Abstract:
An airflow door assembly for an HVAC blower. The assembly includes a primary door and a sub-door. The primary door is configured to be pivotably mounted in the HVAC blower. The primary door includes a first end, a second end, and a wall extending between the first end and the second end. The primary door defines an opening in the airflow door assembly. The sub-door is pivotably mounted to the primary door and is movable between a closed position and an open position. In the closed position the sub-door is seated within the opening to restrict airflow through the opening. In the open position the sub-door is rotated out from within the opening to permit airflow through the opening.

Description:
FIELD 
       [0001]    The present disclosure relates to an automobile air conditioning system. 
       BACKGROUND 
       [0002]    This section provides background information related to the present disclosure which is not necessarily prior art. 
         [0003]    Despite recent advances in manufacturing, automobile production remains very expensive. Major manufacturing costs include development, materials, and labor, among other costs. Some companies have reduced labor costs by strategically locating automobile production near demand or in low-cost regions. Others have sought less expensive materials. However, manufacturing costs continue to rise, particularly as new regulations require difficult development projects. Therefore, automobile manufacturers have further need for lower cost production devices and techniques. 
         [0004]    One device in an automobile that can be designed to reduce automobile manufacturing costs is the automobile&#39;s air conditioning system. In particular, reducing material and development costs of the air conditioning system by decreasing the number of parts or increasing commonality of parts can help reduce automobile manufacturing costs. Furthermore, reducing the number of parts can reduce air flow restrictions through the air conditioning system, such as in complex air conditioning systems with butterfly doors in which the butterfly doors are at intrusive positions. 
       SUMMARY 
       [0005]    This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features. 
         [0006]    In view of the airflow door assembly according to the present teachings, automobile manufacturing costs, particularly material and development costs, are reduced by decreasing the number of parts, yet increasing commonality of parts among automobile air conditioning models. The airflow door assembly includes an apparatus for executing multiple air conditions in a vehicle interior. For example, the apparatus may execute full fresh air, full recirculation air, or dual layer air made including both fresh and recirculation air. Furthermore, more than one type of blowing fan may be used with the apparatus. 
         [0007]    An airflow door assembly for an HVAC blower includes a primary door that is pivotably mounted in the HVAC blower. The primary door includes a first end, a second end, and a partial inner wall. A sub-door is pivotably mounted to the primary door that defines an aperture or opening. The sub-door is movable between a closed position in which the sub-door prohibits fluid communication through the aperture and an open position in which the sub-door allows fluid communication through the aperture. 
         [0008]    An airflow door assembly for an HVAC blower includes a sealing section having a first inlet and a second inlet, an outlet, a primary door having a sealing wall, and a sub-door pivotably mounted to the primary door that defines an aperture. When mounted in an HVAC blower, the sub-door is movable between a first position to direct airflow from the first inlet to the outlet, a second position to direct airflow from the second inlet to the outlet, and a third position to direct airflow from the first inlet and the second inlet to the outlet. 
         [0009]    An airflow door assembly for an HVAC blower includes a case that defines a first inlet, a second inlet, a sealing section, a first outlet, a second outlet, and a blower section. The assembly also includes a primary door having a first end, a second end, an inner wall, sealing tabs, and a sub-door. The primary door and sub-door have a first position, a second position, and a third position. The primary door and sub-door independently and selectively allow fluid communication between the first inlet and the blower section, the second inlet and the blower section, and the first inlet and the second inlet and the blower section. The sealing tabs provide a seal between the primary door and the case when in the first position, second position, or the third position. The primary door and the sub-door are pivotably mounted to a shaft and the sub-door is positioned between the first end and second end of the primary door. 
         [0010]    Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
     
    
     
       DRAWINGS 
         [0011]    The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure. 
           [0012]      FIG. 1  is a perspective view of an airflow door assembly door according to the present teachings; 
           [0013]      FIG. 2  is a perspective view of the airflow door assembly of  FIG. 1  with sub-door closed; 
           [0014]      FIG. 3  is a perspective view of the airflow door assembly of  FIG. 1  with sub-door open; 
           [0015]      FIG. 4  is a cross-section view of the airflow door assembly; 
           [0016]      FIG. 5  is a cross-section view of the airflow door assembly; 
           [0017]      FIG. 6  is a schematic view of an automobile air conditioning case including the airflow door assembly of  FIG. 1  in a first position; 
           [0018]      FIG. 7  is a schematic view of the automobile air conditioning case including the airflow door assembly of  FIG. 1  in a second position; and 
           [0019]      FIG. 8  is a schematic view of an automobile air conditioning case including the airflow door assembly of  FIG. 1  in a third position. 
       
