GB2468285A

GB2468285A - Improvements in air-vents

Info

Publication number: GB2468285A
Application number: GB0903513A
Authority: GB
Inventors: Paul Ray
Original assignee: Nissan Motor Manufacturing UK Ltd
Current assignee: Nissan Motor Manufacturing UK Ltd
Priority date: 2009-03-03
Filing date: 2009-03-03
Publication date: 2010-09-08
Also published as: GB0903513D0

Abstract

An air-vent for directing airflow into a vehicle, the air-vent comprising: a control stern having a first end and a second end; a plurality of flexible vanes arranged generally radially around the control stern(135b) between the first and second ends of the control stem; and a generally tubular housing member surrounding the flexible vanes and control stem. The direction of airflow from the air-vent is adjusted by deforming the flexible vanes (150) between the control stern and the housing member by moving the control stem relative to the housing member (20).

Description

IMPROVEMENTS IN AIR-VENTS

Field of the invention

The present invention relates to an air-vent register or nozzle for a motor vehicle and, more specifically, to an adjustable air-vent with reduced parts complexity and assembly time.

Background of the invention

The air-vents located within an occupant compartment of a vehicle are the most visible component of the heating, ventilation and air conditioning HVAC or system. The air-vent guides air, blown via a bower fan, into the occupant compartment of the vehicle. Due to the highly visible nature of the air-vent and the need for it to be readily adjustable by the user, the air-vent or nozzle must be aesthetically pleasing, functional and robust.

Typically, motor vehicle air-vents are formed from multiple component parts such as vanes or louvers and a means of adjusting their angle such as a louver cage and thumb wheel. The air-vent has a series of louvers or vanes which are pivotably mounted within the air-vent body. The louvers are typically arranged parallel with each other within the air-vent body.

The angle of these louvers may be adjusted by the user to direct the air in the desired direction. In some cases, the louvers may be adjusted to lie flat against each other to block the flow of air from exiting the air-vent. In other cases a separate component known as a shut-off valve or register is employed to block the flow of air from reaching the air-vent from the blower.

Due to their complexity, the air-vent components are invariably assembled largely or completely by hand. Hand assembly of these components greatly adds to the assembly time and cost of the air-vents.

Another problem associated with known air-vents is the requirement for each component to be produced with tight manufacturing tolerances. This is to ensure that the louvers move smoothly with a consistent operating effort and do not rattle against each other when the vehicle is in motion.

It is against this background that the present invention seeks to improve upon the known air-vent by providing an air-vent with flexible vanes or louvers which are moulded in a single operation to reduce parts complexity and the need for hand assembly.

Summary of the invention.

According to an aspect of the present invention there is provided an air-vent for directing airflow into a vehicle comprising: a control stem; a plurality of generally flexible vanes extending generally radially from the control stem between the first and second ends thereof the control stem; and a housing member at least partially surrounding the vanes and control stem, wherein the direction of airflow from the air-vent is adjusted by deforming the vanes between the control stem and the housing member in response to relative movement therebetween.

The present invention provides the advantage that parts complexity for the air vent is reduced as the vanes or louvers of the air vent are adjusted by deform ing in response to the movement of the control stem, rather than a plurality of vanes individually assembled via pivotable mountings to a vent body. In the case of the present invention, the component parts of the air vent are less sensitive to manufacturing or assembly tolerances as there are less pivot points and less individual components to assemble.

According to an embodiment, the control stem further comprises: an adjustment knob at a first end of the control stem, and a ball joint arranged to pivotably connect the control stem to the housing member, wherein the orientation of the control stem relative to the housing member may be adjusted by the user grasping the adjustment knob and moving the control stem about to the ball joint.

The control stem provides the user with an intuitive means of adjusting the direction of airflow from the air-vent. Terminating one end of the control stem with an adjustment knob serves to limit axial movement of the flexible vanes along the control stem whilst providing a feature that is readily grasped by the user in use.

According to an embodiment, the housing member comprises: a first end through which the airflow is directed into the vehicle, and a second end configured to secure an air-vent tube in fluid communication with the air-vent.

