US20180236846A1 - System and method for minimizing air leak in an hvac unit - Google Patents
System and method for minimizing air leak in an hvac unit Download PDFInfo
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- US20180236846A1 US20180236846A1 US15/439,462 US201715439462A US2018236846A1 US 20180236846 A1 US20180236846 A1 US 20180236846A1 US 201715439462 A US201715439462 A US 201715439462A US 2018236846 A1 US2018236846 A1 US 2018236846A1
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- Prior art keywords
- airflow
- damper
- airflow passageway
- heater core
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60H—ARRANGEMENTS OF HEATING, COOLING, VENTILATING OR OTHER AIR-TREATING DEVICES SPECIALLY ADAPTED FOR PASSENGER OR GOODS SPACES OF VEHICLES
- B60H1/00—Heating, cooling or ventilating [HVAC] devices
- B60H1/00642—Control systems or circuits; Control members or indication devices for heating, cooling or ventilating devices
- B60H1/00978—Control systems or circuits characterised by failure of detection or safety means; Diagnostic methods
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60H—ARRANGEMENTS OF HEATING, COOLING, VENTILATING OR OTHER AIR-TREATING DEVICES SPECIALLY ADAPTED FOR PASSENGER OR GOODS SPACES OF VEHICLES
- B60H1/00—Heating, cooling or ventilating [HVAC] devices
- B60H1/00007—Combined heating, ventilating, or cooling devices
- B60H1/00021—Air flow details of HVAC devices
- B60H1/00035—Air flow details of HVAC devices for sending an air stream of uniform temperature into the passenger compartment
- B60H1/0005—Air flow details of HVAC devices for sending an air stream of uniform temperature into the passenger compartment the air being firstly cooled and subsequently heated or vice versa
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60H—ARRANGEMENTS OF HEATING, COOLING, VENTILATING OR OTHER AIR-TREATING DEVICES SPECIALLY ADAPTED FOR PASSENGER OR GOODS SPACES OF VEHICLES
- B60H1/00—Heating, cooling or ventilating [HVAC] devices
- B60H1/00007—Combined heating, ventilating, or cooling devices
- B60H1/00021—Air flow details of HVAC devices
- B60H1/00064—Air flow details of HVAC devices for sending air streams of different temperatures into the passenger compartment
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60H—ARRANGEMENTS OF HEATING, COOLING, VENTILATING OR OTHER AIR-TREATING DEVICES SPECIALLY ADAPTED FOR PASSENGER OR GOODS SPACES OF VEHICLES
- B60H1/00—Heating, cooling or ventilating [HVAC] devices
- B60H1/00457—Ventilation unit, e.g. combined with a radiator
- B60H1/00464—The ventilator being of the axial type
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60H—ARRANGEMENTS OF HEATING, COOLING, VENTILATING OR OTHER AIR-TREATING DEVICES SPECIALLY ADAPTED FOR PASSENGER OR GOODS SPACES OF VEHICLES
- B60H1/00—Heating, cooling or ventilating [HVAC] devices
- B60H1/00507—Details, e.g. mounting arrangements, desaeration devices
- B60H1/00514—Details of air conditioning housings
- B60H1/00521—Mounting or fastening of components in housings, e.g. heat exchangers, fans, electronic regulators
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60H—ARRANGEMENTS OF HEATING, COOLING, VENTILATING OR OTHER AIR-TREATING DEVICES SPECIALLY ADAPTED FOR PASSENGER OR GOODS SPACES OF VEHICLES
- B60H1/00—Heating, cooling or ventilating [HVAC] devices
- B60H1/00507—Details, e.g. mounting arrangements, desaeration devices
- B60H1/00557—Details of ducts or cables
- B60H1/00564—Details of ducts or cables of air ducts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60H—ARRANGEMENTS OF HEATING, COOLING, VENTILATING OR OTHER AIR-TREATING DEVICES SPECIALLY ADAPTED FOR PASSENGER OR GOODS SPACES OF VEHICLES
- B60H1/00—Heating, cooling or ventilating [HVAC] devices
- B60H1/00642—Control systems or circuits; Control members or indication devices for heating, cooling or ventilating devices
- B60H1/00814—Control systems or circuits characterised by their output, for controlling particular components of the heating, cooling or ventilating installation
- B60H1/00821—Control systems or circuits characterised by their output, for controlling particular components of the heating, cooling or ventilating installation the components being ventilating, air admitting or air distributing devices
- B60H1/00864—Ventilators and damper doors
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60H—ARRANGEMENTS OF HEATING, COOLING, VENTILATING OR OTHER AIR-TREATING DEVICES SPECIALLY ADAPTED FOR PASSENGER OR GOODS SPACES OF VEHICLES
- B60H1/00—Heating, cooling or ventilating [HVAC] devices
- B60H1/00007—Combined heating, ventilating, or cooling devices
- B60H1/00021—Air flow details of HVAC devices
- B60H2001/00078—Assembling, manufacturing or layout details
- B60H2001/00099—Assembling, manufacturing or layout details comprising additional ventilating means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60H—ARRANGEMENTS OF HEATING, COOLING, VENTILATING OR OTHER AIR-TREATING DEVICES SPECIALLY ADAPTED FOR PASSENGER OR GOODS SPACES OF VEHICLES
- B60H1/00—Heating, cooling or ventilating [HVAC] devices
- B60H1/00007—Combined heating, ventilating, or cooling devices
- B60H1/00021—Air flow details of HVAC devices
- B60H2001/00185—Distribution of conditionned air
- B60H2001/002—Distribution of conditionned air to front and rear part of passenger compartment
Definitions
- the present disclosure relates to systems and methods for minimizing an air leak in an HVAC unit and, in particular, to systems and methods for minimizing a front to rear air leak in an integrated HVAC unit.
