A WASTE GATE FOR AN ENGINE SYSTEM

Abstract

Wastegate (128, 401), comprehensive: a valve plate (403, 501) comprising a curved multiplane surface (405, 513) on an inner side of the valve plate (403, 501), wherein the curved multiplane surface (405, 513) forms a raised edge (406, 505) on a first side of the valve plate (624) and a side opening (422, 506) on a second side of the valve plate (625); and a channel (410, 604) comprising a narrowed area (414, 612) arranged upstream of the valve plate (403, 501) and aligned with the raised edge (406, 505), wherein the valve plate (403, 501) is positioned at one end of the channel (410, 604), wherein an inner side wall (609) of the channel (410, 604) tapers at the narrowed area (414, 612) to a central axis (603) of the channel (410, 604) and the taper increases as the inner side wall (609) gets closer to the valve plate (403, 501).

Description

Area

[0001] The disclosure concerns a wastegate that is mounted on an exhaust duct of a turbocharger to direct exhaust flow to an exhaust catalyst. Background and brief description

[0002] In a turbocharger system, the exhaust gas flow can be partially directed to an exhaust gas turbocharger to drive a compressor that supplies air to the engine cylinders, while the remaining portion of the exhaust gas can flow through a bypass channel around the turbine to an exhaust gas catalyst located downstream of the turbine. The bypass channel may include a wastegate valve that can be set to an open position, allowing exhaust gases to bypass the turbine and flow to the catalyst. The wastegate valve can also be set to a closed position, which at least partially blocks the exhaust gas flow in the bypass channel, thus directing most of the exhaust gas supplied by the engine to the turbine.During a cold engine start, exhaust gas can be at least partially routed through the bypass channel and wastegate to direct the exhaust flow to the front of the catalytic converter, thus enabling catalytic converter activation to be achieved more quickly.

[0003] An exemplary design of a wastegate valve in the exhaust duct of a turbocharger is disclosed by Grabowska in US 2015 / 0345375 A1. This design provides a wastegate valve assembly with flow formations to direct exhaust gas in a primary flow direction while reducing exhaust gas losses in secondary flow directions. Specifically, the wastegate incorporates flow formations on a valve body supported by a valve arm pivotally mounted on a turbine housing. Exemplary flow formations on the valve body include a concave disk, flat ribs, and an enlarged semicircular surface formed on the valve body to direct exhaust gas flow in the primary direction.

[0004] DE 10 2012 218 137 A1 shows a wastegate comprising: a valve plate, including a curved multiplane surface on an inside of the valve plate, wherein the curved multiplane surface forms a raised edge on a first side of the valve plate and a side opening on a second side of the valve plate.

[0005] EP 2 251 533 A1 discloses a wastegate comprising: a valve plate, a channel including a constricted area arranged upstream of the valve plate, the valve plate being positioned at one end of the channel, an inner side wall of the channel tapering towards a central axis of the channel at the constricted area.

[0006] The inventors of the present invention have recognized potential problems with the exemplary approach disclosed above in US 2015 / 0 345 375 A1. For example, the exhaust gas flow in the valve body, which is formed with the concave disc or flat ribs, can spread in multiple directions, impinging on turbocharger walls and creating turbulent flow conditions. Consequently, exhaust gas energy can be transferred to the turbocharger walls, resulting in reduced flow efficiency and energy losses. Furthermore, because the flow spreads in multiple directions before flowing downstream, less exhaust gas heat can reach the catalyst, potentially leading to delayed catalyst activation.

[0007] Based on this, an object of the present invention is to provide a wastegate arrangement in which the exhaust gas flow guided through the wastegate can be directed in a downstream direction in the region of the valve body without first distributing itself in several directions within the valve body. This object is achieved by the features of the independent claims. Advantageous embodiments of the invention are described in the dependent claims.

[0008] Accordingly, the inventors of the present invention have developed a wastegate design to address the aforementioned problems, at least in part. In an exemplary design, a wastegate can be provided comprising: a valve plate comprising a curved multiplane surface on an inner surface of the valve plate, wherein the curved surface forms a raised edge on a first side of the valve plate and a side opening on a second side of the valve plate; a channel comprising a constricted region arranged upstream of the valve plate and aligned with the raised edge, wherein the valve plate is positioned at one end of the channel.

[0009] In this way, the wastegate design can be used to improve flow efficiency and reduce energy losses in the turbocharger, while simultaneously enhancing catalyst activation. For example, the curved multiplane surface on the valve plate, in conjunction with the constricted area in the channel, can act to direct the exhaust flow and increase the flow velocity downstream of the wastegate. Thus, the wastegate design can provide several advantages. By directing the exhaust flow downstream instead of distributing it in multiple directions, the wastegate can reduce exhaust energy losses to the turbocharger walls. Furthermore, the constricted area in the channel allows the exhaust flow to accelerate before exiting the wastegate. In this way, the wastegate valve can reduce exhaust energy losses to improve catalyst activation conditions while simultaneously reducing fuel emissions. Brief description of the drawings Fig. Figure 1 shows a schematic representation of an engine system, including a turbocharger system with an exhaust bypass channel configured with a wastegate valve. Fig. Figure 2 shows an exemplary turbocharger, including an exhaust gas bypass channel with a wastegate valve. Fig. Figure 3 shows a schematic representation of a first embodiment of a wastegate, comprising a wastegate valve with a valve plate actuator. Fig. Figure 4A shows a first view of a second embodiment of a wastegate valve in a closed wastegate position and with a channel having a constricted area formed on an inner wall of the channel. Fig. Figure 4B shows the second embodiment of the wastegate valve in an open position. Fig. Figure 4C shows an example of an alternative embodiment of a wastegate valve in an open position and with a channel without a constricted area formed on an inner wall of the channel. Fig. Figure 5A shows a first view of a valve plate of a third embodiment of a wastegate valve. Fig. Figure 5B shows a second view of the valve plate of the third embodiment of the wastegate valve. Fig. Figure 5C shows a third view of the valve plate of the third embodiment of the wastegate valve. Fig. Figure 6A shows a first view of the third embodiment of the wastegate valve in a closed position. Fig. Figure 6B shows a second view of the third embodiment of the wastegate valve in the closed position. Fig. Figure 6C shows a fourth embodiment of the wastegate valve in the closed position. Fig. Figure 7A shows a first view of the third embodiment of the wastegate valve in a partially open position. Fig. Figure 7B shows a second view of the third embodiment of the wastegate valve in the partially open position. Fig. Figure 8A shows a first view of the third embodiment of the wastegate valve in a fully open position. Fig. Figure 8B shows a second view of the third embodiment of the wastegate valve in the fully open position. Fig. Figure 9A shows a first cross-sectional view of the third embodiment of the wastegate valve in a closed position. Fig. Figure 9B shows a second cross-sectional view of the third embodiment of the wastegate valve in the closed position. Fig. Figures 2-9B are shown to scale, although other relative dimensions may be used if required. Detailed description

