FORM -2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE
Specification
(See Section 10; rule 13)
Leak Proof Modular Heating, Ventilation and Air Conditioning
(HVAC) Housing Assembly
BEHR INDIA LIMITED
an Indian Company ofGat.No.626/l/2& 622/1/0 29 Milestone, Pune-Nasik Highway, Village Kuruli, Tal. Khed, Pune-410501, Maharashtra, India
NAME OF THE INVENTORS
1. Parthasarathi Garikipati
2. Kulkarni, Mithul Kishor
The following specification particularly describes the invention and the manner in
which it is to be performed.

FIELD OF THE DISCLOSURE
The present disclosure generally relates to systems and methods used for preventing condensate leakage.
Particularly, the present disclosure relates to systems and methods used for preventing condensate leakage in modular HVAC units.
BACKGROUND OF THE INVENTION
HVAC (Heating, Ventilating, and Air Conditioning) refers to a technology of indoor or automotive environmental comfort. With increasing need for conditioning of the environment, there has been considerable demand for HVAC climate boxes or HVAC units. One of the most common problems faced with HVAC units is condensate leakage that leads to leaks in buildings that house the HVAC unit, costly mold prevention means, insect damage, or even complete shutdown of the HVAC system.
There have been a lot of efforts in the prior art for improving the efficiency of HVAC units by improving their design and construction. One such development is a modular HVAC unit which makes the climate box highly flexible and compact, making it convenient for use in all kinds of vehicles. Also, the modular HVAC unit is not limited by the type of fuel used in the vehicle.
Conventionally, a Distribution housing of an HVAC unit is split into two housings, left and right. Accordingly, a single leak proof joint is provided at the

bottom of the HVAC unit in the drain area to avoid condensate leakage. But in modular HVAC units, the HVAC unit has six modules. The single joint used in conventional HVAC unit is not sufficient for leak proofing in modular HVAC units.
Some of the prior art documents are as follows:
For example, US Publication US20110028077 discloses a headliner duct for a heating-venting-air conditioning (HVAC) system in a motor vehicle. The headliner duct includes a headliner and an elongated thermoformed aircap that has a wall and is bonded to a top side of the headliner. The thermoformed aircap and the headliner form an air duct, the air duct having an inlet and being operable to have an air flow pass therethrough. The elongated thermoformed aircap has an air-kick that is integral with the wall of the aircap and extends into an air flow region thereof. However, US Publication US20110028077 is related to the headliner duct that diverts at least part of an air flow past a first register to a second register.
US Publication US20100251893 discloses a filter used in combination with a register for an HVAC system. The register is mounted to a wall, floor, or ceiling. The type of register used has a plurality of parallel blades which are located on the exterior side of the register and a plurality of vane members set behind the parallel blades, where a space is defined between the parallel blades and the plurality of vane members. The filter has a pliable rectangular frame and a pliable filter material spanning across the pliable rectangular frame. The pliable rectangular frame and pliable filter material allow the filter to be inserted between the blades for placement in the space without removing the

register from the wall, floor or ceiling. However, US Publication US20100251893 is related to the filter used for filtering the air discharged at the HVAC outlet.
US Publication US20100294132 discloses an asymmetric membrane having a porous layer and a dense layer adjacent to the porous layer. The porous layer and the dense layer are made of a polymer material. The porous layer and/or the dense layer contains a filler. However, US Publication US20100294132 is related to the asymmetric membrane.
US Publication US20100000170 discloses a fibrous insulation product having at least one facing material adhered thereto. The facing includes a pre-applied waterless, thin-film adhesive that is thermoplastic and heat activated. Accordingly, the facing may be repaired or repositioned in the field with the use of a hot applicator. In at least one embodiment, the fibrous insulation product is a duct board formed of an insulation layer with a vapor barrier adhered to a first major surface and a fibrous web adhered to a second major surface. The vapor barrier is preferably wider than the insulation layer to form a sealing flange. The waterless, thin-film adhesive may be placed on a sealing flange and heat sealed without the use of hand applied foil tape. The waterless, thin-film adhesive reduces odor potential and improves fiberglass recovery. Also, it is stated that the waterless, thin-film adhesive requires less energy to cure than a water-based adhesive, thereby reducing cost. However, the US Publication US20100000170 is related to the fibrous insulation product.
US Patent US6224143 discloses a cowl panel for an automotive vehicle has a plurality of air vents which direct outside air into an air plenum for distribution

