Blower unit and air conditioning unit including the same and method of controlling the same

A blower unit of an air conditioning unit including a scroll casing including a first engaging portion, a fan casing including a first engaging portion, and a controller for controlling an electric motor to move at least one of the scroll casing and the fan casing such that the movement of at least one of the scroll casing and the fan casing stops when the first engaging portion of the scroll casing abuts the first engaging portion of the fan casing. The precision of the position of the scroll casing with respect to the fan casing, the precision of the temperature of air discharged into the compartment, and/or the volume of the blower unit may be improved.

PRIORITY STATEMENT

This U.S. nonprovisional application claims priority on Japanese Patent Application No. 2003-336943 filed on Sep. 29, 2003, the entire disclosure of which is incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to a blower unit, an air conditioning unit including a blower unit, and a method of controlling the same.

BACKGROUND OF THE INVENTION

In conventional blower units, a fan generating air flow may be accommodated in a scroll casing and two ducts may be provided around the scroll casing. The scroll casing may rotate around an axis thereof and stop at two positions. In one position, a discharge port of the scroll casing may be connected to an inlet of one duct. In the other position, a discharge port of the scroll casing may be connected to an inlet of the other duct. In conventional blower units, it may not be clear how to stop the scroll casing. Further, it may be difficult to stop the scroll casing at a desired position.

SUMMARY OF THE INVENTION

Example embodiments of the present invention provide a new blower unit different from conventional blower units.

Example embodiments of the present invention provide a new air conditioning unit with the new blower unit.

Example embodiments of the present invention may improve the precision of the position of a scroll casing with respect to a fan casing of the new blower unit.

Example embodiments of the present invention may improve the precision of the temperature of air discharged into a compartment from the new blower unit.

Example embodiments of the present invention may reduce the volume of the new blower unit.

In an example embodiment, the present invention is directed to a blower unit including a scroll casing accommodating a fan therein, the scroll casing including a first engaging portion, a fan casing accommodating the scroll casing therein, the fan casing including a first engaging portion, and a controller for controlling an electric motor to move at least one of the scroll casing and the fan casing such that the movement of at least one of the scroll casing and the fan casing stops when the first engaging portion of the scroll casing abuts the first engaging portion of the fan casing.

In an example embodiment, the present invention is directed to an air conditioning unit including a blower unit generating air flow, an air conditioning case disposed on a downstream side of the air flow, a first air path accommodated in said air conditioning case, and a second air path accommodated in said air conditioning case, said air conditioning case including an air opening, through which air from said first air path and air from said second air path may pass therethrough, wherein the blower unit further includes a scroll casing accommodating a fan therein, the scroll casing including a first engaging portion, a fan casing accommodating the scroll casing therein, the fan casing including a first engaging portion, and a controller for controlling an electric motor to move at least one of the scroll casing and the fan casing such that the movement of at least one the scroll casing and the fan casing stops when the first engaging portion of the scroll casing abuts the first engaging portion of the fan casing.

In an example embodiment, the present invention is directed to a method of controlling relative movement of a scroll casing and a fan casing of a blower unit, including providing a scroll casing for accommodating a fan therein, the scroll casing including a first engaging portion, providing a fan casing for accommodating the scroll casing therein, the fan casing including first engaging portion, and controlling an electric motor to move at least one of the scroll casing and the fan casing such that the movement of at least one of the scroll casing and the fan casing stops when the first engaging portion of the scroll casing abuts the first engaging portion of the fan casing.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

FIG. 1Aillustrates an air conditioning unit according to an example embodiment of the present invention. A blower unit2, which may be part of the air conditioning unit1, may generate air flow to a vehicle compartment. The blower unit2may suck internal air from a rear tray disposed in the vicinity of a rear window glass and supply the internal air to an evaporator4and a heater5.

The blower unit2may include a fan2a, for example a centrifugal fan, for example, rotated by an electric motor9(shown inFIG. 1B), a scroll casing2baccommodating the fan2a, a discharge port2c, a drive gear2drotating the scroll casing2b, and/or a fan casing2eaccommodating the scroll casing2b.

