Abstract:
An air/water separator drain assembly is provided in a vehicle. The assembly includes a first opening (HVAC intake) beneath a cowl through which air proceeds for use in an environmental control system of the vehicle. A second opening or main drain opening is provided for draining water from the cowl in a first direction. A channel is disposed adjacent the drain opening for collecting water from the cowl. Auxiliary openings in the channel are smaller than the drain opening for removing water from the channel and from adjacent the drain opening.

Description:
BACKGROUND 
       [0001]    The present disclosure relates to a cowl design, and more particularly a cowl that directs water flow to drain holes around a main drain opening. 
         [0002]    In prior designs, the cowl top usually has vent openings that can potentially become clogged, for example with snow or leaves. A problem may arise with water drainage. In addition, the snow or leaves may also impact an airflow path through the vent openings in the cowl to an HVAC intake opening situated under the cowl. As a result of melting snow and under normal circumstances, water drains out of the main drain opening or hole without issue. However, the region around the drain opening in the cowl will fill with water, for example from melting snow, and if a main air pathway is blocked by snow when the HVAC blower is powered on, vacuum pressure exerted by the HVAC blower will draw or pull air through the main drain opening and toward the HVAC intake. The air velocity through the main drain opening is strong enough to pick up water droplets from the drain opening and the surrounding area, and carry the water droplets into the HVAC intake. The airflow directed through the drain opening in the opposite direction as water passing through the drain opening is also strong enough to prohibit water from draining therethrough. 
         [0003]    In prior designs, the drain opening is often located inside or adjacent a fender area of the automotive vehicle and the spacing relative to the HVAC intake is sufficient such that the potential for moisture entering the HVAC intake from the drain opening is not a problem. However, newer designs locate the drain openings more closely adjacent the HVAC intake. 
         [0004]    Accordingly, a solution is required to address situations, such as the cowl becoming blocked and the normal air path to the HVAC being blocked, where air enters through the drain opening at a high velocity, and thereby forces water to stay in the dash upper and eventually enters into the HVAC unit through the HVAC intake beneath the cowl. 
       SUMMARY 
       [0005]    An air/water separator drain assembly is a vehicle includes an HVAC intake opening beneath an associated cowl through which air proceeds for use in the associated vehicle. A drain opening drains water from the cowl in a first direction, and a channel adjacent the drain opening for collecting water from the cowl. At least one auxiliary opening in the channel is smaller than the drain opening for removing water from the channel and from adjacent the drain opening. 
         [0006]    The assembly further includes plural auxiliary openings and each of the auxiliary openings is smaller than the drain opening. 
         [0007]    The auxiliary opening is located along a periphery of the drain opening. 
         [0008]    The auxiliary opening is dimensioned so that water collecting over the auxiliary opening overcomes the force of air in a second direction opposite the first direction when air flow to the HVAC intake opening is blocked. 
         [0009]    The channel has a depth that cooperates with the dimension of the auxiliary opening to assure drainage of water therethrough and thereby limit a potential for moisture to enter the HVAC intake opening. 
         [0010]    A method of separating air and water beneath a cowl includes providing an intake of a HVAC system beneath the cowl, providing a drain opening that serves a dual purpose of (i) draining water from a region of the cowl and (ii) forming part of a secondary airflow path when a primary airflow path to the HVAC intake is at least partially blocked, and providing at least one auxiliary opening adjacent the drain opening that allows water to drain from the cowl region when the primary airflow path to the HVAC intake is at least partially blocked and the drain opening is used as part of the secondary airflow path. 
         [0011]    The drain opening drains water from the cowl region in a first direction and forms part of the secondary airflow path in an opposite, second direction. 
         [0012]    The method further includes sizing the at least one auxiliary opening to avoid water buildup around the drain opening. 
         [0013]    The sizing step includes forming an area of the auxiliary openings and/or depth of a channel that receives the auxiliary opening to overcome a force resulting from airflow in the direction of the secondary airflow path when the primary airflow path is at least partially blocked. 
         [0014]    The method includes positioning a blocker in the secondary airflow path between the drain opening and the HVAC intake. 
         [0015]    The method includes forming a groove at least partially around the drain opening for water to avoid the drain opening and communicating with auxiliary openings located in the groove. 
