A valve for a turbocharger and a turbocharger

Abstract

The utility model discloses a valve and turbocharger for turbocharger, the valve includes valve piece, and its bottom is equipped with valve seat function part, and this function part includes gradually in the air current direction: the gentle section of the current that is used to guide the exhaust gas preliminarily, the air current transition section that is used to guide the air current diffusion is constituted to the air current transition face that extends to the outside by two self -induction gentle parts and inclines upwards, the sealing cooperation section that has two sealing cooperation faces and is used to abut and seal with the supporting surface of the upper end of exhaust gas bypass channel, and sealing cooperation face and air current transition face present non -zero angle. Correspondingly, the supporting surface of turbocharger volute and exhaust gas bypass channel junction is equipped with the air current guide surface, and this guide surface is parallel with the air current transition face of valve, and together constitutes the taper channel of guiding exhaust gas. The utility model ensures reliable sealing while optimizing the air current path and the flow cross section, realizes the accurate control to the exhaust gas discharge amount.

Description

Technical Field

[0001] This invention relates to the field of turbocharging technology, and more particularly to a valve for a turbocharger and a turbocharger. Background Technology

[0002] In the field of turbocharger technology, the wastegate is a key component for preventing over-boosting of the system, and its performance directly affects the efficiency and reliability of the turbocharger system. Traditional wastegates mostly adopt a simple planar structure, which can achieve basic sealing functions, but during valve opening, the exhaust gas flow path changes abruptly, easily generating airflow separation and eddies, resulting in significant flow losses and limited discharge efficiency. In addition, this planar structure has limited control over the exhaust gas flow cross-section, making it difficult to precisely adjust the discharge volume under different operating conditions, and failing to meet the increasingly refined control requirements of OEMs for turbocharger performance.

[0003] To address the aforementioned issues, existing technologies have employed methods that incorporate protrusions or complex contours on the valve. However, these structures are typically small in size and complex in shape, requiring precision machining after casting to meet design requirements. This results in complex manufacturing processes and high costs. Furthermore, castings are prone to defects such as porosity and looseness under high temperature and pressure environments, affecting the strength and durability of the parts. Therefore, there is an urgent need in the field for a novel venting valve structure that ensures reliable sealing, precise flow regulation, and good manufacturability and durability. Summary of the Invention

[0004] To address the aforementioned shortcomings, this invention proposes a valve and turbocharger for turbochargers. By integrating a valve seat functional section consisting of a sealing section, an airflow transition section, and a smooth flow guiding section into the bottom of the valve plate, a reliable surface seal is ensured while the airflow path and flow cross-section are optimized during valve opening through a conical structure. This achieves precise control of the exhaust gas discharge, thus balancing sealing performance and flow regulation capability.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a valve for a turbocharger, comprising: The valve disc includes a valve disc body, the bottom of which has an integrally formed valve seat functional part, which includes, in sequence along the airflow direction: The flow smoothing section consists of a flow smoothing part, which is connected to the bottom of the valve seat functional part and is used to receive and initially guide the inflow of exhaust gas flow. The airflow transition section consists of two airflow transition surfaces that are in contact with the guide smooth section. The airflow transition surfaces extend upward from the guide smooth section and toward the outside of the exhaust gas bypass passage of the turbocharger volute, and are used to smoothly transition and guide the airflow through the guide smooth section. The sealing mating section has two symmetrically arranged sealing mating surfaces. The sealing mating surfaces are connected to the ends of the airflow transition surfaces and are used to abut against the support surface at the upper end of the exhaust gas bypass channel to achieve a seal. The sealing mating surfaces and the airflow transition surfaces form a non-zero angle.

