CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. provisional application serial number 62/644,880, filed March 19, 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 unit having a heat exchanger disposed in a housing. An HVAC distribution system may be operatively connected to the HVAC unit. An HVAC system may have one or more airflow paths for allowing air to flow, for example, to, from, and/or within the HVAC unit and the HVAC distribution system. Doors may be associated with the airflow path for controlling the amount of air flowing to, through, and/or from the HVAC unit and/or the HVAC distribution system.

SUMMARY

[0003] An HVAC module for a vehicle includes a housing. A shaft end is connected to a shaft for connection to a complementary actuator for adjusting a rotational position of the shaft to thereby adjust a position of an airflow control door in the housing. The shaft end defines an actuation axis. An externally threaded boss, coaxial with the shaft end, is defined on an exterior surface of the housing. A rotation stop post projects from the housing to engage a catch defined by the complementary actuator. The housing is to retain the complementary actuator by threading engagement with the externally threaded boss and by engagement between the rotation stop post and the catch to selectably prevent rotation of a shell of the complementary actuator about the actuation axis. The complementary actuator is interchangeably an electrically powered rotary actuator and a manually operable rotary actuator.

INTRODUCTION

[0004] A first aspect disclosed herein is an HVAC module for a vehicle, comprising: a housing; a shaft end connected to a shaft for connection to a complementary actuator for adjusting a rotational position of the shaft to thereby adjust a position of an airflow control door in the housing, the shaft end defining an actuation axis; an externally threaded boss defined on an exterior surface of the housing, the externally threaded boss coaxial with the shaft end; and a rotation stop post, projecting from the housing to engage a catch defined by the complementary actuator; wherein the housing is to retain the complementary actuator by threading engagement with the externally threaded boss and by engagement between the rotation stop post and the catch to selectably prevent rotation of a shell of the complementary actuator about the actuation axis, wherein the complementary actuator is interchangeably an electrically powered rotary actuator and a manually operable rotary actuator.

[0005] In a first example of this first aspect, the shaft end includes a first torque coupling member rotatably located at a wall of the housing; the first torque coupling member is rotatable about the actuation axis from a first angular position to a second angular position; and the complementary actuator includes a second torque coupling member to couple with the first torque coupling member for rotation therewith.

[0006] In a further example of the first example of this first aspect, the first torque coupling member is a hub, attached to the shaft for rotation therewith; the hub includes a male portion protruding through the wall of the housing, the male portion defining a polygonal frustum circumscribing the actuation axis; and the second torque coupling member includes a female portion, complementary to the male portion, to receive the male portion and rotate therewith.

[0007] In a further example of the first example of this first aspect, the polygonal frustum is keyed to engage the second torque coupling member at a predetermined position of the airflow control door relative to an actuator angle of the complementary actuator and to block engagement of the second torque coupling member when an unaligned position of the airflow control door relative to the actuator angle is not the predetermined position of the airflow control door relative to the actuator angle of the complementary actuator.

[0008] In a further example of the first example of this first aspect, the shaft end includes a first radial stop vane and a second radial stop vane; the housing defines a first stop tab projecting toward the actuation axis from the externally threaded boss; the housing defines a second stop tab projecting toward the actuation axis from the externally threaded boss; the first radial stop vane abuts the first stop tab when the first torque coupling member is at the first angular position, thereby preventing rotation of the shaft end beyond the first angular position in a first rotational direction; and the second radial stop vane abuts the second stop tab when the first torque coupling member is at the second angular position, thereby preventing rotation of the shaft end beyond the second angular position in a second rotational direction opposite the first rotational direction.

[0009] In a second example of this first aspect, the HVAC module further comprises: a first boss defined on the exterior surface of the housing; and a second boss defined on the exterior surface of the housing, wherein: the first boss defines a first boss aperture defining a first boss axis at a first center of the first boss aperture; the first boss aperture is to threadingly receive a threaded fastener; the second boss defines a second boss aperture defining a second boss axis at a second center of the second boss aperture; the second center of the second boss aperture is spaced apart from the first center of the first boss aperture; the second boss aperture is to threadingly receive the threaded fastener; and the complementary actuator is one of: the electrically powered rotary actuator having a first flange with a first flange aperture defined in the first flange, the first flange aperture being coaxial with the first boss aperture when the complementary actuator is in a first installed position on the housing, the threaded fastener to be installed through the first flange aperture into the first boss aperture; and the manually operable rotary actuator having a second flange with a second flange aperture defined in the second flange, the second flange aperture being coaxial with the second boss aperture when the complementary actuator is in a second installed position on the housing, the threaded fastener to be installed through the second flange aperture into the second boss aperture.

[0010] In a third example of this first aspect, the manually operable rotary actuator is selected from the group consisting of a pull-pull manually operable rotary actuator and a push-pull manually operable rotary actuator.

[0011] It is to be understood that any features of the HVAC module for a vehicle disclosed herein may be combined together in any desirable manner and/or configuration.

[0012] A second aspect disclosed herein is an HVAC system for a vehicle, comprising: an HVAC module including: a housing to contain a heater core and to direct airflow in an interior of the housing; an airflow control door having a shaft to adjust a position of the airflow control door in the housing; a shaft end connected to the shaft, the shaft end defining an actuation axis; an externally threaded boss defined on an exterior surface of the housing, the externally threaded boss coaxial with the shaft end; and a rotation stop post, projecting from the housing; and a complementary actuator for adjusting a rotational position of the shaft to thereby adjust the position of the airflow control door in the housing, the complementary actuator having a catch defined thereon, the catch to be engaged by the rotation stop post; wherein the housing retains the complementary actuator by threading engagement with the externally threaded boss and by engagement between the rotation stop post and the catch to selectably prevent rotation of the complementary actuator about the actuation axis.

