air vent

Abstract

The air vent for an automotive HVAC includes a control support vane and a controlled vane. The control support vane and the controlled vane are arranged in different orientations in their respective arrays. The control support vane supports a control member connected to a controlled vane arranged behind the control support vane. At least a portion of the control member is at least partially disposed within the control support vane.

Description

[Technical Field]

[0001] The present invention particularly, but not exclusively, relates to the control of air vents in vehicle heating, ventilation and air conditioning (HVAC) systems, and particularly to the control of vanes in air vents for automotive applications. [Background technology]

[0002] Vanes in vehicle air vents are used to direct airflow from HVAC systems around the vehicle to improve passenger comfort. A conventional air vent configuration, illustrated in Figures 17-19, has vanes in two angular positions, with a front vane 101 adjacent to the passenger compartment arranged in a first horizontal angular position and a rear vane 106 positioned behind the front vane in a second vertical angular position. In addition to the vanes that control air direction, air vents often have upstream independently controlled flaps (not shown) to regulate the amount of air flowing to the vanes.

[0003] The horizontal vanes 101 pivot up and down to adjust the vertical air direction, while the vertical vanes 106 pivot left and right to adjust the lateral air output. The vanes shown are typically arranged in arrays, with the horizontal vanes 101 connected to other horizontal vanes (not shown) that move in unison with them, and the vertical vanes 106 connected to other vertical vanes (shown in FIG. 19) that move in unison with them.

[0004] Control of the rear vane 106 is achieved by a control member in the form of a slider 102 mounted around the front vane 101 such that the control member 102 is supported by the front vane 101. A fork 104 is connected to the rear of the slider by a hinge 103, and the two prongs of the fork 104 abut a bar 105 on the front of the rear vane 106 so that the fork 104 can pivot freely vertically. The rear vane 106 has a hole 107 behind the bar 105, allowing the rear vane 106 to pivot unrestricted by a number of protrusions 104 that can protrude into the hole as needed. The arrangement of the slider 102 and fork 104, incorporating the hole 107, seen in this example of a known air vent introduces turbulence, and therefore noise, and also reduces the effectiveness of directional control of the airflow. Furthermore, as vehicles become increasingly quieter, low level sound sources also need to be controlled, and known vane controls rattle when exposed to disturbances caused by uneven road surfaces, which results in undesirable noise for the vehicle. Summary of the Invention [Problem to be solved by the invention]

[0005] The present invention is directed to addressing one or more deficiencies identified in the prior art and / or providing other improvements. [Means for solving the problem]

[0006] According to a first aspect of the present invention there is provided an air vent comprising at least one control support vane supporting a control member, at least a part of the control member being located at least in part within the control support vane.

[0007] In this manner, the present invention provides a configuration in which the airflow over the control support vanes is less likely to be obstructed by the control members, thereby improving airflow directionality, reducing turbulence, and reducing the likelihood of the airflow producing undesirable noises such as whistling.

[0008] At least a portion of the control member may be disposed entirely within the control support vane.

[0009] The control support vane may be substantially planar. The control support vane may include a leading edge and / or a trailing edge. The control support vane may include a first (e.g., upper) air deflection surface and a second (e.g., lower) air deflection surface, where the second air deflection surface may be opposite the first air deflection surface. The first air deflection surface and / or the second air deflection surface may be substantially planar.

[0010] The first air deflection surface and / or the second air deflection surface may be flat. The first air deflection surface and / or the second air deflection surface may be smooth. It is particularly preferred that the upper air deflection surface be flat and / or smooth, as this is the surface most likely to be visible to the user. Deviation from a flat / substantially flat surface is ideally minimized, but deviations can be better accommodated with the lower air deflection surface.

[0011] The cross section of a control support vane can be defined as the shape defined by the leading and trailing edges and the first and second air deflection surfaces, i.e., the cross section across the longitudinal axis of the vane (the cross section extending from one end of the span to the other). The cross section can have a constant thickness (i.e., a substantially constant thickness) throughout the span. The constant thickness of the cross section across the span does not have any bulges or the like that would impede the flow of air over the vane.

[0012] For example, if a bulge is required for the application of a particular material, it is preferably provided on the underside, so that the upper air deflection surface is planar, flat, and smooth.

[0013] The control support vane has a thickness that is the separation distance between the opposing first and second air deflection surfaces, and therefore a mean thickness can be calculated.

[0014] The control member preferably includes a control member knob. The height of the control member knob is the maximum height, defined as the dimension in the direction in which the thickness of the control support vane is measured. For example, if the control support vane is installed horizontally, its average thickness is its average vertical height, and the maximum height of the control member knob is similarly the longest vertical measurement of the control member knob.

[0015] The maximum height of the control member knob is preferably substantially equal to or less than the average thickness of the control support vane. The maximum height of the control knob is preferably substantially equal to or less than the maximum thickness of the cross section of the control support vane.

[0016] A substantially planar shape is beneficial for the vane because it minimizes the cross-sectional area presented to the airflow and maximizes the airflow deflection surface area. A smooth and / or flat upper air deflection surface is similarly beneficial, both of which reduce airflow turbulence.

[0017] A maximum height of the control member knob that is substantially equal to or less than the average thickness of the vane and / or substantially equal to or less than the maximum height of the cross section of the control support vane results in a low profile control member knob that does not unnecessarily obstruct airflow.

[0018] The maximum cross-sectional thickness of the control support vane should not exceed 10mm, 9mm, 8mm, 7mm, 6mm, 5mm, 4mm, 3mm, or 2mm.

