Patent Description:
Some turbomachines include an e-machine, such as an electric motor or generator. More specifically, some turbochargers, superchargers, or other fluid compression devices can include an electric motor that is operably coupled to the same shaft that supports a compressor wheel, turbine wheel, etc. The electric motor may drivingly rotate the shaft, for example, to assist a turbine stage of the device. In further embodiments, the e-machine may be configured as an electric generator, which converts mechanical energy of the rotating shaft into electric energy.

These devices may also include a controller that, for example, controls operation of the e-machine. More specifically, the control system may control the torque, speed, or other operating parameters of the e-machine and, as such, control operating parameters of the rotating group of the turbomachine.

However, conventional controllers of such turbomachines suffer from various deficiencies. These controllers can be heavy and/or bulky. Furthermore, thermal conditions proximate the controller may negatively affect operations. In addition, manufacture and assembly of conventional control systems can be difficult, time consuming, or otherwise inefficient.

Thus, it is desirable to provide a compact and lightweight turbomachine that includes an e-machine and an associated controller. Furthermore, it is desirable to provide a controller for such a turbomachine that operates efficiently and effectively, even in high-temperature environments. It is also desirable to provide improvements that increase manufacturing efficiency for such a turbomachine. Other desirable features and characteristics of the present disclosure will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and this background discussion. A prior art turbomachine is disclosed in document.

In one embodiment, a turbomachine according to claim <NUM> is disclosed that includes a housing and a rotating group that is supported for rotation about an axis of rotation within the housing. The turbomachine also includes a turbomachine stage including a wheel of the rotating group supported within a turbomachine housing of the housing. The turbomachine further includes an e-machine section including an e-machine that is housed within an e-machine housing of the housing. The e-machine is operably coupled to the rotating group and configured to operate as at least one of a motor and a generator. Moreover, the turbomachine includes an integrated controller that extends in a circumferential direction about the axis of rotation. The integrated controller is configured for controlling the e-machine. Additionally, the turbomachine includes a thermally decoupled fastener arrangement that attaches the integrated controller to the e-machine housing. The fastener arrangement thermally decouples the integrated controller from the turbomachine stage.

In another embodiment, a method of manufacturing a turbomachine according to claim <NUM> is disclosed. The method includes supporting a rotating group for rotation about an axis of rotation within a housing. The method includes defining a turbomachine stage that includes a wheel of the rotating group supported within a turbomachine housing of the housing. The method also includes housing an e-machine within an e-machine housing of the housing to define an e-machine section, including operatively coupling the e-machine to the rotating group for operation as at least one of a motor and a generator. Moreover, the method includes extending an integrated controller in a circumferential direction about the axis of rotation, wherein the integrated controller is configured for controlling the e-machine. Additionally, the method includes attaching the integrated controller to the e-machine housing with a thermally decoupled fastener arrangement. The fastener arrangement thermally decouples the integrated controller from the turbomachine stage.

In a further embodiment, a turbocharger according to claim <NUM> is disclosed that includes a housing and a rotating group that is supported for rotation about an axis of rotation within the housing. The turbocharger further includes a compressor stage with a compressor wheel of the rotating group that is supported within a compressor housing of the housing. Furthermore, the turbocharger includes a turbine stage with a turbine wheel of the rotating group that is supported within turbine housing of the housing. The turbocharger further includes an electric motor section including an electric motor that is housed within an e-machine housing of the housing and that is operably coupled to the rotating group. The turbocharger further includes an integrated controller that extends in a circumferential direction about the axis of rotation. The integrated controller is configured for controlling the electric motor. Moreover, the turbocharger includes a thermally decoupled fastener arrangement that attaches the integrated controller to the e-machine housing. The fastener arrangement thermally decouples the integrated controller from the turbine stage.

The present disclosure will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and wherein:.

The following detailed description is merely exemplary in nature and is not intended to limit the present disclosure or the application and uses of the present disclosure. Furthermore, there is no intention to be bound by any theory presented in the preceding background or the following detailed description.

Broadly, example embodiments disclosed herein include an improved turbomachine with an e-machine, such as an electric motor. The turbomachine further includes a controller that is integrated and packaged compactly with the other components of the turbomachine. The turbomachine includes a fastener arrangement that attaches the controller to one or more other components of the turbomachine, and the fastener arrangement thermally isolates (i.e., thermally decouples) one or more components of the controller from other high-temperature components during operation. These features may limit and/or prevent heat from transferring from the high-temperature components to the controller via the thermally conductive components. Accordingly, the controller may operate within preferred thermal conditions.

