Turbine wastegate

Abstract

A component may include: a turbine housing including a hole, a waste gate seat, a waste gate passage extending to the waste gate seat, and a partition wall disposed between the waste gate passages, wherein the partition wall includes a partition wall surface; a rotatable waste gate shaft configured to be received by the hole; a waste gate arm extending from the waste gate shaft; and a waste gate plug extending from the waste gate arm, wherein the waste gate plug includes a contact portion and a mesh, wherein the contact portion contacts the waste gate seat in a closed state to cover the waste gate passage, and the mesh contacts the partition wall surface in the closed state.

Description

Technical Field

[0001] The subject matter disclosed herein relates generally to turbomachinery for internal combustion engines, and in particular, to a turbine wastegate for a turbocharger. Background Art

[0002] A turbine wastegate is a type of valve that can be controlled to selectively allow at least some exhaust gas to bypass the turbine. Where an exhaust turbine drives a compressor to boost the inlet pressure of an internal combustion engine (e.g., as in a turbocharger), the wastegate provides a means of controlling boost pressure.

[0003] A so-called internal wastegate is at least partially integrated into the turbine housing. The internal wastegate may be configured as a type of flapper valve including a flapper, which may be referred to as a plug, wherein the plug may be controlled via rotation of a shaft, in which case an arm may extend from the shaft to the plug. The shaft may be rotatable via actuation of an actuator, which may be mechanical, electrical, etc. A mechanical linkage may operatively couple the actuator to the shaft, for example via a shaft control arm. The plug of the wastegate often includes a flat, disc-shaped surface that seats against a flat seat (e.g., a valve seat or a wastegate seat) disposed around the exhaust bypass opening.

[0004] In the closed position, the wastegate plug should be seated against the wastegate seat (e.g., seating surface) with sufficient force to effectively seal the exhaust bypass opening (e.g., to prevent exhaust from leaking from a high-pressure exhaust supply source to a low-pressure area). Often, the internal wastegate is configured to transmit force from the arm to the plug. During engine operation, the load demand of the wastegate varies with the pressure difference. High load demands can produce high mechanical stresses in the kinematic components of the wastegate, a fact that has led to significantly oversized component designs in some cases to meet reliability levels (e.g., as required by engine manufacturers). The reliability of wastegate components is a concern for diesel engine applications and gasoline engine applications; it is noted that exhaust temperatures will be higher for gasoline engines. In both diesel engines and gasoline engines, exhaust pulsations will be a concern, particularly in the case where the turbine housing receives exhaust via multiple channels, each of which can be dedicated to receiving exhaust from a specific combustion cylinder of the engine. Such a turbine housing may include multiple vortices, each of which can be dedicated to receiving exhaust from a specific combustion cylinder of the engine.

[0005] Various examples of wastegates and wastegate components are described herein, which may optionally provide improved kinematics, reduced exhaust leakage, etc. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The various methods, devices, components, systems, arrangements, etc. described herein, and their equivalents, may be more completely understood by reference to the following detailed description when taken in conjunction with the examples illustrated in the accompanying drawings, in which:

[0007] Figure 1 is a diagram of a turbocharger and an internal combustion engine together with a controller;

[0008] Figure 2 is a view of an example of an assembly including a wastegate;

[0009] Figure 3 yes Figure 2 An example of a cross-sectional view of an assembly along line AA;

[0010] Figure 4 is a series of views of an example of an assembly including two scrolls together with an example of an exhaust manifold;

[0011] Figure 5 is a perspective view of a portion of a turbine housing including two scrolls;

[0012] Figure 6 is a cross-sectional view of a portion of the assembly illustrating a gap between a dividing wall and a plug;

[0013] Figure 7 is a cross-sectional view of a portion of an example of an assembly including a mesh filling a gap between a partition wall and a plug;

[0014] Figure 8 is a series of views of examples of methods;

[0015] Fig. 9 is a perspective view of an example of a wastegate;

[0016] Fig.10 yes Fig. 9 A plan view of the wastegate;

[0017] Fig.11 yes Fig. 9 a plan view of a portion of a wastegate;

[0018] Fig. 12A and Fig. 12B yes Fig. 9 A cross-sectional view of an example of a wastegate along line BB;

[0019] Fig.13 yes Fig. 9 A cross-sectional view of the wastegate along line CC;

[0020] Fig.14 is a series of views of an example of a recess of a plug according to a machining method;

[0021] Fig.15 is a series of views of an example of a recess of a plug further machined according to a machining method;

[0022] Fig.16 is a series of views of an example of a recess of a plug further machined according to a machining method;

[0023] Fig.17 is an approximate perspective view of a portion of an example of a net;

[0024] Fig.18 is a block diagram of an example of a method for making an assembly including a plug having a mesh in a recess of the plug; and

[0025] Fig.19 is an example of a graph showing data regarding torque increase for a plug including a mesh disposed in a recess of the plug that may impede flow relative to a dividing wall. DETAILED DESCRIPTION

[0026] Turbochargers are frequently utilized to increase the output of internal combustion engines. Figure 1 As an example, the system 100 may include an internal combustion engine 110 and a turbocharger 120. Figure 1 As shown in , the system 100 may be part of a vehicle 101 , where the system 100 is positioned in an engine compartment and connected to an exhaust duct 103 that directs exhaust gas to an exhaust outlet 109 , which is located, for example, behind a passenger compartment 105 . Figure 1 In the example of , a processing unit 107 may be provided to process the exhaust (eg, to reduce emissions via catalytic conversion of molecules, etc.).

[0027] like Figure 1 As shown in , the internal combustion engine 110 includes an engine block 118 housing one or more combustion chambers that operatively drive a shaft 112 (e.g., via a piston), an intake port 114 that provides a flow path for air to flow into the engine block 118, and an exhaust port 116 that provides a flow path for exhaust gas to flow out of the engine block 118.

[0028] The turbocharger 120 may be used to extract energy from the exhaust gas and provide the energy to intake air, which may be combined with fuel to form combustion gases. Figure 1As shown in , the turbocharger 120 includes an air inlet 134, a shaft 122, a compressor housing assembly 124 for a compressor impeller 125, a turbine housing assembly 126 for a turbine impeller 127, another housing assembly 128, and an exhaust outlet 136. The housing assembly 128 can be referred to as a center housing assembly because it is disposed between the compressor housing assembly 124 and the turbine housing assembly 126. The shaft 122 can be a shaft assembly including a variety of components. The shaft 122 can be rotatably supported by a bearing system (e.g., (one or more) journal bearings, (one or more) rolling element bearings, etc.) disposed in the housing assembly 128 (e.g., in a hole defined by one or more hole walls), so that the rotation of the turbine impeller 127 causes the rotation of the compressor impeller 125 (e.g., due to the rotatable coupling through the shaft 122). As an example, a center housing rotating assembly (CHRA) may include a compressor wheel 125 , a turbine wheel 127 , a shaft 122 , a casing assembly 128 , and various other components (eg, a compressor side plate disposed at an axial location between the compressor wheel 125 and the casing assembly 128 ).

[0029] exist Figure 1 In the example of FIG. 1 , a variable geometry assembly 129 is shown as being partially disposed between the housing assembly 128 and the housing assembly 126. Such a variable geometry assembly may include vanes or other components to change the geometry of the passage to the turbine wheel space in the turbine housing assembly 126. As an example, a variable geometry compressor assembly may be provided.

[0030] exist Figure 1 In the example of FIG. 1 , a wastegate valve (or simply wastegate) 135 is positioned proximate to the exhaust inlet of the turbine housing assembly 126. The wastegate valve 135 can be controlled to allow at least some exhaust gas from the exhaust port 116 to bypass the turbine wheel 127. Various wastegates, wastegate components, etc. can be applied to conventional fixed nozzle turbines, fixed vane nozzle turbines, variable nozzle turbines, twin scroll turbochargers, etc.

[0031] exist Figure 1 In the example of FIG. 1 , an exhaust gas recirculation (EGR) conduit 115 is also shown, which may optionally be provided with, for example, one or more valves 117 to allow exhaust gas to flow to a location upstream of the compressor impeller 125 .

[0032] Figure 1Also shown are an example arrangement 150 for exhaust gas flow to an exhaust turbine housing assembly 152 and another example arrangement 170 for exhaust gas flow to an exhaust turbine housing assembly 172. In arrangement 150, passages 156 are included in cylinder head 154 to direct exhaust gas from the cylinders to turbine housing assembly 152, while in arrangement 170, manifold 176 provides mounting of turbine housing assembly 172 without, for example, any separate mid-length exhaust conduit. In example arrangements 150 and 170, turbine housing assemblies 152 and 172 may be configured for use with wastegates, variable geometry assemblies, and the like.