[0006] Compared with the prior art, the advantages of the present invention are as follows: The turbocharger valve provided by this utility model achieves significant technological advancements by integrating a valve seat functional section consisting of a sealing mating section, an airflow transition section, and a flow guiding and smoothing section at the bottom of its valve plate. In the closed state, the valve, thanks to the symmetrically arranged sealing mating surfaces on its sealing mating section, can stably abut against the support surface at the upper end of the volute exhaust gas bypass passage, forming a reliable surface seal and effectively ensuring sealing performance and preventing gas leakage. Its innovation lies in the fact that, unlike the simple planar structure of ordinary vent valve plates, this valve uniquely adds a conical structure below the sealing mating surface. Specifically, this manifests as an airflow transition surface extending downwards from the sealing mating surface and inclined towards the centerline, and a flow guiding and smoothing section connecting to its end. The introduction of this conical structure optimizes the cross-sectional area and airflow path of the exhaust gas flow channel formed between the valve and the valve seat during valve opening. By precisely designing and adjusting this conical structure, especially the inclination angle of the airflow transition surface and the contour of the flow guiding and smoothing section, the exhaust gas release volume at different opening degrees can be precisely controlled, thereby flexibly adapting to the differentiated performance requirements of different OEMs for turbochargers. This not only improves the adjustment precision and control freedom of the turbocharger system, but also helps to improve the working efficiency and response characteristics of the turbocharger, while maintaining the reliability of traditional planar seals, thus achieving an organic combination of sealing performance and flow regulation performance.

[0007] As an improvement, the angle between the sealing mating surface and the airflow transition surface ranges from 90° to 150°. When this angle is within this optimized range, it achieves the best balance between ensuring reliable valve sealing and smooth airflow transition during valve opening. This effectively guides the exhaust gas flow from the gently flowing guide section through the airflow transition section to the sealing mating section, significantly reducing airflow separation and eddy currents caused by sharp bends in the flow channel, thereby reducing flow resistance and pressure loss. Simultaneously, this angle range ensures sufficient structural strength and rigidity at key connections in the valve seat functional area, avoiding stress concentration or deformation risks caused by excessively sharp or flat angles. This ensures the valve's sealing stability and durability under harsh high-temperature and high-pressure conditions during long-term operation. Furthermore, this optimized geometry makes the valve's flow characteristics more linear and predictable at different opening degrees, laying the structural foundation for precise control of exhaust gas discharge.

[0008] As an improvement, the ratio between the inward reduction of the flow-guiding smoothing section relative to the sealing mating surface and the downward settlement of the flow-guiding smoothing section relative to the sealing mating surface ranges from 0.5 to 2.5. This ratio defines the optimal profile of the key flow-guiding cavity at the bottom of the valve, allowing the flow-guiding smoothing section to initially guide and accelerate the inflowing exhaust gas with the most effective spatial configuration. When the ratio is too small, the cavity is too flat, which is not conducive to smooth airflow turning and is prone to generating eddies; when the ratio is too large, the cavity is too deep and narrow, which increases flow resistance and weakens structural strength. At this preferred ratio, the valve can form a smooth exhaust gas channel with a gradual change in flow area when opening, significantly reducing the energy loss of exhaust gas flow. At the same time, this ratio ensures that the valve seat functional part has balanced mechanical properties as a whole, avoiding local weakness caused by excessive inward reduction and preventing overall bulkiness and increased inertia caused by excessive settlement. Thus, while achieving excellent fluid performance, it also ensures the sensitivity of valve operation and structural reliability.

[0009] As an improvement, the flow-guiding smoothing section includes a flow-guiding smoothing plane. This structural form greatly simplifies the manufacturing process and mold design of the valve plate, which helps reduce production costs and ensure consistent dimensional accuracy. Compared to complex curved surface configurations, the simple planar structure is easier to process and inspect after casting or stamping. Functionally, this flow-guiding smoothing plane provides a stable and predictable initial guiding reference surface for the inflowing exhaust gas, effectively regulating airflow from different directions and avoiding local eddies or flow separation that may be caused by improper curvature of the curved surface. This lays a good foundation for the smooth diffusion of subsequent airflow in the transition section. At the same time, the planar structure also gives the bottom of the valve seat functional part higher overall rigidity and deformation resistance, ensuring the shape stability and functional reliability of the valve during long-term use.

