Spring washer for turbo charger

Abstract

The present invention provides a spring washer for a turbocharger including a stopper part formed at an inner periphery there and a line contact part formed at an outer periphery thereof, thus to prevent a spring repulsive force from being exerted thereto more than necessary even when exerting excessive compression and continuous compression force from peripheral parts, and prevent an inclination bent section from being flattened, thereby maintaining or improving restoring characteristics of the inclination bent section. The ring-shaped spring washer installed in a bypass valve of a turbocharger includes: an inner periphery having a stopper part fixed to a lower surface thereof with being overlapped therewith; an inclination bent section integrally formed with the inner periphery with being inclined downward; and an outer periphery having a line contact part integrally formed with the inclination bent section to be in line contact with a support of the spring washer.

Claims

1. A ring-shaped spring washer installed in a bypass valve of a turbocharger, comprising: an inner periphery which has a stopper part bent and fixed to a lower surface thereof so as to be overlapped therewith; an inclination bent section which is integrally formed with the inner periphery by extending therefrom with being inclined downward; and an outer periphery which has a line contact part integrally formed with the inclination bent section by extending downward therefrom so as to be in line contact with and supported by a support of the spring washer, wherein the stopper part is fixed to the lower surface of the inner periphery in such a way that a piece of the same material as the inner periphery is laminated in the same area and is welded thereto.

2. The ring-shaped spring washer according to claim 1, further comprising a bent part which is formed integrally with the line contact part by extending therefrom with being bent upward.

3. The ring-shaped spring washer according to claim 2, wherein the bent part is formed in an obtuse angle range.

4. A ring-shaped spring washer installed in a bypass valve of a turbocharger, comprising: an inner periphery which has a stopper part formed on a lower surface thereof so as to be overlapped therewith; an inclination bent section which is integrally formed with the inner periphery by extending therefrom with being inclined downward; and an outer periphery which has a line contact part integrally formed with the inclination bent section by extending downward therefrom so as to be in line contact with and supported by a support of the spring washer, wherein the stopper part is formed on the lower surface of the inner periphery in such a way that a portion extending therefrom is bent downward and is again bent at a right angle, so that an upper surface of the stopper part is in close contact with the lower surface of the inner periphery.

5. The ring-shaped spring washer according to claim 4, further comprising a bent part which is formed integrally with the line contact part by extending therefrom with being bent upward.

6. The ring-shaped spring washer according to claim 5, wherein the bent part is formed in an obtuse angle range.

7. A ring-shaped spring washer installed in a bypass valve of a turbocharger, comprising: an inner periphery which has a stopper part formed on a lower surface thereof so as to be overlapped therewith; an inclination bent section which is integrally formed with the inner periphery by extending therefrom with being inclined downward; and an outer periphery which has a line contact part integrally formed with the inclination bent section by extending downward therefrom so as to be in line contact with and supported by a support of the spring washer, wherein the stopper part is formed on the lower surface of the inner periphery with a gap in such a way that a portion extending therefrom is bent downward and is again bent at a right angle, so that an upper surface of the stopper part faces the lower surface of the inner periphery with being spaced apart therefrom.

8. The ring-shaped spring washer according to claim 7, further comprising a bent part which is formed integrally with the line contact part by extending therefrom with being bent upward.

9. The ring-shaped spring washer according to claim 8, wherein the bent part is formed in an obtuse angle range.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The above and other objects, features and other advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:

(2) FIG. 1 is a schematic view showing a configuration of a conventional typical turbocharger;

(3) FIG. 2 is a cross-sectional view for illustrating a configuration of an example of a bypass valve in the turbocharger of FIG. 1;

(4) FIGS. 3A and 3B are cross-sectional views of a spring washer according to a first embodiment of the present invention;

(5) FIGS. 4A and 4B are cross-sectional views of a spring washer according to a second embodiment of the present invention;

(6) FIGS. 5A and 5B are cross-sectional views of a spring washer according to a third embodiment of the present invention; and

(7) FIG. 6 is a graph illustrating compression characteristics of a bead.

DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS

(8) Hereinafter, exemplary embodiments of the present invention will be described in detail. The following embodiments are described in order to enable those of ordinary skill in the art to embody and practice the present invention. However, the present invention is not limited to the embodiments disclosed below, but can be implemented in various forms. To aid in understanding the present invention, like numbers refer to like elements throughout the description of the drawings, and the description of the same elements will not be described.

(9) In the specification of the present invention, when the explanatory phrase a part includes a component is used, this means that the part may further include the component without excluding other components, so long as special explanation is not given.

(10) FIGS. 3A and 3B are cross-sectional views of a spring washer according to a first embodiment of the present invention, FIGS. 4A and 4B are cross-sectional views of a spring washer according to a second embodiment of the present invention, and FIGS. 5A and 5B are cross-sectional views of a spring washer according to a third embodiment of the present invention.

(11) First, a typical turbocharger will be described with reference to FIGS. 1 and 2, and the same parts as the prior art will be denoted by the same reference numerals.

(12) A turbocharger 1 includes a compressor housing 10, a turbine housing 20, an actuator 30, and a bypass valve 40 installed near the turbine housing 20 and connected to the actuator 30 by a link.

(13) The respective housings 10 and 20 are disposed at a predetermined interval inside of the turbocharger 1 along a rotational shaft (not denoted by a reference numeral). The bypass valve 40 is disposed near the turbine housing 20 and is connected to the actuator 30 by a link so as to be operated.

(14) The bypass valve 40 allows a part of an exhaust gas to bypass the turbine, thus to prevent the boost pressure from being increased beyond a constant range. The bypass valve 40 installed for this purpose selectively opens and closes a bypass flow path between exhaust gas inlet and outlet passages of the turbocharger, and includes a valve body 42, a support 44, and a washer unit 50.

(15) The valve body 42 has an open/close plate 42a integrally formed at a lower end thereof to open and close the bypass flow path.

(16) The support 44 is connected to the valve body 42, and a rotation end 44a extending from the valve body 42 is formed at one end thereof.

(17) Herein, the spring washer 100 of the turbocharger according to the present invention is formed in a ring shape and is made of a metal material having elastic and heat resistance properties to limit a movement and a clearance of the support 44.

(18) The spring washer 100 may generally include a ring-shaped flat inner periphery 110, an outer periphery 130, and an inclination bent section 120 formed between the inner periphery 110 and the outer periphery 130 to connect these peripheries with each other.

(19) As shown in FIGS. 3 to 5, the spring washer 100 having the above-described configuration may include a stopper part 112 formed on a lower surface of the inner periphery 110 and a bent part 134 formed at an end of the outer periphery 130, so as to maintain a spring repulsive force at a certain level or more even when exerting excessive compression and continuous compression force from peripheral parts.

First Embodiment

(20) As shown in FIG. 3A, a ring-shaped spring washer 100 according to the first embodiment of the present invention generally includes an inner periphery 110, an outer periphery 130, and an inclination bent section 120 formed between the inner periphery 110 and the outer periphery 130 to connect these peripheries with each other.

(21) According to characteristics of the present invention, the inner periphery 110 preferably has a stopper part 112 fixed to a lower surface thereof in such a way that a piece of the same material as the inner periphery is overlapped by laminating in the same area, and then is welded thereto.

(22) As shown in FIG. 3A, the stopper part 112 is laminated in one layer, but at least one or more layers may be laminated. Preferably, the welding may use electric welding, CO.sub.2 welding, argon welding, and the like. The laminated stopper part 112 may be fixed to the lower surface of the inner periphery 110 by welding.

(23) The inclination bent section 120, which is formed integrally with the inner periphery 110 by extending outward therefrom, may be a portion configured to integrally connect the inner periphery 110 and the outer periphery 130 with each other and provide a spring repulsive force like a leaf spring by having a height difference.

(24) Therefore, the inclination bent section 120 is formed to be inclined from the inner periphery 110 to an outer downward side. At this time, an inclination degree of the inclination bent section 120 may be set so that the outer periphery 130 is positioned on the support 44 lower than the stopper part 112 of the inner periphery 110 when viewing from the same line of the plane.

