Abstract:
An air control device suitable for use in a heating and/or air-conditioning system comprises an air control member having a portion capable of selectively blocking the flow of air in an air passageway, a shaft member connected to the selective air blocking portion and having an axis about which the selective air blocking portion rotates, and a portion located on at least one end of the shaft that comprises a mechanism for inter-engaging with an actuating device for rotation of the shaft member; wherein the shaft end has at least first and second different mechanical configurations, wherein each configuration is capable of selectively interacting with a different type of actuation device.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    The present invention relates generally to the field of heating and air-conditioning systems that are suitable for use in motor vehicles, and more particularly to an improved design of an air flow control member and to heating and air-conditioning systems that employ the improved air flow control member. 
         [0002]    Because auto manufacturers produce a wide variety of vehicle models that employ in most cases uniquely designed heating and/or air-conditioning systems for each vehicle model, the control system employed for controlling the individual air control members, e.g., flaps, may use mechanical linkage (kinematic) actuators, or direct actuators, such as stepper motors, or in a single heating or air-conditioning system a combination of both types of control mechanism may be used. As can be imagined, this leads to the need to design a very large number of unique control members, both in the sense that two separate models are needed for each control member configuration, a first one for kinematic actuation and a second one for direct actuation, and in the sense that every air control system employs a number of uniquely configured air control members, i.e., the shape of the flap itself. 
         [0003]    It would be advantageous to provide a way to decrease the large number of unique air control member configurations and designs that are needed to supply all of the various heating and air-conditioning systems that vehicle manufacturers employ in their different models. 
       SUMMARY OF THE INVENTION 
       [0004]    It is one object of the present invention to provide an improved air control member design that enables universal connection to any desired type of actuation device, such as a kinematic actuator or a direct actuator, such as a stepper motor. 
         [0005]    Another object of the present invention is to provide an improved air control arrangement for use in a heating and/or air-conditioning system, preferably in a motor vehicle, in which the improved air control member is embodied. 
         [0006]    It is also an object of the invention to provide an improved heating and/or air-conditioning system, especially for use in a motor vehicle. 
         [0007]    Yet another object of the invention resides in the provision of an improved motor vehicle embodying the air control arrangement according to the invention. 
         [0008]    In accordance with one aspect of the present invention, there is provided an air control device suitable for use in a heating and/or air-conditioning system, comprising an air control member comprising a portion capable of selectively blocking the flow of air in an air passageway, a shaft member connected to the selective air blocking portion and having an axis about which the selective air blocking portion rotates, and a portion located at at least one end of the shaft that comprises a mechanism for inter-engaging with an actuating device for rotation of the shaft member; wherein the mechanism comprises the shaft end having at least first and second different mechanical configurations, wherein each configuration is capable of selectively interacting with a first or a second different type of actuation device. 
         [0009]    In accordance with another aspect of the present invention, there is provided an air control arrangement for use in a heating and/or air-conditioning system, comprising an air handling housing that defines at least one air flow passageway and comprises at least a heater for heating air flowing through the air flow passageway; at least one air flow control member located in the air flow passageway for controlling the flow of air; and an actuation device connected to the at least one air flow control member for selectively actuating the at least one air flow control member, wherein the at least one air flow control member comprises an air flow control member as defined above. 
         [0010]    According to another aspect of the present invention, there is provided a motor vehicle, comprising a heating and/or air-conditioning system that includes an air handling housing that defines at least one air flow passageway and comprises at least a heater for heating air flowing through the air flow passageway; at least one air flow control member located in the air flow passageway for controlling the flow of air; and an actuation device connected to the at least one air flow control member for selectively actuating the at least one air flow control member, wherein the at least one air flow control member comprises an air flow control member as defined above. 
         [0011]    According to still another aspect of the invention, this is provided an air control arrangement for use in a heating and/or air-conditioning system, comprising an air handling housing that defines at least one air flow passageway and comprises at least a heater for heating air flowing through the air flow passageway; a plurality of air flow control members located in the air flow passageway for controlling the flow of air; and an air inlet device connected upstream of the air handling housing for admitting air to the air handling housing, the air inlet device comprising a recirculation air control member that is movable between a recirculation mode position and an outside air position, wherein at least a plurality of said air flow control members located in the device have a common size and shape, so as to be interchangeable with one another. In a preferred arrangement, the plurality of air control members having a common size and shape includes the recirculation air control member. 