    
    
       [0020]    Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings. 
       DETAILED DESCRIPTION 
       [0021]    Example embodiments will now be described more fully with reference to the accompanying drawings. 
         [0022]      FIGS. 1-5  illustrate a door assembly  14  according to the present teachings. The door assembly  14  can be included with an airflow management device  10 , which is illustrated in  FIGS. 6-8 . The airflow management device  10  includes a case  12 , which may have a first inlet  15 , a second inlet  16 , a sealing section  18 , a first outlet  20 , a second outlet  22 , and a blower section  24 . The first inlet  15  and the second inlet  16  are typically in fluid communication with separate air sources. For example, the first inlet  15  may be in fluid communication with fresh air while the second inlet  16  may be in fluid communication with recirculation air. The first outlet  20  and the second outlet  22  may be in fluid communication with the first inlet  15  and second inlet  16 , depending on the position of the door assembly  14 . The door assembly  14  is mounted to the airflow management device  10  and may be disposed between the first inlet  15  and second inlet  16 , and between the first outlet  20  and the second outlet  22 . 
         [0023]    With reference to  FIGS. 1-5 , the door assembly  14  may have a first end  28 , a second end  30 , an inner wall  32 , sealing tabs  34 , and a sub-door  36  rotatable about an axis  38 . The first end  28  and the second end  30  extend radially from the axis  38  and have an arcuate profile, such as a near-quarter-circle profile. Between the first end  28  and second end  30 , the door assembly  14  may have rigid features  40  that are shaped to structurally strengthen the door assembly  14 . The rigid features  40  may be on an interior surface  42  or exterior surface  44  of the door assembly  14 . For example, the rigid features  40  may be a plurality of cross-members, which may intersect to further strengthen the door assembly  14 . In addition, the rigid features  40  may also be corrugations. 
         [0024]    The blower section  24  moves air from at least one of the first inlet  15  and second inlet  16  through at least one of the first outlet  20  and second outlet  22  by creating a pressure differential between the first inlet  15  and second inlet  16  and the first outlet  20  and second outlet  22 , depending on the position of the door assembly  14 . For example, a blower, such as a fan  26 , which may be single- or multi-layered, may be used to create the pressure differential. If a single-layered fan is used (not shown), the airflow management device  10  may have a different case  12  and filter  62  than if a multi-layered fan is used. In addition, the sub-door  36  (and opening in which it is seated) may be removed or will close an aperture defined by the primary door. Therefore, the blower section  24  may create a pressure differential to move air from at least one of the first inlet  15  and the second inlet  16 , through the door assembly  14 , then through at least one of the first outlet  20  and second outlet  22 . If a multi-layered fan is used, the airflow management device  10  may have a case with a fan outlet for each layer of the multi-layered fan. 
         [0025]    The sealing tabs  34  are configured to restrict air flow around the exterior surface  44  of the door assembly  14 . In particular, the sealing tabs  34  may include a sealing material, such as a foam or elastomer. The sealing tabs  34  may be held to the door assembly  14  by an adhesive or a fastener. However, a person having ordinary skill would understand that many materials may be used. The sealing tabs  34  are further disposed around a perimeter  46  of the door assembly  14 , particularly along a first edge  48  and second edge  50 . The edge  48  is at a first frame of the door assembly  14  and the second edge  50  is at a second frame of the door assembly  14 , both the first and the second frames generally extend from pivot axis  38 . The first edge  48  and second edge  50  may intersect the axis  38  at the first end  28  and the second end  30 . As shown in  FIG. 1 , the sealing tabs  34  extend from the axis  38  of the door assembly  14  at the first end  28  to the axis  38  at the second end  30 . Depending on the position of the door assembly  14 , the sealing tabs  34  may be selectively engaged with the case  12 , the first inlet  15  and second inlet  16 , and the first outlet  20  and the second outlet  22 . The sealing material may be on both sides of the sealing tabs  34  or just one side as required to restrict air flow around the exterior surface  44  of the door assembly  14 . 
         [0026]    The sealing tabs  34  are configured to restrict fluid communication around the door assembly  14  between the door assembly  14  and the case  12  when in a first position A, a second position B, or a third position C by frictionally engaging the case  12 . The sub-door  36  is mounted to a shaft  64  and the door assembly  14  pivots about the shaft  64  with common axis  38 . The sub-door  36  is positioned between the first end  28  and second end  30  of the door assembly  14 . The first inlet  15  and the second inlet  16  may have independent fluid sources. For example, one fluid source may be recirculation air and another fluid source may be fresh air. Therefore, only the sealing tabs  34  frictionally engage the case  12 , and the sub-door  36  restricts air only by rotating within the door assembly  14 . In this way, the case  12  may be smaller, have increased commonality amongst components, and have fewer components, thereby reducing manufacturing costs. 
