Rough-in plug for connecting a condensate drain hose in the vehicle

Abstract

The invention relates to a condensate drain device for a vehicle, comprising a body plug (1) which is inserted into an opening of a body element (2) and which has a drain opening that extends through the opening of the body element (2), wherein the body plug (1) is sealed to the body element (2) by means of swollen expanding foam (3), and wherein a first connecting coupling (4) connects to the drain opening at the interior end of the body plug (1), wherein the first connecting coupling (4) connects the body plug (1) to a drain hose (5).

Description

[0001] The invention relates to a condensate drain device for a vehicle, a vehicle with such a condensate drain device, and a method for manufacturing a condensate drain device for a vehicle.

[0002] When an air conditioning system is operating in a vehicle, condensation can form. This is especially true when the ambient air is cooled, as the dew point drops to lower temperatures at constant ambient pressure. Condensation describes the process by which water vapor in the air condenses into liquid water, forming mist or water droplets on surfaces. It is advisable to drain this condensation from vehicles using a drain hose or pipe. Several solutions for this are known in the art: EP 1 645 447 B1 relates to a condensate drain hose for vehicle air conditioning systems, comprising a first end suitable for connection to an outlet opening formed in an outer sheet metal wall of the vehicle and a second end suitable for connection to a condensate collection tray located below an evaporator, wherein the condensate drain hose comprises: a connecting element made of a solid plastic material, provided with bayonet connectors for connecting the first end of the hose to the outlet opening, and a body made of an elastomeric material, which is molded together with the connecting element and is provided with an end region shaped for connection to a tubular end of the tray.

[0003] EP 2 093 084 B1 relates to a condensate drain pipe for a heating, ventilation and / or air conditioning system of a vehicle, wherein the condensate drain pipe has a condensate inlet section and a condensate outlet section, wherein, when installed in the vehicle, the condensate inlet section extends between an HVAC module of the HVAC system and a center console of the vehicle, and the condensate outlet section extends from the center console to an opening in a body panel of the vehicle, wherein the condensate inlet section and the condensate outlet section are separably connected to each other by a press-fit coupling assembly comprising an O-ring, and wherein the press-fit coupling assembly further comprises a height adjustment fixing for attaching the drain pipe to the center console in a desired position.

[0004] The object of the invention is to ensure, in a structurally simplified manner, the tightness of a condensate drainage device for a vehicle.

[0005] The invention is defined by the features of the independent claims. Advantageous further developments and embodiments are the subject of the dependent claims.

[0006] A first aspect of the invention relates to a condensate drain device for a vehicle, comprising a body plug which is inserted into an opening of a body element and which has a drain opening which extends through the opening of the body element, wherein the body plug is sealed to the body element by means of swollen expanding foam, and wherein a first connecting coupling is attached to the drain opening at the interior end of the body plug, wherein the first connecting coupling connects the body plug to a drain hose.

[0007] The condensate drainage device therefore comprises the following components: rough construction plug with drain opening, expanding foam, first connecting coupling, drain hose.

[0008] The body-in-white plug serves to create a channel through the body panel. This body panel can be a flat sheet of metal and primarily serves to separate an interior from an exterior space. The aim is to drain condensation, particularly from an air conditioning system, from the interior through the body panel into the exterior. For this purpose, an opening is provided in the body panel into which the body-in-white plug is inserted.

[0009] The body shell plug is sealed against the body panel by placing expanding foam in a contact zone between the plug and the body panel, which increases in volume under the influence of temperature in a body shell oven, i.e. it swells and seals the plug to the body panel.

[0010] Preferably, the body-in-white plug has a radial extension, particularly in the form of a collar, which has a larger diameter than the opening in the body panel. This allows the plug to be installed on the body panel from only one side by inserting it into the opening. Preferably, this is done from an interior side of the body panel, thus securing the plug against falling out of the interior and preventing it from unintentionally falling into the surrounding area.

[0011] The body plug itself has a drain opening, i.e., it is able to release condensation from the interior through its drain opening, which is led through the opening of the body element, into the environment, i.e., an outside space in relation to the body element.

[0012] A first connecting coupling is provided at the interior end of the rough-in plug to allow a connection for draining condensate from the interior through a drain hose located inside the interior to the rough-in plug. For this purpose, the rough-in plug advantageously has a nozzle at its interior end to which the first connecting coupling, preferably a VDA coupling, can be attached.

