Patent Publication Number: US-2019184787-A1

Title: Panel and defrost plenum

Description:
TECHNICAL FIELD 
     This document relates generally to the motor vehicle equipment field and, more particularly, to a new and improved panel and defrost plenum, also known as a panel and defrost duct assembly, that is space efficient and allows delivery of an airstream past a package restriction such as a heads-up display (HUD). 
     BACKGROUND 
     A heads-up display (HUD) is a transparent display that projects data or other information onto the windshield of a motor vehicle where it is visible without requiring the driver/operator of the motor vehicle to look away from the forward view utilized to drive the motor vehicle. The automotive industry is currently adopting new generation HUD technology which enhances the user/driver experience. 
     These new generation HUD units occupy a relatively large space inside the instrument panel of the motor vehicle thereby limiting space available for heating, ventilating and air conditioning (HVAC) system components providing occupant climate comfort. This document relates to a new and improved panel and defrost plenum that is more space efficient and is particularly suited for delivering an airstream past a HUD package restriction while still providing the desired heating and cooling performance at lower noise levels. 
     SUMMARY 
     In accordance with the purposes and benefits described herein, a new and improved panel and defrost plenum is provided. That panel and defrost plenum comprises a manifold section including a first air distribution door, a second air distribution door and at least one actuator to displace said first air distribution door and said second air distribution door between multiple operative positions. In addition, the panel and defrost plenum further comprises an air feed section upstream of the manifold section. The air feed section delivers an airstream past a package restriction to the manifold section. In addition, the panel and defrost plenum further comprises a branch section downstream from the manifold section. 
     The manifold section may include a first air discharge port, a second air discharge port and a third air discharge port. The branch section may include a first branch duct extending from the first air discharge port to an outboard panel duct outlet. The branch section may include a second branch duct extending from the second air discharge port to a windshield defrost duct outlet. The branch section may include a third branch duct extending from the third air discharge port to a side window demist duct outlet. The first air distribution door may be configured to control the flow of the airstream through the first air discharge port to the outboard panel duct outlet. The second air distribution door may be configured to control the flow of the airstream through the second air discharge port to the windshield defrost duct outlet and the third air discharge port to the side window demist duct outlet. 
     The at least one actuator may include a first actuator configured to displace the first air distribution door and a second actuator configured to displace the second air distribution door. 
     In at least one of the many possible embodiments of the panel and defrost plenum, the manifold section may include a third air distribution door. In such an embodiment, the second air distribution door is configured to control the flow of the airstream through the second air discharge port to the windshield defrost duct outlet. The third air distribution door is configured to control the flow of the airstream through the third air discharge port to the side window demist duct outlet. 
     In accordance with an additional aspect, a method is provided of routing an airstream past a package restriction such as, for example, an HUD. That method comprises the steps of delivering the airstream in a feed section of a plenum past the package restriction to a manifold section of the plenum and displacing a plurality of air distribution doors in the manifold section to direct the airstream through a branch section of the plenum, downstream of the manifold section, to a plurality of outlets. 
     The method may include the step of providing the manifold section with a plurality of air discharge ports connected to the branch section. Further, the method may include the step of connecting a first air discharge port with an outboard panel duct outlet. In addition, the method may include the step of connecting a second air discharge port with a windshield defrost duct outlet. Further, the method may include the step of connecting a third air discharge port with a side window demist duct outlet. 
     Still further, the method may include the step of providing a first air distribution door to control flow of the airstream through the first air discharge port and a second air distribution door to control flow of the airstream through the second air discharge port and the third air discharge port. In addition, the method may include the step of controlling displacement of the first air distribution door and the second air distribution door with a single actuator. 
     In an alternative method embodiment, the method may include the step of providing a first air distribution door to control the flow of the airstream through the first air discharge port, a second air distribution door to control the flow of the airstream through the second air discharge port and a third air distribution door to control flow of the airstream through the third air discharge port. Still further, the method may include the step of controlling displacement of the first air distribution door, the second air distribution door and the third air distribution door with a single actuator. 
     In the following description, there are shown and described several preferred embodiments of the panel and defrost plenum and the related method of routing an airstream past a package restriction. As it should be realized, the panel and defrost plenum and related method are capable of other, different embodiments and their several details are capable of modification in various, obvious aspects all without departing from the panel and defrost plenum and method as set forth and described in the following claims. Accordingly, the drawings and descriptions should be regarded as illustrative in nature and not as restrictive. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING FIGURES 
       The accompanying drawing figures incorporated herein and forming a part of the specification, illustrate several aspects of the panel and defrost plenum and related method and together with the description serve to explain certain principles thereof. 
         FIG. 1  is perspective view of the panel and defrost plenum and a schematic view of the HVAC system and air circulation fan of the HVAC system which delivers conditioned air from the HVAC system to the panel and defrost plenum. 
