Wastegate for engine system

Abstract

The present application relates to a wastegate for an engine system, and provides a method and system for a wastegate for a turbocharger, the wastegate including a valve plate, a valve actuation mechanism, and a bifurcated wastegate passage. In one example design, the wastegate may include a valve plate having an interior with a multi-planar curved surface and a first mating feature centered along the curved surface, the curved surface forming a raised edge and a side opening on opposite sides of the valve plate; and a passage bifurcated by a central wall, the end of the central wall including a second mating feature adapted to coplanarly contact the first mating feature. The first mating feature may be a rib or groove formed on the valve plate, and the second mating feature may be one end of the central wall.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application is a continuation-in-part of U.S. Patent Application No. 15 / 347,669, filed on November 9, 2016, entitled “A WASTEGATE FOR AN ENGINE SYSTEM,” the entire contents of which are incorporated herein by reference for all purposes. Technical Field

[0003] The present disclosure relates to methods and systems for a wastegate mounted to an exhaust passage of a turbocharger to direct exhaust gas flow to an exhaust catalyst. Background Art

[0004] The exhaust flow in a turbocharger system can be partially directed to an exhaust-driven turbine to drive a compressor that delivers air to the engine cylinders, while the remainder of the exhaust can flow via a bypass passage around the turbine to an exhaust catalyst located downstream of the turbine. The bypass passage can include a wastegate valve that can be adjusted to an open position, allowing the exhaust to bypass the turbine and flow to the catalyst. The wastegate valve can be adjusted to a closed position that at least partially blocks the exhaust flow in the bypass passage, and thus most of the exhaust delivered from the engine is directed to the turbine. During a cold start of the engine, the exhaust can be at least partially routed through the bypass passage and the wastegate so as to direct the exhaust flow to the front face of the catalyst, thereby allowing the catalyst to be ignited more quickly.

[0005] Other engine systems may include a split exhaust manifold in which at least some of the exhaust from a first group of cylinders is directed to a first scroll of a turbocharger turbine via the first exhaust manifold, and at least some of the exhaust from a second group of cylinders is directed to a second scroll of the turbocharger turbine via the second exhaust manifold. In these systems, at least some of the exhaust from the first group of cylinders and the second group of cylinders may be diverted away from the first scroll and the second scroll and instead routed to a bypass passage coupled to both the first exhaust manifold and the second exhaust manifold, the bypass passage having a wastegate that can be adjusted between a closed position and an open position to direct the exhaust flow to a catalyst positioned downstream of the wastegate and the turbocharger turbine.

[0006] Grabowska discloses an example design of a wastegate valve in an exhaust passage of a turbocharger in U.S. Patent Application 2015 / 0345375. Therein, a wastegate valve assembly having a flow configuration is provided to direct exhaust gas in a primary flow direction while reducing exhaust gas losses in a secondary flow direction. Specifically, the wastegate includes a flow configuration on a valve body that is supported on a valve arm pivotally supported on a turbine housing. Example flow configurations on the valve body include a concave disk, shallow ribs, and an extended semicircular surface formed on the valve body to direct exhaust gas flow in a primary direction.

[0007] The inventors herein have recognized potential issues with the example approaches disclosed above. For example, in a valve body configured with a concave disk or shallow ribs, the exhaust flow may fan out in multiple directions, impinge on the turbocharger walls and create turbulent flow conditions. As a result, exhaust energy may be transferred to the turbocharger walls, resulting in reduced flow efficiency and energy losses. Additionally, because the flow fans out in multiple directions before flowing downstream, less exhaust heat may reach the catalyst and therefore delayed catalyst light-off may occur. Summary of the invention

[0008] The inventors herein have developed a wastegate design to at least partially address the above-mentioned problems. In one exemplary design, a wastegate may be provided that includes a valve plate having an interior with a multi-planar curved surface and a first mating feature centered along the curved surface, the curved surface forming a raised edge and side openings on opposite sides of the valve plate; and a channel bifurcated by a central wall, the end of the central wall including a second mating feature adapted to coplanar contact with the first mating feature.

[0009] In this way, the design of the wastegate can be used to improve flow efficiency and reduce energy losses in the turbocharger while improving catalyst light-off. For example, the multi-plane curved surface on the valve plate can work with the contraction segment in the channel to guide the exhaust flow and increase the flow rate downstream of the wastegate. In another example, the central wall can divide the wastegate channel into a first side and a second side, wherein the first side receives the exhaust flow from the first vortex coupled to the first group of cylinders and the turbine, and the second side receives the exhaust flow from the second vortex coupled to the second group of cylinders and the turbine. In this way, the wastegate design can confer several advantages. By directing the exhaust flow downstream instead of fanning out in multiple directions, the wastegate can reduce the exhaust energy loss to the turbocharger wall. Further, the contraction segment in the channel can allow the exhaust flow to accelerate before leaving the wastegate. By providing a bifurcated channel coupled to the first vortex and the second vortex of the turbocharger, the exhaust flows from two specific groups of cylinders may not be connected to each other.

[0010] For example, two groups of cylinders can be established so that in the firing order of the engine, the exhaust from the subsequent cylinder alternates between the first vortex and the second vortex. Such a configuration can allow a four-cylinder engine to use an exhaust valve lift duration of more than 180 degrees without causing a cylinder with a high exhaust manifold pressure at the beginning of the exhaust event to push the exhaust into the previous cylinder at the end of the exhaust event of the previous cylinder. An exhaust valve lift duration greater than 180 degrees is required to improve the pumping efficiency of the engine. Additionally, the use of a manifold and a turbocharger with a separation channel allows a smaller volume between the cylinder exhaust valve and the turbine, which increases the conversion of the exhaust energy to turbine work. This can improve the fuel economy and transient performance of the vehicle. Further, by including a first mating feature on the valve plate and a second mating feature on the central wall of the channel, when the valve plate is closed against the channel, the first mating feature and the second mating feature can be sealed against each other, thereby reducing the flow communication between the two sides of the channel (and therefore the two vortices of the turbine) of the exhaust. In this way, the wastegate valve can reduce exhaust energy losses to improve catalyst light-off conditions while reducing fuel emissions and improving the performance of the twin-scroll turbocharger.

[0011] It should be understood that the above summary is provided to introduce in a simplified form a selection of concepts that are further described in the detailed description. This is not intended to identify key or essential features of the claimed subject matter, the scope of which is solely defined by the claims attached to the detailed description. Furthermore, the claimed subject matter is not limited to embodiments that address any disadvantages mentioned above or in any part of this disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 A schematic diagram of an engine system including a turbocharger system having a twin-scroll turbine with an exhaust bypass passage configured with a wastegate valve is shown.

[0013] Figure 2A An example turbocharger including an exhaust bypass passage with a wastegate valve is shown.

[0014] Figure 2B A schematic diagram of a first embodiment of a wastegate including a wastegate valve having a valve plate actuator is shown.

[0015] Figure 3A A first view of a second embodiment of a wastegate valve is shown in a closed wastegate position and having a passage with a constricted section formed on an inner wall of the passage.

[0016] Figure 3B A second embodiment of a wastegate valve is shown in an open position.

[0017] Figure 3C An alternative embodiment of a wastegate valve is shown in an open position and having a passage without a constricted section formed on an inner wall of the passage.

[0018] Figure 4A A first three-dimensional view of a third embodiment of a wastegate valve is shown.

[0019] Figure 4B A second three-dimensional view of a third embodiment of a wastegate valve is shown.

[0020] Figure 4C A third embodiment of a wastegate valve is shown in a closed valve position.

[0021] Figure 4D A cross-sectional view of a valve plate of a third embodiment of a wastegate valve is shown.

[0022] Figure 4E A cross-sectional view of a wastegate passage of a third embodiment of a wastegate valve is shown.

[0023] Figure 5A A first view of a valve plate of a fourth embodiment of a wastegate valve is shown.

[0024] Figure 5B A second view of the valve plate of the fourth embodiment of the wastegate valve is shown.

[0025] Figure 5C A third view of a valve plate of a fourth embodiment of a wastegate valve is shown.

[0026] Fig. 6A A schematic diagram of a fourth embodiment of a wastegate valve is shown in a closed position.

[0027] Figure 6B A cross-sectional view of a fourth embodiment of a wastegate valve is shown in a closed position.

[0028] Figure 6C A three-dimensional view of an alternative embodiment of a wastegate valve is shown in a closed position.

[0029] Fig. 7A A schematic diagram of a fourth embodiment of a wastegate valve is shown in a partially open position.

[0030] Figure 7B A cross-sectional view of a fourth embodiment of a wastegate valve is shown in a partially open position.

[0031] Fig. 8A A cross-sectional view of a fourth embodiment of a wastegate valve is shown in a fully open position.

[0032] Figure 8BA three-dimensional view of a fourth embodiment of a wastegate valve is shown in a fully open position.

[0033] Fig. 9A A first cross-sectional view of a fourth embodiment of a wastegate valve is shown in a closed position.

[0034] Fig. 9B A second cross-sectional view of a fourth embodiment of a wastegate valve is shown in a closed position.

[0035] Fig. 10A A first three-dimensional view of a fifth embodiment of a wastegate valve is shown.

[0036] Fig. 10B A second three-dimensional view of a fifth embodiment of a wastegate valve is shown.

[0037] Fig. 10C A fifth embodiment of a wastegate valve is shown in a closed valve position.

[0038] Fig. 10D A cross-sectional view of a valve plate of a fifth embodiment of a wastegate valve is shown.

[0039] Fig.10E A cross-sectional view of a wastegate passage of a fifth embodiment of a wastegate valve is shown.

[0040] Figure 2A-Figure 10E Shown are drawn to scale, but other relative dimensions may be used if desired. DETAILED DESCRIPTION

[0041] The following description relates to a turbocharger system having a bifurcated bypass passage configured with a wastegate to control exhaust gas flow around a twin-scroll turbine and to an exhaust catalyst placed downstream of the turbine in an engine, such as Figure 1 As shown. Figure 2A As shown, an example engine turbocharger is disclosed, which has a wastegate valve, which includes a valve actuation mechanism to control the exhaust gas flow in the bypass passage to bypass the turbine and flow to the exhaust catalyst. The wastegate valve can be adjusted to open or close by using an actuator mechanism including various means including mechanical, hydraulic, electrical and other suitable actuation methods. Figure 2B A schematic diagram of a first embodiment of a wastegate including a valve plate and a valve plate actuator is shown. The wastegate also includes a passage having a curved inner surface that can be used to direct exhaust gas flow delivered from an engine cylinder (via an exhaust passage) to an exhaust catalyst.

[0042] Figure 3AA first view of a second embodiment of a wastegate valve is shown in a closed wastegate position and having a passage with a constricted section formed on an inner wall of the passage. Figure 3B As shown, the wastegate valve may be adjusted into an open position to allow exhaust gas flow through an outlet of the wastegate. Figure 3C An alternative embodiment of a wastegate valve in an open position and having a passage without a constriction segment formed on the inner wall of the passage is shown. In this case, exhaust gas can flow in multiple directions, as shown. Exhaust flow fanning out of the wastegate outlet can impinge on the walls of the exhaust passage downstream of the valve and cause turbulent flow conditions, which can result in exhaust energy loss.

[0043] Figure 4A-4E A third embodiment of a wastegate valve is shown that includes a rib extending from an inner portion of a valve plate. The rib can divide the valve plate into a first segment and a second segment. The valve plate includes a rib connected to a base plate and extends outwardly into the wastegate passage. As an example, Figure 4D As shown, the ribs may include curved portions connected to linear portions. Figure 4E A cross-sectional view of a wastegate channel is depicted in In this case, a central wall divides the channel into a first side and a second side.

[0044] Figure 5A-5C A schematic diagram of a valve plate of a fourth embodiment of a wastegate valve is shown. Figure 5A-Figure 5B A first view and a second view, respectively, of a valve plate of a fourth exemplary embodiment of a wastegate valve are shown. Figure 5C A third view of a valve plate of a fourth embodiment of a wastegate valve is shown. Figure 6A-6B A schematic diagram of a fourth embodiment of a wastegate valve is shown in a closed position. Fig. 6A A first view of a closed wastegate valve is shown. Figure 6B A second view of the wastegate valve is shown in a closed position. Figure 6A-6B In each of the first and second views, there is disclosed a Figure 5A-5C The disclosed valve plate has similar features to that of a wastegate valve. Figure 6C A schematic diagram of an alternative embodiment of a wastegate valve is shown in a closed position.