- HVAC heating, ventilation, and air conditioning
- HVAC heating, ventilation, and air conditioning
- Providing airflow to the front region of the vehicle while terminating airflow to the rear region of the vehicle can cause undesirable air leakage to the vehicle cabin which is discomforting to the vehicle occupants.
- the HVAC unit of the present disclosure restricts air leakage into the vehicle cabin, and therefore, avoids vehicle occupant discomfort.
- a heating, ventilation, and air conditioning (HVAC) unit in one form, includes a casing, an evaporator, a heater core, and a first damper.
- the casing defines a front airflow passageway, a rear airflow passageway having an inlet, and first and second outlets. The first and second outlets are in fluid communication with the rear airflow passageway.
- the evaporator is disposed within the casing such that a first section of the evaporator is disposed in the front airflow passageway and a second section of the evaporator is disposed in the rear airflow passageway.
- the heater core is disposed within the casing such that a first section of the heater core is disposed in the front airflow passageway and a second section of the heater core is disposed in the rear airflow passageway.
- the first damper is disposed within the casing between the evaporator and the heater core and is moveable between a first position in which airflow is directed to the second section of the heater core and a second position in which airflow is directed away from the second section of the heater core. Airflow across the evaporator from the front airflow passageway to the rear airflow passageway is directed to the first and second outlets when the first damper is moved from the first position toward the second position.
- the first damper controls airflow through the rear airflow passageway.
- a first blower unit is configured to blow air to the front airflow passageway.
- a second blowerunit is configured to blow air to the second airflow passageway.
- the first blower unit is in an ON mode and a second blower unit is in an OFF mode when the first damper is moved toward the second position and the airflow from the front airflow passageway to the rear airflow passageway is directed toward the first and second outlets.
- the first damper reduces the airflow from the front airflow passageway to the rear airflow passageway from flowing to the inlet of the rear airflow passageway.
- a second damper is disposed within the casing downstream of the heater core and movable between a first position and a second position.
- the second damper is moved to an intermediate position to distribute the airflow from the front airflow passageway to the rear airflow passageway out the first and second outlets.
- a heating, ventilation, and air conditioning (HVAC) unit in another form, includes a casing, an evaporator, a heater core, and a first damper.
- the casing defines a front airflow passageway, a rear airflow passageway having an inlet, and first and second outlets in fluid communication with the rear airflow passageway.
- the evaporator is disposed within the casing such that a first section of the evaporator is disposed in the front airflow passageway and a second section of the evaporator is disposed in the rear airflow passageway.
- the heater core is disposed within the casing such that a first section of the heater core is disposed in the front airflow passageway and a second section of the heater core is disposed in the rear airflow passageway.
- the first damper is disposed within the casing between the evaporator and the heater core and is moveable between a first position in which airflow is directed to the second section of the heater core and a second position in which airflow is directed away from the second section of the heater core. Moving the first damper from the first position toward the second position reduces airflow across the evaporator from the front airflow passageway to the rear airflow passageway from flowing to the inlet of the rear airflow passageway.
- the first blower unit is in an ON mode and the second blower unit is in an OFF mode when the first damper reduces the airflow from the front airflow passageway to the rear airflow passageway from flowing to the inlet of the rear airflow passageway.
- the airflow from the front airflow passageway to the rear airflow passageway is directed to the first and second outlets when the first damper is moved from the first position toward the second position.
- the present disclosure provides a method for reducing air leakage through an inlet of the rear airflow passageway of an HVAC unit.
- the method includes turning a first blower unit configured to blow air to the front airflow passageway of a casing of the HVAC unit to an ON mode; turning a second blower unit configured to blow air to the rear airflow passageway of the casing of the HVAC unit to an OFF mode; and moving a first damper disposed between an evaporator and a heater core within the casing from a first position toward a second position such that the first damper reduces airflow across the evaporator from the front airflow passageway to the rear airflow passageway from flowing to a first inlet of the rear airflow passageway.
- the airflow from the front airflow passageway to the rear airflow passageway is directed to first and second outlets of the rear airflow passageway when the first damper is moved from the first position toward the second position.
- the method includes moving a second damper disposed downstream of the heater core to an intermediate position such that the airflow is distributed between the first and second outlets of the rear airflow passageway.
- FIG. 1 is a representative vehicle including a heating, ventilation, and air conditioning (HVAC) unit in accordance with the present teachings;
- HVAC heating, ventilation, and air conditioning
- FIG. 2 is a perspective view of the HVAC unit of FIG. 1 ;
- FIG. 3 is a back view of the HVAC unit of FIG. 1 ;
- FIG. 4 is a cross-section view of the HVAC unit of FIG. 1 ;
- FIG. 5 is a flowchart of a control sequence of the HVAC unit.
- Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.
- first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.
- Spatially relative terms such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
- FIG. 1 illustrates a vehicle 10 having a heating, venting, and air cooling (HVAC) unit 12 disposed in a front portion 14 thereof.
- the HVAC unit 12 may provide airflow (heated and/or cooled) to a front region 16 of a vehicle cabin 18 via a front set of duct lines (not shown) and a rear region 20 of the vehicle cabin 18 via a rear set of duct lines (not shown).