         [0012]    Further objects, features and advantages of the present invention will become apparent from the detailed description of preferred embodiments that follows, when considered together with the accompanying figures of drawing. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]    In the drawings: 
           [0014]      FIG. 1  is a schematic illustration showing an arrangement according to the invention for regulating air mixing in a heating or air-conditioning system; 
           [0015]      FIG. 2  is a perspective view showing one embodiment of a shaft portion of an air control member according to the present invention; 
           [0016]      FIG. 3  is a plan view showing the shaft portion of  FIG. 2  connected to a kinematic actuator; 
           [0017]      FIG. 4  is a perspective view showing additional structure of the kinematic actuator of  FIG. 3 ; 
           [0018]      FIG. 5  is a plan view showing the shaft portion of  FIG. 2  connected to a motor actuator; 
           [0019]      FIG. 6  is a perspective view showing the motor actuator connected to the shaft portion according to  FIG. 5 ; 
           [0020]      FIG. 7  is a plan view showing one typical embodiment of a flap type air control member having a shaft portion according to the invention; 
           [0021]      FIG. 8  is a perspective view showing one possible embodiment of an air flow control system for a heating and/or air-conditioning system of the type used in a motor vehicle; 
           [0022]      FIG. 9  is a cross-sectional view showing the portion of the air control system of shown in  FIG. 8  that is downstream of the condenser; and 
           [0023]      FIG. 10  is a perspective cut-away view showing the portion of the air control system depicted in  FIG. 9 , with kinematic actuator members connected to the air control flaps. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0024]    Referring to  FIG. 1 , one typical arrangement  10  is schematically shown of a system for regulating air mixing in a heating or air-conditioning system of a motor vehicle. There are many different designs for such systems, and the present invention is useful in virtually any such system. The schematically illustrated arrangement  10  has an air-guiding housing  12  of an air-conditioning unit. The air-guiding housing  12  contains a fan  14  to which fresh air can be supplied via a fresh-air opening  16  and/or recirculated-air can be supplied via a recirculated-air opening  18 . An air-flow control element  20 , for example, a fresh-air/recirculated-air flap, serves for regulating the proportion of fresh air to recirculated air, which proportion can be set in each case depending on the flap position. Instead of the fresh-air/recirculated-air flap  20 , there could also be provided two individual air flaps which can respectively close the fresh-air opening  16  and the recirculated-air opening  18 . 
         [0025]    The air taken in by the fan  14  is guided in the air-guiding housing  12  through a cooling heat exchanger  22 , for example, an evaporator, of a refrigerant circuit, and is cooled therein. A heating heat exchanger  24  in which the air can be heated is arranged on the downstream side of the cooling heat exchanger  22 . A cold-air bypass  26  is provided parallel to the heating heat exchanger  24 , and by means of this bypass cold air can be guided past the heating heat exchanger  24  into a cold-air/warm-air mixing chamber  28 . The proportion of cold air to warm air, and therefore the air temperature in the air-mixing chamber  28 , can be set via a temperature mixing flap  30 . 
         [0026]    As an alternative, instead of the air temperature regulation which is described, engine coolant (water) regulation could also be provided. In this case the air passes continuously through the heating heat exchanger, i.e., there is no cold-air bypass, and, in order to regulate the temperature, the water throughput through the heating heat exchanger can be regulated by an appropriate valve. 
         [0027]    Several ducts branch off from the air-mixing chamber  28 , including a defrosting-air duct  31 , a ventilating duct  32  and a footwell air duct  34 . These can be closed via the corresponding defrosting-air flap  36 , ventilating flap  38  and footwell air flap  40 . The air is guided via the air ducts  31 ,  32  and  34  to air nozzles arranged in the vehicle passenger compartment, such as defrosting nozzles, central vents and footwell vents, according to the usual practice and in accordance with the design of individual vehicle models. Systems are well known for either providing conditioned air to two zones of the passenger compartment (front right and front left) or to four zones (front right, front left, rear right and rear left). 
