Integrated HVAC Box Layout for Flexible Vehicle Thermal Packaging
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Solution Overview
Problem
The limited space in modern vehicles due to the integration of autonomous driving components and head-up displays necessitates a reconfiguration of the HVAC box to accommodate thermal components in a more flexible and compact manner.
Innovation Solution
An HVAC box with integrated coolant pipes, mounting flanges for a coolant pump and valve, and a flexible design that allows relocation away from the bulkhead, integrating with the vehicle's thermal management system, and incorporating heat exchangers and a refrigerant module for efficient air conditioning and coolant management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the HVAC box is arranged close to the bulkhead to facilitate air conditioning, then the air outlets can efficiently deliver heated or cooled air to the cabin, but the space near the bulkhead is occupied preventing arrangement of other components such as autonomous driving components and head-up displays
Solution Approach 1:
The patent merges the HVAC box functions with thermal management system functions by integrating coolant circulation components (coolant pump, coolant valve, heat exchangers) directly into the HVAC box structure. This allows the HVAC box to serve dual purposes: traditional cabin air conditioning and vehicle thermal management, enabling relocation away from the bulkhead while maintaining air conditioning efficiency through alternative airflow paths via ceiling and floor air outlets.
Solution Approach 2:
The HVAC box is designed as a multi-functional unit that simultaneously performs cabin climate control and vehicle thermal management. By incorporating mounting flanges for coolant pumps, coolant valves, and heat exchangers, the box becomes a universal platform that can be positioned based on thermal management requirements rather than traditional HVAC routing constraints, thus freeing up bulkhead space for autonomous driving components and head-up displays.
2Adaptability or versatility
If thermal components are distributed separately throughout the vehicle, then each component can be optimally positioned for its specific function, but the overall system complexity and space requirements increase
Solution Approach 1:
The patent combines multiple thermal management components (coolant pump, coolant valve, heat exchangers) and HVAC components into a single integrated box structure. This consolidation reduces the number of separate mounting locations needed throughout the vehicle, simplifies system integration, and allows the entire thermal management system to be positioned as one unit, thereby reducing overall system complexity while maintaining positioning flexibility.
3Adaptability or versatility
If the HVAC box is relocated away from the bulkhead to free up space, then more space becomes available for autonomous driving components and head-up displays, but the traditional air outlet arrangement near the dashboard becomes less efficient
Solution Approach 1:
The patent transitions from traditional horizontal air outlet arrangement near the dashboard to a three-dimensional air distribution system utilizing ceiling and floor air outlets. This dimensional change allows the HVAC box to be relocated away from the bulkhead while maintaining efficient air delivery to the cabin through vertical airflow paths, thus freeing up bulkhead space without compromising air distribution efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables compact and flexible arrangement of thermal components, optimizing space utilization and integrating with the vehicle's thermal management system, allowing for improved climate control and efficient coolant distribution.
Implementation Method 1
The first heat exchanger is adapted to transfer heat between the coolant and air
Implementation Method 2
The second heat exchanger is adapted to transfer heat between the refrigerant and/or coolant and air
Implementation Method 3
a chiller is attached to the HVAC Box for exchanging heat between the refrigerant and the coolant
Data Source
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AI summary
The invention relates to a HVAC Box (10) for cooling components of a vehicle with a coolant, the HVAC Box (10) comprising: a box (12) with integrated coolant pipes (14a - 14d), a first mounting flange (16) for a coolant pump (18), a second mounting flange (20) for a coolant valve (22) whereby the first and second mounting flanges (16, 20) are connected with at least one coolant pipe (14a - 14d).