[0033] exist Figure 1 In the example of controller 190, it is shown that it includes one or more processors 192, memory 194 and one or more interfaces 196. Such a controller may include circuits, such as circuits of an engine control unit (ECU). As described herein, various methods or techniques may be implemented in conjunction with the controller, for example, by control logic. The control logic may depend on one or more engine operating conditions (e.g., turbine rpm, engine rpm, temperature, load, lubricant, cooling, etc.). For example, a sensor may transmit information to the controller 190 via one or more interfaces 196. The control logic may rely on such information, and then the controller 190 may output a control signal to control the engine operation. The controller 190 may be configured to control lubricant flow, temperature, variable geometry components (e.g., variable geometry compressors or turbines), wastegates (e.g., via actuators), electric motors, or one or more other components associated with an engine, a turbocharger (or multiple turbochargers), etc. As an example, the turbocharger 120 may include one or more actuators and / or one or more sensors 198, which may be coupled, for example, to one or more interfaces 196 of the controller 190. As an example, the wastegate 135 may be controlled by a controller that includes an actuator responsive to an electrical signal, a pressure signal, etc. As an example, the actuator for the wastegate may be a mechanical actuator, for example, which may operate without the need for electrical power (e.g., considering a mechanical actuator configured to respond to a pressure signal supplied via a conduit).

[0034] Figure 2 and Figure 3 An example of an assembly 200 is shown, which includes a turbine housing 210 including a flange 211, an aperture 212, an inlet duct 213, a turbine wheel opening 214, a spiral wall 215, an exhaust outlet opening 216, a shroud wall 220, a nozzle 221, a volute 222 partially formed by the spiral wall 215, a wastegate wall 223 extending to a wastegate seat 226, and an exhaust chamber 230. Figure 2In the example of the turbine housing 210, the turbine housing 210 can be a single-piece or multi-piece housing. As an example, the turbine housing 210 can be a cast component (e.g., formed via sand casting or other casting processes). The turbine housing 210 includes various walls that can define features such as the hole 212, the turbine impeller opening 214, the exhaust outlet opening 216, the exhaust chamber 230, etc. In particular, the wastegate wall 223 defines a wastegate passage in fluid communication with the inlet conduit 213, wherein the wastegate control linkage 240 and the wastegate arm and plug 250 are configured to open and close the wastegate passage (e.g., for directing exhaust gas through the wastegate).

[0035] exist Figure 2 In the example of , the wastegate control linkage 240 includes a sleeve 242, a control arm 244, and a plug 246, the sleeve being configured to be received by the bore 212 of the turbine housing 210, and the wastegate arm and plug 250 including a shaft 252, a shaft end 253, an arm 254, and a plug 256. As shown, the sleeve 242 is disposed between the bore 212 and the shaft 252, for example to support the rotation of the shaft 252, to seal the exhaust chamber 230 from the external space, etc. The bore 212, the sleeve 242, and the shaft 252 can each be defined by one or more diameters and one or more lengths. For example, the shaft 252 includes a diameter D s , the hole 212 includes a diameter D B , and the sleeve 242 includes an inner diameter D bi and outer diameter D bo .exist Figure 2 In the example of FIG. 1 , when the various components are assembled, the diameter may be as follows: D B >D bo >D bi >D s Regarding length, the length of the shaft 252 exceeds the length of the sleeve 242, and the length of the sleeve 242 exceeds the length of the hole 212. Such a length can be about the axis z of the shaft. s , sleeve axis z b and hole axis z B As shown, the sleeve 242 is axially disposed between the shoulder of the shaft 252 and the control arm 244 of the control linkage 240 .

[0036] exist Figure 2 In the example of , a gap Δz is shown between a surface of bushing 242 and a surface of control arm 244 , which allows axial movement of shaft 252 , for example, to facilitate self-centering of plug 256 relative to wastegate seat 226 .

[0037] As an example, the assembly 200 may be mated to an exhaust conduit or other component of an internal combustion engine via the flange 211 (see, e.g. Figure 1214 ), so that the exhaust gas is received via the inlet duct 213, directed to the volute 222. From the volute 222, the exhaust gas is directed to the turbine impeller disposed in the turbine housing 210 via the nozzle 221, flows to the turbine impeller space partially defined by the cover wall 220 via the opening 214 and expands therein. The exhaust gas can then leave the turbine impeller space by flowing to the exhaust chamber 230 and then out of the turbine housing 210 via the exhaust outlet opening 216.

[0038] With respect to wastegate operation (wastegating), upon actuation of control linkage 240 (e.g., by an actuator coupled to pin 246), wastegate arm and plug 250 may rotate such that at least a portion of the received exhaust gas may flow in a wastegate passage defined by wastegate wall 223, through wastegate seat 226, and into exhaust chamber 230, rather than through nozzle 221 to the turbine wheel space. The wastegate-directed portion of the exhaust gas may then exit turbine housing 210 via exhaust outlet opening 216 (e.g., and pass to the vehicle's exhaust system, be partially recirculated, etc.).

[0039] As an example, the control linkage 240 can apply a force that acts to urge the plug 256 in a direction toward the wastegate seat 226. For example, the actuator may include a biasing mechanism (e.g., a spring, etc.) that applies a force that can be at least partially controllably overcome to rotate the plug 256 away from the wastegate seat 226 (e.g., for wastegate operation). As an example, the actuator can be mounted to a turbocharger (e.g., mounted to a compressor assembly, etc.). As an example, the actuator can be a linear actuator, such as one that includes a rod that moves along an axis. Depending on the orientation of the plug, shaft, control linkage, and such rod, in order to maintain the plug in a closed position, the rod can apply a downward force (e.g., in a Figure 2 In an example of a lever 240 (eg, away from the control linkage) or lever 244, an upward force may be applied (eg, toward the control linkage). For example, where the control arm 244 (eg, and the pin 246) of the control linkage 240 is oriented on the same "side" as the plug 256 relative to the shaft 252, a downward force applied to the control arm 244 (eg, via the pin 246) may act to maintain the plug 256 in a closed position relative to the wastegate seat 226; however, where, for example, there is an approximate 180 degree span between the plug and the control arm, an upward force applied to the control arm may act to maintain the plug in a closed position relative to the wastegate seat.

[0040] As an example, a rod of the actuator may be biased to exert a force on a control linkage that causes the control linkage to exert a force on a plug (see, e.g., plug 256) to seat the plug against a wastegate seat (see, e.g., wastegate seat 226). In such an example, the actuator may at least partially overcome the force of the biasing rod so that the shaft rotates the plug away from the wastegate seat. For example, in Figure 2 In order to initiate wastegate operation, the entire plug 256 is rotated about the axis of the shaft 252 and moved away from the wastegate seat 226 (e.g., no portion of the plug 256 is moved into the wastegate opening defined by the wastegate seat 226). As an example, the movement of the plug 256 away may be facilitated by exhaust pressure. For example, in the closed position, the plug 256 experiences a pressure differential, where the pressure is greater below the plug 256 and less above the plug 256. In such an example, the pressure below the plug 256 acts in the opposite direction of the closing force applied to the plug 256 via the control linkage 240 (e.g., the pressure differential acts to bias the plug 256 toward the open position). Therefore, the closing force applied to the plug 256 should overcome the pressure from below the plug 256. Furthermore, where the shaft 252 may include some play (see, eg, Δz, etc.), the closing force applied to the plug 256 may cause the plug 256 to self-center relative to the wastegate seat 226 (eg, to facilitate sealing, avoid exhaust leakage, etc.).

[0041] exist Figure 2 In the example of , the axes of the bore 212, sleeve 242, and shaft 252 are shown as aligned (e.g., defining a common axis), however, some misalignment may occur during assembly, operation, etc. For example, over time, the gaps between the various components (e.g., plugs, arms, shafts, bores, sleeves, etc.) may change. Forces that may cause such changes include aerodynamic excitation, high temperatures, temperature cycling (e.g., temperatures less than -20 degrees Celsius to temperatures greater than 1000 degrees Celsius), chemical attack, friction, material degradation, etc. For at least the foregoing reasons, it may be difficult to maintain an effective seal on the wastegate opening over the service life of the exhaust turbine assembly. With respect to temperature, problems at high temperatures generally include wear and loss of function and the resulting leakage, loss of controllability, or a combination of leakage and uncontrollability.

[0042] As an example, the plug may include a contact portion. For example, the plug may include an arc portion as a contact portion that contacts the surface of the waste gate seat in the closed state. As an example, in an assembly, such a plug may be configured to self-center relative to the waste gate seat (e.g., in the closed state). As an example, the surface of the waste gate seat may be conical, which may facilitate self-centering of the contact portion of the plug. As an example, one or more gaps may exist in an assembly of a waste gate shaft relative to the bushing so that the waste gate shaft may move in a manner that allows a waste gate plug operatively coupled to the waste gate shaft to self-center relative to the waste gate seat.

[0043] exist Figure 2 In the example of the turbine housing 210, the turbine housing 210 can be a single-piece or multi-piece housing. As an example, the turbine housing 210 can be a cast component (e.g., formed via sand casting or other casting processes). The turbine housing 210 includes various walls that can define features such as the hole 212, the turbine wheel opening, the exhaust outlet opening 216, the exhaust chamber 230, etc.