- the HVAC unit 12 may include a casing 22 , a rear blower unit 24 , a front blower unit 26 , a front damper assembly 28 and a rear damper assembly 30 .
- a controller 31 FIG. 1 ) may control the HVAC unit 12 .
- the controller 31 may determine HVAC inputs from a user through a user interface (not shown) and may control various components of the HVAC unit 12 such as the rear blower unit 24 , the front blower unit 26 , the front damper assembly 28 , and the rear damper assembly 30 .
- the casing 22 may include a first shell 32 , a second shell 34 and an evaporator housing 35 .
- the first shell 32 , the second shell 34 , and the evaporator housing 35 may be formed of a molded plastic material, such as a thermoplastic for example, and can be joined together by any suitable method, including plastic welding, and/or clips for example.
- the first shell 32 , the second shell 34 and the evaporator housing 35 may define a front airflow passageway 36 , a rear airflow passageway 38 , a plurality of front outlets 40 and a plurality of rear outlets 41 .
- An evaporator 42 may be disposed within the evaporator housing 35 of the casing 22 such that a first section 42 a is disposed in the front airflow passageway 36 and a second section 42 b is disposed in the rear airflow passageway 38 .
- the evaporator 42 may be any suitable type of heat exchanger such as a plate-fin heat exchanger or a shell-tube heat exchanger, for example, configured to remove heat from air flowing across or through the evaporator 42 .
- a heater core 44 may be disposed within the first and second shells 32 , 34 of the casing 22 such that a first section 44 a is disposed in the front airflow passageway 36 and a second section 44 b is disposed in the rear airflow passageway 38 .
- the heater core 44 can be any suitable type of heat exchanger, such as a plate-fin heat exchanger or shell-tube exchanger, for example, configured to add heat to the air flowing across or through the heater core 44 .
- the front airflow passageway 36 may include a front supply flue 46 , a front cool flue 48 , and a front heat flue 49 .
- the front supply flue 46 may be located upstream of the evaporator 42 and may fluidly couple the front blower unit 26 and the evaporator 42 .
- the front cool flue 48 is located downstream of the evaporator 42 and upstream of the heater core 44 . That is, the front cool flue 48 is located between the evaporator 42 and the heater core 44 so as to fluidly couple the evaporator 42 and heater core 44 .
- Airflow passing though the evaporator 42 from the supply flue 46 may be cooled as it enters into the front cool flue 48 .
- the front heat flue 49 is located downstream of the heater core 44 and may fluidly couple the heater core 44 and the front outlets 40 . Airflow passing through the heater core 44 from the front cool flue 48 may be heated as it enters into the front heat flue 49 .
- the rear airflow passageway 38 may include an inlet or rear supply flue 50 , a rear cool flue 52 , a rear heat flue 54 , and a rear mix flue 55 .
- the rear supply flue 50 may be located upstream of the evaporator 42 and may fluidly couple the rear blower unit 24 and the evaporator 42 .
- the rear cool flue 52 is located downstream of the evaporator 42 and upstream of the heater core 44 . That is, the rear cool flue 52 is located between the evaporator 42 and the heater core 44 so as to fluidly couple the evaporator 42 and heater core 44 . Airflow passing though the evaporator 42 from the rear supply flue 50 may be cooled as it enters into the rear cool flue 52 .
- the rear heat flue 54 is located downstream of the heater core 44 and may fluidly couple the heater core 44 and the rear mix flue 55 . Airflow passing through the heater core 44 from the rear cool flue 52 may be heated as it enters into the rear heat flue 54 .
- the rear mix flue 55 is located upstream of the rear outlets 41 and may fluidly couple the rear cool flue 52 and/or the rear heat flue 54 to the rear outlets 41 .
- the plurality of front outlets 40 may be in fluid communication with the front region 16 of the of the vehicle cabin 18 .
- the plurality of front outlets 40 may also be fluidly coupled with the front heat flue 49 of the front airflow passageway 36 and may include a vent outlet 40 a , a defrost outlet 40 b , and a foot well outlet 40 c ( FIG. 4 ).
- the vent, defrost and foot well outlets 40 a , 40 b , 40 c may be positioned adjacent to each other at an upper end 56 of the casing 22 .
- Airflow passing through the front airflow passageway 36 may exit out of one or more of the vent, defrost, and foot well outlets 40 a , 40 b , 40 c.
- the plurality of rear outlets 41 may be in fluid communication with the rear region 20 of the of the vehicle cabin 18 .
- the plurality of rear outlets 41 may also be fluidly coupled with the rear mix flue 55 of the rear airflow passageway 38 and may include a rear vent outlet 41 a and a rear foot well outlet 41 b ( FIG. 4 ).
- the vent outlet 41 a and foot well outlet 41 b may be positioned adjacent to each other at the lower end 58 of the casing 22 . Airflow passing through the rear airflow passageway 38 may exit out of one or both of the vent outlet 41 a and foot well outlet 41 b.
- the rear blower unit 24 may be fluidly coupled to the rear supply flue 50 and configured to blow air to the rear supply flue 50 .
- the rear blower unit 24 includes a blower housing 60 , a rear blower fan 62 and a rear blower motor (not shown).
- the blower housing 60 defines a rear air inlet 64 that may be in fluid communication with the vehicle cabin 18 and the rear supply flue 50 .
- the rear blower fan 62 is disposed within the blower housing 60 .
- the rear blower motor (not shown) may be drivingly coupled to the rear blower fan 62 and operable in an ON-OFF mode.
