Vehicle Air-Conditioning Unit Drain Hole Cooling Structure

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Solution Overview

Problem

Conventional vehicle air conditioners with a suction-type layout blow uncooled outside air into the vehicle interior when the blower starts, leading to reduced cooling capacity and discomfort due to high outside temperatures or bad air quality, as the drain hole is positioned downstream of the evaporator, allowing unconditioned air to enter directly.

Innovation Solution

The air-conditioning unit includes a drain-hole formation portion to discharge condensed water and a cooling structure that cools suction air drawn from the drain hole, ensuring it is cooled before being blown into the vehicle interior, improving comfort by enhancing cooling capacity and air quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the drain hole is formed on the air-flow downstream side of the evaporator to discharge condensed water, then condensed water can be discharged effectively, but outside air is drawn into the air-conditioning case without being cooled, reducing cooling capacity

Engineering Contradiction:
Improvecondensed water dischargeVSAvoidcooling capacity
Core Design Contradiction:
ReliabilityVSTemperature

Solution Approach 1:

A drain hole cover is introduced as an intermediary component between the drain hole and the outside air. The cover includes a drain hole passage that allows condensed water to pass through while preventing outside air from being directly drawn into the air-conditioning case. This mediator structure enables the drain hole to fulfill its water discharge function without compromising the cooling capacity by blocking the path of uncooled outside air.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Ease of manufacture

If the drain hole is formed on the air-flow downstream side of the evaporator, then condensed water discharge is simplified, but air in bad state (smell, smoke) is drawn into the air-conditioning case and blown into the vehicle interior

Engineering Contradiction:
Improvedrain hole structureVSAvoidair quality
Core Design Contradiction:
Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The drain hole cover acts as an intermediary barrier that separates the drain hole function from the air intake function. By designing the cover with a specific passage structure, it allows condensed water to be discharged while blocking the entry of air containing harmful factors such as smell and smoke into the air-conditioning case, thus improving air quality without complicating the drain hole structure.

Inventive Principle:
Principle #24Intermediary (Mediator)

3Device complexity

If the blower is positioned on the air-flow downstream side of the evaporator in a suction-type layout, then the structure is compact, but uncooled outside air is drawn in when the blower starts, making occupants feel uncomfortable

Engineering Contradiction:
Improveblower layoutVSAvoidoccupant comfort
Core Design Contradiction:
Device complexityVSEase of operation

Solution Approach 1:

The drain hole cover serves as an intermediary structure that modifies the air flow path without changing the blower's suction-type layout. It prevents outside air from being drawn into the air-conditioning case through the drain hole, ensuring that only cooled air from the evaporator is blown into the vehicle interior, thereby maintaining occupant comfort while preserving the compact blower positioning.

Inventive Principle:
Principle #24Intermediary (Mediator)

4Reliability

If outside air is drawn into the air-conditioning case through the drain hole during operation, then the drain hole remains functional, but the cooling performance is reduced due to introduction of hot outside air

Engineering Contradiction:
Improvedrain hole functionVSAvoidcooling performance
Core Design Contradiction:
ReliabilityVSProductivity

Solution Approach 1:

The drain hole cover is designed as an intermediary structure that maintains the drain hole's functionality for condensed water discharge while simultaneously preventing outside air from entering the air-conditioning case. The cover's passage allows water to pass through under gravity while blocking the air flow path, ensuring that the drain hole remains functional without compromising cooling performance.

Inventive Principle:
Principle #24Intermediary (Mediator)

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 cooling of suction air before entry into the vehicle interior enhances occupant comfort by increasing the cooling capacity and reducing the introduction of bad air quality, such as smells or smoke, into the vehicle.

Implementation Method 1

a cooler disposed in the air-conditioning case and adapted to cool air flowing through the air-conditioning case

Methodology Applied
Scientific EffectHeat exchange: Heat Exchanger

Implementation Method 2

a blower disposed on an air-flow downstream side of the cooler and adapted to blow the air into a vehicle interior

Methodology Applied
Scientific EffectPressure-driven flow: Pressure Gradient

Implementation Method 3

a cooling structure that cools suction air drawn from the drain hole into the air-conditioning case

Methodology Applied
Scientific EffectHeat exchange: Heat Exchanger

Data Source

PatentUS10434843B2Air-conditioning unit for vehicle
Publication Date: 2019.10.08 DENSO CORP
  • US10434843B2 patent drawing
  • US10434843B2 patent drawing
  • US10434843B2 patent drawing

AI summary

An air-conditioning unit for a vehicle includes an air-conditioning case; a cooler disposed in the air-conditioning case and adapted to cool air flowing through the air-conditioning case; and a blower disposed on an air-flow downstream side of the cooler and adapted to blow the air into a vehicle interior. The air-conditioning case includes a drain-hole formation portion that forms a drain hole to discharge condensed water generated in the cooler toward an outside of the air-conditioning case. The air-conditioning case is provided with a cooling structure that cools suction air drawn from the drain hole into the air-conditioning case.