WO2013185012A1

WO2013185012A1 - Flexible material air vent assembly

Info

Publication number: WO2013185012A1
Application number: PCT/US2013/044675
Authority: WO
Inventors: Craig D. Flowerday; Scott A. Hansen; Thomas S. Hodgson; Ronald A. Bozio
Original assignee: Johnson Controls Technology Company
Priority date: 2012-06-08
Filing date: 2013-06-07
Publication date: 2013-12-12

Abstract

A vent assembly for a vehicle includes one or more flexible membranes to direct air as desired by a vehicle occupant. The membranes may be individual, assembled with other parts of the vent assembly, or formed as a single-piece framework then assembled into the vent assembly. The flexible membranes may form divisions within the vent assembly for directing air to the vehicle interior. The flexible membranes may also be used as seals or peripheral panels between interior vent parts and peripheral elements, such as a vent plenum.

Description

FLEXIBLE MATERIAL AIR VENT ASSEMBLY

BACKGROUND

[0001] The present invention relates generally to vents used in vehicles for distributing hot and cold air for the comfort of the vehicle occupants.

[0002] A wide variety of vent systems have been developed for vehicle applications. These are generally designed to receive a flow of air from air conditioning systems or from the exterior of the vehicle and to distribute the air to interior spaces of the vehicle for the comfort of the vehicle occupants. In general, the vents may receive unconditioned air, or heated or cooled air. Currently, vents are made of multiple parts that are assembled in a more or less complex sub-assembly. These vent sub-assemblies often include multiple vanes, control bars, links, and so forth that must be separately be designed, molded, assembled and that consequently add to the cost and complexity of the ventilation system. Moreover, these more complex sub-assemblies may be prone to breakage or inoperability when any of the individual components, bearings, links, or any aspects of their structures is damaged or worn.

[0003] There is a need, therefore, for improvements in vent arrangements that can offer more cost-effective and reliable assemblies for use in a range of vehicles.

SUMMARY

[0004] The present invention offers vent designs and assemblies are adapted to response to these needs. In accordance with certain aspects of the invention, for example, a vehicle air vent is disclosed that comprises a support structure configured to be disposed in a component of a vehicle air system, and at least one flexible membrane secured to the support structure and configured to be deformed during operation to direct an air stream in a direction selected by a vehicle occupant. [0005] In accordance with particular configurations, the invention provides a vehicle air vent, comprising a support structure configured to be disposed in a component of a vehicle air system, and a plurality of membranes secured to the support structure and configured to be deformed during operation to direct an air stream in a direction selected by a vehicle occupant. A control mechanism is configured to permit operator adjustment of the direction of the air stream by deformation of the flexible membranes.

[0006] Still further, the invention provides a vehicle air vent comprising a support structure mounted in a component of a vehicle for receiving a flow of air, a plurality of membranes secured to the support structure and configured to be deformed during operation to direct an air stream in a direction selected by a vehicle occupant, and a control mechanism configured to permit operator adjustment of the direction of the air stream by deformation of the flexible membranes.

DRAWINGS

[0007] FIGS. 1 and 2 illustrate exemplary installations of vents of the type described herein in motor vehicles;

[0008] FIG. 3 and 4 illustrate an exemplary configuration for a vent assembly in accordance with aspects of the present techniques;

[0009] FIGS. 5, 6, 7 and 8 illustrate an alternative configuration utilizing an elastic peripheral panel;

[0010] FIGS. 9, 10 & 1 1 illustrate a further alternative configuration utilizing a bellows-type panel;

[0011] FIG. 12 illustrates an exemplary arrangement utilizing sliding tubes with flexible panels;

[0012] FIG. 13 illustrates a movable assembly surrounded by flexible panel; [0013] FIG. 14 illustrates a further alternative embodiment utilizing a pivoting vent with flexible panels;

[0014] FIG. 15 illustrates a further alternative in which parallel flexible tube-like elements are utilized;

[0015] FIGS. 16-23 illustrate a series of exemplary grid configurations that may be used for flexible and/or elastic members in the novel vent systems; and

[0016] FIGS. 24, 25 and 26 illustrate exemplary control mechanisms for vent systems employing flexible materials.