In some embodiments, the turbomachine includes an electric motor and/or electric generator and at least one turbomachine stage. For example, the turbomachine of the present disclosure comprises a turbocharger with a compressor stage, a turbine stage, and an e-machine section (e.g., a motor section). This turbomachine also includes an e-machine controller (i.e., control system, control assembly, etc.) for controlling the e-machine. The turbocharger may be incorporated in an engine system, a fuel cell system, or other system. The e-machine controller may be integrated within the turbomachine. For example, the e-machine controller may be shaped so as to extend about an axis of rotation of the rotating group of the turbocharger. The turbocharger also includes a fastener arrangement with fasteners that attach a housing of the e-machine to a support structure of the controller. More specifically, in some embodiments, the fasteners may attach the e-machine housing to a fluid-cooled support structure (e.g., a coolant core) of the controller. Despite close proximity to the turbine stage, the fastener arrangement thermally de-couples the fasteners from the turbine stage. For example, in the fastener arrangement, the fasteners may be received in respective apertures of the e-machine housing, and fasteners may be seated within the apertures, recessed and separated away at a distance from the turbine stage. Furthermore, the fastener arrangement may include thermally insulative heatshield coverings that cover over the fasteners, close off the apertures, and/or provide a thermal shield between the turbine stage and the fasteners. Accordingly, the fasteners are unlikely to receive heat from the turbine stage that could otherwise transfer into the controller. Thus, the controller is more likely to operate within desired thermal conditions.

<FIG> is a schematic view of an example turbomachine, such as a turbocharger <NUM> that is incorporated within an engine system <NUM> and that includes one or more features of the present disclosure. It will be appreciated that the turbocharger <NUM> could be another turbomachine (e.g., a supercharger, a turbine-less compressor device, etc.) in additional embodiments of the present disclosure. Furthermore, the turbomachine of the present disclosure may be incorporated into a number of systems other than an engine system without departing from the scope of the present disclosure. For example, the turbomachine of the present disclosure may be incorporated within a fuel cell system for compressing air that is fed to a fuel cell stack, or the turbomachine may be incorporated within another system without departing from the scope of the present disclosure.

Generally, the turbocharger <NUM> includes a housing <NUM> and a rotating group <NUM>, which is supported within the housing <NUM> for rotation about an axis <NUM> by a bearing system <NUM>. The bearing system <NUM> may be of any suitable type, such as a roller-element bearing or an air bearing system.

As shown in the illustrated embodiment, the housing <NUM> includes a turbine housing <NUM>, a compressor housing <NUM>, and an intermediate housing <NUM>. The intermediate housing <NUM> is disposed axially between the turbine and compressor housings <NUM>, <NUM>.

Additionally, the rotating group <NUM> includes components of at least one turbomachine stage as well as an e-machine section. As shown, the rotating group <NUM>, generally, includes a turbine wheel <NUM> of a turbine stage <NUM>, a compressor wheel <NUM> of a compressor stage <NUM>, and a shaft <NUM> that extends through the turbine stage <NUM>, the compressor wheel <NUM> and through an e-machine section <NUM> disposed therebetween. The turbine wheel <NUM> is located substantially within the turbine housing <NUM> to cooperatively define the turbine stage <NUM>. The compressor wheel <NUM> is located substantially within the compressor housing <NUM> to cooperatively define the compressor stage <NUM>. The shaft <NUM> extends along the axis of rotation <NUM>, through the intermediate housing <NUM>, to connect the turbine wheel <NUM> to the compressor wheel <NUM>. Accordingly, the turbine wheel <NUM> and the compressor wheel <NUM> rotate together as a unit about the axis <NUM>.

The turbine stage <NUM> may be cooperatively defined by the turbine housing <NUM> and the turbine wheel <NUM>. The turbine stage <NUM> may be configured to circumferentially receive a highpressure and high-temperature exhaust gas stream <NUM> from an engine, specifically, from an exhaust manifold <NUM> of an internal combustion engine <NUM>. The turbine wheel <NUM> and, thus, the other components of the rotating group <NUM> are driven in rotation around the axis <NUM> by the highpressure and high-temperature exhaust gas stream <NUM>, which becomes a lower-pressure and lower-temperature exhaust gas stream <NUM> that is released into a downstream exhaust pipe <NUM>.