         [0016]    A primary benefit is the ability to effectively drain water from beneath a cowl and preventing moisture entrainment into the HVAC intake under selected circumstances. 
         [0017]    Another advantage relates to handling water when material such as snow, leaves, etc. impact a primary air flow path. 
         [0018]    Other benefits and advantages of the present disclosure will become more apparent from reading and understanding the following detailed description. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0019]      FIG. 1  is a perspective view of an automotive vehicle, and particularly detailing the cowl region between the hood and windshield. 
           [0020]      FIG. 2  is a perspective view of the support structure of the cowl region in the encircled region from  FIG. 1 . 
           [0021]      FIG. 3  is an enlarged perspective view showing the subject cowl air/water separator drain arrangement. 
           [0022]      FIG. 4  is an enlarged perspective view taken generally in the direction of reference arrows  4 - 4  of  FIG. 3 . 
           [0023]      FIG. 5  is a perspective view of the different airflow and water pathways beneath the cowl. 
           [0024]      FIG. 6  is an enlarged perspective view of the cowl air/water separator drain. 
           [0025]      FIG. 7  is a schematic representation of the prior problem. 
           [0026]      FIG. 8  is a cross-sectional view taken generally along the lines  8 - 8  of  FIG. 7 . 
           [0027]      FIG. 9  is a schematic representation of the solution to the prior problem provided by the cowl air/water separator drain. 
           [0028]      FIG. 10  is a cross-sectional view taken generally along the lines  10 - 10  of  FIG. 9 . 
           [0029]      FIG. 11  is a top, plan view of another embodiment of a cowl air/water separator drain. 
           [0030]      FIG. 12  is a cross-sectional view taken generally along the lines  12 - 12  of  FIG. 11 . 
       
    
    
     DETAILED DESCRIPTION 
       [0031]    Turning to  FIG. 1 , there is shown a portion of an automotive vehicle  100  and more specifically, hood  102 , windshield  104 , and an interconnecting region or cowl  106 . An underlying cowl support structure  110  beneath the hood  102  in encircled region  108  adjacent the windshield  104  is more particularly illustrated in  FIGS. 2-5 . As will be appreciated and understood by one skilled in the art, other components receive about the security been removed for ease of illustration. Generally speaking, the encircled region  108  in  FIG. 2  is beneath the cowl  106  and adjacent a fender in a rear corner of the hood  102 . The cowl support structure  110  includes an opening  120  were and HVAC intake is mounted. Thus, with the cowl  106  removed from  FIG. 2 , it is apparent that the HVAC intake opening  120  is positioned adjacent a drain opening  130 . 
         [0032]    In prior arrangements illustrated in  FIGS. 3 and 4 , an enlarged drain opening  140  was provided for removing water from this region of the vehicle. If snow or leaves, for example, collected in the cowl  106  and blocked a primary airflow path to the HVAC intake opening  120 , water headed outwardly through the drain opening  140  could reverse its course and become water droplets  142  when the HVAC blower was turned on are actuated. Airflow represented schematically by reference arrows  144  in  FIGS. 3 and 4 , would be drawn through the drain opening  140 , contact water intending to pass downwardly through the drain opening and become water droplets  142  that could be drawn into the HVAC intake  120 . Snow clogged the cowl top and as the snow melted, the water would flow toward the side drain openings  140 . Alternatively, leaves could also clog the cowl top and rainwater would pass through or under the leaves and flow toward the drain opening  140 . Because the cowl top is blocked, air  144  enters upwardly through the drain openings  140  ( FIGS. 3 and 4 ) at a high velocity thereby forcing the water droplets  142  to stay in the dash upper and eventually flow into the HVAC intake opening  120 . 