[0010] As an improvement, the flow smoothing section includes an inwardly recessed flow smoothing groove. The surface of the flow smoothing groove is a functional molded surface that does not require machining. This groove structure can converge and guide the incoming exhaust gas in three dimensions, collecting and regulating the airflow more effectively compared to a planar structure. This structure significantly increases the initial contact area, allowing the exhaust gas to change its flow direction more smoothly and preparing it for subsequent transition diffusion, thereby fundamentally reducing the loss of flow energy. At the same time, the inwardly recessed structure forms a pre-compression zone in space, which can optimize the release characteristics of the airflow during the valve opening instant. Furthermore, by directly defining the surface of the flow smoothing groove as a functional molded surface, it indicates that the structure has the required airflow guiding function after the casting or forging blank is formed, without the need for subsequent machining processes. This not only avoids the high difficulty and high cost caused by machining small and complex concave features, but also simplifies the manufacturing process, improves production efficiency, and reduces material waste. At the same time, it maintains the consistency and reliability of valve performance, achieving cost reduction and efficiency improvement from the manufacturing process level, and enhancing the product's market competitiveness.

[0011] As an improvement, the upper end of the valve body is integrally equipped with a support column for passing through and connecting external linkage structures. By designing the support column and valve body as a single continuous body, not only are assembly errors and connection gaps that may exist in traditional split connections completely eliminated, significantly improving the structural rigidity and alignment accuracy of the components, but the assembly process is also simplified. This integrated structure ensures that the force transmission path is more direct and reliable when the valve is subjected to high-frequency opening and closing cycles and high-temperature exhaust gas impact, effectively avoiding sealing failure or control inaccuracy caused by loose connections. The support column serves as a unified installation reference, enabling the valve to be quickly and accurately aligned and installed with external linkage components such as bypass structures and gaskets. The fixed connection at the end forms a stable rotating pair, thereby ensuring precise contact between the sealing mating surface and the support surface while providing a smooth and reliable rotation center for the valve. Ultimately, this ensures the sealing stability and operational reliability of the vent valve component under long-term harsh operating conditions.

[0012] A turbocharger employs any of the aforementioned turbocharger valves. An airflow guide surface is provided at the connection between the support surface and the inner wall of the exhaust gas bypass passage. This airflow guide surface and the airflow transition surface are arranged parallel to each other, together forming a converging channel for guiding exhaust gas. This structure eliminates the severe turbulence and throttling losses caused by steps or abrupt changes in flow path at component joints when exhaust gas flows out of the bypass passage and enters the converging channel. This converging channel ensures stable and predictable flow characteristics of the valve at different opening degrees, providing a guarantee for precise engine control. Without excessively increasing structural complexity and manufacturing costs, system-level performance optimization is achieved, resulting in significant synergistic effects.

[0013] As an improvement, the exhaust bypass channel includes a single, continuous, non-splittered flow path, allowing the exhaust gas released from the valve to flow along a concentrated and smooth main path. This effectively avoids flow interference, uneven airflow distribution, and additional splitting losses that may occur in multi-channel designs. The single flow path reduces the contact area between the exhaust gas and the channel wall and the number of local turning points, significantly reducing flow resistance and energy loss, thereby improving the exhaust gas release efficiency. This not only helps the turbocharger to control the boost pressure more quickly and accurately, improving the engine's transient response characteristics, but also reduces the complexity of the volute structure due to the simplified flow path structure, improving the feasibility of the casting process and the consistency of the product, thus enhancing the turbocharger's working efficiency and reliability at the system level.

[0014] As an improvement, the exhaust bypass channel includes two parallel and fluid-connected diversion channels. The parallel operation of the dual channels also improves flow stability, reduces airflow pulsation and local high-speed areas that are prone to occur in a single channel, and helps to reduce airflow noise and suppress related vibrations. In addition, this structure provides a redundant path for exhaust gas flow. Even under abnormal operating conditions such as partial carbon buildup, the system can still maintain a considerable discharge capacity through the other channel, enhancing the robustness of the entire booster system. Together with the smooth flow guiding structure of the aforementioned valve, they form a highly efficient, stable and reliable exhaust bypass system. Attached Figure Description