The compressor stage <NUM> cooperatively defined by the compressor housing <NUM> and compressor wheel <NUM> is operable to be driven in rotation by the exhaust-gas driven turbine wheel <NUM>. The compressor stage <NUM> may be configured to compress received input air <NUM> (e.g., ambient air, or already-pressurized air from a previous-stage in a multi-stage compressor) into a pressurized airstream <NUM> that is ejected circumferentially from the compressor housing <NUM>. The compressor housing <NUM> may have a shape (e.g., a volute shape or otherwise) configured to direct and pressurize the air blown from the compressor wheel <NUM>. Due to the compression process, the pressurized air stream is characterized by an increased temperature, over that of the input air <NUM>.

The pressurized airstream <NUM> is channeled through an air cooler <NUM> (i.e., intercooler), such as a convectively cooled charge air cooler. The air cooler <NUM> is configured to dissipate heat from the pressurized airstream <NUM>, increasing its density. The resulting cooled and pressurized output air stream <NUM> is channeled into an intake manifold <NUM> of the internal combustion engine <NUM>, or alternatively, into a subsequent-stage, in-series compressor.

Furthermore, the turbocharger <NUM> includes the e-machine section <NUM>. The e-machine section <NUM> is cooperatively defined by the intermediate housing <NUM> and by an e-machine <NUM> housed therein. The shaft <NUM> extends through the e-machine section <NUM>, and the e-machine <NUM> may be operably coupled thereto. The e-machine <NUM> may be an electric motor, an electric generator, or a combination of both. Thus, the e-machine <NUM> may be configured as a motor to convert electrical energy to mechanical (rotational) energy of the shaft <NUM> for driving the rotating group <NUM>. Furthermore, the e-machine <NUM> may be configured as a generator to convert mechanical energy of the shaft <NUM> to electrical energy that is stored in a battery, etc. As stated, the e-machine <NUM> may be configured as a combination motor/generator, and the e-machine <NUM> may be configured to switch functionality between motor and generator modes in some embodiments as well.

For purposes of discussion, the e-machine <NUM> will be referred to as a motor <NUM>. The motor <NUM> includes a rotor member (e.g., a plurality of permanent magnets) that are supported on the shaft <NUM> so as to rotate with the rotating group <NUM>. The motor <NUM> also includes a stator member (e.g., a plurality of windings, etc.) that is housed and supported within the intermediate housing <NUM>. In some embodiments, the motor <NUM> is disposed axially between a first bearing <NUM> and a second bearing <NUM> of the bearing system <NUM>. Also, the motor <NUM> may be housed by a motor housing <NUM> of the intermediate housing <NUM>. The motor housing <NUM> may be a thin-walled or shell-like housing that encases the stator member of the motor <NUM>. The motor housing <NUM> may also encircle the axis <NUM>, and the shaft <NUM> may extend therethrough.

Furthermore, the turbocharger <NUM> includes an integrated controller <NUM>. The integrated controller <NUM> generally includes a controller housing <NUM> and a number of internal components <NUM> (e.g., circuitry, electronic components, cooling components, support structures, etc.) housed within the controller housing <NUM>. The integrated controller <NUM> controls various functions. For example, the integrated controller <NUM> may control the motor <NUM> to thereby control certain parameters (torque, angular speed, START/STOP, acceleration, etc.) of the rotating group <NUM>. The integrated controller <NUM> may also be in communication with a battery, an electrical control unit (ECU), or other components of the respective vehicle in some embodiments. More specifically, the integrated controller <NUM> may receive DC power from a vehicle battery, and the integrated controller <NUM> may convert the power to AC power for controlling the motor <NUM>. In additional embodiments wherein the e-machine <NUM> is a combination motor/generator, the integrated controller <NUM> may operate to switch the e-machine <NUM> between its motor and generator functionality.

In some embodiments, the integrated controller <NUM> may be disposed axially between the compressor stage <NUM> and the turbine stage <NUM> of the turbocharger <NUM> with respect to the axis <NUM>. Thus, as illustrated, the integrated controller <NUM> may be disposed and may be integrated proximate the motor <NUM>. For example, as shown in the illustrated embodiment, the integrated controller <NUM> may be disposed on and may be arranged radially over the motor housing <NUM>. More specifically, the integrated controller <NUM> may extend and wrap about the axis <NUM> to cover over the motor <NUM> such that the motor <NUM> is disposed radially between the shaft <NUM> and the integrated controller <NUM>. The integrated controller <NUM> may also extend about the axis <NUM> in the circumferential direction and may cover over, overlap, and wrap over at least part of the motor housing <NUM>. In some embodiments, the integrated controller <NUM> may wrap between approximately forty-five degrees (<NUM>°) and three-hundred-sixty-five degrees (<NUM>°) about the axis <NUM>. For example, as shown in <FIG>, the controller <NUM> may wrap approximately one-hundred-eighty degrees (<NUM>°) about the axis <NUM>.