DETAILED DESCRIPTION

[0017] As illustrated in FIGS. 1 and 2, vents 10, which may generally be referred to as heating, ventilating and air conditioning (HVAC) vents, will typically be provided in vehicles, designated generally by reference numeral 12 at various locations for the comfort of the vehicle occupants. These vents will be interconnected with conduits (not shown) to receive a flow of air, which may be heated and/or cooled depending upon the preferences of the occupants. Details relating to the mechanisms for heating and cooling the air streams are generally known in the art and are beyond the scope of the present disclosure. The vents direct a flow of air, designated generally by reference numeral 14 in directions as determined by the orientation of certain components, such as dividers or membranes within the vents as described more fully below. In general, such vents may be provided in a vehicle dashboard as indicated by reference numeral 16, or in a vehicle console 18, door panels 20 or any other desired location within the vehicle. For example, similar vents may be provided in headliners (not shown), rear consoles (not shown), and so forth. It should be also noted that although a motor vehicle, such as a car or truck is illustrated in FIGS. 1 and 2, the vent systems disclosed herein may be used in any suitable vehicle, including road vehicles, boats, airplanes, and so forth. [0018] To facilitate manufacturing and installation of vent assemblies in accordance with the present techniques, these may be manufactured and assembled as stand-alone sub-assemblies as illustrated in FIG. 3. The vent assembly 22 in this embodiment may include, for example, a front framework 24 and a rear framework 26. These may be made by any suitable technique, such as injection molding of thermoplastic materials. An intermediate air-directing section 28 is disposed between the front and rear frameworks and serves to direct air from an entry side, typically the rear framework, to an exit side, typically the front framework of the assembly. The air-directing section itself comprises side panels 30 that connect the rear framework to the front framework and form a plenum through which air flows. The front framework may include a grid 32 which may be separate or formed with the periphery of the front framework and subdivides the front framework into multiple vent paths. These vent paths correspond to channels defined by intermediate panels 34 disposed between the front and rear frameworks.

[0019] In presently contemplated embodiments, portions of the vent assembly are made of flexible and/or elastic materials that allow air flow paths to be altered during use to direct air as desired by the vehicle occupants. In the embodiment illustrated in FIG. 3, for example, such flexible materials may be used for the side panels 28 as well as for the intermediate panels 34. It should be noted that these panels comprise more than a simple living hinge, but instead are continuous flexible sheet-like segments. These may be made of any suitable material, such as silicone, although various plastics, elastomers, fabrics, coated fabrics, and so forth may be utilized. These may be selected in view of their flexibility, but where desired a substantial degree of elasticity may also be utilized for various embodiments as described below. In general, when described in this disclosure as "flexible", it should be understood that this refers to both the flexible and elastic properties of the continuous sheet-like materials utilized.

[0020] FIG. 4 illustrates a segment of the vent assembly of FIG. 3 showing how such panels may be provided and attached to the frameworks. As shown in FIG. 4, the panels 34 may be secured through the front and rear frameworks 24 and 26 by anchor portions 36. Between these anchor portions flexible material 38 extends and may be deformed by movement of the front framework 24, the rear framework 26, or both. The anchor portions 36 may form part of the flexible material 38, or these may be formed within the frameworks, such as by two-shot molding. In presently contemplated embodiments, the front and rear frameworks may be made of a moldable plastic material such as AVS, polypropylene, or any other suitable material. It should also be noted that in certain embodiments part of the front and rear frameworks may be eliminated, such as internal grids 32 illustrated in FIG. 1. Where the flexible material is subject to control without such arrangements, their elimination may facilitate manufacturing and assembly, and provide a simpler and more reliable vent system. As shown in FIG. 4, as the flexible material 38 is deformed between the front and rear frameworks, airflow paths 40 are altered so as to direct air in a direction desired by a user. Although generally parallel movement of the framework is illustrated in FIG. 4, it should be noted that in certain embodiments relative angular displacement of the front and rear portions of the flexible material may be employed to assist in directing the airflow.

