Abstract:
A climate control system for a vehicle interior, having a housing, a cooling device, and a heating device. At least one first flow channel, a second flow channel, and a third flow channel are disposed in the housing. A mixing chamber is disposed within the housing, which has at least one outflow opening, which is downstream of the mixing chamber in the flow direction. The flow channels are closable by a flap element, a third flow channel leads from the cooling device to the outflow opening while bypassing the mixing chamber, the flap element in the first flow channel and the flap element in the second flow channel are kinematically coupled and can be adjusted by a mutual control device. The flap element in the third flow channel is kinematically coupled to the other two flap elements or can be adjusted independently by a further control device.

Description:
[0001]    This nonprovisional application claims priority under 35 U.S.C. § 119(a) to German Patent Application No. 10 2014 210 264.2, which was filed in Germany on May 28, 2014, and which is herein incorporated by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates to a climate control system for a vehicle interior, with a housing, a cooling device, and a heating device. 
         [0004]    2. Description of the Background Art 
         [0005]    Climate control systems are used for conditioning the air in vehicle interiors. It is routinely possible to regulate both the amount of air blown into the interior and the temperature of the blown-in air by these systems. Numerous devices, which enable ventilation, heating, or air conditioning, are known for this purpose from the prior art. 
         [0006]    Simple designs of a climate control system envisage providing only one temperature zone, so that there is the same or at least approximately the same temperature in the entire vehicle interior or the vehicle interior is supplied with air that cannot be regulated separately for the different interior areas, however. Only one desired temperature for the entire interior can be specified by the vehicle occupants. Higher-quality climate control systems also offer the possibility of ventilating and tempering a number of zones individually. 
         [0007]    In distributor housings of climate control systems, depending on the number of climate-controlled zones, a different number of flow channels and flap elements is provided for this purpose, which allow individual adjustment of the air amount and temperature for the individual zones. The air in this case is released into the interior over different outflow openings, assigned to the particular zones. 
         [0008]    DE 103 34 500 A1, which corresponds to U.S. Pat. No. 6,772,833, discloses a heating, ventilation, and air conditioning system for the independent supplying of four zones within a vehicle interior. The housing of the climate control system has four outlets for this purpose, whereby each of the tempered zones is assigned an outlet. The system has an evaporator that can be used for cooling the air and a heater core that can be used for heating the air. 
         [0009]    DE 10 2004 033 402 B4, which corresponds to U.S. Pat. No. 7,478,670, discloses a modular system for constructing a 1-to-4-zone climate control system for vehicles. To this end, a plurality of air distribution devices and a plurality of air tempering devices are provided, which are placed within the same housing. 
         [0010]    A disadvantage of the prior art solutions in particular is that the distributor housings used in known climate control systems are adapted specifically to the number of zones to be tempered; this results in a great variety of variants, which is not conducive to the preferred use of interchangeable parts. 
       SUMMARY OF THE INVENTION 
       [0011]    It is therefore an object of the present invention to provide a climate control system, which has a distributor housing that can be used both for a one-zone climate control system and for a multi-zone climate control system. Further, the climate control system should have a structure that is as simple as possible and can be manufactured cost-effectively. In addition, the object of the invention is to provide a method for air tempering via the climate control system. 
         [0012]    In an exemplary embodiment of the invention, provided is a climate control system for a vehicle interior, with a housing, with a cooling device, and with a heating device, whereby at least one first flow channel for a first cold air flow, a second flow channel for a hot air flow, and a third flow channel for a second cold air flow are disposed in the housing, whereby a mixing chamber is disposed within the housing, which can be supplied with the hot air flow and with the first cold air flow, whereby the housing has at least one outflow opening, which is downstream of the mixing chamber in the flow direction, whereby the flow channels in each case are closable by a flap element, whereby the third flow channel leads from the cooling device to the outflow opening while bypassing the mixing chamber, whereby the flap element in the first flow channel and the flap element in the second flow channel are kinematically coupled together and can be adjusted by the same control device and the flap element in the third flow channel is kinematically coupled to the other two flap elements or can be adjusted independently by a further control device. 