As illustrated, the housing <NUM> may generally be arcuate (e.g., crescent-shaped) so as to extend about the axis <NUM> and to conform generally to the rounded profile of the turbocharger <NUM>. The housing <NUM> may also be an outer shell-like member that is hollow and that encapsulates the internal components <NUM>. In some embodiments, the housing <NUM> may be cooperatively defined by an outer housing body <NUM> and a cover <NUM> that covers over an open end of the outer housing body <NUM>. The housing <NUM> may attach to the motor housing <NUM>, for example on an inner radial area and/or on an axial face thereof.

Electrical connectors <NUM> extend through the housing <NUM> for electrically connecting the internal components <NUM> to external systems. Furthermore, there may be openings for fluid couplings (e.g., couplings for fluid coolant). In some embodiments, there may be electrical connectors and fluid couplings that extend along a common direction (e.g., a single direction along the axis <NUM>) to facilitate assembly of the turbocharger <NUM>. Additionally, the controller housing <NUM> may define part of the exterior of the turbocharger <NUM>. An outer surface <NUM> of the controller housing <NUM> may extend about the axis <NUM> and may face radially away from the axis <NUM>. At least part of the outer surface <NUM> may be smoothly contoured about the axis <NUM>, and at least part of the outer surface <NUM> may include one or more flat panels that are disposed tangentially with respect to the axis <NUM> at different angular positions. The outer surface <NUM> may be disposed generally at the same radius as the neighboring compressor housing <NUM> and/or turbine housing <NUM> as shown in <FIG>. Accordingly, the overall size and profile of the turbocharger <NUM>, including the controller <NUM>, may be very compact.

The internal components <NUM> of the controller <NUM> are housed within the controller housing <NUM>. Also, at least some of the internal components <NUM> may extend arcuately, wrap about, and/or may be arranged about the axis <NUM> as will be discussed. Furthermore, as will be discussed, the internal components <NUM> may be stacked axially along the axis <NUM> in close proximity such that the controller <NUM> is very compact. As such, the integrated controller <NUM> may be compactly arranged and integrated with the turbine stage <NUM>, the compressor stage <NUM>, and/or other components of the turbocharger <NUM>. Also, internal components <NUM> of the controller <NUM> may be in close proximity to the motor <NUM> to provide certain advantages. For example, because of this close proximity, there may be reduced noise, less inductance, etc. for more efficient control of the motor <NUM>.

In addition to electronics components for electronic control of the motor <NUM>, the controller <NUM> may include a number of components <NUM> that provide robust support. The controller <NUM> may also include components that provide efficient cooling. Thus, the turbocharger <NUM> may operate at extreme conditions due to elevated temperatures, mechanical loads, electrical loads, etc. Regardless, the controller <NUM> may be tightly integrated into the turbocharger <NUM> without compromising performance.

As shown in <FIG>, the internal components <NUM> of the integrated controller <NUM> may include a coolant core <NUM>. The coolant core <NUM> is shown in isolation in <FIG> and <FIG> for clarity. As will be discussed, the coolant core <NUM> may be configured for supporting a number of electronics components, fastening structures, and other parts of the integrated controller <NUM>. As such, the coolant core <NUM> may be referred to as a "support structure. " The coolant core <NUM> may be fluidly-cooled, and as such, the coolant core <NUM> may be referred to as a "cooling plate, etc." The coolant core <NUM> may define one or more coolant passages through which a fluid coolant flows. As such, the coolant core <NUM> may receive a flow of a coolant therethrough for cooling the integrated controller <NUM>.

The coolant core <NUM> may be elongate but curved and arcuate in shape and may extend in a tangential and/or circumferential direction about the axis <NUM>. In other words, the coolant core <NUM> may wrap at least partially about the axis <NUM> to fit about the motor <NUM> of the turbocharger <NUM>. Accordingly, the coolant core <NUM> may define an inner radial area <NUM> that faces the axis <NUM> and an outer radial area <NUM> that faces away from the axis <NUM>. Moreover, the coolant core <NUM> may include a first axial end <NUM> and a second axial end <NUM>, which face away in opposite axial directions. The first axial end <NUM> may face the compressor stage <NUM> of the turbocharger <NUM> in some embodiments and the second axial end <NUM> may face the turbine stage <NUM> in some embodiments. The coolant core <NUM> may also define an axial width <NUM>, which may be defined parallel to the axis <NUM> between the first and second axial ends <NUM>, <NUM>. Additionally, the coolant core <NUM> may be semi-circular and elongate so as to extend circumferentially between a first angular end <NUM> and a second angular end <NUM>, which are spaced apart angularly about the axis (e.g., approximately one-hundred-eighty degrees (<NUM>°) apart).

