Air duct for a motor vehicle air conditioning system and method for manufacturing an air duct

Abstract

A climate air duct (10) for directing conditioned air (28) from an air conditioning system to an outlet leading into the interior of a motor vehicle is provided with an inner pipe (12) for providing a flow cross-section for the conditioned air (28), an outer pipe (14) radially surrounding the inner pipe (12) and an intermediate space (16) formed between the inner pipe (12) and the outer pipe (14) for thermal insulation of the inner pipe (12) from the outer pipe (14), wherein the outer pipe (14) is formed for thermal contact with a motor vehicle component (20).By thermally insulating the space (16), unwanted heat exchange of the conditioned air (28) can be avoided and the outer pipe (14) can be shaped in a space-saving manner for direct and thermally contact with the motor vehicle component (20), thus enabling efficient and space-saving air conditioning of a motor vehicle.

Description

[0001] The invention relates to a climate air duct by means of which conditioned air from an air conditioning system can be directed to an outlet leading into the interior of a motor vehicle, as well as to a climate air duct arrangement and a motor vehicle with such a climate air duct. The invention further relates to manufacturing methods for producing such a climate air duct.

[0002] CN 107284178 A shows a climate air duct for an air conditioning system of a motor vehicle in which two lines are inserted into each other and a space with a heat-insulating vacuum is provided between the lines to prevent heat transfer between the air-conditioned air flowing through the climate air duct and the ambient air.

[0003] There is a constant need to implement air conditioning in a motor vehicle as efficiently and space-savingly as possible.

[0004] The purpose of the invention is to demonstrate measures that enable efficient and space-saving air conditioning of a motor vehicle.

[0005] According to the invention, the problem is solved by a climate air duct with the features of claim 1, a climate air duct arrangement with the features of claim 6, a motor vehicle with the features of claim 7, a method with the features of claim 8, a method with the features of claim 9, and a method with the features of claim 10. Preferred embodiments of the invention are specified in the dependent claims and the following description, each of which may individually or in combination represent an aspect of the invention, the scope of protection being determined by the claims.

[0006] One aspect of the invention relates to a climate air duct for directing conditioned air from an air conditioning system to an outlet leading into the interior of a motor vehicle, comprising an inner pipe for providing a flow cross-section for the conditioned air, an outer pipe radially surrounding the inner pipe, in particular for attachment to a motor vehicle component, and a space formed between the inner pipe and the outer pipe for thermal insulation of the inner pipe from the outer pipe, wherein the outer pipe is shaped for thermal contact with the motor vehicle component.

[0007] The thermally insulating gap formed between the inner and outer pipes prevents or significantly reduces heat transfer from the conditioned air inside the inner pipe to the radially outward-facing outer surface of the outer pipe. This also means that heat transfer from the outer surface of the outer pipe to the conditioned air is prevented or significantly reduced. It has been found that the cooling of heated air in the inner pipe, as well as the heating of cooled air in the inner pipe, is reduced to a negligible level due to the thermally insulating effect of the gap. This finding can be used to relax restrictions on the routing of the air conditioning duct within the vehicle.In particular, it was recognized that it is no longer necessary to route the air conditioning duct as far away from other vehicle components as possible in order to avoid thermal degradation of the conditioned air through the duct due to heat exchange with the vehicle components, especially through heat conduction effects. It was recognized that while heat exchange can occur between the outer pipe and a vehicle component when the air conditioning duct is in thermal contact with the component, no significant heat exchange takes place between the outer and inner pipes due to the thermal insulation of the space between them.In fact, under steady-state conditions, the temperature of the inner pipe can correspond to the temperature of the conditioned air flowing through it, while the temperature of the outer pipe, due to thermal contact with the vehicle components, approaches the temperature of those components. Although this can increase the temperature difference between the outer and inner pipes, this difference does not result in significant heat exchange between them due to the thermal insulation of the space between them.

[0008] This, in turn, allows for the deliberate permissibility of thermal contact between the air conditioning duct and the vehicle component, which would otherwise be considered detrimental. This enables the outer pipe, particularly if it has a flat surface and / or a corresponding shape, to make thermal contact with the vehicle component and is designed accordingly. It is not necessary to attach the air conditioning duct to the vehicle component by using a spacer to mount the outer pipe at a distance from the component. Instead, the outer pipe can be mounted directly against the vehicle component and / or directly against it. This eliminates the need for a spacer and a correspondingly more complex and multi-part mounting system.Since the air conditioning duct does not need to be installed at a distance from the vehicle component, and no air gap needs to be maintained between the outer pipe and the vehicle component, the direct thermal contact of the outer pipe with the vehicle component allows for space savings, which can then be used, for example, to enlarge the vehicle's interior. Likewise, thermal insulation between the outer pipe and the vehicle component is unnecessary, as heat exchange between the two has no significant impact on the temperature of the conditioned air inside the inner pipe.The thermal insulation of the space prevents unwanted heat exchange of the conditioned air and allows the outer pipe to be shaped in a space-saving manner for direct and thermally contact with the vehicle component, thus enabling efficient and space-saving air conditioning of a vehicle.

