Additional objects and advantages of the present invention will be more readily apparent from the following detailed description of preferred embodiments when taken together with the accompanying drawings. In the drawings:
A first embodiment will be now described with reference to
The blower unit has an inside/outside air switching box for selectively introducing an outside air of the passenger compartment and an inside air of the passenger compartment, and a blower for sucking air though the inside/outside air switching box and blowing the air. The blower has a centrifugal multiblade fan (sirocco fan) and an electric motor for driving the centrifugal multiblade fan. The electric motor is driven by a control voltage of an air-conditioning control device (not shown).
The air conditioning unit 10 has an air conditioning case 11 which defines an air passage for leading air toward the passenger compartment. The case 11 is made of a resin (e.g., polypropylene, nylon, and ABS) which has a certain level of elasticity, and a good strength. The case 11 has a separating surface formed in an up-down direction, and disposed at an approximately center portion in the vehicle width direction, for separating the case 11 into right and left parts.
The case 11 houses an evaporator 12 for forming a heat exchanger for cooling, a heater core 13 for forming a heat exchanger for heating, an air mixing door 16, a defroster door 22, a face door 28, and foot door 29, etc. These components (12, 13, 16, 22, 28, and 29) are attached to the case 11 by fastenings such as a metal spring clip and a screw.
The case 11 has an air inlet space 14 which is formed on the most front side of the vehicle. The air blown by the blower flows into the air inlet space 14. The evaporator 12 is disposed in an approximately up-down direction (approximately vertically) on a downstream air side (i.e., rear side of the vehicle) with respect to the air inlet space 14. The evaporator 12 cools air by absorbing heat from air when a low-pressure refrigerant of a refrigeration cycle (not shown) evaporates.
The heater core 13 is disposed approximately vertically at a predetermined distance from the evaporator 12 on a downstream air side. The heater core 13 is introduced with a high-temperature engine cooling water (hot water), and heat exchanges between the hot water and cool air having passed through the evaporator 12, so as to heat air from the evaporator 12.
When the evaporator 12 and the heater core 13 are arranged approximately vertically, their surfaces, which form heat-exchanging cores, extend to the up-down direction. Thus, the air flowing into the air inlet space 14 of the case 11 is cooled while passing through the evaporator 12, and is heated while passing through the heater core 13.
A cool air bypass passage 15 is formed in a portion on a rear side of the evaporator 12. The cool air from the evaporator 12 bypasses the heating core 13 through the cool air bypass passage 15. Between the evaporator 12 and the heater core 13, the air-mixing door 16 is disposed for controlling a ratio of an air volume of the warm air, which is heated by the heater core 13, and an air volume of cool air, which passes through the cool air bypass passage 15 and bypasses the heater core 13.
The air-mixing door 16 controls a temperature of air to be blown to the passenger compartment by controlling the ratio of the air volumes between the warm air and the cool air. The air-mixing door 16 is a rotating door which has a rotation shaft 17 extends to the right-left direction of the vehicle, and a plate-shaped door body 16a which is connected to and rotates with the rotation shaft 17. In the first embodiment, the air-mixing door 16 is a cantilevered door in which the rotation shaft 17 is connected to a side of the door body 16a.
A dotted-line position 16b shows a maximum cooling position of the air-mixing door 16 in which the air-mixing door 16 fully closes an inlet of a passage to the heater core 13 and fully opens the cool air bypass passage 15. In contrast, a dashed-two dotted line position 16c shows a maximum heating position of the air-mixing door 16 in which the air-mixing door 16 fully closes the cool air bypass passage 15 and fully opens the inlet of the passage to the heater core 13.
The rotation shaft 17 is disposed at a front portion of an upper end of the heater core 13. The rotation shaft 17 is rotatably held by bearing holes (not shown) provided in right and left wall surfaces of the case 11. Further, the rotation shaft 17 protrudes to an outside of the case 11, and is connected to a temperature-control operating system (not shown) through a link system (not shown).
