Un-partitioned HVAC Module for Multi-Zone Control
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Solution Overview
Problem
Traditional HVAC systems for vehicles require multiple modules to achieve multi-zone climate control, leading to increased space, energy consumption, cost, and complexity, with each module designed for specific zone configurations, making them inefficient and costly to produce.
Innovation Solution
A high-performance HVAC module with a single housing assembly that trifurcates inlet air into separate streams for front and rear zones, using brushless motor architecture and refined scroll design to provide 14.72 CMM airflow, and a microprocessor-based control system for independent zonal control, allowing autonomous temperature and airflow management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate HVAC modules are used to achieve multi-zone climate control, then each zone can be independently controlled, but the packaging space, device complexity, and manufacturing cost increase significantly
Solution Approach 1:
The patent combines multiple HVAC module functions into a single integrated unit. The housing assembly contains both the evaporator and heater core, with a blower that can simultaneously supply conditioned air to multiple zones. The mode door assembly with multiple mode doors allows a single module to perform what previously required multiple separate modules, thereby reducing packaging space and device complexity while maintaining multi-zone climate control capability.
Solution Approach 2:
The single HVAC module is designed to perform multiple functions: it can condition air for front zones and rear zones simultaneously, provide different airflow modes (defrost, vent, floor, etc.), and serve multiple temperature zones. The mode door assembly can be configured in various positions to direct air to different zones, making the single module universal enough to replace multiple specialized modules.
2Adaptability or versatility
If multiple separate HVAC modules are used for multi-zone control, then zonal independence is achieved, but energy consumption increases
Solution Approach 1:
By merging the compression, heating, and cooling functions into a single module with a shared blower, the system reduces the total energy required to operate multiple zones. The single blower serves all zones, eliminating the need for multiple blowers, and the shared evaporator and heater core reduce the energy needed for conditioning air compared to having separate modules for each zone.
Solution Approach 2:
The system maintains continuous airflow to multiple zones simultaneously through the single blower, allowing all zones to receive conditioned air without interruption. The mode door assembly enables continuous adjustment of airflow distribution to different zones while maintaining overall system efficiency, ensuring that useful action (air conditioning) continues across all zones without the energy penalties of multiple independent systems.
3Manufacturing precision
If HVAC modules are designed for specific zone configurations, then manufacturing precision is optimized, but adaptability to different vehicle models decreases
Solution Approach 1:
The mode door assembly is designed with multiple mode doors that can be positioned in different configurations to serve different zone requirements. This universal design allows the same basic module to be adapted to various vehicle models and zone configurations without requiring entirely different module designs, thereby maintaining manufacturing precision while achieving broad adaptability.
Solution Approach 2:
The mode door assembly incorporates movable mode doors that can be dynamically positioned to change airflow distribution patterns. This dynamic capability allows a single module design to adapt to different vehicle configurations and zone requirements, providing versatility across vehicle models while maintaining the manufacturing benefits of a standardized base design.
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 solution enables efficient, independent control of temperature and airflow in multiple zones without affecting other zones, reducing packaging space, energy consumption, and production costs while maintaining comfort and performance.
Implementation Method 1
an air conditioning evaporator
Implementation Method 2
a heater core
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
An automotive HVAC system (10) includes upper and lower mode cases (12, 14) configured to discharge separate streams (21, 23, 31) of temperature-conditioned air into front and rear passenger zones. The system separates the inlet air into separate mixing chambers, and a third stream through a heater core. Blend doors (48,50) control hot and cold air streams entering their respective mixing chambers (42, 45). Operation is controlled by reading requested temperature, blower rate and mode for system zone outlet, converting requests to a flowrate, calculating total flowrate as a summation of all requests, employing a math model to calculate total zonal flowrate as a summation of all zonal flowrates, calculating a blower control error as a function of the difference between total blower request and total zonal flowrate, modifying the operating state using the calculated control error, positioning and resetting the mode valves (39,41,43) into defrost, heater and vent openings, and resetting the mode valves (39, 52).