CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. provisional application serial number 62/623,216, filed January 29, 2018, which is incorporated herein by reference in its entirety.

BACKGROUND

[0002] HVAC (Heating Ventilation and Air Conditioning) systems are used for climate control of, e.g., internal cabin areas of an automobile. HVAC systems may be configured with an HVAC module having a heat exchanger disposed in a housing. An HVAC distribution system may be operatively connected to the HVAC module. An HVAC system may have one or more airflow paths for allowing air to flow, for example, to, from, and/or within the HVAC module and the HVAC distribution system.

SUMMARY

[0003] An HVAC module for an electric vehicle includes an electric powered heating module having heating elements extending in a cross-car direction in the electric vehicle. Electronic components of the electric powered heating module are separated from a direct path of water. An independent airflow management (1AM) housing is disposed in contact with the electric powered heating module to receive airflow that passes through the electric powered heating module to direct a portion of the airflow independently to driver side ducts and passenger side ducts defined in the HVAC module.

INTRODUCTION

[0004] An aspect disclosed herein is an HVAC module for an electric vehicle, comprising: an electric powered heating module having heating elements extending in a cross-car direction in the electric vehicle wherein the electronic components are separated from a direct path of water; and an independent airflow management (1AM) housing disposed in contact with the electric powered heating module to receive airflow that passes through the electric powered heating module to direct a portion of the airflow independently to driver side ducts and passenger side ducts defined in the HVAC module.

[0005] In an example of this aspect, the 1AM housing has a central wall to separate an 1AM driver side duct from an 1AM passenger side duct. In an example, the 1AM housing defines a driver side intake on an upper portion of the 1AM housing facing the electric powered heating module, wherein the driver side intake spans the 1AM driver side duct and the 1AM passenger side duct, and wherein driver side intake airflow is prevented from flowing into the 1AM passenger side duct by a passenger side front wall of the 1AM passenger side duct and by the central wall. In an example, the 1AM driver side duct has a driver vent outlet defined in an upper face of the 1AM driver side duct to direct at least a portion of airflow from the 1AM driver side duct to a driver vent duct defined in the HVAC module. In an example the 1AM driver side duct has a driver floor outlet defined in a left face of the 1AM driver side duct to direct at least a portion of airflow from the 1AM driver side duct to a driver floor duct defined in the HVAC module. In an example, the 1AM driver side duct has a second row outlet defined in a bottom face of the 1AM driver side duct to direct at least a portion of airflow from the 1AM driver side duct to a second row duct defined in the HVAC module.

[0006] In an example, the 1AM housing defines a passenger side intake on a lower portion of the 1AM housing facing the electric powered heating module, wherein the passenger side intake spans the 1AM passenger side duct and the 1AM driver side duct, wherein passenger side intake airflow is prevented from flowing into the 1AM driver side duct by a driver side front wall of the 1AM driver side duct and by the central wall. In an example, the 1AM passenger side duct has a passenger vent outlet defined in an upper face of the 1AM passenger side duct to direct at least a portion of airflow from the 1AM passenger side duct to a passenger vent duct defined in the HVAC module. In an example, the 1AM passenger side duct has a passenger floor outlet defined in a right face of the 1AM passenger side duct to direct at least a portion of airflow from the 1AM passenger side duct to a passenger floor duct defined in the HVAC module. In an example, the 1AM passenger side duct has a second row outlet defined in a bottom face of the 1AM passenger side duct to direct at least a portion of airflow from the 1AM passenger side duct to a second row duct defined in the HVAC module.

[0007] In an example of this aspect, the heating elements are Positive Temperature Coefficient (PTC) heating elements.