[0010] The following description concerns a turbocharger system with an exhaust bypass channel configured with a wastegate valve to control the exhaust flow around a turbine and to an exhaust catalyst positioned downstream of the turbine in an engine, as shown in Fig. 1 shown. As in Fig. Figure 2 shows an exemplary turbocharger with a wastegate valve that includes a valve actuation mechanism for controlling the exhaust gas flow within a bypass channel around the turbine and to the exhaust catalyst. The wastegate valve can be set to open or closed by the actuation mechanism using various means, including mechanical, hydraulic, electrical, and other suitable actuation means. Fig. Figure 3 shows a schematic view of a first embodiment of the wastegate, including a valve plate and a valve plate actuator. The wastegate also includes a channel with a curved inner surface that can direct the exhaust gas flow supplied from the engine cylinders (via the exhaust manifold) to the exhaust catalyst. Fig. Figure 4A shows a first view of a second embodiment of the wastegate valve in a closed wastegate position and with a channel having a constricted area formed on an inner wall of the channel. The wastegate valve can be placed in an open position to allow exhaust gas to flow through an outlet of the wastegate, as shown in Figure 4A. Fig. 4B is shown. An exemplary alternative embodiment of the wastegate valve in an open position and with a channel without a constricted area formed on an inner wall of the channel is shown in Fig. Figure 4C illustrates this. In this case, the exhaust gas can flow in multiple directions, as shown. The exhaust gas flow dispersing from the wastegate outlet can impinge on the walls of the exhaust duct downstream of the valve, causing turbulent flow conditions that can lead to exhaust energy loss. Fig. Figures 5A-5C showed schematic views of a valve plate of a third embodiment of the wastegate valve. Fig. Figures 5A-5B showed a first and second view of the valve plate of the third embodiment of the wastegate valve. Fig. Figure 5C shows a third view of the valve plate of the third embodiment of the wastegate valve. Fig. Figures 6A-6B show schematic views of the third embodiment of the wastegate valve in a closed position. Fig. Figure 6A shows a first view of the closed wastegate valve. Fig. Figure 6B shows a second view of the wastegate valve in the closed position. In each of the first and second views in the Fig. 6A-6B will be the wastegate valve with features that refer to the Fig. 5A-5C revealed valve plate resembling, revealed. Fig. Figure 6C shows a schematic view of a fourth embodiment of the wastegate valve in the closed position. Fig. Figures 7A-7B show schematic views of the third embodiment of the wastegate valve in a partially open position. Fig. Figure 7A shows a first view of the wastegate valve in the partially open position. Fig. Figure 7B shows a second view of the wastegate valve in the partially open position. In each of the first and second views of the Fig. 7A-7B: The wastegate valve is partially open to allow exhaust gas flow in one direction to an exhaust catalyst located downstream of the wastegate. Fig. Figures 8A-8B show a first and second view of the wastegate valve in a fully open position. When fully open, it can increase the exhaust gas flow through the wastegate outlet, thus reducing the duration of catalyst heating. Fig. Figures 9A-9B show a first and second cross-sectional view of the third embodiment of the wastegate valve in a closed position. A raised edge formed on an inner surface of the wastegate valve, in conjunction with a constricted area formed on an inner wall of a wastegate channel, can act to direct the exhaust gas flow through the valve outlet to the catalytic converter. In this way, the wastegate valve and channel can act to accelerate catalyst activation while minimizing fuel emissions.

[0011] The Fig. Figures 2-9B show exemplary configurations with the relative positioning of the various components of the wastegate valve and the exhaust duct. When such elements are shown to be in direct contact or directly coupled, they may be described as directly contacting or directly coupled, respectively, in at least one example. Similarly, elements shown to be abutting or adjacent may be described as abutting or adjacent, respectively, in at least one example. As an example, components that are in surface-sharing contact with each other may be described as surface-sharing contact. As another example, elements positioned separately from each other, with only a space between them and no other components, may be described as such in at least one example.As a further example, elements depicted above / below each other, on opposite sides, or to the left / right of each other can be described as such relative to one another. Furthermore, as illustrated in the figures, a topmost element or the highest point of an element can be referred to as the "top" of the component in at least one example, and a bottommost element or the lowest point of the element can be referred to as the "bottom" of the component. In the sense used here, top / bottom, upper / lower, and above / below can refer to a vertical axis of the figures and be used to describe the positioning of elements of the figures in relation to one another. Accordingly, elements depicted above other elements are, in one example, positioned vertically above the other elements.As a further example, the shapes of the elements depicted in the figures can be described as having these shapes (such as circular, straight, flat, curved, rounded, beveled, angled, or the like). Furthermore, elements depicted as intersecting each other can, in at least one example, be described as intersecting elements or as intersecting each other. Even further, an element depicted within or outside another element can, in one example, be described as such.

[0012] With reference to Fig. Figure 1 shows a schematic representation of a vehicle system 100, which includes an engine 10 with a turbocharger. The engine 10 can include a plurality of combustion chambers (i.e., cylinders). The engine 10 can include a plurality of cylinders 20 arranged in a linear four-cylinder configuration. However, it is understood that although Fig. Engine 10 shows four cylinders, but it can contain any number of cylinders. For example, engine 10 can have any number of cylinders, e.g., 2, 3, 4, 5, 6, or multiple cylinders in any configuration, e.g., V6, I6, V12, 4 opposed cylinders, etc.

[0013] Each cylinder 20 of the engine 10 can receive intake air from an intake manifold 27 via an intake air duct 28, which may include an intake air throttle 62. The position of the throttle 62 can be adjusted by a control system 14 via a throttle actuator (not shown), which is communicatively coupled to the control unit 12, which is connected to the sensors 16 and actuators 18. By modulating the throttle 62, a quantity of fresh air can be drawn from the atmosphere via the intake duct 29 and delivered through an air filter 30, as well as being compressed by the compressor 90 before being delivered to the engine cylinders. As mentioned above, the intake manifold 27 can communicate with one or more cylinders of the engine 10. In some embodiments, one or more of the inlet channels may include a turbocharger with a compressor 90 driven by an exhaust turbine 92 via a coupled shaft 94.In particular, the blades of turbine 92 can be driven by a portion of the exhaust gas flow or stream emitted from engine 10, causing shaft 94 to rotate and thus driving the compressor. For example, compressor 90 can be coupled to turbine 92 such that compressor 90 can be actuated when turbine 92 blades rotate at a predetermined speed. When actuated, compressor 90 can draw air from the atmosphere via inlet 29 and then direct pressurized air to inlet 28, from where it can then be directed to engine 10. The rotational speed of turbine 92 can be derived from one or more engine operating conditions.Alternatively, the compressed air can be diverted via the bypass channel 164, which is configured with a control valve 126 and connected to the inlet channels 28 and 29, to avoid compressor pumping during steady-state operation and transients.

[0014] The intake manifold 27 can be coupled to the cylinders 20 via intake ports (not shown). Each intake port can supply air and / or fuel to the corresponding cylinder for combustion. Each cylinder intake port can selectively communicate with the cylinder via one or more intake valves. In the illustrated example, each cylinder 20 is shown with two intake valves, I1 and I2. In one example, an intake channel can be formed from the intake manifold 27, which communicates selectively with each intake valve. In other embodiments, an intake channel for a single cylinder can be divided into two adjacent paths with an intervening wall, each divided path of the channel communicating with a single intake valve.In another example, each of the two intake valves can be controlled to open at specific engine speeds, thereby communicating with the intake manifold through a common intake port.

[0015] Each cylinder 20 can discharge combustion gases via an exhaust port (not shown) coupled to it. Each corresponding exhaust port can direct combustion gases from a corresponding cylinder to an exhaust manifold 54. For example, each cylinder exhaust port can selectively communicate with the cylinder via exhaust valves E1 and E2. In some examples, each cylinder can include two or more exhaust valves. The exhaust manifold 54 is fluidically coupled to an exhaust port 59, thereby enabling the exhaust gas flow to the turbine 92. As an example, the exhaust gas discharged from the cylinders 20 flows to an exhaust manifold 54, and the exhaust gas is further conveyed to the turbine via the exhaust port 59. In one example, the exhaust gas delivered to the turbine causes rotation of the turbine blade, which drives the compressor 90 via the shaft 94.Furthermore, the exhaust port 59 can be coupled to an exhaust gas recirculation (EGR) port 140, which has a control valve 142, and connected to the intake port 28. The valve 142 controls the amount of exhaust gas that is recirculated to the intake port 28 via the recirculation port 140.

