Turbocharger Axial Compressor Diffuser Design

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Solution Overview

Problem

Existing turbocharger designs are inefficient due to non-axisymmetric and turbulent flow patterns, leading to reduced performance and increased size and weight.

Innovation Solution

The design features an axial compressor diffuser that reduces velocity uniformly, minimizing turbulent flow and allowing for a more compact and lightweight turbocharger. Additionally, a fluid connection with a non-circular cross-section in the mid-portion reduces turbulent flow and enhances laminar flow.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional turbocharger designs are used, then the turbocharger can provide compression, but the flow patterns are non-axisymmetric and turbulent leading to reduced efficiency

Engineering Contradiction:

Improvecompression efficiencyVSAvoidenergy loss due to turbulent flow

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The patent applies asymmetry by transitioning from non-axisymmetric conventional designs to an axisymmetric diffuser geometry. The diffuser vanes are arranged symmetrically around the central axis, creating uniform flow distribution and eliminating the non-axisymmetric turbulent patterns that cause energy losses in conventional designs.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The patent employs curvature principles through the diffuser vane geometry, where the vanes are curved to guide flow smoothly from the impeller outlet to the compressor outlet. This curved configuration promotes axisymmetric flow patterns and reduces turbulence compared to straight or angular vane arrangements.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Productivity

If conventional turbocharger designs are used, then compression function is provided, but the turbocharger size and weight are increased

Engineering Contradiction:

Improvecompression functionVSAvoidturbocharger weight

Core Design Contradiction:

ProductivityVSWeight of moving object

Solution Approach 1:

The patent extracts and eliminates unnecessary structural components from conventional turbocharger designs. By using a simplified axisymmetric diffuser without complex non-circular cross-sections or additional flow control devices, the design reduces overall turbocharger size and weight while maintaining compression functionality.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent inverts the conventional approach by using a simple circular axisymmetric diffuser geometry instead of complex non-circular cross-sections. This inversion of the design philosophy—prioritizing simplicity and symmetry over complexity—results in a lighter, more compact turbocharger that maintains effective compression.

Inventive Principle:

Principle #13The other way round (Inversion)

3Loss of energy

If fluid connection with non-circular cross-section is used, then turbulent flow is reduced, but the design complexity increases

Engineering Contradiction:

Improveturbulent flow reductionVSAvoidfluid connection design complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The patent applies homogeneity by using a uniform circular cross-section throughout the diffuser geometry. This homogeneous circular design creates consistent axisymmetric flow patterns that reduce turbulence, avoiding the complexity of varying non-circular cross-sections while achieving the desired flow characteristics.

Inventive Principle:

Principle #33Homogeneity

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

This configuration results in improved efficiency, reduced size, and weight, allowing for increased engine performance and the integration of a catalytic converter within the engine compartment.

Implementation Method 1

an axial compressor diffuser that reduces velocity uniformly, minimizing turbulent flow

Methodology Applied

Scientific EffectDiffusion: Diffusion

Implementation Method 2

hot and expanding engine exhaust gas is used to rotate a shaft

Methodology Applied

Scientific EffectTurbine: Turbine

Implementation Method 3

the shaft is used to operate a compressor that itself draws air into the system and forces the air into the engine

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS20250052187A1turbocharger

Publication Date: 2025.02.13 OBERMEYER HENRY K

AI summary

A turbocharger assembly having a turbine assembly and a compressor assembly that are coupled by a rotating shaft. The turbine assembly includes an exhaust incoming-flow duct configured to deliver exhaust gases to a turbine wheel in an annular flow-path. The turbine wheel redirects and discharges the exhaust gases in a direction that is substantially opposite to the incoming exhaust flow direction. The exhaust outgoing flow passes radially inside of the annular flow-path of the exhaust incoming-flow duct. The compressor assembly includes an air incoming-flow duct configured to deliver air to an impeller wheel. The impeller wheel compresses, redirects, and discharges the air in an annular flow-path in a direction that is substantially opposite to the incoming airflow direction. The air incoming flow passes radially inside of the annular flow-path of the air outgoing-flow duct.