[0044] As an example, the wastegate arm and plug 250 can be a unitary wastegate arm and plug (e.g., a monolithic wastegate arm and plug) or a wastegate arm and plug assembly. In contrast, a multi-component arm and plug assembly includes interfaces between components. Such interfaces can be subject to wear, deformation, etc., which over time may interfere with normal operation.

[0045] Figure 4 An example of a twin-scroll turbine assembly 400 is shown, which may be configured to receive exhaust gas from a manifold 401 including two separate exhaust passages, each having its own opening 402 - 1 and 402 - 2 . Figure 4 The views of assembly 400 are shown as “see-through” cross-sectional views, where solid walls may, for example, be shown as hollow to more clearly illustrate the contours of such walls, the shape of channels, etc.

[0046] As an example, manifold 401 can be considered a divided manifold that separates the exhaust flow from cylinders whose cycles may interfere with each other (e.g., in terms of exhaust pulse energy). For example, on a four-cylinder engine with a firing order of 1-3-4-2, cylinder #1 is ending its expansion stroke and opening its exhaust valve, while the exhaust valve of cylinder #2 is still open (cylinder #2 is in its overlapping period). In an undivided exhaust manifold, the pressure pulse of the exhaust gas exhaust event from cylinder #1 may be more likely to contaminate cylinder #2 with high-pressure exhaust gas, which may affect the performance of cylinder #2 (e.g., the ability to properly intake and exhaust) and reduce the pulse energy that should have been better utilized by the turbine. As an example, the correct grouping of the aforementioned engine can keep complementary cylinders grouped together (e.g., the exhaust of cylinder #1 and cylinder #4 as one complementary group, and the exhaust of cylinder #2 and cylinder #3 as another complementary group). Such an approach can better utilize the exhaust pulsation energy and, for example, improve turbine performance (e.g., increase boost more quickly).

[0047] like Figure 4 As shown in FIG. 4 , the assembly 400 includes a housing 410 including a wall 415 defining two scrolls 422-1 and 422-2 (e.g., two volutes) that can direct exhaust gas to a turbine wheel space, such as via one or more nozzles 421. As an example, the turbine wheel space can be defined in part by a shroud wall 420 located axially above the one or more nozzles 421, the shroud wall extending axially to an exhaust chamber 430.

[0048] exist Figure 4 In the example of , the housing 410 includes two wastegate walls 423-1 and 423-2, which are associated with respective vortices 422-1 and 422-2. The two wastegate walls 423-1 and 423-2 form an opening around which there is a wastegate seat 426. As shown, the wastegate wall 423-1 defines a first wastegate passage in fluid communication with a first inlet conduit, and the wastegate wall 423-2 defines a second wastegate passage in fluid communication with a second inlet conduit, where, for example, these inlet conduits can be operatively coupled to respective openings 402-1 and 402-2 of the manifold 401. As an example, Figure 1 The manifold 176 may be configured as a split manifold, such as where the turbine housing assembly 172 may include a dual scroll (eg, two volutes). As an example, Figure 1 The cylinder head 154 may include separate passages, such as where the turbine housing assembly 152 may include a twin scroll (eg, two volutes).

[0049] To control exhaust flow through the wastegate passage, assembly 400 includes a wastegate control linkage 440 and a wastegate arm and plug 450 having an arm member 454 and a plug member 456 configured to open and close the wastegate passage (e.g., for directing exhaust gas through the wastegate) via seating of the plug member 456 relative to the wastegate seat 406.

[0050] Assembly 400 may be described, for example, with respect to various axes. For example, consider the axis of the turbine wheel space, which may coincide with the axis of rotation of the turbine wheel, the axis of the shaft of the wastegate arm and plug 450, and the axis of plug member 456. Furthermore, each of the openings of the wastegate passage may be defined by a respective axis, for example wherein in the closed state of the wastegate, the axis of plug member 456 is aligned approximately parallel to the axis of the opening of the wastegate passage.

[0051] Referring again to assembly 400, the pulse energy may be different in the two channels 423-1 and 423-2, causing a portion of plug component 456 to experience a different force than another portion of plug component 456. Such a difference may be due to the configuration of manifold 401, where one of channels 423-1 and 423-2 receives exhaust from one of openings 402-1 and 402-2, and where the other of channels 423-1 and 423-2 receives exhaust from the other of openings 402-1 and 402-2. Such a difference in pulse energy in the two channels 423-1 and 423-2 may cause vibration, misalignment, wear, etc. For example, when plug component 456 includes a rod seated in an opening of arm component 454, pressure may cause plug component 456 to tilt, causing the axis of the rod to be misaligned relative to the axis of the opening of arm component 454. Over time, wear (e.g., increased clearance) may occur, which may exacerbate wear, leakage, etc.

[0052] Regarding leakage, leakage can occur from a channel to chamber 430 and / or from one channel to another channel (e.g., or vice versa). For example, due to the pressure difference between the channels, the exhaust gas can flow from the channel formed by wall 423-1 to the channel formed by wall 423-2 in the space above the partition wall surface 417 and the plug component 456. Such flow can act to "balance" the pressure, which may be harmful, for example, for a divided manifold method (e.g., or a dual-scroll method). Such flow can be referred to as vortex-to-vortex leakage, which occurs for a closed operating state of the wastegate arm and the plug (e.g., where the controller, actuator, etc. requires the channel to be closed).

[0053] Figure 5An example of a turbine housing 510 is shown that includes a divider wall surface 517 of a divider wall 519, a wastegate seat 526, and exhaust passages 523-1 and 523-2, wherein the divider wall 519 is disposed between passages 523-1 and 523-2, and wherein passage 523-1 includes a corresponding opening 524-1 and wherein passage 523-2 includes a corresponding opening 524-2. The divider wall 519 can be described as dividing passages 523-1 and 523-2. The divider wall 519 is shown as defining a portion of the opening 524-1 and as defining a portion of the opening 524-2.

[0054] The shape of opening 524-1 and the shape of opening 524-2 can be defined geometrically (e.g., mathematically) as a type of bean curve. For example, consider a quartic curve given by the implicit equation:

[0055] x 4 +x 2 y 2 +y 4 =ax(x 2 +y 2 )

[0056] The above equations can produce a curve with horizontal tangents at 2 / 3a, + / -2 / 3a, and vertical tangents at (0,0) and (a,0). Figure 5 , opening 524-2 is shown with vertical tangents at (0,0) and (a,0) in the context of the x-axis and y-axis, noting that horizontal tangents can be defined at a distance + / - value of y along the x-axis. As shown, the partition wall surface 517 can be at least partially defined by a tangent to opening 524-1 and at least partially defined by a tangent to opening 524-2, which can be utilized to define a partition wall surface width Δxm. The partition wall surface 517 can also be defined by a length relative to the y-axis, which can be represented as Δym.

[0057] exist Figure 5 In the example of FIG. 5 , the wastegate seat 526 includes a lower perimeter at zsl and an upper perimeter at zsu, wherein the axis z ws The z-axis (about the wastegate seat or "ws") may extend in a direction from the passages 523-1 and 523-2 toward the exhaust chamber. As shown, the dividing wall surface 517 may be defined by one or more z-coordinates. Figure 5 In the example of , the partition wall surface may include a relatively planar portion at zm, the planar portion having a width Δxm and a length Δym. Figure 5In the example of , zsl (surface lower or "sl") may be greater than zm, and zsu (surface upper or "su") may be greater than zsl. The plug may contact the wastegate seat 526 to form a contact perimeter zc located at a z coordinate greater than zsl and less than zsu. Figure 5 An example of zc is shown as a dotted line, which can be drawn from the axis z ws (eg, where the plug is centered relative to the wastegate seat 526) is defined by a radius or diameter measured; note that zsl and zsu may each correspond to a radius or diameter measured from the axis z ws Measure the radius or diameter.

[0058] exist Figure 5 In the example of , the wastegate seat 526 can be conical, wherein zsl is the lower portion of the cone and zsu is the upper portion of the cone, wherein the cone angle can be defined by the distance between zsl and zsu and the difference in radius or diameter; wherein the radius or diameter at zsu is greater than the radius or diameter at zsl. Figure 6 The cone angle is identified in ).

[0059] As an example, the wastegate seat can be positioned adjacent to the openings and the dividing wall surface, wherein each of the openings and at least a portion of the dividing wall surface can be defined by a bean curve. In such an example, the dividing wall surface can be partially defined by two bean curves. As an example, the dividing wall surface can be at least partially defined by a plane.

[0060] Figure 6 An example of a portion of an assembly 600 is shown that includes a turbine housing 610, a divider wall 619 including a divider wall surface 617, passages 623-1 and 623-2 including corresponding openings 624-1 and 624-2, a wastegate seat 626, an exhaust chamber 630, and a wastegate 650 that includes a shaft 652, an arm 654, and a plug 656, wherein the plug 656 contacts the wastegate seat 626 such that the wastegate is in a closed orientation or state to obstruct exhaust flow from passages 623-1 and 623-2 through their corresponding openings 624-1 and 624-2 to the exhaust chamber 630.