[0013] In a first example of this second aspect, the complementary actuator is selected from the group consisting of an electrically powered rotary actuator and a manually operable rotary actuator.

[0014] In a second example of this second aspect, the complementary actuator is interchangeably an electrically powered rotary actuator and a manually operable rotary actuator. [0015] In a third example of this second aspect, the shaft end includes a first torque coupling member rotatably located at a wall of the housing; the first torque coupling member is rotatable about the actuation axis from a first angular position to a second angular position; and the complementary actuator includes a second torque coupling member to couple with the first torque coupling member for rotation therewith.

[0016] In a further example of the third example of the second aspect, the first torque coupling member is a hub, attached to the shaft for rotation therewith; the hub includes a male portion protruding through the wall of the housing, the male portion defining a polygonal frustum circumscribing the actuation axis; and the second torque coupling member includes a female portion, complementary to the male portion, to receive the male portion and rotate therewith.

[0017] In a further example of the third example of this second aspect, the polygonal frustum is keyed to engage the second torque coupling member at a predetermined position of the airflow control door relative to an actuator angle of the complementary actuator and to block engagement of the second torque coupling member when an unaligned position of the airflow control door relative to the actuator angle is not the predetermined position of the airflow control door relative to the actuator angle of the complementary actuator.

[0018] In a further example of the third example of this second aspect: the shaft end includes a first radial stop vane and a second radial stop vane; the housing defines a first stop tab projecting toward the actuation axis from the externally threaded boss; the housing defines a second stop tab projecting toward the actuation axis from the externally threaded boss; the first radial stop vane abuts the first stop tab when the first torque coupling member is at the first angular position, thereby preventing rotation of the shaft end beyond the first angular position in a first rotational direction; and the second radial stop vane abuts the second stop tab when the first torque coupling member is at the second angular position, thereby preventing rotation of the shaft end beyond the second angular position in a second rotational direction opposite the first rotational direction. [0019] In a fourth example of this second aspect, the HVAC system further comprises: a first boss defined on the exterior surface of the housing; a first boss aperture defined by the first boss, the first boss aperture to threadingly receive a threaded fastener; a first boss axis located at a first center of the first boss aperture; a second boss defined on the exterior surface of the housing; a second boss aperture defined by the second boss, the second boss aperture to threadingly receive the threaded fastener; a second boss axis located at a second center of the second boss aperture, the second center of the second boss aperture spaced apart from the first center of the first boss aperture; and the complementary actuator, wherein the complementary actuator is one of: an electrically powered rotary actuator having a first flange with a first flange aperture defined in the first flange, the first flange aperture being coaxial with the first boss aperture when the complementary actuator is in a first installed position on the housing, the threaded fastener to be installed through the first flange aperture into the first boss aperture; and a manually operable rotary actuator having a second flange with a second flange aperture defined in the second flange, the second flange aperture being coaxial with the second boss aperture when the complementary actuator is in a second installed position on the housing, the threaded fastener to be installed through the second flange aperture into the second boss aperture.

[0020] In a further example of the first example of this second aspect, the manually operable rotary actuator is selected from the group consisting of a pull-pull manually operable rotary actuator and a push-pull manually operable rotary actuator.

[0021] In a further example of the second example of this second aspect, the manually operable rotary actuator is selected from the group consisting of a pull-pull manually operable rotary actuator and a push-pull manually operable rotary actuator.

[0022] It is to be understood that any features of the HVAC system for a vehicle disclosed herein may be combined together in any desirable manner and/or configuration.

[0023] A third aspect disclosed herein is an HVAC module for a vehicle,

comprising: a housing; a shaft end connected to a shaft for connection to a complementary actuator for adjusting a rotational position of the shaft to thereby adjust a position of an airflow control door in the housing, the shaft end defining an actuation axis; an externally threaded boss defined on an exterior surface of the housing, the externally threaded boss coaxial with the shaft end; and a rotation stop post, projecting from the housing to engage a catch defined by the complementary actuator; wherein the housing is to retain the complementary actuator by threading engagement with the externally threaded boss and by engagement between the rotation stop post and the catch to selectably prevent rotation of a shell of the complementary actuator about the actuation axis, wherein the complementary actuator is interchangeably an electrically powered rotary actuator and a pull-pull manually operable rotary actuator.

[0024] In a first example of this third aspect, the shaft end includes a first torque coupling member rotatably located at a wall of the housing; the first torque coupling member is rotatable about the actuation axis from a first angular position to a second angular position; and the complementary actuator includes a second torque coupling member to couple with the first torque coupling member for rotation therewith.

[0025] In a further example of the first example of this third aspect, the first torque coupling member is a hub, attached to the shaft for rotation therewith; the hub includes a male portion protruding through the wall of the housing, the male portion defining a polygonal frustum circumscribing the actuation axis; and the second torque coupling member includes a female portion, complementary to the male portion, to receive the male portion and rotate therewith.

[0026] In a further example of the first example of this third aspect, the polygonal frustum is keyed to engage the second torque coupling member at a predetermined position of the airflow control door relative to an actuator angle of the complementary actuator and to block engagement of the second torque coupling member when an unaligned position of the airflow control door relative to the actuator angle is not the predetermined position of the airflow control door relative to the actuator angle of the complementary actuator.

