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Turbocharger and method

  • US 9,739,238 B2
  • Filed: 03/09/2015
  • Issued: 08/22/2017
  • Est. Priority Date: 03/09/2015
  • Status: Active Grant
First Claim
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1. A turbocharger, comprising:

  • a turbine that includes a turbine wheel;

    a compressor that includes a compressor wheel;

    a bearing housing disposed and connected between the turbine and the compressor, the bearing housing forming a bearing bore therethrough;

    a shaft rotatably disposed within the bearing housing and extending into the turbine and the compressor, wherein the turbine wheel is connected to one end of the shaft and wherein the compressor wheel is connected to an opposite end of the shaft such that the turbine wheel is rotatably disposed in the turbine and the compressor wheel is rotatably disposed in the compressor;

    an outer race disposed within the bearing bore and including a first outer race end portion and a second outer race end portion; and

    an inner race disposed within the outer race and between the outer race and the shaft, the inner race including a first inner race end portion and a second inner race end portion, the first inner race end portion being axially aligned with the first outer race end portion and the second inner race end portion being axially aligned with the second outer race end portion, wherein the inner race is formed by two components, a compressor-side cup and a turbine-side cup, wherein one of the turbine-side and compressor-side cups forms a ledge and a wall that accepts therein a free, annular face of the other cup;

    a first bearing including a first plurality of rollers disposed between the first inner race end portion and the first outer race end portion;

    a second bearing including a second plurality of rollers disposed between the second inner race end portion and the second outer race end portion,wherein the inner race includes a flared portion disposed between the first inner race end portion and the second inner race end portion, the flared portion extending radially outwardly with respect to the first inner race end portion and the second inner race end portion to provide torsional and bending rigidity to the shaft, wherein the flared portion is flanked by two transition portions that reduce an inner diameter of the flared portion to match an outer diameter of the shaft, wherein each of the two transition portions has a smooth or chamfered profile,wherein the shaft is connected to the inner race at the first and second inner race end portions, the shaft having a first shaft diameter adjacent the first and second inner race end portions, the shaft including a slender portion extending from the first inner race end portion to the second inner race end portion, the slender portion having a uniform second shaft diameter that is less than the first shaft diameter.

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