Liquid-cooled housing for turbocharger power modules

Abstract

A turbocharger includes a bearing housing containing a motor within an interior portion of the bearing housing. A liquid-cooled power module is secured to the exterior portion of the bearing housing. The power module has a housing comprising first and second sealed volumes separated by a common wall and contains electrical components that power the motor and control its speed. The first volume is a liquid-cooled compartment for removing heat generated by the electrical components, and the second volume is a liquid-free compartment containing the electrical components. The electrical components are secured to the common wall formed of a thermally conductive material, which may include heat sink fins extending into the first volume to optimize heat transfer from the common wall to the liquid-cooled compartment. Finally, the liquid-cooled power module is in direct communication with the motor through the bearing housing.

Description

Technical Field

[0001] The present invention generally relates to turbochargers including a bearing housing containing an electric motor configured to increase turbocharger speed in response to engine performance demands, and more particularly to liquid cooling of a power module configured to control such an electric motor. Background Art

[0002] Hybrid turbochargers are often employed to avoid the so-called "turbocharger lag" associated with "standard" turbochargers, which rely solely on exhaust pressure for operation. When relying solely on exhaust pressure, the turbocharger turbine typically requires nearly a second to accelerate to the commanded speed. In recent years, particularly in high-performance vehicles, electric motors incorporated into the turbocharger bearing housing have been used to improve acceleration time, thereby improving on-demand engine performance.

[0003] The turbocharger environment presents challenges for the physical placement of the electrical components that provide motor control due to the significant heat generated both inside and outside the turbocharger bearing housing that houses the motor. Consequently, the associated motor controls are typically placed on or near the turbocharger compressor housing, which is cooler than the area near the turbocharger turbine and bearing housing. However, the greater the physical separation between the electronic controls and the turbocharger motor, the greater the potential for electromagnetic interference (EMI).

[0004] Ideally, the power module containing the motor control would be mounted to the bearing housing to reduce the EMI signature and allow the phase lead from the module to be connected directly to its associated motor through the bearing housing. Summary of the Invention

[0005] In one described embodiment of the present invention, a turbocharger bearing includes a motor contained within a bearing housing. A liquid-cooled power module, including electrical components for controlling the motor, is secured to an exterior portion of the bearing housing. The power module has a housing comprising first and second sealed volumes separated by a common wall; the first volume defines a liquid-cooled compartment, and the second volume defines a liquid-free compartment for the electrical components secured to the common wall. Heat from the power components is transferred through the common wall into the liquid-cooled compartment. The liquid-cooled power module communicates directly with the motor through the bearing housing.

[0006] In another described embodiment of the present invention, a hybrid turbocharger includes a turbocharger bearing housing containing a motor within the bearing housing. A liquid-cooled power module, including electrical components for controlling the motor, is secured to an exterior portion of the bearing housing. The power module has a housing comprising first and second sealed volumes separated by a common wall; the first volume defines a liquid-cooled compartment, and the second volume defines a liquid-free compartment for the electrical components secured to the common wall. Heat from the power components is transferred through the common wall into the liquid-cooled compartment. The liquid-cooled power module communicates directly with the motor through the bearing housing.

[0007] In yet another described embodiment of the present invention, a method of manufacturing a turbocharger bearing housing includes the steps of mounting an electric motor within the interior of the bearing housing and providing a liquid-cooled power module including electrical components for controlling the electric motor. The method also includes securing the power module to the exterior of the bearing housing and forming a housing for the power module to include first and second sealed volumes separated by a common wall. The method further provides that the first volume defines a liquid-cooled compartment and the second volume defines a liquid-free compartment for the electrical components, the electrical components being secured to the common wall such that heat from the power components is transferred through the common wall into the liquid-cooled compartment. Finally, the method also provides that the liquid-cooled power module is directly connected to the motor through the bearing housing. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] One or more embodiments of the present invention will be described below with reference to the accompanying drawings, wherein like reference numerals represent like elements, and wherein:

[0009] Figure 1 is a perspective view of a turbocharger including a power module constructed in accordance with one embodiment of the present invention;

[0010] Figure 2 It is along Figure 1 The line 2-2 intercepts Figure 1 An enlarged cross-sectional view of an embodiment of the present invention;

[0011] Figure 3 It is along Figure 1 The line 3-3 intercepts Figure 1 Another view of the same embodiment of FIG. 1; and

[0012] Figure 4 is a perspective view of a power module, but with portions removed and / or cut away to show internal details constructed in accordance with one embodiment of the present invention.

[0013] Figure 5 yes Figure 4 FIG. 1 is a front cross-sectional view of a power module of the same embodiment. DETAILED DESCRIPTION

[0014] First refer to Figure 1 The turbocharger 10 includes a turbine housing 12 at one end and a compressor housing 14 at the other end. A bearing housing 16 is located between the turbine housing 12 and the compressor housing 14. Those skilled in the art will appreciate that the internal components of a turbocharger typically include a turbine unit (although not shown) within the turbine housing 12 and a compressor unit (not shown) within the compressor housing 14. A scroll shaft (also not shown) rotates within bearings (not shown) within the bearing housing 16 and physically connects the turbine and compressor units.