[0045] Figure 7A-7B A schematic diagram of a fourth embodiment of a wastegate valve is shown in a partially open position. Fig. 7A A first view of a wastegate valve is shown in a partially open position. Figure 7B A second view of the wastegate valve is shown in a partially open position. Figure 7A-7B In each of the first and second views, the wastegate valve is partially open to allow exhaust gas flow in a flow direction toward an exhaust catalyst positioned downstream of the wastegate. Figure 8A-B A first view and a second view of a wastegate valve in a fully open position are shown. When fully open, exhaust flow through the wastegate outlet may increase and thereby reduce catalyst warm-up duration. Figure 9A-9B A first cross-sectional view and a second cross-sectional view of a fourth embodiment of a wastegate valve in a closed position are shown. A raised edge formed on an inner surface of the wastegate valve can work with a constricted segment formed on an inner wall of a passage of the wastegate to direct exhaust gas flow to an exhaust catalyst via a valve outlet. In this way, the wastegate valve and passage can function to accelerate catalyst light-off while minimizing fuel emissions.

[0046] Fig. 10A and Fig.10E A fifth embodiment of a wastegate valve is shown that includes a recessed slot formed on an inner portion of a valve plate. The recess may be sized to receive a central wall that divides a passageway into a first side and a second side. Fig. 10C A fifth embodiment of a valve plate coupled to one end of a wastegate passage is shown in FIG. The valve plate includes a recess configured to mate with a mating portion of a central wall that divides the wastegate passage into a first side and a second side. Each side of the passage can be configured to direct the exhaust flow toward the valve plate with no or minimal exhaust flow mixing. Fig. 10D As shown, the groove may be formed between the first portion and the second portion of the raised edge of the valve plate. Fig.10E A cross-sectional view of a wastegate passage is depicted in FIG. In this view, a central wall bifurcates the passage into a first side and a second side, the first side being formed at an opposite side of the central wall compared to the second side. In this manner, each of the first side and the second side of the passage can route exhaust gas toward an outlet of the passage at the location of the valve plate with no or minimal mixing of exhaust gas flows between the two sides of the passage.

[0047] Figure 2A-Figure 10EAn example configuration of relative positioning of various components with a wastegate valve and an exhaust passage is shown. In at least one example, if shown to be in direct contact or directly coupled to each other, then these elements can be referred to as being in direct contact or directly coupled, respectively. Similarly, in at least one example, elements that are shown to be adjacent or adjacent to each other can be adjacent or adjacent to each other, respectively. As an example, components placed in coplanar contact with each other can be referred to as coplanar contact. As another example, in at least one example, components that are positioned to be spaced apart from each other with only space and no other components between them can be referred to as such. As yet another example, elements that are shown above / below each other, on opposite sides of each other, or on the left / right of each other can be referred to as such relative to each other. Further, in at least one example, as shown in the accompanying drawings, the highest element or point of an element can be referred to as the "top" of a component, and the lowest element or point of an element can be referred to as the "bottom" of a component. As used herein, top / bottom, up / down, above / below can be relative to the vertical axis of the accompanying drawings and are used to describe the positioning of elements in the accompanying drawings relative to each other. Likewise, in one example, the elements shown above other elements are positioned vertically above other elements. As another example, the shapes of the elements depicted in the accompanying drawings can be referred to as having those shapes (e.g., such as being circular, straight, planar, curved, rounded, chamfered, angled, etc.). Further, in at least one example, the elements shown intersecting each other can be referred to as intersecting elements or intersecting each other. Further, in one example, an element displayed in another element or displayed outside another element can be referred to as such.

[0048] refer to Figure 1 , discloses a schematic diagram of a naturally aspirated multi-cylinder internal combustion engine 10 that may be included in a propulsion system of an automobile. The engine 10 may include a plurality of cylinders 20, 21, 22, and 23 (e.g., combustion chambers). In the depicted example, the engine 10 includes four cylinders, cylinders 1 through 4, arranged in an inline configuration. However, in alternative examples, the engine 10 may include one or more cylinders, such as 2, 3, 4, 5, 6, 8, 10, or more cylinders, arranged in an alternating configuration (such as a V-6, I-6, V-12, opposed 4, boxer, etc.).

[0049] Each cylinder 20-23 of the engine 10 can be configured to receive intake air from the intake manifold 27 via an intake passage 28. The intake passage 28 can include an intake throttle 62 downstream of the compressor 90 of the turbocharger. The intake passage 28 receives intake air via an upstream intake passage 29 including an air filter 30. The position of the throttle 62 can be adjusted by the control system 15 via a throttle actuator (not shown) that is communicatively coupled to the controller 12. By adjusting the throttle 62, a certain amount of fresh air can be introduced into the engine 10 from the atmosphere and delivered to the engine cylinders via the intake passage 28 at or below atmospheric pressure (or atmospheric pressure). The intake manifold 27 can be coupled to the combustion chamber via an intake passage (not shown). Each intake passage can supply air and / or fuel to the cylinder to which it is coupled for combustion. Each cylinder intake passage can selectively communicate with the cylinder via one or more intake valves. In the example shown, each cylinder 20-23 is shown with two intake valves I1 and I2. In one example, an intake passage may be formed by an intake manifold 27 that selectively communicates with each intake valve. In other embodiments, the intake passage for a single cylinder may be split into two adjacent paths with a wall between them near the cylinder, each split path of the passage being in communication with a single intake valve. In another example, each of the two intake valves may be controlled to open at a specific engine speed and may therefore be in communication with the intake manifold through a common intake duct.

[0050] Each combustion chamber can exhaust combustion gases via two exhaust ports coupled thereto. In the example shown, each cylinder 20-23 is coupled to the first exhaust port 31 via the first exhaust valve E1, and is coupled to the second exhaust port 33 via the second exhaust valve E2. Each exhaust port of each cylinder of the first cylinder group and the second cylinder group can lead to different exhaust manifolds for separately directing a first initial portion of the exhaust gas (also referred to herein as a discharge portion) and a second rear portion of the exhaust gas (also referred to herein as a purification portion). For example, each of the first exhaust ports 31 and the second exhaust ports 33 from the outer cylinders 20 and 23 of the first cylinder group are combined into a first exhaust manifold 54A, and each of the first exhaust ports 31 and the second exhaust ports 33 from the inner cylinders 21 and 22 of the second cylinder group are combined into a second exhaust manifold 54B. Such an exhaust system including two exhaust manifolds will be referred to herein as a "split exhaust system." Although Figure 1 The split exhaust system shown in has a particular configuration of exhaust passages and exhaust manifolds, but in alternative embodiments, different arrangements of the exhaust passages and manifolds are possible while still causing the cylinders of a first subset to direct exhaust gas to a first scroll of a turbocharger turbine and causing the cylinders of a second subset to direct exhaust gas to a second scroll of the turbocharger turbine.

[0051] The engine 10 may include a turbocharger 190 including a turbine 92 and a compressor 90 coupled rotationally by a shaft. The compressor 90 is positioned in the intake passage and receives intake air from the intake passage 29. The compressor bypass valve 126 is arranged in a bypass passage 164 around the compressor 90. The turbine 92 may be a twin (e.g., two) scroll turbine including and receiving exhaust gas from a first scroll 59A (coupled to the first exhaust manifold 54A) and a second scroll 59B (coupled to the second exhaust manifold 54B). Further, a wastegate 127A may be included in a bypass 166 coupled between the inlet and outlet of the exhaust twin scroll turbine 92 to control the amount of exhaust gas delivered to the twin scroll turbine 92. A portion of the bypass 166 located upstream of the wastegate valve 127A may be a bifurcated passage having a first passage 170 and a second passage 172. The first passage 170 can be fluidly coupled to the second scroll 59B, and the second passage 172 can be coupled to the first scroll 59A. The first exhaust portion from the first scroll 59A can be diverted to the bypass 166 via the second passage 172, and the second exhaust portion from the second scroll 59B can be diverted to the bypass 166 via the first passage 170. When the wastegate valve is adjusted to the open position, the first exhaust portion and the second exhaust portion can be directed to the catalyst 72 placed downstream of the wastegate 127A without impinging on the sidewalls of the bypass. By directing the exhaust flow to the catalyst without the exhaust fanning out to the sidewalls of the bypass, exhaust energy losses can be reduced or minimized while accelerating catalyst light-off during engine operation.

[0052] As described above, the exhaust manifold can be designed to separately direct exhaust gas to different scrolls of turbine 92. For example, exhaust from a first group of cylinders can be directed to first scroll 59A (or a first exhaust passage directly coupled to the first scroll of the turbine) via first exhaust manifold 54A. Exhaust from a second group of cylinders can be directed to second scroll 59B (or a second exhaust passage directly coupled to the second scroll) via second exhaust manifold 54B.

[0053] Exhaust gas exiting turbine 92 may also pass through catalyst 72. In one example, catalyst 72 may include multiple catalyst bricks. In another example, multiple catalysts may be used, each catalyst having multiple catalyst bricks. In some examples, catalyst 72 may be a three-way catalyst. In other examples, catalyst 72 may include one or more of a diesel oxidation catalyst (DOC) and a selective catalytic reduction catalyst (SCR). After passing through catalyst 72, the exhaust gas may be directed out to tail pipe 58.

[0054] In this manner, twin scroll turbine 92 may receive exhaust gas from a first subset of cylinders via a first scroll and exhaust gas from a second subset of cylinders via a second scroll. Figure 4A-4E and Figures 10A-10E To explain further, the wastegate valve 127A may be fluidly coupled to each of the two scrolls and may be adapted to maintain exhaust flow in the two scrolls separate when the wastegate valve is in a closed position.

[0055] For example, in Figure 1 , fuel injectors are shown coupled directly to the combustion chambers for injecting fuel directly into the combustion chambers in proportion to the pulse width of signal FPW received from controller 12 via an electronic driver. Each cylinder 20-23 is shown coupled with two injectors 74 and 76 per cylinder at each intake valve. In this manner, the fuel injectors provide what is referred to as direct injection of fuel into the combustion chambers. For example, each respective fuel injector may be mounted on the side of a respective combustion chamber, or at the top of a respective combustion chamber. In some examples, one or more injectors may be arranged in intake manifold 27 in a configuration that provides what is referred to as port injection of fuel into the intake port upstream of the respective combustion chamber. Although Figure 1 Fuel may be delivered to the fuel injectors via a fuel system including a fuel tank, a fuel pump, a fuel line, and a fuel rail, not shown, but in some examples, a distributorless ignition system (not shown) may provide an ignition spark to a spark plug (not shown) coupled to cylinder 20 in response to controller 12.

[0056] The engine 10 may be controlled at least in part by a control system 15 including a controller 12 and by input from a vehicle operator via an input device (e.g., an accelerator pedal input). The control system 15 is shown receiving information from a plurality of sensors 16 (various examples of which are described herein) and sending control signals to a plurality of actuators 81. As an example, the sensors 16 may include an actuator coupled to a wastegate 127A, a turbine compressor inlet pressure and temperature sensor, and a manifold air pressure (MAP) sensor located in the intake passage. Other sensors may include a throttle inlet pressure (TIP) sensor for estimating throttle inlet pressure (TIP), and / or a throttle inlet temperature sensor coupled downstream of the throttle in the intake passage for estimating throttle air temperature (TCT). Reference is made below to the control system 15 for information about the control system 15 and the actuator 81. Figure 2A-2B Additional system sensors and actuators are detailed. As another example, actuators 81 may include fuel injectors and throttle 62. Controller 12 may receive input data from various sensors, process the input data, and trigger actuators in response to the processed input data based on instructions or code programmed therein corresponding to one or more routines.

