Turbocharger with variable nozzle having vane sealing surfaces

1. A variable nozzle for a turbocharger, comprising:

a generally annular nozzle ring defining a plurality of circumferentially spaced bearing apertures extending axially through an axially facing face of the nozzle ring;

a nozzle wall defining a face axially spaced from and opposing the face of the nozzle ring, a nozzle flow path being defined between the opposing faces of the nozzle ring and nozzle wall; and

a plurality of circumferentially spaced vanes disposed in the nozzle flow path, each vane comprising a shaft defining a pivot axis for the vane, the shafts of the vanes being respectively received in the bearing apertures of the nozzle ring and being rotatable therein about the respective pivot axes such that the vanes are adjustable in setting angle between a closed position and an open position, each vane including an aerodynamic airfoil portion having an outer airfoil surface, each airfoil portion being joined to the respective shaft and extending along the pivot axis from a first end to an opposite second end, the first and second ends of each airfoil portion respectively defining first and second end faces that are substantially perpendicular to the pivot axis, clearances existing between the first end faces of the airfoil portions and the face of the nozzle ring and between the second end faces of the airfoil portions and the face of the nozzle wall, wherein each airfoil portion has a suction side and an opposite pressure side and has a leading edge and a trailing edge, and the airfoil surfaces of each vane have a length in a flow direction from the leading edge to the trailing edge, the pivot axis of each vane being located intermediate the leading and trailing edges;

wherein at least the face of the nozzle ring includes at least one step defining sealing surfaces that are positioned to be substantially abutted by the airfoil surfaces in the closed position of the vanes and to be spaced from the airfoil surfaces in positions other than the closed position, and wherein the at least one step includes leading-edge step portions positioned to be substantially abutted by leading-edge portions of the airfoil surfaces on the pressure sides of the airfoil portions, and trailing-edge step portions positioned to be substantially abutted by trailing-edge portions of the airfoil surfaces on the suction sides of the airfoil portions;

wherein each vane has a bearing portion disposed between the first end of the airfoil portion and the shaft, the bearing portion having a substantially circular outer peripheral surface of larger diameter than the shaft, and wherein the at least one step in the face of the nozzle ring includes medial step portions defining sealing surfaces in substantial abutment with the outer peripheral surfaces of the bearing portions.

2. The variable nozzle of claim 1 , wherein the sealing surfaces are configured such that each point on the airfoil surface that is in substantial abutment with a corresponding point on the sealing surfaces in the closed position moves into said substantial abutment along a direction that is generally parallel to a normal of the sealing surface at said point.

3. The variable nozzle of claim 2 , wherein the sealing surfaces have surface normals that are generally perpendicular to the pivot axes of the vanes.

4. The variable nozzle of claim 1 , wherein the at least one step comprises a single step that extends as a continuous loop about a circumference of the nozzle ring face and is configured to provide the leading-edge, medial, and trailing-edge step portions for each vane.

5. The variable nozzle of claim 1 , wherein the face having the at least one step defines a recess for each vane, the recess substantially conforming in shape to an area swept by the respective airfoil portion when the vane is rotated from the closed position to the open position, the sealing surfaces being defined by an outer peripheral wall of each recess.

6. The variable nozzle of claim 1 , wherein the face of the nozzle wall includes the at least one step.

7. The variable nozzle of claim 1 , wherein the faces of the nozzle ring and nozzle wall both define recesses for the vanes, each recess substantially conforming in shape to an area swept by the respective airfoil portion when the vane is rotated from the closed position to the open position, the sealing surfaces on the nozzle ring and nozzle wall being defined by an outer peripheral wall of each recess.

8. A turbocharger having a variable nozzle, the turbocharger comprising:

a turbine wheel disposed within a turbine housing, the turbine housing defining an axially extending bore and a generally annular chamber surrounding the bore for receiving exhaust gas from an internal combustion engine;

a generally annular nozzle ring defining a plurality of circumferentially spaced bearing apertures extending axially through an axially facing face of the nozzle ring;

a nozzle wall defining a face axially spaced from and opposing the face of the nozzle ring, the opposing faces of the nozzle ring and nozzle wall defining a nozzle flow path therebetween through which exhaust gas in the chamber is directed generally radially inwardly into the turbine wheel; and

a plurality of circumferentially spaced vanes disposed in the nozzle flow path, each vane comprising a shaft defining a pivot axis for the vane, the shafts of the vanes being respectively received in the bearing apertures of the nozzle ring and being rotatable therein about the respective pivot axes such that the vanes are adjustable in setting angle between a closed position and an open position, each vane including an aerodynamic airfoil portion having an outer airfoil surface, each airfoil portion being joined to the respective shaft and extending along the pivot axis from a first end to an opposite second end, the first and second ends of each airfoil portion respectively defining first and second end faces that are substantially perpendicular to the pivot axis, clearances existing between the first end faces of the airfoil portions and the face of the nozzle ring and between the second end faces of the airfoil portions and the face of the nozzle wall, wherein each airfoil portion has a suction side and an opposite pressure side and has a leading edge and a trailing edge, and the airfoil surfaces of each vane have a length in a flow direction from the leading edge to the trailing edge, the pivot axis of each vane being located intermediate the leading and trailing edges;

wherein at least the face of the nozzle ring includes at least one step defining sealing surfaces that are positioned to be substantially abutted by the airfoil surfaces in the closed position of the vanes and to be spaced from the airfoil surfaces in positions other than the closed position, and wherein the at least one step includes leading-edge step portions positioned to be substantially abutted by leading-edge portions of the airfoil surfaces on the pressure sides of the airfoil portions, and trailing-edge step portions positioned to be substantially abutted by trailing-edge portions of the airfoil surfaces on the suction sides of the airfoil portions;

wherein each vane has a bearing portion disposed between the first end of the airfoil portion and the shaft, the bearing portion having a substantially circular outer peripheral surface of larger diameter than the shaft, and wherein the at least one step includes medial step portions defining sealing surfaces in substantial abutment with the outer peripheral surfaces of the bearing portions.

9. The turbocharger of claim 8 , wherein the sealing surfaces are configured such that in the closed position of the vanes each point on the airfoil surface that is in substantial abutment with a corresponding point on the sealing surfaces moves into said substantial abutment along a direction that is generally parallel to a normal of the sealing surface at said point.

10. The turbocharger of claim 9 , wherein said normals of the sealing surfaces are generally perpendicular to the pivot axes of the vanes.

11. The turbocharger of claim 8 , wherein the face having the at least one step defines a recess for each vane, the recess substantially conforming in shape to an area swept by the respective airfoil portion when the vane is rotated from the closed position to the open position, the sealing surfaces being defined by an outer peripheral wall of each recess.

12. The turbocharger of claim 8 , wherein the face of the nozzle wall defines the at least one step.

13. The turbocharger of claim 8 , wherein the at least one step comprises a single step that extends as a continuous loop about a circumference of the respective face.

14. The turbocharger of claim 8 , wherein the at least one step comprises a plurality of separate and discrete steps, one per vane.