         FIG. 2  is a schematic block diagram further illustrating the panel and defrost plenum also shown in  FIG. 1 . 
         FIG. 3 a -3 d    are schematic block diagrams of the control systems for four different embodiments of the new and improved panel and defrost plenum. 
     
    
    
     In the embodiment of the panel and defrost plenum illustrated in  FIG. 3 a   , a single controller controlled actuator controls displacement of a first air distribution door and a second air distribution door. 
     In the embodiment of the panel and defrost plenum illustrated in  FIG. 3 b   , a single controller controlled actuator controls displacement of a first air distribution door, a second air distribution door and a third air distribution door. 
     In the embodiment of the panel and defrost plenum illustrated in  FIG. 3 c   , a controller controlled first actuator displaces a first air distribution door and a controller controlled second actuator displaces a second air distribution door. 
     In the embodiment of the panel and defrost plenum illustrated in  FIG. 3 d   , a controller controlled first actuator displaces a first air distribution door, a controller controlled second actuator displaces a second air distribution door and a controller controlled third actuator displaces a third air distribution door. 
     Reference will now be made in detail to the present preferred embodiments of the panel and defrost plenum, as well as the related method of routing an airstream past a package restriction, examples of which are illustrated in the accompanying drawing figures. 
     DETAILED DESCRIPTION 
     Reference is now made to  FIG. 1  illustrating a first embodiment of the panel and defrost plenum  10 . As illustrated, the panel and defrost plenum  10  includes a manifold section  12 , an air feed section  14 , upstream of the manifold section, and a branch section  16  downstream from the manifold section. 
     The air feed section  14  includes an inlet end  18  connected to the conditioned air supply manifold  20  of the HVAC system  22  and an outlet end  24  connected to the inlet port  26  of the manifold section  12 . As shown in  FIG. 1 , the air feed section  14  functions to deliver an airstream past a HUD package restriction  28  (note HUD package  30  in the instrument panel  32 ) to the manifold section  12 . In the illustrated embodiment, the air feed section  14  includes a single lumen for receiving and directing the airstream delivered by the fan  25  of the HVAC system  22 . 
     In the embodiment illustrated in  FIGS. 1 and 2 , the manifold section  12  includes a housing  36  defining the inlet port  26 , a first air discharge port  38 , a second air discharge port  40  and a third air discharge port  42 . A first branch duct  44  extends from the first air discharge port  38  to an outboard panel duct outlet  46 . A second branch duct  48  extends from the second air discharge port  40  to a windshield defrost duct outlet  50 . A third branch duct  52  extends from the third air discharge port  42  to the side window demist duct outlet  54 . 
       FIG. 3 a    illustrates a control system  56  for one possible embodiment of the panel and defrost plenum  10  wherein the manifold section  12  includes a first air distribution door  58 , a second air distribution door  60 , a third air distribution door  62 , a single controller controlled actuator  64  and a controller  66 . 
     In the embodiment illustrated in  FIG. 3 a   , the first air distribution door  58  is configured to control flow of the airstream through the first air discharge port  38  to the outboard panel duct outlet  46 . The second air distribution door  60  is configured to control flow of the airstream through the second air discharge port  40  to the windshield defrost duct outlet  50 . The third air distribution door  62  is configured to control flow of the airstream through the third air discharge port  42  to the side window demist duct outlet  54 . 
     The single controller controlled actuator  64  may comprise any type of actuator known in the art to be suitable for this purpose including, for example, a cam wheel connected by cables or other linkage to the first, second and third air distribution doors,  58 ,  60  and  62  which may be pivoted between opened and closed positions. 
     The controller  66  comprises a computing device such as a dedicated microprocessor or an electronic control unit (ECU) operating in accordance with instructions from appropriate control software. Thus, the controller  66  may comprise one or more processors, one or more memories and one or more network interfaces all in communication with each other over a communication bus. If desired, the controller  66  may comprise the controller for the HVAC system. 
       FIG. 3 b    illustrates a control system  68  for an alternative embodiment of the panel and defrost plenum  10 . In the embodiment illustrated in  FIG. 3 b   , the manifold section  12  includes a first air distribution door  58 , configured to control flow of the airstream through the first air discharge port  38  and the first branch duct  44  to the outboard panel duct outlet  46 , a second air distribution door  60  configured to control flow of the airstream through the second air discharge port  40  and the second branch duct  48  to the windshield defrost duct outlet  50  and a third air distribution door  62  configured to control flow of the airstream through the third air discharge port  42  and the third branch duct  52  into the side window demist duct outlet  54 . 
     The control system  68  of the  FIG. 3 b    embodiment also includes a controller  66 , a controller controlled first actuator  70 , a controller controlled second actuator  72  and a controller controlled third actuator  74 . More specifically, the controller controlled first actuator  70  is configured to selectively displace the first air distribution door  58  between opened and closed positions. The controller controlled second actuator  72  is configured to selectively displace the second air distribution door  60  between opened and closed positions. The controller controlled third actuator  74  is configured to selectively displace the third air distribution door  62  between opened and closed positions. 