         [0033]      FIGS. 5-10  illustrates one embodiment that resolves this problem. Specifically, the first war enlarged drain opening  130  is maintained. In addition, at least one and perhaps multiple auxiliary or second opening(s)  150  is(are) provided adjacent the drain opening  130 . The auxiliary openings  150  are preferably smaller in size than the main drain opening  130 . Under the scenario described above were snow (SN in  FIG. 7 ) and/or leaves clogged the primary airflow path to the HVAC intake  120 , water will collect in a channel or groove  152  disposed adjacent to the main drain opening  130 . The channel  152  collects the water and the smaller, auxiliary openings  150  are provided in a lower region of the channel. The auxiliary openings  150  are also subjected to the airflow  144  when the HVAC blower is turned on. However, the smaller dimension of the auxiliary openings  150  provides a cohesive effect that requires an increased separation force for the water to be dislodged from the smaller openings. As water collects in the channel  152 , an increased head (downward force) develops over the auxiliary openings  150 . This allows the water to continue to drain through the auxiliary openings  150 —either intermittently or continuously—until such time as the water is drained completely from the channel  152  via the auxiliary openings or the upward airflow through the auxiliary openings temporarily prevents further water drainage until more water collects in the channel. 
         [0034]    It is also contemplated that a physical barrier or wall  170  be interposed between the drain opening  130  and the HVAC intake opening  120 . As particularly illustrated in  FIGS. 5-7 , the wall  170  at least partially extends into a secondary airflow path established between the drain opening  130  and the HVAC intake when snow/leaves clog the primary airflow path. As represented by reference numeral  144  in  FIGS. 6-7 , air flows through the drain opening  130  in the opposite direction of water flow when a clog or obstruction occurs as described above. Without the auxiliary openings  150 , water droplets could develop and be carried by or entrained in the airflow  144 . There is also the possibility that water around the drain opening  130  could still become entrained in the airflow when auxiliary openings  150  are provided. The water droplets would fall out if the airflow  144  contacts wall  170 , or the wall at least makes it more difficult for the water droplets to remain suspended in the secondary airflow path directed toward the HVAC intake opening  120 . 
         [0035]    While the embodiment of  FIGS. 5-10  situated the auxiliary openings  150  adjacent and off to one side of the main drain opening  130 , it is also recognized that other patterns could be used with equal success. For example, the embodiment of  FIGS. 11 and 12  provides a greater number of auxiliary openings  150 ′ in the channel  152 ′. Here, the auxiliary openings  150 ′ are still disposed adjacent the drain opening  130  and preferably extend around the entire perimeter of the drain opening. 
         [0036]    By creating a channel adjacent the drain hole with one or more auxiliary openings, water flows into the channel, accumulates until the weight of the water exceeds the force that air puts on it through the openings on its path toward the HVAC intake. When a sufficient force or head of water builds over the auxiliary openings, the water either streams out, or intermittently flows from the channel, and the process repeats itself until all of the water is drained from the cowl region under the circumstances. The auxiliary openings provide an effective countermeasure for removing the water that collects from the cowl if snow or leaves clog the arrangement. The the channel disposed adjacent to the drain hole with auxiliary openings formed therein allows the water to effectively accumulate until the weight of the water exceeds the force of the air puts on the auxiliary openings. Water can then stream continuously or intermittently and the process repeated until all the water is drained. The barrier or wall may also be used to limit turbulent water droplets from entering the HVAC intake. It&#39;ll be understood that the depth and shape of the channel must be large enough to hold an amount of water weight to overcome the air force pushing upwardly on the auxiliary drain openings. The cross-sectional area of the auxiliary openings varies with the amount of water weight (volume) and force of the airflow. The force of the airflow through the main drain varies proportionally with the blockage bond the main air intake for the HVAC system. Correlation is made between the area of the auxiliary drain openings relative to the main drain opening. The depth and shape of the channel must be large enough to hold an amount of water with a quick enough drain rate through the auxiliary openings to avoid water buildup around the main drain opening. If water does not drain from the auxiliary openings of the channel quickly enough, a wall of water could potentially build up around the main drain opening the velocity air pickup water droplets. Thus appropriately sizing the auxiliary drain openings to avoid water buildup around the mean drain opening is required. The area of the auxiliary openings with the waterway above them must be sized to overcome the force of the air pushing upwardly. 
         [0037]    This written description uses examples to describe the disclosure, including the best mode, and also to enable any person skilled in the art to make and use the disclosure. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims. Moreover, this disclosure is intended to seek protection for a combination of components and/or steps and a combination of claims as originally presented for examination, as well as seek potential protection for other combinations of components and/or steps and combinations of claims during prosecution.