Multi-layer Spring Washer for Turbocharger Thermal Insulation

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Solution Overview

Problem

Existing turbochargers face challenges in providing effective axial fixation of the variable turbine geometry cartridge near the turbine wheel while also requiring improved thermal insulation for the bearing housing, which is not adequately addressed by single-layer heat shields.

Innovation Solution

A spring washer composed of multiple material layers, which generates biasing force and enhances thermal insulation by creating an air gap and using a pot-like configuration with a raised edge, allowing for improved thermal resistance and potentially omitting liquid cooling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a single-layer heat shield is used, then the structure is simple, but the thermal insulation properties are insufficient

Engineering Contradiction:

Improvestructure simplicityVSAvoidthermal insulation properties

Core Design Contradiction:

Ease of manufactureVSTemperature

Solution Approach 1:

The heat shield is constructed as a multi-layer composite structure consisting of a first heat shield layer and a second heat shield layer with different material properties. The first layer has higher thermal conductivity to conduct heat away, while the second layer has lower thermal conductivity to provide thermal insulation, creating a composite material structure that optimizes both heat management and insulation properties.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The heat shield is divided into multiple separate layers (first heat shield layer and second heat shield layer) rather than using a single homogeneous layer. This segmentation allows each layer to be optimized for its specific function - one layer for heat conduction and another for thermal insulation - thereby improving overall thermal performance while maintaining structural simplicity.

Inventive Principle:

Principle #1Segmentation

2Temperature

If a multi-layer spring washer is used, then thermal insulation is improved, but the device complexity increases

Engineering Contradiction:

Improvethermal insulationVSAvoidspring washer structure

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The spring washer combines multiple material layers with different thermal properties into a single integrated component that performs both the biasing function and the thermal insulation function. By merging these functions into one part rather than using separate components, the design improves thermal insulation without proportionally increasing device complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The spring washer is designed as a multi-functional component that simultaneously provides mechanical biasing force and thermal insulation. The first material layer provides the elastic biasing function while the second material layer provides thermal insulation, allowing one component to serve multiple purposes and reduce overall system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Stability of the object's composition

If the cartridge is fixed axially near the turbine wheel, then the variable turbine geometry function is ensured, but thermal insulation requirements increase

Engineering Contradiction:

Improveaxial fixationVSAvoidthermal protection requirements

Core Design Contradiction:

Stability of the object's compositionVSTemperature

Solution Approach 1:

The spring washer acts as an intermediary component between the cartridge and the surrounding structure, providing both axial fixation and thermal protection. The multi-layer construction of the spring washer includes materials specifically selected to provide thermal insulation, thereby protecting the bearing housing from high temperatures while maintaining the axial position of the cartridge.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 multi-layer spring washer effectively ensures axial fixation and enhances thermal insulation, maintaining performance even at elevated exhaust gas temperatures, thereby reducing the need for additional cooling measures.

Implementation Method 1

The spring washer of the turbocharger of the invention is formed by at least two, but optionally also more than two, material layers and has the function of generating the biasing force

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

the spring washer... has the function of generating the biasing force and of improving the shielding function by increasing thermal resistance

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 3

Thanks to the provision of several material layers it is possible to provide an air gap between the material layers for further improving the biasing force and/or thermal insulation properties

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS7600969B2Turbocharger

Publication Date: 2009.10.13 BORGWARNER INC

AI summary

A turbocharger comprising a cartridge which is arranged in a turbine casing for variable turbine geometry; a bearing housing which is arranged between the turbine casing and a compressor housing of a compressor impeller and in which a bearing assembly is arranged for a shaft which supports the turbine wheel and the compressor impeller; and a spring washer which is arranged between the cartridge and the bearing housing, the spring washer being composed of at least two material layers.