to the interior of the vehicle through the heating, air conditioning and ventilation system. An air permeable mat is bonded to the underside of the cowl to cover the air vents. The mat permits the passage of air but restricts the passage of liquids such as water thereby reducing the volume of water that must be drained from the plenum. However, the US Patent US6224143 is related to the cowl panel.
US Patent US5325893 discloses an air duct that includes a tubular member formed from a metal sheet. A paper is disposed around an outer periphery of the tubular member for preventing condensation droplets condensed on the tubular member from dripping, and an adhesive is interposed between the tubular member and the paper to adhesively secure the tubular member and the paper. Furthermore, a paper for an air duct, adapted to be secured to an outer periphery of the air duct. The paper is produced from a material including a papermaking pulp. However, the US Patent US5325893 is related to the air duct.
US patent US5106447 discloses insulation assemblies for the HVAC industry. The insulation assemblies are bonded by spray application of a hot melt adhesive composition comprising 10 to 50 percent of an isostactic thermoplastic polybutene-1/ethylene copolymer containing from about 5.5 to about 10% by weight ethylene; 20 to 50 percent of a tackifier; 15 to 50 percent of an amorphous diluent having a softening point greater than 90.degree. C; 0 to 2 percent antioxidant; and 0 to 5 percent wax. However, the insulation assemblies provided by the US patent US5106447 are ineffective in providing leak proof joints in modular HVAC units.

Accordingly, there is a need of a method and a system to provide leak proof joints in modular HVAC units.
OBJECTS OF THE INVENTION
An object of the invention is to provide leak proof joints in modular HVAC units.
Another object of the invention is to provide leak proof joints in modular HVAC units which are flexible with interchangeable modules.
Still another object of the invention is to provide leak proof joints in modular HVAC units which can be used without any restriction on the type of fuel.
Yet another object of the invention is to provide leak proof joints in modular HVAC units which can be used for any type of vehicle as well as for various indoor applications.
One more object of the invention is to provide optimum number of leak proof joints in modular HVAC units.
SUMMARY OF THE INVENTION
In accordance with one aspect of the present invention, a leak proof modular Heating, Ventilation and Air Conditioning (HVAC) housing assembly for preventing condensate leakage is disclosed. The leak proof modular HVAC housing assembly includes a blower housing and a distribution housing. The

blower housing is configured to accommodate at least a blower. The distribution housing includes an evaporator unit, a heater unit and a distribution unit. The evaporator unit is configured to accommodate at least an evaporator. The evaporator unit includes a pair of evaporator sub-elements assembled together by means of a plurality of leak proof joints to form the evaporator unit. The heater unit is connected to the evaporator unit. The heater unit is configured to accommodate at least a heater. The heater unit includes a pair of heater sub-elements assembled together by means of at least one leak proof joint to form the heater unit. The distribution unit is disposed over the heater unit and connected to the evaporator unit. The distribution unit is configured to accommodate a plurality of flaps to achieve various airflow modes. The distribution unit includes a pair of distribution sub-elements assembled together to form the distribution unit.
Further, the blower housing is connected to the distribution housing by a duct.
In one embodiment of the present invention, the blower housing is further configured to accommodate a scroll assembly, a motor, a motor holder and a fresh/re-circulating housing assembly.
Further, the evaporator unit may be further configured to accommodate a filter.
Typically, the heater unit is further configured to accommodate a secondary flap.
In accordance with another aspect of the present invention, a method of forming a leak proof modular HVAC housing assembly for preventing condensate

leakage is disclosed. The method includes the following steps: forming an evaporator unit by assembling a pair of evaporator sub-elements by means of a plurality of leak proof joints; forming a heater unit by assembling a pair of heater sub-elements by means of at least one leak proof joint; forming a distribution unit by assembling a pair of distribution sub-elements; assembling said evaporator unit with said heater unit and said distribution unit for forming a distribution housing; and connecting said distribution housing to a blower housing to form said leak proof modular HVAC housing assembly.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The invention will now be explained in relation to the accompanying drawings, in which:
FIGURE 1 illustrates a perspective view of a leak proof modular HVAC housing assembly, in accordance with one embodiment of the present invention;
FIGURE 2 illustrates a sectional side view of the leak proof modular HVAC housing assembly of FIGURE 1;
FIGURE 3 illustrates a sectional front view of an Evaporator unit of the leak proof modular HVAC housing assembly of FIGURE 1;
FIGURE 4 illustrates a schematic representation of two halves of the Evaporator unit of FIGURE 3 during the process of assembly thereof;
FIGURE 5 illustrates a schematic representation of two halves of a Heater unit during the process of assembly thereof;