         [0028]    All of the flaps of the air-conditioning unit and the fan  14  can be controlled via a control unit  42  and can be connected to the latter via signal lines and/or mechanical connectors  44 ,  46 ,  48 ,  50 ,  52  and  54 . In a typical embodiment, the control unit  42  has, for example, three operating elements  56 ,  58  and  60 , which are preferably arranged in the dashboard and with which specific instructions can be set. In the exemplary embodiment illustrated, the operating element  56  is designed as an air-distributing switch or flap switch, the operating element  58  is designed as a temperature selection switch, and the operating element  60  is designed as a fan output switch. 
         [0029]    The control unit  42  preferably contains a microcomputer for activating the individual air flaps and the fan in accordance with the settings on the operating elements  56 ,  58 ,  60 . The air flaps themselves can be adjusted via stepping motors and/or by means of mechanical linkage (kinematic) control elements, both of which are conventional. For example, one mode of kinematic operation is disclosed in U.S. Pat. No. 5,645,479, the disclosure of which is hereby incorporated by reference. 
         [0030]    As discussed above, because auto manufacturers produce a wide variety of uniquely designed heating and/or air-conditioning systems for the multitude of vehicle models they produce, there is a need to design and produce a very large number of unique control members, both in the sense that two separate models are needed for each control member configuration (one for kinematic actuation and a second one for direct actuation), and in the sense that every air control system employs a number of uniquely configured air control members, i.e., the shape of the flap itself. 
         [0031]    According to the present invention, one feature that greatly simplifies the design and construction of air control systems for heating and air-conditioning systems resides in providing the shaft portion of the air control members with a universal connection configuration. In other words, the end of the axis shaft is configured so that it can interact with a plurality of different actuation devices, such as both a kinematic actuator as well as, alternatively, a direct actuator, which is typically a stepper motor. In carrying out this feature, a large number of different design possibilities exist. This feature is characterized by at least two different mechanical configurations, wherein each configuration is capable of interacting with a different type of actuation device. Typically, the two configurations are mutually exclusive, and preferably, the two configurations are chosen to correspond with existing connection configurations, where possible, of standard actuation devices. 
         [0032]      FIG. 2  is a perspective view showing one preferred configuration for the air flow control member shaft end according to the invention. On at least one end of shaft  70 , to which air control flap  72  is attached in order to rotate around the axis of shaft  70 , a specially configured end portion is provided that is capable of interacting with at least two different types of actuation device. In order to inter-engage with a first type of actuation device, for example, a mechanical or kinematic actuator, the end of shaft  70  is provided with two keyed portions, shown as slots  74 . Preferably, to assist in the correct orientation of the actuator at the time of installation, the slots  74  are of different configuration, in this case different width. The end of shaft  70  is preferably also provided with a mechanism for attaching or retaining a kinematic actuator that cooperates with the shaft. In this case, one preferred embodiment is shown in the form of at least one and preferably two locking windows or recesses  76 . Obviously, many other configurations for the shaft end as well as for the retaining mechanism are possible. 
         [0033]      FIG. 3  illustrates the cooperation and inter-engagement of the first configuration of the end of shaft  70  with a kinematic actuation device  80 . The kinematic actuator  80  has two assembly keys  82  that inter-engage in the keyed slots  74 . Because the slots  74  are of different configuration and the assembly keys  84  are of matching configuration, the kinematic actuator can be applied to the shaft end in only a single orientation, which aids in the assembly operation. 
         [0034]    A typical kinematic actuation device is more completely illustrated in  FIG. 4 . Actuator  80  has a keyed frame portion having the profile seen in  FIG. 3 , to which is attached a geared section  83  that carries a plurality of gear teeth  84 . This typical kinematic actuator is shown for illustration only, inasmuch as a wide variety of different kinematic actuation assemblies are possible, with many being well known.  FIG. 4  also shows one example of a latching mechanism  81  on the kinematic actuator  80  that engages with the locking window or recess  76 , in order to retain the actuator on the shaft end after it is mounted there. Preferably, there are two latching mechanisms  81 , one on either side, that engage with opposing locking windows or recesses  76 . 