[0057] In this way, Figure 1The system may include: a turbocharger including a bypass channel arranged around a turbine of the turbocharger; a catalyst positioned downstream of the turbine and the bypass channel; a wastegate positioned in the bypass channel, the wastegate comprising: a wastegate channel coupled in the bypass channel, at an end of the wastegate channel, the wastegate channel including a contraction segment and a lip formed downstream of the contraction segment; a valve plate positioned at the end of the wastegate channel downstream of the lip, the valve plate including a multi-planar curved surface on an interior of the valve plate, the curved surface forming a raised edge on a first side of the valve plate, and forming a side opening on a second side of the valve plate, wherein the contraction segment is aligned on the same side of the wastegate channel as the first side of the valve plate. By providing the multi-planar curved surface in the wastegate valve plate and providing the contraction segment in the wastegate channel, the exhaust flow can be directed to the exhaust catalyst downstream in the bypass channel without impinging on the sidewall of the bypass channel to minimize exhaust energy loss while accelerating catalyst light-off.

[0058] refer to Figure 2A , discloses an internal combustion engine (such as a Figure 1 2 is a three-dimensional view of an example turbocharger 200 of an engine 10 shown in FIG. 2 . The turbocharger 200 includes a compressor housing 202, a center housing 208 coupled to the compressor housing, and a turbine housing 216 having a main opening 240. As indicated by arrow 206, the compressor housing 202 may contain a compressor that compresses air and delivers it to the engine via an air flow conduit 204. When the wastegate valve 220 is adjusted to an open position, a bypass passage (not shown) configured with the wastegate valve 220 may be fluidly coupled to the main opening 240.

[0059] like Figure 2A As shown, exhaust gas flow from the engine may enter the turbine housing 216 via passage 205, as indicated by arrow 244. Passage 205 may be coupled to a plurality of engine cylinders (such as Figure 1 of the cylinder 20) of the exhaust manifold (such as Figure 1The turbine housing 216 may be provided with an exhaust passage 59 to allow exhaust gas from the engine to enter the turbine. A plurality of slots 219 formed on an inlet flange 218 attached to a base area of ​​the turbine housing 216 may receive bolts or suitable fasteners to securely attach the turbine housing 216 to an exhaust manifold connected to the engine. At its upstream end, the turbine housing 216 may be connected to the compressor housing 202 via a center housing 208. In this example, the turbine housing 216 is mounted to the center housing 208 by a V-band clamp assembly 212. The outlet 203 in the center housing 208 leads to a main opening 240 having an inner wall 213 of the turbine housing 216. A flange 214 formed on the outlet end 242 of the turbine housing 216 may be coupled to an exhaust conduit to deliver exhaust gas from the main opening 240 to an exhaust catalyst (e.g., Figure 1 The flange 214 is securely fastened to the exhaust conduit using bolts or suitable fasteners that are inserted into slots 215 formed on the flange so that the main opening 240 is fluidly coupled to the exhaust conduit. In this case, for example, exhaust gas flow from the turbine housing 216 can be conveyed through the main opening 240, where the exhaust gas flows further downstream to the exhaust catalyst.

[0060] Exhaust flow delivered from the engine to the turbine housing 216 enters the turbine through the passage 205 on the inlet flange 218 and the bypass passage (not shown), as indicated by arrow 244. A wastegate 220 mounted to the bypass passage (not shown) may be provided to control the flow of exhaust gas from the bypass passage into the main opening 240, where the exhaust gas is further delivered to the exhaust catalyst along the flow direction 246. The wastegate 220 may include an extendable arm 222 having one end fixed to a valve plate 223 of the wastegate 220 and the other end coupled to a first arm 224 of a valve actuation mechanism 225 at a joint position 227. As an example, the extendable arm 222 may be an L-shaped arm extended to connect with the first arm 224, which is coupled to the second arm 226 at an extendable joint 233.

[0061] The valve actuation mechanism 225 can be coupled to the plunger mechanism 228 by firmly fastening the distal end of the second arm 226 to the annular tube 230 of the plunger. As shown, the plunger mechanism 228 is installed in the orifice 235 formed by the integral bracket 234, which is attached to the compressor housing 202 and has a plurality of cylindrical elements 236 and annular cylinders 237. As an example, the cylindrical elements 236 and the annular cylinders 237 can provide additional structural integrity for the integral bracket 234. The plunger mechanism 228 is coupled to the electric motor 232, which can provide electrical power to operate the valve actuation mechanism 225. As an example, the valve actuator is controlled to open the wastegate to allow excess air to bypass the turbine to generate the required power to increase the compressor boost pressure under a given engine operating condition. In other examples, the valve actuation mechanism 225 can be mechanically, hydraulically or electrically controlled to open and close the wastegate valve during engine operation. In further examples, a combination of mechanical, hydraulic, and electrical methods may be employed to actuate the wastegate valve during engine operation.

[0062] The wastegate valve can be actuated to fully open in the direction 246 of the exhaust flow, thereby allowing exhaust gas from the engine to be delivered via the turbine passage 205 to the main opening 240, where the exhaust gas further flows to the exhaust catalyst. The wastegate valve can be configured with a flow configuration (such as a curved inner wall and side openings in the valve plate 223) that can work with a contraction segment in the wastegate passage to direct the exhaust flow more directly to the exhaust catalyst rather than the side walls of the main opening 240 of the turbine housing 216. In this way, the wastegate valve can reduce exhaust energy losses caused by exhaust gas impinging on the walls of the main opening 240 of the turbine housing 216. Therefore, catalyst ignition can be accelerated during engine operation while minimizing fuel emissions. The following reference Figure 2B-Figure 4B Details of the curved inner wall on the wastegate valve and the constricted section in the wastegate passage are further disclosed.

[0063] Go to Figure 2B , a schematic diagram 250 of a first embodiment of a wastegate valve 251 and a valve actuation mechanism 252 is shown. The wastegate valve 251 includes a valve plate 270, which includes a raised edge 276, a first mating feature 278, side openings 259A-259B, and an annular portion 268. The valve actuation mechanism 254 includes a shaft portion 253 connected to an arm portion 255. The first mating feature 278 is located at a position adjacent to the valve actuation mechanism 254. Figure 2B Depicted as ribs (similar to Figures 4A-4E However, in alternative embodiments, the first mating feature 278 may instead be a groove (such as a Figures 10A-10E , as further described below).

[0064] As shown, a raised edge 276 on the valve plate 270 can be formed on a top circular surface 271 having a side surface 272 connected to the stepped annular cylinder 268 and a downwardly extending portion 273. As an example, the raised edge 276 can be formed on the top circular surface 271 and partially surround the inner wall 265. For example, when the wastegate is open, the raised edge 276 can be configured with a multi-planar curved surface 274 forming a portion of the inner wall 277 and side openings 257A and 257B to guide the exhaust flow in a first direction 275. The first mating feature 278 can be centered along the multi-planar curved surface 274, thereby dividing the opening on the curved surface into the side openings 257A and 257B. For example, the first mating feature 278 can be a rib extending outward from the inner wall 265 and the inner wall 277 to divide the raised edge 276 into a first segment and a second segment. The annular portion 268 is coupled to a side portion (e.g., an articulated joint) 266 of the arm portion 255. The arm portion 255 is coupled to the shaft portion 253 so that it rotates about the axis of the shaft. There may be a joint between the arm portion 255 and the wastegate valve 251 to allow some articulation of the valve so that the surface (e.g., seating surface) 271 can seal against a mating portion on the turbocharger under all conditions.

[0065] The wastegate valve 251 can be mounted to a wastegate passage (not shown) to control the exhaust flow from the passage to the exhaust catalyst placed downstream of the wastegate. The wastegate passage can be bifurcated by a central wall that cooperates with a first mating feature 278 on a curved surface 274 of the valve plate 270. In this case, the central wall in the wastegate passage divides the passage into a first side and a second side, wherein the first side is fluidly coupled to the side opening 257A and the second side is fluidly coupled to the side opening 257B. In this way, the first exhaust portion in the first side of the wastegate passage flows to the wastegate valve without mixing with the second exhaust portion flowing on the second side of the passage. When in the open wastegate position, the exhaust flow through the wastegate passage can be directed out of the passage toward the exhaust catalyst via the side openings 257A and 257B in a direction 275. As an example, the first exhaust portion in the first side of the wastegate passage can flow toward the valve plate and be discharged via the side opening 257A. The second exhaust portion on the second side of the passage can flow toward the valve plate and be discharged via the side opening 257B. The flow configurations on the wastegate valve 251 including the multi-planar curved surface 274 and the side openings 257A and 257B can work together to direct the exhaust flow downstream to the exhaust catalyst while minimizing exhaust energy losses due to the exhaust flow impinging on the walls of the wastegate passage. Although not shown, the wastegate passage can also be configured with a constricted section upstream of the wastegate valve to direct the exhaust flow to the exhaust catalyst downstream of the wastegate. Figure 4A-4CDetails of the flow configuration on the wastegate valve 251 and the flow configuration of the constricted section in the wastegate passage are further disclosed. For example, the wastegate valve 251, the actuation mechanism 252 and the wastegate passage may be composed of stainless steel or cast iron.

[0066] In this way, a multi-planar curved surface and side openings may be provided on the wastegate valve to more directly deliver the exhaust flow to the exhaust catalyst. As an example, a constricted section in the wastegate passage may work with a curved surface on the valve plate to direct the exhaust flow downstream to the exhaust catalyst, thereby allowing for faster catalyst light-off.

[0067] Go to Figure 3A and Figure 3B , a cross-sectional view of a wastegate 301 including a valve plate 303 and a wastegate passage 310 is disclosed. Figure 3A A first view 300 of a wastegate passage 310 with a closed wastegate valve is shown. The wastegate passage 310 includes a converging section 314 formed on a first inner wall 315 of the passage. In one embodiment, the wastegate passage 310 may be coupled to a twin-scroll turbine such as Figure 1 The first scroll of the turbine 92 shown in FIG. Figure 1 The first scroll 59A in the embodiment and the second scroll (eg, Figure 1 The bifurcated passage (eg, Figure 1 A portion of channels 170 and 172) is shown in FIG. Figure 3C An alternative embodiment 304 of a wastegate passage 310 is shown in FIG. 3 , wherein no constriction segments are formed on the first inner wall 315 and the second inner wall 317 of the passage. Figure 3A-3C The cross-sectional view shown is rotated so that the mating feature 278 (which is Figure 3A-3C The example is shown as a rib and will be referred to below Figure 4A-4E Detailed description) and the dividing wall of the wastegate passage 310 are located in the plane of the page. Figure 4C As further explained, wastegate passage 310 is divided into two passages via a dividing wall, and the combination of the dividing wall and mating feature 278 prevents flow communication between the two passages when the valve is closed.

[0068] like Figure 3A and Figure 3B As shown, wastegate passage 310 may be configured to have a first diameter 326 at contraction segment 314 and a second diameter 328 upstream of contraction segment 314, wherein first diameter 326 may be smaller than second diameter 328. Further, a portion of wastegate passage 310 downstream of contraction segment 314 and upstream of valve plate 303 may have second diameter 328. Figure 3BA second view 302 of the wastegate passage 310 is shown, wherein the wastegate valve is adjusted to an open position. In each of the first view and the second view, the second inner wall 317 of each wastegate passage does not have a constricted segment. In this manner, the constricted segment 314 may be on only a single side of the wastegate passage 310 relative to the central axis 330 of the wastegate passage 310. The valve plate 303 and the wastegate passage 310 may be included as a bypass passage around the turbine (e.g., such as described above with reference to Figure 1 A portion of the disclosed bypass channel 166).

[0069] The valve plate 303 may include an annular portion 313 formed on the top cylindrical portion 307 (which may be coupled to the Figure 2B 306 is a valve plate 303 that is configured to fit within an outlet 309 of a wastegate passage. When closed, a base 308 of the raised edge is located adjacent to a constricted segment 314 formed on a first inner wall 315 of the wastegate passage 310. The base 308 of the raised edge 306 may be located a distance 329 from a lip 335 of the constricted segment 314. The mating feature 278 is shown in the form of a rib and is flush with the base 308. When installed within the wastegate passage 310, the raised edge 306 of the valve plate 303 may be adjacent to or in coplanar contact with a lip surface 332 of the passage 310. For example, the constricted segment 314 formed in the wastegate passage 310 may be located upstream of the raised edge 306. The lip surface 332 of the wastegate passage 310 can be a portion of the passage, positioned downstream of the contraction segment 314, with the raised edge 306 of the valve plate 303 located within the contraction segment 314 when in the closed position. As an example, the lip surface 332 of the wastegate passage 310 can have a length 336. In this case, the lip surface 332 in the wastegate passage 310 can extend from the wastegate outlet 309 to the lip edge 335. In other examples, the lip surface 332 is an inner wall of the wastegate passage 310 that forms the lip, and the lip edge 335 is a portion of the wall that forms the contraction segment 314.