[0013] Advantageous effects of the invention include the reduced number of components required to ensure a leak-proof drainage of condensate from an air conditioning system through a body panel to an exterior space of the vehicle. Complex Poka-Yoke concepts are unnecessary. Poka-Yoke is a Japanese term describing a multi-element principle that includes technical features or devices for direct fault detection and prevention. One such fault-prevention principle is the lock-and-key principle. Furthermore, assembly time is advantageously reduced, particularly since only a body plug, sealed with expanding foam against the body panel, needs to be connected to a drain hose via a first coupling. This drain hose is then connected to an air conditioning system, preferably via a second coupling.

[0014] According to an advantageous embodiment, the first connecting coupling is a VDA coupling.

[0015] The VDA coupling is a standardized connection component frequently used in the automotive industry. It is manufactured according to the standards of the German Association of the Automotive Industry (VDA) and is used in various areas, such as radiator hose repairs.

[0016] According to a further advantageous embodiment, a second connecting coupling is arranged at one end of the drain hose opposite the end of the drain hose with the first connecting coupling, which serves to attach it to an air conditioning system of the vehicle.

[0017] According to another advantageous embodiment, the second connecting coupling is a VDA coupling.

[0018] Another aspect of the invention relates to a vehicle with a condensate drain device as described above and below, wherein the drain opening forms a liquid line from the first connecting coupling at the interior end of the body plug to an exterior end of the body plug.

[0019] Advantages and preferred further developments of the proposed vehicle result from an analogous and substantive transfer of the above statements made in connection with the proposed condensate drainage device.

[0020] Another aspect of the invention relates to a method for manufacturing a condensate drain device for a vehicle, comprising the steps of: - Fitting a body shell plug with a drain hole into an opening of a body panel; - Introducing expanding foam into a contact area of ​​the body shell plug on the body element; - Applying heat to the expanding foam so that it swells and seals the contact area between the body shell plug and the body panel; - Attaching a first connecting coupling to the drain opening at the interior end of the rough construction plug; - Connecting a drain hose to the first coupling;

[0021] The order of these steps is not necessarily limited to the order described above.

[0022] According to another advantageous embodiment, the method further comprises the following steps: - Attaching a second coupling to an end of the drain hose opposite the end of the drain hose with the first coupling; - Connecting the second coupling to the vehicle's air conditioning system.

[0023] The order of these steps is also not necessarily limited to the order described above.

[0024] According to a further advantageous embodiment, a VDA coupling is used for both the first connecting coupling and the second connecting coupling.

[0025] Advantages and preferred further developments of the proposed method result from an analogous and substantive transfer of the above statements made in connection with the proposed condensate drainage device.

[0026] Further advantages, features and details will become apparent from the following description, in which - possibly with reference to the drawing - at least one embodiment is described in detail.

[0027] They show: Fig. 1: A rough-in plug for a condensate drain device according to an embodiment of the invention. Fig. 2: A construction of a condensate drainage device according to an embodiment of the invention. Fig. 3: A method for manufacturing a condensate drain device according to an embodiment of the invention.

[0028] The representations in the figures are schematic and not to scale.

[0029] Fig. Figure 1 shows a rough-in plug 1 of a condensate drain device for a vehicle, in particular a motor vehicle such as a passenger car. In the Fig. Figure 1 shows the body-in-white plug 1, which is preferably made of plastic, in perspective. The body panel 2, which consists of a substantially flat sheet metal, is indicated by a dashed line. The body-in-white plug 1 is inserted from the inside through the opening of the body panel 2 until the plug 1 rests against the body panel 2 due to its locally increased radius. The outwardly opening drain opening is schematically sketched in the right half of the image, while at the Fig. 1 The left end, the interior end of the rough construction plug 1, is shown, where a nozzle serves for connection with a first connecting coupling 4, see Fig. 2 more details.

[0030] Fig. Figure 2 shows a schematic diagram of a condensate drain device. A rough-in plug 1 is used, as exemplified in... Fig. This body plug 1 is inserted into an opening in a body panel 2 and has a drain opening that leads through the opening of the body panel 2. The body plug 1 is also sealed to the body panel 2 by expanded expanding foam 3. A first connecting coupling 4 is connected to the interior end of the body plug 1 and allows water to flow from a drain hose 5 through the first connecting coupling 4 to the drain opening of the body plug 1 in the vehicle's surroundings. Further along its course, the drain hose 5 is connected to an air conditioning unit 7 of the vehicle, where condensation forms, by means of a second connecting coupling 6. Therefore, as it flows from the air conditioning unit 7, the condensate flows through a nozzle of the air conditioning unit 7, through the second connecting coupling 6, to the drain hose 5, which, for simplification, is shown in the Fig. 2 is shown in abbreviated form, with the drain hose 5 continuing into a first connecting coupling 4, whereby the condensate flows to the rough construction plug 1 and can pass through its drain opening to the other side of the body element 2 into the environment in order to be discharged.