         [0013]    The first flow channel can be used to guide an air flow flowing from the cooling device toward a mixing chamber. The first flow channel can be used to guide an air flow flowing from the heating device toward a mixing chamber. The third flow channel guides an air flow flowing from the cooling device past the mixing chamber to an outflow opening of the housing. The third flow channel represents a cold air bypass, which makes it possible to cool in addition the air flowing out of the mixing chamber to the outflow opening, in order to achieve a greatly reduced air temperature at the outflow opening. This is especially advantageous because consequently an especially great cooling of the air can be produced in a simple manner, as a result of which an advantageous tempering of the interior can be achieved. 
         [0014]    The first flap element in the first flow channel and the second flap element in the second flow channel can be coupled together kinematically and thus can be adjusted interdependently. A desired temperature can be produced from the cold air flow and the hot air flow in the mixing chamber by a dependent adjustment of the two flap elements 
         [0015]    The third flap element can be also kinematically coupled to the other two flap elements. The three flap elements in this case can be adjusted by a mutual control device. This is advantageous because only one control device, for example, an electric motor, is necessary for all three flap elements. 
         [0016]    In an embodiment, the third flap element can also be adjusted via a separate, additional control device. This is especially advantageous, because an adjustment decoupled from the other two flap elements is made possible. 
         [0017]    The flap element of the third flow channel can be kinematically coupled to the flap element of the first flow channel and to the flap element of the second flow channel, and the three flap elements can be adjusted by a mutual control device. 
         [0018]    Such a coupling of flap elements is especially advantageous for a one-zone climate control system, which produces only one defined temperature level at the outflow opening or outflow openings. Different scenarios can be realizing depending on the kinematic systems used for coupling the flap elements, whereby the individual flap elements in the different scenarios have different opening degrees, as a result of which the flowing air can be brought to different temperature levels especially advantageously and simply. 
         [0019]    The first flow channel and/or the second flow channel and/or the mixing chamber and/or the outflow opening and/or the third flow channel can be divided into a plurality of zones by one or more separation elements, whereby each flow subchannel of each zone can be closed by a flap element in each case. 
         [0020]    In an embodiment, the otherwise unchanged housing can be divided into a plurality of zones by separation elements mounted in the interior. A multi-zone climate control system can be produced especially simply in this way with retention of the housing of a one-zone climate control system. This is especially advantageous, because the housing can be used as an interchangeable part for a plurality of different climate control systems. Each zone is advantageously assigned at least one first flow subchannel, a second flow subchannel, and a third flow subchannel. The flow subchannels are the areas separated from the original flow channel by the separation elements. The totality of the particular flow subchannels corresponds to the original undivided flow channel with respect to the flow cross section. 
         [0021]    The employed flap elements can be made substantially structurally identical with the flap elements of a one-zone climate control system and be adapted only slightly to the geometry of the produced flow subchannels. This can occur advantageously, for example, by adaptation of the longitudinal extension of the particular flap elements. 
         [0022]    Each zone has one or more outflow openings, each of which opens in a defined area of the vehicle interior and is used for tempering this area. 
         [0023]    It can also be expedient, if the flap element of the first flow subchannel and the flap element of the second flow subchannel of a zone are kinematically coupled together and can be adjusted by a mutual control device, whereby the flap element of the third flow subchannel of a zone can be adjusted by an additional control device independently of the other flap elements. 
         [0024]    A greater variability with respect to the tempering of the air in the individual zones can be achieved by a configuration with a third flap element decoupled kinematically from the first two flap elements. The kinematic coupling between the first flap element and the second flap element can be substantially identical to the design for a one-zone climate control system, in which all three flap elements are kinematically coupled together. This is advantageous in order to increase further the proportion of interchangeable parts between a one-zone and a multi-zone design of the climate control system. 
         [0025]    The cross-sectional area of the first flow subchannels, the second flow subchannels, and/or the third flow subchannels, except for the cross-sectional area occupied by the separation elements, can be identical to the respective cross-sectional area of the flow channels that are not divided by separation elements. 