In an example embodiment, the fan2amay be a centrifugal fan, for example, Japanese Industrial Standard (JIS) B 0132, No. 1004, etc., which may suck air from an axial direction thereof and may discharge air in a radial direction thereof, and the scroll casing2bmay form a scroll-shaped air passage for gathering the air discharged from the centrifugal fan2a.

According to an example embodiment, the blower unit2may be disposed such that a rotating axis of the centrifugal fan2ais parallel or substantially parallel to a vehicle width direction.

Further, the scroll casing2bmay rotate around an axis thereof. The axis of the scroll casing2band that of the centrifugal fan2amay be coaxial.

When the drive gear2dis rotationally driven by the electric motor9, such as a servo motor, shown inFIG. 1B, the scroll casing2bmay rotate around the axis of the fan2aso that the position of the discharge port2cchanges.

As shown inFIG. 1B, the electric motor9may be controlled by an ECU (electric control unit)10. The ECU10may be supplied with an input signal or input signals, for example, a signal or signals from an internal air temperature sensor11for detecting the air temperature in a compartment, a signal or signals from an outside air temperature sensor12for detecting the air temperature outside the compartment, a signal or signals from a sunlight sensor13for detecting a sunlight amount, for example, the sunlight amount radiated on a rear seat, and/or a signal or signals from a temperature setting device14for setting the target temperature in the compartment by, for example, an occupant.

Based on the input signal or signals described above, the ECU10may calculate or otherwise determine a target blowout temperature (TAO). The ECU10may calculate or otherwise determine the target blowout temperature (TAO) in accordance, for example, with a computer program stored therein, for example, in a ROM (read-only memory) or the like.

A driven gear2f, which may have an arc shape and may be engaged with the drive gear2d, may be provided integrally with the scroll casing2bon an outer wall of the scroll casing2b. The driven gear2fmay be provided separately from the scroll casing2band fixed to the scroll casing2bby using joining elements, for example, a screw or screws or by using a bonding element, such as an adhesive.

In an example embodiment, when the scroll casing2brotates counterclockwise to the position shown inFIG. 2, which may be considered a maximum cooling mode, an edge portion2hof the driven gear2f, acting as a first engaging portion, may abut a first step portion2gof the fan casing2e, also acting as a first engaging portion in a maximum cooling position and the ECU10may position the scroll casing2bmechanically. Further, when the scroll casing2brotates clockwise to the position shown inFIG. 3, which may be considered a maximum heating mode, an edge portion2jof the discharge port2c, acting as a second engaging portion, may abut a second step portion2kof the fan casing2e, also acting as a second engaging portion in a maximum heating position and the ECU10may position the scroll casing2bmechanically.

The fan casing2emay have a bent portion2mbent inward. The first step portion2gand the second step portion2kmay be formed at both ends of the bent portion2m.

An air conditioning case3, which may be disposed on a downstream side of air flow, may accommodate an evaporator4and an heater5, and may form one or more air passages or air paths, through which air discharged from the blower unit2passes. The air conditioning case3may be formed of resin, such as polypropylene.

The evaporator4which may act as a cooling heat exchanger for cooling air discharged into the compartment and the heater5which may act as a heating heat exchanger for heating air discharged into the compartment may be accommodated, on the air discharging side of the blower unit2, in the air conditioning case3. The evaporator4and the heater5may be arranged in parallel with each other with respect to a flow of air discharged from the blower unit2, where parallel indicates that no air passes through the air path formed by the evaporator4and through the air path formed by the heater5.

The evaporator4may be a low-pressure side heat exchanger of a vapor compression refrigeration cycle. The heater5may be a heating heat exchanger deriving heat from waste heat generated in a vehicle engine or the like. In an example embodiment, engine cooling water may be a heat source of the heater5.

The evaporator4may be disposed below the heater5and substantially horizontally, so that air passes through the evaporator4downwardly. The evaporator4and the heater5may be arranged in a V-shape protruded toward the vehicle front in such a manner as to surround the blower unit2.

The air conditioning case3may include air openings including a face air opening6, a foot air opening7and/or a seat air conditioning opening8in the air downstream of the evaporator4and the heater5.

