Turbocharger Diffuser O-Ring Restraint for Leakage Reduction
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Solution Overview
Problem
Contemporary vaned diffusers in turbochargers suffer from performance losses due to leakage and require complex, costly structures for pressure loading and sealing, which complicates manufacturing and assembly.
Innovation Solution
A vaned diffuser restraint system utilizing a single O-ring structure for both sealing and pressure loading, made from high-performance materials like fluoroelastomers, to maintain vanes in contact with the opposing wall, reducing clearance gaps and eliminating leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional separate structures for pressure loading and sealing are used, then reliable pressure loading and sealing are achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the pressure loading function and sealing function into a single integrated O-ring structure. The O-ring simultaneously contacts the diffuser vane assembly to provide pressure loading while sealing the clearance gap between the diffuser ring and compressor housing, eliminating the need for separate pressure loading springs and sealing elements.
Solution Approach 2:
The O-ring is designed to perform multiple functions: it acts as both a sealing element that prevents gas leakage and a pressure loading element that maintains contact between diffuser vanes and the opposing wall. This multi-functional design simplifies the overall structure while maintaining reliable pressure loading and sealing.
2Loss of energy
If complex sealing structures are used, then leakage is reduced, but manufacturing and assembly complexity increase
Solution Approach 1:
The patent integrates sealing and pressure loading into a single O-ring component, reducing the number of parts that need to be manufactured and assembled. The O-ring is installed in a simple annular groove, eliminating complex assembly procedures while effectively sealing the clearance gap to prevent leakage.
Solution Approach 2:
The O-ring is a flexible elastomeric component that can deform to accommodate manufacturing tolerances and thermal expansion, maintaining effective sealing without requiring precision machining or complex adjustment procedures. This flexibility simplifies manufacturing while ensuring leakage prevention.
3Reliability
If multiple components are used for pressure loading and sealing, then functional reliability is improved, but cost increases
Solution Approach 1:
The patent consolidates multiple components (pressure loading springs, separate sealing elements, and associated mounting structures) into a single O-ring component. This dramatic reduction in component count lowers material costs, manufacturing costs, and assembly costs while maintaining the essential pressure loading and sealing functions through the O-ring's dual role.
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 system effectively reduces or eliminates performance losses by maintaining a consistent pressure load and seal, enhancing efficiency and reducing costs while simplifying the manufacturing and assembly process.
Implementation Method 1
a restraint system comprising an O-ring that seals the diffuser ring and maintains a pressure load on the diffuser ring
Implementation Method 2
an O-ring that seals the diffuser ring and biases the diffuser ring thereby abutting the plurality of compressor vanes against an opposing wall of the diffuser
Data Source
AI summary
A restraint system (300, 300′, 500) for a vaned diffuser (225) of a turbocharger (100) or other fluid boosting device is provided that can reduce or eliminate losses. The system (300, 300′, 500) uses a structure to provide both a pressure load on the vaned diffuser (225) and a seal for the vaned diffuser (225). The structure can be a fluoroelastomer O-ring (350, 350′, 550). The O-ring (350, 350′, 550) can be positioned at least partially in a channel (325, 325′, 525) formed in at least one of the diffuser ring (206, 206′), the compressor housing (103) and the center housing (102).