[0027] In a further example of the first example of this third aspect, the shaft end includes a first radial stop vane and a second radial stop vane; the housing defines a first stop tab projecting toward the actuation axis from the externally threaded boss; the housing defines a second stop tab projecting toward the actuation axis from the externally threaded boss; the first radial stop vane abuts the first stop tab when the first torque coupling member is at the first angular position, thereby preventing rotation of the shaft end beyond the first angular position in a first rotational direction; and the second radial stop vane abuts the second stop tab when the first torque coupling member is at the second angular position, thereby preventing rotation of the shaft end beyond the second angular position in a second rotational direction opposite the first rotational direction.

[0028] In a second example of this third aspect, the HVAC module further comprises: a first boss defined on the exterior surface of the housing; and a second boss defined on the exterior surface of the housing, wherein: the first boss defines a first boss aperture defining a first boss axis at a first center of the first boss aperture; the first boss aperture is to threadingly receive a threaded fastener; the second boss defines a second boss aperture defining a second boss axis at a second center of the second boss aperture; the second center of the second boss aperture is spaced apart from the first center of the first boss aperture; the second boss aperture is to threadingly receive the threaded fastener; and the complementary actuator is one of: the electrically powered rotary actuator having a first flange with a first flange aperture defined in the first flange, the first flange aperture being coaxial with the first boss aperture when the complementary actuator is in a first installed position on the housing, the threaded fastener to be installed through the first flange aperture into the first boss aperture; and the pull-pull manually operable rotary actuator having a second flange with a second flange aperture defined in the second flange, the second flange aperture being coaxial with the second boss aperture when the complementary actuator is in a second installed position on the housing, the threaded fastener to be installed through the second flange aperture into the second boss aperture.

[0029] It is to be understood that any features of the HVAC module for a vehicle disclosed herein may be combined together in any desirable manner and/or configuration. [0030] A fourth aspect disclosed herein is an HVAC system for a vehicle, comprising: an HVAC module including: a housing to contain a heater core and to direct airflow in an interior of the housing; an airflow control door having a shaft to adjust a position of the airflow control door in the housing; a shaft end connected to the shaft, the shaft end defining an actuation axis; an externally threaded boss defined on an exterior surface of the housing, the externally threaded boss coaxial with the shaft end; and a rotation stop post, projecting from the housing; and a complementary actuator for adjusting a rotational position of the shaft to thereby adjust the position of the airflow control door in the housing, the complementary actuator having a catch defined thereon, the catch to be engaged by the rotation stop post; wherein the housing retains the complementary actuator by threading engagement with the externally threaded boss and by engagement between the rotation stop post and the catch to selectably prevent rotation of the complementary actuator about the actuation axis.

[0031] In a first example of this fourth aspect, the complementary actuator is selected from the group consisting of an electrically powered rotary actuator and a pull-pull manually operable rotary actuator.

[0032] In a second example of this fourth aspect, the complementary actuator is interchangeably an electrically powered rotary actuator and a pull-pull manually operable rotary actuator.

[0033] In a third example of this fourth aspect, the shaft end includes a first torque coupling member rotatably located at a wall of the housing; the first torque coupling member is rotatable about the actuation axis from a first angular position to a second angular position; and the complementary actuator includes a second torque coupling member to couple with the first torque coupling member for rotation therewith.

[0034] In a further example of the second example of the fourth aspect, the first torque coupling member is a hub, attached to the shaft for rotation therewith; the hub includes a male portion protruding through the wall of the housing, the male portion defining a polygonal frustum circumscribing the actuation axis; and the second torque coupling member includes a female portion, complementary to the male portion, to receive the male portion and rotate therewith.

[0035] In a further example of the third example of this fourth aspect, the polygonal frustum is keyed to engage the second torque coupling member at a predetermined position of the airflow control door relative to an actuator angle of the complementary actuator and to block engagement of the second torque coupling member when an unaligned position of the airflow control door relative to the actuator angle is not the predetermined position of the airflow control door relative to the actuator angle of the complementary actuator.

[0036] In a further example of the third example of this fourth aspect: the shaft end includes a first radial stop vane and a second radial stop vane; the housing defines a first stop tab projecting toward the actuation axis from the externally threaded boss; the housing defines a second stop tab projecting toward the actuation axis from the externally threaded boss; the first radial stop vane abuts the first stop tab when the first torque coupling member is at the first angular position, thereby preventing rotation of the shaft end beyond the first angular position in a first rotational direction; and the second radial stop vane abuts the second stop tab when the first torque coupling member is at the second angular position, thereby preventing rotation of the shaft end beyond the second angular position in a second rotational direction opposite the first rotational direction.

[0037] In a fourth example of this fourth aspect, the HVAC system further comprises: a first boss defined on the exterior surface of the housing; a first boss aperture defined by the first boss, the first boss aperture to threadingly receive a threaded fastener; a first boss axis located at a first center of the first boss aperture; a second boss defined on the exterior surface of the housing; a second boss aperture defined by the second boss, the second boss aperture to threadingly receive the threaded fastener; a second boss axis located at a second center of the second boss aperture, the second center of the second boss aperture spaced apart from the first center of the first boss aperture; and the complementary actuator, wherein the complementary actuator is one of: an electrically powered rotary actuator having a first flange with a first flange aperture defined in the first flange, the first flange aperture being coaxial with the first boss aperture when the complementary actuator is in a first installed position on the housing, the threaded fastener to be installed through the first flange aperture into the first boss aperture; and a pull-pull manually operable rotary actuator having a second flange with a second flange aperture defined in the second flange, the second flange aperture being coaxial with the second boss aperture when the complementary actuator is in a second installed position on the housing, the threaded fastener to be installed through the second flange aperture into the second boss aperture.