[0015] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments: Figure 1 This is a schematic diagram of a valve for a turbocharger and a cross-sectional structure of a turbocharger, as shown in Embodiment 1. Figure 2 This is a schematic diagram of a valve structure for a turbocharger, as shown in Embodiment 1. Figure 3 This is a schematic diagram of a valve for a turbocharger and a cross-sectional structure of a turbocharger, as shown in Embodiment 2. Figure 4 This is a schematic diagram of a valve structure for a turbocharger, as shown in Embodiment 2. Figure 5 This is a schematic diagram of a flow channel without branching. Figure 6 This is a schematic diagram of the diversion channel structure.

[0016] The markings in the above figures are as follows: 1. Valve plate; 1.1. Valve plate body; 1.2. Valve seat functional part; 1.2.1. Sealing mating surface; 1.2.2. Airflow transition surface; 1.2.3. Flow guiding smooth plane; 1.2.4. Flow guiding smooth groove; 1.3. Support column; 2. Turbocharger; 2.1. Support surface; 2.2. Airflow guiding surface; 2.3. No flow splitter channel; 2.4. Flow splitter channel. Detailed Implementation

[0017] In this utility model, it should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "planar direction", "circumferential", etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this utility model and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.

[0018] Example 1 like Figures 1 to 2 As shown, a valve for a turbocharger includes a valve plate 1 comprising a valve plate body 1.1. The bottom of the valve plate body 1.1 has an integrally formed valve seat functional portion 1.2. The valve seat functional portion 1.2, along the airflow inflow direction, sequentially includes a flow guiding and smoothing section, an airflow transition section, and a sealing and mating section. The flow guiding and smoothing section is composed of a flow guiding and smoothing part connected to the bottom end of the valve seat functional portion 1.2, used to receive and initially guide the inflowing exhaust gas flow. The airflow transition section is composed of two airflow transition surfaces 1.2.2 that are in contact with the flow guiding and smoothing part. The airflow transition surface 1.2.2 extends upward from the guide smooth section and inclined towards the outside of the exhaust gas bypass passage of the turbocharger 2 volute, which is used to smoothly transition and guide the airflow through the guide smooth section. The sealing mating section has two symmetrically arranged sealing mating surfaces 1.2.1. The sealing mating surface 1.2.1 is connected to the end of the airflow transition surface 1.2.2, which is used to abut against the support surface 2.1 at the upper end of the exhaust gas bypass passage to achieve a seal. The sealing mating surface 1.2.1 and the airflow transition surface 1.2.2 form a non-zero included angle.

[0019] The included angle between the sealing mating surface 1.2.1 and the airflow transition surface 1.2.2 is in the range of 90°-150°, and preferably, the included angle in this embodiment is 125°.

[0020] The ratio between the inward shrinkage of the flow guiding smooth portion relative to the sealing mating surface 1.2.1 and the downward sinking of the flow guiding smooth portion relative to the sealing mating surface 1.2.1 ranges from 0.5 to 2.5. Preferably, the ratio in this embodiment is 0.7, wherein the inward shrinkage is 2.24 mm and the downward sinking is 3.20 mm.

[0021] The flow smoothing section includes the flow smoothing plane 1.2.3.

[0022] The upper end of the valve body 1.1 is integrally provided with a support column 1.3 for passing through and connecting an external linkage structure. Preferably, the external linkage structure includes a bypass structure and a gasket that are sequentially sleeved and installed on the support column 1.3. One end of the transition tube of the bypass structure is provided with a first limiting surface, and one end of the gasket is provided with a second limiting surface that cooperates with the first limiting surface to control the rotation of the valve. This is prior art and will not be described in detail here.

[0023] A turbocharger 2 has an airflow guide surface 2.2 at the connection between the support surface 2.1 and the inner wall of the exhaust gas bypass passage. The airflow guide surface 2.2 is arranged parallel to the airflow transition surface 1.2.2 to jointly form a narrowing passage for guiding exhaust gas.