         [0026]    This is especially advantageous, because the housing for a one-zone and a multi-zone design can be substantially identical. The division into a plurality of zones is achieved by separation elements inserted in the interior. 
         [0027]    An exemplary embodiment provides that the individual positions of the flap elements can be predefined based on a control curve, which predefines the positions of the flap elements as a function of a predefinable target temperature at a specific outflow opening. 
         [0028]    The control curve can be created advantageously by a special kinematic system, which by the use of force transfer and transmissions leads to a predefined adjustment of the individual flap elements in an interdependent manner. In this case, all kinematically connected flap elements are advantageously adjusted by the movement of a single control device according to a scheme predefined by a control curve; as a result, the released cross-sectional area of the individual flow channels is varied and different temperature levels at the outflow openings are produced. The target temperature is advantageously predefined by the desire of an occupant or a control signal from a central control unit and corresponds to an air temperature at a specific outflow opening. 
         [0029]    The kinematic coupling between the first flap element and the second flap element or between the first flap element, the second flap element, and the third flap element can be produced by lever elements and/or joints and/or gears. 
         [0030]    The kinematic coupling by lever elements and/or joints and/or gears such as, for example, a link gear, is advantageous in order to achieve an interaction of the individual flap elements that enables a defined temperature regulation. By adapting the kinematic coupling, an adapting of the adjustment of the flap elements in the case of an otherwise unchanged climate control system can be achieved in a simple way. 
         [0031]    In an embodiment of the invention, it is provided in addition that in a first position of the flap elements, the first flow channel can be completely released by the first flap element, the second flow channel can be completely closed by the second flap element, and the third flow channel can be completely released by the third flap element. Such a position is particularly advantageous to achieve an especially low temperature at the specific outflow opening associated with the flow channels. Such a position of the flap elements is used in particular in the case of a high cooling demand in the vehicle interior. 
         [0032]    In a second position of the flap elements, the first flow channel can be completely closed by the first flap element, the second flow channel can be completely released by the second flap element, and the third flow channel can be completely closed by the third flap element. Such a position is especially advantageous to achieve an especially high temperature at the respective outflow opening associated with the flow channels. Such a position of the flap elements is especially advantageous in the case of a high heating demand. 
         [0033]    In a third position of the flap elements, the first flow channel can be partially released by the first flap element and the second flow channel can be partially released by the second flap element, and the third flow channel can be completely closed by the third flap element. Such a position of the flap elements allows the production of a mixed temperature between the cold air flow from the first flow channel and the hot air flow from the second flow channel. Depending on the temperature level to be achieved, the first flap element and the second flap element can more or less release the respective flow cross sections to achieve a predetermined air temperature in this way. This third position of the flap elements is advantageous for creating a temperature level between the extreme positions of the flap elements in the first position (exceptionally cold air) and in the second position (exceptionally hot air). 
         [0034]    An exemplary embodiment of the invention relates to a method for air tempering by via a climate control system according to the invention, whereby the third flap element can be completely closed until the temperature falls below a defined target temperature of the air at an outflow opening, whereby the third flap element starting when the air at the outflow opening falls below the defined target temperature increasingly releases the third flow channel to the outflow opening and the third flap element completely releases the third flow channel at a defined minimum target temperature of the air at the outflow opening. 
         [0035]    Such a method is especially advantageous, because different temperature levels at the outflow openings can be produced by the method by interdependently adjusting the individual flap elements. This is advantageous particularly in association with a kinematic coupling of the flap elements. 
         [0036]    When the third flow channel is opened, an especially cold air temperature can be achieved with utilization of the cool air flow in the third flow channel. This is accordingly especially advantageous when there is a high cooling demand. By a continuous closing of the third flow channel and by a continuous closing of the first flow channel and a simultaneous continuous opening of the second flow channel, the air temperature at the respective outflow opening can be successively increased until the maximum temperature is achieved. 