[0016] Furthermore, a wastegate (e.g., the wastegate valve) 128 can be located in a bypass 166, which is coupled between an inlet (or upstream of the inlet) and downstream of an outlet of the exhaust-driven turbine, to control the amount of exhaust gas supplied to the turbine and an exhaust catalyst 72, which is mounted downstream of the turbine. When the wastegate 128 is closed, most or all of the exhaust gas from the engine 10 is supplied to the turbine and then to the exhaust catalyst. The wastegate 128 can be fully opened to divert exhaust gas around the turbine 92 and to a front face of the exhaust catalyst 72, particularly during cold starts, thus allowing accelerated warm-up of the catalyst. As an example, the wastegate 128 and the bypass duct 166 can incorporate flow formations to direct the exhaust flow downstream to the exhaust catalyst.In one example, the flow formations can include a constricted area formed in a channel of the wastegate 128, located upstream of a valve plate of the wastegate 128, with the wastegate channel forming part of and directly coupled to the bypass channel 166. In another example, the wastegate 128 can include a valve plate configured with a semicircular raised edge extending into the wastegate channel and a side opening that directs the exhaust gas flow downstream into the bypass channel 166, while reducing the tendency of the exhaust gas to impact the channel walls. When open, the wastegate 128 can act to direct exhaust gas flow downstream to the catalyst 72, while minimizing exhaust gas energy losses due to exhaust gas impacting the walls of the bypass channel 166.Details regarding wastegate 128 and bypass channel 166 are given below with reference to the . Fig. 3-9C revealed.

[0017] Exhaust gases exiting bypass channel 166 and turbine 92 can, in one example, flow through catalyst 72, which may contain multiple catalyst modules. In another example, multiple catalysts, each containing multiple modules, can be used. In some examples, catalyst 72 can be a three-way catalyst. In other examples, catalyst 72 can contain one or more diesel oxidation catalysts (DOC) and selective catalytic reduction catalysts (SCR). After flowing through catalyst 72, exhaust gas can be directed to the outside via an exhaust pipe 58.

[0018] In this way, the system can be made up of Fig. 1. The following shall include: a turbocharger comprising a bypass channel arranged around the turbine of the turbocharger; a catalyst positioned downstream of the turbine and the bypass channel; a wastegate positioned within the bypass channel, the wastegate comprising: a wastegate channel coupled within the bypass channel, the wastegate channel comprising a constricted region and a rim formed downstream of the constricted region at one end of the wastegate channel;A valve plate positioned at the end of the wastegate channel, downstream of the edge, wherein the valve plate incorporates a curved multiplane surface on an inner surface of the valve plate, the curved surface forming a raised edge on a first side of the valve plate and a side opening of the valve plate, the constricted area being oriented on the same side of the wastegate channel as the first side of the valve plate. By providing a curved multiplane surface in the wastegate valve plate and the constricted area in the wastegate channel, the exhaust gas flow can be directed downstream in the bypass channel to the exhaust catalyst without impacting the side walls of the bypass channel, thereby minimizing exhaust energy losses while accelerating catalyst activation.

[0019] With reference to Fig. Figure 2 shows a three-dimensional view of an exemplary turbocharger 200 of an internal combustion engine (such as the one in Fig. Figure 1 of the engine 10 shown, which may be included in a propulsion system of a motor vehicle, is disclosed. The turbocharger 200 comprises a compressor housing 202, a central housing 208 coupled to the compressor housing, and a turbine housing 216 with a main opening 240. The compressor housing 202 may contain a compressor that compresses air and supplies it to the engine via an airflow line 204, as indicated by arrow 206. A bypass channel (not shown), configured with a wastegate valve 220, may be fluidically coupled to the main opening 240 when the wastegate valve 220 is in an open position.

[0020] As in Fig. As shown in Figure 2, exhaust gas flow from the engine can enter the turbine housing 216 via a channel 205, as indicated by arrow 245. The channel 205 can be connected to an exhaust manifold (such as the exhaust port 59 from the engine). Fig. 1), which is equipped with a large number of engine cylinders (such as cylinders 20 from Fig. 2) is connected, coupled to allow exhaust gas from the engine to enter the turbine. A plurality of grooves 219, formed on an inlet flange 218 attached to a base region of the turbine housing 216, can accommodate screws or suitable fasteners to securely attach the turbine housing 216 to the exhaust manifold connected to the engine. At its upstream end, the turbine housing 216 can be connected to the compressor housing 202 via the center housing 208. In this example, the turbine housing 216 is mounted to the center housing 208 via a V-band clamp assembly 212. The outlet 203 in the center housing 208 leads into the main opening 240, which has inner walls 213 of the turbine housing 216. A flange 214, formed on an outlet end 242 of the turbine housing 216, can be coupled to an outlet line to direct the exhaust gas from the main opening 240 to an exhaust catalyst (e.g.Catalyst 72 from . Fig. 1), which is positioned downstream of the line. The flange 214 can be securely attached to the outlet line by means of screws or suitable fasteners inserted into grooves 215 formed on the flange, so that the main opening 240 is fluidically coupled to the outlet line. In this case, exhaust gas flow, for example, from the turbine housing 216, can be conveyed through the main opening 240, where the exhaust gas flows further downstream to the exhaust catalyst.

[0021] The exhaust gas flow supplied from the engine to the turbine housing 216 enters the turbine through the channel 205 on the inlet flange 218 and the bypass channel (not shown), as indicated by arrow 245. The wastegate 220, mounted on the bypass channel (not shown), can be provided to control the exhaust gas flow from the bypass channel into the main opening 240, where the exhaust gas is conveyed in the flow direction 250 to the exhaust catalyst. The wastegate 220 can include an extendable arm 222, which is secured at one end to a valve plate 223 of the wastegate 220 and coupled at the other end to a first arm 224 of a valve actuation mechanism 225 at a joint 227. As an example, the extendable arm 222 can be an L-shaped arm that is extended to connect with the first arm 224, which is coupled to a second arm 226 at a stretchable joint 233.

[0022] The valve actuation mechanism 225 can be coupled to a piston mechanism 228 by securely attaching a distal end of the second arm 226 to an annular hose 230 of the piston. As shown, the piston mechanism 228 is mounted in a recess 235 formed by an integrated holder 234 attached to the compressor housing 202 and comprises a plurality of cylindrical elements 236 and an annular cylinder 237. For example, the cylindrical elements 236 and the annular cylinder 237 can provide additional structural integrity to the integrated holder 234. The piston mechanism 228 is coupled to an electric motor 232, which can supply electrical energy to operate the valve actuation mechanism 225.As one example, the valve actuator is controlled to open the wastegate, allowing excess air to bypass the turbine to generate the energy needed to increase compressor boost pressure for a given engine operating condition. In other examples, the valve actuation mechanism 225 can be controlled mechanically, hydraulically, or electrically to open and close the wastegate valve during engine operation. In further examples, a combination of mechanical, hydraulic, and electrical methods can be used to actuate the wastegate valve during engine operation.

[0023] The wastegate valve can be actuated to open fully in the direction 250 of the exhaust flow, allowing exhaust gas from the engine to be delivered via the turbine channel 205 into the main opening 240, where the exhaust gas flows on to the exhaust catalyst. The wastegate valve can be configured with flow-forming features, such as a curved inner wall and a side opening in the valve plate 223, which, in conjunction with a constricted area in the wastegate channel, can direct the exhaust gas flow more directly to the exhaust catalyst and away from the side walls of the main opening 240 of the turbine housing 216. In this way, the wastegate valve can reduce exhaust energy losses due to exhaust gas impacting the walls of the main opening 240 of the turbine housing 216. Consequently, catalyst activation during engine operation can be accelerated while minimizing fuel emissions.Details regarding the curved inner wall on the wastegate valve and the narrowed area in the wastegate channel are described below with reference to the . Fig. 3-9B further revealed.

[0024] With renewed reference to Fig. Figure 3 shows a schematic view 300 of a first embodiment of a wastegate valve 301 and a valve actuation mechanism 302. The wastegate valve 301 includes a valve plate 320, comprising a raised edge 326, a side opening 307, and stepped annular cylinders 318. The valve actuation mechanism 302 includes an annular arm 303 connected to a transition arm 305.

[0025] As shown, the raised edge 326 on the valve plate 320 can be formed on an upper circular surface 321, which has a side surface 322 and a downwardly extending section 323 connected to the stepped annular cylinders 318. For example, the raised edge 326 can be formed on the upper circular surface 321 and partially surround the inner wall 315. The raised edge 326 can be configured with a curved multiplane surface 324, which forms a section of an inner wall 327, and a side opening 307 to, for example, direct the exhaust gas flow in a first direction 325 when the wastegate is open.The stepped annular cylinders 318 can include a first and second annular cylinder coupled to a side section 316 of the transition arm 305; wherein the side section adjoins one or more surfaces of the stepped cylinders 318 and a downwardly extending section 323.

