Description:FIELD OF INVENTION
[0001] Embodiments of the present disclosure relate to the field of automotive heating, ventilation, and air conditioning (HVAC) systems, and more particularly, an assembly and a method for controlling valve accelerations in an automotive HVAC module.
BACKGROUND
[0002] A typical HVAC system, positioned beneath the instrument panel (IP) of a vehicle, consists of heat exchanges encompassed withing the plastic housings. Air flow through the housing is controlled by doors or valves, directing it along a designed flow path from the vehicle’s inlet cowl towards the HVAC module and finally passing through distribution ducts into a cabin. Velocity of the air flows through the designed flow path, accelerates or decelerates depending on the available cross section area which in turn is influenced by the available packaging space.
[0003] The doors or valves within the HVAC module control and direct airflow. These components are typically designed as butterfly, flag-type, or drum valves. Drum or cylindrical valves generally present a smaller surface area to the airflow and are less directly exposed to air pressure forces. In contrast, butterfly and flag-type valves feature larger frontal surface areas, making them more susceptible to significant forces from air pressure. Higher airflow velocities and accelerations exert greater forces on these surfaces, causing them to rotate or displace about a pivot axis.
[0004] The movement, acceleration, and direction of airflow significantly affect the forces acting on the doors or valves. While cylindrical and butterfly valves inherently counteract fluid forces due to their design, flag-type valves tend to rotate in the direction of airflow, particularly when closing against it. This additional force accelerates valve closure, potentially leading to failures in the drive mechanism. The increased forces and resulting acceleration cause abrupt valve closures, leading to abnormal air and structural noise. Moreover, the valve may close faster than intended, requiring greater force to reopen it from a fully closed to a fully open position. This, in turn, necessitates a more robust and costly drive mechanism. Beyond functional concerns and added costs, such issues may negatively impact user satisfaction.
[0005] Hence, there is a need for an assembly and a method for controlling valve accelerations in an automotive HVAC module which addresses the aforementioned issue(s).
OBJECTIVES OF THE INVENTION
[0006] Primary objective of the invention is to control valve or door acceleration and airflow distribution in an automotive HVAC system by integrating a bypass arrangement that reduces pressure gradients acting across the valve or door, ensuring smooth and controlled movement.
[0007] Another objective of the invention is to develop a bypass structure that may be implemented as either a full pressure relief chamber covering the entire swing of the valve or door or as a localized channel positioned on the side, top, or bottom of the valve or door, depending on available space constraints.
[0008] Another objective of the invention is to ensure the bypass arrangement remains sealed at fully open and fully closed positions to prevent air leakage while allowing controlled pressure relief in intermediate positions, thereby minimizing excessive forces, noise, and the like.
BRIEF DESCRIPTION
[0009] In accordance with an embodiment of the present disclosure, an assembly for controlling valve accelerations in an automotive heating, ventilation, and air conditioning module is provided. The assembly includes a housing adapted to direct airflow through a predefined flow path from a vehicle inlet cowl to a cabin distribution duct pertaining to the automotive heating, ventilation, and air conditioning module. The housing includes at least one valve adapted to rotate about a pivot axis to control the airflow. The housing includes a bypass structure integrated into the at least one valve. The bypass structure is adapted to provide a bypass airflow path to reduce a plurality of static pressure gradients across an inflow surface and an outflow surface of the at least one valve, thereby ensuring uniform airflow distribution and controlling the valve acceleration when the at least one valve is in an intermediate rotational position. The bypass structure is adapted to seal and close when the at least one valve reaches a fully open position and a fully closed position, thereby preventing air leakage. The bypass structure is at least one of a full pressure relief chamber and a localized channel. The full pressure relief chamber covers a rotational path of the at least one valve. The localized channel is positioned on at least one of a top side, a bottom side and lateral side of the at least one valve. The localized channel is adapted to fit within an available space of the housing.