[0019] The average thickness of the control support vanes should not exceed 10mm, 9mm, 8mm, 7mm, 6mm, 5mm, 4mm, 3mm, or 2mm.

[0020] Throughout the span of the control support vane, the maximum thickness of the control support vane may deviate from the average thickness of the control support vane by no more than 3 mm, 2 mm, 1 mm, or 0.5 mm. Minimizing deviation from the average thickness ensures a uniform thickness and contributes to the overall configuration of the control support vane, with minimal modifications to accommodate its role in supporting the control member, but without substantial bulging to accommodate the thickness of the control member, particularly the thickness of the control member knob.

[0021] The control member knob may be elongated, in particular the control member knob may be elongated with a major axis coinciding with the longest axis of the control support vane.

[0022] The air flow is unimpeded by the control member before being deflected by the first air deflection surface.

[0023] The knob of the control member may not extend, or may only extend minimally, beyond the plane of the first and second air deflection surfaces, which is also important to avoid disrupting the airflow.

[0024] The control support vane may include a slot, with at least a portion of the control member at least partially located within the slot of the control support vane.

[0025] The slot may be formed as a recess in the first air deflection surface and / or the second air deflection surface of the control support vane. The recess may extend from the leading edge to the trailing edge. In this manner, when at least a portion of the control member is at least partially located within the recess, the control member may extend less from the air deflection surface than a control member that surrounds the control support vane, thereby advantageously maintaining as large an unobstructed area within the air vent as possible to reduce airflow disturbance, reduce noise, and improve efficiency.

[0026] Alternatively, and preferably, the slot may be formed by a hole extending through the support vane from the trailing edge of the control support vane to the leading edge of the control support vane (between the first air deflection surface and the second air deflection surface). At least a portion of the control member may be at least partially located within the slot of the control support vane, or in this case, at least a portion of the control member may be located completely within the slot of the control support vane and surrounded by the control support vane.

[0027] Control members located within the control support vanes can be thinner than those located around the control support vanes because the control support vanes provide structural stability, thereby reducing the material required for production. This is especially true when at least a portion of the control member is located completely within the support vane hole. This also reduces the footprint of the control slider, improving the aesthetic appearance of the air vent. Furthermore, fewer control members in the airflow can result in less turbulence.

[0028] The control member may be movable within a slot. The movement of the control member may be crucial. The movement of the control member may be pivotal. The movement of the control member may be rotational. Preferably, however, the movement of the control member is translational, more preferably slidable, and most preferably slidable laterally along the trailing edge of the control support vane (the trailing edge is typically the edge through which air passes after passing the leading edge, and is therefore located at the front of the air vent facing the user).

[0029] Movement of the control member allows the transfer of control input between the trailing and leading edges of the control support vanes.

[0030] The control member knob can be grasped by a user. The control member can include a connecting member (at least a portion of which can be at least partially (or completely) located within the slot). The control member can include a carrier (which can be located on a leading edge of the control support vane and can be connected to the control member knob by a connecting member).

[0031] By at least partially locating at least a portion of the control member in the control support vane, the control member knob no longer needs to fulfill a structural role as an integral part of the slider and can be designed primarily according to ergonomic and aesthetic requirements.

[0032] The cross section of the slot may be substantially the same height as the cross section of the connecting member. Thus, the connecting member may fit snugly into the slot. The cross section of the slot may be wider than the cross section of the connecting member. For example, the cross section of the slot may be twice as wide as the cross section of the connecting member, three times as wide as the cross section of the connecting member, four times as wide as the cross section of the connecting member, or five times as wide as the cross section of the connecting member. The cross section of the connecting member and / or the cross section of the slot may be rectangular.

[0033] Particularly when the slot is a hole, for example, the configuration of the slot and cross section of the control member allows the control member to move independently of the control support vane along one axis (width in one embodiment), rotate about that axis, and move with the control support vane.

[0034] The control member carrier may be configured, sized, and arranged to prevent air flow through the slots (e.g., holes) in the vane, thereby preventing the slots / holes themselves from causing noise / turbulence.

[0035] The control member carrier may be mounted within a recess in the leading edge of the control support vane. The control member may be mounted on a track. The track may be provided in the recess in the leading edge of the control support vane. The recess in the leading edge of the control support vane may have a lip and a corresponding groove in the carrier to provide a track in which the control member carrier is mounted.

[0036] By locating the control member carrier within a recess in the leading edge of the control support vane, the control member carrier causes little or no disturbance to the airflow, secures the control member to the control support vane, avoids rattle, and guides the movement of the control member.

[0037] The air vent may further include a controlled vane, the orientation of which is controlled by the control member.

[0038] The control member may be connected to the controlled vane by a linkage (hereinafter "linkage" unless otherwise specified) such that movement of the control member adjusts the orientation of the controlled vane. The linkage may be an extension linkage, i.e., a linkage operable to extend or retract in response to movement of the control member and / or movement of the control support vane.

[0039] The orientation of the control support vanes is preferably adjustable, for example by pivoting the control support vanes about an axis which may be a horizontal / transverse axis.

[0040] A second aspect of the present invention provides an air vent including a control support vane and a controlled vane, the control support vane including a control member, and the control member connected to the controlled vane by a link, the link being an extension link, such that movement of the control member adjusts the orientation of the controlled vane, the extension link being operable in use to extend or retract in response to movement of the control member and / or movement of the control support vane.

