Sliding Intermediate Door for HVAC Fresh Air Leakage
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Solution Overview
Problem
Conventional HVAC systems face issues with fresh air entering the vehicle cabin through the re-circulation air interface in partial re-circulation mode, leading to discomfort and increased energy consumption, and existing solutions like intermediate butterfly flaps are inefficient and difficult to package in limited spaces.
Innovation Solution
A sliding intermediate door is introduced between the fresh air and re-circulation air interfaces, which can be deployed to block fluid communication and prevent fresh air from entering the cabin, while requiring minimal operating space and not interfering with other elements inside the HVAC housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If an intermediate butterfly flap is provided to prevent fresh air from entering the vehicle cabin through the re-circulation interface, then fresh air leakage is reduced, but the device requires more operating space and is difficult to package in limited space inside the HVAC housing
Solution Approach 1:
The intermediate door is designed as a movable component that can dynamically adjust its position between a retracted state (allowing air flow) and a deployed state (blocking air flow). This dynamic configuration allows the door to perform its sealing function only when needed, minimizing its impact on the available space within the HVAC housing while effectively preventing fresh air leakage through the re-circulation interface.
Solution Approach 2:
The intermediate door is positioned and configured to nest within the existing HVAC housing structure when in the retracted state. The door utilizes the available space efficiently by aligning with the housing contours and not protruding into the operational space of other components, thereby packaging the additional sealing mechanism within the limited space constraints of the HVAC system.
2Loss of energy
If an intermediate blocking arrangement is provided to prevent fresh air from entering the vehicle cabin through the re-circulation air interface, then fresh air leakage is prevented, but the device complexity increases
Solution Approach 1:
The intermediate door is designed as a segmented or divided structure that can be implemented as a simple panel rather than a complex mechanism. The door is positioned at a specific location within the housing where it can effectively block the air path without requiring complex actuation mechanisms, thereby adding minimal complexity to the overall device while achieving the energy conservation goal.
Solution Approach 2:
The intermediate door serves as a simple intermediary element between the fresh air inlet and the re-circulation air interface. Rather than redesigning the entire HVAC control system, the door acts as a straightforward mechanical barrier that can be integrated into the existing air flow paths, minimizing the increase in device complexity while effectively preventing fresh air leakage.
3Loss of energy
If the HVAC system operates in partial re-circulation mode with both fresh air inlet and re-circulation air inlet open, then energy consumption is reduced and frosting is avoided, but fresh air enters the cabin through the re-circulation interface causing discomfort
Solution Approach 1:
The intermediate door extracts or removes the harmful effect of fresh air leakage by physically blocking the unintended air path through the re-circulation interface. By isolating the fresh air inlet and re-circulation air inlet pathways, the door ensures that fresh air enters the cabin only through the intended fresh air interface, thereby eliminating occupant discomfort while maintaining the energy-efficient partial re-circulation mode operation.
Data Source
AI summary
A HVAC system (100) includes a housing (10) with at least one first inlet (20) and at least one second inlet (30) formed thereon, at least one first door (20a), at least one second door (30a) and an intermediate door (40). The first inlet (20) and the second inlet (30) is for ingress of a first fluid stream and a second fluid stream inside the housing (10). The first door (20a) and the second door (30a) moves with respect to the first inlet (20) and the second inlet (30) respectively to define an open configuration, a closed configuration and a partially open configuration thereof. The intermediate door (40) is disposed between the first inlet (20) and the second inlet (30) and moves between a deployed and an un-deployed configuration to respectively disrupt and allow fluid flow there across. The intermediate door (40) is a sliding door.