Turbocharger

Abstract

An integrated turbocharger/manifold ( 100 ) for an internal combustion engine comprises an inner ductwork ( 111 - 115, 120, 121, 125 ) and a turbine housing ( 130, 131 ). An outer shell ( 200, 210 ) covers a majority of the ductwork ( 111 - 115, 120, 121, 125 ) and the turbine housing ( 130, 131 ). A method for manufacturing the integrated turbocharger/manifold comprising an inner ductwork ( 111 - 115, 120, 121, 125 ), a turbine housing ( 130, 131 ), a manifold inlet flange ( 110 ), a bearing housing flange ( 150 ), a turbine outlet flange ( 144 ), and two outer shell portions ( 200, 210 ) includes a first production stage wherein the manifold inlet flange ( 110 ), the bearing housing flange ( 150 ), and the turbine outlet flange ( 144 ) are held in mutually fixed positions as one of the outer shell portions ( 200, 210 ) is welded to said components.

1 . An integrated turbocharger/manifold ( 100 ) for an internal combustion engine comprising: 
 an inner ductwork ( 111 - 115 ,  120 ,  121 ,  125 );    a turbine housing ( 130 ,  131 ); and    an outer shell ( 200 ,  210 ) covering a majority of the ductwork ( 111 - 115 ,  120 ,  121 ,  125 ) and the turbine housing ( 130 ,  131 ).    
   
   
       2 . The integrated turbocharger/manifold ( 100 ) according to  claim 1  wherein the inner ductwork ( 111 - 115 ,  120 ,  121 ,  125 ) comprises primary pipes, ( 111 - 115 ), branched pipes ( 120 ,  121 ), one double branched pipe ( 125 ) comprising an upper portion ( 125 ′) and a lower portion ( 125 ), said components being joined to form said inner ductwork ( 111 - 115 ,  120 ,  121 ,  125 ).  
   
   
       3 . The integrated turbocharger/manifold ( 100 ) according to  claim 1  wherein the distance between the inner ductwork ( 111 - 115 ,  120 ,  121 ,  125 ) and the outer shell is 1-10 mm.  
   
   
       4 . The integrated turbocharger/manifold ( 100 ) according to  claim 1  wherein the inner ductwork ( 111 - 115 ,  120 ,  121 ,  125 ) is manufactured from sheet metal.  
   
   
       5 . The integrated turbocharger/manifold ( 100 ) according to  claim 4  wherein the sheet metal is manufactured from austenitic 1.48.28 sheet metal or a substantially equivalent material.  
   
   
       6 . The integrated turbocharger/manifold ( 100 ) according to  claim 1  wherein the inner ductwork ( 111 - 115 ,  120 ,  121 ,  125 ) has a thickness of about 1 mm.  
   
   
       7 . The integrated turbocharger/manifold ( 100 ) according to  claim 1  wherein the outer shell ( 200 ,  210 ) is manufactured from ferritic 1.45.09 sheet metal having a thickness of about 2 mm.  
   
   
       8 . A method for manufacturing an integrated turbocharger/manifold for an internal combustion engine, the integrated turbocharger/manifold having an inner ductwork ( 111 - 115 ,  120 ,  121 ,  125 ), a turbine housing ( 130 ,  131 ), a manifold inlet flange ( 110 ), a bearing housing flange ( 150 ), a turbine outlet flange ( 144 ), and two outer shell portions ( 200 ,  210 ), said method comprising: 
 welding one of the outer shell portions ( 200 ,  210 ) to said manifold inlet flange ( 110 ), the bearing housing flange ( 150 ), and the turbine outlet flange ( 144 ) wherein the manifold inlet flange ( 110 ), the bearing housing flange ( 150 ), and the turbine outlet flange ( 144 ) are held in mutually fixed positions.    
   
   
       9 . The method of  claim 8 , further comprising: 
 welding two turbine housing portions ( 130 ,  131 ) together to form a turbine housing ( 130 ,  131 ); and    welding the turbine housing ( 130 ,  131 ) to the bearing housing flange ( 150 ).    
   
   
       10 . The method of  claim 8 , further comprising: welding the outer shell portions ( 200 ,  210 ) together to form an outer shell ( 200 ,  210 ) covering the inner ductwork ( 111 - 115 ,  120 ,  121 ,  125 ).  
   
   
       11 . The method of  claim 9 , further comprising: welding the outer shell portions ( 200 ,  210 ) together to form an outer shell ( 200 ,  210 ) covering the inner ductwork ( 111 - 115 ,  120 ,  121 ,  125 ).