As shown in <FIG> and <FIG>, the coolant core <NUM> may be cooperatively defined by a plurality of parts, such as a reservoir body <NUM> and a cover plate <NUM>. Both the reservoir body <NUM> and the cover plate <NUM> may be made from strong and lightweight material with relatively high thermal conductivity characteristics (e.g., a metal, such as aluminum). In some embodiments, the reservoir body <NUM> and/or the cover plate <NUM> may be formed via a casting process (e.g., high pressure die casting).

The cover plate <NUM> may be relatively flat, may be arcuate (e.g., semi-circular), and may lie substantially normal to the axis <NUM>. Also, the cover plate <NUM> may define the first axial end <NUM> of the coolant core <NUM>. The reservoir body <NUM> may be a generally thin-walled and hollow body with an open side <NUM> that is covered over by the cover plate <NUM> and a second side <NUM> that defines the second axial end <NUM> of the coolant core <NUM>. The cover plate <NUM> may be fixed to the reservoir body <NUM> and sealed thereto with a gasket, seal, etc. One or more fasteners (e.g., bolts or other fasteners may extend axially through the cover plate <NUM> and the reservoir body <NUM> for attaching the same. The cover plate <NUM> and the reservoir body <NUM> may include one or more fastener holes <NUM> that receive a bolt or other fastener for attaching the first side electronics to the coolant core <NUM>. Accordingly, the cover plate <NUM> and the reservoir body <NUM> may cooperate to define a fluid passage <NUM> that extends through the coolant core <NUM>. In some embodiments, the fluid passage <NUM> may be elongate and may extend generally about the axis <NUM> from the first angular end <NUM> to the second angular end <NUM>.

The coolant core <NUM> may also include at least one fluid inlet <NUM> to the fluid passage <NUM> and at least one fluid outlet <NUM> from the fluid passage <NUM>. In some embodiments, for example, there may be a single, solitary inlet <NUM>. The inlet <NUM> may be disposed proximate the first angular end <NUM> and may include a round, cylindrical, and hollow connector <NUM> that projects along the axis <NUM> from the cover plate <NUM> away from the first axial end <NUM>. Also, in some embodiments, there may be a single, solitary outlet <NUM>. The outlet <NUM> may be disposed proximate the second angular end <NUM> and may include a round, cylindrical, and hollow connector <NUM> that projects along the axis <NUM> from the cover plate <NUM> away from the first axial end <NUM>.

The coolant core <NUM> may be fluidly connected to a coolant circuit <NUM>, which is illustrated schematically in <FIG>. The coolant circuit <NUM> may circulate any suitable fluid, such as a liquid coolant, between the fluid passage <NUM> and a heat exchanger <NUM> (<FIG>). More specifically, coolant may flow from the inlet <NUM>, through the fluid passage <NUM>, to the outlet <NUM>, thereby removing heat from the integrated controller <NUM>, and may continue to flow through the heat exchanger <NUM> to be cooled before flowing back to the inlet <NUM> of the coolant core <NUM>, and so on. Furthermore, as shown in <FIG>, the heat exchanger <NUM> may, in some embodiments, be separate and fluidly independent of an engine coolant system <NUM> that cools the engine <NUM>.

As shown in <FIG>, the second axial end <NUM> of the coolant core <NUM> may include one or more inner apertures <NUM>. The inner apertures <NUM> may include a plurality of pockets, recesses, receptacles, etc. that are open at the second side <NUM> of the reservoir body <NUM> and that are disposed proximate the inner radial area <NUM> of the core <NUM> in the radial direction. As shown, the inner apertures <NUM> may be generally cylindrical in some embodiments with circular profiles and with the longitudinal axis thereof arranged parallel to the axis <NUM>. There may be a plurality of inner apertures <NUM> arranged at different angular positions with respect to the axis <NUM> along the inner radial area <NUM> of the core <NUM>. The size and shape of the inner apertures <NUM> may correspond to certain ones of the internal components <NUM> of the integrated controller <NUM>. For example, the inner apertures <NUM> may be cylindrical, as shown, to receive and support inner electronics components, such as a series of capacitors <NUM> (<FIG>) of the controller <NUM>. Furthermore, as shown in <FIG> and <FIG>, the reservoir body <NUM> may define the apertures <NUM> with relatively thin walls <NUM> or other structures that separate the capacitors <NUM> within the apertures <NUM> from the coolant within the fluid passage <NUM>. Accordingly, the capacitors <NUM> may be effectively cooled by the coolant circuit <NUM>.

