Abstract:
An improved vehicle air conditioning system and a method for its installation, having a control assembly used for temperature and blower adjustments or settings which makes use of existing control panel equipment, as well as new electrical controls, where cables are provided between the original equipment and the new electrical control assembly, and the cables are engaged with a cable integrator including a potentiometer to enable marking of the desired setting adjustments within the vehicle and translation of the settings or adjustments from the manual control panel adjustment to the electrical control assembly which regulates the system output.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of Provisional U.S. Patent Application No. 61/508,467, filed Jul. 15, 2011, the subject matter of which is incorporated herein by reference. 
    
    
     FIELD 
     The present application is directed to an air conditioning system for use in classic vehicles, and more particularly, to a system and method for controlling air conditioning systems in classic vehicles which makes use of cables 
     BACKGROUND 
     The use of air conditioning systems within vehicles is a relatively recent addition. It was not until about 1953 when luxury cars began providing an optional air conditioning system as original equipment. In 1954 a more efficient and affordable air conditioning unit was eventually mass produced for the auto industry, with improved performance and fuel economy. However, as comfortable as air conditioning was known to be, it wasn&#39;t a frequently ordered accessory until the late 70&#39;s, when it became the reliable and efficient system in use today. As a result, many older, restored and rebuilt vehicles do not have air conditioning systems. Moreover, some of the older vehicles which did include early air conditioning systems are in need of repair or replacement. 
     The use of air conditioning system kits for installation in older vehicles has arisen to provide a solution to the problem of adding or replacing air conditioning systems in these older vehicles. Numerous problems exist with respect to such installation and replacement kits. Original parts are not available or desirable in such systems, since modern electronic components can provide such an improvement in system performance. The appearance and mounting of air conditioning system kits may also be problematic for old car hobbyists, who desire to retain the original appearance and operation of their vehicle. The need for an improved air conditioning system and method for its installation which solves these problems is desired. 
     SUMMARY 
     The present application provides an improved vehicle air conditioning system and a method for its installation. The system includes a compressor, condenser, expansion valve, receiver/drier, evaporator and an electrical control assembly. Refrigerant is compressed within the compressor and turns into a gas. The gas is cooled to a liquid state in the condenser and travels to the expansion valve. As the liquid refrigerant goes through the expansion valve it rapidly cools in the evaporator. A fan blows over the evaporator and cools the air that blows out through air vents. The receiver/drier separates gas and liquid. The control assembly is used for temperature and blower adjustments or settings and makes use of existing equipment, as well as new electrical controls. Interconnected with the original equipment are cables provided between the original equipment and the new control assembly, which includes potentiometers, which enable marking of the desired setting adjustments within the vehicle and translation of the settings or adjustments to the control assembly which regulates the system output. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  schematically illustrates the components of a vehicle air conditioning system as used in the present application; 
         FIG. 2  is a schematic illustration of the more detailed components of the vehicle air conditioning system of  FIG. 1 , including fluid flow and air flow paths; 
         FIG. 3  is an exploded partial schematic illustration of the control panel for the vehicle temperature and blower system being removed from the interior of a vehicle prior to replacement with the air conditioning system of the present application; 
         FIG. 4  is an enlarged view of the control panel shown in  FIG. 3 ; 
         FIG. 5  is a chart illustrating the number of blower switch positions and resulting air flow distribution provided within the vehicle using the air conditioning system of the present application; 
         FIG. 6  is a schematic perspective rear view of the control panel shown in  FIG. 4 ; 
         FIG. 7  shows the control panel of  FIG. 6 , but with an exploded view of the blower bracket and blower switch positioned prior to attachment to the rear of the control panel; 
         FIG. 8  illustrates the cable integrators of the air conditioning system of the present application; 
         FIG. 9  illustrates the cables interconnecting the cable integrators and the control panel in the air conditioning system of the present application; 
         FIG. 10  shows an enlarged view of the cable of  FIG. 9  secured to the rear of the control panel shown in  FIG. 7 ; 
         FIG. 11  is a side view of the control panel of  FIG. 6 , with a portion of the cable illustrated in phantom at the location where the cable will be secured; 
         FIG. 12  is a schematic illustration of a slidable clamp on the sheathed cable of  FIG. 9 ; 
         FIG. 13  is a partial exploded schematic rear view of the cables of  FIG. 9  engaged with the levers of  FIG. 11  and prior to attachment to the base portion of the control panel; 
         FIG. 14  is a partial end view at the location indicated of the clamps on the sheathed cable engaged with the base portion of the control panel; 
         FIG. 15  is a schematic view of the wiring harness of the electrical control assembly of the present application; 
         FIG. 16  is a partial schematic exploded rear view of the control panel of  FIG. 6 , engaged with the cables and cable integrators of the present application; 
         FIGS. 17A to 17C  are schematic illustrations of the front view of the control panel of  FIG. 4 , and the proper direction for replacement of the knobs of the control panel; 
         FIG. 18  is a schematic partial rear view of the control panel, cables, and cable integrators, with the blower switch connector about to be connected with the blower switch; and 
         FIG. 19  is a schematic illustration of the assembled control panel being inserted into the vehicle dash; and 
         FIG. 20  is a schematic illustration of the unconnected components and the associated electrical wiring system elements for the vehicle air conditioning system of the present application. 