[0038] It is to be understood that any features of the HVAC system for a vehicle disclosed herein may be combined together in any desirable manner and/or

configuration.

[0039] Further, it is to be understood that any combination of features of any aspect of the HVAC module for a vehicle and/or of any aspect of the HVAC system for a vehicle 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

[0040] 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.

[0041] Fig. 1 is a coordinate system diagram depicting an example of vehicle space;

[0042] Fig. 2 is a rear perspective view of an example of an HVAC module housing depicting an externally threaded boss and a rotation stop post according to the present disclosure; [0043] Fig. 3 is a rear perspective view of an example of an electrically powered rotary actuator mounted on the example of the HVAC module housing depicted in Fig. 2 according to the present disclosure;

[0044] Fig. 4 is a front perspective view of the example of the electrically powered rotary actuator depicted in Fig. 3 according to the present disclosure;

[0045] Fig. 5 is a rear perspective view of an example of a pull-pull manually operable rotary actuator mounted on the example of the FIVAC module housing depicted in Fig. 2 according to the present disclosure; and

[0046] Fig. 6 is a front perspective view of the example of the pull-pull manually operable rotary actuator depicted in Fig. 5 according to the present disclosure.

DETAILED DESCRIPTION

[0047] The HVAC module 14 of the present disclosure includes a housing 12, a blower (not shown), and a heater core (not shown). In some examples, the HVAC module 14 may also include an evaporator (not shown). The evaporator is to provide cold air and the heater core is to provide hot air. These components are typical components for an HVAC module 14 and operate similarly to the components in a conventional HVAC system. Thus, the operation of the blower, evaporator, and heater core will not be explained in further detail. Any reference to“volume of air” or“airflow” in the specification does not specifically refer to cold air, hot air or mixed air but rather is just a generic term used for simplicity.

[0048] As used herein,“left” means in the negative Ύ” direction as depicted in Fig.

1. Fig. 1 depicts a similar coordinate system to the coordinate system depicted in SAE J182,“Motor Vehicle Fiducial Marks and Three-dimensional Reference System”, reaffirmed April 2005, Figure 1. Using the same coordinate system,“right” means in the positive Ύ” direction as depicted in Fig. 1. “Forward” means in the negative“X” direction as depicted in Fig. 1 ; and“aft” or“rearward” means in the positive“X” direction as depicted in Fig. 1. As used herein,“behind” means“aft of”. “Up”,“upper” and similar terms mean in the positive“Z” direction as depicted in Fig. 1 ; and“down”, “lower”, and similar terms mean in the negative“Z” direction as depicted in Fig. 1. [0049] Vehicles generally have a limited amount of interior space. The space is allocated to passengers and various systems in the vehicle. As content is added for the convenience and comfort of vehicle passengers, efficiency in the use of space becomes more important.

[0050] There are several types of door currently used for the blend function in HVAC modules. A flag door has a single leaf that rotates about an axis at an edge of the leaf. A butterfly door has two leaves that rotate about a common axis between the two leaves. A barrel door has an outer surface in the shape of a‘slice’ of a hollow cylinder closed on both ends. The barrel door rotates about an axis at the center of the hollow cylinder.

[0051] Rotation of the doors may be accomplished by using an electrically powered actuator, or a manually powered actuator. In the manually powered actuators of the present disclosure, a pull-pull manually operable rotary actuator or a push-pull manually operable rotary actuator may be used. Fig. 5 and Fig. 6 depict, in part, an example of a pull-pull manually operable rotary actuator 31 according to the present disclosure. Pull-pull manually operable rotary actuators may be part of a control mechanism that includes, for example, a rotary knob or a slider disposed on a control panel of a vehicle. An action of the rotary knob or slider ultimately results in a corresponding adjustment of a door or valve in the FIVAC module. The knob or slider is connected to the pull-pull manually operable rotary actuator 31 by a dual control cable 32. In an example, turning the knob clockwise pulls on a first cable 50 in the dual control cable 32, which is connected to a pulley 45 or lever in the pull-pull manually operable rotary actuator 31. In the same example, turning the knob counter clockwise pulls on a second cable 51 in the dual control cable 32, which is connected to the pulley 45 or lever in the pull-pull manually operable rotary actuator 31 in such a way as to rotate the pull-pull manually operable rotary actuator 31 in an opposite direction compared to the direction that pulling on the first cable 50 causes the pull-pull manually operable rotary actuator 31 to turn. It is to be understood that the words “first” and“second” are used herein to distinguish the names of certain elements (e.g. “first cable, second cable”); therefore,“first” and“second” convey no temporal significance in this context. The pulley 45 or lever turns a shaft, gear, or cam connected through a torque transmitting shaft end to adjust a shaft of the airflow control door or valve. The pull-pull manually operable rotary actuator 31 may have gearing between the pulley or lever and the torque transmitting shaft end.

[0052] A push-pull manually operable rotary actuator is similar to the pull-pull manually operable rotary actuator except the dual control cable 32 is replaced by a single control cable connected to a pulley or lever in the push-pull manually operable rotary actuator in such a way as to rotate the push-pull manually operable rotary actuator in a first direction when the single control cable pushes on the pulley or lever and a second direction, opposite the first direction, when the single control cable pulls on the pulley or lever. The single control cable may include a solid wire or stranded cable inner member movable inside an outer conduit.