[0041] In this way, it is possible to maintain a mechanical link between the two vanes without compromising the aerodynamics of the controlled vane, as was the case in the prior art. The airflow over the controlled vane is less disturbed by the link, improving airflow directionality. Additionally, there is less chance of unwanted whistling noises caused by the airflow. Additionally, the extension link engages each vane, reducing rattle.

[0042] The extension link is attached to the trailing edge of the controlled vane. Noji The vanes may be connected to vanes controlled by joints.

[0043] This arrangement of the trailing edges of the rear vanes results in reduced airflow turbulence compared to the known arrangement described above, where the rear vanes have cut-outs.

[0044] The extension link may include two portions. The first portion may be connected to the control support vane via the control member. The second portion may be connected to the controlled vane. The extension link may be telescopically extended, with one portion being telescopically received by the other portion. This telescopic configuration means that the two portions are always in contact, thereby avoiding rattle between the two portions.

[0045] Extension links are 1 or more Noji An extension link can contain two elements, one for each of the two joints. Noji It may contain one element from each of the joints. Noji A joint may have at least two degrees of freedom (i.e., the freedom to move up and down and left and right). Noji The joint may have at least three degrees of freedom (in particular, degrees of freedom to move up and down, left and right, and to rotate). It may be, for example, a ball-and-socket joint. It may be the joint between the second part of the extension link and the controlled vane. It may be a ball-and-socket joint provided by a socket in the second part of the extension link and a ball connected to the controlled vane. Noji The joint may protrude from the trailing edge of the controlled vane toward the control support vane, and the ball may be provided on a rod extending from the controlled vane toward the control support vane.

[0046] Or, for example, the second Noji The joint may have one degree of freedom. It may be, for example, a hinge. It may be a hinge between the first portion of the extension link and the control member. It may be a hinge between the first portion of the extension link and the carrier of the control member.

[0047] First, having at least two degrees of freedom Noji joint and the second one with one degree of freedom Noji The combination of joints allows the extendable link to transfer input from the control member to the controlled vane about the first axis without transferring input from the control member to the controlled vane about the second axis, thereby allowing the control support vane to move independently of the controlled vane and the controlled vane to move independently of the control support vane. Noji Allowing the joints freedom to rotate is beneficial in order to provide a more fluid, i.e. less jerky, movement.

[0048] For example, the control support vanes may extend horizontally in normal use and be pivotable about a horizontal axis to deflect air upwards or downwards, the controlled vanes may extend vertically in normal use and be pivotable about a vertical axis to deflect air leftwards or rightwards, and the second Noji Without significant change in joint position, lateral movement of the control member may affect the axial rotation of the controlled vane independently of the movement of the control support vane, and the first (vertical) axis while rotating the control support vane. Noji The movement of the joint may be independent of the movement of the controlled vane, and the second Noji The joint movement is about its (horizontal) axis, Noji Movement of the joint is about its second (horizontal) axis, but at the same lateral position, not about its first (vertical) axis.

[0049] The controlled vane may be located behind the control support vane (in normal use, behind the control support vane from the user's perspective), i.e. the control support vane may be a front vane and the controlled vane may be a rear vane.

[0050] The control support vanes may be arranged in a first array of co-ordinated vanes, and the controlled vanes may be arranged in a second array of co-ordinated vanes.

[0051] The air vent of the second aspect of the invention (optionally including any feature thereof) may of course be an air vent according to the first aspect of the invention (optionally including any feature thereof). For example, one specifically envisaged aspect of the invention is an air vent comprising at least one control support vane and a controlled vane, the control support vane supporting a control member, wherein at least a part of the control member is located at least partially within the control support vane, and the control member is connected to the controlled vane by an extension link such that movement of the control member adjusts the orientation of the controlled vane.

[0052] Furthermore, any feature of the first aspect may be included in the second aspect in the absence of an essential feature of the first aspect (e.g., the air vent of the second aspect of the present invention may include any of the details of the control member described in relation to the first aspect (e.g., including the knob, connecting member, and carrier) without necessarily including the feature that at least a portion of the control member is at least partially located within the control support vane). Similarly, any feature described in relation to the second aspect may be included in the first aspect in the absence of an essential feature of the second aspect (e.g., that in either the first or second aspect of the present invention, the control support vane and / or the controlled vane may be arranged in an array of multiple vanes that move in unison).

[0053] A third aspect of the present invention provides an air vent comprising at least one control support vane supporting a control member, the control member including a control member knob, at least a portion of the control member being at least partially disposed within the control support vane, the air vent further comprising a regulator wherein the control member knob frictionally engages the control support vane to provide a damping resistance when the control member knob is actuated.

[0054] By providing a damped resistance to the control member knob (eg, a resistance proportional to the force applied to the control member knob), smooth actuation can be achieved when a range of forces is applied.

[0055] The regulator may reduce static friction between the control support vane and the control member knob.

[0056] By reducing the static friction that exists between the control support vane material and the control member knob material, less force is required to initiate actuation of the control member knob, thus achieving a more responsive input for the user. Combined with the damping effect, the end result is a low friction damping resistance, which is a sign of the high quality manufacturing that is characteristic of luxury automobiles.

[0057] The regulator may be constructed from an elastomer or silicone rubber. The regulator may have a Shore hardness between 50 and 100, for example, between 60 and 70. Preferably, it may have a Shore hardness of 65. The regulator may engage with the control member knob with an interference fit. One skilled in the art can adjust the damping resistance by varying the Shore hardness and interference fit of the regulator. The reduction in stiction can likewise be adjusted by varying the Shore hardness and interference fit of the pad.