[0010] In accordance with another embodiment of the present disclosure, a method for controlling valve accelerations in an automotive heating, ventilation, and air conditioning module is provided. The method includes directing, by a housing, airflow through a predefined flow path from a vehicle inlet cowl to a cabin distribution duct pertaining to the automotive heating, ventilation, and air conditioning module. The method includes rotating, by at least one valve, about a pivot axis to control the airflow. The method includes providing, by the bypass structure, a bypass airflow path to reduce a plurality of static pressure gradients across an inflow surface and an outflow surface of the at least one valve, thereby ensuring uniform airflow distribution and controlling the valve acceleration when the at least one valve is in an intermediate rotational position. The method includes sealing and closing, by the bypass structure, when the at least one valve reaches a fully open position and a fully closed position, thereby preventing air leakage. The bypass structure is at least one of a full pressure relief chamber and a localized channel. The full pressure relief chamber covers a rotational path of the at least one valve. The localized channel is positioned on at least one of a top side, a bottom side and lateral side of the at least one valve, wherein the localized channel is adapted to fit within an available space of the housing.
[0011] To further clarify the advantages and features of the present disclosure, a more particular description of the disclosure will follow by reference to specific embodiments thereof, which are illustrated in the appended figures. It is to be appreciated that these figures depict only typical embodiments of the disclosure and are therefore not to be considered limiting in scope. The disclosure will be described and explained with additional specificity and detail with the appended figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The disclosure will be described and explained with additional specificity and detail with the accompanying figures in which:
[0013] FIG. 1(a) is a schematic top-view representation of an assembly for controlling valve accelerations in an automotive heating, ventilation, and air conditioning module, in accordance with an embodiment of the present disclosure and FIG. 1(b) is a schematic front-view representation of the assembly;
[0014] FIG. 2 is a schematic representation providing an application overview of an assembly of FIG. 1(a) and FIG. 1(b) in accordance with an embodiment of the present disclosure; and
[0015] FIG. 3 illustrates a flow chart representing the steps involved in a method for controlling valve accelerations in an automotive heating, ventilation, and air conditioning module in accordance with an embodiment of the present disclosure.
[0016] Further, those skilled in the art will appreciate that elements in the figures are illustrated for simplicity and may not have necessarily been drawn to scale. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the figures by conventional symbols, and the figures may show only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the figures with details that will be readily apparent to those skilled in the art having the benefit of the description herein.
DETAILED DESCRIPTION
[0017] For the purpose of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiment illustrated in the figures and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Such alterations and further modifications in the illustrated system, and such further applications of the principles of the disclosure as would normally occur to those skilled in the art are to be construed as being within the scope of the present disclosure.
[0018] The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such a process or method. Similarly, one or more devices or subsystems or elements or structures or components preceded by "comprises... a" does not, without more constraints, preclude the existence of other devices, sub-systems, elements, structures, components, additional devices, additional sub-systems, additional elements, additional structures or additional components. Appearances of the phrase "in an embodiment", "in another embodiment" and similar language throughout this specification may, but not necessarily do, all refer to the same embodiment.
[0019] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this disclosure belongs. The system, methods, and examples provided herein are only illustrative and not intended to be limiting.
[0020] In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings. The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.
[0021] Embodiments of the present disclosure relate to an assembly for controlling valve accelerations in an automotive heating, ventilation, and air conditioning module. The assembly includes a housing adapted to direct airflow through a predefined flow path from a vehicle inlet cowl to a cabin distribution duct pertaining to the automotive heating, ventilation, and air conditioning module. The housing includes at least one valve adapted to rotate about a pivot axis to control the airflow. The housing includes a bypass structure integrated into the at least one valve. The bypass structure is adapted to provide a bypass airflow path to reduce a plurality of static pressure gradients across an inflow surface and an outflow surface of the at least one valve, thereby ensuring uniform airflow distribution and controlling the valve acceleration when the at least one valve is in an intermediate rotational position. The bypass structure is adapted to seal and close when the at least one valve reaches a fully open position and a fully closed position, thereby preventing air leakage. The bypass structure is at least one of a full pressure relief chamber and a localized channel. The full pressure relief chamber covers a rotational path of the at least one valve. The localized channel is positioned on at least one of a top side, a bottom side and lateral side of the at least one valve. The localized channel is adapted to fit within an available space of the housing.