         [0037]    Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0038]    The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus, are not limitive of the present invention, and wherein: 
           [0039]      FIG. 1  shows a schematic view of three flap elements, as they are used in the three flow channels, whereby all three flap elements are connected to one another by kinematic coupling and can be adjusted by a mutual control device; 
           [0040]      FIG. 2  shows a schematic view of three flap elements, whereby only two of the three flap elements are kinematically coupled to one another and can be adjusted via a mutual control device, whereas the third flap element can be adjusted by an additional control device independently of the other flap elements; 
           [0041]      FIG. 3  shows a sectional view through a housing of a climate control system, whereby the three flap elements in particular are illustrated in the interior; 
           [0042]      FIG. 4  shows a diagram, which represents the opening and closing of the three flap elements as a function of a temperature level to be achieved; and 
           [0043]      FIG. 5  shows a perspective view of a housing of a climate control system, whereby in particular the area of the housing is indicated that can be used as an interchangeable part for a one-zone and a multi-zone climate control system, as well as an area, connected to the housing in addition for a multi-zone climate control system, to enable the supplying of one or more additional zones. 
       
    
    
     DETAILED DESCRIPTION 
       [0044]      FIG. 1  shows a schematic view of a flap arrangement  1  for a one-zone climate control system. Flap arrangement  1  has a first flap element  2 , which can be used for opening a cold air bypass or for closing this cold air bypass. Flap element  3  is used for opening or for closing a flow channel for cold air. Flap element  4  is used for opening or for closing a flow channel for hot air. 
         [0045]    In the exemplary embodiment of  FIG. 1 , all three flap elements  2  to  4  are connected together via a mutual kinematic system  6 . Kinematic system  6  is formed by a plurality of lever elements  10 , which in  FIG. 1  schematically represent the connection of the individual flap elements  2  to  4 . 
         [0046]    Flap element  2  is rotatable about rotation axis  7 , flap element  3  is rotatable about rotation axis  8 , and flap element  4  is rotatable about rotation axis  9 . The individual flap elements  2  to  4  can be rotated about their respective rotation axes  7  to  9  via a control device  5 , which is connected via a drive axle  11  to kinematic system  6 . 
         [0047]    Each of the individual flap elements  2  to  4  can also be rotated about different angles by a suitable design of kinematic system  6  and lever elements  10 . For this purpose, joints and gears, which correspondingly transmit the angle of twist predefined by control device  5 , such as, for example, link gears, can be provided in particular on lever elements  10 . 
         [0048]    In the exemplary embodiment of  FIG. 1 , all three flap elements  2  to  4  can be adjusted by a control device  5  and thus interdependently connected via kinematic system  6 . 
         [0049]      FIG. 2  shows a perspective view of a flap arrangement  40 , which has three flap elements  41 ,  42 , and  43  and lever elements  17 . Flap elements  41  to  43  are constructed substantially identical to flap elements  1  to  4  of  FIG. 1 . Because flap arrangement  40  is intended for a multi-zone climate control system, the extension of flap elements  41  to  43  in width is shorter than that of flap elements  2  to  4  in  FIG. 1 . This is due to the fact that the flow channels for the different zones in the climate control system, with the same width for the housing, are disposed lying next to one another, as a result of which the width of each individual zone is smaller. 
         [0050]    Flap element  41  can be rotated about rotation axis  13  and is moved by its own control device  12 . The movement of flap element  41  is therefore independent of the movement of flap elements  42  and  43 . 
         [0051]    The two flap elements  42  and  43  are coupled to one another via a kinematic system  16  and can be rotated via a control device  18 . 
         [0052]    Flap element  42  can be rotated about rotation axis  13 , which in the present case also represents the drive axle of control device  12 . Flap element  42  can be rotated about rotation axis  14  and flap element  43  about rotation axis  15 . Similar to the embodiment for  FIG. 1 , in particular kinematic system  16  can be designed in various ways, so that a variable coupling of the two flap elements  42  and  43  is possible. For this purpose, different lever elements, joints, or gears in particular can be provided. 