[0058] Multiple elastomers provide different hardness levels by selecting the appropriate material and adjusting the size of the regulator. The tactile performance (tactile response) of the control knob can be adjusted to improve the user experience.

[0059] The regulator may be a pad, or preferably a ring, which may be provided, for example, to extend around the connecting member of the control knob. The regulator may engage with the front face of the control support vane.

[0060] The air vent of the third aspect of the present invention (optionally including any feature thereof) may of course be an air vent according to the first or second aspect of the present invention (optionally including any feature thereof).

[0061] Furthermore, any feature of the first aspect and / or the second aspect may be included in the third aspect in the absence of an essential feature of the first aspect and / or the second aspect.

[0062] A fourth aspect of the present invention is an air vent comprising a control support vane and a controlled vane, the control support vane including a control member, the control member connected to the controlled vane by an extension link such that translational movement of the control member adjusts the orientation of the controlled vane, wherein at least a portion of the control member is at least partially disposed within the control support vane.

[0063] The combination of an extension link between the control member and the controlled vane and at least a portion of the control member being at least partially disposed within the control support vane is particularly beneficial as it provides for a reduction in airflow turbulence from the desired path.

[0064] The air vent of the fourth aspect of the present invention may of course be an air vent according to the first, second and / or third aspect of the present invention (optionally including any features thereof).

[0065] Furthermore, any feature of any of the first to third aspects of the present invention may be included in the third aspect in the absence of essential features of the first / second / third aspects and will not be repeated here. The air vent (and optionally including any functions or combinations of functions) of any aspect is preferably an air vent for a vehicle, more preferably an air vent for an automobile, and most preferably an air vent for use in a dashboard.

[0066] In a further aspect of the present invention, there is provided a vehicle, preferably a motor vehicle, comprising an air vent according to the first aspect of the invention and / or the second aspect of the invention (and optionally any feature or combination of features), preferably in the dashboard of the vehicle. [Brief explanation of the drawings]

[0067] In order that the invention may be more clearly understood, an embodiment thereof will now be described, by way of example, with reference to the accompanying drawings, in which: [Figure 1] FIG. 1 is a perspective view of the interior of a vehicle with an air vent for an HVAC system. [Figure 2] FIG. 2 is a front view of one major component of the air vent of FIG. 1 from the perspective of a user during normal operation. [Figure 3] FIG. 3 is a front view of the control slider and control support vane of FIGS. 1 and 2. [Figure 4]FIG. 4 is a rear view of the control slider of FIGS. [Figure 5] FIG. 5 is a rear perspective view of the control member carrier and first telescoping linkage portion of the air vent of FIGS. [Figure 6] 6 is a partially exploded rear perspective view of the control slider of FIGS. 3 and 4 attached to a control support vane with the control member carrier of FIG. 5. FIG. [Figure 7] FIG. 3 is a front view of elements of the telescoping linkage portion of the air vent of FIGS. 1 and 2; [Figure 8] FIG. 3 is a front view of the main rear vane of FIG. 2. [Figure 9] FIG. 3 is a rear perspective view of a series of rear vanes connected to a control support vane via a telescoping linkage and the main rear vane in all air vents of FIGS. 1 and 2. [Figure 10] FIG. 3 is a partially exploded rear view of the assembled control support vane, control member, and telescoping linkage of the air vent of FIGS. 1 and 2. [Figure 11] FIG. 3 is a side view of the telescoping linkage of the air vent of FIGS. 1 and 2 with the assembled control support vane, main rear vane, control member, and two vanes in a neutral position. [Figure 12] FIG. 12 is a side view of the air vent assembly of FIG. 11 installed to deflect air maximally downward and to the right when viewed by a user in normal operation. [Figure 13] FIG. 12 is a side perspective view of the air vent assembly of FIG. 11 positioned to deflect air maximally upward and to the right as viewed by a user in normal operation. [Figure 14] FIG. 12 is a side view of the air vent assembly of FIG. 11 installed to deflect air upward and to the left when viewed by a user in normal operation. [Figure 15] FIG. 3 is a cross-sectional view of the air vent of FIGS. 1 and 2. [Figure 16] FIG. 3 is a cross-sectional schematic view of the control support vane of FIG. 2. [Figure 17] 1 is a cross-sectional schematic view of a horizontal vane of a conventional air vent assembly. FIG. [Figure 18] FIG. 1 is a rear perspective view of the front and rear vanes and control member of a conventional air vent assembly. [Figure 19] FIG. 19 is a cross-sectional view of the conventional air vent assembly of FIG. 18. DETAILED DESCRIPTION OF THE INVENTION

[0068] Referring to Figures 1 through 16, an embodiment of an HVAC vent 2 for a vehicle, and in particular its vane control system, is shown. Figure 1 illustrates the interior of a vehicle 1 with two central air vents 2 for the HVAC system. As best shown in Figure 2, each air vent 2 includes a control support vane 3 and additional horizontal vanes 5, forming a first array of vanes positioned at horizontal angles and connected by a front array connecting member 10. A control member or control slider 4 is attached to the control support vane 3. A second array of vanes 6, 7 is positioned at vertical angles aft of the first array (from the user's perspective during normal operation) and includes five equally spaced rear vanes 6, 7. The central vane 6 is the controlled or main rear vane 6. Two additional rear vanes 7 are flanked on either side of the central vane 6. The five vertically positioned vanes are connected by a rear array connecting member 9. The main rear vanes 6 are connected to the control slider 4 by a telescoping linkage 8. Upstream of the vanes are independently controlled flap arrangements (not shown) to regulate the amount of air reaching the vanes 3, 5, 6, 7.

