Integrated HVAC Seal and Drain Structure for Automotive Climate Control
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Solution Overview
Problem
Conventional dual HVAC systems for vehicles require separate housings, evaporators, and heating cores for front and rear units, leading to increased assembly and manufacturing costs, longer refrigerant and coolant lines, and reduced storage space due to the rear unit's location in the center console.
Innovation Solution
An integrated HVAC system with a shared housing, evaporator, and heating core, featuring separate airflow paths and drainage systems to prevent airflow leakage and condensation buildup, allowing for efficient heating and cooling of both front and rear compartments without compromising efficiency or space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate housings, evaporators, and heating cores are used for front and rear HVAC units, then each unit can operate independently, but assembly and manufacturing costs increase
Solution Approach 1:
The patent combines the front and rear HVAC units into a single integrated housing with shared evaporator and heating core. This merging approach reduces the total number of components from six separate parts (two housings, two evaporators, two heating cores) to three integrated components, directly addressing the manufacturing cost issue while maintaining independent airflow paths for reliable operation of both front and rear climate zones
2Adaptability or versatility
If the rear HVAC unit is located in the center console, then climate control is provided to the rear, but the refrigerant and coolant lines become longer
Solution Approach 1:
By integrating the rear HVAC unit into the same housing as the front unit, the patent positions both evaporators and heating cores in close proximity to each other. This eliminates the need for long refrigerant and coolant lines that would be required if separate units were distributed throughout the vehicle, reducing material costs and potential leak points while maintaining the ability to provide independent climate control to the rear
3Adaptability or versatility
If the rear HVAC unit is placed in the center console, then rear climate control is achieved, but storage space in the center console is reduced
Solution Approach 1:
The patent integrates the rear HVAC unit into the dashboard housing structure rather than placing it in the center console volume. This spatial repositioning moves the rear climate control components to a different location (the dashboard area) while maintaining rear airflow capability, thereby preserving center console storage space for passenger use
4Ease of manufacture
If a single evaporator is used for both front and rear airflow paths, then manufacturing costs are reduced, but airflow leakage between paths may occur
Solution Approach 1:
The patent divides the single evaporator into distinct first and second portions, with each portion dedicated to serving a specific airflow path (front or rear). This segmentation approach maintains the manufacturing benefits of a single integrated component while ensuring proper airflow separation through physical division and sealing between the portions, preventing cross-contamination of climate zones
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
The integrated system reduces material and assembly costs, increases storage capacity, and maintains high heating and cooling efficiency while minimizing the risk of fluid leaks and condensation issues, providing improved comfort and convenience.
Implementation Method 1
A seal is situated between the first portion and the second portion to prevent airflow from crossing from the first portion to the second portion and from the second portion to the first portion
Implementation Method 2
Water condensation generated by the second portion of the evaporator drains into both the first-rear drain opening and the second-rear drain opening
Implementation Method 3
a water trap filter to direct all the water condensation generated by the second portion of the evaporator to the first-rear drain opening
Implementation Method 4
The upper drain housing and the lower drain housing form a rear-exit drain whereby the upper drain housing directs the water condensation exiting through the first-rear drain opening to the rear-exit drain and the lower drain housing directs the water condensation exiting through the second-rear drain opening to the rear-exit drain
Data Source
AI summary
A dual-integrated HVAC system for an automotive vehicle is provided that includes a housing, a front HVAC unit with a front blower, and rear HVAC unit with a rear blower whereby both the front and rear HVAC units are housed in the housing. The front blower generates an airflow through a front airflow path and the rear blower generates an airflow through a rear airflow path. A separating wall separates the front airflow path from the rear airflow path. The HVAC system further includes an evaporator with a first portion in the front airflow path, a second portion in the rear airflow path, and a seal situated between the first portion and the second portion.