Integrated HVAC system for an automotive vehicle

[0002] 1. Field of the Invention

[0003] The present invention relates generally to heating, ventilation, and air conditioning (HVAC) systems for automotive vehicles, and more particularly to an integrated, modular HVAC system for automotive vehicles.

[0004] 2. Disclosure Information

[0005] FIG. 1 shows a typical HVAC system, steering column support assembly, and cross-car beam as presently used in most automotive vehicles. Those familiar with such currently known systems will realize that these systems involve a multiplicity of individual (and sometimes redundant) parts that must be assembled together, which makes such approaches expensive, difficult to assemble, and so forth.

[0006] It would be desirable, therefore, to provide a single system for an automotive vehicle which provides the functions served by the individual HVAC, steering column support, and cross-car beam systems while simplifying and improving upon the prior art designs.

[0007] The present invention overcomes the disadvantages of the prior art approaches by providing an integrated HVAC system for an automotive vehicle, including mating forward and rearward shells each have mating portions of left and right duct arms for delivering conditioned air therethrough. The mating shells define a central enclosure within which a drop-in heater core module may be operatively placed.

[0008] It is an object and advantage that the HVAC system of the present invention provides a generic forward/rearward shell structure which can fit into a wide variety of cars, with a drop-in heater core module that can be custom-designed to accommodate specific car models. Thus, customization for any given car can be accomplished by designing a special drop-in heater core module for that car and installing such module into the generic forward/rearward shell.

[0009] Another advantage is that the integrated HVAC system of the present invention is non-handed; that is, it may be used on either left-hand drive or right-hand drive vehicles.

[0010] These and other advantages, features and objects of the invention will become apparent from the drawings, detailed description and claims which follow.

[0011] FIG. 1 is a front view of an HVAC/cross-car beam/steering column support system according to the prior art.

[0012] FIG. 2 is a perspective sectioned view of a portion of an HVAC system according to the prior art.

[0013] FIGS. 3-4 are exploded perspective and exploded side sectional views, respectively, of an integrated HVAC system according to the present invention.

[0014] FIG. 5 is an assembled side sectional view of the HVAC system shown in FIG. 4

[0015] FIG. 6 is an exploded, perspective, partial view of an integrated HVAC system according to a preferred embodiment of the present invention.

[0016] FIG. 7 is a perspective, assembled view of the HVAC system according to the present invention.

[0017] Referring now to the drawings, FIGS. 2-7 show an integrated HVAC system for an automotive vehicle. (Note that forward and rearward directions and left and right transverse outboard directions are defined graphically in FIG. 2, to assist in referencing the various elements of the HVAC system). The integrated HVAC system comprises mating plastic-molded forward and rearward shells each having mating portions of left and right duct arms for delivering conditioned air therethrough into the passenger compartment of the vehicle. The mating shells define a central enclosure within which a drop-in heater core module may be operatively placed.

[0018] To assist the reader in understanding the present invention, all reference numbers used herein are summarized in the table below, along with the elements they represent:

[0019] 100=Rearward shell

[0020] 110=Rearward enclosure

[0021] 112=Forward-facing opening in rearward enclosure

[0022] 114=Floor outlet

[0023] 116=Bottom wall

[0024] 118=Rearward wall

[0025] 120=Left channel

[0026] 121=U-shaped cross-section of left channel

[0027] 122=First transverse portion

[0028] 124=First left distal end of first transverse portion

[0029] 126=Second rearward-extending portion

[0030] 130=Right channel

[0031] 132=Third transverse portion

[0032] 134 First right distal end of third transverse portion

[0033] 136=Fourth rearward-extending portion

[0034] 200=Forward shell

[0035] 210=Forward enclosure

[0036] 212=Rearward-facing opening in forward enclosure

[0037] 213=Blower inlet

[0038] 214=Top wall

[0039] 215=Forward wall

[0040] 216=Defroster outlet

[0041] 217=Sealing flange

[0042] 220=Left elongate vertical wall

[0043] 222=Fifth transverse portion

[0044] 224=Second left distal end of fifth transverse portion

[0045] 226=Sixth rearward-extending portion

[0046] 230=Right elongate vertical wall

[0047] 232=Seventh transverse portion

[0048] 234=Second right distal end of seventh transverse portion

[0049] 236=Eighth rearward-extending portion

[0050] 300=Central enclosure

[0051] 315=Central interior volume

[0052] 320=Left duct

[0053] 325=Left interior volume

[0054] 330=Right duct

[0055] 335=Right interior volume

[0056] 400=Heater core module

[0057] 410=Module enclosure

[0058] 411=Top wall of module enclosure

[0059] 412=Bottom wall of module enclosure

[0060] 413=Forward wall of module enclosure

[0061] 414=Rearward wall of module enclosure

[0062] 415=Left wall of module enclosure

[0063] 416=Right wall of module enclosure

[0064] 420=Inlet port of module enclosure

[0065] 430=Outlet port of module enclosure

[0066] 440=Blend door

[0067] 450=Mode door

[0068] 460=Defroster door

[0069] 470=Heater core

[0070] 500=Evaporator core

[0071] 600=Integrated (one-piece) steering column support

[0072] 700=Control panel (for mode, temperature, fan speed)