[0069] Referring to Figures 3-6, the direction of airflow over the control support vane 3 is indicated by arrow 11. The control support vane 3 is planar, with a planar upper air deflection surface 12 (first air deflection surface) and a planar lower air deflection surface 13 (second air deflection surface) extending between a rear edge 15 and a trailing edge 16. The upper air deflection surface 12 is flat, which improves the air deflection qualities of the vane and provides an aesthetically pleasing vane when viewed by a vehicle occupant (when the upper air deflection surface 12 of the control support vane 3 is in use). The cross-sectional thickness of the control support vane 3 is constant throughout its span, from one end to the other. That is, the shape defined by the leading edge 15 and trailing edge 16 and the first and second air deflection surfaces 12 and 13, i.e., the cross section across the longitudinal axis of the vane (extending from one end of the span to the other), is of uniform thickness and does not have any bulges that would impede the flow of air over the vane. Specifically, in this embodiment, the cross section is substantially rectangular, with uniform thickness throughout the entire span, both between the leading edge 15 and the trailing edge 16. (As noted above, if a bulge is required for some mechanical reason, it is preferably on the underside.) The vane has a control member slot 14 through its body from a major edge 21 of a recess in the leading (rear) edge 15 of the control support vane 3 to a forward trailing edge 16. A plurality of spurs 17 protrude from the trailing edge 16 of the control support vane 3 and are adjacent to lateral edges of the control member slot 14. The leading and trailing edges 15, 16 are rounded to improve airflow. One end 18 of the control support vane 3 adjacent the trailing edge 16 is provided with a protrusion 19. The centerline axis of the protrusion 19 is parallel to the trailing edge 16 and lies in the plane of the control support vane 3. The protrusion 19 is received in a hole (not shown) in the housing of the air vent 2 to pivotally secure the control support vane 3 in place.

[0070] As shown in FIG. 6 , the control slider recess 20 is provided in the leading edge 15 of the control support vane 3, and extends a quarter of the distance from the leading edge 15 to the trailing edge 16 of the control support vane 3. The control slider recess 20 creates three new edges in the control support vane 3: a main recess edge 21 that is parallel to the leading edge 15 and includes the control member slot 14; and two recess side edges 23 a, 23 b that connect to the main recess edge 21 at 90-degree angles from the leading edge 15. Extending along the center of the main recess edge 21 are two tracks 22. The first track 22 a extends from the first recess side edge 23 a to the control member slot 14, and the second track 22 b extends from the second recess side edge 23 b to the control member slot 14. Both tracks 22 have a substantially square cross section and a width that is one-third the width of the control support vane 3.

[0071] The leading edge 15 also includes a horizontal vane connection point 24, which is formed in a second recess 24 in the control support vane 3. The second recess 24 extends from the leading edge 15 toward the trailing edge 16 to the same depth as the control slider recess 20. Two semicircular protrusions 25 extend from opposite sides of the second recess, and are perpendicular to the plane of the lower air deflection surface 13. As shown in FIG. 2, a connecting rod 26 is provided between the two semicircular protrusions 25 for connection to the front array connecting member 10.

[0072] 3 and 4, the control slider 4 is comprised of a control member knob 30 and a connecting member 31. The control member knob 30 is elongated and, in this embodiment, is diamond-shaped with flat sides. The long axis of the control member knob 30 is aligned with the longest axis of the control support vane 3. The long axis of the control member knob 30 does not extend beyond the plane of the first air deflection surface 12 and the second air deflection surface 13, respectively, to avoid disrupting the airflow.

[0073] The connecting member 31 is elongated and has a substantially rectangular cross section. The connecting member 31 is fixed to the control member knob 30 at the center of the back surface 33 of the control member knob 30 so that the connecting member 31 is perpendicular to the back surface 33 of the control member knob 30. At the end of the connecting member 31, between the two major surfaces of the connecting member 31 distal to the control member knob 30, a slit 32 is formed, thereby forming two fixing protrusions 34. The end of each protrusion 34 is formed with a lip 35 on its outer edge.

[0074] 4, the back surface 33 of the control member knob 30 is recessed to provide a channel 40 along the major axis of the control member knob. The width of the channel 40 is greater than the thickness of the connecting member 31 so that the connecting member 31 is entirely within the channel 40 and does not contact the channel lip 41. In use, the plurality of spars 17 reside within the channel 40.

[0075] A regulator in the form of a silicone pad / ring 45, i.e., a rectangular spacer with a hole 46 through its center and the same cross section as the connecting member 31, is also provided. During use, it sits around the connecting member 31 on the back surface 33 of the control member knob 30 and is held in place by an interference fit. The regulator 45 allows for control of the movement of the control member knob 30, and in particular, allows for the actuation force required to move it to be set to a predetermined value. The silicone material of the regulator 45 reduces static friction between the control member knob 30 and the control support vane 3 and provides damping resistance (i.e., resistance proportional to the force applied to the control support knob 30) when the control member knob 30 is being moved laterally. The silicone material of the regulator 45 also reduces static friction between the control member knob 30 and the control support vane 3. The reduced damping resistance and static friction provide a smoother movement of the control member knob 30 when the force required to actuate the control member knob 30 is constant. Desired tactile performance can be achieved by varying the degree of resistance. The degree of resistance is adjusted by varying the hardness of the silicone pad 45 and the degree of interference fit between the regulator 45 and the control member knob 30. In this embodiment, the regulator has a Shore hardness of 65.