FIGURE 6 illustrates a schematic representation of a Distribution unit disposing over the Heater unit of FIGURE 5; and
FIGURE 7 illustrates a schematic representation depicting assembling of the Evaporator unit of FIGURE 4 with the Heater unit - Distribution unit assembly of FIGURE 6.
DETAILED DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The invention will now be described with reference to the accompanying drawings which do not limit the scope and ambit of the invention. The description provided is purely by way of example and illustration.
The present invention provides a leak proof modular Heating, Ventilation and Air Conditioning (HVAC) housing assembly for accommodating various components of the HVAC system. The leak proof modular HVAC housing assembly of the present invention prevents condensate leakage there from. As the components of the leak proof modular HVAC housing assembly of the present invention are interchangeable, such interchange ability of various components of the leak proof modular HVAC housing assembly does not hamper the leakage preventing capacity of the leak proof modular HVAC housing assembly of the present invention.
The diagrams and description hereto are merely illustrative and only exemplify the invention and in no way limit the scope thereof.

The invention will now be described with reference to FIGURES 1 - 7. FIGURE 1 illustrates a perspective view of a leak proof modular HVAC housing assembly 100. The components of the leak proof modular HVAC housing assembly 100 of FIGURE 1 are housed in various zones. The leak proof modular HVAC housing assembly 100 includes a blower housing 10, a duct 20 and a distribution housing 30. The distribution housing 30 includes an evaporator unit 12, a heater unit 14, a distribution unit 16, and an adapter duct unit 18.
More specifically, the distribution housing 30 is formed by assembly of the evaporator unit 12, the heater unit 14, the distribution unit 16, and the adapter duct unit 18. In one embodiment of the present invention, the Evaporator unit 12, the Heater unit 14, the Distribution unit 16 and the Adapter Duct unit 18 are assembled with each other by rigid joints to form the Distribution Housing 30. However, the present invention is not limited to any particular method or any particular fastening means used for assembling the Evaporator unit 12, the Heater unit 14, the Distribution unit 16 and the Adapter Duct unit 18 to form the Distribution housing 30. In one embodiment of the present invention, the Blower housing 10 is connected to the Distribution Housing 30 by means of a Duct 20 depending on the construction of the climate box i.e. Centre stack or Inline. However, the present invention is not limited to any particular connecting means used for connecting the Blower housing 10 to the Distribution Housing 30.
The Blower housing 10 is configured to accommodate at least a blower (not shown). The blower hosing is also configured to accommodate a scroll

assembly (not shown), a motor (not shown), a motor holder (not shown) and a fresh / recirculation housing assembly (not shown).
The Evaporator unit 12 is configured to accommodate at least an evaporator (not shown). The Evaporator unit 12 is also configured to accommodate a filter depending on the requirement of the same. The Heater unit 14 is configured to accommodate a heater. The Heater unit 14 is also configured to accommodate, optionally, a secondary flap. The Distribution unit 16 is configured to accommodate a plurality of flaps used to achieve different air flow modes. The Adapter Duct unit 18 is an optional part used to interface with a vehicle duct having indeterminate orientation. In the absence of an Adapter Duct unit 18, the Distribution unit 16 is used to interface with the vehicle duct.
In the leak proof modular HVAC housing assembly 100 of FIGURE 1, due to split of the climate box into six parts there is a need to provide an additional joint on the side walls of HVAC housing assembly 100 in the Evaporator unit 12 to avoid condensate leakage. The conventional method of a single joint is not adequate if adopted in a modular HVAC unit.
FIGURE 2 illustrates a sectional view of the leak proof modular HVAC housing assembly 100 of FIGURE 1 with a splitting plane, referenced generally as PLN and a leak proof joint SP1 provided for the housing of the Evaporator unit 12.
FIGURE 3 illustrates a sectional front view of an Evaporator unit 12. FIGURE 4 illustrates an assembling procedure of a pair of evaporator sub-elements 12-L and 12-R, of the Evaporator unit 12 of FIGURE 3 using a leak proof joint SP2.

The direction of assembly is generally referenced as DRN, the left and right evaporator sub-elements being referenced as 12 -L and 12 - R respectively. The two halves of the Evaporator unit 12 are assembled together first with a first leak proof joint SP1 as illustrated in FIGURE 2. After assembling the two halves of the housing of the Evaporator unit 12, a leak proof joint SP3 is provided as illustrated in FIGURE 3. A bypass bridge BR is provided in the housing of the Evaporator unit 12 from the bottom between the leak proof joint SP1 and the leak proof joint SP2 to ensure that the leak proof joint SP3 is assembled without any break and prevents any condensate which drips from the leak proof joints SP1 and SP2 from leaking out of the housing.
FIGURE 5 illustrates an assembly of the two heater sub-elements 14-L and 14-R, of the Heater unit 14. The pair of heater sub-elements 14-L and 14-R is assembled together by means of at least one leak proof joint to form the heater unit 14. The two distribution sub-elements of the Distribution unit 16 are then assembled over the Heater unit 14 as illustrated in FIGURE 6. The direction of assembly is generally referenced as DRN.
FIGURE 7 illustrates an assembly of the Evaporator unit 12 of FIGURE 4 with the Heater unit 14 and the Distribution unit 16 assembly of FIGURE 6.
The method of forming the leak proof modular HVAC housing assembly 100 for preventing condensate leakage of the present invention includes following steps:
• forming the evaporator unit 12 by assembling the pair of evaporator sub-elements 12-L and 12-R by means of a plurality of leak proof joints;

• forming the heater unit 14 by assembling a pair of heater sub-elements 14-L and 14-R by means of at least one leak proof joint;
• forming the distribution unit 16 by assembling a pair of distribution sub-elements;
• assembling the evaporator unit 12 with the heater unit 14 and the distribution unit 16 for forming a distribution housing 30; and
• connecting the distribution housing 30 to the blower housing 10 to form the leak proof modular HVAC housing assembly 100.
In one embodiment of the present invention, the distribution housing 30 also includes an Adapter Duct unit 18.
The leak proof modular HVAC housing assembly 100 of the present invention and the method used for forming the same, can be effectively be applied to both indoor and automotive HVAC.
TECHNICAL ADVANCEMENTS
The leak proof modular HVAC housing assembly 100 of the present invention and the method used for forming the same has several technical advantages including but not limited to the realization of:
• leak proof joints in modular HVAC units;
• leak proof joints in modular HVAC units which are flexible with interchangeable modules;

• leak proof joints in modular HVAC units which can be used without any restriction on the type of fuel;
• leak proof joints in modular HVAC units which can be used for any type of vehicle as well as various indoor applications; and
• optimum number of leak proof joints in modular HVAC units.
The numerical values given of various physical parameters, dimensions and quantities are only approximate values and it is envisaged that the values higher or lower than the numerical value assigned to the physical parameters, dimensions
and quantities fall within the scope of the invention and the claims unless there is a
statement in the specification to the contrary.
While considerable emphasis has been placed herein on the specific features of the preferred embodiment, it will be appreciated that many additional features can be added and that many changes can be made in the preferred embodiment without departing from the principles of the invention, these and other changes in the preferred embodiment of the invention will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation.

We claim:
I. A leak proof modular Heating, Ventilation and Air Conditioning (HVAC) housing assembly for preventing condensate leakage, said leak proof modular HVAC housing assembly comprising:
• a blower housing configured to accommodate at least a blower; and
• a distribution housing connected to said blower housing, said distribution housing comprising,
o an evaporator unit configured to accommodate at least an evaporator, said evaporator unit comprising a pair of evaporator sub-elements assembled together by means of a plurality of leak proof joints to form said evaporator unit;
o a heater unit connected to said evaporator unit, said heater unit configured to accommodate at least a heater, said heater unit comprising a pair of healer sub-elements assembled together by means of at least one leak proof joint to form said heater unit; and
o a distribution unit disposed over said heater unit and connected to said evaporator unit, said distribution unit configured to accommodate a plurality of flaps to achieve various airflow modes, said distribution unit comprising a pair of distribution sub-elements assembled together to form said distribution unit.

2. The leak proof modular HVAC housing assembly as claimed in claim 1, wherein said blower housing is connected to said distribution housing by a duct.
3. The leak proof modular HVAC housing assembly as claimed in claim 1, wherein said blower housing is further configured to accommodate a scroll assembly, a motor, a motor holder and a fresh/re-circulating housing assembly.
4. The leak proof modular HVAC housing assembly as claimed in claim 1, wherein said evaporator unit is further configured to accommodate a filter.
5. The leak proof modular HVAC housing assembly as claimed in claim 1, wherein said heater unit is further configured to accommodate a secondary flap.
6. A method of forming a leak proof modular HVAC housing assembly for preventing condensate leakage, the method comprising the steps of:
• forming an evaporator unit by assembling a pair of evaporator sub-elements by means of a plurality of leak proof joints;
• forming a heater unit by assembling a pair of heater sub-elements by means of at least one leak proof joint;

• forming a distribution unit by assembling a pair of distribution sub-elements;
• assembling said evaporator unit with said heater unit and said distribution unit for forming a distribution housing; and
• connecting said distribution housing to a blower housing to form said leak proof modular HVAC housing assembly.