[0061] Figure 6 Three pressures are also shown: P with respect to the chamber pressure c , P1 with respect to the pressure in channel 623-1 and P2 with respect to the pressure in channel 623-2; note that during operation, at least pressures P1 and P2 may vary with respect to time (see e.g. Figure 4and manifold 401 , scroll 422 - 1 and scroll 422 - 2 , such as in a twin-scroll or dual-scroll arrangement, where exhaust gas may flow from manifold 401 to scrolls 422 - 1 and 422 - 2 ).

[0062] Figure 6 Also shown are various examples of forces, such as a force applied to the wastegate seat 626 via the wastegate plug 656 and a reaction force of the wastegate seat 626. As described by Newton's third law of motion of classical mechanics, forces can come in pairs, such that if one object exerts a force on another object, the second object exerts an equal and opposite reaction force on the first object. As an example, an actuator can apply a force to a shaft of a wastegate, which can be rotational, whereby a plug coupled to the wastegate can apply at least a portion of the force to the wastegate seat. In such an example, the force applied can be greater than the force applied to the wastegate seat in one channel (P1 or P2) or multiple channels (P1 and P2) and chambers (e.g., P c ) between the pressure differences.

[0063] Can be about Figure 5 to understand the various features of assembly 600. For example, Figure 5 The wastegate seat 626 and the partition wall 619 are defined as described with respect to the wastegate seat 526 and the partition wall 519 in FIG. As mentioned, Figure 6 The cone angle of the wastegate seat 626 is shown It can be relative to the axis z ws (See for example parallel to z ws A wastegate seat including a conical profile defined by a cone angle may seat a plug having a profile that may be curved. For example, plug 656 includes a curved profile. In such an approach, a contact perimeter may be formed, such as, for example, Figure 5 . In the presence of such contact, exhaust gas is substantially prevented from flowing from channels 623-1 and 623-2 to exhaust chamber 630. However, since the exhaust pressure in channels 623-1 and 623-2 varies with respect to time in such a way that the exhaust pressure in one of the channels is greater than the exhaust pressure in the other of the channels, the exhaust gas can flow from one channel to the other via a gap, which can be approximately defined by dimensions Δzg, Δxm, and Δym. Thus, there is a volume for inter-channel exhaust gas flow as driven by pulsations, which can originate from the movement of a piston in a cylinder of an internal combustion engine (e.g., via an exhaust stroke that drives the exhaust gas to a channel of a turbine housing). Depending on the various dimensions of the components, the gap dimension Δzg can be in the range from approximately 0.01 mm to approximately 1 mm, and, for example, the dimension Δxm can be approximately several millimeters or larger (e.g., 2 mm to 10 mm).

[0064] As mentioned, in Figure 6 In the example of FIG. 1 , in the closed state, there is an axial gap between the partition wall surface 617 and the lower surface 657 of the plug 656, which is located along the axis z. ws When is shown as Δzg, Figure 5 and Figure 6 As shown, the partition wall surface 617 can be defined by a width Δxm (see also, for example Figure 5 Δxm in). In such a configuration, the exhaust in channel 623-1 can flow to channel 623-2 through the gap, and / or the exhaust in channel 623-2 can flow to channel 623-1 through the gap. Such flow can be referred to as leakage, which can be referred to as vortex-to-vortex leakage. Such leakage is different from leakage from one of channels 623-1 or 623-2 to chamber 630. Scroll-to-scroll leakage can act to reduce the energy in the scroll. For example, if the scroll is sealed without a scroll-to-scroll leakage path, the energy in the scroll will be better maintained (e.g., on its way to the volute and turbine wheel of the turbine assembly of the exhaust turbocharger).

[0065] Experiments have shown that engine torque can be affected by vortex-to-vortex leakage. For example, engine torque can be reduced due to vortex-to-vortex leakage. As an example, a turbine wastegate can include features for achieving a reduction in vortex-to-vortex leakage, which can result in an increase in torque (e.g., considering that engine rpm increases by 30 rpm as engine torque increases by 10 Nm). Fig.19 An example curve 1900 of engine torque versus engine speed is shown, wherein for various tests, a mesh is utilized to reduce vortex-to-vortex leakage in the gap between the partition wall and the plug of the turbine wastegate. The data in curve 1900 illustrates how the mesh can increase torque by reducing exhaust flow across the gap. As an example, the mesh can be configured to withstand a temperature of 1080 degrees Celsius. Such a mesh can be made of a material including metal (e.g., a metal mesh).

[0066] Modern gasoline turbochargers benefit from precise turbocharger control to meet regulatory standards. A turbocharger that provides a seal between the scrolls can improve turbocharger performance and control because the seal can reduce the effects of pulsations that can cause scroll-to-scroll leakage, and thus the seal can also improve the efficiency of the turbocharger.

[0067] As an example, the seal can be or can include a wire mesh that can be made of a suitable material, such as, for example, a stainless steel material that can operate up to maximum exhaust temperatures (e.g., up to 1080 degrees Celsius peak or optionally higher). Such a material can be a kinematic material in that it changes shape in response to forces during operation. For example, the mesh can have a free-standing shape and a compressed shape (e.g., a loaded shape). As an example, when the wastegate is transitioned from an open state to a closed state, the mesh can transition from a free-standing shape to a compressed shape. In the closed state, the compressed shape can be caused by the mesh being compressed between the plug of the wastegate and the dividing wall surface of the turbine housing.

[0068] As an example, the mesh can be attached to the plug via one or more techniques. As an example, the plug can be manufactured to include a recess (e.g., a cavity) for attaching the mesh. As an example, the mesh can be partially fitted into and held by the recess, wherein a portion of the mesh is outside the recess and can be used to contact the partition wall surface of the turbine housing and be compressed relative to the partition wall surface of the turbine housing. As an example, the attachment mechanism can be implemented via one or more welding points (e.g., consider laser welding, etc.). As an example, the attachment mechanism can be implemented via melting and hardening of the material. For example, consider positioning a portion of the mesh in a recess of the plug, wherein the molten material can harden in the recess to attach the mesh to the plug. When hardened, such a material is able to withstand the operating temperatures of the exhaust turbine assembly.

[0069] As an example, the stiffness of the mesh may be selected in a manner that takes into account the actuator force required to maintain the wastegate in a closed state. For example, a stiff mesh may increase the force required to maintain the plug in a closed state; whereas a less stiff mesh may increase that force to a lesser extent. As an example, an actuator may be rated with respect to the force that the actuator may apply to the plug in a closed state. In such an example, a mesh may be selected that adds a minimal amount of force such that the assembly is within the operating range of the actuator's force (e.g., without requiring the actuator to be redesigned to implement the mesh).

[0070] As an example, the mesh can be constructed with an amount of overlap relative to the dividing wall surface. As an example, the mesh can provide an increase in torque, a reduction in transient response (e.g., on the order of several hundred milliseconds), and can be durable in operating conditions. Regarding overlap, a range of 0.01 mm to approximately 0.5 mm can be utilized (e.g., or optionally larger, such as approximately 1 mm to 3 mm). As an example, the amount of overlap can be selected to depend on the stiffness of the mesh, where a stiffer mesh can have less overlap than a softer mesh. As an example, the amount of overlap can be selected based on experiments, such as, for example, corresponding to Fig.19 Experiment with the data in curve 1900.

[0071] As an example, the wire mesh can be made of an alloy. As an example, the alloy used for the mesh can be a cobalt-based alloy or a nickel-based alloy. Some examples include L605 (a cobalt alloy, also known as 25); 694 (e.g., CM-64); (Nickel alloy); T-800 (cobalt-chromium-molybdenum alloy); René 41 (hardened nickel alloy); C263 (aluminum-titanium age-hardened nickel-based superalloy); 188 (cobalt-based alloy); (austenitic nickel-chromium-based superalloy); etc. As an example, it is possible to use 600, 601, 617, 625, 690, 718 or X-750 which include nickel in the range of approximately 44 to approximately 72 or more mass percent and chromium in the range of approximately 14 to approximately 30 mass percent.

[0072] As an example, a wire mesh can be formed of a wire that is shaped to achieve desired properties. For example, the wire can be formed into a mesh via compression, wherein the mesh can be defined by a total volume and a porosity (e.g., a fractional void volume of the mesh). As an example, a wire mesh can include a braid (e.g., a knit, etc.). As an example, a mesh can be formed via cutting (e.g., via stamping, etc.) from a raw mesh. As an example, a mesh can be a compressible mesh having an independent unsupported porosity, an installed porosity, etc., which can be compressed against a partition wall to reduce its porosity (e.g., a closed state porosity).