[0076] Referring to FIG. 2 , the additional horizontal vane 5 is substantially flat with a rectangular shape. A hole 29 is drilled in a short side 37 adjacent to a corner with the trailing edge 27 of the additional horizontal vane. The hole 29 is drilled perpendicular to the short side 37 to receive a protrusion (not shown) in the housing of the air vent 2, thereby pivotally securing the additional horizontal vane 5. The leading edge 28 of the additional horizontal vane is provided with a horizontal vane connector slit 36 ​​extending from the leading edge 28 of the additional horizontal vane toward the trailing edge 27 of the additional horizontal vane, adjacent to the corner between the leading edge 28 of the additional horizontal vane and the short edge 37 containing the hole 29, which receives the front array connecting member 10. This ensures that the control support vane 3 and the additional horizontal vane 5 pivot in unison.

[0077] 5 shows a control member carrier 50 and a first telescopic section 51. The control member carrier 50 is elongated with a U-shaped cross section such that a slider channel 54 is formed along the length of the control member carrier 50. A rear surface 52 opposite the slider channel 54 has two hinge protrusions 53 extending perpendicular to the rear surface 52, each hinge protrusion 53 being located one-third of the way down the length of the control member carrier 50 from its respective end.

[0078] Each hinge projection 53 has a hinge hole 56 that extends from an inner surface 57 of each hinge projection 53 (the inner surface facing the other projection) to an outer surface 58 of the same hinge projection 53 (the outer surface facing the inner surface). A groove 59 is formed in the inner surface 57 of each hinge projection 53, and the groove 59 extends from the widest portion of the hinge hole 56 through the back surface 52 to the distal end of the hinge projection 53. The width of the hinge groove 59 is substantially equal to the diameter of the hinge hole 56, and the depth of the hinge groove 59 increases from one-third the thickness of the hinge projection 53 at the hinge hole 56 to two-thirds the thickness of the hinge projection 53 at the distal end.

[0079] The ridges 55 extend along the centerline of the back surface 52 along the major length of the control member carrier 50 from the ends of the control member carrier 50 to the corresponding hinge projections 53 .

[0080] Two connecting slots 60 are provided between the two hinge protrusions 53, and the two connecting slots extend from the rear surface 52 to opposite sides including the slider channel 54. Each connecting slot 60 is provided on the rear surface 52 side with a retaining tooth 61 that protrudes slightly from the cross section of the connecting slot 60. As shown in Figure 10, the protrusion 34 of the connecting member 31 extends through the slot 60 of the control member carrier 50 and engages with the retaining tooth 61.

[0081] Also shown in FIG. 5 is the first telescoping section 51. The first telescoping section 51 is T-shaped, with a main portion 62 having a tubular configuration with a dodecagonal outer cross-section 63 and an octagonal inner cross-section 64. A cross section 66 forms part of the T-shaped first telescoping section 51. The cross sections 66 are symmetrically positioned vertically on either side of the main section 62, and the ends of the cross sections 66 distal from the main section 62 each include a shaft 68 that shares a common vertical axis with the main section 62. Located behind the shafts 68 is a collar 67 that sets the length of each shaft 68 as the thickness of the hinge projection 53. The two shafts 68 clip into the two hinge holes 56, allowing the main portion 62 of the first telescoping section 51 to be hingedly connected to the control member carrier 50 and pivot up and down relative to the control member carrier.

[0082] 7 shows the second telescoping section 70. The second telescoping section is formed from an elongated rod 71 having an octagonal cross-section, with a first end 72 that is chamfered to facilitate insertion into the main portion 62 of the first telescoping section 51. The second end 73 is provided with a partial spherical socket 74 with two slits 75 on diametrically opposite sides of the socket 74, allowing it to elastically expand to receive a ball 92 and then contract to retain the ball.

[0083] The controlled vane, i.e., primary rear vane 6, is best seen in FIG. 8, where the primary rear vane has a flattened shape. The primary rear vane edge 80 is rounded. The upper short edge 81 of the primary rear vane 6 supports a short, first cylindrical protrusion 82, located close to the corner between the upper short edge 81 and the primary rear vane's aft edge 85, allowing the primary rear vane 6, rotating about its vertical axis, to fit securely into the air vent housing. Arrow 83 indicates the general airflow direction (it is understood that this air may be turbulent, but the general airflow direction is as indicated); the primary rear vane's leading edge 84 is the edge of the primary rear vane 6 that first comes into contact with the airflow in normal use, and the primary rear vane's aft edge 85 is the edge opposite the leading edge 84. A second cylindrical protrusion 87 is located on the lower short edge 86. The two protrusions 82, 87 share a common axis. Attached to the end of the distal second projection 87 of the main rear vane 6 is a tie bar 88 which is perpendicular to the second projection and is flush with the main rear vane 6. At the opposite end and side of the tie bar 88 is a third cylindrical projection 89 which has a chamfered unattached end 90.

[0084] The rod 91 is connected perpendicularly to the main rear vane 6 on its trailing edge 85 adjacent the upper short edge 81. The end of the rod 91 distal to the main rear vane 6 has a sphere 92 attached to it to form the ball 92 of the ball-and-socket joint 77. Between the ball 92 and the lower short edge 86, the trailing edge 85 extends away from the leading edge 84, with this extension 94 having its greatest extent at the lower short edge 86 and tapering to its narrowest extent adjacent the ball 92.