The temperature-control operating system includes an actuator having a servomotor, and controls a rotational position of the air-mixing door 16. The actuator is driven by a control signal of the air-conditioning control device (not shown). The temperature-control operating system may include a manual operation system. A wall 18 is integrally formed with the case 11 on a downstream air side with respect to the heater core 13. The wall 18 extends to the up-down direction, and disposed at a predetermined distance from the heater core 13. The wall 18 is located downstream of the heater core 13 to form a hot air passage 19 in which the hot air flows upwardly from just behind the heater core 13.
An air-mixing space 20 is formed in a space which is provided on an upper side of the hot air passage 19, at an upper side of the heater core 13, and on a rear side of the cool air bypass passage 15. In the air-mixing space 20, the hot air passing through the heater core 13 and the cool air passing through the cool air bypass passage 15 are mixed for controlling a temperature of air flowing from the air-mixing space 20 to the passenger compartment. Thus, the temperature-control operating system controls the rotational position of the air-mixing door 16, for controlling the temperature of the conditioned air so as to be a predetermined temperature.
A defroster opening 21 is provided in an upper portion of the case 11 and an intermediate portion between the evaporator 12 and the heater core 13 in the front-rear direction. The defroster opening 21 is an opening for blowing the conditioned air from the air-mixing space 20 to an inner surface of a windshield.
Specifically, the defroster opening 21 is connected to a defroster outlet (not shown) provided in the passenger compartment, through a defroster duct (not shown). The conditioned air is blown from the defroster outlet to the inner surface of the windshield. Between the air-mixing space 20 and the defroster outlet, a defroster air passage 24, in which the conditioned air flows, is formed.
A face opening 26 is provided in an upper portion of the case 11 and on a rear side of the defroster opening 21. The face opening 26 is connected to a face outlet (not shown) provided on an upper side of the instrument panel, through a face duct. The conditioned air is blown from the face outlet to an upper body of a passenger in the passenger compartment.
At a lower portion of the face opening 26, a foot opening 27 is provided for flowing the conditioned air to a foot are of the passenger. Specifically, the face opening 27 is connected to foot outlets 31 provided at right and left lower ends on a rear side of the case 11. The air is discharged from the right and left foot outlets 31 to the under foot of the passenger. Between the air-mixing space 20 and the foot outlets 31, the foot air passage 30, in which the conditioned air flows, is formed.
The defroster door 22, the face door 28, and the foot door 29 are respectively disposed in the air passages from the air-mixing space 20 to the defroster opening 21, the face opening 26, and the foot opening 27. The air passages are switched by outlet mode doors (i.e., the defroster door 22, the face door 28, and the foot door 29).
In the first embodiment, the defroster door 22 has a rotation shaft 22a extending to the right-left direction of the vehicle, and plate-shaped door body 22b which is connected to the rotation shaft 22a to rotate integrally. The defroster door 22 is a butterfly door in which the rotation shaft 22a is disposed at a center portion of the door body 22b.
The face door 28 is a cantilever door in which the rotation shaft 28a is disposed at an end of a plate-shaped door body 28b, similarly to the air-mixing door 16. The foot door 29 is a butterfly door in which its rotation shaft 29a is disposed at a center portion of a plate-shaped door body 29b, similarly to the defroster door 22.
The outlet mode doors 22, 28 and 29 are simultaneously operated by a common outlet-mode door operation system (not shown). Specifically, the rotation shafts 22a, 28a and 29a of the outlet mode doors 22, 28 and 29 are rotationally held by bearing holes in the right and left walls of the case 11, and one ends of the rotation shafts 22a, 28a and 29a protrude to the outside of the case 11.
The protruded ends of the rotation shafts 22a, 28a and 29a are connected to the outlet-mode door operation system through a link system. The outlet-mode door operation system includes an actuator having a servomotor, for opening and closing the outlet mode doors 22, 28 and 29. The actuator is driven by a control signal of the air-conditioning control device.
When the outlet-mode door operation system operates the outlet mode doors 22, 28 and 29, an air outlet mode is switched to a face mode, a bi-level mode, a foot/defroster mode, or a defroster mode. The outlet-mode door operation system may include a manual operation system for manually switching an air outlet mode.