(25) In addition, the inclination bent section 120 integrally formed with the inner periphery 110 by extending therefrom has a line contact part 132 formed at one end thereof.

(26) As compared with a conventional spring washer in which a flat section thereof is in surface contact with the support 44, the spring washer of the present invention is in line contact with the support 44 through the line contact part 132, such that it is possible to maintain or improve restoring characteristics of the inclination bent section 120.

(27) Furthermore, as shown in FIG. 3B, the spring washer according to the present embodiment may further include a bent part 134 formed integrally with the line contact part 132 by extending therefrom with being bent upward. In this case, the bent part 134 may be formed in an obtuse angle range.

(28) The bent part 134 may be integrally manufactured when manufacturing a mold, and may be subjected to bending in a constant degree, preferably, in a range exceeding 90 degrees, so as to allow the bent part 134 to be in line contact with the support 44.

Second Embodiment

(29) Components of a spring washer according to the second embodiment of the present invention shown in FIG. 4A have the same configuration as those of the spring washer according to the first embodiment except for the shape of the stopper part 112, such that these components will be described by denoting the same reference numerals.

(30) A ring-shaped spring washer 100 according to the second embodiment of the present invention may generally include an inner periphery 110, an outer periphery 130, and an inclination bent section 120 formed between the inner periphery 110 and the outer periphery 130 to connect these peripheries with each other.

(31) According to characteristics of the present invention, the inner periphery 110 may have a stopper part 112 formed on a lower surface thereof in such a way that a portion extending therefrom is bent downward and is again bent at a right angle, so that an upper surface of the stopper part 112 is in close contact with the lower surface of the inner periphery 110.

(32) That is, when manufacturing a mold, after preparing an annular plate to be the spring washer according to the present embodiment having a ring-shaped central hole with a smaller diameter than that of the first embodiment, an end side of the inner periphery 110 is bent inward to be rolled upward, and surfaces facing each other by bending are in close contact with each other by compression, so as to be overlapped with each other.

(33) The inclination bent section 120, which is formed integrally with the inner periphery 110 by extending outward therefrom, may be a portion configured to integrally connect the inner periphery 110 and the outer periphery 130 with each other and provide a spring repulsive force like a leaf spring by having a height difference.

(34) Therefore, the inclination bent section 120 is formed to be inclined from the inner periphery 110 to an outer downward side. At this time, an inclination degree of the inclination bent section 120 may be set so that the outer periphery 130 is positioned on the support 44 lower than the stopper part 112 of the inner periphery 110 when viewing from the same line of the plane.

(35) In addition, the inclination bent section 120 integrally formed with the inner periphery 110 by extending therefrom has a line contact part 132 formed at one end thereof.

(36) As compared with a conventional spring washer in which a flat section thereof is in surface contact with the support 44, the spring washer of the present invention is in line contact with the support 44 through the line contact part 132, such that it is possible to maintain or improve restoring characteristics of the inclination bent section 120.

(37) Furthermore, as shown in FIG. 4B, the spring washer according to the present embodiment may further include a bent part 134 formed integrally with the line contact part 132 by extending therefrom with being bent upward. In this case, the bent part 134 may be formed in an obtuse angle range.

(38) The bent part 134 may be integrally manufactured when manufacturing a mold, and may be subjected to bending in a constant degree, preferably, in a range exceeding 90 degrees, so as to allow the bent part 134 to be in line contact with the support 44.

Third Embodiment

(39) Components of a spring washer according to the third embodiment of the present invention shown in FIG. 5A have the same configuration as those of the spring washer according to the first embodiment except for the shape of the stopper part 112, such that these components will be described by denoting the same reference numerals.

(40) A ring-shaped spring washer 100 according to the third embodiment of the present invention may generally include an inner periphery 110, an outer periphery 130, and an inclination bent section 120 formed between the inner periphery 110 and the outer periphery 130 to connect these peripheries with each other.