[0085] 1 to 15 of the accompanying drawings, the silicone pad 45 is slid onto the connecting member 31 until it contacts the rear surface 33. The control slider 4 is then inserted into the control member slot 14 so that the control knob 30 is adjacent to the trailing edge 16 of the control support vane 3, as seen in FIG. 6. Also shown in FIG. 6, the first telescopic section 51 is clipped to the control member carrier 50 at the two hinge grooves 59, which guide the two cross-sectional shafts 68 into the two corresponding hinge holes 56. The control member carrier 50 and the first telescopic section 51 together form the first hinge 47 (i.e., a one-degree-of-freedom hinge).

[0086] The first hinge 47 is connected to the control slider 4 by clipping the two locking protrusions 34 of the connecting member 31 into two connecting slots 60 on the control member carrier 50. Two lips 35 on the two locking protrusions 34 engage two retaining teeth 61 on the control member carrier 50 to hold the parts together. As can be seen in FIG. 10, this results in the control member carrier 50 sitting within the recess 20 of the control support vane, with the slider channel 54 spanning the two tracks 22 within the recess. As can be seen in FIG. 15, the control slider 4 is held in the control member slot 14 by the control knob 30 and the control member carrier 50.

[0087] Next, the second telescopic section 70 is first inserted into the first telescopic section 51 with the first end 72 chamfered, the cross section limiting the rotation of the two sections relative to each other, and together the first telescopic section 51 and the second telescopic section 70 form the telescopic link 8 as an extension link.

[0088] 11 and 15, the expansion link 8 is attached to the main rear vane 6 by engaging a ball 9 in a partial spherical socket 74, which together form a ball-and-socket joint 77. The ball 9 and partial spherical socket 74 are sized relative to one another to allow the joint to move up and down, left and right, and rotate, thereby facilitating smooth control movement between the control slider 4 and the main rear vane 6. The planes of both the control support vane 3 and the main rear vane 6 are perpendicular with the control support vane 3 mounted horizontally and the main rear vane 6 mounted vertically.

[0089] Referring to Figure 2, the additional horizontal vane 5 is installed below and parallel to the control support vane 3. The control support vane 3 and the additional horizontal vane 5 are connected by a front array connecting member 10, which is a bar with two recesses that clip the connecting rod 26 of the control support vane 3 and the shaft of the slot 36 of the additional horizontal vane 5.

[0090] As shown in FIG. 11 , with both the control support vane 3 and the primary rear vane 6 in their initial neutral positions, the airflow 11 emerges perpendicular to the leading edge 15, 84 of each vane. During operation, the control slider 4 may move laterally within the control member slot 14, e.g., to the right, along the axis of the trailing edge, with the regulator 45 providing damping resistance to actuation. As the control slider moves to the right, the control member carrier 50 also moves to the right, and because the first hinge 47 is only free to rotate vertically, the telescoping link 8 also traverses to the right. The primary rear vane 6 is held in place by a short, first cylindrical projection 82 connected to the air vent housing (not shown), and therefore cannot move; instead, it pivots about the short, first cylindrical projection 82 to assume an orientation that directs the airflow to the right. The ball and socket joint 77 pivots to maintain engagement between the telescoping link 8 and the main rear vane 6 during operation, while the width of the control member carrier 50 ensures that the hole 14 through the control support vane 3 is blocked even when the control slider 4 is in its rightmost position.

[0091] Similarly, when the control slider 4 is moved to the left, the control member carrier 50 is also moved to the left, the first hinge 47 cannot pivot to accommodate this movement, and the telescoping link 8 moves to the left. The primary rear vane 6 is also restricted from moving to the left, so it pivots about the first cylindrical projection 82 to an orientation that directs air to the left. In this case, even in the extreme left position, the hole 14 through the control support vane 3 is blocked by the control member carrier 50 to avoid a whistling sound.

[0092] Starting with the control slider 4 in its rightmost position, if the control slider 4 is moved vertically, e.g., downward, the control member slot 14 does not provide freedom of movement for the control slider 4 in this direction, and the control support vane 3 is also secured from vertical translation by the protrusion 19. Thus, the control support vane 3 pivots about the protrusion 19, as shown in Figure 12, with the upper air deflection surface 12 directing air downward. As the control support vane 3 pivots from the position of Figure 12 to the position of Figure 13 in response to pushing the control member knob 30 upward, the control member carrier 50 moves relative to the main rear vane 6, and the space between the first hinge 47 and the ball-and-socket joint 77 first decreases, then increases, until the plane of the control support vane 3 is approximately horizontal. The first telescoping section 51 is integrated into the first hinge 47 and the second telescoping section 70 is restricted from disengaging from the ball 93 on the main rear vane 6, so that the two telescoping sections 51, 70 telescopically contract and then extend relative to each other until the control support vane 3 (and other vanes in the same array) are positioned to direct the airflow upwards (the main rear vane 6 and other vanes in the same array direct the air to the right).

[0093] While the control support vane 3 is at its maximum upward orientation, the telescoping link 8 is extended to maintain engagement between the control support vane 3 and the primary rear vane 6. When the control slider 4 is moved laterally from the position of Figure 13 to the position of Figure 14, the control member carrier 50 also moves laterally, as it would if the control support vane 3 were in the neutral position, so the first hinge 47 cannot pivot laterally and, as a result, the telescoping link 8 moves laterally with the control slider 4.