     
    
    
     DETAILED DESCRIPTION 
     As shown in  FIG. 1 , schematically depicted within an automobile A, the vehicle air conditioning system  10  of the present application includes a compressor  12 , a condenser  14 , expansion valve  16 , a receiver/drier  18 , an evaporator  20  with a blower fan  21  and an electrical control assembly  22 . A further schematic illustration of these system  10  components is shown in  FIG. 2 . It should be understood that the present illustrations are provided showing a classic 1967-1968 Ford Mustang, but that numerous other vintage vehicles with similar original equipment heating systems may be replaced with the present environmental system, which provides not only cool air conditioning, but also heating. 
     In the present system  10 , the original equipment control panel  26  of the control assembly  22  is preferably used.  FIGS. 3 and 4  illustrate the control panel  26  of the electrical control assembly  22 , which is being removed from the dash D of the vehicle in  FIG. 3 . The control assembly  24  is interconnected with the evaporator  20  and blower fan  21  for controlling the system temperature and fan operating level.  FIG. 5  illustrates in chart format the levels of adjustment of the mode lever  28  (there are 11 modes illustrated) which may be moved to direct air flow between the vents V to the vehicle floor F and the vents to the vehicle dash D, and in various combinations of air flow. The present system thus provides the ability to blend the air between the face of anyone in the vehicle, the heat and the defrost mode, simultaneously. The fan switch  30  on the control panel  26  works like the original equipment switch, where the far left position is OFF such that all power to the system is off in this position, and in the far right position, the fan is ON. The temperature lever  32  also works like an original equipment control, with the COLD position at the top and the HOT position at the bottom. When the temperature lever  32  is in the full COLD position at the top, the compressor is ON (as set forth in  FIG. 5 ). This may be thought of as a compressor-override, since the compressor is ON, no matter what position the mode lever is in. 
     Prior to installation of the present system, the original heater assembly, with its interconnected control cables, blower motor, and electrical harness, is removed for disposal. Coolant should also be drained from the radiator for reuse or recycling. The heater hose is also removed, as well as any fresh air vent assemblies. The original control panel  26  is then removed from the dash as shown in  FIG. 3 . An original blower switch  29 , depicted in phantom in  FIG. 6 , is removed from the back of the control panel for disposal. A replacement fan or blower switch  30  is then installed, as shown from the back of the control panel in  FIG. 7 . 
     Sheathed cables, or Bowden-style conventional control cables  34 , are then provided as shown in  FIG. 9 . The cables  34  are attached to the rear of the control panel  26  to the appropriate mode and temperature levers,  28  or  30 , in the manner illustrated in  FIG. 10 , placing the loop ends  36  around the lever ends  38 . To attach the cables  34  to a base portion  40  of the rear of the control panel  26 , the slidable cable clamps  42 , shown in  FIG. 12 , are secured via threaded fasteners within the grooves  43  or other locations provided in the base portion  40  of the control panel  26 . The attachment of the cable clamps  42  to the base portion  40  is shown in  FIG. 13 , while an end view of the cable  34  alignment within the grooves  43  is best shown in  FIG. 14 . 
