Turbocharger Disk Spring with Insulator for Thermal Protection
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Solution Overview
Problem
Existing turbochargers face challenges in effectively protecting the bearing housing from excessive temperatures due to exhaust gases, as the thermal insulation properties of single-layer heat shields are inadequate, and there is a need for improved axial fixation of the variable turbine geometry cartridge.
Innovation Solution
A disk spring constructed with multiple material layers, combined with an insulator, provides both axial fixation and enhanced thermal insulation by increasing thermal resistance, allowing for effective shielding of hot components from the bearing housing, and can be integrated in a materially-bonding or form-fitting manner.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a single-layer heat shield is used to protect the bearing housing, then the structure is simple, but the thermal insulation properties are insufficient
Solution Approach 1:
The patent applies composite materials by combining a disk spring made of elastomeric material with a thermal insulation layer having low thermal conductivity. This composite structure provides both the mechanical pretensioning function of the disk spring and the thermal insulation function of the insulation layer, effectively protecting the bearing housing from high temperatures while maintaining structural integrity.
Solution Approach 2:
The patent merges two separate functions into a single integrated component: the axial pretensioning function ( originally performed by the disk spring alone) and the thermal insulation function (previously requiring a separate heat shield). The insulation layer is applied directly to the disk spring, creating a unified component that performs both functions simultaneously.
2Force
If the disk spring is exposed to high temperatures, then the thermal protection is reduced, but the axial pretensioning force decreases
Solution Approach 1:
The thermal insulation layer acts as an intermediary between the hot exhaust gases and the disk spring. It reduces heat transfer to the elastomeric material of the disk spring, maintaining its temperature within acceptable limits and ensuring that the axial pretensioning force remains effective even in high-temperature environments.
3Object-affected harmful factors
If thermal insulation is improved, then heat transfer to bearing housing is reduced, but the device complexity increases
Solution Approach 1:
The patent combines the thermal insulation function with the existing disk spring component by applying an insulation layer directly to it. This eliminates the need for a separate heat shield and reduces assembly complexity, as the insulation is integrated into the disk spring structure rather than being an additional component.
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 solution effectively reduces component temperatures and heat transfer to adjacent components, potentially eliminating the need for liquid cooling, while maintaining functionality even at increased exhaust gas temperatures.
Implementation Method 1
The insulator for one thing brings about a lower component temperature of the disk spring, and therefore a higher pressing-on force, and for another thing brings about a lower heat yield into the adjacent components (bearing housings). The combination consisting of a thermal protection layer, insulator and disk spring layer
Implementation Method 2
a disk spring is used, which exerts an axial pretensioning force upon the blade bearing ring which is to be axially fixed
Data Source
AI summary
The invention relates to a turbocharger (1) having a cartridge (K), which is arranged in a turbine housing (2), for the variable turbine geometry, having a bearing housing (3) which is arranged between the turbine housing (2) and a compressor housing of a compressor wheel and in which is arranged a bearing arrangement for a shaft (W) which supports the turbine wheel and the compressor wheel, and having a plate spring (4) which is arranged between the cartridge (K) and the bearing housing (3), wherein the plate spring (4) is constructed from at least two material layers (5, 6) and an isolator (17).