         [0027]    The inner wall  32  is a solid, generally flat planar wall that extends between the first end  28  and the second end  30  to restrict air moving through the door assembly  14 . The inner wall  32  extends from the first edge  48  toward the axis  38 , but may not reach the axis  38 . Therefore, the inner wall  32  has a generally rectangular shape and defines an opening between the inner wall  32  and the axis  38 . 
         [0028]    The sub-door  36  is a solid, generally flat door that extends between the first end  28  and the second end  30  to selectively restrict air moving through the door assembly  14 . The sub-door  36  may be known as a flag door. The sub-door  36  is rotatably disposed about the axis  38  and extends radially outward therefrom. The sub-door  36  may rotate within the door assembly  14  and have a width that complements the inner wall  32  such that the sub-door  36  may form a wall from the first edge  48  of the door assembly  14  to the axis  38  that restricts air from moving through the door assembly  14 . 
         [0029]    The sub-door  36  may have a smooth perimeter  52 . Alternatively, the sub-door  36  may have a sealing feature  54  at the perimeter  52  to further restrict fluid communication when the sub-door  36  is proximate the inner wall  32 . For example, the sealing feature  54  may be a cupped lip ( FIG. 4 ) made of many materials such as soft rubber. Furthermore, the sealing feature  54  may be an elastomer or foam ( FIG. 5 ). A person having ordinary skill in the art would appreciate that the configuration allows for the sealing feature  54  to be any suitable material, such as caulk, cellulose, or cork. 
         [0030]    Now referring to  FIGS. 6-8 , the door assembly  14  and sub-door  36  are configured to independently selectively allow fluid communication between the first inlet  15  and the blower section  24 , the second inlet  20  and the blower section  24 , and the first inlet  15  and the second inlet  16  and the blower section  24 . The door assembly  14  and sub-door  36  allow fluid communication by having at least first position A ( FIG. 6 ), second position B ( FIG. 7 ), and third position C ( FIG. 8 ), as adjusted by any suitable actuating mechanism, such as any suitable motor or servo in cooperation with the airflow management device  10 . 
         [0031]    In the first position A of  FIG. 6 , the door assembly  14  is positioned proximate to the second inlet  16  and the sub-door  36  is positioned to open the aperture defined by the door assembly  14 . Therefore, the first inlet  15  is in fluid communication with the first outlet  20  and the second outlet  22 , the filter  62 , and the blower section  24 . In this instance, for example, the first position  56  may allow fresh air to flow to the blower section  24 , but restrict recirculation air from flowing to the blower section  24 . 
         [0032]    In the second position B of  FIG. 7 , the door assembly  14  is positioned proximate to the first inlet  15  and the sub-door  36  is positioned intermediate of the first edge  48  and second edge  50  of the door assembly  14 . Therefore, the second inlet  16  is in fluid communication with the first outlet  20  and the second outlet  22 , the filter  62 , and the blower section  24 . In this instance, for example, the second position  58  may allow recirculation air to flow to the blower section  24 , but restrict fresh air from flowing to the blower section  24 . 
         [0033]    In the third position C of  FIG. 8 , the door assembly  14  is positioned intermediate of the first inlet  15  and the second inlet  16 . The sub-door  36  is positioned proximate to the inner wall  32  of the door assembly  14 . Therefore, the first inlet  15  is in fluid communication with the first outlet  20 , the filter  62 , and the blower section  24 . In this instance, for example, the third position  60  may allow recirculation air to flow to the blower section  24  and allow fresh air to flow to the blower section  24 . 
         [0034]    One skilled in the art will appreciate that the configuration allows for the door assembly  14  and sub-door  36  to each be arranged in any suitable position in addition to those described above, such as, for example directing and restricting fluid communication of more than two fluid sources, or in which the door assembly  14  is slidable rather than rotatable. 
         [0035]    The airflow management device  10  according to the present teachings thus advantageously provides for two doors configured to allow airflow between selected inlets and outlets of an air conditioning case. Therefore, the airflow management device  10  reduces automobile manufacturing costs in an automobile&#39;s air conditioning system by using the door assembly  14  to provide for independent fluid sources. The door assembly  14  therefore reduces material and manufacturing costs by decreasing the size of the case  12 , reducing the number of parts included therewith, and increasing the commonality of parts. The sub-door  36  is advantageously located at a non-intrusive position so that the sub-door  36  will only engage portions of the door assembly  14 . 
         [0036]    The description has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure. 
         [0037]    Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.