[0015] As shown, turbocharger 10 includes a boost control actuator 18 coupled to an actuation control lever 20, which in turn is coupled to an actuator valve arm 21. As will be understood by those skilled in the art, this latter element controls a bypass valve assembly 22, which in turn controls a wastegate device (not shown) or other valve arrangement to control boost pressure and prevent over-pressurization of the turbine unit. An oil and coolant manifold 24 is mounted on bearing housing 16 and includes connection ports to accommodate the movement of the latter fluid into and out of bearing housing 16.

[0016] Reference Figure 2 As shown in FIG. 1 , the power module 30 includes a sealed protective housing 31 attached to the bearing housing 16. To this end, upper and lower brackets 32 securely support the rectangular or box-shaped power module housing 31 in place on the generally circular outer portion 48 of the generally annular bearing housing 16. A power receptacle 26 and a communication receptacle 28 extend from the housing 31 to accommodate the power and signal management needs of the power module 30, respectively.

[0017] exist Figure 3 In the cross-sectional view of FIG, a turbocharger motor 40 is shown coaxially located within the annular bearing housing 16 to drive the scroll shaft as desired. To this end, the power module communicates with the motor 40, which may be a three-phase motor, as in the embodiment shown, having phase leads 42, 44, and 46 connected to the stator 41 of the motor 40. In the depicted embodiment, the phase leads enter the power module 30 directly through a sealed bore 43 extending from an inner portion 49 to an outer portion 48 of the bearing housing 16.

[0018] Reference Figure 4 , showing the internal portion of the power module 30 in more detail. The power module 30 controls the power and speed of the motor 40, which must quickly accelerate to speeds of up to 40-50,000 RPM. To this end, the component 30a of the power module 30 may include, among other components, a ferrite snubber 62; a main power connector 70 extending from the snubber 62, a busbar assembly 66, and a printed circuit board (PCB) 68. In the disclosed embodiment, additional components of 30a include various phase leading front ends 42', 44', and 46' that are connected to the power module 30 (see FIG. Figure 5 As described below, each component 30a is contained within a sealed housing 31 having a double volume defining a liquid-tight compartment. Figure 4 , the upper panel of the housing 31 has been removed, revealing a pair of side panels 50 and a bottom panel 52 of the housing 31. Those skilled in the art will appreciate that the buffer 62 is designed to reduce electromagnetic interference (EMI) in high-power and / or high-frequency electronic control system environments. In the illustrated configuration, the plastic overmold 64 is configured to permanently force the busbar contacts against the PCB 68.

[0019] Also reference Figure 5 , the housing 31 includes coolant nozzles 36 and 38 ( Figure 1 ). Volume 72 defines a liquid-cooled compartment 72a for removing and dissipating heat generated by the aforementioned electronic components 30a of power module 30. A second upper volume 74 defines a liquid-free compartment 74a configured to contain the electrical components 30a, all of which are mounted and / or secured to the common wall 60 located between compartments 72a and 74a. To most effectively transfer heat into the common wall 60, the components 30a can be secured directly to a thermal pad, adhesive, or even to a conductive putty applied between the components 30a and the upper surface of the common wall 60.

[0020] In the illustrated embodiment, the housing 31 including the common wall 60 may be formed of aluminum or other thermally conductive materials, particularly to ensure that heat is effectively transferred and dissipated from the common wall 60 into the liquid-cooled compartment 72a. The common wall 60 may also include heat dissipation fins 80 extending from the common wall 60 into the compartment 72a, as shown, to optimize heat transfer into the liquid-cooled compartment 72a. Obviously, the heat dissipation fins 80 will allow the liquid to pass through the flow channel 54 ( Figure 4 ) is arranged in a manner that minimizes impedance to the flow of cooling fluid.

[0021] Finally, to provide effective protection for the power module 30 (including its electrical components 30a), the compartments 72a and 74a may be sealed from each other and from the external turbocharger environment.

[0022] A method of manufacturing a turbocharger bearing housing may include the steps of mounting an electric motor 40 within the interior 49 of the bearing housing 16 and providing a liquid-cooled power module 30 including electrical components 30a for controlling the electric motor. The method may also include securing the power module 30 to the exterior 48 of the bearing housing and forming a housing for the power module, the housing including first and second sealed volumes 72, 74 separated by a common wall 60. The method may further provide that the first volume 72 defines a liquid-cooled compartment 72a and the second volume 74 defines a liquid-free compartment 74a for the electrical components 30a, the latter of which is secured to the common wall such that heat is transferred from the power components through the common wall to the sealed, liquid-cooled compartment. Finally, the method also provides that the liquid-cooled power module 30 is in direct communication with the motor 40 through the bearing housing 16.