In
Next, the defroster door 22 will be described with reference to
The defroster door 22 may have two door bodies 22b. The rotation shaft 22a are disposed between the two door bodies 22b which are arranged to be parallel, so that the door bodies 22b integrally rotates with the rotation shaft 22a. As shown in
The rotation shaft 22a and the door bodies 22b are integrally formed with a material having a high rigidity and an inelasticity, such as resin. As a resin material for forming the rotation shaft 22a and the door bodies 22b, polypropylene, nylon, and ABS may be used. A filler such as glass fiber may be mixed into a resin material for enhancing the strength of the rotation shaft 22a and the door bodies 22b. Further, the rotation shaft 22a and the door bodies 22b may be formed with the same resin material as that of the case 11.
Seal members 22c are attached to outer peripheral portions of the door bodies 22b. The seal members 22c are made of an elastic material such as rubber, silicon rubber, and thermoplastic elastomer (TPE). The seal members 22c have thin plate shapes extending from the outer peripheral portions of the door bodies 22b to an outside.
As shown in
When the door bodies 22b close the defroster air passage 24, an upstream side surface of a first seal member 22c of a first door body 22b arranged on an upper side of the rotation shaft 22a contacts the fist rib 11a to be sealed therebetween. In addition, downstream side surface of the second seal member 22c of a second door body 22b arranged on a lower side of the rotation shaft 22a contacts the second rib 11a to be sealed therebetween. Thus, the seal members 22c tightly seal a gap between the door bodies 22b and the case 11 when the door bodies 22b close the defroster air passage 24.
When the door bodies 22b open the defroster air passage 24, the door bodies 22b rotate in a direction shown by the arrow B (anticlockwise in
As shown in
When the door bodies 22b close the defroster air passage 24, the defroster air passage 24 is divided into an upstream space 24a on an upstream air side and a downstream space 24b on a downstream air side, and the first protruding parts 22d are arranged on a side of the upstream space 24a.
As shown in
The door bodies 22b and the seal members 22c and the first protruding parts 22d are easily formed integrally by insert-molding. For example, rubber material for forming the seal members 22c and the first protruding parts 22d are set in predetermined positions in a mold used for forming the door bodies 22b. Then, the resin material is injected in the mold for integrally forming and fixing the door bodies 22b and the seal members 22c and the first protruding parts 22d.
Shaft holding parts 22e are formed at two axial ends of the rotation shaft 22a. The shaft holding parts 22e protrude outside more than the first protruding parts 22d, in an axial direction of the rotation shaft 22a. The shaft holding parts 22e are inserted in bearing holes 11b formed in the case 11 on an approximately same axis as the axial center C, so that the defroster door 22 is rotatably held by the case 11.
Next, the first protruding parts 22d, the shaft holding parts 22e, and portions surrounding the bearing holes 11b in the case 11 will be described with reference to
As shown in
Further, the outer peripheral surfaces of the second protruding parts 11c are formed to have shapes fitting to shapes of the inner peripheral surfaces of the first protruding parts 22d when the door bodies 22b close the defroster air passage 24. In other words, when the door bodies 22b close the defroster air passage 24, the inner peripheral surfaces of the first protruding parts 22d are in contact with the outer peripheral surfaces of the second protruding parts 11c.
The inner peripheral surfaces of the first protruding parts 22d are tilted toward sides of the outer peripheral surfaces of the second protruding parts 11c. In other words, the inner peripheral surfaces of the first protruding parts 22d presses to the second protruding parts 11c toward sides of the axial ends of the rotation shaft 22a. In this way, the first protruding parts 22d are in contact with the second protruding parts 11c for sealing gaps between the first protruding parts 22d and the second protruding parts 11c.
That is, in the first embodiment, the inner peripheral surfaces of the first protruding parts 22d form first seal parts 22f, and the outer peripheral surfaces of the second protruding parts 11c form second seal parts 11d. The seal parts 22f and 11d constructs a seal structure for preventing an air leak from gaps between surroundings of the ends of the rotation shaft 22a and the case 11.
The first seal parts 22f are formed on surfaces which extend to a circumferential direction around the axial center C, and the second seal parts 11d are formed on surfaces which extend to the circumferential direction around the axial center C. Therefore, the seal structure is easily formed by contacting the both surfaces of the first seal parts 22f and the second seal parts 11d.