[0009] The air conditioning duct can run from the vehicle's air conditioning system to an outlet into the vehicle's interior. The air conditioning duct can be a single unit or composed of several sections connected in series in the direction of airflow. The outlet into the vehicle's interior can be designed, in particular, by means of an inlet, which can also be used to influence the direction and / or mass flow of the incoming air conditioning. The air conditioning duct can be attached upstream at an inlet on the air conditioning system, where the air conditioned in the system can flow into the inner pipe of the air conditioning duct.At a downstream outlet side of the air conditioning duct, the air conditioning duct can form the outlet and / or be connected to an inlet and / or to a trim part of the motor vehicle that forms the outlet.

[0010] The air conditioning system can heat the intake air using a heater and / or cool it using a cooler, with particular attention paid to influencing the humidity of the conditioned air. The air conditioned in the air conditioning system can be fed into the air conditioning duct to distribute it into the vehicle's interior. Since unwanted heat exchange between the conditioned air and the surrounding environment and / or vehicle components can be avoided, the inlet temperature of the conditioned air in the air conditioning duct can, under steady-state conditions, essentially correspond to the outlet temperature of the conditioned air. This eliminates the need for additional cooling capacity from the air conditioning system to compensate for heat exchange losses, thereby reducing energy consumption and increasing efficiency.

[0011] The interior of the motor vehicle can be formed by a passenger cabin, the volume of which may be limited by body panels of the motor vehicle.

[0012] The inner and outer tubes can be substantially coaxial. Both the inner and outer tubes can have a substantially circular cross-section, although cross-sections other than circular, such as rectangular or square, are also possible. Preferably, the outer contour of the inner tube corresponds substantially to the inner contour of the outer tube, so that the space between them can be substantially annular with a preferably uniform ring thickness in the circumferential and / or axial direction. In particular, the outer contour of the outer tube differs from the inner contour of the outer tube and the outer contour of the inner tube to allow for the largest possible contact area with the vehicle component on its outer surface. Preferably, the outer contour of the outer tube is adapted to the contour of the vehicle component in a contact area.For this purpose, the outer tube may have depressions and / or protrusions that can interact with corresponding protrusions and / or depressions of the motor vehicle component with regard to their shape design.

[0013] The vehicle component can be any fixture of the vehicle that is positioned between the air conditioning system and the outlet near the planned routing of the air conditioning duct within the vehicle. The vehicle component can be, for example, an instrument panel, an instrument integrated into the instrument panel, a steering wheel mounting assembly, or other components.

[0014] In particular, the outer tube has a flat contact surface designed to correspond to the vehicle component, enabling heat transfer through thermal contact with the vehicle component. Preferably, the contact surface is shaped for a positive-locking and / or stationary grip on the vehicle component. The contact surface of the outer tube against the vehicle component establishes not just point or line contact, but a flat contact. This flat contact can facilitate a greater degree of heat exchange between the outer tube and the vehicle component, which, however, does not adversely affect the conditioned air flowing through the inner tube due to the thermal insulation of the space between the tubes.Especially when the mounting surface is not flat, it is possible to provide a form-fitting adaptation of the outer contour of the outer tube to the contour of the vehicle component in the area of ​​thermal contact. This allows for at least a rough centering of the air conditioning duct on the vehicle component, which facilitates the installation of the air conditioning duct in the vehicle during routing. In particular, the adapted contour can be designed to such an extent that a fixed mounting of the air conditioning duct on the vehicle component is achieved, virtually eliminating installation errors.

[0015] Preferably, the inner and outer tubes are connected to each other in a radially defined relative position via a first connecting wall and a second connecting wall, wherein the space between the inner tube, the outer tube, the first connecting wall, and the second connecting wall is enclosed, in particular gas-tightly. The connecting walls allow the relative position of the inner tube to be defined and fixed, thereby also defining and fixing the shape of the space. Simultaneously, the connecting walls can provide a seal at each end face of the space, thus preventing airflow and convective heat exchange within it.It is even possible to create a negative pressure or a technical vacuum in the space between the walls, as the gas-tight seal of the connecting walls can prevent ambient air from entering. This can further improve the thermal insulation.