[0008] In an example of this aspect, the electric powered heating module has a mounting flange for attaching the electric powered heating module to an HVAC module housing. In an example, the electric powered heating module has a heating module housing attached to the mounting flange. In an example, the electric powered heating module has electrical connectors disposed on the heating module housing, and wherein the electrical connectors are to receive mating connectors by moving the mating connectors vertically relative to the electrical connectors. In an example, the 1AM housing has a central wall to separate an 1AM driver side duct from an 1AM passenger side duct; the 1AM housing defines a driver side intake on an upper portion of the 1AM housing facing the electric powered heating module; the driver side intake spans the 1AM driver side duct and the 1AM passenger side duct; driver side intake airflow is prevented from flowing into the 1AM passenger side duct by a passenger side front wall of the 1AM passenger side duct and by the central wall; the 1AM housing defines a passenger side intake on a lower portion of the 1AM housing facing the electric powered heating module; the passenger side intake spans the 1AM passenger side duct and the 1AM driver side duct; passenger side intake airflow is prevented from flowing into the 1AM driver side duct by a driver side front wall of the 1AM driver side duct and by the central wall; and the electric powered heating module is to

independently control heat in the driver side intake airflow and the passenger side intake airflow. [0009] It is to be understood that any features of the aspect of the HVAC module disclosed herein may be combined together in any desirable manner and/or configuration.

[0010] Further, it is to be understood that any combination of features of the HVAC module may be used and/or combined together in any desirable manner, and/or may be used and/or combined with any of the examples disclosed herein.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Features of examples of the present disclosure will become apparent by reference to the following detailed description and drawings, in which like reference numerals correspond to the same or similar, though perhaps not identical,

components. For the sake of brevity, reference numerals or features having a previously described function may or may not be described in connection with other drawings in which they appear.

[0012] Fig. 1 is a three-dimensional graph/representation depicting a vehicle coordinate system for use with the present disclosure;

[0013] Fig. 2 is a semi-schematic front perspective drawing of an independent airflow management (IAM) housing according to an example of the present disclosure;

[0014] Fig. 3 is a semi-schematic rear perspective drawing of the IAM housing depicted in Fig. 2 according to an example of the present disclosure;

[0015] Fig. 4 is a semi-schematic right side cross-sectional view taken along line 4- 4 through the driver side of the IAM housing of Fig. 2 shown in an HVAC module according to an example of the present disclosure;

[0016] Fig. 5 is a detailed semi-schematic right side cross-sectional view taken along line 5-5 through the driver side of the IAM housing of Fig. 2 shown in an HVAC module according to an example of the present disclosure;

[0017] Fig. 6 is a semi-schematic right side cross-sectional view taken along line 6- 6 through the passenger side of the IAM housing of Fig. 2 shown in an HVAC module according to an example of the present disclosure; [0018] Fig. 7 is a detailed semi-schematic right side cross-sectional view taken along line 7-7 through the passenger side of the IAM housing of Fig. 2 shown in an FIVAC module according to an example of the present disclosure;

[0019] Fig. 8 is a semi-schematic rear perspective view of the electric heating module, and the IAM housing from Fig. 2 shown with the cross-section from Fig. 5 superimposed on the electric heating module and the IAM housing according to an example of the present disclosure; and

[0020] Fig. 9 is a semi-schematic front perspective view of the electric heating module, and the IAM housing from Fig. 2 shown with the cross-section from Fig. 5 superimposed on the electric heating module and the IAM housing according to an example of the present disclosure.

DETAILED DESCRIPTION

[0021] In examples of the present disclosure, an HVAC module 10 (Fig. 4) for an electric vehicle 20 (Fig. 1 ) includes an electric powered heating module 30 (Fig. 8) and an independent airflow management (IAM) housing 40 (Fig. 2). As used herein, an electric vehicle may be any vehicle that uses electric power, at least in part, to move the vehicle. Examples of electric vehicles as contemplated herein include battery electric hybrid automobiles, plug-in electric automobiles, solar powered automobiles and fuel cell powered automobiles. The vehicle may have a gasoline or diesel engine as long as at least some electric power is capable of moving the vehicle for at least a portion of the useful life of the vehicle 20. The HVAC module 10 may have a heater core 34 that uses engine coolant/water as a heat exchange medium. The heater core 34 may be in addition to the electric powered heating module 30, or combined with the electric powered heating module 30. In some examples of the present disclosure, there may be no engine coolant/water type heater core.