[0021] In the embodiment illustrated in FIGS. 3 and 4, and indeed for the other embodiments described in the present disclosure, it should be borne in mind that various mechanical attachment structures may be utilized for securing the vent assemblies in place in a vehicle. As will be apparent to those skilled in the art, the vehicle receiving surfaces will typically be contoured and prepared to receive the vent assembly either from a front side or a rear side of the receiving component. Screws, adhesives, clips, and various other mechanical structures may be utilized to hold the vent assembly in place and, where desired, to permit its removal for servicing or replacement. Such mechanical attachment structures are believed to be within the purview of those skilled in the art, and are, themselves, generally beyond the scope of the present disclosure.

[0022] In addition to flexible materials used to direct airflow, the present disclosure is intended to encompass arrangements in which similar materials are used to seal or prevent the flow or escape of air in vent assemblies. FIGS. 5, 6, 7 and 8 illustrate one exemplary embodiment for such a vent assembly. In this embodiment, the vent assembly 22 includes a plenum 42 designed to surround the vent assembly and to capture the air directed to a vent assembly. A rigid vent piece 44 is mounted within this plenum and may subdivide the airflow into segments as illustrated. A flexible peripheral panel 46 is secured to the interior or front of the plenum and to the periphery of the vent piece 44. This peripheral panel, which may be made in one or multiple sections, serves to ensure that air does not flow or leak passed the plenum and vent piece, but is directed through the vent piece in the direction desired by vehicle occupant.

[0023] FIG. 6 illustrates the same assembly in a straight-on position, as indicated generally by reference numeral 48. In this position, the vent piece 44 is oriented generally straight forward, so as to create flow paths 50 generally parallel to the plenum. The peripheral panels 46 are illustrated as generally relaxed, directing these air paths only through the vent piece. Where desired, as illustrated in FIG. 6, an additional grill 52 may be provided to assist in directing air to the vehicle occupant. FIGS. 7 and 8 illustrate the same arrangement in tilted positions, as indicated generally by reference numeral 54. In the left tilted position of FIG. 7, the vent piece 44 causes deformation of the peripheral panels 46 to allow the flow path 50 to be directed to the left, while the panels nevertheless force all air through the vent piece. The arrangement of FIG. 8, on the contrary, directs the flow paths to the right, maintaining the seal around the vent piece by deformation of the peripheral panel 46.

[0024] FIGS. 9, 10 and 1 1 illustrate a similar embodiment in which the peripheral panel or panels are somewhat less elastic but nevertheless flexible. As shown in FIG. 9, for example, the vent assembly 22 includes components similar to those shown in the previous embodiment, but the vent piece 44 is surrounded by a folded or somewhat collapsible bellows-type arrangement made of a flexible material. This bellows 56 effectively forms a similar seal between the plenum 42 and the vent piece 44. Moreover, in this embodiment the vent piece 44 is pivotable by a central stem 58 which interfaces with a pivot attachment or bearing 60. Thus, in a straight-on orientation shown in FIG. 9, the flow paths 50 are directed forwardly. In tilted or angled positions 54, shown in FIGS. 10 and 1 1 , the peripheral panel or panels 56 are deformed to allow for movement of the vent piece while maintaining a peripheral seal between the plenum and the vent piece.

[0025] Other arrangements employing flexible materials in the vent assembly may be envisaged, as illustrated, for example, in FIGS. 12 and 13. In the embodiment of FIG. 12, the vent assembly 22 is formed by a series of generally parallel tubes 62. These may be somewhat flexible or fairly rigid, in the latter case, being made of a thermoplastic material. The tubes may also be extruded and cut to length prior to assembly. Moreover, the tubes may have a desired cross-sectional shape, such as round, square, triangular, hexagonal, and so forth. The tubes may be situated such that they merely abut or come close to one another, or they may be interfaced with one another, such as by slide arrangements indicated by reference numeral 64. The front faces of the tubes may be secured to a front panel 66 by means of flexible membranes 68. These flexible membranes assist in sealing and guiding air directed through tubes to openings in the front panels 66. In the arrangement shown in FIG. 13, a similar tube is provided, but is pivotable by means of support by a peripheral panel 46, 56, which may be elastic or bellows-type as described above. In this embodiment, the tube 70 may be made of a rigid or semi-rigid material, such as molded or extruded plastic. The peripheral panel 46, 56 may be attached to attachment points of 72 in the plenum in which the tube is placed. On the tube-side, attachments 74 are provided so that the peripheral panel 46, 56 forms a seal between the tube and the plenum.