[0022] FIG. 1(a) is a schematic top-view representation of an assembly (100) for controlling valve accelerations in an automotive heating, ventilation, and air conditioning module, in accordance with an embodiment of the present disclosure and FIG. 1(b) is a schematic front-view representation of the assembly (100). The assembly (100) includes a housing (not shown in FIG. 1(a) and FIG. 1(b)) adapted to direct airflow through a predefined flow path from a vehicle inlet cowl to a cabin distribution duct pertaining to the automotive heating, ventilation, and air conditioning module.
[0023] The housing includes at least one valve (110) adapted to rotate about a pivot axis (125) to control the airflow. During the airflow, a plurality of static pressure gradients develops across the surfaces of the at least one valve (110), namely, an inflow side (front) and an outflow side (back). This pressure differential results in a positive pressure on the inflow side and a negative pressure on the outflow side, which accelerates the at least one valve (110) in the direction of airflow.
[0024] It must be noted the term "valve" may also refer to a "door." The at least one valve or door (110) may include, but is not limited to, butterfly valves, drum valves, and flag-type valves or doors. While the assembly (100) is particularly effective for flag-type valve or door designs, it may also be applicable to other valve or door configurations.
[0025] In one embodiment, for flag-type valve or door designs, when the rotation angle is minimal and the air flow velocity in the flow cross-section exceeds 18–20 m/s, the flag-type flap behaves as a bluff body, leading to a ramming effect that increases static pressure levels on the flap surfaces. This static pressure buildup results in a higher resisting torque at the flap pivot, making it difficult to regulate movement. If uncontrolled, the flap may slam into its stopper, generating a noticeable, abrupt, and uncomfortable noise inside the vehicle cabin.
[0026] Furthermore, if the flag-type flap needs to be held at a certain intermediate position, the resisting torque at the flap pivot may exceed 100 N·cm, making it almost impossible to restrict the flap’s movement. This issue compromises airflow control accuracy and reduces system efficiency.
[0027] The housing includes a bypass structure (115) integrated into the at least one valve (110). The bypass structure (115) is adapted to provide a bypass airflow path to reduce the plurality of static pressure gradients across the inflow surface and the outflow surface of the at least one valve (110) bypass provided to relieve the pressure gradient, thereby ensuring uniform airflow distribution and controlling the valve acceleration when the at least one valve (110) is in an intermediate rotational position. Additionally, the bypass structure (115) enables the flap movement to mimic an isobaric process, stabilizing airflow around the flap and improving motion control.
[0028] It must be noted that, an actuator motor (driver) may precisely regulate the flap position, reducing resistance torque and allowing for accurate positioning.
[0029] The bypass structure (115) is adapted to seal and close (120) when the at least one valve (110) reaches a fully open position and a fully closed position, thereby preventing air leakage.
[0030] It must be noted that, the assembly (100) is particularly beneficial in applications where high air velocities (above 18–20 m/s) would otherwise lead to excessive static pressure buildup, uncontrolled flap movement, and high torque demands at the pivot. By incorporating a bypass airflow path, the assembly (100) ensures smooth operation, prevents abrupt flap slamming, and enables precise airflow regulation at all speeds.
[0031] Further, the assembly (100) is particularly beneficial for small and medium-sized automotive HVAC systems, where the use of butterfly valves, which naturally generate minimal resisting torque is limited due to space constraints. The bypass-integrated flag-type flap ensures that the desired airflow mode can be achieved at all airspeeds, despite manufacturing limitations.
[0032] The bypass structure (115) is at least one of a full pressure relief chamber and a localized channel. The full pressure relief chamber covers a rotational path of the at least one valve (110) and allowing uniform pressure distribution.