[0022] In examples of the present disclosure, the electric powered heating module 30 has heating elements 32 extending in a cross-car direction in the electric vehicle 20. As used herein,“cross-car” direction mean a direction parallel to the Y-axis shown in the coordinate system depicted in Fig. 1. The electronic components are separated from a direct path of water. The independent airflow management (1AM) housing 40 is disposed in contact with the electric powered heating module 30 to receive airflow that passes through the electric powered heating module 30 to direct a portion of the airflow independently to driver side ducts and passenger side ducts defined in the HVAC module 10.

[0023] As used herein,“driver side” means the left side, also called the -Y side of the vehicle using the coordinate system depicted in Fig. 1. Also, as used herein, “passenger side” means the right side, also called the +Y side of the vehicle using the coordinate system depicted in Fig. 1. It is to be understood that the present disclosure is not limited to vehicles that have a driver onboard the vehicle. It is to be further understood that the present disclosure is not limited to vehicles with driver controls on the left side of the vehicle. The present disclosure also includes mirror images of what is expressly described herein.

[0024] In examples, the electric powered heating module 30 may include Positive Temperature Coefficient (PTC) heating elements 32. PTC heating elements use positive temperature coefficient materials. Positive temperature coefficient materials exhibit a positive resistance change in response to an increase in temperature. As the temperature increases, the electrical resistance of the material also increases; thereby limiting current flow through the element.

[0025] PTC heaters draw full power when energized with electric current to quickly reach a target temperature. As the heat increases, the power consumption of the PTC heater simultaneously drops. In examples of the present disclosure, the electric powered heating module 30 may have heating elements 32 in zones that are independently controllable to give independently controllable heat for each zone of the IAM housing 40. An IAM driver side duct 44 and an IAM passenger side duct 46 are examples of zones in an IAM housing 40 that can have independently controllable heat from PTC heating elements.

[0026] In examples of the present disclosure, the IAM housing 40 has a central wall 42 to separate an IAM driver side duct 44 from an IAM passenger side duct 46. The IAM housing 40 defines a driver side intake 50 on an upper portion 48 of the IAM housing 40 facing the electric powered heating module 30. The driver side intake 50 spans the 1AM driver side duct 44 and the 1AM passenger side duct 46. Driver side intake airflow is prevented from flowing into the 1AM passenger side duct 46 by a passenger side front wall 52 of the 1AM passenger side duct 46 and by the central wall 42.

[0027] The 1AM driver side duct 44 may have a driver vent outlet 54 defined in an upper face 56’ of the 1AM driver side duct 44 to direct at least a portion of airflow from the 1AM driver side duct 44 to a driver vent duct defined in the HVAC module 10. The IAM driver side duct 44 may have a driver floor outlet 60 defined in a left face 62 of the IAM driver side duct 44 to direct at least a portion of airflow from the IAM driver side duct 44 to a driver floor duct defined in the HVAC module 10.

[0028] In examples of the present disclosure, the IAM driver side duct 44 may have a second row outlet 66 defined in a bottom face 68’ of the IAM driver side duct 44 to direct at least a portion of airflow from the IAM driver side duct 44 to a second row duct defined in the HVAC module 10.

[0029] The IAM housing 40 may define a passenger side intake 72 on a lower portion 76 of the IAM housing 40 facing the electric powered heating module 30. The passenger side intake 72 spans the IAM passenger side duct 46 and the IAM driver side duct 44. Passenger side intake airflow is prevented from flowing into the IAM driver side duct 44 by a driver side front wall 52’ of the IAM driver side duct 44 and by the central wall 42.