- the rear blower motor When the rear blower motor (not shown) is in the ON mode, the rear blower motor rotates the rear blower fan 62 to draw air through the rear air inlet 64 from the vehicle cabin 18 and into the rear supply flue 50 .
- air can be drawn through the rear air inlet 64 from an exterior of the vehicle 10 , in addition to, or instead of, the vehicle cabin 18 .
- the front blower unit 26 is fluidly coupled with the front supply flue 46 and configured to blow air to the front supply flue 46 .
- the front blower unit 26 includes a front blower housing 66 , an inlet duct 68 and an outlet duct 70 .
- the front blower housing 66 is coupled to the inlet duct 68 at one side 72 and coupled to the outlet duct 70 at another side 74 ( FIG. 3 ).
- a front blowerfan (not shown) is disposed within the front blower housing 66 .
- a front blower motor (not shown) may be drivingly coupled to the front blower fan (not shown) and operable in an ON-OFF mode. When the front blower motor is in the ON mode, the front blower motor rotates the front blower fan to draw air through the inlet duct 68 and into the front supply flue 46 via the front blower housing 66 and the outlet duct 70 .
- the inlet duct 68 includes a first air inlet 76 fluidly coupled with the exterior of the vehicle 10 and/or the HVAC unit 12 , a second air inlet 78 fluidly coupled with the vehicle cabin 18 , and a third air inlet 79 fluidly coupled with the exterior of the vehicle 10 and/or HVAC unit 12 .
- air may be drawn in from the exterior of the vehicle 10 and/or the HVAC unit 12 through the first and third air inlets 76 , 79 and into the front supply flue 46 .
- air may be drawn through the second air inlet 78 from the vehicle cabin 18 and into the front supply flue 46 .
- the front damper assembly 28 is disposed within the casing 22 proximate to the plurality of front outlets 40 ( FIG. 4 ).
- the front damper assembly 28 includes a first damper 80 and a second damper 82 .
- the first damper 80 is pivotally attached to the casing 22 and movable between a first position and a second position. When the first damper 80 is in the first position (shown in FIG. 4 ), airflow may exit the casing 22 through the defrost outlet 40 b . When the first damper 80 is in the second position (shown in phantom lines in FIG. 4 ), airflow may exit the casing 22 through the foot well outlet 40 c . It should be understood that the first damper 80 may be moved to an intermediate position (i.e., between the first and second positions) such that airflow may exit the casing 22 through both the defrost and foot well outlets 40 b , 40 c.
- the second damper 82 is pivotally attached to the casing 22 and movable between a first position and a second position.
- airflow may exit the casing 22 through one or both of the defrost and foot well outlets 40 b , 40 c (depending on the position of the first damper 80 , as described above).
- the second damper 82 is in the second position (shown in phantom lines in FIG. 4 )
- airflow may exit the casing 22 through the vent outlet 40 a . In this position, airflow is prevented from exiting the casing 22 through either the defrost and foot well outlets 40 b , 40 c .
- the second damper 82 may be moved to an intermediate position (i.e., between the first and second positions) such that airflow may exit through the casing 22 through the vent outlet 40 a and one or both of the defrost and foot well outlets 40 b , 40 c (depending on the position of the first damper 80 , as described above).
- the rear damper assembly 30 is disposed within the casing 22 proximate to the plurality of rear outlets 41 .
- the rear damper assembly 30 includes a first damper 84 and a second damper 86 .
- the first damper 84 is pivotally attached to the casing 22 and disposed between the evaporator 42 and the heater core 44 .
- the first damper 84 is also movable between a first position and a second position. When the first damper 84 is in the first position ( FIG. 4 ), airflow through the rear cool flue 52 is directed through the heater core 44 and the rear heat flue 54 to the rear mix flue 55 .
- the first damper 84 is in the second position (shown in phantom lines in FIG.
- airflow through the rear cool flue 52 is directed directly to the rear mix flue 55 .
- the first damper 84 may be moved to an intermediate position (i.e., between the first and second positions) such that airflow through the rear cool flue 52 may be directed to both the heater core 44 and directly to the rear mix flue 55 .
- the temperature of the airflow through the rear mix flue 55 may be a blend or mixed of the airflow through the rear cool flue 52 and the rear heat flue 54 .
- the second damper 86 is pivotally attached to the casing 22 and movable between a first position and a second position.
- first position shown in FIG. 4
- second damper 86 When the second damper 86 is in the first position (shown in FIG. 4 ), airflow through the rear mix flue 55 is directed to the foot well outlet 41 b .
- second position shown in phantom lines in FIG. 4
- airflow through the rear mix flue 55 is directed to the vent outlet 41 a .
- the second damper 86 may be moved to an intermediate position (i.e., between the first and second positions) such that the airflow through the rear mix flue 55 may be directed to both the foot well outlet 41 b and the vent outlet 41 a.
- a flowchart 500 showing an example implementation of a control algorithm for reducing air leakage through the rear air inlet 64 fluidly coupled to the rear airflow passageway 36 of the HVAC unit 12 is shown.
- the control algorithm begins at 504 when the vehicle 10 is turned on by a vehicle operator (not shown) in the front region 16 of the vehicle cabin 18 .
- the control algorithm determines if the vehicle operator desires airflow (heated and/or cooled) only in the front region 16 of the vehicle cabin 18 . This determination maybe based on the user inputs received through the user interface (not shown) of the vehicle 10 .
- the vehicle 10 may have occupants (not shown) in the rear region 20 of the vehicle cabin 18 who do not wish to have airflow to the rear region 20 .