[0053] In the electrically powered mechanisms of the present disclosure, an electrically powered rotary actuator, rather than a manually operable rotary actuator, may be used. Electrically powered rotary actuators are part of a control system that includes, for example, a rotary knob or a slider disposed on a control panel of a vehicle, or an automatic climate control system. An action of the rotary knob or slider changes a sensor output that is used to control the electrically powered rotary actuator, ultimately resulting in a corresponding adjustment of a door or valve in the HVAC module. The knob or slider is connected to the electrically powered rotary actuator by electrically conductive wires. In an example, turning the knob clockwise turns an encoder monitored by an electronic controller. The electronic controller sends power through the electrically conductive wires to cause the electrically powered rotary actuator to turn in a first direction to a particular position. In the same example, turning the knob counter clockwise turns the encoder and ultimately causes the electrically powered rotary actuator to turn in a second direction (opposite to the first direction) to a second position. The electrically powered rotary actuator turns a shaft, gear, or cam connected through a torque transmitting shaft end to adjust the shaft of the airflow control door or valve. The electrically powered rotary actuator may have gearing in a powertrain connected to the torque transmitting shaft end. A powertrain is a plurality of gears and shafts that are meshingly connected to transmit torque.

[0054] In examples of the present disclosure, a single interface on the HVAC module housing allows the same HVAC module to be assembled with either the electrically powered rotary actuator or a manually operable rotary actuator. An interchangeable interface eliminates the need for dedicated tooling or complicated inserts on HVAC housings to manufacture electronically controlled HVAC modules and manually controlled HVAC modules in a common package space.

[0055] Fig. 2 depicts an example of an HVAC module housing 12 with an externally threaded boss 22 and a rotation stop post 21 according to the present disclosure. Fig. 3 shows an example of an electrically powered rotary actuator 30 mounted on the example of the HVAC module housing 12 depicted in Fig. 2 according to the present disclosure. Fig. 4 shows further details of the example of the electrically powered rotary actuator 30 from Fig. 3. Fig. 5 is a rear perspective view of an example of a pull-pull manually operable rotary actuator 31 mounted on the example of the HVAC module housing 12 depicted in Fig. 2 according to the present disclosure. Fig. 6 shows further details of the example of the pull-pull manually operable rotary actuator 31 from Fig. 5.

[0056] In examples of the present disclosure, a single“twist-lock” interface using a large threaded feature is to retain the complementary actuator axially, and a second rotational retention feature (e.g. a rotation stop post) is to engage a flexible catch on the complementary actuator. In some examples of the present disclosure, the complementary actuator is retained by molded features that allow semi-permanent fastening without additional fasteners (such as separate screws). A redundant screw may optionally be installed. The redundant screw may save resources and reduce scrap during production by allowing a threaded fastener to be used for anti-rotation if an element of the molded features intended to serve as a rotational retention feature become damaged. It is to be understood that the large threaded feature, which is not the same as the redundant screw, may include screw threads, or a cam-lock interface. Further, the complementary actuator 20 may be fully installed by rotating a shell 35 of the complementary actuator 20 a fraction of a revolution relative to the housing 12.

For example, one quarter turn or one eighth turn of the shell 35 may be sufficient to install the complementary actuator 20 on the housing 12 as disclosed herein.

[0057] As depicted in Fig. 2, Fig. 3 and Fig. 5 together, in examples of the present disclosure, an FIVAC module 14 for a vehicle 16, includes a housing 12. A shaft end 18 is connected to a shaft (not shown) for connection to a complementary actuator 20 for adjusting a rotational position of the shaft to thereby adjust a position of an airflow control door (not shown) in the housing 12. The airflow control door may be any suitable airflow control door, non-limiting examples being a flag door, a butterfly door, and a barrel door as described herein above. The shaft for adjusting the position of the airflow control door may have any suitable structure. For example, the shaft may be a single rod, like a hinge pin; or the shaft may have separate upper and lower pins. The shaft may be a single part with the airflow control door (i.e. , molded into the airflow door), or the airflow control door may have separable parts (e.g., the shaft may be pressed into the airflow control door). The airflow control door may have a resilient seal (not shown) disposed at a perimeter of the airflow control door.

[0058] In examples of the present disclosure, the shaft end 18 defines an actuation axis 26. An externally threaded boss 22 is defined on an exterior surface 28 of the housing 12. As used herein, the“exterior surface 28 of the housing 12” means a surface distal to the volume substantially surrounded by the housing 12. “Substantially surrounded” is used herein because the housing 12 may have openings for example, vents or ducts, such that the housing 12 does not completely enclose the volume. As disclosed herein, the volume enclosed by the housing 12 is defined, in part, by an imaginary closure covering such an opening wherein the imaginary closure has the smallest possible surface area. It is to be understood that the exterior surface 28 of the housing 12 may be inside the vehicle 16, outside the vehicle 16, or extending both inside and outside the vehicle 16. As used herein, the“interior of the housing 12” means the volume substantially surrounded by the housing 12.

[0059] In examples of the present disclosure, the externally threaded boss 22 is coaxial with the shaft end 18. A rotation stop post 21 projects from the housing 12 to engage a catch 24, defined by the complementary actuator 20. The housing 12 is to retain the complementary actuator 20 by threading engagement with the externally threaded boss 22 and by engagement between the rotation stop post 21 and the catch 24 to selectably prevent rotation of a shell 35 of the complementary actuator 20 about the actuation axis 26.