Providing a feature on the end of the housing member arranged to secure the air-vent tube and hold the air-vent tube in fluid communication with the air-vent minimises parts complexity and further provides an air-vent which may be used in various locations around the vehicle.

According to an embodiment, the vanes are formed with a profiled section arranged to control the airflow through the air-vent.

According to an embodiment, the vanes are formed as a unitary moulding of a flexible rubber or rubber-like polymer.

Forming all of the vanes for an air-vent as a single unitary component reduces parts complexity and assembly time. In addition, moulding the air-vent vanes from a rubber or rubber-like material provides an advantage that the shape and section or form is less restricted than may otherwise be the case using metal or rigid plastics material. The vanes of the present invention may be readily adapted to include features that serve to further control the direction and flow of the air. In addition, features may be readily included in the shape or appearance of the flexible vanes to enhance an aesthetic property or to match the vehicle structures surrounding the air-vent.

According to an embodiment, the vanes are formed as an over-moulding flexibly securing the control stem and the housing member together.

Forming all of the vanes by over-moulding the control stem and housing member with the rubber or rubber-like polymer creating a unitary component reduces parts complexity and assembly time. In addition, over-moulding the control stem and housing member improves fit and finish and minimises the possibility of the control stem and housing member rattling when the vehicle is in motion. Over-moulding the flexible vanes into the air-vent reduces the sensitivity to manufacturing tolerances, further reducing manufacturing costs whilst improving reliability in use.

According to an embodiment, surface features are formed along the control stem between first and second ends thereof, the surface features being arranged to support the flexible vanes.

According to an embodiment, surface features are formed along the inner surface of the housing member between first and second end thereof, the surface features being arranged to support the vanes.

Providing surface features along either the control stem or the housing member, in the areas where the flexible vanes are to be over-moulded, improves the adhesion between the different materials of the control stem or housing member and the flexible vanes. This improved reliability and reduces the chances of the vanes becoming detached from either the control stem or housing member in use.

According to an embodiment, the housing member is arranged to be mounted within a co-operating feature provided in an instrument panel of a vehicle.

The co-operating feature may take the form of a bezel or trim-piece. The co-operating feature in the instrument panel allows the air-vent to be inserted easily into the instrument panel during the assembly of the instrument panel. The air- vent is then secured to the instrument panel by fitting the bezel around the air-vent and locating the bezel over it via clips or other suitable means directly to the instrument panel itself.

According to an embodiment, relative movement between the housing member and the instrument panel is permitted by the co-operating feature of the instrument panel.

Permitting relative movement between the housing member of the air-vent and the instrument panel allows for a greater range of adjustment of airflow direction than is available by deform ing the flexible vanes alone. Additionally, permitting relative movement between the housing member and the instrument panel provides a convenient means of closing off the airflow through vent.

Assembling an air-vent of the present invention greatly reduces the amount of hand assembly required by comparison with known air-vents. The control stem and housing member may be brought together as a sub-assembly before being placed into the moulding tool. The moulding tool may have multiple cavities in order to perform the over-moulding process on multiple air-vent assemblies simultaneously.

In addition, the materials chosen for the control stem and the housing member are entirely independent of each other, as long as the polymer chosen for the flexible vanes is compatible. In this way the same air-vent may be made in different colour-ways, with the flexible vanes being formed from a contrasting colour to that of either the control stem or housing member. Similarly, the control stem may be made from metal and the housing member from a plastics material or vice-versa.

According to another aspect of the present invention there is provided a method of controlling airflow into the interior of a vehicle comprising: directing air through a duct comprising a plurality of deformable vanes and, deforming at least some of the vanes so as to alter the flow properties through the duct.

Controlling the airflow into a vehicle by deform ing vanes, rather than pivoting them within a housing, allows for a greatly simplified air-vent assembly.

Additionally, this method provides the benefit of an air-vent utilising vanes which are far less sensitive to manufacturing tolerances than is possible with known air-vents.

It will be appreciated by one skilled in the art that the air-vent of the present invention may be suitable for use in applications unrelated to vehicles.

It will also be appreciated by one skilled in the art that the preferred and/or optional features relating to the present invention may be used either alone or in appropriate combination.