(41) According to characteristics of the present invention, the inner periphery 110 may have a stopper part 112 formed on a lower surface thereof with a gap in such a way that a portion extending therefrom is bent downward and is again bent at a right angle, so that an upper surface of the stopper part 112 faces the lower surface of the inner periphery 110 with being spaced apart therefrom.

(42) That is, when manufacturing a mold, after preparing an annular plate to be the spring washer according to the present embodiment having a ring-shaped central hole with a smaller diameter than that of the first embodiment, an end side of the inner periphery 110 is bent inward to be rolled upward, and surfaces facing each other by bending come close to each other with a gap by compression. In this process, the inner periphery 110 and the stopper part 112 may be spaced apart from each other with the gap.

(43) The inclination bent section 120, which is formed integrally with the inner periphery 110 by extending outward therefrom, may be a portion configured to integrally connect the inner periphery 110 and the outer periphery 130 with each other and provide a spring repulsive force like a leaf spring by having a height difference.

(44) Therefore, the inclination bent section 120 is formed to be inclined from the inner periphery 110 to an outer downward side. At this time, an inclination degree of the inclination bent section 120 may be set so that the outer periphery 130 is positioned on the support 44 lower than the stopper part 112 of the inner periphery 110 when viewing from the same line of the plane.

(45) In addition, the inclination bent section 120 integrally formed with the inner periphery 110 by extending therefrom has a line contact part 132 formed at one end thereof.

(46) As compared with a conventional spring washer in which a flat section thereof is in surface contact with the support 44, the spring washer of the present invention is in line contact with the support 44 through the line contact part 132, such that it is possible to maintain or improve restoring characteristics of the inclination bent section 120.

(47) Furthermore, as shown in FIG. 5B, the spring washer according to the present embodiment may further include a bent part 134 formed integrally with the line contact part 132 by extending therefrom with being bent upward. In this case, the bent part 134 may be formed in an obtuse angle range.

(48) The bent part 134 may be integrally manufactured when manufacturing a mold, and may be subjected to bending in a constant degree, preferably, in a range exceeding 90 degrees, so as to allow the bent part 134 to be in line contact with the support 44.

(49) An operation of the spring washer of the turbocharger having the above-described configuration according to the embodiments of the present invention will be described.

(50) The spring washer 100 is mounted on the support (44 in FIG. 2) so as to limit a movement and a clearance thereof. According to the first, second and third embodiments of the present invention, the stopper part 112 is formed in the inner periphery 110, and the line contact part 132 capable of being in line contact with the support 44 and/or the bent part 134 are/is formed in the outer periphery 130.

(51) Therefore, as shown in the graph of FIG. 6, the repulsive force is not exerted on the spring washer 100 more than necessary during the compression due to the stopper part 112, the line contact part 132, and the bent part 134. Further, during restoring, as compared with the conventional spring washer, by preventing the bent part 120 from being flattened as much as A section, it is possible to maintain or improve the restoring characteristics of the inclination bent section 120.

(52) Furthermore, it is possible to maintain the restoring property of the inclination bent section 120 by allowing the spring washer 100 and the support 44 to be in line contact rather than surface contact like the conventional spring washer due to the line contact part 132.

(53) As described above, in accordance with the spring washer of the turbocharger according to the embodiments of the present invention, even when exerting excessive compression and continuous compression force from peripheral parts, it is possible to maintain the spring repulsive force in a certain level or more due to the ring-shaped stopper part welded to the inner periphery or bent so as to be overlapped therewith and the line contact part.

(54) While the present invention has been described with reference to the preferred embodiments and modified examples, the present invention is not limited to the above-described specific embodiments and the modified examples, and it will be understood by those skilled in the related art that various modifications and variations may be made therein without departing from the scope of the present invention as defined by the appended claims, as well as these modifications and variations should not be understood separately from the technical spirit and prospect of the present invention.

(55) TABLE-US-00001 Description of Reference Numerals 100: Spring washer 110: Inner periphery 112: Stopper part 120: Inclination bent section 130: Outer periphery 132: line contact part 134: Bent part