embodiments according to the present disclosure can be further modified within the scope and spirit of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the disclosure using its general principles. A practitioner may determine in a particular implementation that a plurality of components of the disclosed assembly may be combined in various ways, or that different components or different variations of the components may be employed to accomplish the same results. Each such implementation falls within the scope of the present disclosure as disclosed herein and in the appended claims. Furthermore, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this disclosure pertains.