[0073] As an example, the mesh may be elastic and elastically deform or at least partially elastically deform such that it changes shape when a force is applied and changes shape when at least a portion of such force is released. As an example, the mesh may be plastically deformable to a limited extent, for example, the mesh will first undergo a certain amount of elastic deformation within the range of plastic deformation, which is reversible, so that the mesh will at least partially return to a previous shape. As an example, the assembly may be configured such that the mesh will be substantially elastically deformed during operation, for example, subjected to a force in the closed state of the plug and releasing such a force in the open state of the plug. As an example, a mesh attached to the plug may undergo a certain amount of plastic deformation while still being able to reduce leakage between the plug and the partition wall.

[0074] As an example, a network may be composed of For example, consider a wire with a diameter of approximately 0.112 mm. 601 (W.Nr.2.4851) alloy. As an example, the mesh can be a wire mesh whose wire diameter is selected to be in the range from approximately 0.03 mm to approximately 0.3 mm. As an example, the mesh can be a wire mesh having a wire diameter of approximately 0.1 mm (e.g., 0.1 mm + / - 25%). As an example, the mesh can be a wire mesh having a wire diameter of approximately 0.15 mm (e.g., 0.15 + / - 25%). As an example, the mesh can be a wire mesh having a maximum cross-sectional dimension that is less than approximately 0.5 mm or less than approximately 0.25 mm. As an example, the mesh can be selected (e.g., configured) such that a break in the mesh (which break can release mesh particles, short strips of wire of the mesh, etc.) releases material that is small enough to reduce impact on a turbine wheel of a turbine assembly. For example, in the case where a wire mesh having a wire diameter of approximately 0.25 mm or less causes a short portion of the wire (e.g., a few millimeters or less) to break, the short portion can pass through the turbine impeller located in the turbine wheel space of the turbine housing without a substantial risk of damaging the turbine impeller. In such an example, the wire mesh can allow for a reduced risk of damage to the turbine impeller (e.g., due to breakage and small-sized, low-quality debris, etc.). In the event that a substantial portion of the mesh breaks, the risk of catastrophic damage to the turbine wheel can be reduced because the mesh can be resilient. In such an example, this portion of the mesh can pass through the turbine impeller without causing substantial damage to the turbine impeller, and can enter the exhaust system without similarly causing substantial risk to the catalytic converter, the environment, etc.

[0075] As an example, the mesh may be formed from an alloy including nickel and chromium. As an example, the mesh may be formed from an austenitic nickel-chromium based superalloy. As an example, one or more types of Alloys. For example, Alloy 601 or higher Alloy. The following table 1 lists Various percentages of 601 alloy:

[0076] Table 1. 601 Alloy

[0077] Nickel..................................58.0 to 63.0

[0078] Chromium .................................................21.0 to 25.0

[0079] Iron...................................................Remaining amount

[0080] Aluminum................................................1.0 to 1.7

[0081] Carbon..................................0.10 max.

[0082] Manganese..................................1.0 max.

[0083] Sulfur..................................0.015 max.

[0084] Silicon......................................0.50 max.

[0085] Copper................................................1.0 max.

[0086] Table 2 below lists Various percentages of 718 alloy:

[0087] Table 2. 718 Alloy

[0088] Nickel (with cobalt) .................................50.00 to 55.00

[0089] Chrome .................................................17.00 to 21.00

[0090] Iron............................................Remainder*

[0091] Niobium (with tantalum) ..................................4.75 to 5.50

[0092] Molybdenum......................................2.80 to 3.30

[0093] Titanium ..................................................0.65 to 1.15

[0094] Aluminum..................................0.20 to 0.80

[0095] Cobalt Cobalt....................................1.00 max.

[0096] Carbon......................................0.08 max.

[0097] Manganese......................................0.35 max.

[0098] Silicon................................................0.35 max

[0099] Phosphorus................................0.015 max.

[0100] Sulfur......................................0.015 max.

[0101] Boron......................................0.006 max.

[0102] Copper......................................0.30 max.

[0103] As an example, the mesh may provide a lateral overlap of approximately 1.5 mm with the dividing wall surface. As an example, the mesh may be defined by a height, a width, and a length, which may define the volume of the mesh in a freestanding, unsupported state. As an example, in a freestanding, unsupported state, the mesh may have a height of approximately 2 mm, a width of approximately 5 mm, and a length of approximately 26 mm. As an example, the mesh may have a width greater than its height, and a length greater than its width.

[0104] As an example, the net can be retained in the recess of the plug via an expansion force applied by the net on the surface defining the recess of the plug. As an example, the independent unsupported volume of the net can be larger than the installed volume of the net, in which case the net is fitted to the plug by having at least a portion of the net disposed in the recess of the plug. As an example, the net can have a waist or tightening section when it is fitted to the plug. In such an example, the recess can include an opening to an inner cavity, wherein the size of the inner cavity can be larger than the size of the opening, so that the opening is used to compress the net (e.g., tighten the net to form a waist). In such an example, removing the net from the recess can involve compressing the net when the net squeezes through the opening.

[0105] As an example, the mesh may be secured to the plug via a force applied by the mesh. Such a force may be an outward force that causes the mesh to contact surfaces defining the recess of the plug and apply force to these surfaces. As mentioned, one or more other mechanisms may be utilized to attach the mesh to the plug (e.g., welding, hardened molten material, etc.).

[0106] Figure 7 An example of a portion of an assembly 700 is shown that includes various features of assembly 600 except that wastegate 650 is replaced with an example wastegate 750. Figure 5 and / or Figure 6 The dimensions shown in Figure 7 In addition, it is possible to Figure 6 To understand the various pressures and forces. Additionally, Figure 7 Forces associated with a mechanism that may reduce exhaust flow from one passage to another, which may be referred to as scroll-to-scroll leakage, are shown.

[0107] like Figure 7 As shown in , wastegate 750 includes shaft 752, wastegate arm 754, and plug 756 having lower surface 757, wherein plug 756 includes a recess 780 in lower surface 757 that provides for attachment of mesh 790. Figure 7 In the example of FIG. 7 , the mesh 790 contacts the partition wall surface 617 so that the mesh 790 blocks the exhaust gas flow across the gap. Figure 7 As shown in , the contact can be made with an amount of force that is sufficient to cause an amount of compression of at least a portion of the mesh 790 (e.g., to be in a compressed state) relative to the mesh 790.

[0108] In the compressed state, the mesh 790 may have reduced internal void space (e.g., reduced porosity) compared to an uncompressed state (e.g., a freestanding, unsupported state). Thus, the force may compress the mesh 790 and thereby increase the ability of the mesh 790 to impede flow to increase sealing across a gap. For example, at least a portion of the mesh 790 may be denser and have less porosity in a closed state of the plug 756 relative to the wastegate seat 626 than in an open state of the plug 756 relative to the wastegate seat 626.

[0109] As an example, the assembly 700 may include: a turbine housing 610 including a bore, a wastegate seat 626, wastegate passages 623-1 and 623-2 extending to the wastegate seat 626, and a partition wall 619 disposed between the wastegate passages 623-1 and 623-2, wherein the partition wall 619 includes a partition wall surface 617; a rotatable wastegate shaft 752 configured to be received by the bore; a wastegate arm 754 extending from the wastegate shaft 753; and a plug 756 extending from the wastegate arm 754, wherein the plug 756 includes a contact portion and a mesh 790, wherein the contact portion contacts the wastegate seat 626 in a closed state to cover the wastegate passages 623-1 and 623-2, and the mesh contacts the partition wall surface 617 in a closed state. Figure 7 As shown in the example of , the mesh 790 can include a portion disposed in the recess 780 of the plug 756 and another portion exposed for contacting the dividing wall surface 617. In such an example, the mesh 790 can reduce the exhaust flow from one of the wastegate passages 623-1 and 623-2 to the other of the wastegate passages 623-1 and 623-2. In such an example, the reduction of exhaust flow between the wastegate passages 623-1 and 623-2 (e.g., via the mesh partially disposed in the gap) can provide an increase in the torque of the internal combustion engine (see, e.g., Fig.19 Curve 1900), the internal combustion engine includes a turbocharger, and the turbocharger includes component 700.

[0110] As an example, during operation of a turbine wastegate, the mesh may contact the dividing wall before a plug of the turbine wastegate contacts the wastegate seat. Figure 7 In the embodiment of the present invention, contact may be made between the mesh 790 and the partition wall 619 before the plug 756 makes contact between the contact portion of the wastegate seat 626 at the peripheral contact portion.