[0060] In an example, the rotation stop post 21 may include a ridge, fin, rib 29 or wall projecting from the exterior surface 28 of the housing 12. The catch 24 may include a flexible tab 27 that may, without significant additional installation effort, bend enough to allow the shell 35 of complementary actuator 20 to be rotated in an install direction (e.g., clockwise as shown in Fig. 3) while the complementary actuator 20 is threadingly installed on the externally threaded boss 22 as the flexible tab 27 slides past the rotation stop post 21. When the complementary actuator 20 reaches an installed position, the flexible tab 27 may return to a free position (i.e. , an unbent state) and abut the rotation stop post 21 ; thereby preventing the complementary actuator 20 from rotating in an uninstall direction (e.g. counter-clockwise as shown in Fig. 3) opposite the install direction. The flexible tab 27 may cause an audible“click” and/or a pulse may be palpable when the flexible tab 27 snaps into the free position. Such an audible click or palpable pulse may be an assembly aid to help determine that the complementary actuator 20 has been installed in the installed position. Uninstallation of the complementary actuator 20 may be accomplished by bending the flexible tab 27 (e.g. with a tool) to allow the flexible tab 27 to slide past the rotation stop post 21 when the shell 35 of the complementary actuator 20 is turned in the uninstall direction. It is to be understood that installing with right-hand or left-hand rotation is contemplated herein.

[0061] In an example, the rotation stop post 21 may include a ridge, fin, rib 29 or wall projecting from the exterior surface 28 of the housing 12. The catch 24 may include a slot 36 to receive a portion of the rotation stop post 21. The slot 36 may include a detent to hold the rotation stop post 21 in an installed location. Engagement of the detent by the rotation stop post 21 may cause an audible“click” and/or a pulse may be palpable. Such an audible click or palpable pulse may be an assembly aid to help determine that the complementary actuator 20 has been installed in the installed position. Uninstallation may be accomplished by overcoming a detent retention torque and turning the complementary actuator 20 in the uninstall direction. The detent retention torque is greater than torques that may result from vibration in

service/operation of the HVAC module 14 in the vehicle 16. It is to be understood that installing with right-hand or left-hand rotation is contemplated herein.

[0062] In examples of the present disclosure, the complementary actuator 20 is interchangeably an electrically powered rotary actuator 30 and a manually operable rotary actuator 31. In examples, the manually operable rotary actuator 31 may be selected from the group consisting of a push-pull manually operable rotary actuator and a pull-pull manually operable rotary actuator. In examples, the manually operable rotary actuator 31 may be a pull-pull manually operable rotary actuator. In examples, the manually operable rotary actuator 31 may be a push-pull manually operable rotary actuator. As such, in examples of the present disclosure, an electrically powered rotary actuator 30 and a manually operable rotary actuator 31 are each

interchangeably installable on the same housing 12 connected to the same shaft end 18 as otherwise disclosed herein. Thus, manufacturing complexity is reduced, and the need for dedicated tooling or complicated inserts for the housings 12 is eliminated to facilitate manufacture of electronically controlled HVAC modules and manually controlled HVAC modules in a common package space.

[0063] In some examples of the HVAC module 14 as disclosed herein, the shaft end 18 includes a first torque coupling member 40 rotatably located at a wall 25 of the housing 12. The first torque coupling member 40 is rotatable about the actuation axis 26 from a first angular position to a second angular position. In the example depicted in Fig. 2, the first torque coupling member 40 is shown in the first angular position. In the example depicted in Fig. 2, when the first torque coupling member 40 is rotated about the actuation axis 26 counter clockwise (in the orientation shown in Fig. 2) as far as possible, the first torque coupling member 40 is in the first angular position. An example of the second angular position (not shown) would be the position of the first torque coupling member 40 after the first torque coupling member 40 is rotated about the actuation axis 26 clockwise as far as possible. The complementary actuator 20 may include a second torque coupling member 41 to couple with the first torque coupling member 40 for rotation therewith. The first torque coupling member 40 and the second torque coupling member 41 may have any suitable shapes as long as the first torque coupling member 40 and the second torque coupling member 41 may be coupled together for rotating together as one piece. For example, the first torque coupling member 40 may be a male member, and the second torque coupling member may be a female member. In another example, the first torque coupling member 40 may be a female member, and the second torque coupling member may be a male member.

[0064] In some examples of the HVAC module 14 of the present disclosure, the first torque coupling member 40 is a hub 37, attached to the shaft for rotation therewith. The hub 37 may include a male portion 38 protruding through the wall 25 of the housing 12, the male portion 38 defining a polygonal frustum 39 circumscribing the actuation axis 26. Similarly, the male portion 38 may define a prism. A prism is a solid geometric figure whose two end faces are similar, equal, and parallel rectilinear figures, and whose sides are parallelograms. A frustum is a solid geometric figure whose two end faces are similar and parallel rectilinear figures. A polygonal frustum has polygonal ends that are similar, but the base of the polygonal frustum is larger than the other end. A truncated pyramid is an example of a polygonal frustum. Two polygons are similar if and only if: all pairs of corresponding angles are congruent; and the ratios of the measures of corresponding sides are equal. Examples having the male portion 38 define a polygonal frustum 39 may be easier to assemble compared to an example with a prismatic male portion because the polygonal frustum 39 has a draft angle to ease alignment.

[0065] In examples of the present disclosure, the second torque coupling member 41 may include a female portion 52, complementary to the male portion 38, to receive the male portion 38 and rotate therewith.