[0024] like Figure 2 As shown, the arrows indicate the direction of gas flow. When the turbocharger 2 is working, exhaust gas flows out from the exhaust gas bypass passage and sequentially passes through the valve seat functional part 1.2 of the valve plate 1. Specifically, the airflow first reaches the guide smoothing section, where the guide smoothing plane 1.2.3 guides and converges the dispersed airflow, forming a preliminary flow. Subsequently, the airflow enters the airflow transition section, guided by two symmetrically arranged airflow transition surfaces 1.2.2. The airflow flows upward and outward from the guide smoothing section. The airflow transition surface 1.2.2 and the sealing mating surface 1.2.1 form a non-zero angle, preferably 125°, to achieve a smooth transition and change of direction for the airflow. Finally, the airflow flows through the sealing mating section, where the two symmetrically arranged sealing mating surfaces 1.2.1 abut against the support surface 2.1 at the upper end of the exhaust gas bypass passage of the turbocharger 2 volute. However, when the valve is open, airflow is allowed to pass through. The contact area between the sealing mating surface 1.2.1 and the support surface 2.1 ensures sealing. At the same time, the airflow finally flows out from the valve and enters the subsequent flow channel.

[0025] Example 2 like Figures 3 to 4As shown, a valve for a turbocharger includes a valve plate 1 comprising a valve plate body 1.1. The bottom of the valve plate body 1.1 has an integrally formed valve seat functional portion 1.2. The valve seat functional portion 1.2, along the airflow inflow direction, sequentially includes a flow guiding and smoothing section, an airflow transition section, and a sealing and mating section. The flow guiding and smoothing section is composed of a flow guiding and smoothing part connected to the bottom end of the valve seat functional portion 1.2, used to receive and initially guide the inflowing exhaust gas flow. The airflow transition section is composed of two airflow transition surfaces 1.2.2 that are in contact with the flow guiding and smoothing part. The airflow transition surface 1.2.2 extends upward from the guide smooth section and inclined towards the outside of the exhaust gas bypass passage of the turbocharger 2 volute, which is used to smoothly transition and guide the airflow through the guide smooth section. The sealing mating section has two symmetrically arranged sealing mating surfaces 1.2.1. The sealing mating surface 1.2.1 is connected to the end of the airflow transition surface 1.2.2, which is used to abut against the support surface 2.1 at the upper end of the exhaust gas bypass passage to achieve a seal. The sealing mating surface 1.2.1 and the airflow transition surface 1.2.2 form a non-zero included angle.

[0026] The included angle between the sealing mating surface 1.2.1 and the airflow transition surface 1.2.2 is in the range of 90°-150°, and preferably, the included angle in this embodiment is 125°.

[0027] The ratio between the inward shrinkage of the flow guiding smooth portion relative to the sealing mating surface 1.2.1 and the downward sinking of the flow guiding smooth portion relative to the sealing mating surface 1.2.1 ranges from 0.5 to 2.5. Preferably, the ratio in this embodiment is 0.7, wherein the inward shrinkage is 2.24 mm and the downward sinking is 3.20 mm.

[0028] The flow smoothing section includes an inwardly recessed flow smoothing groove 1.2.4, the surface of which is a functional shaped surface that does not require machining.

[0029] The upper end of the valve body 1.1 is integrally provided with a support column 1.3 for passing through and connecting an external linkage structure. Preferably, the external linkage structure includes a bypass structure and a gasket that are sequentially sleeved and installed on the support column 1.3. One end of the transition tube of the bypass structure is provided with a first limiting surface, and one end of the gasket is provided with a second limiting surface that cooperates with the first limiting surface to control the rotation of the valve. This is prior art and will not be described in detail here.

[0030] A turbocharger 2 has an airflow guide surface 2.2 at the connection between the support surface 2.1 and the inner wall of the exhaust gas bypass passage. The airflow guide surface 2.2 is arranged parallel to the airflow transition surface 1.2.2 to jointly form a narrowing passage for guiding exhaust gas.