[0070] As indicated by arrow 327, a curved surface (e.g., a multi-planar curved surface) 305 on the valve plate 303 can form a raised edge 306 and a side opening 322 to direct the exhaust flow in a first direction. As an example, the curved surface 305 can work with a contraction segment 314 in the passage 310 to direct the exhaust flow directly to the exhaust catalyst downstream of the valve plate 303. The raised edge 306 of the valve plate 303 can have a length 334. In one example, based on the position of the contraction segment 314 on the first inner wall 315 of the wastegate passage 310, the length 334 of the raised edge 306 can be selected to have a first length. In a further example, the length 334 of the raised edge 306 can be specific to the geometry of the wastegate passage 310 and the amount of flow diversion required to direct the exhaust flow to the catalyst surface.

[0071] In addition, the top cylindrical portion 307 of the valve plate 303 may have an extended surface 311 that forms a lower portion of the top cylindrical portion that may be connected to the raised edge. When closed, the extended surface 311 of the valve plate 303 may contact (or coplanarly contact) the top surface 312 at the outlet of the wastegate passage 310. Figure 3B As shown, exhaust gas flow from the engine may be turned into the wastegate passage 310 at the passage inlet 316 as shown by direction 320. When the valve plate 303 is open, the exhaust gas flows through the wastegate passage 310 and increases in velocity as it approaches the contraction segment 314 and flows through the side opening 322 in the valve plate 303 before exiting the passage at the passage outlet 314. As an example, the contraction segment 314 may be positioned only on a first side of the wastegate passage and not on a second side of the passage, where the second side of the passage is opposite the first side of the passage relative to the central axis 330 of the passage. Figure 3A-3B The wastegate valve is shown pivoting (when moved by the actuator arm, as shown in FIG. Figure 2B 340 about which the valve body 200 is provided. As seen in these figures, the side opening 322 is on the side of the valve opposite the pivot point 340.

[0072] In another example, a contracting segment 314 including a raised circumferential surface can be positioned on the first inner wall 315 to contract the flow upstream of the valve plate 303. In one example, the distance 329 can be selected so that the contracting segment 314 is positioned at a first distance from the base 308 of the raised edge 306 of the valve plate 303. In other examples, the distance 329 can be selected to be a second distance, wherein the second distance is greater than the first distance. In a further example, the contracting segment 314 can be selected to have a first diameter that is less than a second diameter of the wastegate passage to accelerate the flow in the wastegate passage when the wastegate is opened. In one example, the first diameter can be the contracting segment diameter, and the second diameter can be the passage diameter. The contracting segment diameter can be selected to be less than the passage diameter so as to increase the exhaust flow velocity at the passage outlet while minimizing turbulent conditions. Further, the contracting segment diameter can be selected so that the exhaust flow is directed toward the side of the wastegate including the curved surface 305 and the side opening 322. As Figure 3A and Figure 3B As shown, the contraction segment 314 can be angled inwardly toward the central axis 330 and then suddenly diverge outwardly back toward the first inner wall 315 of the wastegate passage 310. However, in alternative embodiments, the contraction segment 314 can be more pronounced, or gradually angled inwardly and then back outwardly. As an example, the contraction segment 314 can be configured with a circular or elliptical shape having different angles or radii of curvature. As shown, the shape of the contraction segment 314 provides a means for directing the exhaust flow toward the passage outlet 309, as shown by arrow 325. Further, the contraction segment 314 can work with the curved surface 305 on the valve plate to direct the exhaust flow through the side opening 322, as shown by arrow 327.

[0073] In the case where no contraction section is formed on the first inner wall and the second inner wall of the wastegate passage, a portion of the exhaust gas can flow downstream, while the remaining portion of the exhaust gas flows downstream. Figure 3C As shown, the exhaust gas may be turned in direction 324 before being delivered downstream. When turned in direction 324, the exhaust gas may impinge on the passage walls (not shown) downstream of the wastegate before flowing downstream to the exhaust catalyst. In this case, the exhaust gas may lose a significant amount of energy (due to energy transferred to the passage walls by conduction) before reaching the exhaust catalyst, thereby delaying catalyst light-off.

[0074] Return to Figure 3A and Figure 3B, the contraction segment 314 is formed on the first side of the wastegate passage 4310 relative to the central axis 330. The raised edge 306 is formed on the first side of the valve plate 303, wherein the valve plate 303 and the first side of the wastegate passage 310 are aligned with each other. Further, the contraction segment 314 is bent inwardly toward the central axis 330, and the curved surface 305 is bent inwardly toward the central axis 330, and the second side of the valve plate 303 is bent in the direction of the exhaust gas flow through the wastegate passage 310. In this way, the contraction segment 314 formed on the first inner wall 315 of the wastegate passage 310 can work together with the curved surface 305 on the wastegate valve plate 303 to guide the exhaust gas flow downstream to the exhaust catalyst, thereby allowing the catalyst to be lighted off faster while reducing fuel emissions.

[0075] Figure 4A-4E A bypass passage such as a Figure 1 Schematic diagram of a third embodiment of a wastegate in a bypass passage 166 and a turbine 92 as shown, wherein the wastegate includes a valve plate and a wastegate passage. In the third embodiment, the wastegate passage may be bifurcated and adapted to cooperate with a matching feature of the valve plate. First, refer to Figure 4A and Figure 4B , schematic diagrams 400 and 402 of a third embodiment of a wastegate valve are disclosed. A valve plate 410 includes an annular portion 412, a base 414, a raised edge 416, a side opening 420, and a rib 422. An annular element 418 formed on the outer surface of the annular portion 412 may provide a means for coupling the valve plate 410 to an actuator (not shown). The annular portion 412 may be connected to the raised edge 416 via the base 414 to form a single integral valve plate. The side opening 420 may be formed on one end of the raised edge 416 between a side edge 424 of the raised edge 416 of the valve plate 410 and an outer edge 426 of an inner surface 428. Although not shown, when the valve plate 410 is adjusted to an open valve position, the inner surface 428 may form a curved surface (e.g., a multi-planar curved surface) on the valve plate 410 that guides exhaust gas in a particular direction.

[0076] The rib 422 formed on the central portion of the raised edge 416 of the valve plate 410 relative to the central axis 409 of the valve plate 410 divides the raised edge 416 into a first segment 429 and a second segment 430, as shown in FIG. Figure 4A As shown. The raised edge 416 can further include a lip 432 and an inner wall 434 extending to the first segment 429 and the second segment 430 of the valve plate 410. For example, the rib 422 can extend outward and away from the inner surface 428 of the valve plate. In another example, the rib 422 can extend toward the lip 432 of the raised edge 416. Figure 4AAs shown, the end of the rib 422 (which is away from the inner surface 428) is arranged to be flush with the outer edge of the raised edge 416. Figure 4B As shown, the rib 422 of the valve plate 410 may include an inner surface 436 , a mating surface 438 , and an outer surface 440 .

[0077] refer to Figure 4C , a cross-sectional view 404 of a third embodiment of a wastegate valve is disclosed. The wastegate valve includes a valve plate 410 coupled to a wastegate passage 452 . Figure 4C A simplified version of the valve plate 410 may be shown, which includes a base 414, a raised edge 416, a side opening 420, and a rib 422. As described above, the rib 422 of the valve plate 410 may divide the raised edge 416 into a first segment 429 and a second segment 430. In this case, the rib 422 extends from the inner surface 428 to the lip 432 of the raised edge 416. The base 414 may be connected to the raised edge 416 to form a single integral valve plate. The inner surface 461 on the raised edge 458 may form a curved surface (e.g., a multi-planar curved surface) on the valve plate 410. The wastegate passage 452 includes a lip surface 472 formed at a junction between a first inner wall 474 and a second inner wall 475 of the wastegate passage 452. A central wall 476 formed in a central portion of the wastegate passage 452 divides the wastegate passage into a first side 478 and a second side 480. Further, the mating portion 479 of the central wall 476 is arranged flush with the lip surface 472 .

[0078] When the valve plate 410 is adjusted to the closed position, Figure 4C As shown, the mating surface 477 of the rib 422 can be in coplanar contact with the mating portion 479 of the central wall 476 formed in the wastegate passage 452. When in the closed wastegate position, the valve plate 410 is disposed in the opening 468 in the wastegate passage 452. The rib 422 on the valve plate 410 and the central wall 476 of the wastegate passage 452 separate the exhaust flow in the first side and the second side of the passage. For example, a first exhaust portion on the first side 478 of the passage can flow toward the first segment 429 of the valve plate 410 without mixing with a second exhaust portion on the second side 480 of the passage flowing toward the second segment 430 of the valve plate 410. In this way, the rib 422 of the valve plate 410 and the central wall 476 of the wastegate passage 452 can stop or minimize flow interaction between the first exhaust portion and the second exhaust portion on the first segment 478 and the second segment 480 of the wastegate passage.

[0079] When the valve plate 450 is adjusted to the open valve position, the mating surface 477 of the rib 422 can be disengaged from the mating portion 479 of the central wall 476, thereby allowing the curved surface of the valve plate 410 to direct the exhaust flow to the exhaust catalyst downstream of the wastegate. As an example, the first exhaust portion in the first segment 429 of the valve plate 410 and the second exhaust portion in the second segment 430 of the valve plate 410 can both be directed to the exhaust catalyst by the curved surface of the valve plate 410 without impinging on the sidewalls of the wastegate passage, thereby minimizing exhaust energy loss and accelerating catalyst light-off. Figure 4D and Figure 4E Further details of the ribs 422 on the valve plate 410 and the central wall 476 of the wastegate passage 452 are disclosed.

[0080] refer to Figure 4D , a cross-sectional view 406 of a third embodiment of a wastegate valve plate 410 is disclosed. The rib 422 of the valve plate 410 includes a linear portion 482 and a curved portion 484. The linear portion 482 is connected to an intermediate segment of the curved portion 484, thereby forming a single continuous component connected to the base 414. As an example, the linear portion 482 of the rib 422 can be connected to the curved portion 484 at a junction having a first curved segment 488 and a second curved segment 490. The curved portion 484 can include a terminal end 486 that extends partially around an inner portion of the base 414. For example, the linear portion 482 of the rib 422 can divide the valve plate 410 into a first segment 429 and a second segment 430. The linear portion 482 of the rib 422 can have a height 491 and a width 492. As an example, the height 491 of the linear portion 482 of the rib 422 may vary from minimal bifurcation to full bifurcation of the wastegate inlet, and the width 492 of the linear portion 482 may vary from minimal thickness to equal to or less than the thickness of the central wall 476 .

[0081] When valve plate 410 is coupled to a wastegate passage (eg, Figure 4C 452), the first segment 429 of the valve plate 410 can be aligned with the first side 478 of the wastegate passage 452, and the second segment 430 of the valve plate can be aligned with the second side 480 of the wastegate passage 452. In this way, the rib 422 can be aligned with the central wall of the wastegate passage (e.g., Figure 4C 476 ) shown in FIG. 4A and 47B act together to separate the exhaust flow in the first side 478 and the second side 480 of the wastegate passage 452 .

[0082] refer to Figure 4E, discloses a cross-sectional view 408 of a wastegate passage 452. A central wall 476 of the wastegate passage 452 may be connected to a first portion 494 and a second portion 495 of the inner wall of the passage, thereby dividing the passage into a first side 478 and a second side 480. The central wall 476 of the wastegate passage 452 may have a height 496 and a width 498. As an example, the height 496 is sized such that the areas of the first side 478 and the second side 480 are sized such that maximum wastegate flow can pass through the passage depending on engine operation.

[0083] Go to Figure 5A-5C , depicts a schematic diagram of a fourth embodiment of a wastegate valve plate 501 . Figure 5A A first view 500 of a wastegate valve plate 501 is shown. Figure 5B A second view 502 of a wastegate valve plate 501 is shown. The valve plate in the first and second views is shown with a front end 503 and a rear end 521 visible. Figure 5C A third view 504 of the wastegate valve plate 501 is shown from the side of the valve plate 501 .