[0066] In some examples, the polygonal frustum 39 may be keyed to engage the second torque coupling member 41 at a predetermined position of the airflow control door relative to an actuator angle of the complementary actuator 20 and to block engagement of the second torque coupling member 41 when an unaligned position of the airflow control door relative to the actuator angle is not the predetermined position of the airflow control door relative to the actuator angle of the complementary actuator 20. As used herein, the“actuator angle” means the angle of rotation of the second torque coupling member 41 about the actuation axis 26 relative to the shell 35 of the complementary actuator 20. Thus, it will be possible to determine the position of the airflow control door from the actuator angle.

[0067] In some examples of the HVAC module 14 as disclosed herein, the shaft end 18 includes a first radial stop vane 33 and a second radial stop vane 34. The housing 12 may define a first stop tab 43 projecting toward the actuation axis 26 from the externally threaded boss 22. The housing 12 may also define a second stop tab 44 projecting toward the actuation axis 26 from the externally threaded boss 22. The first radial stop vane 33 abuts the first stop tab 43 when the first torque coupling member 40 is at the first angular position (as shown in Fig. 2), thereby preventing rotation of the shaft end 18 beyond the first angular position in a first rotational direction 47. It is to be understood that although the first rotational direction 47 is shown to be counterclockwise in Fig. 2, in other examples, the first rotational direction may be clockwise. The second radial stop vane 34 abuts the second stop tab 44 when the first torque coupling member 40 is at the second angular position, thereby preventing rotation of the shaft end 18 beyond the second angular position in a second rotational direction 48 opposite the first rotational direction 47.

[0068] Some examples of the FIVAC module 14 of the present disclosure may include a first boss 55 and a second boss 56 defined on an exterior surface 28 of the housing 12. The first boss 55 defines a first boss aperture 65 defining a first boss axis

75 at a first center 85 of the first boss aperture 65. The first boss aperture 65 is to threadingly receive a threaded fastener (not shown).

The second boss 56 defines a second boss aperture 66 defining a second boss axis

76 at a second center 86 of the second boss aperture 66. The second center 86 of the second boss aperture 66 is spaced apart from the first center 85 of the first boss aperture 65. The second boss aperture 66 is to threadingly receive a second threaded fastener (not shown). The complementary actuator 20 may be one of the electrically powered rotary actuator 30 and the manually operable rotary actuator 31. In examples, the electrically powered rotary actuator has a first flange 70 with a first flange aperture 72 defined in the first flange 70, the first flange aperture 72 being coaxial with the first boss aperture 65 when the complementary actuator 20 is in a first installed position on the housing 12. The threaded fastener is to be installed through the first flange aperture 72 into the first boss aperture 65. In examples, the manually operable rotary actuator has a second flange 71 with a second flange aperture 73 defined in the second flange 71 , the second flange aperture 73 being coaxial with the second boss aperture 66 when the complementary actuator 20 is in a second installed position on the housing 12. The threaded fastener is to be installed through the second flange aperture 73 into the second boss aperture 66. The second center 86 of the second boss aperture 66 may be positioned to prevent the threaded fastener from being installed through the first flange aperture 72 into the second boss aperture 66. It is to be understood that the threaded fastener may be any suitable threaded fastener, for example, a Torx ® pan head screw, a Phillips pan head screw, a hex head bolt, or any threaded fastener to retain the complementary actuator 20 at the second boss 56.

[0069] Examples of the present disclosure also include an HVAC system 10 for a vehicle 16. The HVAC system 10 includes an an HVAC module 14 including a housing 12 to contain a heater core (not shown) and to direct airflow in an interior of the housing 12. An airflow control door having a shaft to adjust a position of the airflow control door in the housing 12. The airflow control door and the shaft are further described herein above. A shaft end 18 is connected to the shaft, the shaft end 18 defining an actuation axis 26. An externally threaded boss 22 is defined on an exterior surface 28 of the housing 12. The externally threaded boss 22 is coaxial with the shaft end 18. A rotation stop post 21 projects from the housing 12. The HVAC system 10 includes a complementary actuator 20 for adjusting a rotational position of the shaft to thereby adjust the position of the airflow control door in the housing 12.

The complementary actuator 20 has a catch 24 defined thereon. The catch 24 is to be engaged by the rotation stop post 21. The housing 12 retains the complementary actuator 20 by threading engagement with the externally threaded boss 22 and by engagement between the rotation stop post 21 and the catch 24 to selectably prevent rotation of the complementary actuator 20 about the actuation axis 26.

[0070] In examples of the HVAC system 10 as disclosed herein, the rotation stop post 21 and the catch 24 may be as described herein above.

[0071] In some examples of the HVAC system 10 the complementary actuator 20 is selected from the group consisting of an electrically powered rotary actuator 30 and a manually operable rotary actuator 31. In examples, the manually operable rotary actuator 31 may be selected from the group consisting of a push-pull manually operable rotary actuator and a pull-pull manually operable rotary actuator. In examples, the manually operable rotary actuator 31 may be a pull-pull manually operable rotary actuator. In examples, the manually operable rotary actuator 31 may be a push-pull manually operable rotary actuator.

[0072] In examples of the HVAC system 10 disclosed herein, the complementary actuator 20 is interchangeably an electrically powered rotary actuator 30 and a manually operable rotary actuator 31. In examples, the manually operable rotary actuator 31 may be selected from the group consisting of a push-pull manually operable rotary actuator and a pull-pull manually operable rotary actuator. In examples, the manually operable rotary actuator 31 may be a pull-pull manually operable rotary actuator. In examples, the manually operable rotary actuator 31 may be a push-pull manually operable rotary actuator. As such, in examples of the present disclosure, an electrically powered rotary actuator 30 and a manually operable rotary actuator 31 are each interchangeably installable on the same housing 12 connected to the same shaft end 18 as otherwise disclosed herein.