[0111] As an example, the mesh can be used to reduce the force via compression in a manner that is used to reduce the force when the plug and the wastegate seat are in contact. For example, in the case where the plug 756 is controlled to transition from an open orientation (e.g., an open state) to a closed orientation (e.g., a closed state), the mesh 790 can absorb a certain amount of energy so that the acceleration of the plug 756 toward the wastegate seat 626 is reduced, which in turn can reduce the noise and / or wear of the plug 756 and / or the wastegate seat 626. In such an example, the mesh 790 can be a damping mesh that attenuates the noise that may be associated with the rapid movement of the plug 756 stopping when in contact with the wastegate seat 626. For example, the damping mesh can slow the movement of the plug 756 just before the plug 756 contacts the wastegate seat 626. Once in contact, the force applied to the plug 756 to maintain it in the closed orientation (e.g., the closed state) can be approximately the same as without the damping mesh. In such an approach, the damping mesh can reduce noise and / or wear without burdening the actuator or other closing mechanism with a force that would require oversizing the actuator or other closing mechanism. For example, the damping mesh can add an amount of spring-like force that is selected to be within a pre-existing operational safety margin for the sizing of the actuator or other closing mechanism so that the plug with the damping mesh can be implemented without changing the actuator or other closing mechanism of the turbocharger. As an example, the spring-like force of the mesh can be selected to be a portion of the total closing force intended to maintain the plug in a closed orientation (e.g., closed state) relative to the wastegate seat (e.g., considering a force less than approximately 10% of the total closing force).

[0112] Reference again Figure 5 As an example, the partition wall surface 517 can be smooth and / or textured. As an example, the partition wall surface 517 can include a recess that can receive a portion of the mesh. For example, referring to Figure 7 In the example assembly 701, the partition wall surface 617 is considered to include a recess having an opening whose width is smaller than the opening of the recess 780, so that a portion of the mesh 790 can be received in the recess of the partition wall surface 617 to produce a more tortuous flow path because the sides of the mesh 790 can contact the sides of the recess.

[0113] exist Figure 7In an example of the embodiment of the present invention, the assembly 701 includes a recessed portion, which may be formed as a groove in the partition wall surface 617, the groove including a triangular cross-sectional profile. Such an approach may provide for applying less stress to a portion of the mesh 790, which may be manifested as less wear of the mesh 790 over time (e.g., the operating time of the turbocharger). In such an example, in the case where the plug 756 may wear or other types of misalignment relative to the wastegate seat 626, a portion of the mesh 790 may be "newer" because it is less compressed due to the recessed portion of the partition wall surface 617. In such an approach, the mesh 790 may generally exhibit a longer service life and may be more adaptable to changes that may occur over time relative to various components of the turbocharger. As an example, in the case of a small shift to the left or right relative to the groove of the partition wall surface 617, the portion of the mesh 790 that was previously aligned with the groove may now be aligned with a flatter portion (e.g., a planar portion) of the partition wall surface 617, in which case it now experiences compression that it has not previously experienced. Thus, that portion of the mesh 790 may experience less compression (e.g., cyclic compression) and therefore have a longer life than adjacent portion(s) of the mesh 790 that may experience greater compression (e.g., cyclic compression). Where a recess in the dividing wall surface is utilized, the turbine housing may be adapted for use with a plug that includes or does not include a mesh.

[0114] As an example, the partition wall may be free of recesses or have one or more recesses.As an example, the stopper may include one or more nets at least partially received in the one or more recesses.

[0115] Figure 8 An example of a method 800 is shown, the method comprising: rotating 810 the wastegate 750 relative to the wastegate seat 626 to a closed position where an exposed portion of the mesh 790 extending away from the lower surface 757 of the plug 756 is in a freestanding, unsupported state; contacting 820 a portion of the mesh 790 and a portion of the divider wall surface 617; and closing 830 the wastegate 750 such that the exposed portion of the mesh 790 is in a compressed state and in contact with the divider wall surface 617. As shown, the contact 820 occurs at an angle of rotation about the axis of the shaft of the wastegate 750 that is less than approximately 10 degrees (e.g., optionally less than approximately 5 degrees), where approximately 0 degrees corresponds to a closed state (e.g., the lower surface 757 of the plug 756 is substantially parallel to the divider wall surface 617). Figure 8 , the size of the force arrows does not represent magnitude, but rather approximate direction; note that the force arrows are shown at the periphery of the plug 756 of the wastegate 750 relative to the wastegate seat 626.

[0116] exist Figure 8In the example of , a mesh 790 is shown in a cross-sectional view in which the mesh height Δz can be a freestanding, unsupported height Δzmf or a compressed height (e.g., loaded height) Δzml in the closed state of the wastegate 750. As shown, the mesh deforms, which can be an elastic deformation. As an example, the mesh can undergo plastic deformation. For example, consider installing the mesh in a freestanding, unsupported state about a portion of the mesh (the portion extending outward from the surface of the plug of the wastegate), and then compressing the portion of the mesh against the dividing wall surface during operation of the wastegate, in which case the mesh does not fully return to its freestanding, unsupported state. As an example, the mesh can exhibit a certain amount of elasticity.

[0117] As further described below Fig. 12B As explained, the mesh 790 can be inclined by, for example, being disposed in an inclined recess. Alternatively, for example, the mesh 790 can be cut at an angle. In such an example, the force shown in the contact 820 can be reduced so that the closing resistance can be reduced at the corresponding angle at which the contact occurs, or so that the contact occurs at a smaller angle while still providing for filling the gap with the mesh.

[0118] Fig. 9 An example of a wastegate 900 is shown including a shaft 920 , an arm 940 , and a plug 960 . Fig. 9 Also shown is an example of a mesh 990 that can be combined with the wastegate 900 to form an assembly. An approximately enlarged view of a portion of the example of the mesh 990 shows how the wire can be constructed to form the mesh 990. The wastegate 900 can be a flapper valve, where the plug 960 is a flapper that covers the exhaust passage in the closed state. The shaft 920 is rotated about the axis of rotation z of the shaft 920. S With rotation of the wastegate 900, the wastegate 900 can transition from an open state to a closed state and from a closed state to an open state. The wastegate 900 can be substantially L-shaped or a hockey stick shape, wherein the long portion corresponds to the shaft 920 and the shorter portion corresponds to the arm 940 and the plug 960. The plug 960 can be considered a functional portion of the wastegate 900 because it can be positioned to regulate the flow of exhaust gas from the passage to the chamber (e.g., as in the function of the wastegate operation). In such an approach, when the plug 960 is in an open state, exhaust gas can flow from the passage to the chamber, which can be in fluid communication with the exhaust system of the vehicle so that the amount of exhaust gas directed through the wastegate can flow to the environment via the exhaust system.

[0119] The shaft 920 may be partially defined by a longitudinal axis (shown as z) as an axis of rotation. S ) and the plug 960 may be partially defined by an axis (shown as z) perpendicular to the plane defined by the plug 960. P ) is defined. In the closed state, the axis z of the plug 960 PCan be aligned with the axis of the wastegate seat (see e.g. Figure 5 z in WS ) is aligned, the axis of the wastegate seat can be, for example, the axis of a cone, in which case the wastegate seat consists of a conical section (see, for example, cone angle )limited.

[0120] like Fig. 9 As shown in the example of , the wastegate 900 includes opposing ends 902 and 904 that can define the overall length of the wastegate 900, wherein the end 902 is defined by the shaft 920, and wherein the end 904 is defined by the plug 960. With respect to the shaft 920, it can include a portion 903 for attaching a control arm, a shoulder 905 radially stepped to a journal surface 922, a shoulder 923 radially stepped to a surface 926, and a shoulder 925 radially stepped to another journal surface 924. The journal surfaces 922 and 924 can contact the inner surface of a sleeve disposed in a bore of the turbine housing. As an example, a mechanical linkage device can be coupled to the shaft 920 at portion 903 (e.g., via a control arm) such that the shaft 920 is rotatable in the bore of the turbine housing, wherein such rotation is substantially along the axis z of the shaft 920. S In such a method, plug 960 is rotated with shaft 920 to move plug 960 closer to or further away from the wastegate seat (see e.g. Figure 5 Exhaust valve seat 526).

[0121] like Fig. 9 As shown in the example of FIG. 9 , arm 940 includes a shoulder 942 that radially steps to shaft 920, and another portion 944 that extends to plug 960. Fig. 9 As shown in the example of , the plug 960 may include a contact surface 965, which may be formed as a portion of an annular surface, in which case the contact surface may be defined by the axial height and radius of the annular surface. As shown, the contact surface 965 extends to an annular surface 967, which surrounds a portion 970 of the plug 960.

[0122] exist Fig. 9 970 , portion 970 of plug 960 includes surface 972 defined by boundaries 973 and 974, and surface 976 defined by boundaries 977 and 978. As shown, boundaries 973 and 977 can be boundaries having annular surface 967, which can be a planar annular surface. As shown, surfaces 972 and 976 can be substantially planar and separated by recess 980, which can be at least partially defined by boundaries 974 and 978. In such an example, recess 980 can be utilized to secure a mesh, such as mesh 990, to wastegate 900, wherein the mesh at least partially extends outwardly from surfaces 972 and 976 to contact a dividing wall surface (see, e.g., Figure 5In such an example, surface 972 may be positioned above a first exhaust passage having a corresponding opening, and surface 976 may be positioned above a second exhaust passage having a corresponding opening, wherein the two passages are separated by a dividing wall having a dividing wall surface, wherein recess 980 is positioned substantially above the dividing wall surface in the closed state of wastegate 900. For example, Figure 5 to understand such feature arrangement.