[0084] like Figure 5A-5C As shown, the wastegate valve plate 501 includes an inner circular surface 512 and a circular portion 510 formed circumferentially around an outer portion of the valve plate. The valve plate 501 may include a curved surface (e.g., a multi-planar curved surface) 513 forming a raised edge 505 on a first side 532 of the valve plate 501, and a side opening 506 on a second side 533 of the valve plate 501. When mounted to a wastegate passage (such as Figure 3A and Figure 3B 4) and the wastegate valve is in the closed position, the inner circular surface 512 and the curved surface 513 on the valve plate 501 face the interior of the wastegate passage. The raised edge 505 may include a sidewall 514 and a curved edge 516. The sidewall 514 emerges (e.g., extends outwardly) from the inner circular surface 512 to the outer edge of the raised edge 505. As an example, the raised edge 505 may have a length 525, which is similar to Figure 3A4. The length 434 of the raised edge 406 shown in FIG. The curved surface 513 gradually tapers from the raised edge 505 to a deep portion 520 that forms a portion of the side opening 506. As an example, the raised edge 505 can be in a semicircular shape, wherein the side opening 506 is formed opposite the raised edge 505 to guide the exhaust flow in a first direction, as shown by arrow 515. In another example, the raised edge 505 of the valve plate 501 can be arranged in other suitable geometric configurations. In other examples, the side opening 506 can be formed on a second side 533 of the valve plate opposite the first side 532 of the valve plate 501, which includes most of the raised edge 505. As an example, most of the raised edge 505 can be located below the first axis 540 of the valve plate, while the second axis 550 divides the valve plate into two symmetrical parts. The side opening 506 on the curved surface 513 can deliver the exhaust flow to an exhaust catalyst placed downstream of the valve plate 501. As an example, the size of the side opening 506 can be set to allow sufficient exhaust flow through the valve outlet to accelerate catalyst ignition. The curved edge 516 may terminate at the opposite end of the raised edge 505 to form a curved segment 523 that tapers gradually into the side opening 506. The curved surface 513 curves in multiple directions between the sidewalls 514 of the raised edge 505 to form a multi-planar curved surface that directs the exhaust flow in a first direction, as indicated by arrows 515.

[0085] The valve arm 507 having a flat surface 509 and a side edge 511 can be attached to a cylindrical member 517 formed on a circular member 519 that is mounted to a rear surface 522 of the valve plate. As an example, a proximal portion 526 of the valve arm 507 can be attached to the valve plate 501, while a distal portion 527 of the valve arm 507 can be connected to an actuation mechanism (such as a valve body) in a direction 530. Figure 2A The mechanism 225 shown in FIG. 225 is used to install the wastegate passage (such as Figure 3A and Figure 3B The valve plate is opened and closed when the wastegate passage 410 shown in FIG. 4 is controlled. In one example, the actuation mechanism that controls the valve plate can be operated using various methods including mechanical, hydraulic, or electrical, but other suitable actuation methods can also be used. In this way, the valve plate can be adjusted to open using the actuation mechanism attached to the distal end of the plate, thereby directing the exhaust flow from the wastegate passage to the catalyst placed downstream of the valve plate.

[0086] Although not shown, the valve plate 501 may also include a first mating feature in the form of a rib or groove formed in a central portion of the valve plate. For example, the first mating feature on the valve plate 501 may be a rib (such as a groove) extending outwardly and away from the base portion of the valve plate. Figure 4C In this example, the ribs may divide the interior portion of the valve plate into a wastegate passage (e.g., Figure 4C 452) shown in the first segment (eg, Figure 4C 429) and a second segment (eg, Figure 4C When valve plate 501 is coupled to a wastegate passage, the ribs on the valve plate can cooperate with the central wall in the wastegate passage to separate the passage into a first flow side of the wastegate passage (e.g., Figure 4C 478 shown in FIG. 4 and a second flow side (eg, Figure 4C In one example, the first segment and the second segment of the valve plate 501 can be fluidly coupled to the first flow side and the second flow side of the wastegate passage, respectively.

[0087] In another example, the recess on the valve plate 501 can be sized to receive a central wall of a wastegate passage coupled to the valve plate, thereby dividing the wastegate passage into a first flow side and a second flow side. The first flow side can be coupled to a turbine (e.g., Figure 1 The first scroll of the turbine 72 shown in FIG. Figure 1 55A in the turbine, and the second flow side can be coupled to a second scroll of the turbine (e.g., scroll 55B). In this way, the exhaust flows in the first scroll and the second scroll can flow in separate flow sides of the wastegate passage (towards downstream of the wastegate valve) without mixing. After reaching the wastegate valve, the exhaust flows can remain separated until the valve plate 501 is adjusted to an open position that allows the exhaust in the wastegate passage to flow downstream to the catalyst. The curved surface on the valve plate can direct the exhaust flow directly downstream to the catalyst without impinging on the side walls of the passage, thereby minimizing exhaust energy losses and accelerating catalyst ignition.

[0088] Go to Figure 6A-6B , discloses a schematic diagram showing a Figures 5A-5C A fourth embodiment of a wastegate (eg, a wastegate valve) of a valve plate 501 and a valve arm 507 of an actuating mechanism and a wastegate passage 604 is provided. Fig. 6A A first view 600 of a fourth embodiment of a wastegate valve is shown in a closed position. Figure 6B A second view 602 of the fourth embodiment of the wastegate valve is shown in a closed position. In each of the first and second views, the valve plate 501 includes a first mating feature 606 in the form of a rib and a first mating feature 606 in the form of a rib ... Figures 5A-5C636 and 638. Exhaust flow from the engine (shown by flow direction 601) enters a main opening 614 formed in an interior region of the wastegate passage 604 at an upstream end 607 of the passage. Exhaust flow from the upstream end 607 can flow through a first opening 614A and a second opening 614B of the wastegate passage 604 to a downstream end 608 of the wastegate. A central wall 615 formed in the wastegate passage 604 divides the passage into a first side 636 and a second side 638.

[0089] The valve plate 501 can be mounted at the downstream end 608 of the wastegate passage 604. When the valve plate 501 is closed, the inner circular surface 512 of the valve plate abuts (e.g., coplanar contact) the inner segment 620 of the wastegate passage 604 and tightly seals the passage. In the closed wastegate position, the raised edge 505 is disposed within the first opening 614A and the second opening 614B at the downstream end 608 of the wastegate, wherein the side openings 506 are formed on opposite ends of the raised edge closed by the passage wall. The wastegate passage 604 is divided into a first side 636 and a second side 638 so that the first side 636 can be connected to the turbine ( Figure 1 The first scroll of the turbine 72 shown (eg, Figure 1 Scroll 55A shown), and the second side 638 can be connected to a second scroll of the turbine (e.g., Figure 1 Scroll 55B shown). In this case, the first exhaust portion from the first scroll can flow into the first side 636 of the wastegate passage 604 via the first opening 614A, and the second exhaust portion from the second scroll can flow into the second side 638 of the wastegate passage 604 via the second opening 614B of the passage. In this way, the first mating feature (e.g., rib) 606 of the valve plate 501 and the central wall 615 of the wastegate passage 604 can minimize flow interaction between the first exhaust portion and the second exhaust portion on the first side 636 and the second side 638 of the wastegate passage.

[0090] As referenced below Figure 7A-7B Further disclosed, when the valve plate 501 is adjusted to the open position, the curved surface 513 forming the side opening 506 can direct the exhaust flow through the outlet of the wastegate passage. In one example, when the valve plate 501 is adjusted to the open position, the side opening 506 can have a diameter 650 that is sized to accelerate the exhaust flow through the outlet of the wastegate passage 604. In other examples, the diameter 650 of the side opening 506 can be equal to or greater than the diameter 652 of the wastegate passage 604. In a further example, the valve plate 501 can be adjusted to close so that the base of the valve plate 501 covers the opening at the end of the passage, and the inner side of the base abuts the end of the passage.

[0091] Further, the curved surface 513 forming the raised edge 505 and the side opening 506 may be configured to have an inclined concave surface (eg, Figure 5A-5C 506 and the raised edge 505. For example, the curved surface 513 may bend toward the side opening 506 to direct the exhaust gas flow toward the exhaust catalyst, as described below with reference to Figure 7A-7B Further shown.

[0092] like Fig. 6A As shown, a first gap 616 and a second gap 617 can be formed between the side wall 514 of the raised edge 505 and the lip 613 on the first inner wall 609 of the wastegate passage 604. Each of the first gap and the second gap can be sized to allow easy opening and closing of the valve plate 501 without rubbing against the inner wall of the wastegate passage. The raised edge 505 can be sized to have a length 622 that minimizes turbulent exhaust flow conditions at the wastegate outlet. Figure 6B As shown, based on the location of the contraction segment 612 formed between the first inner wall 609 of the wastegate passage and the lip surface 610, and / or based on the desired curvature angle of the curved surface 513, the length 622 of the raised edge 505 can have a first length (e.g., the length 622 can be increased to provide a large curvature angle for the curved surface 513). In other examples, the length 622 of the raised edge 505 can be selected to have a second length, wherein the second length can be greater than the first length. In further examples, the length 622 can be specific to the geometry of the wastegate passage 604 and the amount of flow diversion required to direct the exhaust gas flow toward the exhaust catalyst.

[0093] For example, the raised edge 505 can be positioned at a distance 618 from the constricted segment 612. In one example, the distance 618 can be reduced such that the raised edge 505 is in coplanar contact with or adjacent to an edge of the constricted segment 612.

[0094] like Figure 6A-6BAs shown, the contraction segment 612 is formed at the junction between the first inner wall 609 of the wastegate passage and the lip surface 610. As an example, the contraction segment 612 can be formed only on the first side 644 of the wastegate passage relative to the central axis 603 of the passage, and the first side 644 is the same side as the first side 624 of the valve plate. The contraction segment 612 has a height 627 that can be less than a threshold height. As an example, the threshold height can be the height of the contraction segment that minimizes turbulent flow conditions at the passage outlet. The height 627 of the contraction segment 612 and its distance 618 from the valve plate 501 can be selected to produce an exhaust flow rate from a minimum required wastegate flow rate to a maximum required wastegate flow rate at the passage outlet. The range of exhaust flow at the passage outlet can vary depending on the type of engine, the type of turbocharger installed to the engine, and the number of turbochargers.

[0095] The valve arm 507 mounted on the rear surface 522 of the valve plate 501 can be coupled to an actuation mechanism, as shown in the direction 530. The actuation mechanism can be adjusted to open the valve plate 501, thereby allowing exhaust gas to flow through the passage outlet to the exhaust catalyst downstream of the valve plate 501. For example, the actuation mechanism can be controlled by various methods including hydraulic, mechanical or electrical. Figure 7A-7B Further disclosed is an example of a valve plate 501 shown in an open position.

[0096] Now go to Figure 6C , discloses a schematic diagram 605 showing an alternative embodiment of a wastegate (e.g., a wastegate valve) including a valve plate 501, a valve arm 507 of an actuating mechanism, and a wastegate passage 604. The valve plate 501 mounted to the downstream end 608 of the wastegate passage 604 may include a first mating feature 606 forming a raised edge 505 and a curved surface 513 of a side opening 506. The first mating feature may be a rib formed on the curved surface 513. The raised edge 505 includes a sidewall 514, a curved edge 516, and a curved segment 523 that tapers into the side opening 506 of the valve plate 501. In this example, the valve plate 501 is mounted to the downstream end 608 of the wastegate passage 604. Figures 5A-6B The length 622 of the raised edge 505 is shown to be longer than the raised edge disclosed in FIG. 5 . In addition, the inner circular surface 512 around the raised edge 505 and the side opening 506 is similar to the embodiment of the present invention. Figures 5A-6B The inner circular surface disclosed in has a smaller surface area than that disclosed in FIG.

[0097] like Figure 6CAs shown, the raised edge 505 is shown as a circular shape, but other geometric shapes can be utilized. Further, the valve plate 501 includes a circular portion 510 that connects the side wall 514 to a circular element 519 formed on the rear surface 522 of the valve plate. When the wastegate is closed, the valve plate 501 can be axially mounted to the downstream end 608 of the wastegate passage along the central intake passage axis 603.