[0026] The annular arm 303 has a larger diameter at its distal end 311, which tapers to a uniform cylindrical section 304 that is coupled to a transition arm 305 having a top surface 312, a front surface 317, and a side surface 319. For example, a first end of the transition arm 305 can be centrally coupled to the annular arm 303, with the front side 308 merging with the top surface 312 of the transition arm 305. A second end of the transition arm 305 can be coupled to a lower section 330 of the wastegate valve 301 below the valve plate 320. The lower section 330 of the valve plate 320 includes stepped annular cylinders 318 that are interconnected and connected to a section of the transition arm 305.

[0027] The wastegate valve 301 can be mounted on a wastegate channel (not shown) to control the exhaust gas flow from the channel to an exhaust catalyst located downstream of the wastegate. When in an open wastegate position, the exhaust gas flow can be directed through the wastegate channel via the side opening 307 in a second direction from the channel to the exhaust catalyst. For example, flow formations at the wastegate valve 301, which includes the curved multiplane surface 324 and the side opening 307, can work in concert to direct the exhaust gas flow downstream to the exhaust catalyst while minimizing exhaust energy losses due to exhaust gas impacting the walls of the wastegate channel. Although not shown, the wastegate channel can also be configured with a constricted section upstream of the wastegate valve to direct the exhaust gas flow to the exhaust catalyst downstream of the wastegate.Details regarding current formation at wastegate valve 301 and the constricted area in the wastegate channel are described below with reference to the . Fig. 4A-4C further reveals. The wastegate valve 301, the actuating mechanism 302 and the wastegate channel can, for example, be made of stainless steel or cast iron.

[0028] In this way, a curved multi-plane surface and a side opening can be provided on the wastegate valve to direct the exhaust gas flow more directly to the catalytic converter. For example, the constricted area in the wastegate channel, in conjunction with the curved surface on the valve plate, can act to direct the exhaust gas flow downstream to the catalytic converter, thereby enabling accelerated catalyst activation.

[0029] With reference to the Fig. Figures 4A-4C disclose schematic views showing exemplary embodiments of a wastegate 401 comprising a valve plate 403 and a wastegate channel 410. Fig. Figure 4A shows a first view 400 of the wastegate channel 410 with a closed wastegate valve. The wastegate channel 410 includes a constricted section 414 formed on a first inner wall 415 of the channel. Furthermore, the wastegate channel 410 can be configured with a first diameter 426 at the constricted section 414 and a second diameter 428 upstream of the constricted section 414, the first diameter 426 being smaller than the second diameter 428. Additionally, a section of the wastegate channel 410 downstream of the constricted section 414 and upstream of the valve plate 403 can have the second diameter 428. Fig. Figure 4B shows a second view 402 of the wastegate channel 410 with the wastegate valve in an open position. In each of the first and second views, a second inner wall 417 of each wastegate channel has no constricted area. Thus, the constricted area 414 can only be on a single side of the wastegate channel 410 relative to a central axis 430 of the wastegate channel 410. The valve plate 403 and the wastegate channel 410 can be included as a section of a bypass channel around a turbine (e.g., as shown above with reference to Fig. 1 disclosed of the bypass channel 166). An exemplary alternative embodiment 404 of the wastegate channel 410 without a constricted area formed on each of the first inner wall 415 and the second inner wall 417 of the channel is described in Fig. 4C shown.

[0030] The valve plate 403 can include an annular section 413 formed on an upper cylindrical section 407 and a raised edge 406 configured to fit into an inlet 409 of the wastegate channel. When closed, a base 408 of the raised edge sits adjacent to the constricted area 414 formed on the first inner wall 415 of the wastegate channel 410. The base 408 of the raised edge 406 can be located at a distance 429 from an edge 435 of the constricted area 414. If mounted inside the wastegate channel 410, the raised edge 406 of the valve plate 403 can be adjacent to or in common contact with an edge surface 432 of the channel 410. The narrowed area 414, which is formed in the wastegate channel 410, can, for example, be positioned upstream of the raised edge 406.The boundary surface 432 of the wastegate channel 410 can be a section of the channel downstream of the constricted region 414, in which the raised edge 406 of the valve plate 403 is located in the closed position. For example, the boundary surface 432 of the wastegate channel 410 can have a length 436. In this case, the boundary surface 432 in the wastegate channel 410 can extend from the wastegate outlet 409 to the boundary edge 435. In other examples, the boundary surface 432 is an inner wall of the wastegate channel 410, forming a boundary, and the boundary edge 435 is a section of a wall forming the constricted region 414.

[0031] A curved surface (e.g., a curved multiplane surface) 405 on the valve plate 403 can form the raised edge 406 and a side opening 422 to direct the exhaust gas flow in a first direction, as shown by the arrow 427. As an example, the curved surface 405, in conjunction with the narrowed area 414 in the channel 410, can direct the exhaust gas flow directly to an exhaust catalyst downstream of the valve plate 403. The raised edge 406 of the valve plate 403 can have a length 434. In one example, the length 434 of the raised edge 406 can be selected to have a first length, based on the position of the narrowed area 414 on the first inner wall 415 of the wastegate channel 410. In other examples, the length 434 of the raised edge 406 can be selected to have a second length greater than the first length.In other examples, the length 434 of the raised edge 406 can be specific to a geometry of the wastegate channel 410 and an extent of current rotation required to direct the exhaust flow to one side of the catalyst.

[0032] Furthermore, the upper cylindrical section 407 of the valve plate 403 can have an extended surface 411 that forms a lower section of the upper cylindrical section which can be connected to the raised edge. When closed, the extended surface 411 of the valve plate 403 can touch or be in common contact with upper surfaces 412 at the outlet of the valve channel 410. As shown in Fig. As shown in Figure 4B, the exhaust gas flow from an engine can enter the wastegate channel 410, as indicated by the direction 420 at the channel inlet 416. When the valve plate 403 is open, the exhaust gas flows through the wastegate channel 410 and can increase in flow velocity when it reaches the constricted area 414, before exiting the channel at the channel outlet 409 and flowing through the side opening 422 in the valve plate 403. As an example, the constricted area 414 can be positioned only on a first side of the wastegate channel and not on a second side of the channel, with the second side of the channel being opposite the first side of the channel relative to the central axis 430 of the channel. In another example, the constricted area 414, which includes a raised circumferential area, can be positioned on the first inner wall 415 to constrict the flow upstream of the valve plate 403.In one example, the distance 429 can be selected such that the constricted area 414 is positioned at a first distance from the base 408 of the raised edge 406 of the valve plate 403. In other examples, the distance 429 can be selected to be a second distance, with the second distance being larger than the first. In further examples, the constricted area 414 can be selected to have a first diameter that is smaller than a second diameter of the wastegate channel, in order to accelerate the flow in the wastegate channel when the wastegate is open. In one example, the first diameter can be a diameter of the constricted area, and the second diameter can be a diameter of the channel. The diameter of the constricted area can be selected to be smaller than the diameter of the channel to increase the exhaust gas flow velocity at the channel outlet while minimizing turbulent flow conditions.Furthermore, the diameter of the constricted area can be selected such that the exhaust gas flow is directed to one side of the wastegate that includes the curved surface 405 and the side opening 422. As shown in the... Fig. As shown in Figures 4A-4B, the constricted area 414 can be angled inwards towards the central axis 430 and then abruptly diverge back outwards towards the first inner wall 415 of the wastegate channel 410. However, in alternative embodiments, the constricted area 414 can be more pronounced or angled gradually both inwards and back outwards. For example, the constricted area 414 can be configured with a circular or elongated shape with varying angles or radii of curvature. As shown, the shape of the constricted area 414 provides a means of guiding exhaust gas flow to the channel outlet 409, as indicated by arrow 425. Furthermore, the constricted area 414, in conjunction with the curved surface 405 on the valve plate, can act to direct the exhaust gas flow through the side opening 422, as indicated by arrow 427.