[0031] like Figure 4As shown, the arrows indicate the direction of gas flow. When the turbocharger 2 is working, exhaust gas flows out from the exhaust gas bypass passage and sequentially passes through the valve seat functional part 1.2 of the valve plate 1. Specifically, the airflow first reaches the guide smoothing section, where the guide smoothing groove 1.2.4 guides and converges the dispersed airflow, forming a preliminary flow collection. Subsequently, the airflow enters the airflow transition section, guided by two symmetrically arranged airflow transition surfaces 1.2.2. The airflow flows upward and outward from the guide smoothing section, and the airflow transition surface 1.2.2 and the sealing mating surface 1.2.1 form a non-zero angle, preferably 125°, to achieve a smooth transition and change of direction of the airflow. Finally, the airflow flows through the sealing mating section, where the two symmetrically arranged sealing mating surfaces 1.2.1 abut against the support surface 2.1 at the upper end of the exhaust gas bypass passage of the turbocharger 2 volute. However, when the valve is open, airflow is allowed to pass through. The contact area between the sealing mating surface 1.2.1 and the support surface 2.1 ensures sealing, and the airflow finally flows out from the valve into the subsequent flow channel.

[0032] like Figure 5 As shown, the exhaust bypass channel includes a single, continuous, non-splitting flow channel 2.3.

[0033] like Figure 6 As shown, the exhaust bypass channel includes two parallel flow channels 2.4 with fluids connected in parallel.

[0034] The above description only illustrates the preferred embodiments of the present invention and should not be construed as limiting the scope of the claims. The present invention is not limited to the above embodiments, and variations in its specific structure are permitted. All modifications made within the scope of the independent claims of this invention are also within the scope of protection of this invention.

Claims

1. A valve for a turbocharger, characterized by, include: A valve disc, including a valve disc body, wherein the bottom of the valve disc body is constructed with an integrally formed valve seat functional part, the valve seat functional part comprising, in sequence along the airflow inflow direction: The flow smoothing section is composed of a flow smoothing part, which is connected to the bottom end of the valve seat functional part and is used to receive and initially guide the inflow of exhaust gas flow. The airflow transition section consists of two airflow transition surfaces that are in contact with the smooth flow section. The airflow transition surfaces extend upward from the smooth flow section and toward the outside of the exhaust gas bypass passage of the turbocharger volute, and are used to smoothly transition and guide the airflow through the smooth flow section. The sealing mating section has two symmetrically arranged sealing mating surfaces. The sealing mating surfaces are connected to the ends of the airflow transition surfaces and are used to abut against the support surface at the upper end of the exhaust gas bypass channel to achieve a seal. The sealing mating surfaces and the airflow transition surfaces form a non-zero angle.

2. The valve for a turbocharger according to claim 1, characterized in that: The angle between the sealing mating surface and the airflow transition surface ranges from 90° to 150°.

3. The valve for a turbocharger as set forth in claim 1, wherein: The ratio between the inward reduction of the flow guiding smoothing part relative to the sealing mating surface and the downward sinking of the flow guiding smoothing part relative to the sealing mating surface ranges from 0.5 to 2.

5.

4. The valve for a turbocharger as set forth in claim 1, wherein: The flow-guiding smoothing section includes a flow-guiding smoothing plane.

5. The valve for a turbocharger as set forth in claim 1, wherein: The flow guiding and smoothing portion includes an inwardly recessed flow guiding and smoothing groove, the surface of which is a functional shaped surface that does not require cutting and finishing.

6. The valve for a turbocharger as set forth in claim 1, wherein: The upper end of the valve plate body is integrally provided with a support column for passing through and connecting to an external linkage structure.

7. A turbocharger employing a valve according to any one of claims 1 to 6. An airflow guiding surface is provided at the connection between the support surface and the inner wall of the exhaust gas bypass channel. The airflow guiding surface and the airflow transition surface are arranged parallel to each other to form a gradually narrowing channel for guiding exhaust gas.

8. A turbocharger as claimed in claim 7, characterised in that: The exhaust gas bypass channel comprises a single, continuous, non-splittered flow channel.

9. A turbocharger as claimed in claim 7, wherein: The exhaust gas bypass channel includes two parallel diversion channels with fluids connected in parallel.

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