[0031] Fig. Figure 3 shows a method for manufacturing a condensate drain device for a vehicle, comprising the steps: - Mounting S1 of a body shell plug 1 with a drain opening into an opening of a body panel 2; - Introducing S2 of expanding foam 3 into a contact area of ​​the body shell plug 1 on the body element 2; - Applying heat S3 to the expanding foam 3 so that it expands and seals the contact area between the shell plug 1 and the body element 2; - Attaching S4 of a first connecting coupling 4 to the inside end of the rough construction plug 1 at the drain opening; - Connect S5 of a drain hose 5 to the first connecting coupling 4; - Attaching S6 of a second connecting coupling 6 to a side of the drain hose 5 that is opposite the side of the drain hose 5 with the first connecting coupling 4; - Connect S7 of the second coupling 6 to an air conditioning system 7 of the vehicle.

[0032] This results in an overall condensate drain device upon completion of the process, as described in... Fig. 2 sketched, which has a rough construction plug 1, as it is in Fig. 1 is outlined.

[0033] Although the invention has been further illustrated and explained in detail by means of preferred embodiments, the invention is not limited by the disclosed examples, and other variations can be derived from them by a person skilled in the art without departing from the scope of protection of the invention. It is therefore clear that a multitude of possible variations exist. It is also clear that the embodiments mentioned as examples are truly only examples and are not to be understood in any way as limiting, for example, the scope of protection, the possible applications, or the configuration of the invention.Rather, the preceding description and the description of the figures enable the person skilled in the art to implement the exemplary embodiments in concrete terms, whereby the person skilled in the art, with knowledge of the disclosed inventive concept, can make various changes, for example with regard to the function or the arrangement of individual elements mentioned in an exemplary embodiment, without leaving the scope of protection defined by the claims and their legal equivalents, such as further explanations in the description. Reference symbol list 1 rough construction plug 2 Bodywork element 3. Expanding foam 4 first connecting coupling 5 drain hose 6 second connecting coupling 7 Air conditioning QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] EP 1 645 447 B1

[0002] EP 2 093 084 B1

[0003]

Claims

[1] Condensate drain device for a vehicle, comprising a body plug (1) which is inserted into an opening of a body element (2) and which has a drain opening which extends through the opening of the body element (2), wherein the body plug (1) is sealed to the body element (2) by means of swollen expanding foam (3), and wherein a first connecting coupling (4) at the interior end of the body plug (1) connects to the drain opening, wherein the first connecting coupling (4) connects the body plug (1) to a drain hose (5). [2] Condensate drain device according to claim 1, wherein the first connecting coupling (4) is a VDA coupling. [3] Condensate drain device according to one of the preceding claims, wherein a second connecting coupling (6) is arranged at an end of the drain hose (5) opposite the end of the drain hose (5) with the first connecting coupling (4), which serves to attach to an air conditioning system (7) of the vehicle. [4] Condensate drain device according to claim 3, wherein the second connecting coupling (6) is a VDA coupling. [5] Vehicle with a condensate drain device according to one of the preceding claims, wherein the drain opening forms a fluid line from the first connecting coupling (4) at the interior end of the body plug (1) to an exterior end of the body plug (1). [6] Method for manufacturing a condensate drain device for a vehicle, comprising the steps: - Mounting (S1) a body shell plug (1) with a drain opening into an opening of a body panel element (2); - Introducing (S2) expanding foam (3) into a contact area of ​​the body shell plug (1) on the body element (2); - Applying (S3) heat to the expanding foam (3) so that it expands and seals the contact area between the body shell plug (1) and the body element (2); - Attaching (S4) a first connecting coupling (4) to the inside end of the rough construction plug (1) to the drain opening; - Connecting (S5) a drain hose (5) to the first connecting coupling (4); [7] The method of claim 6, further comprising the steps of: - Attaching (S6) a second coupling (6) to an end of the drain hose (5) opposite the end of the drain hose (5) with the first coupling (4); - Connecting (S7) the second coupling (6) to an air conditioning system (7) of the vehicle. [8] Method according to claims 6 to 7, wherein a VDA coupling is used for the first connecting coupling (4) and the second connecting coupling (6).

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