[0098] Exhaust flow from the engine enters the wastegate passage 604 via a first opening 614A and a second opening 614B at an upstream end 607 of the passage. A central wall 615 formed in the wastegate passage 604 divides the passage into a first side 636 and a second side 638. When adjusted to a closed wastegate position, the raised edge 505 of the valve plate 501 may be disposed within the first opening 614A and the second opening 614B at the downstream end 608 of the wastegate passage 604. For example, in the closed wastegate position, the side walls 514 of the raised edge 505 do not contact the first inner wall 630 of the wastegate passage 604, and the side openings 506 formed on the opposite sides 626 of the raised edge 505 face the second inner wall 632 of the passage. In another example, the first mating feature 606 may be disposed within the passage such that a mating surface of the first mating feature is in coplanar contact with one end of the central wall 615.

[0099] The first side 636 of the wastegate passage 604 may be connected to the turbine ( Figure 1 The first scroll of the turbine 72 shown (eg, Figure 1 Scroll 55A shown), and the second side 638 can be connected to a second scroll of the turbine (e.g., Figure 1 Scroll 55B shown). In this example, the first exhaust portion from the first scroll can flow into the first side 636 of the wastegate passage 604 via the first opening 614A, and the second exhaust portion from the second scroll can flow into the second side 638 of the wastegate passage 604 via the second opening 614B of the passage. In this manner, the first mating feature 606 of the valve plate 501 and the central wall 615 of the wastegate passage 604 can minimize flow interaction between the first exhaust portion and the second exhaust portion on the first side 636 and the second side 638 of the wastegate passage.

[0100] When the wastegate valve is adjusted to the open position, the curved surface 513 on the valve plate 501 can direct the exhaust flow in a first direction 628A and a second direction 628B. As an example, a first exhaust portion flowing on a first side 636 of the wastegate passage 604 can exit the passage via the first direction 628A, and a second exhaust portion flowing on a second side 638 of the wastegate passage 604 can exit the passage via the second direction 628B. In one example, the curved surface 513 can bend between the sidewalls 514 in multiple directions to form a multi-planar curved surface that forms the side opening 506 and the raised edge 505. In one example, the curved surface 513 can bend toward the side opening 506 to direct the exhaust flow along the direction 628.

[0101] A valve arm 507 having a flat surface 509 and a planar edge 511 can be coupled to a rear surface 522 of a valve plate 501 at a first end 634, and a second end 635 of the valve arm 507 can be connected to an actuation mechanism in a direction 530. As an example, the actuation mechanism can be a mechanical actuator, a hydraulic actuator, or an electric actuator that can be adjusted to open and close the valve plate during engine operation. During engine operation, the actuation mechanism can be adjusted to move the valve arm 507 to pivotally open the valve plate 501 and hold the valve plate open, thereby allowing exhaust gas to flow to an exhaust catalyst placed downstream of the wastegate. When the wastegate is open, the sidewall 514 and the curved surface 513, which can be partially disposed within the main opening, can direct the exhaust flow to the exhaust catalyst via the side opening 506.

[0102] In this way, the wastegate can direct the exhaust flow directly to the exhaust catalyst through the wastegate passage while minimizing exhaust energy losses caused by the exhaust flow impinging on the passage walls. By more directly directing the exhaust flow to the exhaust catalyst, the exhaust energy can be effectively used to preheat the catalyst, thereby speeding up catalyst light-off while reducing fuel emissions.

[0103] Go to Figure 7A-7B , a schematic diagram is shown showing a fourth embodiment of a wastegate (eg, wastegate valve) including a valve plate 501 in a partially open position, a valve arm 507 of an actuation mechanism, and a wastegate passage 604 . Fig. 7A A first view 700 of a fourth embodiment of a wastegate valve is shown in a partially open position. Figure 7BA second view 702 of a fourth embodiment of a wastegate valve is shown in a partially open position. The partially open position of the wastegate valve may be a position between the fully closed position and the fully open position. When in the fully closed position, there is no exhaust flow through the channel outlet 720, while the fully open position involves a maximum amount of opening, wherein the maximum amount of exhaust flow is through the channel outlet 720 and downstream in the bypass channel. In each of the first and second views, the valve plate 501 is partially open to allow exhaust flow in a first direction, as indicated by arrow 709. The wastegate channel 604 includes a circular inner edge 705, a circular outer edge 706, and a main opening 614.

[0104] When adjusted to partially open by the actuation mechanism placed in direction 530, the valve arm 507 can tilt the valve plate 501 to open outwardly in direction 716, so that the inner face 715 of the valve plate 501 can be aligned along the axis 712 to form a first tilt angle 710 between the axis 712 and the axis 714. For example, when the wastegate moves from the closed position to the partially open position (or toward the fully open position), the raised edge 505 on the valve plate 501 pivots within the lip surface 610 and the side opening 506 moves outwardly and away from the channel 604. In another example, the valve plate 501 can be adjusted to open so that the first side 624 of the valve plate 501 is hinged within the channel 604 at the first side 644 of the channel 604 including the constriction segment 612, and the second side 625 of the valve plate 501 is spaced apart from the channel at the second side 645 of the channel that does not include the constriction segment. As an example, the first side 624 of the valve plate 501 may include the raised edge 505, while the second side 625 includes the side opening 506. In another example, the first inner wall 609 and the lip surface 610 of the wastegate passage 604 may form a first side 644 of the passage, while the second inner wall 611 may form a second side 645 of the passage. Further, the first side 624 of the valve plate 501 and the first side 644 of the wastegate passage may be aligned with each other (e.g., on the same side of the wastegate relative to the central axis 603). Similarly, the second side 625 of the valve plate 501 and the second side 645 of the wastegate passage 604 may be aligned with each other (e.g., on the same side of the wastegate relative to the central axis 603).

[0105] For example, the wastegate valve can be adjusted to a partially open position, wherein the tilt angle 710 ranges from 5 degrees to 12 degrees. When the wastegate is adjusted to the partially open position, the sidewall 514 of the raised edge 505 can remain partially disposed within the downstream end 608 of the first opening 614A and the second opening 614B to direct the exhaust flow through the wastegate outlet 720. In the partially open wastegate position, the first mating feature 606 on the valve plate 501 can remain disposed in the wastegate passage at a position adjacent to the central wall 615, which divides the passage into a first side 636 and a second side 638.

[0106] Exhaust flow from the engine (shown by flow arrows 601A and 601B) can continue into the first opening 614A and the second opening 614B via the upstream end 607 of the wastegate passage 604. In this case, the first exhaust portion can enter the first side 636 as shown by flow arrow 601A, and the second exhaust portion can enter the second side 638 as shown by flow arrow 601B. The first exhaust portion on the first side 636 of the passage can flow toward the valve plate 501 and exit along the flow direction 709A, and the second exhaust portion on the second side 638 of the passage can flow toward the valve plate 501 and exit along the flow direction 709B. In this way, the first mating feature 606 of the valve plate 501 and the central wall 615 of the wastegate passage 604 can minimize flow interaction between the exhaust portions on the first side 636 and the second side 638 of the wastegate passage during engine operation.

[0107] The contraction section 612 formed at the junction between the first inner wall 609 and the lip surface 610 of the wastegate passage 604 can increase the exhaust flow velocity upstream of the valve plate 501 before the flow exits the side opening 506 along the first direction, as shown by arrow 709. The exhaust flow volume (e.g., the amount of exhaust) leaving the wastegate outlet 720 can depend on the size of the inclination angle 710 of the wastegate valve. As the inclination angle 710 increases, the volume of exhaust gas leaving the wastegate outlet 720 and reaching the exhaust catalyst placed downstream of the wastegate valve can increase. In this way, the inclination angle 710 of the valve plate 501 can be selectively adjusted to change the amount of exhaust gas delivered to the exhaust catalyst downstream of the wastegate.

[0108] Go to Figure 8A-B , shows a schematic diagram illustrating a fourth embodiment of a wastegate (eg, a wastegate valve) including a valve plate 501 in a fully open position, a valve arm 507 of an actuation mechanism, and a wastegate passage 604 . Fig. 8A A cross-sectional view 800 of a portion of a wastegate valve is shown in a fully open position. Figure 8BA three-dimensional view 802 of the wastegate valve in a fully open position is shown. In cross-sectional view 800, valve plate 501 is fully open to allow exhaust flow in the second side of the channel to exit in direction 709B. Three-dimensional view 802 shows exhaust flow in the first side and the second side of the channel exiting along flow directions 70A and 70B.

[0109] The wastegate passage 604 includes a first inner wall 609 formed upstream of the lip surface 610. In one example, the first inner wall 609 has a lip edge 613 formed at a contraction segment 612 that tapers to the lip surface 610 of the wastegate passage 604. As an example, the lip surface 610 can be formed downstream of the contraction segment 612, with the lip surface 610 having a first diameter 722 that is greater than a second diameter 724 of the contraction segment 612. In another example, the first diameter 722 of the lip surface 610 can be the same as a third diameter 725 of the passage 604 upstream of the contraction segment 612. In other examples, the contraction segment 612 can extend around only a portion of the circumference of the passage 604, where the portion is aligned with the first side 624 of the valve plate 501. The first inner wall 609 and the lip surface 610 can define a first side 644 of the wastegate passage, while the second inner wall 611 defines a second side 645 of the passage.

[0110] like Figure 8A-B As shown, the valve arm 507 attached to the rear surface 522 of the valve plate 501 can be adjusted by an actuator positioned in direction 530 to fully open the wastegate valve. For example, when the wastegate moves from a partially open position to a fully open position, the raised edge 505 on the valve plate 501 pivots within the lip surface 610 and the side opening 506 moves outward and away from the passage 604. In another example, as shown in FIG. Fig. 8A As shown, the wastegate valve can be pivotally opened by tilting the valve plate 501 at a second tilt angle 806 formed between the axes 712 and 714. Fig. 8A As shown in the flow direction 709B in FIG. 8 , the wastegate valve can be held pivotally open with an inclination angle 806 ranging from 12 degrees to 25 degrees, thereby allowing a large amount of exhaust gas to flow through the wastegate outlet 720. A first exhaust portion on the first side 636 of the wastegate passage 604 can exit the outlet 720 via flow direction 709A, while a second exhaust portion on the second side 638 of the passage can exit the outlet via flow direction 709B, as shown in FIG. Figure 8BIn this case, the first mating feature 606 and the central wall 615 can form a dividing barrier in the wastegate passage 604 that reduces or minimizes mixing of exhaust flows in the first side 636 and the second side 638 of the passage when the valve plate 501 is adjusted to the open position. In other examples, the valve plate 501 may include a curved surface (such as a curved surface) that forms the side opening 506. Fig. 7A 604 ) and may work with the contracting section 612 on the passage 604 to direct the exhaust flow via the wastegate outlet 720 to an exhaust catalyst placed downstream of the wastegate valve.

[0111] In this way, the curved surface forming the side opening 506 on the valve plate 501 can work together with the contraction section 612 on the wastegate passage 604 to direct the exhaust flow directly to the exhaust catalyst while reducing exhaust energy losses caused by the exhaust flow impinging on the walls of the passage. By directing the exhaust flow downstream directly to the exhaust catalyst, the warm-up duration of the catalyst can be reduced to speed up catalyst light-off while minimizing fuel emissions.

[0112] Go to Figure 9A-9B , shows a schematic diagram illustrating a fourth embodiment of a wastegate (eg, a wastegate valve) including a valve plate 501 in a closed position, a valve arm 507 attached to an actuation mechanism, and a wastegate passage 604 . Fig. 9A A first cross-sectional view 900 of a portion of a first side of a wastegate passage is shown with the wastegate valve in a closed position. Fig. 9B A second cross-sectional view 902 of the fifth embodiment of the wastegate valve is shown in a closed position. In each of the first and second cross-sectional views, the valve plate 501 is mounted to the downstream end 608 of the wastegate passage 604. Fig. 9A As shown, the exhaust gas flow enters the channel at the upstream end 607 of the channel through the first opening 614A. Fig. 9B As shown, exhaust gas flow may enter the passage bifurcated by central wall 615 at the upstream end 607 of the passage via first opening 614A and second opening 614B.

