U.S. patent application number 15/289478 was filed with the patent office on 2017-01-26 for flexible turbocharger air duct with constricting rings.
The applicant listed for this patent is FORD GLOBAL TECHNOLOGIES, LLC. Invention is credited to CHRISTOPHER B. BISHOP, ERIK H. HERMANN, ROGER KHAMI, RANDALL A. STEC.
Application Number | 20170022946 15/289478 |
Document ID | / |
Family ID | 53275471 |
Filed Date | 2017-01-26 |
United States Patent
Application |
20170022946 |
Kind Code |
A1 |
STEC; RANDALL A. ; et
al. |
January 26, 2017 |
FLEXIBLE TURBOCHARGER AIR DUCT WITH CONSTRICTING RINGS
Abstract
A turbocharger system includes a flexible duct having an
elongated elastomeric body extending longitudinally between first
and second ends configured to attach to respective turbocharger
devices. A plurality of constricting rings are spaced
longitudinally between the ends. Each constricting ring applies a
radial compression force around a respective circumference of the
duct. Each ring is comprised of a molded thermoplastic retained in
a concentric shape by a clasp. The spacing of the constricting
rings has a density sufficient to limit a volume increase of the
duct under turbocharger operating pressure to less than 20%. Each
constricting ring has an inner surface including an intrusion
feature providing a reduced compression force on the duct so that a
portion of the duct enters the intrusion feature, thereby anchoring
the constricting ring in a substantially fixed position.
Inventors: |
STEC; RANDALL A.; (CANTON,
MI) ; KHAMI; ROGER; (TROY, MI) ; BISHOP;
CHRISTOPHER B.; (SOUTH LYON, MI) ; HERMANN; ERIK
H.; (ANN ARBOR, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
FORD GLOBAL TECHNOLOGIES, LLC |
DEARBORN |
MI |
US |
|
|
Family ID: |
53275471 |
Appl. No.: |
15/289478 |
Filed: |
October 10, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
14133876 |
Dec 19, 2013 |
9494113 |
|
|
15289478 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F02M 35/10157 20130101;
F02M 35/10144 20130101; Y02T 10/12 20130101; Y02T 10/144 20130101;
F02M 35/10137 20130101; F02M 35/10354 20130101; F02M 35/10321
20130101 |
International
Class: |
F02M 35/10 20060101
F02M035/10 |
Claims
1. A turbocharger air-transfer system comprising: a flexible duct
having an elongated elastomeric body extending longitudinally
between first and second ends configured to attach to respective
turbocharger devices; and a plurality of constricting rings spaced
longitudinally between the ends, each constricting ring applying a
radial compression force around a respective circumference of the
duct, wherein each ring is comprised of a molded thermoplastic
being retained in a concentric shape by a clasp, wherein the
spacing of the constricting rings has a density sufficient to limit
a volume increase of the duct under turbocharger operating pressure
to less than 20%, and wherein each constricting ring has an inner
surface including an intrusion feature providing a reduced
compression force on the duct so that a portion of the duct enters
the intrusion feature, thereby anchoring the constricting ring in a
substantially fixed position.
2. The system of claim 1 wherein the intrusion feature includes
interior pockets spaced around the inner surface.
3. The system of claim 1 wherein the intrusion feature includes a
substantially cylindrical groove sunk into the inner surface.
4. The system of claim 1 further comprising: a linking rib
extending longitudinally between and connected to adjacent
constricting rings to generally maintain spacing between the
constricting rings.
5. The system of claim 4 wherein the linking rib is integrally
molded with the adjacent constricting rings from the same molded
thermoplastic.
6. The system of claim 5 wherein the linking rib is substantially
straight and is oriented substantially perpendicular to the
adjacent constricting rings.
7. The system of claim 5 wherein the linking rib follows a
serpentine path substantially along an outer surface of the
duct.
8. The system of claim 4 wherein the linking rib is comprised of a
substantially planar strap having longitudinally spaced apertures,
and wherein the adjacent constricting rings each include at least
one outwardly projecting nub received in a respective aperture.
9. The system of claim 1 wherein the spacing of the constricting
rings has a density sufficient to limit the volume increase of the
duct under turbocharger operating pressure to less than 10%.
10. A turbocharger air-transfer system comprising: an elastomeric
duct extending longitudinally between respective turbocharger
devices; and a plurality of molded thermoplastic constricting rings
each applying a radial compression force to the duct and each
retained in a concentric shape by a clasp, wherein spacing of the
constricting rings has a density sufficient to limit a duct volume
increase under turbocharger operating pressure to 20%, wherein each
constricting ring has an inner surface including an intrusion
feature providing a reduced compression force on the duct so that a
portion of the duct enters the intrusion feature, thereby anchoring
the constricting ring in a substantially fixed position.