[0026] FIG. 14 illustrates a further alternative configuration utilizing flexible panels. In this embodiment, the vent assembly 22 is formed of a pivoting vent 76, here shown in vertical section. The pivoting vent has a body or housing that is mounted by a pivot point 78 so that the entire vent may pivot about this point for directing air. The pivoting vent includes a front panel 80 through which air exits, and it may include one or more internal dividers 82 for partitioning the airflow into individual streams. These dividers may be made of a flexible material or in certain embodiments may be molded or assembled with the relatively rigid pivoting vent housing. In either case, the pivoting vent is bounded by one or more peripheral panels 46, 56. As before, these may be formed as elastic panels or as bellows for sealing the flow paths between the plenum 42 and the pivoting vent housing.

[0027] In a further exemplary embodiment, shown in FIG. 15, a multitude of generally parallel flexible tubes 84 may be employed. These may be made of any suitable material, such as silicone. Moreover, the embodiment of FIG. 15 allows for ease of manufacture through extrusion and cutting of material to the desired length for the subassembly. The individual flexible tubes 84 may be mounted between a rear anchor framework 86 and a movable front framework 88. By movement of some or all of the front framework, the tubes may be caused to flex in the direction of movement to direct air as desired by the vehicle occupant.

[0028] A wide range of configurations, subdivisions, grid works, and so forth may be envisaged for the various embodiments contemplated in the present disclosure. As noted before, these may take various forms, and need not be simply a rectilinear grid. FIGS. 16-23 illustrate a range of possible grid patterns, although it should be understood that these again are simply exemplary. For example, the grid work 90 of FIG. 16 forms a honeycomb-like pattern, while other repeating and semi-repeating patterns may be formed, as indicated by reference numerals 92 and 94 in FIGS. 17 and 18. Other patterns, both repeating and non-repeating, symmetrical and non-symmetrical may be provided as indicated by reference numerals 96, 98 and 100 in FIGS. 19, 20 and 21 , respectively. It should be noted that the present approach to vent assembly design may allow for considerable aesthetic variation such that the vents may lend themselves to accents within the vehicle interior, complementing the aesthetic approach offered by dashboard designs, door panel designs, console designs, and so forth.

[0029] Embodiments such as those illustrated in FIGS. 22 and 23 may be configured to be both aesthetic and functional insomuch as they may be deformed in desired ways. The embodiments of these figures are generally radial, as indicated by reference numerals 102 and 104. Deformation of these may be contemplated to direct air in particular ways, such as spirals, fans, and so forth. It should be appreciated that in all of the foregoing designs, the flexible material utilized in the vent assemblies may comprise individual membranes, or entire areas or regions of membranes, such as through molding of the air- directing gridwork. As noted above, these gridworks may be attached to a rigid or semirigid framework to assist in orienting the individual membranes as desired for airflow direction. However, where the molded gridwork itself is capable of controlled deformation, particularly of its individual dividing membranes, such additional components may be dispensed with or limited only to certain regions of the vent.

[0030] Various structures may be designed to allow for control of the deformation of the flexible materials used in the vent assemblies contemplated. These may include simple friction slides, or more complex positioning and orienting structures. Certain exemplary control mechanisms are illustrated in FIGS. 24, 25 and 26. In the embodiment of FIG. 24, for example, the control mechanism 106 comprises a control stem 108 extending between the front framework 24 and the real framework 26. This control stem allows for manipulation by a user to alter the position of the front framework 24, the rear framework 26, or both, and consequently the orientation of the flexible material between these frameworks, indicated by reference numeral 38. The control stem 108 has a bearing piece 1 10 at its rear end that interfaces with a bearing 1 12 of the rear framework to allow for pivotable movement of the stem. A control mechanism housing 1 14 surrounds the stem and includes a rear opening 1 16 and a front opening 1 18 through which the stem extends. A retention enlargement 120, in this case a generally spherical portion of the stem 108 is positioned within the housing 1 14. The housing itself is comprised of at least two parts so that the internal components of the housing may be mounted as shown. The housing is further mounted to the front framework 24 so that movement of the stem allows for displacement of the front framework. To allow the stem to be held in place, compression members 122 and 124 flank the retention enlargement 120 on front and rear sides thereof, and are compressed against this enlargement by a spring 126 disposed in the housing. Movement of the stem left, right, and where allowed up and down, thus, permits for the membranes to be deformed for directing air, while holding the front framework in a desired position to maintain the orientation of the membranes.