[0023] Industrial Applicability

[0024] The described embodiments of the hybrid turbocharger can be used in a variety of applications that can benefit from the present invention. Physically placing the power module 30 on the bearing housing provides an effective way to minimize the EMI signature typically associated with turbocharger motor control. Furthermore, while the described turbocharger 10 can be used to increase on-demand vehicle engine performance, other environments and uses involving non-vehicle applications may be suitable for the disclosed technology.

[0025] Furthermore, it should be understood that the foregoing may be a description of only one embodiment of the present invention. However, the present invention is not limited to the specific embodiments disclosed. For example, with appropriate modifications, the phase advance may be oriented and / or contained within the bearing housing in other configurations not shown or described herein. Furthermore, statements contained in the specification relating only to specific embodiments should not be construed as limitations on the scope of the invention or on specific terms used in the claims, except where a term or phrase may have been expressly defined otherwise. Various other embodiments, changes, and modifications to the disclosed embodiments will be apparent to those skilled in the art and are intended to fall within the spirit and scope of the appended claims.

[0026] As used herein, when used in conjunction with a list of one or more components or other items, the various terms "such as," "for example," "for example," "such as," and "etc.", as well as the verbs "comprise," "have," "include," and other verb forms, are to be interpreted as open-ended, meaning that the list should not be considered to exclude other or additional components or items. Unless used in a context that clearly requires a specific interpretation, all terms are to be given their broadest reasonable meaning.

Claims

1. A bearing box comprising: a motor, said motor being contained within said bearing housing; a power module secured to an exterior portion of the bearing housing, the power module containing electrical components that power the motor and control the speed of the motor, the power module having a housing including a sealed first volume and a second volume separated by a common wall; the first volume defining a liquid-cooled compartment including a plurality of heat sink fins extending from the common wall; the second volume defining a liquid-free compartment containing the electrical component, the electrical component being secured to the common wall; wherein heat is transferred from the electrical components into the liquid-cooled compartment through the common wall; and The power module is directly connected to the motor through the bearing housing.

2. The bearing housing of claim 1 wherein the motor has at least one phase lead extending from the motor directly through the bearing housing and into the power module.

3. The bearing housing according to claim 1, wherein the motor is a three-phase motor.

4. The bearing housing of claim 3, wherein at least three phase leads are attached to the stator of the motor, the phase leads extending directly from the motor through the bearing housing and into the power module.

5. The bearing housing of claim 1, wherein the power module is secured to the bearing housing by a bracket, wherein the housing defined by the power module is formed of aluminum.

6. The bearing housing of claim 1, wherein the power module includes separate communication and power receptacles, wherein the power receptacle includes a ferrite snubber for limiting electromagnetic interference.

7. The bearing housing of claim 1 , wherein the power module comprises a printed circuit board, spaced apart busbar contacts, and a plastic overmold in the second volume, wherein the plastic overmold is configured to permanently force the busbar contacts against the printed circuit board.

8. A turbocharger comprising: A turbocharger bearing housing containing a motor within the bearing housing: a power module secured to an outer portion of the bearing housing; the power module having a housing and containing electrical components for supplying power to the motor and controlling the speed of the motor, the housing including a sealed first volume and a second volume separated by a common wall, the first volume providing a liquid-cooled compartment including a plurality of heat sink fins extending from the common wall, the second volume providing a liquid-free compartment containing the electrical components, the electrical components being secured to the common wall; wherein heat from the electrical components is transferred through the common wall into the liquid-cooled compartment, and The power module is directly connected to the motor through the bearing housing.

9. The turbocharger of claim 8, wherein the motor has at least one phase lead extending from the motor directly through the bearing housing and into the power module.

10. The turbocharger of claim 8, wherein the motor is a three-phase motor.

11. The turbocharger of claim 10, wherein at least three phase leads are attached to the stator of the motor, the phase leads extending from the motor directly through the bearing housing and into the power module.

12. The turbocharger of claim 8, wherein the power module is secured to the bearing housing by a bracket, wherein the housing defined by the power module is formed of aluminum.

13. The turbocharger of claim 8, wherein the power module includes separate communication and power receptacles, wherein the power receptacle includes a ferrite snubber for limiting electromagnetic interference.

14. The turbocharger of claim 8, wherein the power module comprises a printed circuit board, spaced apart busbar contacts, and a plastic overmold in the second volume, wherein the plastic overmold is configured to permanently force the busbar contacts against the printed circuit board.

15. A method for manufacturing a turbocharger bearing housing, comprising the following steps: Install the electric motor inside the bearing housing; providing a power module including electrical components for powering and controlling the electric motor, and securing the power module to the exterior of the bearing housing; forming a housing for the power module to include a sealed first volume and a second volume separated by a common wall; securing the electrical components to the common wall; wherein the first volume defines a liquid-cooled compartment for cooling the electrical components, the liquid-cooled compartment including a plurality of heat sink fins extending from the common wall, and the second volume defines a liquid-free compartment containing the electrical components; wherein heat is transferred from the electrical components into the liquid-cooled compartment through the common wall; and The power module is directly connected to the motor through the bearing housing.

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