- the operator positioned in the front region 16 of the vehicle cabin 18 may desire to have airflow thereto, and therefore, may operate the user interface of the vehicle 10 so that airflow is allowed only in the front region of the vehicle cabin 18 .
- the control algorithm proceeds to 512 ; otherwise, the control algorithm remains at 508 until the operator desires airflow only to the front region 16 of the vehicle cabin 18 .
- the control algorithm uses the controller 31 , determines if the front blower motor of the front blower unit 26 is in the ON mode. If the front blower motor of the front blower unit 26 is in the ON mode, the control algorithm proceeds to 520 ; otherwise, the control algorithm proceeds to 516 where the front blower is turned to the ON mode and then proceeds to 520 .
- the control algorithm uses the controller 31 , determines if the rear blower motor of the rear blower unit 24 is in the OFF mode. If the rear blower motor of the rear blower unit 24 is in the OFF mode, the control algorithm proceeds to 528 ; otherwise, the control algorithm proceeds to 524 where the rear blower motor is turned to the OFF mode and then proceeds to 528 .
- airflow through the front airflow passageway 36 may leak across the evaporator 42 into the rear supply flue 50 and out the rear air inlet 64 into the front region 16 of the vehicle cabin 18 .
- This air leakage may be discomforting to the operator in the front region 16 of the vehicle 10 .
- the control algorithm moves the first damper 84 of the rear damper assembly 30 from the first position toward, or to, the second position. In this way, the pressure drop of the rear airflow passageway 38 is reduced, which, in turn, reduces the air leakage to the rear supply flue 50 and out the rear air inlet 64 into the front region 16 of the vehicle cabin 18 . Instead, the air leakage is directed to the rear mix flue 55 and out the rear outlets 41 .
- the first damper 84 of the rear damper assembly 30 may be moved to the intermediate position when the vehicle cabin 18 is warm so that the air leakage may be directed partially through the heater core 44 .
- the control algorithm After moving the first damper 84 of the rear damper assembly 30 from the first position toward, or to, the second position, the control algorithm then proceeds to 532 .
- the control algorithm moves the second damper 82 of the rear damper assembly 30 to, or near, the intermediate position to further distribute any air leakage from the rear mix flue 55 between the vent outlet 41 b and the vent outlet 41 b so that the air leakage is unnoticeable by the occupants in the rear region 20 .
- the controller 31 then proceeds to 536 and ends.
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Abstract
Description
- The present disclosure relates to systems and methods for minimizing an air leak in an HVAC unit and, in particular, to systems and methods for minimizing a front to rear air leak in an integrated HVAC unit.
- This section provides background information related to the present disclosure, which is not necessarily prior art.
- HVAC (heating, ventilation, and air conditioning) units provide airflow (heated and/or cooled) to a front region and a rear region of a vehicle cabin, for example. In some instances, airflow may only be desired in the front region of the vehicle cabin, and therefore, airflow to the rear region is terminated. Providing airflow to the front region of the vehicle while terminating airflow to the rear region of the vehicle can cause undesirable air leakage to the vehicle cabin which is discomforting to the vehicle occupants.
- The HVAC unit of the present disclosure restricts air leakage into the vehicle cabin, and therefore, avoids vehicle occupant discomfort.
- This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.
- In one form, a heating, ventilation, and air conditioning (HVAC) unit includes a casing, an evaporator, a heater core, and a first damper. The casing defines a front airflow passageway, a rear airflow passageway having an inlet, and first and second outlets. The first and second outlets are in fluid communication with the rear airflow passageway. The evaporator is disposed within the casing such that a first section of the evaporator is disposed in the front airflow passageway and a second section of the evaporator is disposed in the rear airflow passageway. The heater core is disposed within the casing such that a first section of the heater core is disposed in the front airflow passageway and a second section of the heater core is disposed in the rear airflow passageway. The first damper is disposed within the casing between the evaporator and the heater core and is moveable between a first position in which airflow is directed to the second section of the heater core and a second position in which airflow is directed away from the second section of the heater core. Airflow across the evaporator from the front airflow passageway to the rear airflow passageway is directed to the first and second outlets when the first damper is moved from the first position toward the second position.
- In some configurations, the first damper controls airflow through the rear airflow passageway.
- In some configurations, a first blower unit is configured to blow air to the front airflow passageway.
- In some configurations, a second blowerunit is configured to blow air to the second airflow passageway.
- In some configurations, the first blower unit is in an ON mode and a second blower unit is in an OFF mode when the first damper is moved toward the second position and the airflow from the front airflow passageway to the rear airflow passageway is directed toward the first and second outlets.
- In some configurations, the first damper reduces the airflow from the front airflow passageway to the rear airflow passageway from flowing to the inlet of the rear airflow passageway.
- In some configurations, a second damper is disposed within the casing downstream of the heater core and movable between a first position and a second position.
- In some configurations, the second damper is moved to an intermediate position to distribute the airflow from the front airflow passageway to the rear airflow passageway out the first and second outlets.
- In another form, a heating, ventilation, and air conditioning (HVAC) unit includes a casing, an evaporator, a heater core, and a first damper. The casing defines a front airflow passageway, a rear airflow passageway having an inlet, and first and second outlets in fluid communication with the rear airflow passageway. The evaporator is disposed within the casing such that a first section of the evaporator is disposed in the front airflow passageway and a second section of the evaporator is disposed in the rear airflow passageway. The heater core is disposed within the casing such that a first section of the heater core is disposed in the front airflow passageway and a second section of the heater core is disposed in the rear airflow passageway. The first damper is disposed within the casing between the evaporator and the heater core and is moveable between a first position in which airflow is directed to the second section of the heater core and a second position in which airflow is directed away from the second section of the heater core. Moving the first damper from the first position toward the second position reduces airflow across the evaporator from the front airflow passageway to the rear airflow passageway from flowing to the inlet of the rear airflow passageway.