Likewise, as shown in <FIG>, the second side <NUM> of the reservoir body <NUM> may include a second side aperture <NUM> that has an ovate profile and that is recessed in the axial direction into the reservoir body <NUM>. The second side aperture <NUM> may be arranged with the major axis of its ovate shape extending tangentially with respect to the axis <NUM>. Also, the minor axis may extend radially and may be large enough to extend over both the inner radial area <NUM> and the outer radial area <NUM> of the coolant core <NUM>. Furthermore, the second side aperture <NUM> may be shaped correspondingly to another electronics component, such as an inverter, capacitor, a battery, or another piece of control equipment.

Additionally, the outer radial area <NUM> of the coolant core <NUM> may extend about the axis <NUM> and may include one or more outer seats <NUM>. The seats <NUM> may be rectangular and may lie in a respective tangential plane with respect to the axis <NUM>. The seats <NUM> may be disposed and spaced apart circumferentially at different angular positions with respect to the axis <NUM>. Furthermore, seats <NUM> may include a respective outer aperture <NUM> extending radially through to the interior of the core <NUM>. In some embodiments, at least one outer aperture <NUM> may be a rectangular hole that is centered within the respective seat <NUM> and that passes through the reservoir body <NUM> to the fluid passage <NUM> therein. The seat <NUM> may include the rectangular rim of the respective aperture <NUM>.

These outer apertures <NUM> may be sized and configured to receive an outer electronics component <NUM> (<FIG>). This component <NUM> may be and/or may include a semiconductor circuit component, such as a substantially-flat and rectangular transistor <NUM>. The transistor <NUM> may be a circuit component, switch component, MOSFET transistor, or another type.

The transistor <NUM> may be seated on a respective one of the seats <NUM>. The transistor <NUM> may be partially received in one of the apertures <NUM> and may be supported and mounted on a respective seat <NUM> so as to cover over the respective outer aperture <NUM>. There may be a gasket or other sealing member that seals the transistor <NUM> to the seat <NUM>. Also, the transistor <NUM> may include one or more thermally-conductive projections <NUM> (<FIG>), such as an array of fins, rails, posts, pins, etc.) that project from an underside thereof to extend into the fluid passage <NUM>. Accordingly, coolant within the coolant circuit <NUM> may flow across the projections <NUM> to provide highly effective cooling to the transistor <NUM>.

The first axial end <NUM> of the core <NUM> (defined substantially by the cover plate <NUM>) may provide a seat <NUM> (i.e., a second seat) for mounting and supporting a first side electronics package <NUM> of the controller <NUM>. The seat <NUM> may include one or more axially-facing surfaces of the first axial end <NUM>. The seat <NUM> may be planar and/or may include a plurality of co-planar surfaces that are spaced apart across the first axial end <NUM>. The seat <NUM> may include one or more surfaces on the end <NUM> that are arranged and/or that extend about the axis <NUM>.

The first side electronics package <NUM> is represented schematically in <FIG> as a semi-circular body that corresponds generally to the shape of the coolant core <NUM>. One or more parts of the first side electronics package <NUM> may be arcuate, may be elongate but extend about the axis <NUM>, or may otherwise extend about the axis <NUM>. The first side electronics package <NUM> may include at least one bus bar. The bus bar may be elongate and may extend about the axis <NUM>. The first side electronics package <NUM> may also include an arcuate circuit board assembly, an arcuate stiffening plate, fasteners, and/or other components arranged about the axis <NUM>. The bus bar and/or other components of the first side electronics package <NUM> may be attached to the first axial end <NUM> of the core <NUM> in any suitable fashion, such as fasteners. Accordingly, the first side electronics package <NUM> may be in close proximity with the coolant core <NUM> such that the coolant core <NUM> may absorb heat therefrom with high efficiency and effectiveness.