11. The system of claim 10 further comprising: a linking rib
extending longitudinally between and connected to adjacent
constricting rings to generally maintain spacing between the
constricting rings.
12. The system of claim 11 wherein the linking rib is integrally
molded with the adjacent constricting rings from the same molded
thermoplastic, and wherein the linking rib is substantially
straight and is oriented substantially perpendicular to the
adjacent constricting rings.
13. The system of claim 11 wherein the linking rib is integrally
molded with the adjacent constricting rings from the same molded
thermoplastic, and wherein the linking rib follows a serpentine
path substantially along an outer surface of the duct.
14. The system of claim 11 wherein the linking rib is comprised of
a substantially planar strap having longitudinally spaced
apertures, and wherein the adjacent constricting rings each include
at least one outwardly projecting nub received in a respective
aperture.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a division of co-pending U.S.
application Ser. No. 14/133,876, filed Dec. 19, 2013, entitled
"Flexible Turbocharger Air Duct with Constricting Rings," which is
hereby incorporated by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] Not Applicable.
BACKGROUND OF THE INVENTION
[0003] The present invention relates in general to turbocharger
systems for motor vehicles with internal combustion engines, and,
more specifically, to air ducts for moving pressurized air between
separate components within a turbocharged system.
[0004] Turbo systems can increase the power derived from an
internal combustion engine by compressing the intake air provided
to the engine. Turbochargers require ducting to move air from a
compressor to a charge air cooler, and then to a throttle body on
the engine. Elastomeric duct sections are typically used in order
to provide easy installation, to accommodate variable
alignment/distances between the components being joined, and to
handle engine vibration or roll during vehicle operation.
[0005] The elastomeric duct sections typically experience internal
air pressures of up to 3.5 bar, for example. Moreover, the ducts
are typically exposed to high temperatures. The high temperatures
and pressures may cause an air duct or hose to expand during
turbocharger operation. Such a change in shape could have several
drawbacks. The inflation of the duct outside diameter can cause
interference with surrounding components, potentially resulting in
abrasion of the duct surface, breaking of mounting brackets, burst
hoses (resulting in lack of power), or slow leaks with a resulting
hissing noise. In addition, a unrestrained pressurized duct surface
can result in radiated sound from the turbocharger that reaches the
passenger compartment, causing unacceptable noise disturbances to
the passengers.
[0006] To address the foregoing issues, some kind of duct
reinforcement is typically provided. One known approach has been to
provide a metal helix (i.e., a slinky-shaped body) around the duct
and then covering the duct and helix with a heat shrink polymeric
sock. This results in a greatly increased manufacturing cost, as
well as a greater difficulty of installation due to a higher
stiffness.
[0007] Another approach has been to use composite, multi-layered
charge air ducts with reinforcing plies and specialized polymers.
Such composite ducts suffer the same drawbacks, such as increased
manufacturing costs and environmental issues.
SUMMARY OF THE INVENTION
[0008] The present invention overcomes the disadvantages of the
prior art by limiting duct expansion at a very low cost while
maintaining use of conventional rubber materials for the
elastomeric duct.
[0009] In one aspect of the invention, a turbocharger system
comprises a flexible duct having an elongated elastomeric body
extending longitudinally between first and second ends configured
to attach to respective turbocharger devices. A plurality of
constricting rings are spaced longitudinally between the ends. Each
constricting ring applies a radial compression force around a
respective circumference of the duct. Each ring is comprised of a
molded thermoplastic retained in a concentric shape by a clasp. The
spacing of the constricting rings has a density sufficient to limit
a volume increase of the duct under turbocharger operating pressure
to less than 20%. Each constricting ring has an inner surface
including an intrusion feature providing a reduced compression
force on the duct so that a portion of the duct enters the
intrusion feature, thereby anchoring the constricting ring in a
substantially fixed position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a plan view of an elastomeric duct carrying a
plurality of constricting rings of the present invention.
[0011] FIG. 2 is a perspective view of a first embodiment of a
molded constricting ring in an open state.
[0012] FIG. 3 is a perspective view of the constricting ring of
FIG. 2 in a nearly closed state.
[0013] FIG. 4 is a perspective view of constricting rings joined by
straight linking ribs.
[0014] FIG. 5 is a perspective view of constricting rings joined by
a serpentine linking rib.
[0015] FIG. 6 is an exploded, perspective view of constricting
rings joined by a linking rib formed as a separate strap.