[0113] The wastegate passage 604 includes a first inner wall 609 and a lip surface 610 that form a first side 644 of the passage. The wastegate passage 604 also includes a second inner wall 611 that forms a second side 645 of the passage. The second inner wall 611 includes a front end 912 that can be in coplanar contact with the inner circular surface 512 of the valve plate 501. The first inner wall 609 includes a side edge 909 that defines a boundary between the first inner wall 609 and the second inner wall 611. The first inner wall 609 can be formed upstream of the lip surface 610 so that a contraction segment 612 formed between the two walls tapers to the lip surface 610 along a lip edge 613. In one example, the lip surface 610 can be formed downstream of the contraction segment 612, and the lip surface 610 has a first diameter (such as a second diameter 920 of the contraction segment 612) that is larger than the second diameter 920 of the contraction segment 612. Fig. 8A 722 shown in FIG. 7 ). For example, when the wastegate is closed, the raised edge 505 on the valve plate 501 can be located within the lip surface 610. In other examples, the constricted segment 612 can bend inwardly toward the central axis 603 of the passage 604 from a position upstream of the valve plate 501 to a position at the lip surface 610 and proximate to the valve plate 501.

[0114] The first inner wall 609 has a wall thickness 906, and the size of the wall thickness 906 can gradually increase in the direction 601 of the exhaust gas flow within the wastegate passage 604. As an example, the wall thickness 906 of the first inner wall 609 can have a first wall thickness at the upstream end 607, and a second wall thickness at the contraction section 612 of the wastegate passage 604, and the second wall thickness is greater than the first wall thickness. In one example, the wall thickness 906 of the first inner wall 609 can vary from 4 mm to 8 mm. In other examples, the side wall 913 of the wastegate passage 604 can narrow toward the central axis 603 of the passage 604 at the contraction section 612, and the narrowing can increase as the side wall 913 is closer to the valve plate. In contrast, the second inner wall 611 can have a uniform wall thickness 907 throughout the length of the wastegate passage 604. As an example, the second inner wall 611 can have a wall thickness that varies from 4 mm to 5 mm.

[0115] When the valve plate 501 is closed, the raised edge 505 can be disposed within the wastegate passage 604, wherein the curved edge 516 of the raised edge 505 forms a gap 927 between the curved edge 516 and the lip 613 upstream of the lip surface 610, as shown in FIG. Fig. 9AAs shown. As an example, when the wastegate is in a closed position, the raised edge 505 can fit within the lip surface 610. When the wastegate valve is adjusted to an open position, a curved surface 513 opposite the raised edge 505 forming a side opening 506 can direct the exhaust flow to the exhaust catalyst. For example, the curved surface 513 can bend between the sidewalls 514 in multiple directions to form a multi-planar curved surface that forms the side opening 506 and the raised edge 505. In one example, the curved surface 513 can work with the contraction segment 612 in the channel 604 to direct the exhaust flow to the exhaust catalyst.

[0116] The front portion of the lip surface 610 may be in coplanar contact with the inner circular surface 512 of the wastegate valve, wherein the raised edge 505 forms an annular housing 917 between the lip edge 613, the inner circular surface 512, and the lip surface 610. The inner circular surface 512 of the valve plate 501 may abut the front portion 912 of the wastegate passage 604 along a contact interface 914. Similarly, an annular opening 908 may be formed between the surface of the lip surface 610, the inner circular surface 512, and the surface of the side wall 514 of the raised edge 505, wherein the side edge 916 forms one of the surrounding walls.

[0117] The valve arm 507 can be attached to the central segment 910 of the valve plate 501, and the downstream end 935 of the valve arm 507 can be coupled to the actuation mechanism in the direction 530. As an example, different types of actuators including mechanical actuators, hydraulic actuators, and electric actuators can be used to adjust the valve arm 507 to open and close the wastegate valve during engine operation. When adjusted to the open wastegate position, the raised edge 505 of the valve plate 501 can work with the contracted segment 612 on the wastegate passage 604 to direct the exhaust flow to the exhaust catalyst downstream of the wastegate valve. When the valve plate is adjusted to the open position, the first mating feature 606 on the valve plate 501 can disengage from one end of the central wall 615. When the wastegate valve is adjusted to the open position, a first exhaust portion on the first side 636 of the wastegate passage 604 can flow toward the valve plate 501 and exit the passage outlet via a first direction, and a second exhaust portion on the second side 638 of the passage can flow toward the valve plate and exit the passage outlet via a second direction, both exhaust portions being directed to a catalyst placed downstream of the wastegate without impinging on the sidewalls of the passage. In this way, by minimizing exhaust energy losses due to exhaust flow impinging on the sidewalls of the wastegate passage, the wastegate can improve exhaust flow efficiency, thereby reducing catalyst warm-up duration, while minimizing fuel emissions.

[0118] although Figures 6A-9B The rib is shown as a first mating feature of the valve plate that mates with the central wall of the wastegate passage, but in alternative embodiments, Figures 6A-9B The wastegate valve shown in may instead include a recess as a first mating feature of the valve plate that mates with an extended central wall of the wastegate passage, such as Figures 10A-10E As shown, as further described below.

[0119] Figures 10A-10E A bypass passage such as a Figure 1 Schematic diagram of a fifth embodiment of a wastegate in a bypass passage 166 and a turbine 92 as shown, wherein the wastegate includes a valve plate and a wastegate passage. In the fifth embodiment, the wastegate passage may be bifurcated and adapted to cooperate with a mating feature of the valve plate. Fig. 10A and 1 FIG0B , schematic diagrams 1000 and 1002 of a fifth embodiment of a wastegate valve are disclosed. The valve plate 1010 includes an annular portion 1012, a base 1014, a raised edge 1016, a side opening 1020, and a groove 1022. An annular element 1018 formed on the outer surface of the annular portion 1012 may provide a means of coupling the valve plate 1010 to an actuator (not shown). The annular portion 1012 is connected to the raised edge 1016 via the base 1014, thereby forming a single integral valve plate. The side opening 1020 may be formed on one end of the raised edge 1016 between a side edge 1024 of the raised edge 1016 and an outer edge 1026 of the inner surface 428. Although not shown, the inner surface 1028 may form a curved surface (e.g., a multi-planar curved surface) of the valve plate 1010.

[0120] like Fig. 10A As shown, a groove 1022 formed in a central portion of the raised edge 1016 of the valve plate 1010 relative to the central axis 1009 of the valve plate 1010 can divide the raised edge 1016 into a first segment 1029 and a second segment 1030. The raised edge 1016 can also include a lip 1032 and an inner wall 1034 extending to the first segment 1029 and the second segment 1030. The groove 1022 can extend from the inner surface 1028 of the valve plate 1020 to the lip 1032 of the raised edge 1016. The groove 1022 can be recessed in the inner wall 1034 and / or the inner surface 1028 of the valve plate 1020. As an example, as shown in reference Fig. 10C As further disclosed, the recess 1022 can be sized to receive a mating surface of the central wall.

[0121] When valve plate 1010 is coupled to a wastegate passage in a closed position (eg, Figure 3A and Figure 3B1022), the central wall of the wastegate passage can be positioned against and disposed in the groove 1022, wherein the mating surface of the central wall is in coplanar contact with the inner surface of the groove 1022. In this case, the central wall can divide the wastegate passage into a first side and a second side, wherein a first exhaust portion on the first side of the passage flows to the first segment 1029 of the valve plate 1010, and a second exhaust portion in the second side of the passage flows into the second segment 1030 of the valve plate 1010. The central wall in the wastegate passage can extend into the groove 1022 to separate the first exhaust portion on the first side of the passage from the second exhaust flow portion on the second side of the passage, thereby minimizing flow interaction between the first exhaust portion and the second exhaust portion in the passage.

[0122] When the valve plate 1010 is adjusted to the open valve position, the mating surface of the central wall in the wastegate passage can be disengaged from the groove 1022, and the curved surface of the valve plate 1010 can guide the exhaust flow to the exhaust catalyst downstream of the wastegate. As an example, the curved surface of the valve plate 1010 can guide the first exhaust portion on the first side of the wastegate passage and the second exhaust portion on the second passage to the exhaust catalyst without impinging on the side wall of the wastegate passage, thereby minimizing exhaust energy loss and accelerating catalyst light-off. Fig. 10C Details of the groove 1022 on the valve plate 1010 and the central wall in the wastegate passage are further disclosed.

[0123] refer to Fig. 10C , a cross-sectional view 1004 of a fifth embodiment of a wastegate valve is disclosed. Figure 10C-10E The embodiment shown in FIG. 1 can be compared with Figure 10A-10B The embodiments shown in are simplified; however, Figure 10C-10E The features of the embodiments shown in the drawings may be similar, but different reference numerals may be used between the drawings, as further explained below. The wastegate valve includes a valve plate 1050 (similar to Figures 10A-10C10). The valve plate 1050 includes a base 1054, a raised edge 1058, a side opening 1059, and a recess 1060. For example, the recess 1060 of the valve plate 1050 can receive a mating portion 1075 of a central wall 1076 of the wastegate passage 1052, which divides the raised edge 1016 into a first segment 1062 and a second segment 1064. As an example, the mating portion 1075 of the central wall 1076 can be an end of the central wall. The central wall 1076 can extend from the wastegate passage 1052 into the valve plate 1050, pass through the lip 1070 of the raised edge 1058 and enter the recess 1060, thereby dividing the valve plate 1050 into the first segment 1062 and the second segment 1064 of the valve plate 1050. In this way, the central wall 1076 extends all the way to the inner surface 1053 of the base 1054. An annular element 1056 formed on the outer surface of the base 1054 of the valve plate 1050 can provide a means for coupling the valve plate 1050 to an actuator (not shown). The base 1054 is connected to the raised edge 1058 to form a single integral valve plate. The inner surface 1061 on the raised edge 1058 can form a curved surface (e.g., a multi-planar curved surface) on the valve plate 1050. Although not shown, the wastegate passage 1052 can include a lip surface (e.g., a lip surface) formed at the junction between the first inner wall and the second inner wall of the wastegate passage. Figure 4C A central wall 1076 formed in the central portion of the wastegate passage 1052 divides the wastegate passage into a first side 1078 and a second side 1080 .

[0124] When the valve plate 1050 is adjusted to the closed valve position, the mating portion 1075 of the central wall 1076 of the wastegate passage 1052 is disposed in the recess 1022 on the valve plate 1050. In the closed wastegate position, the valve plate 1050 is disposed within the opening 1068 in the wastegate passage 1052. When the valve plate 1050 is closed, a first exhaust portion on a first side 1078 of the passage can flow toward the first segment 1029 of the valve plate 1050, and a second exhaust portion on a second side 1080 of the passage can flow toward the second segment 1030 of the valve plate 1050. In this manner, the central wall 1076 of the wastegate passage 1052 can provide a barrier that prevents the first exhaust portion on the first side 1078 of the passage from mixing with the second exhaust portion on the second side 1080 of the passage. In this manner, the central wall 1076 of the wastegate passage 1052 may be positioned within the recess of the valve plate 1050 to stop flow interaction between exhaust gas portions in the first side 1078 and the second side 1080 of the wastegate passage.

[0125] When the valve plate 1050 is adjusted to the open position, the exhaust flow in the wastegate passage is directed to the catalyst placed downstream of the wastegate. In this case, the first exhaust portion and the second exhaust portion on the first side 1078 and the second side 1080 of the wastegate passage 1052 can be directed to the catalyst without allowing the exhaust flow to impinge on the sidewalls of the wastegate passage 1052. In this way, exhaust energy losses in the wastegate passage are minimized while accelerating catalyst light-off. Fig. 10D and Fig.10E Details of the groove 1022 on the valve plate 1050 and the central wall 1076 of the wastegate passage 1052 are further disclosed.

