Turbocharger Bypass Valve Deflector for Thermal Shock Mitigation
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Solution Overview
Problem
The existing closure flaps in bypass ducts of turbocharger turbines are prone to cracking due to thermal shocks, which affects the optimal operation and longevity of the engine, especially when the flap opening is between 2mm to 5mm, leading to suboptimal gas flow direction and potential pressure losses.
Innovation Solution
A closure flap with a deflector on its contact surface, featuring a chamfer or concave rounded corner, is designed to reduce gas flow speed and guide gases more diffusely, minimizing the risk of cracking and maintaining optimal gas distribution, while the deflector extends radially to the valve body in the closed configuration, enhancing the sealing and resistance force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the closure flap is opened with a gap of 2mm to 5mm to maintain optimal flow distribution, then engine performance is optimized, but thermal shocks cause cracks to appear in the flap
Solution Approach 1:
A deflector element is introduced as an intermediary component between the closure flap and the hot gas flow. This deflector absorbs and redirects the thermal shock and mechanical stress away from the flap, allowing the flap to remain open with a 2-5mm gap for optimal performance while protecting it from cracking caused by thermal shocks
Solution Approach 2:
The deflector is positioned upstream to preemptively intercept and redirect the hot gas flow before it can directly impact the closure flap. This preliminary action prevents the thermal shocks from reaching the flap, eliminating the cracking issue while maintaining the optimal opening gap for engine performance
2Volume of moving object
If the side wall is positioned closer to the inlet chamber to reduce dimensioning constraints, then engine compactness is improved, but gases strike the side wall causing blowtorch effect and potential cracking
Solution Approach 1:
The deflector serves as a mediator between the hot gas flow and the side wall of the inlet chamber. It redirects the gas flow away from the side wall, preventing the blowtorch effect while allowing the side wall to be positioned closer to the inlet chamber, thus reducing the overall engine volume
Solution Approach 2:
The deflector extracts or removes the harmful direct impingement of hot gases on the side wall by redirecting the flow path. This allows the side wall to be repositioned closer to the inlet chamber without exposing it to thermal shock, achieving both compactness and protection from the blowtorch effect
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively reduces the occurrence of cracks and maintains an ideal gas distribution, ensuring optimal engine performance and torque without significant pressure losses, even at varying engine speeds.
Implementation Method 1
A closure flap with a deflector on its contact surface, featuring a chamfer or concave rounded corner, is designed to reduce gas flow speed and guide gases more diffusely
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The valve (2) has a cylindrical valve body (4) projecting into an opening of an inlet wall of a gas inlet chamber, and having an oblique opening (5). A closure flap (1) includes a contact surface (3) intended to cooperate with the valve body, so ??as to close the oblique opening of the valve body in a closed configuration of the valve. The closure flap includes a deflector (6) arranged on a portion of an outer periphery of the contact surface, where the deflector is formed by a chamfer including a rectilinear segment having a dimension equal to 2 mm. An independent claim is also included for a power unit of a car.