[0016] FIG. 7A is a perspective view of an constricting ring with
an oblate shape.
[0017] FIG. 7B is a cross-sectional view along line B-B of FIG.
7A.
[0018] FIG. 8 is a cross section of an alternative embodiment for
the constricting ring.
[0019] FIG. 9 is a perspective view showing the clasp of FIG. 8 in
greater detail.
[0020] FIG. 10 is a perspective view of the constricting ring of
FIG. 8 on a portion of a duct.
[0021] FIG. 11 is a perspective view of an alternative embodiment
of a molded constricting ring formed as a bendable strip with a
clasp at the ends.
[0022] FIG. 12 is a perspective view of the ends of the strip in
FIG. 11 brought together for being clasped.
[0023] FIG. 13 is a partial perspective view of the strip of FIG.
11 installed on a duct.
[0024] FIGS. 14-16 are perspective views showing an alternative
embodiment of a strip with an alternate clasp arrangement.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0025] Referring now to FIG. 1, a flexible air duct 10 has an
elongated elastomeric body extending longitudinally between a first
end 11 and second end 12. Ends 11 and 12 are configured to attach
to respective turbocharger devices, such as a compressor 13 and a
charge air cooler 14. A set of constricting rings 15 has individual
rings 16, 17, and 18 spaced longitudinally between ends 11 and 12.
Each ring 16-18 applies a radial compression force around a
respective circumference of duct 10. The compression force limits
local expansion of duct 10 when subjected to turbocharger operating
pressure (which may rise to between 25 and 35 psi, for example). By
appropriate spacing of the rings, a density (e.g., the aggregate
longitudinal width of all the rings divided by the longitudinal
length of duct 10 between devices 13 and 14) is obtained which is
sufficient to limit a volume increase of duct 10 under turbocharger
operating pressure to less than about 20% (as compared to the
expansion that would occur without the presence of constricting
rings 16-18). More preferably, the volume increase of duct 10 may
be limited to less than about 10%.
[0026] To obtain an overall low cost for the system, constricting
rings 16-18 are each comprised of a molded thermoplastic. Each
molded ring is installed over (e.g., clamped onto) duct 10 and is
retained concentrically on duct 10 by a respective clasp (not
shown) that closes each ring. To facilitate placement over duct 10,
each ring 16-18 may preferably include a living hinge 20 formed by
molding a thin lateral portion in the ring. For added strength,
each ring 16-18 may include a concentric strengthening rib 21 on
its outer surface.
[0027] To maintain a desired spacing of rings 16-18, one or more
linking ribs 22-24 may be provided. Each linking rib 22-24 extends
between adjacent constricting rings and is preferably integrally
molded therewith. Linking ribs 22 and 23 extend substantially
straight between constricting rings 16 and 17, and they may
preferably be diametrically opposed on opposite sides of living
hinge 20. By being placed substantially perpendicularly to rings 16
and 17, linking ribs 22 and 23 provide a maximum stiffness
longitudinally between rings. A single rib between rings or more
than two rings can also be employed.
[0028] Relative longitudinal movement between rings (i.e., in the
axial direction of duct 10) may be provided by using a linking rib
24 having a serpentine path running substantially along an outer
surface of duct 10. The serpentine shape can act as a spring that
flexes as the distance between rings contracts or expands. Use of a
serpentine linking rib near an end of duct 10 may facilitate
installation of duct 10 within the turbocharger system.
[0029] A basic form for a first embodiment of a constricting ring
25 is shown in FIG. 2. Ring 25 is formed from a substantially
rigid, molded thermoplastic such as PVC with first and second jaws
26 and 27 joined by a living hinge 28. As molded, ring 26 is in an
open state shown in FIG. 2. By pivoting about hinge 28, a state as
shown in FIG. 3 can be obtained during closing of ring 25 wherein a
clasp 30 locks ring 25 by the insertion of a tab 31 into a slot 32.
An inside surface 33 defines an inside diameter configured to be
slightly less than an outside diameter of the air duct when ring 25
is closed. By providing a slight radial compression force even
while the air duct is unpressurized, ring 25 remains at a desired
position on the air duct. To increase the anchoring effect of
constructing ring 25 at a fixed location on the air duct, inner
surface 33 preferably includes one or more intrusion features at a
central portion of surface 33 so that a portion of the elastomeric
duct expands and enters the intrusion feature. In the embodiment of
FIGS. 2 and 3, intrusion pockets 34 are spaced along the
circumference of inner surface 33. Pockets 34 can be depressions or
may extend completely through first and second jaws 26 and 27, for
example.