[0016] Preferably, the space between the layers is evacuated to provide a technical vacuum and / or negative pressure. An opening provided for evacuating the space can be closed and / or sealed after evacuation to prevent ambient air from entering the space. This further improves the thermal insulation.

[0017] In particular, the space between the two pipes is filled with air and / or a porous foam. Due to the low thermal conductivity of air, sufficient thermal insulation can be achieved without creating a vacuum in the space. Even if the outer pipe is damaged or perforated, the thermal insulation effect of the space between the pipes is maintained. This allows the outer pipe to have a thinner wall than the inner pipe, thus saving weight and material.

[0018] Preferably, the inner tube has at least one radially outwardly projecting centering projection and / or the outer tube has at least one radially inwardly projecting centering projection, wherein, in particular, the outer tube and / or the inner tube has a locking recess for the centering projection of the other tube. During assembly of the air conditioning duct, the inner tube can be inserted into the outer tube, with the insertion depth being predefined by the centering projection snapping into the corresponding locking recess. This also ensures a secure, captive locking connection between the inner and outer tubes. The centering projection can define the radial thickness of the gap and, for this purpose, bear against the other tube.

[0019] Another aspect concerns an air conditioning duct arrangement for a motor vehicle, comprising an air conditioning system for climate control of the vehicle's interior, an outlet leading to the interior, an air conditioning duct connected to the air conditioning system and the outlet (which can be designed and further developed as described above), and a motor vehicle component located between the air conditioning system and the outlet, wherein the outer pipe of the air conditioning duct is in thermal contact with the motor vehicle component. Thermal insulation of the space between the components prevents unwanted heat exchange of the conditioned air, and the outer pipe can be designed in a space-saving manner for direct and thermal contact with the motor vehicle component, thus enabling efficient and space-saving air conditioning of the motor vehicle.

[0020] Another aspect concerns a motor vehicle with an air conditioning duct system, which can be designed and further developed as described above. The motor vehicle may have an interior, in particular a passenger cabin, which is to be air-conditioned. By thermally insulating the space between the ducts, unwanted heat exchange of the conditioned air can be prevented, and the outer duct can be shaped in a space-saving manner for direct and thermally contact with the motor vehicle component, thus enabling efficient and space-saving air conditioning of the motor vehicle.

[0021] Another aspect of the invention relates to a method for manufacturing an air conditioning duct, which can be designed and further developed as described above, wherein the inner and outer pipes are simultaneously produced by injection molding and the space between them is formed by means of a lost core, in particular designed as a porous rigid foam. This enables rapid production of the air conditioning duct, making it suitable for mass production. The thermal insulation of the space between the pipes prevents unwanted heat exchange of the conditioned air, and the outer pipe can be designed in a space-saving manner for direct and thermally contact with the vehicle component, thus enabling efficient and space-saving air conditioning of a motor vehicle.

[0022] Another aspect of the invention relates to a method for manufacturing an air conditioning duct, which can be designed and further developed as described above, wherein the inner and outer pipes are simultaneously produced by an additive manufacturing process, in particular 3D printing, along a designated flow direction of the conditioned air through the inner pipe, leaving the space between them open. This enables material-saving manufacturing of complex geometries of the air conditioning duct without the need for a lost core. The thermal insulation of the space prevents unwanted heat exchange of the conditioned air, and the outer pipe can be shaped in a space-saving manner for direct and thermally contact with the vehicle component, thus enabling efficient and space-saving air conditioning of a vehicle.

[0023] A further aspect of the invention relates to a method for manufacturing a climate air duct, which can be designed and further developed as described above, wherein the inner and outer pipes are provided separately, the inner pipe having at least one radially outwardly projecting centering projection and / or the outer pipe having at least one radially inwardly projecting centering projection, wherein, in particular, the outer pipe and / or the inner pipe has a locking recess for the centering projection of the other pipe, the inner pipe is subsequently inserted substantially coaxially into the outer pipe, wherein, in the inserted state, the at least one centering projection defines a radial relative position of the inner pipe to the outer pipe, forming the gap. This enables simple and rapid production of the climate air duct on demand, without the need to store prefabricated, complex semi-finished products.The thermal insulation of the space prevents unwanted heat exchange of the conditioned air and allows the outer pipe to be shaped in a space-saving manner for direct and thermally contact with the vehicle component, thus enabling efficient and space-saving air conditioning of a vehicle.

[0024] The invention is now explained by way of example with reference to the accompanying drawing, using a preferred embodiment as an example. The features shown below can represent an aspect of the invention, either individually or in combination, and the scope of protection is defined by the claims. The drawing shows: Fig. 1: A schematic side sectional view of part of an air conditioning duct.