[0126] refer to Fig. 10D , a cross-sectional view 1006 of a fifth embodiment of a wastegate valve plate 1050 is disclosed. A recess 1022 of the valve plate 1050 can be formed between a first curved portion 1082 of the raised edge 1058 and a second curved portion 1084 of the raised edge 1058. For example, the recess 1022 of the valve plate 1050 can be formed between a first end 1086 of the first curved portion 1082 and a first end 1088 of the second curved portion 1084. Each of the first curved portion 1082 and the second curved portion 1084 can include second ends 1090 and 1092 that extend partially around an inner portion 1085 of the base 1054. The recess 1022 can be sized to receive a central wall of a wastegate passage that divides the wastegate passage into a first side and a second side (e.g., Fig. 10C The groove 1022 may have a height 1094 and a width 1096, and the groove 1022 is sized and shaped to fit over the central wall 1076 when the valve plate 1050 is closed against the wastegate passage.

[0127] When valve plate 1050 is coupled to a wastegate passage (eg, Fig. 10C 1052), the first segment 1062 of the valve plate 1050 can be aligned with the first side 1078 of the wastegate passage 1052, and the second segment 1064 of the valve plate can be aligned with the second side 1080 of the wastegate passage 1052. In this manner, the central wall of the wastegate passage (e.g. Fig. 10C A central wall 1076 , shown in FIG. 1 , may be positioned in recess 1022 to separate exhaust flow in the first and second portions of wastegate passage 1052 .

[0128] refer to Fig.10E, discloses a cross-sectional view 1008 of a wastegate passage 1052. A central wall 1076 of the wastegate passage 1052 may be connected to a first segment 1095 and a second segment 1097 of the passage inner wall, thereby dividing the passage into a first side 1078 and a second side 1080. The central wall 1076 of the wastegate passage 1052 may have a height 1098 and a width 1099, which are sized such that the areas of the first side 1078 and the second side 1080 are sized such that maximum wastegate flow through the passage is achieved based on engine operation.

[0129] In this manner, the wastegate valve may include a central wall that divides a passage into a first side and a second side, wherein the first side of the passage receives a first exhaust portion from a first scroll of the turbine, and the second side of the passage receives a second exhaust portion from a second scroll of the turbine. The central wall is adapted to mate with a mating feature on an interior of a valve plate of the wastegate valve. The mating feature on the valve plate may be a rib (e.g., Figure 4A-4E as shown) or grooves (as shown Figures 10A-10E ). Either the rib embodiment or the groove embodiment may be combined with any other embodiment of the wastegate valve disclosed herein. The central wall extends to a lip of the raised edge of the valve plate (in the rib embodiment) or extends past the lip and to the inner wall of the base of the valve plate (in the groove embodiment). In this way, when the valve plate is closed against the wastegate passage, the end of the central wall of the wastegate passage may be adapted to be in coplanar contact with a mating feature of the valve plate. In this position, the flow between the two vortices on either side of the intermediate wall remains separated. By separating the exhaust flow in the wastegate passage, flow interaction between the exhaust portions in the first side and the second side of the wastegate passage is minimized.

[0130] The technical effect of directing the exhaust flow to the catalyst downstream of the wastegate without fanning the exhaust in multiple directions allows the wastegate to reduce the exhaust energy loss to the turbocharger wall. Further, the technical effect of providing a contraction segment in the wastegate channel allows the exhaust flow in the channel to be accelerated before leaving the wastegate, thereby reducing the exhaust energy loss of the channel wall and accelerating the catalyst to light off. Further, the technical effect of providing a matching feature on the valve plate and the central wall in the wastegate channel allows the channel to be divided into a first side and a second side, wherein the exhaust flow in any side of the channel is not mixed. Two groups of cylinders can be established so that in the ignition order of the engine, the exhaust from the subsequent cylinder alternates between the first vortex and the second vortex. Such a configuration can allow a four-cylinder engine to use an exhaust valve lift duration of more than 180 degrees without having a cylinder with a high exhaust manifold pressure at the beginning of the exhaust event push the exhaust into the previous cylinder at the end of the exhaust event of the previous cylinder. An exhaust valve lift duration greater than 180 degrees is required to improve the pumping efficiency of the engine. Additionally, using a manifold and turbocharger with split passages allows for a smaller volume between the cylinder exhaust valves and the turbine, which increases the conversion of blowdown exhaust energy into turbine work. This can improve vehicle fuel economy and transient performance.

[0131] In one example, a wastegate includes a valve plate including an interior portion having a multi-planar curved surface and a first mating feature centered along the curved surface, the curved surface forming a raised edge and side openings on opposite sides of the valve plate; and a channel bifurcated by a central wall, an end portion of the central wall including a second mating feature portion adapted for coplanar contact with the first mating feature portion.

[0132] In the foregoing examples, additionally or alternatively, the valve plate is positioned at the end of the channel, and wherein the channel includes a constricted segment positioned upstream of the valve plate and aligned with the raised edge. In any or all of the foregoing examples, additionally or alternatively, the curved surface forms a raised edge on a first side of the valve plate and a side opening on a second side of the valve plate. In any or all of the foregoing examples, additionally or alternatively, the first mating feature is a rib extending outwardly from the curved surface and toward a central wall in the channel. In any or all of the foregoing examples, additionally or alternatively, the rib includes a linear portion connected to a curved portion, the linear portion extending outwardly along the raised edge, and the curved portion extending circumferentially along a portion of the curved surface.

[0133] In any or all of the foregoing examples, additionally or alternatively, the first mating feature is a groove formed on the curved surface, the groove being shaped to receive the second mating feature of the central wall. In any or all of the foregoing examples, additionally or alternatively, when the valve plate is in the closed position, the first mating feature and the central wall divide the channel into a first side and a second side, wherein the first side is formed opposite to the second side. In any or all of the foregoing examples, additionally or alternatively, the channel includes a constriction segment extending only around a portion of the circumference of the channel, wherein the portion is aligned with the first side of the valve plate. In any or all of the foregoing examples, additionally or alternatively, the channel further includes a lip formed downstream of the constriction segment, the lip having a larger diameter than the constriction segment.

[0134] In another example, a wastegate includes: a valve plate including a multi-planar curved surface formed on an inner base of the valve plate, the curved surface forming a raised edge on a first side of the valve plate and forming a side opening on a second side of the valve plate, and a rib centered in the valve plate and extending outwardly from the curved surface; and a channel bifurcated by a central wall, the ends of the central wall being adapted to cooperate with the rib, the valve plate being positioned at the ends of the channel. In the foregoing examples, additionally or alternatively, the channel includes a contraction segment positioned on a first side of the channel upstream of the valve plate, wherein the first side of the channel is aligned with the second side of the valve plate. In any or all of the foregoing examples, additionally or alternatively, the channel further includes a lip formed downstream of the contraction segment, the lip having a larger diameter than the contraction segment. In any or all of the foregoing examples, additionally or alternatively, the end of the central wall is arranged flush with the lip, and wherein the outer end of the rib adapted to cooperate with the end of the central wall is arranged flush with the raised edge. In any or all of the foregoing examples, additionally or alternatively, when the valve plate is in the closed position, the ribs and the central wall divide the channel into a first side and a second side, wherein the first side is formed opposite to the second side. In any or all of the foregoing examples, additionally or alternatively, when the valve plate is in the closed position, the ribs and the multi-planar curved surface of the valve plate face the interior of the channel, and the side opening faces the interior side wall of the channel.

[0135] In yet another example, a system includes: a twin-scroll turbine including a first scroll and a second scroll; a bypass passage coupled to the first scroll and the second scroll at a first end and coupled to a catalyst positioned downstream of the turbine at a second end; and a wastegate disposed within the bypass passage, the wastegate passage including: a wastegate passage coupled within the bypass passage, the wastegate passage including a central wall dividing the wastegate passage into a first passage in fluid communication with the first scroll and a second passage in fluid communication with the second scroll, wherein an end of the central wall extends past an end of an outer wall and a lip of the wastegate passage; and a valve plate positioned at an end of the wastegate passage and including a multi-planar curved surface on an interior of the valve plate, the curved surface forming a raised edge on a first side of the valve plate and a side opening on a second side of the valve plate, wherein a slot is formed in a center of the raised edge and an end of the central wall is adapted to mate with the slot. In the foregoing example, additionally or alternatively, the wastegate passage includes a converging segment, and a lip is formed at an end of the wastegate passage downstream of the converging segment. In any or all of the foregoing examples, additionally or alternatively, the valve plate is positioned at an end of the wastegate passage downstream of the lip, and wherein the raised edge is positioned against the lip when the valve plate is in the closed position. In any or all of the foregoing examples, additionally or alternatively, the constriction segment is aligned on the same side of the wastegate passage as the first side of the valve plate.

[0136] It should be noted that the example systems included herein can be used with various wastegate valve system configurations. It should be understood that the configurations disclosed herein are exemplary in nature, and these specific embodiments should not be considered in a limiting sense, as many variations are possible. For example, the above-described techniques can be applied to various wastegate valve systems. The subject matter of the present disclosure includes all novel and non-obvious combinations and sub-combinations of the various systems and configurations, and other features, functions, and / or properties disclosed herein.

[0137] The following claims particularly point out certain combinations and subcombinations deemed novel and non-obvious. These claims may refer to "an" element or "a first" element or the equivalent thereof. It should be understood that these claims include combinations of one or more of these elements, and neither require nor exclude two or more of these elements. Other combinations and subcombinations of the disclosed features, functions, elements, and / or characteristics may be claimed by amendment of the present claims or by presenting new claims in this or a related application. Such claims, whether broader, narrower, equal to, or different in scope from the original claims, are also deemed to be included within the subject matter of the present disclosure.

Claims

1. A wastegate comprising: a valve plate including an interior portion having a multi-planar curved surface and a first mating feature centered along the curved surface, the curved surface forming a raised edge and side openings on opposite sides of the valve plate; as well as a channel bifurcated by a central wall, an end of the central wall including a second mating feature adapted to be in coplanar contact with the first mating feature; wherein the first mating feature is a rib extending outwardly from the curved surface and toward the central wall in the channel; wherein the passage includes a constricted section positioned upstream of the valve plate and on a first side of the passage, wherein the first side of the passage is aligned with a second side of the valve plate; wherein the passage further comprises a lip formed downstream of the contraction segment, the lip having a larger diameter than the contraction segment; Wherein the end of the central wall is arranged flush with the lip, and the outer end of the rib is arranged flush with the raised edge, wherein the outer end of the rib is adapted to cooperate with the end of the central wall. 2 . The wastegate of claim 1 , wherein the valve plate is positioned at an end of the passage. 3 . The wastegate of claim 1 , wherein the curved surface forms the raised edge on a first side of the valve plate and forms the side opening on a second side of the valve plate. 4 . The wastegate of claim 1 , wherein the rib includes a linear portion connected to a curved portion, the linear portion extending outwardly along the raised edge, and the curved portion extends circumferentially along a portion of the curved surface.

5. The wastegate according to claim 1, wherein: When the valve plate is in a closed position, the first mating feature and the central wall divide the passage into a first side and a second side, wherein the first side is formed opposite to the second side. 6 . The wastegate of claim 1 , wherein the passage includes a constricted section extending around only a portion of a circumference of the passage, wherein the portion is aligned with the first side of the valve plate.

7. A method comprising: Providing a valve plate for a wastegate, the valve plate comprising a multi-planar curved surface formed on an interior base of the valve plate, the curved surface forming a raised edge on a first side of the valve plate and forming a side opening on a second side of the valve plate, and a rib centered in the valve plate and extending outwardly from the curved surface; as well as providing a passage for the wastegate, the passage bifurcated by a central wall, the ends of the central wall being adapted to cooperate with the ribs, the valve plate being positioned at the ends of the passage, wherein the passage includes a constricted section positioned upstream of the valve plate and on a first side of the passage; aligning the first side of the passage with the second side of the valve plate, wherein the passage further includes a lip formed downstream of the constriction segment, the lip having a larger diameter than the constriction segment; The end of the central wall is arranged flush with the lip and the outer end of the rib is arranged flush with the raised edge, the outer end of the rib being adapted to cooperate with the end of the central wall.

8. The method of claim 7, wherein when the valve plate is in the closed position, the rib and the central wall divide the passage into a first side and a second side, wherein the first side is formed opposite to the second side.

9. The method according to claim 7, wherein: When the valve plate is in the closed position, the ribs and the multi-planar curved surface of the valve plate face the interior of the channel, and the side opening faces the interior sidewall of the channel.

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