The first seal parts 22f are arranged in the upstream space 24a on the upstream air side of the defroster door 24 when the door bodies 22b close the defroster air passage 24.
The seal parts 22f and 11d are formed along the shapes of first and second protruding parts 22d and 11c. Therefore, a first distance between each of the first seal parts 22f and the axial center C, and a second distance between each of the second seal parts 11d and the axial center C gradually decrease toward the direction shown by the arrow B. Here, the direction shown by the arrow B is an opening direction of the door bodies 22b, for opening the defroster passage 24. Thus, the first seal parts 22f and the second seal parts 11d have scroll shapes centering on the axial center C.
In this embodiment, the scroll shape is a shape in which a distance (scroll diameter) from the axial center C to a predetermined point on the scroll shape of the seal parts 22f or 11d gradually changes around the axial center C. The scroll shape draws a spiral excursion on a cross-sectional surface perpendicular to the axial center C. The scroll shape may include a shape drawing a spiral excursion in a range within 360°.
The shaft holding part 22e is inserted into the bearing hole 11b formed in the inner peripheral surface of the second protruding part 11c. The shaft holding part 22e is formed into a cylindrical shape. Inside the shaft holding part 22e, a link-member connecting hole 22g for connecting a link member which links the rotation shaft 22a with the outlet-mode door operation system.
Next, an operation of the defroster door 22 will be described with reference with
In the first embodiment, the first protruding parts 22d forming the first seal parts 22f, are integrally formed with the sealing member 22c of the defroster door 22. Thus, boundaries between outer peripheral portions of the door bodies 22b and the rotation shaft 22f are sealed appropriately. Therefore, an air leak from the upstream air side of the defroster door 22 to the downstream air side of the defroster door 22 is prevented.
Further, the first seal parts 22f are arranged in the upstream space 24a when the door bodies 22b close the defroster air passage 24. Therefore, when the door bodies 22b close the defroster air passage 24, the door seal parts 22f prevent an air leak from the upstream air side of the defroster door 22 to the downstream air side of the defroster door 22 without being formed in whole area around the rotation shaft 22a.
When the first seal parts 22f are positioned in the upstream space 24a, the bearing holes 11b in the case 11 and the shaft holding parts 22e are positioned on the downstream air side with respect to the first seal parts 22f. Therefore, an air leak from the gap between the bearing holes 11b and the shaft holding parts 22e to the outside of the case 11 is also prevented.
The first seal parts 22f are tilted toward the second seal parts 11d to contact the second seal parts 11d with lines. Therefore, a pressing force of contact interfaces of the first seal parts 22f and the second seal parts 11d is increased compared with that when the first seal parts 22f are in contact with the second seal parts 11d with faces.
Further, the first protruding parts 22d for forming the first seal parts 22f are made of the elastic material. Therefore, the pressing force of contact interfaces of the first seal parts 22f and the second seal parts 11d are increased compared with that when the first seal parts 22f and the second seal parts 11d are made of inelastic materials. As a result, the seal structure of the first embodiment has a high sealing property.
As shown in
In the first embodiment, the first seal parts 22f and the second seal parts 11d have scroll shapes in which the first distance and the second distance change around the axial center C. The first seal part 22f is disposed on the outer peripheral side of the second seal part 11d, and the first distance and the second distance decrease toward the direction shown by the arrow B in
When the door bodies 24 rotate in the direction to open the defroster air passage 24 (i.e., the direction shown by the arrow B), the first distance becomes longer compared with the second distance in a certain radial direction. Thus, when the door bodies 24 rotate in the direction to open the defroster air passage 24, the first seal parts 22f rotate in a direction to separate from the second seal parts 11d as shown in
When the rotation shaft 22a rotates, an area of the contact interfaces between the first seal parts 22f and the second seal parts 11d is reduced. Therefore, a friction between the first seal parts 11f and the second seal parts 11d is reduced. As a result, the rotation shaft 22a is rotatable without increasing an operation force. Further, a noise due to the friction between the first seal parts 22f and the second seal parts 11d is prevented.