[0030] As shown in FIG. 4, adjacent constricting rings 40 and 41
may preferably be strung together via linking ribs extending
longitudinally between and connected to adjacent rings for
generally maintaining a desired spacing between the rings. As shown
in FIG. 4, linking ribs 42 and 43 may preferably be integrally
molded with adjacent rings 40 and 41. If desired, a greater number
than 2 constricting rings can be integrally molded together with
respective linking ribs between adjacent pairs of rings to
constrict expansion over a longer section of air duct. Besides
being substantially straight and oriented substantially
perpendicular to the adjacent rings, the linking ribs can also be
arranged at other orientations to accommodate other duct shapes or
orientations.
[0031] FIG. 5 shows an alternative embodiment wherein rings 44 and
45 are connected by a linking rib 46 that follows a serpentine path
in order to act as a spring to allow a range of axial movement
between rings 44 and 45. Rib 46 is integrally molded with rings 44
and 45.
[0032] FIG. 6 shows yet another embodiment for a linking rib
wherein adjacent constricting rings 50 and 51 each includes an
outwardly projecting nub 52 and 53 for capturing by a planar strap
54 in spaced receiving-apertures 55. The linking of adjacent rings
can be performed either before or after installing the rings on an
air duct by snapping nubs 52 and 53 into matching apertures 55.
[0033] As shown in FIG. 7A, the cross-sectional shape of an
internal passage inside a closed constricting ring 60 need not be
circular. For example, an air duct may have a non-circular cross
section. Alternatively, it may be desirable to distort a circular
air duct from its round shape in order to facilitate bending of the
duct to avoid other engine components. Thus, an oblique shape can
be provided for a constricting ring 60 which could be arranged with
its minor internal diameter radially aligned in the direction of a
bending air duct, for example. Also shown in FIG. 7A is a
substantially cylindrical groove 61 sunk into the inner ring
surface for creating an intrusion feature that helps anchor ring 60
onto the air duct. As shown in cross section in FIG. 7B, after
constricting ring 60 is placed over an air duct 62, the snapping
closed of ring 60 causes a radial compression force around duct 62
which results in an expanded portion or fold 63 of duct 62 entering
groove 61. Thus, a single constricting ring can be strongly
anchored in a fixed position to withstand vibrations even in the
event that no linking ribs are employed.
[0034] FIGS. 8 and 9 show an alternate embodiment of a constricting
ring 65 having a clasp 66. Ring 65 is integrally molded using a
moderately firm thermoplastic material into a shape having a spring
arm 67 that is deflectable to accommodate variations in the size of
an air duct. Clamps 66 includes a hook tab 68 projecting from one
end of ring 65 for being captured in a slot 69 in the other end of
ring 65. A grip 70 is provided for facilitating manipulation of the
slotted end when either clasping or unclasping clasp 66. Spring arm
67 has a bent shape configured to provide nearly the same radial
compression force when ring 65 is installed over a range of air
duct outside diameters. FIG. 10 shows ring 65 mounted on a section
of an air duct 71.
[0035] As shown in FIGS. 11 and 12, a constricting ring 75 may be
formed of a molded, bendable strip. In order to be bendable, a
softer thermoplastic material may be employed. Ring 75 is molded
flat and is installed by wrapping around an air duct and closing a
clasp in order to form a ring that applies a radial compression
force around a respective circumference of the duct. Moreover, the
clasp may be adjustable in order to adapt the circumferential size
of a constricting ring to a particular air duct size. Thus,
constricting ring 75 has an end wall 76 with a slot 77. A second
end 78 of ring 75 includes a series of ramped teeth for ratcheting
through slot 77 until a desired circumference is obtained.
Intrusion features 82 help anchor ring 75 onto the duct. FIG. 13
shows ring 75 installed on a portion of a duct 81. Depending on the
axial length of an air duct, an appropriate number of constricting
rings would be installed, that could preferably joined by linking
ribs (not shown) either integrally molded with the bendable strips
or that can be snapped onto the rings.
[0036] FIGS. 14-16 show an alternative embodiment of a constricting
ring 85 formed as a bendable strip. Strip 85 includes a clasp
having a slot 86 at one end and a plurality of angled teeth 87 at
the other end for selectively capturing a desired one of teeth 87
in slot 86. Preferably, strip 85 includes a plurality of apertures
88 for providing the intrusion feature to anchor strip 85 as a
constricting ring on an air duct. To further stabilize the position
of a constricting ring, linking ribs (not shown) can also be added
as described above.
* * * * *