[0025] The in Fig. A partially illustrated air duct 10 can connect a motor vehicle's air conditioning system to an outlet leading to the vehicle's interior. The air duct 10 has an inner pipe 12 and an outer pipe 14, which is arranged, in particular, coaxially, between which a thermally insulating space 16 is formed. A technical vacuum, air, or porous foam can be provided in the space 16 to provide thermal insulation. The space 16 can be closed off at its end faces by a first connecting wall 18 and a second connecting wall 19 spaced longitudinally from the first connecting wall 18 along the air duct 10, and can be sealed, in particular, gas-tight. The connecting walls 18 and 19 can fasten the inner pipe 12 to the outer pipe 14 in a defined relative position. In the illustrated embodiment, the connecting walls 18 and 19 are...19 formed by end-face covers to which the air conditioning system or the outlet can be flanged, although other design implementations are also conceivable.

[0026] The outer tube 14 can bear against a motor vehicle component 20 over a flat area and with thermal contact, and for this purpose has a correspondingly shaped contact surface 22 in a corresponding contact area. In particular, the contact surface 22 can effect coarse centering, fixed positioning and / or a positive fit with the motor vehicle component 20.

[0027] In the illustrated embodiment, the inner tube 12 has a radially outwardly projecting centering projection 24, which can engage, in particular, in a detent recess 26 of the outer tube 14, whereby kinematic reversal can additionally or alternatively be provided. This enables the inner tube to be separated from the Fig.1. To be inserted securely into the outer pipe 14 from the right side. Air-conditioned air 28 coming from the air conditioning system can flow through the flow cross-section of the inner pipe 12, whereby heat exchange with the outer pipe 14 and also with the vehicle component 20 thermally in contact with the outer pipe 14 is prevented by the thermal insulation of the space 16. 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] CN 107284178 A

[0002]

Claims

[1] Air conditioning duct (10) for directing conditioned air (28) from an air conditioning system to an outlet leading into the interior of a motor vehicle, with an inner tube (12) to provide a flow cross-section for the conditioned air (28), an outer tube (14) radially surrounding the inner tube (12) and a space (16) formed between the inner tube (12) and the outer tube (14) for thermal insulation of the inner tube (12) from the outer tube (14) characterized by , that the outer tube (14) is shaped to form the thermally contacting system on a motor vehicle component (20). [2] Climate air duct (10) according to claim 1, wherein the outer tube (14) has a planar contact surface (22) designed corresponding to the motor vehicle component (20) for producing a heat transfer in the thermal contact with the motor vehicle component (20). [3] Climate air duct (10) according to claim 1 or 2, wherein the inner tube (12) and the outer tube (14) are connected to each other in a radially defined relative position via a first connecting wall (18) and a second connecting wall (19), wherein the space (16) between the inner tube (12), the outer tube (14), the first connecting wall (18) and the second connecting wall (19) is enclosed. [4] Climate air duct (10) according to one of claims 1 to 3, wherein the intermediate space (16) is evacuated to provide a technical vacuum and / or a negative pressure. [5] Climate air duct (10) according to one of claims 1 to 3, wherein the space (16) is filled with air and / or a porous foam. [6] Climate air duct arrangement for a motor vehicle, comprising an air conditioning system for air conditioning an interior of the motor vehicle, an outlet leading to the interior, a climate air duct (10) connected to the air conditioning system and the outlet according to one of claims 1 to 5 and a motor vehicle component (20) provided between the air conditioning system and the outlet, wherein the outer pipe (14) of the climate air duct (10) is in thermal contact with the motor vehicle component (20). [7] Motor vehicle with a climate air duct arrangement according to claim 6. [8] Method for manufacturing a climate air duct (10) according to one of claims 1 to 5, wherein the inner tube (12) and the outer tube (14) are produced simultaneously by plastic injection molding and the space between (16) is formed using a lost core. [9] Method for manufacturing a climate air duct (10) according to any one of claims 1 to 5, wherein the inner tube (12) and the outer tube (14) are simultaneously produced by an additive manufacturing process along a designated flow direction of the conditioned air (28) through the inner tube (12), leaving the space (16) free. [10] Method for manufacturing a climate air duct (10) according to one of claims 1 to 5, wherein the inner tube (12) and the outer tube (14) are provided separately, wherein the inner tube (12) has at least one radially outwardly projecting centering projection (24) and / or the outer tube (14) has at least one radially inwardly projecting centering projection, the inner tube (12) is subsequently inserted substantially coaxially into the outer tube (14), wherein, in the inserted state, the at least one centering projection (24) determines a radial relative position of the inner tube (12) to the outer tube (14) forming the space (16).

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