[0033] In an exemplary case where no constricted area is formed on the first and second inner walls of the wastegate channel, some of the exhaust gas can flow downstream, while the remaining portion of the exhaust gas is deflected along direction 424 before being carried downstream, as in Fig. 4C is shown. If it is deflected along direction 424, the exhaust gas can strike channel walls (not shown) downstream of the wastegate before flowing downstream to the exhaust catalyst. In this case, the exhaust gas can lose a significant amount of energy (due to energy transferred to the channel walls) before reaching the exhaust catalyst, resulting in delayed catalyst activation.

[0034] As in the Fig. As shown in Figures 4A-4B, the narrowed area 414 is formed on a first side of the wastegate channel 410 relative to the central axis 430. The raised edge 406 is formed on a first side of the valve plate 403, where the first sides of the valve plate 403 and the wastegate channel 410 are aligned with each other. Furthermore, the constricted area 414 curves inwards towards the central axis 430, and the curved surface 405 curves inwards towards the central axis 430 and one side of the valve plate 403 in the direction of the exhaust gas flow through the wastegate channel 410. In this way, the constricted area 414, which is formed on the first inner wall 415 of the wastegate channel 410, can, in conjunction with the curved surface 405 on the wastegate valve plate 403, act to direct the exhaust gas flow downstream to the exhaust catalyst, thereby enabling accelerated catalyst activation while reducing fuel emissions.

[0035] With reference to the Fig. Figures 5A-5C show schematic views of a third embodiment of a wastegate valve plate 501. Fig. Figure 5A shows a first view 500 of the wastegate valve plate 501. Fig. Figure 5B shows a second view 502 of the wastegate valve plate 501. The valve plate in the first and second views is shown with a visible front end 503 and a rear end 521. Fig. Figure 5C shows a third view 504 of the wastegate valve plate 501 from one side of the valve plate 501.

[0036] As in the Fig. As shown in Figures 5A-5C, the wastegate valve plate 501 includes an inner circular side 512 and a circular section 510 that forms a circumference around an outer section of the valve plate. The valve plate 501 may include a curved surface (e.g., a curved multiplane surface) 513 that forms a raised edge 505 on a first side 532 of the valve plate 501 and a side opening 506 on a second side 533 of the valve plate 501. When connected to a wastegate channel (such as the one shown in the Fig. When the wastegate channel 410 (shown in Figures 4A-4B) is mounted and the wastegate valve is in a closed position, the inner circular surface 512 and the curved surface 513 on the valve plate 501 face an inner side of the wastegate channel. The raised edge 505 may include a side wall 514 and the curved edge 516. The side wall 514 rises (e.g., extends outward) from the inner circular surface 512 to an outer edge of the raised edge 505. As an example, the raised edge 505 may have a length 525 similar to the length 434 of the one shown in Figure 4A-4B. Fig. 4A have a raised edge 406. The curved surface 513 gradually tapers from the raised edge 505 to a deep section 520, which forms part of the side opening 506. As an example, the raised edge 505 can have a semicircular shape, with the side opening 506 formed opposite the raised edge 505 to direct the exhaust flow in a first direction, as shown by the arrow 515. In another example, the raised edge 505 of the valve plate 501 can be provided in other suitable geometric configurations. In other examples, the side opening 506 can be formed on the second side 533 of the valve plate opposite the first side 532 of the valve plate 501, which includes a plurality of the raised edge 505.For example, the multiple raised edges 505 can be located below a first axis 540 of the valve plate, while a second axis 550 divides the valve plate into two symmetrical sections. The side opening 506 on the curved surface 513 can convey exhaust gas flow to an exhaust catalyst located downstream of the valve plate 501. For example, the side opening 506 can be dimensioned to allow an adequate exhaust gas flow through the valve outlet to accelerate catalyst activation. The curved edge 516 can terminate at opposite ends of the raised edge 505 to form a curved area 523 that gradually tapers to a point at the side opening 506. The curved surface 513 curves between the side walls 514 of the raised edge 505 in a multitude of directions, forming a curved multiplane surface that conducts the current in the first direction, as shown by the arrow 515.

[0037] A valve arm 507 with a flat surface 509 and a side edge 511 can be attached to a cylindrical element 517 formed on a circular element 519, which is mounted on a rear surface 522 of the valve plate. For example, a proximal section 526 of the valve arm 507 can be attached to the valve plate 501, while a distal section 527 of the valve arm 507 can be connected to an actuating mechanism (such as the one shown in Figure 519). Fig. 2 mechanism 225) can be connected in the direction of 530 to control the opening and closing of the valve plate when it is connected to a wastegate channel (such as the one shown in the Fig. The wastegate channel (410) is mounted as shown in Figures 4A-4B. In one example, the actuating mechanism that controls the valve plate can be operated by various methods, including mechanical, hydraulic, or electrical, although other suitable actuating methods may be used. In this way, the valve plate can be adjusted to open by means of the actuating mechanism attached to the distal end of the plate, thereby directing the exhaust gas flow from the wastegate channel to the catalyst located downstream of the valve plate.

[0038] With renewed reference to the Fig. Figures 6A-6B show schematic views of a third embodiment of a wastegate (e.g., wastegate valve) comprising the valve plate 501 and the valve arm 507 of an actuating mechanism. Fig. 5A-C and includes a wastegate channel 604, shows. Fig. Figure 6A shows a first view 600 of the third embodiment of the wastegate valve in a closed position. Fig. Figure 6B shows a second view 602 of the third embodiment of the wastegate valve in the closed position. In each of the first and second views, the valve plate 501 has similar features to those described above with reference to the Fig. Figures 5A-5C show the valve plate. The exhaust gas flow from an engine (shown through the flow direction 601) enters a main opening 614, which is formed in an inner region of the wastegate channel at an upstream end 607 of the channel. The exhaust gas flow from the upstream end 607 can flow through the main opening 614 of the wastegate channel to a downstream end 608 of the wastegate.

[0039] The valve plate 501 can be mounted at the downstream end 608 of the wastegate channel 604. When the valve plate 501 is closed, an inner circular surface 512 of the valve plate abuts (e.g., is in common contact with) an inner region 620 of the wastegate channel 604, sealing the channel tightly. In the closed wastegate position, the raised edge 505 is located within the main opening 614 at the downstream end 608 of the wastegate, forming a side opening 506 at an opposite end of the raised edge, which is sealed by the channel walls. As an example, a curved surface 513 forming the side opening 506 can direct the exhaust gas flow through an outlet of the wastegate channel when the valve plate 501 is set to an open position, as described below with reference to the Fig. Figures 7A-7B disclose. In one example, the side opening 506 can have a diameter 650 adequately sized to accelerate the flow of exhaust gas through an outlet of the wastegate channel 604 when the valve plate 501 is set to the open position. In other examples, the diameter 650 of the side opening 506 can be equal to or greater than a diameter 652 of the wastegate channel 604. In further examples, the valve plate 501 can be set to be closed, such that a base of the valve plate 501 covers an opening at the end of the channel and an inner surface of the base rests on the end of the channel.

[0040] Furthermore, the curved surface 513, which forms the raised edge 505 and a side opening 506, can be configured with an inclined concave surface (as in the Fig. (5A-5C) to direct exhaust gas flow in one direction towards the exhaust catalyst when the valve plate 501 is set to an open position. The curved surface 513 can be curved in multiple directions between a side wall 514, forming a curved multiplane surface that defines the side opening 506 and the raised edge 505. As an example, the curved surface 513 can curve towards the side opening 506, thereby directing the exhaust gas flow to the exhaust catalyst, as further described below with reference to the Fig. 7A-7B shown.

[0041] As in Fig. As shown in Figure 6A, a first gap 616 and a second gap 617 can be formed between the side wall 514 of the raised edge 505 and a boundary edge 613 on a first inner wall 609 of the wastegate channel 604. Each of the first and second gaps can be dimensioned to allow easy opening and closing of the valve plate 501 without rubbing against the inner walls of the wastegate channel. The raised edge 505 can be dimensioned with a length 622, which minimizes turbulent exhaust gas flow conditions at the wastegate outlet. As shown in Fig. As shown in Figure 6B, the length 622 of the raised edge 505 can have a first length based on the position of a constricted area 612 formed between the first inner wall 609 and an edge surface 610 of the wastegate channel, and / or based on a desired angle of curvature of the curved surface 513 (e.g., the length 622 can increase to provide a large angle of curvature of the curved surface 513). In other examples, the length 622 of the raised edge 505 can be selected to have a second length, the second length being larger than the first. In further examples, the length 622 can be specific to a geometry of the wastegate channel 604 and an extent of flow rotation required to direct the exhaust gas flow to an exhaust catalyst.