For obtaining the above-described effect, the door seal structure is only required to have a structure such that the first seal parts 22f are in contact with the second seal parts 11d only when the door bodies 22b close the defroster air passage 24, and the first seal parts 22f separate from the second seal parts 11d when the door bodies 22b start to move in the direction to open the defroster air passage 24.
In the first embodiment, the first protruding parts 22d are made of the elastic material for increasing the pressing force of the contact interfaces between the first seal parts 22f and the second seal parts 11d, and for improving the sealing property of the door seal structure.
Thus, when the door bodies 22b start to move in the direction to open the defroster air passage 24, the contact interfaces remain a little. However, at this time, the first seal parts 22f move in the direction to separate from the second seal parts 11d, thereby, the operation force to rotate the rotation shaft 22a is reduced.
When the door bodies 22b fully open the defroster air passage 24, the seal members 22c of the door bodies 22b separate from the ribs 11a of the case 11, and the first seal parts 22f separate from the second seal parts 11d, as shown in
As described above, in the air passage switching device according to the first embodiment, when the door bodies 22b close the defroster air passage 24, the first seal parts 22f positioned at axial end portions of the defroster door 22 are in contact with the second seal parts 11d for preventing an air leak from the upstream air side to the downstream air side of the defroster door 22. Further, when the door bodies 22b rotate in the direction to open the defroster air passage 24, the first seal parts 22f rotate in the direction to separate from the second seal parts 11d. Therefore, the rotation shaft 22a is suitably rotatable without increasing the operation force.
In the above-described first embodiment, the first seal parts 22f of the first protruding parts 22d press-contact the second seal parts 11d of the second protruding parts 11c from the radial outside of the second protruding part 11C. However, an air passage switching device according to a second embodiment of the invention has a seal structure in which the first protruding parts 22d are inserted in the second protruding parts 11c in a radial direction, as shown in
The first protruding parts 22d are formed so that a distance between the outer peripheral surfaces of the first protruding parts 22d and the axial center C gradually increases toward the direction in which the door bodies 22b open the defroster air passage 24 (i.e., the direction shown by the arrow B).
The second protruding parts 11c are formed around the bearing holes 11b of the case 11, to protrude to the sides of the defroster door 22. The first protruding parts 22d are inserted into the second protruding part 11c in the radial direction. The second protruding part 11c are formed so that a distance between the inner peripheral surfaces of the second protruding parts 11c and the axial center C gradually increases toward the direction in which the door bodies 22b open the defroster air passage 24, similarly to the first seal parts 22f.
Further, the inner peripheral surfaces of the second protruding parts 11c are formed to have shapes fitting to shapes of the outer peripheral surfaces of the first protruding parts 22d when the door bodies 22b close the defroster air passage 24. As shown in
In this way, when the outer peripheral surfaces of the first protruding parts 22d are in contact with the inner peripheral surfaces of the second protruding parts 11c, the gaps between the first protruding parts 22d and the second protruding parts 11c are sealed. Thus, in the second embodiment, the outer peripheral surfaces of the first protruding parts 22d form the first seal parts 22f, and the inner peripheral surfaces of the second protruding parts 11c form the second seal parts 11d. The first seal parts 22f and the second seal parts 11d are formed to construct the seal structure.
The first seal parts 22f and the second seal parts 11d have scroll shapes in which the first distance between each of the first seal parts 22f and the axial center C and the second distance between each of the second seal parts 11d and the axial center C gradually increase toward the direction (i.e., the direction shown by the arrow B in
In the second embodiment, the direction in which the door bodies 22b open the defroster air passage 24, i.e., the direction shown by the arrow B is a clockwise, contrary to that of the first embodiment. The other parts of the air passage switching device according to the second embodiment are similar with those of the first embodiment.
When the door bodies 22b close the defroster air passage 24, the door seal structure constructed with the sealing members 22c and the ribs 11a is formed to seal the gap between the door bodies 22b and the case 11. Further, the seal structure constructed with the first seal parts 22f and the second seal parts 11d is formed to seal the gap between the end portions of the rotation shaft 22a and the case 11. Therefore, the air passage switching device according to the second embodiment prevents an air leak from the upstream air side to the downstream air side of the defroster door 22.