[0031] FIG. 25 illustrates a similar arrangement where, however, the stem 108 has a bulbous front portion 128 that abuts a bearing piece 130. The stem includes a bearing piece 1 10 as described above at its rear end to permit pivotable movement. In this embodiment a spring 132 is disposed between the bearing piece 130 and the enlarged bulb 128 of the stem to create a friction engagement to hold the housing in the desired orientation. A small stem extension 134 runs between the stem 108 and the bearing piece 1 10 and is itself surrounded by a smaller spring 136 to hold the entire arrangement in tight compression.

[0032] FIG. 26 illustrates a simple slide arrangement as may be used in certain embodiments. In this case, the membranes 38 extend between the forward and rear frameworks 24 and 26, while a slide 138 is provided in a recess 140 formed in the front framework. Movement of the slide may be made by finger adjustment by the vehicle occupant, and the slide will be held in place by friction, interaction of the slide with the front framework, or by any other means. With all of these control mechanisms, however, it should be understood that those skilled in the art may devise a wide range of mechanisms that allow for movement or deformation of the flexible members used in the vent assemblies, while maintaining these in a desired position or orientation. The particular control mechanisms described are intended to be exemplary only.

[0033] While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.

Claims

CLAIMS:

1. A vehicle air vent, comprising:

a support structure configured to be disposed in a component of a vehicle air system; and

at least one flexible membrane secured to the support structure and configured to be deformed during operation to direct an air stream in a direction selected by a vehicle occupant.

2. The vehicle air vent of claim 1 , wherein the flexible membrane subdivides the air vent into multiple flow paths.

3. The vehicle air vent of claim 1 , wherein the flexible membrane forms a peripheral border around a vent piece to force the air stream through the vent piece.

4. The vehicle air vent of claim 1, comprising a plurality of flexible membranes.

5. The vehicle air vent of claim 4, wherein the flexible membranes are disposed in generally parallel orientations.

6. The vehicle air vent of claim 1 , wherein the flexible membrane is part of a molded gridwork.

7. The vehicle air vent of claim 1, wherein the support structure comprises a front framework and a rear framework, and wherein the flexible membrane extends between the front and rear frameworks.

8. The vehicle air vent of claim 1, wherein the support structure comprises a pivoting structure, and wherein the flexible membrane extends between the pivoting structure and a fixed structure to direct the air stream.

9. The vehicle air vent of claim 1, comprising a control mechanism configured to permit operator adjustment of the direction of the air stream by deformation of the flexible membrane.

10. The vehicle air vent of claim 1, wherein the flexible membrane is stretched as the support structure is moved to direct the air stream.

11. The vehicle air vent of claim 1 , wherein the flexible membrane is a bellows-like element.

12. A vehicle air vent, comprising:

a support structure configured to be disposed in a component of a vehicle air system;

a plurality of membranes secured to the support structure and configured to be deformed during operation to direct an air stream in a direction selected by a vehicle occupant; and

a control mechanism configured to permit operator adjustment of the direction of the air stream by deformation of the flexible membranes.

13. The vehicle air vent of claim 12, wherein the flexible membrane is stretched as the support structure is moved to direct the air stream.

14. The vehicle air vent of claim 12, wherein the flexible membrane is a bellows-like element.

15. The vehicle air vent of claim 12, wherein the flexible membranes are disposed in generally parallel orientations.

16. The vehicle air vent of claim 12, wherein the flexible membrane is part of a molded gridwork.

17. A vehicle air vent, comprising:

a support structure mounted in a component of a vehicle for receiving a flow of air;

18. The vehicle air vent of claim 17, wherein the flexible membrane is stretched as the support structure is moved to direct the air stream.

19. The vehicle air vent of claim 17, wherein the flexible membrane is a bellows-like element.

20. The vehicle air vent of claim 17, wherein the component comprises a vehicle dash board, a vehicle console or a vehicle interior liner part.