The face air opening6may be connected to a face air duct (not shown). A face air outlet may be disposed at the end of the face air duct, and air generated by the blower unit2may be discharged from the face air outlet into the vehicle compartment. The face air duct may be embedded in a C pillar acting as a support at a rear window side and the face air outlet may be disposed on the vehicle ceiling above the rear seat.

The foot air opening7may be connected to a foot air duct (not shown). A foot air outlet, located at lower side of the rear seat of the vehicle, may be disposed at the end of the foot air duct and air generated by the blower unit2may be discharged from the foot air outlet into the vehicle compartment.

The seat air conditioning opening8may be connected to a seat air duct (not shown). A seat air outlet, located at the seatback, may be disposed at the end of the seat air duct and air generated by the blower unit2may be discharged from the seat air outlet into the vehicle compartment.

The air passed through the evaporator4and the air passed through the heater5may be mixed in an air mixing chamber3ain the air conditioning case3, at which the face air opening6, the foot air opening7, and the seat air conditioning opening8are disposed.

Air passing through the heater5, when viewed from the evaporator4side, may be supplied to the compartment while bypassing the evaporator4. An air passage having the heater5thus constituted, when viewed from the evaporator4, may be a bypass passage of the air flowing into the compartment which bypasses the evaporator4.

In a similar fashion, air passing through the evaporator4, when viewed from the heater5, may be supplied to the compartment while bypassing the heater5. An air passage having the evaporator4, therefore, when viewed from the heater5, may constitute a bypass passage of the air flowing into the compartment which bypasses the heater5.

Next, rotational control of the scroll casing2b, in an example embodiment is explained.

The amount of rotational angle of the scroll casing2bmay be controlled according to the target blowout temperature TAO.

For example, as shown inFIG. 4, the scroll casing2bmay be at position 0° in a maximum cooling mode, and may be at position Θ° in a maximum heating mode. The rotational angle of the scroll casing2bmay be increased (or decreased) in proportion to the increase (or decrease) in the target blowout temperature TAO.

The flow rates of air discharged from the blower unit2to the evaporator4and the heater5may be adjusted by changing the rotational angle of the scroll casing2b.

For example, the discharge port2cmay be directed toward the evaporator4, so that a flow rate of air supplied to the evaporator4is increased, while a flow rate of air supplied to the heater5is decreased.

By directing the discharge port2ctoward the heater5, in contrast, the flow rate of the hot air may be increased, while the flow rate of the cool air may be decreased. As described, the ratio between the cool air flow rate and the hot air flow rate can be adjusted by rotating the scroll casing2b.

That is, in a maximum cooling mode shown inFIG. 2, all the air discharged from the blower unit2may be supplied to the evaporator4thereby to set the cool air ratio to 100%, and in a maximum heating mode shown inFIG. 3, all the air discharged from the blower unit2may be supplied to the heater5, thereby to set the hot air ratio to 100%.

Further, in an air-mixing mode, mixing the cool air and the hot air shown inFIG. 1A, the temperature of the air discharged into the compartment may be controlled by adjusting the ratio between the cool air flow rate and the hot air flow rate based on the target blowout temperature TAO.

As described above, in an example embodiment, the edge portion2hof the movable driven gear2fmay abut the first step portion2gof the immovable fan casing2eand the ECU10may position the scroll casing2bmechanically. Further, the edge portion2jof the movable discharge port2cmay abut the second step portion2kof the immovable fan casing2eand the ECU10positions the scroll casing2bmechanically.

After the ECU10positions the scroll casing2bmechanically, the precision of the position of the scroll casing2band/or the precision of the temperature of air discharged into the compartment can be improved.

According to example embodiments, the temperature of air discharged into the compartment may be controlled by adjusting the ratio between the cool air flow rate and the hot air flow rate. According to example embodiments, the temperature of air discharged into the compartment may be controlled without an air-mixing door. According to example embodiments, the temperature of air discharged into the compartment may be controlled with a smaller (for example, smaller volume) air conditioning unit.

According to example embodiments, the evaporator4may be disposed below the heater5and/or substantially horizontally, so that condensed water generated in the evaporator4may be discharged out from the air conditioning case3.

According to example embodiments, the evaporator4and the heater5may be arranged in a V-shape protruded toward the vehicle front to surround the blower unit2. As a result, the volume of the air conditioning unit1may be reduced.