[0123] exist Fig. 9 , recess 980 is shown as being partially defined by dimension z R Characteristically, this dimension may be substantially the same as the inner diameter of the annular surface 967. In such an arrangement, there is a boundary between the recess 980 of the plug 960 and the contact surface 965. Such a characteristic arrangement may provide a safety margin intended to isolate the mesh to the extent that it does not interfere with the contact between the contact surface 965 and the wastegate seat; more specifically, the mesh is isolated for contact with the dividing wall surface that separates the two exhaust passages (see, e.g., Figure 5 The partition wall surface 517 and the wastegate seat 526).

[0124] like Fig. 9 As shown in FIG. , the mesh 990 may be partially composed of a mesh size z M and may be defined in part by the compressible web dimension z MC Limited. About Fig. 9, the mesh 990 may be in a compressed state or an uncompressed state. Once insertably secured in the recess 980 of the plug 960, the mesh 990 may be in an at least partially compressed state such that the mesh 990 applies an outwardly directed force to one or more walls defining the recess 980 to help secure the mesh 990 in the recess 980. For example, the mesh 990 may be a spring mesh such that it is compressed to fit inside the recess 980 and, because it applies an outwardly directed force to one or more walls defining the recess 980, the mesh 990 will not be likely to easily "fall" out of the recess 980. In such an example, in order to remove the mesh 990 from the recess 980, a force such as a pulling force by a mechanical forceps gripping the mesh 990 may be required to extract the mesh 990 from the recess 980. In such an example, the applied force from the grip of the forceps (e.g., needle-nosed pliers) may cause portions of the mesh 990 to break apart before the mesh 990 is removed from the recess 980. In other words, the force holding the web 990 in the recess 980 may be greater than the force required to pull the fibers away from the web 990, particularly if the web 990 has been utilized in operation and exposed to repeated temperature cycles from hot exhaust gas, etc. As described above, the web 990 may be resiliently fixed in the recess 980 via its own material properties, particularly its own spring-like properties, which may be approximated via the Hooke's equation F = -kΔx, where k is a property of the web 990, and Δx is the dimension by which the web 990 is compressed in the recess 980 (e.g., relative to the dimension z). R orthogonal).

[0125] exist Fig. 9 In an example of, the recess 980 includes a mouth or neck at its opening that is narrower than the internal dimensions of the recess 980. In such an approach, the mesh can be compressed to fit into the opening and partially pass through the mouth or neck, where the mesh can be at least partially expanded. In such an approach, in order to remove the mesh from the recess 980, the expanded portion will need to be compressed to pass outward through the mouth or neck of the recess 980, which will require the application of force. Therefore, the shape of the recess 980 can be used to help secure the mesh in the plug of the wastegate. For example, the recess 980 can include a dimension that is wider inside the plug 960 than at the mouth or neck of the recess 980. Inside the recess 980, a portion of the mesh can be in a freestanding, unsupported state (e.g., fully expanded) such that in order to remove the mesh, the portion must be compressed from the freestanding, unsupported state to fit through the mouth or neck of the recess 980. As mentioned, a portion of the net may be in a compressed state inside the recess, where to remove the net, the portion needs to be further compressed to fit through the mouth or neck of the recess. In various examples, the properties of the net may be utilized to help maintain the net in the recess of the plug.

[0126] Fig.10 The plan view shows Fig. 9 The wastegate 900 is provided with various dimensions including: O1, which is the offset between the axis of the shaft 920 and the axis of the plug 960; and O2, which is the offset between one end of the shaft 920 and the axis of the plug 960. Fig.10 In the view of FIG. 1 , the plug 960 can be defined in part via an x, y, z Cartesian coordinate system and / or an r, z, θ cylindrical coordinate system. In such a coordinate system, z can correspond to the axis of the plug 960 (see, e.g., Fig. 9 z in P ). As an example, surfaces 972 and 976 can be defined about a bean curve or semicircle, optionally with an offset so that dimension "a" is along boundary 974 or boundary 978.

[0127] The bean curve can be defined by a quartic curve given by the implicit equation: 4 +x 2 y 2 +y 4 =ax(x 2 +y 2 ), which has horizontal tangents at (0.66a,+ / -0.66a) and vertical tangents at (0,0) and (a,0).

[0128] like Fig.10 As shown in FIG. 8 , the recess 980 may include a length (eg, z R ) and width (e.g., w R ), where the length is greater than the width. Fig.10 In the example of , the length of the recess 980 is less than the diameter of the annular surface 967 , which is less than the diameter of the contact surface 965 , which may be referred to as a contact portion of the wastegate plug 960 .

[0129] Fig.11 An enlarged view of a portion of recess 980 is shown, which can be machined using a milling machine, such as a milling cutter having a diameter of approximately 0.5 mm to approximately 5 mm, depending on the size of the recess to be formed, etc. Such a cutter (e.g., a cutting tool) can be employed to make multiple cuts at each end to form recess 980.

[0130] Fig. 12A and Fig. 12B The wastegate 900 is shown along the Fig.10 . A cross-sectional view of the line BB represented in the view of FIG. The recess 980 can be seen in the cross section along the major axis, which is the axis to be aligned with the dividing wall of the turbine housing. As mentioned, the recess 980 can be used to fix the net.

[0131] exist Fig. 12AIn the example of FIG. 1 , the depth of the recess 980 (eg, the recess height h R ) can be relatively constant over the length of the recess 980, while Fig. 12B In the example of FIG. 1 , the depth of the recess 980 (eg, the recess height h R1 and h R2 ) can vary. Fig. 12B In the example of , the depth variation of recess 980 can be configured to expose less mesh at the end of recess 980 closer to the axis of rotation of the shaft and expose more mesh at the end of recess 980 distal to the axis of rotation of the shaft. Fig. 12B Medium, depth h R2 Greater than depth h R1 Such an approach can accommodate the geometry of the transition from the open state to the closed state, where one portion of the web approaches and contacts the partition wall surface before another portion of the web. Figure 8 In the embodiment of the present invention, the portion of the mesh 790 close to the axis of the shaft may contact the partition wall surface 617 before the portion of the mesh 790 located far from the axis of the shaft. Fig. 12B The angled recesses shown in FIG. 4 can help reduce compression of one portion of the mesh relative to another portion of the mesh, which may otherwise cause uneven loading throughout the mesh and / or increase the resistance of the wastegate to closing (e.g., as shown in FIG. 4 ). Figure 8 In the example above, you can start at an angle of approximately 3 degrees).

[0132] Fig.13 The wastegate 900 is shown along the Fig.10 Another cross-sectional view of the line CC represented in the view of FIG. Fig.13 As shown in , the recess 980 may include two halves that may be symmetrical and rotated approximately 40 degrees relative to each other. As shown, the cross-sectional profile of the recess 980 in the transverse shorter dimension may be approximately a pentagon, wherein the base may be slightly recessed from the lower surface of the plug 960 of the wastegate 900. As shown, the recess 980 may include a symmetry plane that may be imparted via machining the recess 980 into the plug 960. Fig.13 The mouth or neck of recess 980 (eg, the opening of recess 980) is shown having a dimension w R , it is noted that the widthwise dimension of the recess 980 may be increased within the plug 960. For example, Fig.13 The width dimension w is shown in RMAX About size h R , which is shown as the depth of the recess 980, where the widthwise dimension may vary from the surfaces 972 and 976 of the plug 960 to a maximum depth h R .

[0133] Fig.14 , Fig.15 and Fig.16 An example of a machining method for machining a recess into a plug for a wastegate is shown. Fig.14 As shown, a first machining process 1410 may machine a slot into a plug of a wastegate. Fig.15 As shown, a second machining process 1420 may machine an offset crown into the plug of the wastegate. Fig.16 As shown in , a third machining process 1430 may machine another offset crown into the plug of the wastegate, where a cross-sectional view 1432 is shown.

[0134] As shown, the recess may include an inner dimension that is larger than the opening of the recess. Fig.16 As shown in , the two crowns may provide a transverse dimension ycwmax that is greater than the transverse dimension ycwo of the opening of the recess. Such a method may provide for fitting a portion of the mesh into the recess by compressing the mesh to fit through the opening, so that the mesh expands and applies force to the walls of the recess to hold the mesh, and whereby removal of the mesh will require recompression to squeeze the mesh through the opening.

[0135] As an example, the recess of the plug may include a transverse inner dimension that is greater than the transverse opening dimension, such that the mesh may be narrowest at the opening in its transverse dimension. In such an example, the mesh may have a waist defined by a portion of the mesh received in the recess and a portion of the mesh outside the recess. In such an example, the portion of the mesh outside the recess may be utilized to impede flow in a gap between exhaust passages of the turbine housing.