[0073] 810=Defroster nozzle

[0074] 820=Blower

[0075] 830=Cross-car beam (prior art)

[0076] 840=Steering column support assembly (prior art)

[0077] 850=HVAC system (prior art)

[0078] The rearward shell 100 comprises: (1) a rearward enclosure 110 generally having the shape of a 5-sided box with a forward-facing opening 112 defined therein, the rearward enclosure further including a floor outlet 114 defined in a bottom or rearward wall 116/118 thereof; (2) a generally L-shaped, elongate left channel 120 having a generally U-shaped cross-section, the left channel comprising a first transverse portion 122 extending outward and leftward from the rearward enclosure, wherein the first transverse portion transitions at a first left distal end 124 thereof into a second rearward-extending portion 126; and (3) a generally L-shaped, elongate right channel 130 having a generally U-shaped cross-section, the right channel comprising a third transverse portion 132 extending outward and rightward from the rearward enclosure, wherein the third transverse portion transitions at a first right distal end 134 thereof into a fourth rearward-extending portion 136. The left and right channels 120/130 are arranged such that their generally U-shaped cross-sections are open toward the front of the vehicle for the first and third transverse portions 122/132, and open toward the left and right outboard directions respectively for the second and fourth rearward-extending portions 126/136.

[0079] The forward shell 200 comprises: (1) a forward enclosure 210 generally having the shape of a 5-sided box with a rearward-facing opening 212 defined therein, the forward enclosure further including a blower inlet 213 defined in a top or forward wall 214/215 thereof, a defroster outlet 216 defined in the top wall 214, and an evaporator core 500 operatively disposed within the forward enclosure; (2) a generally L-shaped, elongate left vertical wall 220 comprising a fifth transverse portion 222 extending outward and leftward from the forward enclosure, wherein the fifth transverse portion transitions at a second left distal end 224 thereof into a sixth rearward-extending portion 226; and (3) a generally L-shaped, elongate right vertical wall 230 comprising a seventh transverse portion 232 extending outward and rightward from the forward enclosure, wherein the seventh transverse portion transitions at a second right distal end 234 thereof into an eighth rearward-extending portion 236.

[0080] As illustrated in FIGS. 3 and 7, the forward and rearward shells 200/100 are molded so as to be matingly and removably attached together, such that: (1) the forward and rearward enclosures 210/220 form a central enclosure 300 having a central interior volume 315 therewithin; (2) the left channel 120 and the left vertical wall 220 form a left duct 320 having a left interior volume 325 therewithin in fluid communication with the central interior volume 315; and (3) the right channel 130 and the right vertical wall 230 form a right duct 330 having a right interior volume 335 therewithin in fluid communication with the central interior volume 315.

[0081] As mentioned above, the integrated HVAC system is non-handed; that is, it may be used on either left-hand drive or right-hand drive vehicles. The only left- or right-handedness occurs in the placement of the one-piece steering column assembly 600; for example, the assembly 600 may be attached on the right-hand side of the HVAC central enclosure for most European and Asian (i.e., right-hand drive) cars. By integrating all the previously existing components, the assembly 600 may be molded as one piece, preferably out of magnesium or other suitable materials.

[0082] In most vehicles, the passenger-side cross-car beam 830 supports only the airbag, any wiring that is attached thereto, and sometimes perhaps a small amount of the instrument panel weight. (Incidentally, the cross-car beam is not intended to stiffen or rigidize the body/frame of the vehicle.) The integrated system of the present invention eliminates the need for a separate cross-car beam by providing an integral passenger-side duct which serves the same function as the cross-car beam.

[0083] Various other modifications to the present invention may occur to those skilled in the art to which the present invention pertains. For example, it may be desirable to mold troughs and retaining features into the left/right ducts for routing/retaining any adjacent electrical wiring. Also, the defroster outlet may be molded completely into the rearward shell, or completely into the forward shell, or split between the forward and rearward shells. Other modifications not explicitly mentioned herein are also possible and within the scope of the present invention. It is the following claims, including all equivalents, which define the scope of the present invention.