According to example embodiments, the evaporator4and the heater5may be disposed so as to not overlap with each other. However, as shown inFIG. 5, in other example embodiments, the evaporator4and the heater5may be disposed to overlap such that a part of the cool air passed through the evaporator4passes through the heater5.

According to example embodiments, the evaporator4and the heater5may be arranged in a V-shape with either no overlap, as shown inFIGS. 1A,2, and3or with partial overlap, as shown inFIG. 5.

According to example embodiments, the evaporator4and the heater may be provided as independent parts. However, as shown inFIG. 6, in other example embodiments, the evaporator4and the heater5may be integrated with each other, for example, curved in a substantially arc shape.

Example embodiments are directed to an air conditioning unit including an evaporator4and a heater5. However, as shown inFIG. 7, the heater5may be eliminated and be replaced by a bypass passage5afor supplying air bypassing the evaporator4.

In example embodiments, an air-mixing door may be eliminated and, therefore, the volume of the air conditioning unit1may be reduced.

In example embodiments, the temperature of the air supplied to the compartment may be adjusted by mixing the cool air cooled by the evaporator4and the air bypassed the evaporator4in the air mixing chamber3a.

Example embodiments are directed to an air conditioning unit including an evaporator4and a heater5. However, as shown inFIG. 8, the evaporator4may be eliminated and replaced by a bypass passage4afor supplying air bypassing the heater5.

In example embodiments, the air-mixing door may be eliminated and, therefore, the volume of the air conditioning unit1may be reduced.

In example embodiments, the temperature of the air supplied to the compartment may be adjusted by mixing the hot air heated by the heater5with the air bypassing the heater5in the air mixing chamber3a.

According to example embodiments, the ECU10may position the scroll casing2bwhen the edge portion2habuts the first step portion2gand when the edge portion2jabuts the second step portion2k. However, the ECU10may position the scroll casing2beither when the edge portion2habuts the first step portion2gor when the edge portion2jabuts the second step portion2k.

Although as described above, the scroll casing2bincludes first and second outward protruding portions and the fan casing2eincludes first and second inward protruding portions, any or all of these could be reversed as would be known to one of ordinary skill in the art.

Although as described above, the scroll casing2bmoves and the fan casing2eremains stationary, this could also be reversed as would be known to one of ordinary skill in the art. Further, both the scroll casing2band the fan casing2ecould move, and example embodiments of the present invention could control the relative movement therebetween, as would be known to one of ordinary skill in the art.

According to example embodiments, the evaporator4may be disposed below the heater5. However, as an alternative, the heater5may be disposed below the evaporator4.

Also, according to example embodiments, the evaporator4and the heater5may be arranged in a V-shape, such that the evaporator4and the heater5do not overlap or partially overlap, protruding toward the vehicle front in such a manner as to surround the blower unit2. However, the evaporator4and the heater5may be arranged in other configurations, for example, in parallel with each other (no overlap), as shown inFIG. 1A,2, and3, partly in parallel and partly in series (partial overlap), as shown inFIG. 5, or in series (complete overlap) with each other.

In example embodiments, the air conditioning unit according to the present invention may be used for air-conditioning a vehicle compartment, for example, a rear side of a vehicle compartment. In example embodiments, the air conditioning unit according to the present invention may be installed in a trunk behind a rear seat in such a manner that an inclined portion of the air conditioning unit shown inFIG. 1Ais arranged substantially along a back of the rear seat. However, example embodiments of the present invention may also be used for air-conditioning a front side of a vehicle compartment and/or in a stationary compartment, for example, in a building.

Although the scroll casing2bmay be rotated by the drive gear2din the example embodiments described above, the present invention is not limited to this configuration.

In the example embodiments described above, the blower unit2amay include a fan2a, for example a centrifugal fan, for sucking air from an axial direction thereof and discharging the air toward a radial direction thereof. However, the blower unit2may include an axial-flow fan, for example, JIS B 0132, No. 1017 for allowing the air to pass through the cross section orthogonal to the rotating shaft, and a casing for accommodating the axial-flow fan to form an air passage.

Such variations are not to be regarded as departure from the spirit and scope of the example embodiments of the present invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.