[0094] 16 and 17, the minimum thickness 36 of the control support vane 3 of the embodiment of the present invention and the minimum thickness 136 of the prior art horizontal vane 101 are determined by the requirement to withstand a predetermined load (i.e., the load applied during use, plus an excess to accommodate misuse / abuse). Due to the presence of the control member slot 14 in the control support vane 3 of the embodiment, the minimum thickness 36 of the control support vane 3 is slightly greater than the minimum thickness 136 of the robust prior art horizontal vane 101.

[0095] However, because connecting member 31 is located within control member slot 14, which is itself located within control support vane 3, it does not increase the overall thickness of the vane and control slider assembly of this embodiment of the invention. To ensure smooth movement of connecting member 31 within control member slot 14, clearances 38a and 38b are provided between connecting member 31 and control member slot 14, and clearances 38a and 38b are achieved by having the thickness of connecting member 31 slightly less than the height of control member slot 14. Again, because clearances 38a and 38b are located within control support vane 3, it does not increase the overall thickness of the combined control support vane 3 and connecting member 31.

[0096] This is not the case with the prior art horizontal vane 101, in which the slider 102 is mounted around the horizontal vane 101. Smooth movement of the slider 102 along the horizontal vane 101 is provided by providing two clearances: one clearance 138a above the horizontal vane 101 and one clearance 138b below the horizontal vane 101 (between the horizontal vane 101 and the slider 102, respectively). Because the slider 102 and clearances 138a and 138b are mounted outside the horizontal vane 101, they increase the overall thickness of the combined horizontal vane 101 and slider 102.

[0097] Therefore, the control support vane 3 must have a minimum thickness 36 greater than the minimum thickness 136 of the prior art horizontal vane 101 to accommodate the connecting member 31 therein, but the combined thickness of the control support vane 3 and connecting member 31 remains equal to the thickness 36 of the control support vane 3. The combined thickness of the horizontal vane 101 and slider 102 is equal to the thickness 136 of the horizontal vane 101 plus the clearances 138a and 138b between the horizontal vane 101 and slider 102 and the thicknesses 137a and 137b of the slider 102, which in total is greater than the thickness 36 of the control support vane 13.

[0098] In particular, in the prior art, the slider 102 necessarily has a height greater than the thickness of the horizontal vane 101, and the average thickness of the control support vane 3 (i.e., the average separation distance between the opposing first and second air deflection surfaces) is approximately equal to the maximum height of the control member knob 30 (i.e., the dimension in the direction in which the thickness of the control support vane is measured).

[0099] Therefore, the control member knob should be thin and not unnecessarily obstruct the air flow. In this embodiment, the maximum thickness of the control support vane is about 5 mm and is substantially the same throughout, so the average thickness of the control support vane 3 is also about 5 mm, and the maximum thickness of the control support vane 3 does not deviate from the average thickness of the control support vane 3.

[0100] The above embodiments have been described by way of example only, and many variations are possible without departing from the scope of the invention as defined in the appended claims.

Claims

1. 1. An air vent comprising at least one control support vane and at least one controlled vane, the control support vane supporting a control member, the control member comprises a control member knob, a control member carrier, and a connecting member connecting the control member knob to the control member carrier; the control member controls the orientation of the controlled vane, and the control support vane has a flat upper air deflection surface; at least a portion of the connecting member is located completely within and surrounded by a hole in the control support vane, the hole extending from the leading edge to the trailing edge between opposing first and second air deflection surfaces of the control support vane; The cross section of the hole is wider than the cross section of the connecting member, The air vent, wherein the control member carrier is positioned outboard of the leading edge of the control support vane, and the control member carrier is configured to prevent air flow through the hole.

2. 2. The air vent of claim 1, wherein the air flow is unimpeded by the control member prior to being deflected by the upper air deflection surface, and the upper air deflection surface is smooth.

3. An air vent as described in claim 1 or 2, wherein the cross section of the hole is substantially equal in height to the cross section of the connecting member.

4. 4. The air vent of claim 1, wherein the control member is translatable within the control support vane, and the translational movement of the control member is by sliding laterally along an axis parallel to the trailing edge of the control support vane.

5. An air vent as described in any one of claims 1 to 4, wherein the control member carrier is positioned within a recess in the leading edge of the control support vane.

6. 6. The air vent of any one of claims 1 to 5, wherein the controlled vane is connected to the control member by a linkage such that movement of the control member adjusts the orientation of the controlled vane, the control support vane and the controlled vane are arranged at different angular positions, and the controlled vane is arranged at the leading edge of the control support vane.

7. 7. The air vent of claim 6, wherein the link is an extension link, the extension link extending telescopically, the extension link being formed of two portions, a first portion connected to the control support vane by the control member and a second portion connected to the controlled vane, the extension link being connected to the controlled vane by a first joint located at the trailing edge of the controlled vane.

8. 8. The air vent of claim 7, wherein the first joint is a ball-and-socket joint, and the first joint allows movement in at least three degrees of freedom: up / down, left / right, and rotation.

9. 9. The air vent of claim 1, wherein the control support vane is arranged in an array of vanes that move in unison, and the controlled vane is arranged in an array of vanes that move in unison.

10. 10. The air vent of any preceding claim, wherein the maximum thickness of the control support vane across the span of the control support vane does not deviate from the average thickness by more than 1 mm.

11. An air vent as described in claim 10, wherein the separation distance between the opposing first air deflection surface and the second air deflection surface is 5 mm or less, and the average separation distance of the separation distances is 4 mm or less.

12. A vehicle comprising an air vent according to any one of claims 1 to 11.

13. An air vent as described in claim 1, wherein the maximum thickness of the control support vane across the span of the control support vane does not deviate from the average thickness of the control support vane by more than 1 mm.

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