[0042] The raised edge 505 can, for example, be positioned at a distance 618 from the narrowed area 612. In one example, the distance 618 can be reduced such that the raised edge 505 is in common contact with or adjacent to an edge of the narrowed area 612.

[0043] As in the Fig. As shown in Figures 6A-6B, the constricted area 612 is formed at the junction between the first inner wall 609 and the boundary surface 610 of the wastegate channel. For example, the constricted area 612 can be formed only on a first side 644 of the wastegate channel relative to a central axis 603 of the channel, and the first side 644 is on the same side as a first side 624 of the valve plate. The constricted area 612 has a height 627, which may be below a threshold height. For example, the threshold height may be a height of the constricted area that minimizes turbulent flow conditions at the channel outlet. The height 627 of the constricted area 612 and its distance 618 from the valve plate 501 can be selected to generate exhaust gas flow rates at the channel outlet ranging from a minimum to a maximum required wastegate flow rate.The range of exhaust gas flow rates at the channel outlet can vary depending on the engine type, the turbocharger type, and the number of turbochargers fitted to the engine.

[0044] The valve arm 507, which is mounted on a rear surface 522 of the valve plate 501, can be coupled to an actuating mechanism shown by the direction 530. The actuating mechanism can be adjusted to open the valve plate 501, thereby allowing exhaust gas to flow to the exhaust catalyst downstream of the valve plate 501 via the channel outlet. The actuating mechanism can be controlled by various methods, including hydraulic, mechanical, or electrical. An example showing the valve plate 501 in the open position is shown below with reference to the Fig. 7A-7B shown.

[0045] With renewed reference to Fig. Figure 6C discloses a schematic view showing a fourth embodiment 605 of a wastegate (e.g., wastegate valve) comprising a valve plate 501, a valve arm 507 of an actuating mechanism, and a wastegate channel 604. The valve plate 501, mounted at a downstream end 608 of the wastegate channel 604, may include a curved surface 513 forming a raised edge 505 and a side opening 506. The raised edge 505 includes a side wall 514, a curved edge 516, and a curved region 523 that tapers to a point at the side opening 506 of the valve plate 501. In this example, the length 622 of the raised edge 505 is greater than that shown in the Fig. Figures 5A-6B revealed a raised edge that is longer in the illustration. Furthermore, the inner circular surface 512, which surrounds the raised edge 505 and the side opening 506, is longer compared to the one shown in the Fig. Figures 5A-6B revealed a smaller area of ​​the inner circular surface.

[0046] As in Fig. As shown in Figure 6C, the raised edge 505 is depicted as a circular shape, although other geometric shapes can also be used. Furthermore, the valve plate 501 includes a circular section 510 that connects the side wall 514 to a circular element 519 formed on a rear surface 522 of the valve plate. When the wastegate is closed, the valve plate 501 can be mounted axially to a downstream end 608 of the wastegate channel along the central connection axis 603.

[0047] The exhaust gas flow from an engine enters the wastegate channel 604 through a main opening 614 at an upstream end 607 of the channel. When the wastegate is set to a closed position, the raised edge 505 of the valve plate 501 can be located within the main opening 614 at the downstream end 608 of the wastegate channel 604. In this closed wastegate position, the side wall 514 of the raised edge 505 does not contact a first inner wall 630 of the wastegate channel 604, and a side opening 506, formed on an opposite side 626 of the raised edge 505, faces a second inner wall 632 of the channel. The curved surface 513 on the valve plate 501 can guide the exhaust gas flow in a direction 628 when the wastegate valve is set to an open position.For example, the curved surface 513 between the side wall 514 can be curved in several directions, forming a curved multiplane surface that defines the side opening 506 and the raised edge 505. In one example, the curved surface 513 can curve towards the side opening 506, thereby directing the exhaust gas along direction 628.

[0048] The valve arm 507, which has a flat surface 509 and a flat edge 511, can be coupled at its first end 634 to the rear surface 522 of the valve plate 501, while a second end 635 of the valve arm 507 can be connected to an actuating mechanism in the direction 530. For example, the actuating mechanism can be a mechanical, hydraulic, or electrical actuator that can be adjusted to open and close the valve plate during engine operation. During engine operation, the actuating mechanism can be adjusted to move the valve arm 507 to pivotally open the valve plate 501 and hold the valve plate open, thereby allowing exhaust gas flow to an exhaust catalyst located downstream of the wastegate.When the wastegate is open, the side wall 514 and the curved surface 513, which may be partially located inside the main opening, can direct the exhaust gas flow through the side opening 506 to the exhaust catalyst.

[0049] In this way, the wastegate can direct the exhaust gas flow directly through the wastegate channel to the catalytic converter, minimizing exhaust energy losses due to exhaust gas impacting the channel walls. By directing the exhaust gas more directly to the catalytic converter, exhaust energy can be used efficiently to heat the converter, thereby accelerating its activation and reducing fuel emissions.

[0050] With reference to the Fig. Figures 7A-7B show schematic views of a third embodiment of the wastegate (e.g. wastegate valve) which includes a valve plate 501 in a partially open position, a valve arm 507 of an actuating mechanism and a wastegate channel 604. Fig. Figure 7A shows a first view 700 of the third embodiment of the wastegate valve in the partially open position. Fig. Figure 7B shows a second view 702 of the third embodiment of the wastegate valve in the partially open position. The partially open position of the wastegate valve can be a position between a fully closed position and a fully open position. When it is in the fully closed position, no exhaust gas flow occurs through a channel outlet 720, while the fully open position comprises a maximum degree of opening, with a maximum degree of exhaust gas flow passing through the channel outlet 720 and downstream in a bypass channel. In each of the first and second views, the valve plate 501 is partially open to allow exhaust gas flow in a first direction, as indicated by arrow 709. The wastegate channel 604 includes a circular inner edge 705, a circular outer edge 706, and a main opening 614.

[0051] When the actuating mechanism, located at direction 530, sets the wastegate to a partially open position, the valve arm 507 can tilt the valve plate 501 to move outwards in direction 716, so that an inner surface 715 of the valve plate 501 can be aligned along the axis 712 to form a first tilt angle 710 between the axis 712 and the axis 714. As the wastegate moves from the closed to the partially open (or fully open) position, the raised edge 505 on the valve plate 501 pivots within a boundary surface 610, and the side opening 506, for example, moves outwards and away from the channel 604.In another example, the valve plate 501 can be adjusted to open such that a first side 624 of the valve plate 501 pivots within the channel 604 at a first side 644 of the channel 604, which includes the constricted area 612, and a second side 625 of the valve plate 501 is spaced from the channel at a second side 645 of the channel, which does not include the constricted area. For example, the first side 624 of the valve plate 501 can include the raised edge 505, while the second side 625 includes the side opening 506. In another example, a first inner wall 609 and the edge surface 610 of the wastegate channel 604 can form the first side 644 of the channel, while a second inner wall 611 can form the second side 645 of the channel. Furthermore, the first side 624 of the valve plate 501 and the first side 644 of the wastegate channel can be aligned with each other (e.g.on the same side of the wastegate relative to the central axis 603). Similarly, the second side 625 of the valve plate 501 and the second side 645 of the wastegate channel 604 can be aligned with each other (e.g. on the same side of the wastegate relative to the central axis 603).