         [0053]    The flap elements and the employed kinematic systems in the exemplary embodiments of  FIGS. 1 and 2  can be partially similar in construction, so that a large portion of interchangeable parts can be used for different variants of a climate control system. 
         [0054]    Actuators that produce a rotational movement are suitable as control device  5 ,  12 , and  18 . These include, for example, electric motors, as they are already used diversely in climate control systems. Flap elements  2  to  4  and  41  to  43  in  FIGS. 1 and 2  are formed by flap elements known in a variety of ways in the prior art. 
         [0055]      FIG. 3  shows a sectional view through a climate control system  20 . A plurality of housing sections are shown in climate control system  20 , which is formed substantially by housing  27 . The so-called defrost housing section is designated with the reference character  21 ; it has an air outlet opening which can be directed directly onto the panes of the motor vehicle in order to enable defrosting of the panes. Furthermore, the main distributor housing section is designated with the reference character  22 , which can have the outflow opening for the dashboard. A rear distributor housing section is designated with the reference character  23 , which has at least one outflow opening for the back area of the vehicle interior. 
         [0056]    Furthermore, the flap element for cold air bypass  24 , the flap element for cold air  25 , and the flap element for hot air  26  are disposed in housing  27 . The individual flap elements  24 ,  25 , and  26  are each kinematically coupled together according to the embodiment of climate control system  20  in analogy to the principles in  FIGS. 1 and 2 . 
         [0057]    Furthermore, an evaporator and a heating core, which are used respectively for cooling or heating one air flow or a plurality of air flows flowing through housing  27  of climate control system  20 , are arranged in climate control system  20 . 
         [0058]    In particular, the arrangement of the individual elements within housing  27  of climate control system  20  in  FIG. 3  is exemplary and can be varied beyond what is shown in  FIG. 3  within the scope of solutions, routinely used in the prior art for climate control systems and the arrangement of the main components within the climate control systems. 
         [0059]    In particular, the section of housing  27 , which forms rear distributor housing section  23 , can be omitted in a one-zone climate control system, because then no separate air tempering occurs for the rear area of the vehicle interior. The rest of housing  27  is preferably identical for both one-zone climate control systems and multi-zone climate control systems and, for separation into a plurality of zones, is divided in the interior by separation elements. The housing can therefore be used as an interchangeable part, as a result of which the manufacturing costs due to higher quantities can be reduced. In a one-zone climate control system a flap arrangement  1  according to  FIG. 1  is preferably integrated into housing  27 , whereas in a multi-zone climate control system a plurality of flap arrangements  40  according to  FIG. 2  are used. In this regard, a flap arrangement  40  is preferably used per zone within the climate control system. 
         [0060]      FIG. 4  shows a diagram  30 , which illustrates in particular how the individual flap elements of a flap arrangement can be adjusted interdependently in order to produce a defined temperature at an outflow opening. 
         [0061]    In diagram  30 , the x-axis is labeled with reference character  31 , which indicates a predefinable target temperature at a specific outflow opening or in a specific housing area, whereby a minimum cold target temperature is designated by point  36  and a maximum hot target temperature by point  37 . 
         [0062]    Furthermore, diagram  30  has the y-axis  32  on which the opening degrees of the individual flap elements are plotted. In this case, point  38  designates the particular adjusted position of the flap elements in which the associated flow channel is closed, and point  39  an adjusted position of the particular flap elements in which the respectively associated flow channel is completely open. 
         [0063]    The specific position of the flap elements for the cold air bypass is designated with the reference character  33 . The specific position of the flap element of the flow channel for cold air is labeled with the reference character  34  and the position of the flap element for the flow channel for hot air is labeled with the reference character  35 . 
         [0064]    For the case that an especially cold target temperature is predefined, the flap element for cold air bypass  33  and the flap element for cold air  34  are completely open. In contrast, the flap element for hot air  35  is completely closed. With such a setting, only cold air flows through the climate control system to the respective outflow opening. Because of the additionally open cold air bypass  33 , the amount of cold air is increased overall, as a result of which a greater cooling effect can be achieved. A larger flow cross-sectional area is available overall because of opened cold air bypass  33  and the fully opened flap element for cold air  34 , as a result of which better flow properties can be achieved with respect to acoustics as well. 