     Improved cable integrators  44 , shown in  FIG. 8  are next attached to the cables  34 . As shown in  FIGS. 16 and 18 , the control panel  26  is interconnected with the cable integrators  44  at a base plate  43  which is secured to the base portion  40  of the control panel  26 . The cable integrators  44  further include a slotted control plate  50  with a post  52  extending through the slot  54 , which post  52  is interconnected with a potentiometer  41  on the rear side of the cable integrator which interconnects with the electrical control assembly  22  via a wiring harness  56 . The wiring harness  56  is shown in  FIG. 8 . Using this interconnection between the cable  34  and cable integrator  44  with a potentiometer, the electrical control assembly  22  is used for marking both the location of the desired temperature and mode setting via the control panel  26 . The sheathed portion  48  of the cables  34  is attached to the slotted control plate  50 . The opposed looped ends  46  of the cables  34  are mechanically secured onto the posts  52  of the cable integrators  44 . The cables  34  are attached to the appropriate mode or temperature control posts, consistent with the attachment of the loops  36  to the mode or temperature lever ends  38 . In the depicted embodiment, the center lever of the original control panel is unused. 
     Before installing the control panel  26  back into the dash D, the original equipment knobs  58  are removed from their positions on the levers  28 ,  32 . The knobs  58  are rotated 180 degrees to a position which is upside down from their original mounted position, and then reinstalled on the opposite levers, as shown in  FIGS. 17A and 17B . The center, unused, knob  58  should also be removed and rotated 180 degrees and then reinstalled at the same center location, as shown in  FIG. 17C . In these new positions, any letters on the knobs will not likely be visible, and the user will quickly adjust to the new positions of the mode and temperature control levers  28 ,  32 . The blower or fan knob  59  should also be reinstalled. The fan or blower switch connection  60  on the wiring harness  56  should also be connected to the fan or blower switch  30  on the back of the control panel  26 , as indicated in  FIG. 18 . Once connected at all the relevant locations, the wiring harness  56  should extend from the dash D, for connection to the control panel  26 , which is then re positioned within the dash D and secured with conventional fasteners in its original location, as shown in  FIG. 19 . 
     Following completion of the control panel installation, additional components are also installed to obtain a functional system. For example, the original fuses are upgraded, air inlet and heater motor opening block offs may be installed, new water drainage and heater hoses are connected, and a firewall block off may be installed. The new evaporator and blower fan are installed and interconnected with the electrical control assembly  22 , having an ECU or electrical control unit  62 , via the wiring harness  56 . An electrical diagram for the electrical control assembly  22  is depicted in  FIG. 20 . Once the electrical control assembly  22  is installed, the electrical control unit  62  should be calibrated by conventional methods to ensure operation at the desired maximum efficiency. Additional duct work and hoses should likewise be installed to connect the defrost and heat duct assembly to the appropriate vents and outlets. 
     Within the engine compartment, spaced apart by the firewall F, additional installation of the condenser  14  and drier  18  and the high and low pressure lines, liquid lines and pressure switch  19  are also required. Once the pressure switch  19  is installed, the wiring harness  56  may be interconnected. Finally, the compressor  12  is installed and the necessary hoses and lines are interconnected, as well as the pressure switch  19 . Prior to operation, all hoses and clamps should be tightened, the compressor  12  must be appropriately charged with refrigerant, the radiator should be refilled with coolant and the battery reconnected. 
     Although the system, devices and method of the present application have been described in detail sufficient for one of ordinary skill in the art to practice the invention, it should be understood that various changes, substitutions and alterations may be made without departing from the spirit or scope of the system as defined in the attached claims. Moreover, the scope of the present system, devices and method is not intended to be limited to the specific embodiments described here, which are provided by way of example. As one of ordinary skill in the art will readily appreciate from the disclosure of the present system, devices, methods and embodiments, other systems, components or methods, presently existing or later to be developed that perform substantially the same function to achieve substantially the same result as those of the corresponding embodiments described here, may be utilized according to the present application. Accordingly, the appended claims are intended to include within their scope such other systems, devices, components or methods.