[0033] The localized channel is positioned on at least one of a top side, a bottom side and lateral side of the at least one valve (110). The localized channel is adapted to fit within an available space of the housing.
[0034] It must be noted that the bypass structure (115) may have any shape or dimension, depending entirely on the available space within the housing, rather than being limited to a full pressure relief chamber or a localized channel.
[0035] FIG. 2 is a schematic representation providing an application overview of an assembly of FIG. 1(a) and FIG. 1(b) in accordance with an embodiment of the present disclosure. A pivot axis (125), and a bypass structure (115) previously marked in FIG. 1(a) and FIG. 1(b), is depicted in FIG. 2. Additionally, at least one valve is positioned inside the automotive heating, ventilation, and air conditioning (HVAC) module.
[0036] Let's consider a butterfly valve used in a vehicle's HVAC system to regulate airflow between the vehicle inlet cowl and the cabin distribution duct. The butterfly valve rotates about the pivot axis (125) to control airflow by opening or closing. As the valve moves through an intermediate rotational position, the bypass structure activates, opening a secondary airflow path to allow a controlled amount of air to pass through. This ensures even airflow distribution across both sides of the valve while maintaining smooth valve movement. Once the valve reaches a fully open or fully closed position, the bypass structure deactivates, preventing air leakage. The integration of the bypass structure enhances valve operation while ensuring consistent airflow within the HVAC system.
[0037] FIG. 3 illustrates a flow chart representing the steps involved in a method (200) for controlling valve accelerations in an automotive heating, ventilation, and air conditioning module in accordance with an embodiment of the present disclosure. The method (200) includes directing, by a housing, airflow through a predefined flow path from a vehicle inlet cowl to a cabin distribution duct pertaining to the automotive heating, ventilation, and air conditioning module in step 205.
[0038] The method (200) includes rotating, by at least one valve, about a pivot axis to control the airflow in step 210. It must be noted the term "valve" may also refer to a "door." The at least one valve or door may include, but is not limited to, butterfly valves, drum valves, and flag-type valves or doors. While the assembly is particularly effective for flag-type valve or door designs, it may also be applicable to other valve or door configurations.
[0039] It must be noted that, during the airflow, a plurality of static pressure gradients develops across the surfaces of the at least one valve or door, namely, an inflow side (front) and an outflow side (back). This pressure differential results in a positive pressure on the inflow side and a negative pressure on the outflow side, which accelerates the at least one valve or door in the direction of airflow.
[0040] The method (200) includes providing, by the bypass structure, a bypass airflow path to reduce the plurality of static pressure gradients across the inflow surface and the outflow surface of the at least one valve, thereby ensuring uniform airflow distribution and controlling the valve acceleration when the at least one valve is in an intermediate rotational position in step 215. Additionally, the bypass structure enables the flap movement to mimic an isobaric process, stabilizing airflow around the flap and improving motion control.
[0041] The method (200) includes sealing and closing, by the bypass structure, when the at least one valve reaches a fully open position and a fully closed position, thereby preventing air leakage. The bypass structure is at least one of a full pressure relief chamber and a localized channel. The full pressure relief chamber covers a rotational path of the at least one valve. The localized channel is positioned on at least one of a top side, a bottom side and lateral side of the at least one valve, wherein the localized channel is adapted to fit within an available space of the housing in step 220.
[0042] It must be noted that, the assembly is particularly beneficial in applications where high air velocities (above 18–20 m/s) would otherwise lead to excessive static pressure buildup, uncontrolled flap movement, and high torque demands at the pivot. By incorporating a bypass airflow path, the assembly ensures smooth operation, prevents abrupt flap slamming, and enables precise airflow regulation at all speeds.
[0043] Further, the assembly is particularly beneficial for small and medium-sized automotive HVAC systems, where the use of butterfly valves, which naturally generate minimal resisting torque is limited due to space constraints. The bypass-integrated flag-type flap ensures that the desired airflow mode can be achieved at all airspeeds, despite manufacturing limitations.