         [0065]    In another extreme case, which is shown on the right in diagram  30 , both flap element  33  for the cold air bypass and flap element  34  for the cold air are completely closed. In contrast, the flap element for hot air  35  is completely open, so that only hot air flows at the particular outflow opening. 
         [0066]    According to the control curve predefined by diagram  30 , proceeding from an especially cold target temperature the flap element for cold air bypass  33  is steadily closed with a rising specified target temperature, whereas the flap element for cold air  34  and the flap element for hot air  35  remain completely open or closed, respectively. At a time when the flap element for cold air bypass  33  is completely closed, the flap element for hot air  35  is then opened continuously and the flap element for cold air  34  is closed simultaneously. At a point formed by the intersection of the two lines  34  and  35 , the flap elements for cold air  34  and hot air  35  are opened equally wide. Over the further course toward a higher target temperature, the flap element for hot air  35  is opened further, whereas the flap element for cold air  34  is closed further. 
         [0067]    Linear courses for the opening or closing of the individual flap elements are shown in the diagram in  FIG. 4 . In alternative embodiments, nonlinear courses can also be provided, as a result of which a different opening relationship of the individual flow channels to one another can be achieved. In alternative embodiments, courses can also be provided in which the individual flap elements stay in a predefined position before a further adjustment is called for. To this end, in particular the control devices or the kinematic systems between the individual flap elements are to be appropriately adapted in order to achieve a further decoupling or coupling of the adjusting of the individual flap elements. 
         [0068]    Overall, diagram  30  shows a suitable position for the individual flap elements in order to achieve the target temperature for each possible predefinable target temperature at an outflow opening. 
         [0069]      FIG. 5  shows a perspective view of a housing  50  of a climate control system. Housing  50  corresponds to housing  27  shown in  FIG. 3 . Housing  50  can be used with an identical construction for both a one-zone climate control system and a multi-zone climate control system. 
         [0070]    For use for a one-zone climate control system, the flow channels for hot air, for cold air, and for the cold air bypass extend over the entire width of housing  50 . For a multi-zone use, housing  50  is divided in the interior in width by separation elements (not shown), so that in each case two or more flow subchannels, arranged next to one another, arise within the cross-sectional area of flow channels that are not divided in the one-zone design. Advantageously, a division is made into two adjacent zones in particular. In  FIG. 5 , the possible zones are labeled with the reference characters  51  and  52 . 
         [0071]    On the front bottom end region, furthermore, a rear distributor housing section  55  is shown, which is also divided into a zone  53  and a zone  54 . An interior separator can also be used for this purpose. Rear distributor housing section  55  is used to supply air to the rear region of the vehicle interior. Rear distributor housing section  55  can be in fluid communication either with the mixing chambers and flow channels in housing  50  or have its own flow channels for connection to the cooling device and the heating device. 
         [0072]    Rear distributor housing section  55  is optional and is provided only in a multi-zone design. To this end, rear distributor housing section  55  is preferably connected from the outside to housing  50 . 
         [0073]    Housing  50  furthermore has an opening  56  through which, for example, an evaporator as the cooling device or a heating element as the heating device can be pushed into housing  50 . 
         [0074]    The embodiments shown in  FIGS. 1 ,  2 ,  3 , and  5  for the individual flap elements or the housing of the climate control system are exemplary. Likewise, the shown kinematic systems for coupling the individual flap elements are exemplary and are not limiting in nature. In particular, other arrangements and embodiments of the individual elements beyond those shown in  FIGS. 1 ,  2 ,  3 , and  5  are possible, which furthermore fall within the scope of the inventive concept. An exemplary diagram is also shown in  FIG. 4 , which represents a possible and advantageous adjustment of the three flap elements. Variations herefrom are always possible. 
         [0075]    The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are to be included within the scope of the following claims.