[0052] The wastegate valve can be set to the partially open position, with the inclination angle 710 ranging, for example, from 5 to 12 degrees. When the wastegate is set to the partially open position, the side wall 514 of the raised edge 505 can remain partially within a downstream end 608 of the main opening 614 to guide the exhaust gas flow through the wastegate outlet 720. The exhaust gas flow from the engine (indicated by the flow direction 601) can then proceed through an upstream end 607 of the wastegate channel 604 into the main opening 614. The constricted area 612, formed at a junction between the first inner wall 609 and the edge surface 610 of the wastegate channel 604, can increase the exhaust gas flow velocity upstream of the valve plate 501 before the flow exits the side opening 506 along the first direction, as indicated by the arrow 709. An exhaust gas flow volume (e.g.The amount of exhaust gas leaving the wastegate outlet 720 can depend on the angle of inclination 710 of the wastegate valve. Increasing the angle of inclination 710 can increase the volume of exhaust gas leaving the wastegate outlet 720 and reaching the catalytic converter located downstream of the wastegate valve.

[0053] With reference to the Fig. Figures 8A-8B show schematic views of the third embodiment of a wastegate (e.g. wastegate valve) which includes a valve plate 501 in a fully open position, a valve arm 507 of an actuating mechanism and a wastegate channel 604. Fig. Figure 8A shows a first view 800 of the third embodiment of the wastegate valve in the fully open position. Fig. Figure 8B shows a second view 802 of the third embodiment of the wastegate valve in the fully open position. In both the first and second views, the valve plate 501 is fully open to allow exhaust gas flow in the direction 709.

[0054] The wastegate channel 604 includes a first inner wall 609 formed upstream of a boundary surface 610. In one example, the first inner wall 609 has a boundary edge 613 formed at a constricted region 612 that tapers to a point at the boundary surface 610 of the wastegate channel 604. As an example, the boundary surface 610 can be formed downstream of the constricted region 612, with the boundary surface 610 having a first diameter 722 larger than a second diameter 724 of the constricted region 612. In another example, the first diameter 722 of the boundary surface 610 can be the same as the third diameter 725 of the channel 604 upstream of the constricted region 612. In other examples, the narrowed area 612 can extend only around a section of the circumference of the channel 604, with the section being aligned with a first side 624 of the valve plate 501.The first inner wall 609 and the edge surface 610 can define a first side 644 of the wastegate channel, while a second inner wall 611 defines a second side 645 of the channel.

[0055] As in the Fig. As shown in Figures 8A-8B, the valve arm 507, which is attached to a rear surface 522 of the valve plate 501, can be adjusted by an actuator positioned in the direction 530 to fully open the wastegate valve. For example, when the wastegate moves from the partially open position to the fully open position, the raised edge 505 on the valve plate 501 pivots within a boundary surface 610, and a side opening 506 moves outward and away from the channel 604. In another example, the wastegate valve can be pivotally opened by tilting the valve plate 501 at a second tilt angle 806 formed between the axes 712 and 714. In one example, the wastegate valve can remain pivotally open, with the tilt angle 806 ranging from 12 to 25 degrees, thereby enabling a large volume of exhaust gas flow through the wastegate outlet 720 along a first direction, as shown by the arrow 709.In other examples, the valve plate 501 can be a curved surface (such as the curved surface 513 from . Fig. 7A) which forms the side opening 506 and, in conjunction with the narrowed area 612 on the channel 604, act to direct the exhaust gas flow via the wastegate outlet 720 to an exhaust catalyst located downstream of the wastegate valve.

[0056] In this way, the curved surface formed by the side opening 506 on the valve plate 501, in conjunction with the constricted area 612 on the wastegate channel 604, can direct the exhaust gas flow directly to the exhaust catalyst, while reducing exhaust energy losses due to exhaust gas impacting the channel's side walls. By directing the exhaust gas flow directly downstream to the exhaust catalyst, the catalyst's heating time can be reduced, thus decreasing catalyst activation and minimizing fuel emissions.

[0057] With reference to the Fig. Figures 9A-9B show schematic views of the third embodiment of the wastegate (e.g. wastegate valve) which includes a valve plate 501 in a closed position, a valve arm 507 attached to an actuating mechanism, and a wastegate channel 604. Fig. Figure 9A shows a first cross-sectional view 900 of the third embodiment of the wastegate valve in the closed position. Fig. Figure 9B shows a second cross-sectional view 902 of the third embodiment of the wastegate valve in the closed position. In each of the first and second cross-sectional views, the valve plate 501 is mounted at a downstream end 608 of the wastegate channel 604, and the exhaust gas flow enters the channel via a main opening 614 at an upstream end 607 of the channel.

[0058] The wastegate channel 604 includes a first inner wall 609 and a boundary surface 610, forming a first side 644 of the channel. The wastegate channel 604 also includes a second inner wall 611, forming a second side 645 of the channel. The second inner wall 611 includes a front end 912, which can be in common contact with an inner circular surface 512 of the valve plate 501. The first inner wall 609 includes a side edge 909, which defines a boundary between the first inner wall 609 and the second inner wall 611. The first inner wall 609 can be formed upstream of the boundary surface 610, so that a narrowed region 612 is formed between the two walls, tapering to a point at the boundary surface 610 along a boundary edge 613. In one example, the boundary surface 610 can be formed downstream of the narrowed region 612, wherein the boundary surface 610 has a first diameter (such as the diameter 722 from Fig.8A) larger than a second diameter 920 of the constricted area 612. When the wastegate is closed, the raised edge 505 on the valve plate 501 may, for example, be located within the edge surface 610. In other examples, the constricted area 612 may curve inward toward a central axis 603 of the channel 604 from a position upstream of the valve plate 501 to a position at the edge surface 610 and close to the valve plate 501.

[0059] The first inner wall 609 has a wall thickness 906, the thickness of which can gradually increase towards 601 of the exhaust gas flow within the wastegate channel 604. For example, the wall thickness 906 of the first inner wall 609 can have a first wall thickness at the upstream end 607 and a second wall thickness at the constricted region 612 of the wastegate channel 604, with the second wall thickness being greater than the first. In one example, the wall thickness 906 of the first inner wall 609 can range from 4 mm to 8 mm. In other examples, a side wall 913 of the wastegate channel 604 can taper towards the central axis 603 of the channel 604 at the constricted region 612, and the taper can increase as the side wall 913 approaches the valve plate. In contrast, the second inner wall 611 can have a uniform wall thickness 907 over the entire length of the wastegate channel 604.As an example, the second inner wall 611 can have a wall thickness in a range of 4 mm to 5 mm.

[0060] When the valve plate 501 is closed, the raised edge 505 can be positioned within the wastegate channel 604, with a curved edge 516 of the raised edge 505 forming an intermediate gap 927 between the curved edge 516 and the edge 613 upstream of the edge surface 610. For example, the raised edge 505 can fit into the edge surface 610 when the wastegate is in a closed position. When the wastegate valve is moved to an open position, a curved surface 513, forming a side opening 506 opposite the raised edge 505, can direct the exhaust gas flow to an exhaust catalyst. For example, the curved surface 513 between a side wall 514 can be curved in several directions, forming a curved multiplane surface that forms the side opening 506 and the raised edge 505.In one example, the curved surface 513 can act in conjunction with the narrowed area 612 in the channel 604 to guide the exhaust gas flow to the exhaust catalyst.

[0061] A front section of the edge surface 610 can be in common contact with an inner circular surface 512 of the wastegate valve, the raised edge 505 forming an annular housing 917 between the edge edge 613, the inner circular surface 512, and the edge surface 610. The inner circular surface 512 of the valve plate 501 can abut the front section 912 of the wastegate channel 604 along the contact interface 914. Similarly, an annular opening 908 can be formed between surfaces of the edge surface 610, the inner circular surface 512, and the side wall 514 of the raised edge 505, with a side edge 916 forming one of the enclosing walls.

[0062] The valve arm 507 can be attached to a central section 910 of the valve plate 501, while a downstream end 935 of the valve arm 507 can be coupled to a one-way actuating mechanism 530. For example, the valve arm 507 can be adjusted using various types of actuators, including mechanical, hydraulic, and electrical actuators, to open and close the wastegate valve during engine operation. When set to an open wastegate position, the raised edge 505 of the valve plate 501, in conjunction with the constricted area 612 of the wastegate channel 604, can act to direct the exhaust gas flow to an exhaust catalyst downstream of the wastegate valve.In this way, the wastegate can improve the efficiency of the exhaust flow by minimizing exhaust energy losses due to exhaust gas striking the side walls of the wastegate channel, thereby reducing the catalyst heating time while minimizing fuel emissions.