[0030] In examples of the present disclosure, the IAM passenger side duct 46 may have a passenger vent outlet 78 defined in an upper face 56 of the IAM passenger side duct 46 to direct at least a portion of airflow from the IAM passenger side duct 46 to a passenger vent duct defined in the HVAC module 10. The IAM passenger side duct 46 may have a passenger floor outlet 82 defined in a right face 84 of the IAM passenger side duct 46 to direct at least a portion of airflow from the IAM passenger side duct 46 to a passenger floor duct defined in the HVAC module 10.

[0031] The IAM passenger side duct 46 may have a second row outlet 66 defined in a bottom face 68 of the IAM passenger side duct 46 to direct at least a portion of airflow from the 1AM passenger side duct 46 to a second row duct defined in the HVAC module 10.

[0032] As depicted in Fig. 8, in examples of the present disclosure, the electric powered heating module 30 may have a mounting flange 88 for attaching the electric powered heating module 30 to an HVAC module housing 90. The electric powered heating module 30 hay have a heating module housing 92 attached to the mounting flange 88. The electric powered heating module 30 may have electrical connectors 94 disposed on the heating module housing 92. The electrical connectors 94 may be to receive mating connectors (not shown) by moving the mating connectors vertically relative to the electrical connectors 94.

[0033] Referring now to Fig. 2, in examples of the present disclosure, the IAM housing 40 may have a central wall 42 to separate an IAM driver side duct 44 from an IAM passenger side duct 46. The IAM housing 40 may define a driver side intake 50 on an upper portion 48 of the IAM housing 40 facing the electric powered heating module 30. The driver side intake 50 may span the IAM driver side duct 44 and the IAM passenger side duct 46.

[0034] Driver side intake airflow 51 may be prevented from flowing into the IAM passenger side duct 46 by a passenger side front wall 52 of the IAM passenger side duct 46 and by the central wall 42. The IAM housing 40 may define a passenger side intake 72 on a lower portion 76 of the IAM housing 40 facing the electric powered heating module 30. The passenger side intake 72 may span the IAM passenger side duct 46 and the IAM driver side duct 44.

[0035] In examples of the present disclosure, passenger side intake airflow may be prevented from flowing into the IAM driver side duct 44 by a driver side front wall 52’ of the IAM driver side duct 44 and by the central wall 42. The electric powered heating module 30 may be to independently control heat in the driver side intake airflow and the passenger side intake airflow.

[0036] It is to be understood that when“about” is utilized to describe a value, this is meant to encompass minor variations (up to +/- 10%) from the stated value. [0037] Reference throughout the specification to“one example”,“another example”, “an example”, and so forth, means that a particular element (e.g., feature, structure, and/or characteristic) described in connection with the example is included in at least one example described herein, and may or may not be present in other examples. In addition, it is to be understood that the described elements for any example may be combined in any suitable manner in the various examples unless the context clearly dictates otherwise.

[0038] In describing and claiming the examples disclosed herein, the singular forms “a”,“an”, and“the” include plural referents unless the context clearly dictates

otherwise.

[0039] The terms“connect/connected/connection”,“attach/attached/a ttachment” and/or the like are broadly defined herein to encompass a variety of divergent connected arrangements and assembly techniques. These arrangements and techniques include, but are not limited to (1 ) the direct communication between one component and another component with no intervening components therebetween; and (2) the communication of one component and another component with one or more components therebetween, provided that the one component being“connected to” or“attached to” the other component is somehow in communication with the other component (notwithstanding the presence of one or more additional components therebetween). Additionally, two components may be permanently, semi-permanently, or releasably engaged with and/or connected to one another.

[0040] It is to be further understood that“communication” is to be construed to include all forms of communication, including direct and indirect communication.

Indirect communication may include communication between two components with additional component(s) located therebetween.

[0041] While several examples have been described in detail, it is to be understood that the disclosed examples may be modified. Therefore, the foregoing description is to be considered non-limiting.