As shown in
When the door bodies 22b open the defroster air passage 24, the first seal parts 22f formed in the first protruding parts 22d integrally rotate with the rotation shaft 22a. The first seal parts 22f are arranged to an inner peripheral side with respect to the second seal parts 11d. Furthermore, the first distance and the second distance gradually increase toward the direction in which the door bodies 22b open the defroster air passage 24.
Therefore, when the door bodies 22b rotate in the direction to open the defroster air passage 24, the first distance becomes shorter compared with the second distance in a certain radial direction as shown in
Therefore, in the air passage switching device according to the second embodiment, similar effects with those of the first embodiment can be obtained.
Although the present invention has been fully described in connection with the preferred embodiments thereof with reference to the accompanying drawings, it is to be noted that various changes and modifications will become apparent to those skilled in the art.
For example, in the first and second embodiments, the shapes of the first seal parts 22f and the second seal parts 11d are scroll shapes in which the first distance between each of the first seal parts 22f and the axial center C and the second distance between each of the second seal parts 11d and the axial center C gradually change around the axis of the axial center C. However, excursions of the first seal parts 22 and the second seal parts 11d in a direction perpendicular to the axial center C may be a part of an involute curve and a part of a cycloid curve.
In the first and second embodiments, the air passage switching device according to the invention is typically used for the switching system for the defroster air passage 24, for example. However, an application of the invention is not limited to the switching system for the defroster air passage 24. For example, the invention may be applied to an air passage switching device for the foot air passage 30 switched by the foot door 29 which is the butterfly door similar with the defroster door 22.
When the face door 28 and the air-mixing door 16 are butterfly doors, the invention may be applied to an air passage switching devices for the air passage switched by the face door 28 or the air-mixing door 16. The invention may be applied not only to the vehicle air conditioner but also to any air passage switching device being within the scope of the invention.
In the first and second embodiments, the first seal parts 22f are arranged in the first area 24a which is located on an upstream air side (the direction shown by the arrow A) when the door bodies 22b close the defroster air passage 24. However, even when the first seal parts 22f are arranged in the second area 24b which is located on a downstream air side of the defroster door 22, the seal structure can prevent an air leak from upstream air side to the downstream air side of the defroster door 22, when the door bodies 22b close the defroster passage 24.
In the butterfly door of the first and second embodiments, the rotation shaft 22a is disposed between the two door bodies 22b which are arranged in approximately parallel. Therefore, both the first area 24a and the second area 24b are provided around the axial center C in the range of 180°. Thus, the first seal parts 22f are arranged around the axial center C in the range of 180°.
When the two door bodies 22b are arrange in nonparallel across the rotation shaft 22a, as shown in
In the first and second embodiments, the first protruding parts 22d are made of the elastic material and the second protruding parts 11c are made of the inelastic material. Alternatively, the first protruding parts 22d may be made of the inelastic material and the second protruding parts 11c may be made of the elastic material. In this case, the second protruding parts 11c is fixed with the case 11 by integrally formed with the case 11, and surfaces of the second protruding parts 11c which form the second seal parts 11d are tilted toward surfaces of the first protruding parts 22d which form the first seal parts 22f. Thus, the similar effect with those of the first and second embodiments can be obtained.
Further, each of the two door bodies 22b may have a different shape. When the door bodies 22b close the defroster air passage 24, the door bodies 22b are in contact with the ribs 11a on the surfaces on different sides. When the door bodies 22b have different lengths in the axial direction of the rotation shaft 22a, the sealing members 22c disposed in the outer end part of the both door bodies 22b and the first protruding parts 22d are integrally formed easily.
In the above-described embodiments, the present invention is applied to an air passage switching device with a butterfly door. However, the present invention can be applied to an air passage switching device with a door in which the rotation shaft 22a is not positioned at a center portion of the door body 22b. In this case, the rotation shaft 22a is disposed at a portion of the door body 22b to be rotated integrally with the door body 22b.
Such changes and modifications are to be understood as being within the scope of the present invention as defined by the appended claims.
Number | Date | Country | Kind |
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2006-155733 | Jun 2006 | JP | national |