- In some configurations, the first blower unit is in an ON mode and the second blower unit is in an OFF mode when the first damper reduces the airflow from the front airflow passageway to the rear airflow passageway from flowing to the inlet of the rear airflow passageway.
- In some configurations, the airflow from the front airflow passageway to the rear airflow passageway is directed to the first and second outlets when the first damper is moved from the first position toward the second position.
- In yet another form, the present disclosure provides a method for reducing air leakage through an inlet of the rear airflow passageway of an HVAC unit. The method includes turning a first blower unit configured to blow air to the front airflow passageway of a casing of the HVAC unit to an ON mode; turning a second blower unit configured to blow air to the rear airflow passageway of the casing of the HVAC unit to an OFF mode; and moving a first damper disposed between an evaporator and a heater core within the casing from a first position toward a second position such that the first damper reduces airflow across the evaporator from the front airflow passageway to the rear airflow passageway from flowing to a first inlet of the rear airflow passageway.
- In some configurations, the airflow from the front airflow passageway to the rear airflow passageway is directed to first and second outlets of the rear airflow passageway when the first damper is moved from the first position toward the second position.
- In some configurations, the method includes moving a second damper disposed downstream of the heater core to an intermediate position such that the airflow is distributed between the first and second outlets of the rear airflow passageway.
- Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
- The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
-
FIG. 1 is a representative vehicle including a heating, ventilation, and air conditioning (HVAC) unit in accordance with the present teachings; -
FIG. 2 is a perspective view of the HVAC unit ofFIG. 1 ; -
FIG. 3 is a back view of the HVAC unit ofFIG. 1 ; -
FIG. 4 is a cross-section view of the HVAC unit ofFIG. 1 ; and -
FIG. 5 is a flowchart of a control sequence of the HVAC unit. - Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
- Example embodiments will now be described more fully with reference to the accompanying drawings.
- The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable; are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.
- Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.
- The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms, “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.
- When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
- Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.
- Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
-
FIG. 1 illustrates avehicle 10 having a heating, venting, and air cooling (HVAC)unit 12 disposed in afront portion 14 thereof. TheHVAC unit 12 may provide airflow (heated and/or cooled) to afront region 16 of avehicle cabin 18 via a front set of duct lines (not shown) and arear region 20 of thevehicle cabin 18 via a rear set of duct lines (not shown). With additional reference toFIGS. 2-4 , theHVAC unit 12 may include acasing 22, arear blower unit 24, afront blower unit 26, afront damper assembly 28 and a rear damper assembly 30. A controller 31 (FIG. 1 ) may control theHVAC unit 12. That is, thecontroller 31 may determine HVAC inputs from a user through a user interface (not shown) and may control various components of theHVAC unit 12 such as therear blower unit 24, thefront blower unit 26, thefront damper assembly 28, and the rear damper assembly 30. - The
casing 22 may include afirst shell 32, asecond shell 34 and an evaporator housing 35. Thefirst shell 32, thesecond shell 34, and the evaporator housing 35 may be formed of a molded plastic material, such as a thermoplastic for example, and can be joined together by any suitable method, including plastic welding, and/or clips for example. Thefirst shell 32, thesecond shell 34 and the evaporator housing 35 may define afront airflow passageway 36, arear airflow passageway 38, a plurality offront outlets 40 and a plurality of rear outlets 41. An evaporator 42 may be disposed within the evaporator housing 35 of thecasing 22 such that afirst section 42 a is disposed in thefront airflow passageway 36 and asecond section 42 b is disposed in therear airflow passageway 38. The evaporator 42 may be any suitable type of heat exchanger such as a plate-fin heat exchanger or a shell-tube heat exchanger, for example, configured to remove heat from air flowing across or through the evaporator 42. Additionally, aheater core 44 may be disposed within the first andsecond shells casing 22 such that afirst section 44 a is disposed in thefront airflow passageway 36 and asecond section 44 b is disposed in therear airflow passageway 38. Theheater core 44 can be any suitable type of heat exchanger, such as a plate-fin heat exchanger or shell-tube exchanger, for example, configured to add heat to the air flowing across or through theheater core 44. - The
front airflow passageway 36 may include afront supply flue 46, a frontcool flue 48, and afront heat flue 49. Thefront supply flue 46 may be located upstream of the evaporator 42 and may fluidly couple thefront blower unit 26 and the evaporator 42. The frontcool flue 48 is located downstream of the evaporator 42 and upstream of theheater core 44. That is, the frontcool flue 48 is located between the evaporator 42 and theheater core 44 so as to fluidly couple the evaporator 42 andheater core 44. Airflow passing though the evaporator 42 from thesupply flue 46 may be cooled as it enters into the frontcool flue 48. Thefront heat flue 49 is located downstream of theheater core 44 and may fluidly couple theheater core 44 and thefront outlets 40. Airflow passing through theheater core 44 from the frontcool flue 48 may be heated as it enters into thefront heat flue 49. - The