[0073] In some examples of the HVAC system 10 the shaft end 18 includes a first torque coupling member 40 rotatably located at a wall 25 of the housing 12. The first torque coupling member 40 is rotatable about the actuation axis 26 from a first angular position (as shown in Fig. 2) to a second angular position. The complementary actuator 20 includes a second torque coupling member 41 to couple with the first torque coupling member 40 for rotation therewith.

[0074] In some examples of the HVAC system 10 of the present disclosure, the first torque coupling member 40 is a hub 37, attached to the shaft for rotation therewith.

The hub 37 includes a male portion 38 protruding through the wall 25 of the housing 12. The male portion 38 may define a polygonal frustum 39 circumscribing the actuation axis 26. The second torque coupling member 41 includes a female portion, complementary to the male portion 38, to receive the male portion 38 and rotate therewith.

[0075] In examples of the HVAC system 10 the polygonal frustum 39 may be keyed to engage the second torque coupling member 41 at a predetermined position of the airflow control door relative to an actuator angle of the complementary actuator 20 and to block engagement of the second torque coupling member 41 when an unaligned position of the airflow control door relative to the actuator angle is not the

predetermined position of the airflow control door relative to the actuator angle of the complementary actuator 20. As depicted in Fig. 2, the ends of the polygonal frustum 39 are 13 sided polygons, with one of the sides of each polygon being larger than the other 12 equally sized sides. The larger side of the end polygons allows the first torque coupling member 40 and the second torque coupling member 41 to be installed together in only the proper rotational relationship between the complementary actuator 20 and the airflow control door.

[0076] In some examples of the HVAC system 10 disclosed herein, the shaft end 18 includes a first radial stop vane 33 and a second radial stop vane 34. The housing 12 defines a first stop tab 43 projecting toward the actuation axis 26 from the externally threaded boss 22. The housing 12 defines a second stop tab 44 projecting toward the actuation axis 26 from the externally threaded boss 22. The first radial stop vane 33 abuts the first stop tab 43 when the first torque coupling member 40 is at the first angular position, thereby preventing rotation of the shaft end 18 beyond the first angular position in a first rotational direction 47. The second radial stop vane 34 abuts the second stop tab 44 when the first torque coupling member 40 is at the second angular position, thereby preventing rotation of the shaft end 18 beyond the second angular position in a second rotational direction opposite the first rotational direction 47.

[0077] In some examples of the present disclosure, the HVAC system 10 further includes a first boss 55 defined on an exterior surface 28 of the housing 12. A first boss aperture 65 is defined by the first boss 55. The first boss aperture 65 is to threadingly receive a threaded fastener. A first boss axis 75 is located at a first center 85 of the first boss aperture 65. A second boss 56 is defined on an exterior surface 28 of the housing 12. A second boss aperture 66 is defined by the second boss 56. The second boss aperture 66 is to threadingly receive the threaded fastener. A second boss axis 76 is located at a second center 86 of the second boss aperture 66. The second center 86 of the second boss aperture 66 is spaced apart from the first center 85 of the first boss aperture 65. The HVAC system 10 may further include the complementary actuator 20. In examples, the complementary actuator 20 is one of the electrically powered rotary actuator 30 and the manually operable rotary actuator 31. In examples, the manually operable rotary actuator 31 may be selected from the group consisting of a push-pull manually operable rotary actuator and a pull-pull manually operable rotary actuator. In examples, the manually operable rotary actuator 31 may be a pull-pull manually operable rotary actuator. In examples, the manually operable rotary actuator 31 may be a push-pull manually operable rotary actuator. In examples in which the complementary actuator 20 is the electrically powered rotary actuator 30, the electrically powered rotary actuator 30 has a first flange 70 with first flange aperture 72 is defined in the first flange 70. The first flange aperture 72 is coaxial with the first boss aperture 65 when the complementary actuator 20 is in a first installed position on the housing 12. The threaded fastener is to be installed through the first flange aperture 72 into the first boss aperture 65. In examples in which the complementary actuator 20 is the manually operable rotary actuator 31 , the manually operable rotary actuator 31 has a second flange 71 with a second flange aperture 73 defined in the second flange 71 , the second flange aperture 73 being coaxial with the second boss aperture 66 when the complementary actuator 20 is in a second installed position on the housing 12. The threaded fastener is to be installed through the second flange aperture 73 into the second boss aperture 66.

[0078] It is to be understood that the electrically powered rotary actuator 30 is to be installed in the first installation position, and the manually operable rotary actuator 31 is to be installed in the second installation position. The electrically powered rotary actuator 30 is not installable in the second installation position, and the manually operable rotary actuator 31 is not installable in the first installation position. It is to be further understood that the use of“first” and“second” relating to features of the complementary actuator 20 are to distinguish between features of the electrically powered rotary actuator 30 and the manually operable rotary actuator 31. To illustrate by example, although the manually operable rotary actuator 31 has a second flange 71 , first flange 70 is not a feature of the manually operable rotary actuator 31. First flange 70 is a feature of the electrically powered rotary actuator 30.

[0079] 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.

[0080] In describing and claiming the examples disclosed herein, the singular forms “a”,“an”, and“the” include plural referents unless the context clearly dictates

otherwise.

[0081] 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.

[0082] 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.

[0083] 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.