[0136] Fig.17 An example of a mesh 1790 as may be at least partially received in a recess of a plug is shown, wherein Fig.17 17 shows the shape of mesh 1790 when the mesh can be deformed due to being in such a recess. As shown, mesh 1790 includes a recessed portion 1793, a waist portion 1795, and an outer portion 1797. Fig.17 In the example of FIG. 1 , the recessed portion 1793 and the waisted portion 1795 can be disposed in a recess or plug, while the outer portion 1797 can be exposed by being outside the plug. Fig.17 Also shown are various arrows representing forces that may be applied to the surface of the recess to help secure the mesh 1790 in the recess. Fig.17 Also shown is an approximately enlarged view of the wire mesh including three different states, in which the recessed portion 1793 is compressed, the waist portion 1795 is compressed to a greater extent, and the outer portion 1797 is substantially uncompressed (e.g., in a substantially freestanding, unsupported state).

[0137] As an example, a mesh may include a recessed portion that is greater than approximately 50% of the mesh and an exposed portion that is less than approximately 50% of the mesh.

[0138] Fig.18 An example of a method 1800 is shown, the method comprising: a tool frame 1810 for using a tool to position a mesh relative to a recess of a plug; a compression frame 1820 for compressing the mesh to push a portion of the mesh into the recess of the plug; and a manufacturing frame 1830 for manufacturing an assembly including a plug and a mesh at least partially disposed in the recess of the plug. The method 1800 is illustrated with respect to a plurality of figures that provide cross-sectional views of a portion of the plug 960 to expose the recess 980 and the mesh 990 as the plug is processed to form an assembly. Fig.18 18, tool 1801 may help position mesh 990, and tool 1803 may be used to compress mesh 990 to fit at least a portion of mesh 990 within recess 980. As an example, mesh 990 may be cut or trimmed using a cutting or trimming tool at one or more times during the execution of method 1800. As an example, a cutting or trimming tool may be used to achieve a desired mesh height and / or mesh shape with respect to a portion of mesh 990 extending outward from recess 980, wherein such a portion at least partially contacts a partition wall disposed between two exhaust passages in a closed state of plug 960 relative to the wastegate seat.

[0139] Fig.19 An example curve 1900 of engine torque in Newton meters (Nm) versus engine speed in revolutions per minute (RPM) is shown. Curve 1900 includes baseline data, a mesh having high stiffness data when overlap "A", a mesh having high stiffness data when there is no overlap, and a mesh having high stiffness data when overlap "B". Overlap refers to the widthwise dimension of the mesh relative to the dividing wall. As an example, the overlap can be selected to achieve a desired performance. As shown, the use of the mesh can increase engine torque over a range of engine speeds.

[0140] As an example, an assembly may include: a turbine housing including a hole, a wastegate seat, a wastegate passage extending to the wastegate seat, and a partition wall disposed between the wastegate passages, wherein the partition wall includes a partition wall surface; a rotatable wastegate shaft configured to be received by the hole; a wastegate arm extending from the wastegate shaft; and a wastegate plug extending from the wastegate arm, wherein the wastegate plug includes a contact portion and a mesh, the contact portion contacts the wastegate seat in a closed state to cover the wastegate passage, and the mesh contacts the partition wall surface in a closed state. In such an example, the mesh may be a wire mesh. As an example, the wire mesh may be made of an alloy, which may be a nickel-based alloy, a cobalt-based alloy, or another type of alloy. As an example, the mesh may be made of a nickel-chromium alloy.

[0141] As an example, a wastegate plug may include a recess in which a portion of the net is disposed. In such an example, the portion of the net disposed in the recess may be greater than 50% of the net. The recess may include an opening through which the net protrudes from the recess. In a closed state of the plug (which includes a portion of the net in the recess), another portion of the net protruding from the recess may contact a partition wall disposed between two exhaust passages. In the closed state, the net may impede the flow of exhaust gas from one of the exhaust passages to the other exhaust passage, and vice versa, for example.

[0142] As an example, the recess may include an inner portion and an opening, wherein the inner portion includes a transverse dimension that exceeds the transverse dimension of the opening. In such an example, the mesh may be constricted in the recess, wherein the mesh includes a waist created by the mouth or neck of the recess.

[0143] As an example, the wastegate arm and the wastegate plug may be formed as a unitary piece, for example, by machining or by casting, from a single piece of raw material. In such an example, the mesh may be a separate piece that cooperates with the wastegate plug. As an example, the wastegate shaft, the wastegate arm and the wastegate plug may be formed as a unitary piece, for example, by machining or by casting, from a single piece of raw material. In such an example, the mesh may be a separate piece that cooperates with the wastegate plug.

[0144] As an example, each of the two wastegate passages may have a corresponding opening defined in part by a dividing wall.

[0145] As an example, in a closed state, the mesh can reduce exhaust flow from one of the two wastegate passages to the other of the two wastegate passages. In such an example, the assembly can be operatively coupled to an internal combustion engine, wherein the reduction in exhaust flow increases torque of the internal combustion engine.

[0146] As an example, the contact portion of the wastegate plug may include a contour defined by a portion of an annulus. As an example, the wastegate seat may include a contour defined by a portion of a cone. As an example, the wastegate plug may include a contour defined by a portion of an annulus, and the wastegate seat may include a contour defined by a portion of a cone, wherein the contours contact to form a contact perimeter in a closed state of the wastegate plug relative to the wastegate seat.

[0147] As an example, in an open state of the wastegate plug relative to the wastegate seat, the mesh may include: a compressed inner portion that is seated in a recess of the wastegate plug; and an uncompressed exposed portion. In such an example, in a closed state, the exposed portion is compressed by contact with the partition wall surface. In such an example, the compressed exposed portion in the closed state includes a void space that is smaller than the void space of the uncompressed exposed portion in the open state.

[0148] As an example, a method may include: rotating a wastegate plug to cover a wastegate passage separated by a partition wall, the partition wall including a partition wall surface; compressing a portion of the mesh to engage the wastegate plug via contact between the portion of the mesh and the partition wall surface; and obstructing exhaust gas flow from one of the wastegate passages to another of the wastegate passages via the compressed portion of the mesh. Such a method may include: increasing engine torque with respect to an engine speed of an internal combustion engine by reducing vortex-to-vortex leakage of the exhaust (e.g., passage-to-passage leakage of the exhaust).

[0149] Although certain examples of methods, apparatus, systems, arrangements, etc. have been illustrated in the drawings and described in the foregoing detailed description, it will be understood that the disclosed example embodiments are not limiting but are capable of numerous rearrangements, modifications, and substitutions.

Claims

1. A component comprising: a turbine housing comprising a bore, a wastegate seat, a wastegate passage extending to the wastegate seat, and a divider wall disposed between the wastegate passages, wherein the divider wall comprises a divider wall surface; a rotatable wastegate shaft configured to be received by the aperture; a wastegate arm extending from the wastegate shaft; and A wastegate plug extending from the wastegate arm, wherein the wastegate plug includes a contact portion and a net, the contact portion contacts the wastegate seat in a closed state to cover the wastegate passage, and the net contacts the partition wall surface in the closed state.

2. The assembly according to claim 1, wherein The mesh is a wire mesh.

3. The assembly according to claim 2, wherein: The mesh comprises a nickel-chromium alloy.

4. The assembly according to claim 1, wherein: The wastegate plug includes a recess, wherein a portion of the mesh is seated in the recess.

5. The assembly according to claim 4, wherein: The portion of the web disposed in the recess is greater than 50% of the web.

6. The assembly according to claim 4, wherein: The recess comprises an opening, and wherein the mesh protrudes from the recess via the opening.

7. The assembly according to claim 4, wherein: The recess includes an inner portion and an opening, wherein the inner portion includes a lateral dimension that exceeds a lateral dimension of the opening.

8. The assembly of claim 1, wherein: The wastegate arm and the wastegate plug are a unitary piece.

9. The assembly according to claim 8, wherein: The mesh is a separate piece that cooperates with the wastegate plug.

10. The assembly of claim 1, wherein: The wastegate shaft, the wastegate arm and the wastegate plug are a unitary piece.

11. The assembly according to claim 10, wherein The mesh is a separate piece that cooperates with the wastegate plug.

12. The assembly of claim 1, wherein: Each of the wastegate passages includes a corresponding opening defined in part by the dividing wall.

13. The assembly of claim 1, wherein: In the closed state, the mesh reduces exhaust gas flow from one of the wastegate passages to another of the wastegate passages.

14. The assembly of claim 13, wherein: The assembly is operatively coupled to an internal combustion engine, wherein a reduction in exhaust gas flow increases torque of the internal combustion engine.

15. The assembly of claim 1, wherein: The contact portion of the wastegate plug includes a profile defined by a portion of an annulus.

16. The assembly of claim 1, wherein: The wastegate seat includes a profile defined by a portion of a cone.

17. The assembly of claim 1, wherein: In an open state of the wastegate plug relative to the wastegate seat, the mesh includes a compressed inner portion seated in a recess of the wastegate plug and an uncompressed exposed portion.

18. The assembly of claim 17, wherein: In the closed state, the exposed portion is compressed by contact with the partition wall surface.

19. The assembly of claim 18, wherein: The compressed exposed portion of the closed state includes a void space that is smaller than a void space of the uncompressed exposed portion of the open state.

Images