As represented in <FIG>, the second axial end <NUM> of the coolant core <NUM> may provide a seat <NUM> (i.e., a third seat) for mounting and supporting a second side electronics package <NUM> of the integrated controller <NUM>. Like the first side electronics package <NUM>, the second side electronics package <NUM> is represented schematically in <FIG>. The second side electronics package <NUM> may include at least one bus bar that is elongate and that extends about the axis <NUM>. The second side electronics package <NUM> may also include an arcuate circuit board assembly, an arcuate stiffening plate, fasteners, and/or other components arranged about the axis <NUM>, and at least some of these components may be similarly stacked in the axial direction. The second side electronics package <NUM> may be attached to the second axial end <NUM> of the core <NUM> in any suitable fashion, such as fasteners. Accordingly, the second side electronics package <NUM> may be in close proximity with the coolant core <NUM> such that the coolant core <NUM> may absorb heat therefrom with high efficiency and effectiveness.

The fluid passage <NUM> for the coolant within the coolant core <NUM> may be defined between the inner surfaces of the reservoir body <NUM>, the inner face of the cover plate <NUM>, and the inner faces of the transistors <NUM>. The fluid passage <NUM> may also extend arcuately about the axis <NUM>, from the inlet <NUM> to the outlet <NUM>. Coolant may enter via the inlet <NUM>, flow generally from the first angular end <NUM> to the second angular end <NUM> and exit via the outlet <NUM>. Accordingly, the coolant may flow in close proximity and across the core-facing surfaces of the transistors <NUM>, the capacitors <NUM>, the first side electronics package <NUM>, and the second side electronics package <NUM>.

Accordingly, the controller <NUM> may be integrated and packaged among the turbine stage <NUM>, the motor <NUM>, and/or the compressor stage <NUM> of the turbocharger <NUM>. The coolant core <NUM> and the coolant circuit <NUM> may provide effective cooling despite compact packaging of these components. Moreover, the controller <NUM> may be robustly supported.

Referring now to <FIG>, additional details of the present disclosure will be discussed. The embodiments illustrated in <FIG> may correspond to at least one of those discussed above in relation to <FIG>. Components in <FIG> that correspond to those of <FIG> are identified with corresponding reference numbers increased by <NUM>. For purposes of brevity, those details included above will not be repeated.

The turbocharger <NUM> includes the e-machine <NUM> with the motor housing <NUM>. The turbocharger <NUM> may further include the integrated controller <NUM> that has the coolant core <NUM> and the internal components <NUM> supported thereon as discussed above. The turbocharger <NUM> may include a turbomachine stage, such as the turbine stage <NUM> discussed above. Similar to the embodiments of <FIG>, the turbocharger <NUM> may further include a compressor stage, and in some embodiments, the e-machine <NUM> and controller <NUM> may be disposed axially between the turbine stage <NUM> and the compressor stage relative to the axis of rotation <NUM> of the rotating group.

The turbocharger <NUM> may further include a thermally decoupled fastener arrangement <NUM> that attaches the coolant core <NUM> of the integrated controller <NUM> to the motor housing <NUM>. The fastener arrangement <NUM> also thermally de-couples the coolant core <NUM> from the turbine stage <NUM>.

For example, the fastener arrangement <NUM> includes one or more fasteners <NUM>, such as bolts, screws, or other threaded fasteners, that are received in respective fastener apertures <NUM>. At least one fastener aperture <NUM>, as shown in <FIG>, may include a motor housing portion <NUM> and a coolant core portion <NUM>, which may be aligned along a fastener axis <NUM>. The fastener axis <NUM> may be substantially parallel to the axis of rotation <NUM> of the rotating group. In some embodiments, the coolant core portion <NUM> may be a blind hole or a through-hole with a substantially constant diameter and with an internal threading. The motor housing portion <NUM> may be a through-hole with a diameter that varies along its length. The motor housing portion <NUM> may be disposed proximate an outer, radial flange <NUM> of the motor housing <NUM>. The motor housing portion <NUM> of the aperture <NUM> may include a first end <NUM> that extends through an outer axial face <NUM> of the motor housing <NUM>. The motor housing portion <NUM> may also include a second end <NUM> that has a smaller diameter than the first end <NUM>. Furthermore, the motor housing portion <NUM> may include an intermediate segment <NUM> that is disposed axially between the first end <NUM> and the second end <NUM> and that has a diameter less than that of the first end <NUM> and greater than that of the second end <NUM>. The motor housing portion <NUM> also includes a fastener seat <NUM> that is recessed into the outer axial face <NUM> of the motor housing <NUM> facing the turbine stage <NUM>. The head of the fastener <NUM> may be seated on the fastener seat <NUM> and may be threadably attached within the coolant core portion <NUM> to attach the motor housing <NUM> to the coolant core <NUM>. In some embodiments, the fastener arrangement <NUM> may include at least one washer <NUM> (e.g., a spring washer) or other similar component for seating and securing the attachment of the fastener <NUM>. It will be appreciated that there may be a plurality of fasteners <NUM> received in respective fastener apertures <NUM>, for example, spaced apart equally in the circumferential direction about the axis <NUM>.