rear airflow passageway 38 may include an inlet orrear supply flue 50, a rearcool flue 52, arear heat flue 54, and arear mix flue 55. Therear supply flue 50 may be located upstream of the evaporator 42 and may fluidly couple therear blower unit 24 and the evaporator 42. The rearcool flue 52 is located downstream of the evaporator 42 and upstream of theheater core 44. That is, the rearcool flue 52 is located between the evaporator 42 and theheater core 44 so as to fluidly couple the evaporator 42 andheater core 44. Airflow passing though the evaporator 42 from therear supply flue 50 may be cooled as it enters into the rearcool flue 52. Therear heat flue 54 is located downstream of theheater core 44 and may fluidly couple theheater core 44 and therear mix flue 55. Airflow passing through theheater core 44 from the rearcool flue 52 may be heated as it enters into therear heat flue 54. Therear mix flue 55 is located upstream of the rear outlets 41 and may fluidly couple the rearcool flue 52 and/or therear heat flue 54 to the rear outlets 41. - The plurality of
front outlets 40 may be in fluid communication with thefront region 16 of the of thevehicle cabin 18. The plurality offront outlets 40 may also be fluidly coupled with thefront heat flue 49 of thefront airflow passageway 36 and may include avent outlet 40 a, adefrost outlet 40 b, and afoot well outlet 40 c (FIG. 4 ). The vent, defrost and foot welloutlets upper end 56 of thecasing 22. Airflow passing through thefront airflow passageway 36 may exit out of one or more of the vent, defrost, and foot welloutlets - The plurality of rear outlets 41 may be in fluid communication with the
rear region 20 of the of thevehicle cabin 18. The plurality of rear outlets 41 may also be fluidly coupled with therear mix flue 55 of therear airflow passageway 38 and may include arear vent outlet 41 a and a rearfoot well outlet 41 b (FIG. 4 ). Thevent outlet 41 a andfoot well outlet 41 b may be positioned adjacent to each other at thelower end 58 of thecasing 22. Airflow passing through therear airflow passageway 38 may exit out of one or both of thevent outlet 41 a andfoot well outlet 41 b. - The
rear blower unit 24 may be fluidly coupled to therear supply flue 50 and configured to blow air to therear supply flue 50. Therear blower unit 24 includes ablower housing 60, a rear blower fan 62 and a rear blower motor (not shown). Theblower housing 60 defines arear air inlet 64 that may be in fluid communication with thevehicle cabin 18 and therear supply flue 50. The rear blower fan 62 is disposed within theblower housing 60. The rear blower motor (not shown) may be drivingly coupled to the rear blower fan 62 and operable in an ON-OFF mode. When the rear blower motor (not shown) is in the ON mode, the rear blower motor rotates the rear blower fan 62 to draw air through therear air inlet 64 from thevehicle cabin 18 and into therear supply flue 50. In some configurations, air can be drawn through therear air inlet 64 from an exterior of thevehicle 10, in addition to, or instead of, thevehicle cabin 18. - The
front blower unit 26 is fluidly coupled with thefront supply flue 46 and configured to blow air to thefront supply flue 46. Thefront blower unit 26 includes afront blower housing 66, aninlet duct 68 and anoutlet duct 70. Thefront blower housing 66 is coupled to theinlet duct 68 at oneside 72 and coupled to theoutlet duct 70 at another side 74 (FIG. 3 ). A front blowerfan (not shown) is disposed within thefront blower housing 66. A front blower motor (not shown) may be drivingly coupled to the front blower fan (not shown) and operable in an ON-OFF mode. When the front blower motor is in the ON mode, the front blower motor rotates the front blower fan to draw air through theinlet duct 68 and into thefront supply flue 46 via thefront blower housing 66 and theoutlet duct 70. - The
inlet duct 68 includes afirst air inlet 76 fluidly coupled with the exterior of thevehicle 10 and/or theHVAC unit 12, a second air inlet 78 fluidly coupled with thevehicle cabin 18, and athird air inlet 79 fluidly coupled with the exterior of thevehicle 10 and/orHVAC unit 12. When the front blower motor (not shown) rotates the front blower fan (not shown), air may be drawn in from the exterior of thevehicle 10 and/or theHVAC unit 12 through the first andthird air inlets front supply flue 46. Alternatively or additionally, air may be drawn through the second air inlet 78 from thevehicle cabin 18 and into thefront supply flue 46. - The
front damper assembly 28 is disposed within thecasing 22 proximate to the plurality of front outlets 40 (FIG. 4 ). Thefront damper assembly 28 includes afirst damper 80 and asecond damper 82. Thefirst damper 80 is pivotally attached to thecasing 22 and movable between a first position and a second position. When thefirst damper 80 is in the first position (shown inFIG. 4 ), airflow may exit thecasing 22 through thedefrost outlet 40 b. When thefirst damper 80 is in the second position (shown in phantom lines inFIG. 4 ), airflow may exit thecasing 22 through thefoot well outlet 40 c. It should be understood that thefirst damper 80 may be moved to an intermediate position (i.e., between the first and second positions) such that airflow may exit thecasing 22 through both the defrost and foot welloutlets - The
second damper 82 is pivotally attached to thecasing 22 and movable between a first position and a second position. When thesecond damper 82 is in the first position (FIG. 4 ), airflow may exit thecasing 22 through one or both of the defrost and foot welloutlets first damper 80, as described above). When thesecond damper 82 is in the second position (shown in phantom lines inFIG. 4 ), airflow may exit thecasing 22 through thevent outlet 40 a. In this position, airflow is prevented from exiting thecasing 22 through either the defrost and foot welloutlets second damper 82 may be moved to an intermediate position (i.e., between the first and second positions) such that airflow may exit through thecasing 22 through thevent outlet 40 a and one or both of the defrost and foot welloutlets first damper 80, as described above). - The rear damper assembly 30 is disposed within the