Brief Description of the Drawings

In order that the invention may be more readily understood reference is made, by way of example only, to the accompanying drawings in which: Figure 1 a is a perspective view of part of a known air vent assembly; Figures 2a and 2b are section views of an air vent of the present invention; Figure 3 is a perspective frontal view of an embodiment of the present invention in-situ; Figures 4a and 4b are section views through another embodiment of the present invention, with Figure 4a showing the vent in the open condition and Figure 4b showing the vent in the closed condition; Typically, air vents for vehicles are formed from multiple component parts which are invariably assembled by hand due to their complexity. The air vent guides air blown via a blower fan in a heating ventilation and air conditioning (HVAC) system into an occupant compartment of the vehicle. The vent has a series of pivotably mounted vanes which form a plurality of passageways through which air may flow. The vanes may be adjusted by the user to direct the air in the desired direction or adjusted so as to lie flat against each other to close-off the air vent if the user wishes to stop the air flowing out of the vent.

Referring to Figure 1, a part of a known air vent assembly is presented in a perspective view to show the key components and their configuration. Figure 1 shows a plurality of vanes 3 pivotably linked together via a connecting member 5.

The orientation of the vanes 3 is controlled by a thumbwheel 2. At the top of the thumbwheel 2 is a control surface 2a with which the user may adjust the orientation of the vanes 3. The thumbwheel 2 is pivotably mounted via a thumbwheel pivot 2b to a housing (not shown). The thumbwheel 2 controls the vanes via a lever 7 distal from the control surface 2a. In order to re-direct the airflow downwards in relation to the image, the user must rotate the thumbwheel 2 in the direction of the arrow 2c. Moving the control surface 2a in the direction of arrow 2c will cause the lever 7 to rotate about the thumbwheel pivot 2b in the opposite direction to the arrow 2c. The vanes 3 are pivotably mounted to the housing (not shown) via trunnions 8. The vanes 3 pivotably linked mounted to the connecting member 5 vane pivots 6.

The known air vent comprises many component parts, the majority of which must be assembled by hand due to their size and complexity. Hand assembly greatly adds to the cost and assembly time for the assembled air vent.

Figures 2a and 2b show section views through an air vent 10 of the present invention. The air vent 10 comprises a control stem 30 pivotably mounted at one end via a ball 36 and cup 25 arrangement to form a ball joint. Distal from the ball joint is a control knob 35. A housing member 20 comprises a rear face or inlet 22 and a front face or outlet 21. The control knob 35 is adjacent to the outlet 21 and the cup 25 of the ball joint is supported by a support feature (not shown) extending from the rear face or inlet 22 of the housing 20.

The air vent 10 further comprises a plurality of flexible rubber vanes 50 (shown in Figure 2b) extending generally radially from the control stem 35 between the ends of the control stem. The housing member 20 surrounds at least part of the vanes 50 and control stem 35. The housing member 20 is assembled into a trim piece 40 which forms part of the interior of a vehicle.

The air vent 10 is arranged to guide air from a blower (not shown) via an air vent tube (also not shown) towards the interior of a vehicle (also not shown) in the direction of arrow A. The direction of the air is adjusted by adjusting the orientation of the control stem 30 relative to the ball joint. Air flows through the housing 20 of the air vent 10 towards the interior of the vehicle via a plurality of passageways 15 formed between the vanes 50 and the housing 20. By moving the control knob 35 in the desired direction of airflow, the vanes 50, which are secured between the stem 30 and the housing 20, are caused to deform which deforms the passageways.

When the control stem 30 is set to a straight ahead position, the control stem 30 is held substantially co-axially with the housing 20 by the vanes 50. In this position, the maximum amount of airflow is permitted through the air vent 10 towards the interior of the vehicle.

The cup 25 of the ball joint is mounted to a feature extending from the inlet 22 in the example shown in the Figures, however, the cup 25 may alternatively be secured to the air vent tubing or instrument panel as required. For the control stem 30 to hold the desired orientation after it has been adjusted, there must be sufficient friction in the ball joint to overcome the natural tendency of the vanes to centre the control stem 30.

