Turbocharger thrust bearing and manufacturing method

Abstract

A thrust bearing, particularly for a turbocharger, having unique configurations on the thrust pad faces, including free-form curvatures or non-linear configurations defined by a geometric equation. The thrust pad faces can be configured by a programmed linear actuator system and cutting tool.

1 . A fluid-film thrust bearing comprising:
 a disc member having a first surface on one side and a second surface on an opposite side from said first surface;   said first surface having a plurality of thrust pad members thereon, each of said thrust pad members having an outer axial oriented surface;   each of said outer axial oriented surfaces having a curved profile configuration on at least a portion thereof; said curved profile configuration extending perpendicular to said first surface and being defined by a non-linear geometric equation.   
     
     
         2 . The fluid-film thrust bearing as set forth in  claim 1  further comprising a central opening in said disc member, wherein said disc member can be positioned on a shaft member, and wherein said thrust pad members have a wedge-shaped configuration. 
     
     
         3 . The fluid-film thrust bearing as set forth in  claim 1  wherein said thrust pad members are arranged in a circular orientation on said first surface, and said thrust bearing is a turbocharger thrust bearing. 
     
     
         4 . The fluid-film thrust bearing as set forth in  claim 1  further comprising a plurality of fluid channels positioned on said first surface, wherein a fluid can be applied to said thrust pad members on said first surface. 
     
     
         5 . The fluid-film thrust bearing as set forth in  claim 1  wherein said second surface has said thrust pad members thereon. 
     
     
         6 . The fluid-film thrust bearing as set forth in  claim 5  wherein each of said thrust pad members on said second surface has a wedge-shape configuration with an outer surface having a curved profile configuration. 
     
     
         7 . The fluid-film thrust bearing as set forth in  claim 6  wherein said curved profile configuration on the outer surfaces of said thrust pad members on said second surface is defined by the same equation defining said curved profile configuration on the outer surfaces of the thrust pad members on said first surface. 
     
     
         8 . A fluid-film thrust bearing comprising:
 a disc member having a first surface on one side and a second surface on an opposite side from said first surface;   said first surface having a plurality of thrust pad members thereon, each of said thrust pad members having an outer axial oriented surface;   each of said outer axial oriented surfaces having a curved profile configuration on at least a portion thereof; said curved profile configuration extending perpendicular to said first surface and being free-formed defined by an equation h=a(x) k ; where “h” is a pad elevation relative to a datum located on said thrust pad member, “a” is a constant, “x” is a point location on said outer axial oriented surface;   and “k” is a power.   
     
     
         9 . The fluid-film thrust bearing as set forth in  claim 8  wherein said second surface has said thrust pad members thereon. 
     
     
         10 . The fluid thrust bearing as set forth in  claim 8  wherein “k” is greater than 1. 
     
     
         11 - 16 . (canceled) 
     
     
         17 . The fluid-film thrust bearing as set forth in  claim 1 , wherein each of said first and second surfaces are oriented to face axially in a longitudinal direction. 
     
     
         18 . The fluid-film thrust bearing as set forth in  claim 8 , wherein each of said first and second surfaces are oriented to face axially in a longitudinal direction. 
     
     
         19 . The fluid-film thrust bearing as set forth in  claim 1 , wherein said non-linear geometric equation is h=a(x) k ; where “h” is a pad elevation-relative to a datum located on said thrust pad member, “a” is a constant, “x” is a point location on said outer axial oriented surface; 
       and “k” is a power.