casing 22 proximate to the plurality of rear outlets 41. The rear damper assembly 30 includes a first damper 84 and a second damper 86. The first damper 84 is pivotally attached to thecasing 22 and disposed between the evaporator 42 and theheater core 44. The first damper 84 is also movable between a first position and a second position. When the first damper 84 is in the first position (FIG. 4 ), airflow through the rearcool flue 52 is directed through theheater core 44 and therear heat flue 54 to therear mix flue 55. When the first damper 84 is in the second position (shown in phantom lines inFIG. 4 ), airflow through the rearcool flue 52 is directed directly to therear mix flue 55. It should be understood that the first damper 84 may be moved to an intermediate position (i.e., between the first and second positions) such that airflow through the rearcool flue 52 may be directed to both theheater core 44 and directly to therear mix flue 55. In this way, the temperature of the airflow through therear mix flue 55 may be a blend or mixed of the airflow through the rearcool flue 52 and therear heat flue 54. - The second damper 86 is pivotally attached to the
casing 22 and movable between a first position and a second position. When the second damper 86 is in the first position (shown inFIG. 4 ), airflow through therear mix flue 55 is directed to thefoot well outlet 41 b. When the second damper 86 is in the second position (shown in phantom lines inFIG. 4 ), airflow through therear mix flue 55 is directed to thevent outlet 41 a. It should be understood that the second damper 86 may be moved to an intermediate position (i.e., between the first and second positions) such that the airflow through therear mix flue 55 may be directed to both thefoot well outlet 41 b and thevent outlet 41 a. - With reference to
FIG. 5 , aflowchart 500 showing an example implementation of a control algorithm for reducing air leakage through therear air inlet 64 fluidly coupled to therear airflow passageway 36 of theHVAC unit 12 is shown. The control algorithm begins at 504 when thevehicle 10 is turned on by a vehicle operator (not shown) in thefront region 16 of thevehicle cabin 18. - At 508, the control algorithm, using the
controller 31, determines if the vehicle operator desires airflow (heated and/or cooled) only in thefront region 16 of thevehicle cabin 18. This determination maybe based on the user inputs received through the user interface (not shown) of thevehicle 10. For example, thevehicle 10 may have occupants (not shown) in therear region 20 of thevehicle cabin 18 who do not wish to have airflow to therear region 20. In this case, the operator positioned in thefront region 16 of thevehicle cabin 18 may desire to have airflow thereto, and therefore, may operate the user interface of thevehicle 10 so that airflow is allowed only in the front region of thevehicle cabin 18. If the vehicle operator desires airflow only in thefront region 16 of thevehicle cabin 18, the control algorithm proceeds to 512; otherwise, the control algorithm remains at 508 until the operator desires airflow only to thefront region 16 of thevehicle cabin 18. - At 512, the control algorithm, using the
controller 31, determines if the front blower motor of thefront blower unit 26 is in the ON mode. If the front blower motor of thefront blower unit 26 is in the ON mode, the control algorithm proceeds to 520; otherwise, the control algorithm proceeds to 516 where the front blower is turned to the ON mode and then proceeds to 520. - At 520, the control algorithm, using the
controller 31, determines if the rear blower motor of therear blower unit 24 is in the OFF mode. If the rear blower motor of therear blower unit 24 is in the OFF mode, the control algorithm proceeds to 528; otherwise, the control algorithm proceeds to 524 where the rear blower motor is turned to the OFF mode and then proceeds to 528. - In response to the rear blower motor turned to the OFF mode, airflow through the
front airflow passageway 36 may leak across the evaporator 42 into therear supply flue 50 and out therear air inlet 64 into thefront region 16 of thevehicle cabin 18. This air leakage may be discomforting to the operator in thefront region 16 of thevehicle 10. - At 528, the control algorithm moves the first damper 84 of the rear damper assembly 30 from the first position toward, or to, the second position. In this way, the pressure drop of the
rear airflow passageway 38 is reduced, which, in turn, reduces the air leakage to therear supply flue 50 and out therear air inlet 64 into thefront region 16 of thevehicle cabin 18. Instead, the air leakage is directed to therear mix flue 55 and out the rear outlets 41. In some configurations, the first damper 84 of the rear damper assembly 30 may be moved to the intermediate position when thevehicle cabin 18 is warm so that the air leakage may be directed partially through theheater core 44. In this way, the temperature of any air leakage out of the plurality of rear outlets 41 is substantially similar to the temperature of thevehicle cabin 18, and therefore, unnoticeable to the occupants in therear region 20 of thevehicle cabin 18. After moving the first damper 84 of the rear damper assembly 30 from the first position toward, or to, the second position, the control algorithm then proceeds to 532. - At 532, the control algorithm moves the
second damper 82 of the rear damper assembly 30 to, or near, the intermediate position to further distribute any air leakage from therear mix flue 55 between thevent outlet 41 b and thevent outlet 41 b so that the air leakage is unnoticeable by the occupants in therear region 20. Thecontroller 31 then proceeds to 536 and ends.
Claims (13)
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US15/439,462 US10065479B1 (en) | 2017-02-22 | 2017-02-22 | System and method for minimizing air leak in an HVAC unit |
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US15/439,462 US10065479B1 (en) | 2017-02-22 | 2017-02-22 | System and method for minimizing air leak in an HVAC unit |
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