[0063] In one example, a wastegate comprises: a valve plate including a curved multiplane surface on an inner side of the valve plate, the curved surface forming a raised edge on a first side of the valve plate and a side opening on a second side of the valve plate; a channel including a constricted region located upstream of the valve plate and aligned with the raised edge, the valve plate being positioned at one end of the channel. In the preceding example, the constricted region additionally or optionally extends only around a portion of the channel's circumference, the portion being aligned with the first side of the valve plate. In any or all of the preceding examples, an inner sidewall of the channel tapers at the constricted region toward a central axis of the channel, and the taper increases as the inner sidewall approaches the valve plate.In any or all of the preceding examples, the channel additionally or optionally includes a rim located downstream of the constricted region, the rim having a larger diameter than the constricted region.

[0064] Furthermore, in any or all of the preceding examples, the diameter of the rim is additionally or optionally the same as a diameter of the channel upstream of the constricted region. In any or all of the preceding examples, the constricted region additionally or optionally curves inward toward a central axis of the channel, from a position upstream of the valve plate to a position at the rim and close to the valve plate. In any or all of the preceding examples, when the valve is in a closed position, the raised edge additionally or optionally fits within the rim. In any or all of the preceding examples, when the valve plate is in the closed position, the curved multiplane surface of the valve plate additionally or optionally faces an inside of the channel, and the side opening faces an inside side wall of the channel.

[0065] In other preceding examples, when the valve plate is in an open position, the raised edge additionally or optionally rotates within the rim, and the side opening moves outward and away from the channel. In any or all of the preceding examples, the second side of the valve plate additionally or optionally faces the first side of the valve plate relative to a common central axis of the channel and the valve plate. In any or all of the preceding examples, the curved multiplane surface is additionally or optionally concave. In any or all of the preceding examples, the constricted region is additionally or optionally only a single side of the first channel relative to a central axis of the channel, and the single side is the same side as the first side of the valve plate.In any or all of the preceding examples, when the valve plate is in an open position, the first side of the valve plate additionally or optionally pivots within the channel on a first side of the channel containing the constricted area, and the second side of the valve plate is spaced from the channel on a second side of the channel not containing the constricted area.

[0066] In another example, a wastegate additionally or optionally comprises: a valve plate comprising a curved multiplane surface formed on an inner base of the valve plate, the curved surface forming a raised edge on a first side of the valve plate and a side opening on a second side of the valve plate; a channel comprising a constricted region located upstream of the valve plate on a first side of the channel, the first side of the channel being aligned with the second side of the valve plate, the valve plate being positioned at one end of the channel; and a valve actuator coupled to the valve plate and configured to pivot the valve plate on the first side of the channel to open the valve plate on a second side of the channel.

[0067] In further examples, the second side of the channel is additionally or optionally opposite the first side of the channel relative to a central axis of the channel, with the constricted region positioned only on the first side of the channel and not on the second side. In any or all of the preceding examples, when the wastegate is in a closed position, the base of the valve plate additionally or optionally covers an opening at the end of the channel, and an inner side of the base sits at the end of the channel. In any or all of the preceding examples, when the wastegate is in the closed position, the raised edge of the valve plate additionally or optionally sits within a rim formed at the end of the channel downstream of the constricted region, the rim having a larger diameter than the constricted region.

[0068] In other examples, a system additionally or optionally includes: a turbocharger incorporating a bypass channel arranged around a turbine of the turbocharger; a catalyst positioned downstream of the turbine and bypass channel; a wastegate positioned within the bypass channel, the wastegate comprising: a wastegate channel coupled within the bypass channel, the wastegate channel comprising a constricted region and a rim formed downstream of the constricted region at one end of the wastegate channel; a valve plate positioned at the end of the wastegate channel, downstream of the rim, the valve plate comprising a curved multiplane surface on an inside of the valve plate, the curved surface forming a raised edge on a first side of the valve plate and a side opening of the valve plate.wherein the constricted area is aligned on the same side of the wastegate channel as the first side of the valve plate. In any or all of the preceding examples, a wastegate actuator is additionally or optionally coupled to an outer side of the valve plate, wherein the wastegate actuator has a vertically extending arm coupled to a pivoting mechanism. In any or all of the preceding examples, a wastegate actuator is additionally or optionally coupled to an outer side of the valve plate, wherein the wastegate actuator has a vertically extending arm coupled to a pivoting mechanism that rotates the wastegate to an open position, resulting in an airflow,which bypasses the turbine. In any or all of the preceding examples, the curved multiplane surface on the inside of the valve plate additionally or optionally acts in conjunction with the narrowed section of the wastegate channel to direct the exhaust gas flow from the channel to an exhaust catalyst downstream of the valve plate.

Claims

[1] Wastegate (128, 401), comprising: a valve plate (403, 501) comprising a curved multiplane surface (405, 513) on an inner side of the valve plate (403, 501), wherein the curved multiplane surface (405, 513) forms a raised edge (406, 505) on a first side of the valve plate (624) and a side opening (422, 506) on a second side of the valve plate (625); and a channel (410, 604) comprising a narrowed area (414, 612) arranged upstream of the valve plate (403, 501) and aligned with the raised edge (406, 505), wherein the valve plate (403, 501) is positioned at one end of the channel (410, 604), wherein an inner side wall (609) of the channel (410, 604) tapers at the narrowed area (414, 612) to a central axis (603) of the channel (410, 604) and the taper increases as the inner side wall (609) gets closer to the valve plate (403, 501). [2] Wastegate (128, 401) according to claim 1, wherein the narrowed area (414, 612) extends only around a section of the circumference of the channel (410, 604), the section being aligned with the first side of the valve plate (624). [3] Wastegate (128, 401) according to claim 1, wherein the channel (410, 604) includes a rim (432, 610) arranged downstream of the constricted region (414, 612), wherein the rim (432, 610) has a larger diameter than the constricted region (414, 612). [4] Wastegate (128, 401) according to claim 3, wherein the diameter of the rim (432, 610) is the same as the diameter of the channel (410, 604) upstream of the constricted area (414, 612). [5] Wastegate (128, 401) according to claim 3, wherein the narrowed area (414, 612) curves inwards towards the central axis (603) of the channel (410, 604), from a position upstream of the valve plate (403, 501) to a position at the edge (432, 610) and near the valve plate (403, 501). [6] Wastegate (128, 401) according to claim 3, wherein when the valve plate (403, 501) is in a closed position, the raised edge (406, 505) fits into the rim (432, 610). [7] Wastegate (128, 401) according to the preceding claim, wherein when the valve plate (403, 501) is in the closed position, the curved multiplane surface (405, 513) of the valve plate (403, 501) faces an inside of the channel (410, 604) and the side opening (422, 506) faces the inner side wall (609) of the channel (410, 604). [8] Wastegate (128, 401) according to claim 3, wherein when the valve plate (403, 501) is in an open position, the raised edge (406, 505) rotates within the rim (432, 610) and the side opening (422, 506) moves outwards and away from the channel (410, 604). [9] Wastegate (128, 401) according to claim 1, wherein the second side of the valve plate (625) is opposite the first side of the valve plate (624) relative to a common central axis of the channel (410, 604) and the valve plate (403, 501). [10] Wastegate (128, 401) according to claim 1, wherein the curved multiplane surface (405, 513) is concave. [11] Wastegate (128, 401) according to claim 1, wherein the narrowed area (414, 612) is only a single side of the channel (410, 604) relative to the central axis of the channel (603) and the single side is the same side as the first side of the valve plate (624). [12] Wastegate (128, 401) according to claim 1, wherein when the valve plate (403, 501) is in an open position, the first side of the valve plate (624) pivots within the channel (410, 604) on a first side of the channel (644) which includes the constricted area (414, 612) and the second side of the valve plate (625) is spaced apart from the channel (410, 604) on a second side of the channel (645) which does not include the constricted area (414, 612).

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