As shown in <FIG>, the fastener seat <NUM> is recessed axially from the axial face <NUM> of the motor housing <NUM>. This allows the head of the fastener <NUM> to be spaced apart at a distance <NUM> from the opposing face of the turbine stage <NUM>. This distance <NUM> limits or inhibits heat transfer from the turbine stage <NUM> to the fastener <NUM> and, thus, may thermally decouple the turbine stage <NUM> from the fastener <NUM>. Accordingly, the fastener <NUM> is less likely to receive radiative or other heat transferred from the turbine stage <NUM>.

The fastener arrangement <NUM> may further include at least one heatshield covering <NUM>. As shown in <FIG>, there may be at least one heatshield covering <NUM> that is rounded and cap-shaped. The heatshield covering <NUM> may be made from and/or may include material that has a relatively low heat transfer coefficient (i.e., thermally insulative material such as a polymeric material).

The heatshield covering <NUM> may be received within the intermediate segment <NUM> and a flange of the covering <NUM> may be seated on a heatshield seat <NUM> at a transition between the intermediate segment <NUM> and the first end <NUM> of the fastener aperture <NUM>. The heatshield seat <NUM> may be recessed from the face <NUM> of the motor housing <NUM>, away from the turbine stage <NUM>. This allows the heatshield covering <NUM> to be spaced apart at a distance <NUM> from the opposing face of the turbine stage <NUM>. This distance <NUM> limits or inhibits heat transfer from the turbine stage <NUM> to the heatshield covering <NUM> and, thus, may thermally decouple the turbine stage <NUM> from the fastener <NUM>. Accordingly, the fastener <NUM> is less likely to receive radiative or other heat transferred from the turbine stage <NUM> and otherwise heat the internal components <NUM> of the integrated controller <NUM>.

The heatshield covering <NUM> and may cover over and close off the fastener aperture <NUM>. Also, the heatshield covering <NUM> may be disposed axially between the fastener <NUM> and the turbine stage <NUM> to thereby cover over the respective fastener <NUM> and protect it from heat radiating from the turbine stage <NUM>. Additionally, the intermediate segment <NUM> may include an airgap <NUM> between the heatshield covering <NUM> and the fastener <NUM>. This airgap <NUM> may provide additional thermal insulation from heat transferring from the turbine stage <NUM> to the integrated controller <NUM>. It will be appreciated that there may be a plurality of heatshield coverings <NUM> for the number of fastener apertures <NUM> included, for example, spaced apart equally in the circumferential direction about the axis <NUM>.

Accordingly, the fastener arrangement <NUM> may protect the integrated controller <NUM> from excessive heating and maintain thermal conditions within a predetermined range for effective and efficient operation of the turbocharger <NUM>. Furthermore, the fastener arrangement <NUM> may be installed quickly and easily with relatively few parts or processing steps. For example, the apertures <NUM> may be formed using a cutting tool, such as a mill. Also, the fasteners <NUM> may be highly available fasteners that may be installed quickly and easily. Then, the heatshield coverings <NUM> may be attached, for example, manually by pressing the coverings <NUM> onto the heatshield seats <NUM>.

Claim 1:
A turbomachine comprising:
a housing (<NUM>);
a rotating group (<NUM>) that is supported for rotation about an axis of rotation within the housing;
a turbomachine stage including a wheel (<NUM>, <NUM>) of the rotating group that is supported within a turbomachine housing (<NUM>, <NUM>) of the housing;
an e-machine section including an e-machine (<NUM>, <NUM>) that is housed within an e-machine housing of the housing, the e-machine being operably coupled to the rotating group and configured to operate as at least one of a motor and a generator;
an integrated controller (<NUM>, <NUM>) that extends in a circumferential direction about the axis of rotation, the integrated controller configured for controlling the e-machine; and
a thermally decoupled fastener arrangement (<NUM>) that attaches the integrated controller to the e-machine housing, the fastener arrangement thermally decoupling the integrated controller from the turbomachine stage.