[0044] Various embodiments of the assembly and the method for controlling valve accelerations in an automotive HVAC module as described above provides several advantages. By integrating the bypass structure, the assembly effectively reduces pressure gradients acting across the valve or door, ensuring smooth and controlled movement while improving airflow distribution in the automotive HVAC system. The bypass structure may be implemented as a full pressure relief chamber or a localized channel, providing design flexibility based on space constraints. Additionally, the bypass arrangement remains sealed at fully open and fully closed positions, preventing air leakage and enhancing system efficiency. In intermediate positions, the bypass structure allows controlled pressure relief, minimizing excessive forces, reducing noise, and the like, thereby improving durability and overall performance.
[0045] It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the disclosure and are not intended to be restrictive thereof.
[0046] While specific language has been used to describe the disclosure, any limitations arising on account of the same are not intended. As would be apparent to a person skilled in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein.
[0047] The figures and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, the order of processes described herein may be changed and are not limited to the manner described herein. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all of the acts need to be necessarily performed. Also, those acts that are not dependent on other acts may be performed in parallel with the other acts. The scope of embodiments is by no means limited by these specific examples.
, Claims:WE CLAIM:
1. An assembly (100) for controlling valve accelerations in an automotive heating, ventilation, and air conditioning module comprising:
a housing adapted to direct airflow through a predefined flow path from a vehicle inlet cowl to a cabin distribution duct pertaining to the automotive heating, ventilation, and air conditioning module, wherein the housing comprising:
at least one valve (110) adapted to rotate about a pivot axis (125) to control the airflow;
a bypass structure (115) integrated into the at least one valve (110), wherein the bypass structure (115) is adapted to:
provide a bypass airflow path to reduce a plurality of static pressure gradients across an inflow surface and an outflow surface of the at least one valve (110), thereby ensuring uniform airflow distribution and controlling the valve acceleration when the at least one valve (110) is in an intermediate rotational position; and
seal and close (120) when the at least one valve (110) reaches a fully open position and a fully closed position, thereby preventing air leakage,
wherein the bypass structure (115) is at least one of a full pressure relief chamber and a localized channel, wherein the full pressure relief chamber covers a rotational path of the at least one valve (110), and wherein the localized channel is positioned on at least one of a top side, a bottom side and lateral side of the at least one valve (110), wherein the localized channel is adapted to fit within an available space of the housing.
2. The assembly (100) as claimed in claim 1, wherein the at least one valve (110) comprises one of butterfly valve, drum valve, and flag-type door.

3. The assembly (100) as claimed in claim 1, wherein the assembly (100) is applicable to small automotive heating, ventilation, and air conditioning systems and medium-sized automotive heating, ventilation, and air conditioning systems.

4. A method (200) for controlling valve accelerations in an automotive heating, ventilation, and air conditioning module comprising:
directing, by a housing, airflow through a predefined flow path from a vehicle inlet cowl to a cabin distribution duct pertaining to the automotive heating, ventilation, and air conditioning module; (205)
rotating, by at least one valve, about a pivot axis to control the airflow; (210)
providing, by the bypass structure, a bypass airflow path to reduce a plurality of static pressure gradients across an inflow surface and an outflow surface of the at least one valve, thereby ensuring uniform airflow distribution and controlling the valve acceleration when the at least one valve is in an intermediate rotational position; and (215)
sealing and closing, by the bypass structure, when the at least one valve reaches a fully open position and a fully closed position, thereby preventing air leakage, wherein the bypass structure is at least one of a full pressure relief chamber and a localized channel, wherein the full pressure relief chamber covers a rotational path of the at least one valve, and wherein the localized channel is positioned on at least one of a top side, a bottom side and lateral side of the at least one valve, wherein the localized channel is adapted to fit within an available space of the housing. (220)

Dated this 14th Day of April 2025

Signature

Manish Kumar
Patent Agent (IN/PA-5059)
Agent for the Applicant