         [0035]      FIGS. 5 and 6  illustrate the second inter-engagement configuration that is formed on the end of shaft  70  in the illustrated embodiment. In this embodiment, the outer shaft configuration  78  is designed for inter-engagement with a second type of actuation device, in this case a direct actuator  86 , such as a stepper motor. The opposing sides  78  of shaft  70  have been flattened in this embodiment, to form a so-called Double D shape, which can interlock and be driven by the direct actuator  86 .  FIG. 6  shows more completely the assemblage of shaft  70  carrying flap  72  and the stepper motor  86  mounted on the end of shaft  70 . The second inter-engagement configuration provides mutually exclusive structural features vis-à-vis the first inter-engagement configuration. 
         [0036]    According to a further aspect of the invention, the design and assembly of air control devices for heating and/or air-conditioning systems can be simplified even further by providing an air control element of standard shape and size. This advantage can be gained in any air control system, but preferably is employed in an air control system that embodies the multi-functional attaching configuration of the air control element shaft that is provided according to this invention. An air control device that is designed to employ only a single standardized air control element in multiple locations, preferably in each location, where needed in the device will require far fewer different parts to be supplied for its assembly. Further, by designing multiple heating and/or air-conditioning systems to employ the standardized air control element, an auto manufacturer can significantly decrease the number of different parts that need to be purchased and supplied. Obviously, great latitude exists for the shape and size of such a standardized air control member.  FIG. 7  illustrates one such preferred shape for air flap  72 , in this case a rectilinear shape, i.e., a rectangle as illustrated here. Although it is understood that the dimensions of the air control member will depend on the configuration of the system in which it is included, a typical rectangular air control member may have dimensions ranging between a length of about 240-280 mm and a width of between about 90-110 mm. In one embodiment the flap is approximately 290×95 mm. Other figures illustrate that different shapes, such as a square shape can also be used with advantage. 
         [0037]    One exemplary preferred heating and air-conditioning system embodying the air control member according to the invention is illustrated in  FIGS. 8-10 . This system is generally representative of the type of system schematically illustrated in  FIG. 1 , and the same reference numerals have been used in  FIGS. 8-10  as those used in  FIG. 1 . The entire system is depicted in  FIG. 8 , wherein a single air control member (flap)  20  serves to select and adjust the mixture of fresh outside air OSA and recirculated air Recirc. After passing through a fan  14  and condenser  22 , shown generally, the conditioned air is fed upwardly either through heater  24  or through bypass passage  26 , where the amount of bypass air is controlled by flap  30   a . As seen more clearly in  FIG. 9  (which shows only the portion downstream of the condenser), the amount of bypass air is controlled by two separate flaps  30   a  and  30   b , which, for example, can be kinematically connected together, as shown in  FIG. 10  air passing through heater  24  and bypass passage  26  are combined in air mixing chamber  28 . Air flap  36  controls both the amount of air that is permitted to pass to the defrost outlet through defrost duct  31  as well as the amount of air that is permitted to pass to the panel vents through ventilating duct(s)  32  and/or to the footwells via footwell air duct  34 . In this regard, a fourth air flap  38 / 40  serves the dual purposes of determining the respective amount of air flowing to the ventilating ducts  32  and the footwell air duct  34 . In other words, in this embodiment, a single air flap performs the function of two flaps  38  and  40  in the schematic illustration of  FIG. 1 . This again illustrates that the improved air control device according to the invention can be used with advantage in virtually any heating and/or air-conditioning system. Preferably, at least some of the air control flaps, preferably including at least the recirculation air flap, and most preferably all of them, share a common size and shape and are interchangeable. Although not necessarily, but again most preferably, the flaps that share the common size and shape also embody the universal flap connection system according to the invention. In this embodiment, the air flaps  36  and  38 / 40  are also advantageously kinematically connected together, as shown in  FIG. 10 . 
         [0038]    The foregoing description of preferred embodiments of the invention has been presented for purposes of illustration and description only. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and modifications and variations are possible and/or would be apparent in light of the above teachings or may be acquired from practice of the invention. The embodiments were chosen and described in order to explain the principles of the invention and its practical application to enable one skilled in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto and that the claims encompass all embodiments of the invention, including the disclosed embodiments and their equivalents. For example, it is apparent that benefit will be gained by employing at least some of the air control members according to the invention in any particular heating or air-conditioning system, Without employing the air control members of this invention in each location where an air control member is present.