       FIG. 3 c    illustrates a control system  76  for a third possible embodiment of the panel and defrost plenum  10  wherein the manifold  12  includes only two air distribution doors: a first air distribution door  58  and a second air distribution door  60 . As illustrated in  FIG. 3 c   , the manifold section  12  also includes a single controller controlled actuator  78  for selectively displacing the first air distribution door  58  and the second air distribution door  60  between opened and closed positions. The controller  66  is configured to control the operation of the actuator  78 . In this embodiment, the first air distribution door  58  is configured to control flow of the airstream through the first air discharge port  38  and first branch duct  44  to the outboard panel duct outlet  46 . The second air distribution door  60  is configured to control flow of the airstream through the second air discharge port  40  to both (a) the second branch duct  48  and the windshield defrost duct outlet  50  and (b) the third branch duct  52  and the side window demist duct outlet  54 . 
     The control system  80  for yet another possible embodiment of the panel and defrost plenum  10  that is illustrated in  FIG. 3 d    is identical to that illustrated in  FIG. 3 c    except that two actuators  82 ,  84  are provided instead of one actuator  78 . More specifically, controller controlled first actuator  82  is configured to displace the first air distribution door  58  while the controller controlled second actuator  84  is configured to displace the second air distribution door  60 . Thus, the controller controlled first actuator  82  may open the first air distribution door  58  to direct the airstream through the first air discharge port  38  and the first branch duct  44  to the outboard panel duct outlet  46 . The controller controlled second actuator  84  is configured to control the flow of the airstream through the second air distribution door  60  and then through the second air discharge port  40  and the second branch duct  48  to the windshield defrost duct outlet  50  and the third branch duct  52  to the side window demist duct outlet  54 . 
     Consistent with the above description, a method is provided for routing an airstream past a package restriction such as HUD package restriction  28 . That method comprises the steps of delivering the airstream through a feed section  14  of the panel and defrost plenum  10  past the HUD package restriction  28  to a manifold section  12  of the panel and defrost plenum and (b) displacing a plurality of air distribution doors  58 ,  60  or  58 ,  60 ,  62  in the manifold section  12  to direct the airstream through a branch section  16  of the panel and defrost plenum, downstream of the manifold section, to a plurality of outlets including the outboard panel duct outlet  46 , the windshield defrost duct outlet  50  and the side window demist duct outlet  54 . 
     Toward this end, the method may include the step of providing the manifold section  12  with a plurality of air discharge ports  38 ,  40  or  38 ,  40 ,  42  connected to the branch section  16 . Thus, in some embodiments the method may include the step of connecting the first air discharge port  38  through a first branch duct  44  to an outboard panel duct outlet  46 . In some embodiments the method may include connecting the second air discharge port  40  through a second branch section duct  48  to the windshield defrost duct outlet  50 . Further, some embodiments may include the step of connecting the third air discharge port  42  through a third branch section duct  52  to a side window demist duct outlet  54 . 
     In some embodiments the method may include providing the first air distribution door  58  to control the flow of the airstream through the first air discharge port  38  and the second air distribution door  60  to control flow of the airstream through the second air discharge port  40  and the third air discharge port  42  (see  FIG. 3 d   ). 
     Further, in some embodiments of the method, the method includes the additional step of controlling displacement of the first air distribution door  58  and the second air distribution door  60  with a single actuator  78  (see  FIG. 3 c   ). 
     In some embodiments, the method includes providing the first air distribution door  58  to control flow of the airstream through the first air discharge port  38 , the second air distribution door  60  to control flow of the airstream through the second air discharge port  40  and the (optional) third air distribution door  62  to control flow of the airstream through the third air discharge port  42 . (See, for example,  FIG. 3 b   .) In still other embodiments, the method may include the step of controlling displacement of the first air distribution door  58 , the second air distribution door  60  and the third air distribution door  62  with a single actuator  64  as illustrated in  FIG. 3   a.    
     The panel and defrost plenum  10  includes a single duct, single lumen  34 , air feed section  14  for delivering an airstream past a package restriction  28  to a manifold section  12  located on the downstream side of the package restriction: that is outboard of the package restriction and oriented in front of the instrument cluster, the steering wheel and the driver. Thus all operating systems of the manifold section  12  including the first, second and third air distribution doors  58 ,  60 ,  62  and all branch ducts  44 ,  48 ,  52  are located downstream and outboard of the package restriction to conserve space and for more effective and efficient operation. 
     The foregoing has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the embodiments to the precise form disclosed. Obvious modifications and variations are possible in light of the above teachings. All such modifications and variations are within the scope of the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled.