Vehicle Structural Air Duct Integrating HVAC and Roof Support
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Solution Overview
Problem
Conventional HVAC systems in vehicles require multiple separate components, including structural cross members and air ducts, which increase complexity, reduce headroom, and increase costs, while also not efficiently utilizing space above the second and third rows of seats.
Innovation Solution
Integration of a structural air duct into the vehicle's roof structure, where bows and interconnecting members provide both structural support and air distribution, replacing traditional cross members and allowing for a multipurpose component that enhances headroom and reduces parts, using a design that includes open channels and outlet ports for air supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional HVAC systems use separate structural cross members and air ducts, then structural support and air distribution functions are provided, but device complexity increases, headroom decreases, and manufacturing costs increase
Solution Approach 1:
The patent combines the structural cross member and air duct into a single integrated component. The air duct is formed as part of the cross member structure, with channels defined within the cross member itself to distribute air to passenger cabins. This eliminates the need for separate air duct components while maintaining both structural support and air distribution functions.
Solution Approach 2:
The cross member is designed to perform multiple functions simultaneously: it provides structural support for the vehicle body and serves as an air distribution duct for the HVAC system. The integrated design allows the same component to fulfill both mechanical and thermal management roles, reducing overall system complexity.
2Length of stationary object
If separate air ducts are located under cross members, then air distribution is achieved, but headroom is reduced and space utilization is inefficient
Solution Approach 1:
The air duct function is merged into the cross member structure itself. The channels for air distribution are defined within the cross member, eliminating the need for separate duct components located underneath. This integration maximizes the use of available space and maintains headroom while achieving efficient air distribution.
3Ease of manufacture
If multiple separate components are used for HVAC system, then functional requirements are met, but manufacturing efficiency decreases and costs increase
Solution Approach 1:
The cross member and air duct are manufactured as a single integrated component. The design allows the air duct channels to be formed as part of the cross member structure, reducing the number of parts that need to be manufactured, assembled, and sealed. This integration improves manufacturing efficiency and reduces assembly complexity.
Data Source
AI summary
A vehicle body structure includes spaced roof rails and a structural air duct. The air duct has at least two bows connecting between the roof rails and defining first and second channels. An interconnecting member is connected between the bows and defines a third channel connecting the first and second channels in fluid communication with each other. At least one of the bows defines an outlet port configured to supply air to a cabin.