As the control stem 30 is moved, the vanes 50 are deflected between an exterior surface 54 of the control stem 30 and an interior surface 52 of the housing 20. As the vanes 50 are deflected their shape is deformed. Where the gap between the control stem 30 and the housing 20 has been reduced, the vanes 50 are distorted, their shape changing from being substantially flat to being curved in section. Where the gap between the control stem 30 and the housing 20 has been increased the vanes 50 are stretched and remain substantially flat in section. The result of this localised deflection of the control stem 30 relative to the housing 20 and associated deformation of the vanes 50 is that one side of the vent 10 has blocked or restricted passageways 15 whilst on the opposite side, the passageways 15 are unrestricted. Additionally, the deformation of the otherwise parallel passageways 15 formed by the vanes 50 between the control stem 30 and the housing 20 creates a passageway 15 for the air which guides the air flow in the direction of the control stem 30.

The vanes 50 may be formed from a flexible rubber or rubber-like polymer such as latex, butyl rubber or poly urethane by injection moulding or extrusion. The plurality of vanes 50 may be formed as a separate unitary component to be assembled around the control stem 30 before the control knob 35 is fitted.

Alternatively, the plurality of vanes 50 may be formed by over-moulding them between the control stem 30 and the housing 20, effectively joining the two, between the ball joint and the control knob 35.

If the vanes 50 are to be formed by over-moulding, the control stem 30, formed from metal or plastics material which is relatively more rigid then the material forming the vanes 50, is held in a jig within a moulding tool. The housing 20 is positioned around the control stem 30 and held in place in the same jig. The flexible vanes 50 are then formed by injecting molten rubber or rubber-like material between the control stem 30 and the housing 20. The rubber bonds to the control stem 30 and the housing 20 where the moulding tool cavity has permitted the molten rubber to flow.

Once the vanes 50 have been over-moulded between the control stem 30 and the interior surface of the housing 20, the resulting vanes 50 radiate like spokes between the control stem 30, acting as a hub, and the interior surface of the housing 20 acting as a wheel rim. The spaces between the vanes 50 form substantially parallel passageways 15. These passageways 15 run from the back of the housing member or inlet 22 to the outlet 21. The inlet 22 is arranged to attach to an air vent tube (not shown) from the blower (also not shown). The outlet 21 is arranged to be substantially flush with the surface of the instrument panel (not shown) and is visible to the user in the vehicle interior.

Specific surface features may be provided around the exterior surface 54 of the control stem 30, and the interior surface 52 of the housing 20, to provide a surface to which the molten rubber may adhere. Such surface features provide a localized zone of increased surface area to encourage the molten rubber to cool and solidify. In the example shown in Figure 2b, these surface features co-operate with local ised zones of additional material thickness of the vanes 50.

These zones of localised material thickness increase the robustness and reliability of the vanes and may be provided with a form to provide further control over the flow of the passing air.

Figure 3 shows a perspective view of an air vent 10 of the present invention as viewed from the interior of the vehicle. The relative positions of the control knob 35, control stem 30 and the vanes 50 are clearly shown surrounded at least in part by the housing 20. The vanes 60 shown in Figure 3 have a twisted profile to encourage the air flowing into the vehicle to diffuse so are to avoid the air vent forming a jet or column of air which may not be desirable by the user. The air vent 10 is mounted within the trim piece 40. In the example shown in Figure 3, trim piece 40 forms part of an instrument panel.

Figure 3 also clearly shows the passageways 15 formed between the vanes 50 and housing 20. In an embodiment of the present invention, the housing 20 is rotatably mounted within the trim piece 40. In this way, a greater amount of adjustment of the direction of the airflow is permitted by allowing a greater degree of movement between the control stem 30 and the vehicle. Additionally, the housing 20 may be rotated to face away from the vehicle interior so as to close off the airflow through the air vent as desired.

Figure 4 shows an alternative embodiment which further comprises a means of folding over the vanes 50 from the inlet 22 side of the vent 10 towards the outlet 21 side of the vent 10 to selectively close-off the passageways 15 formed between the vanes 50.

In this alternative embodiment of the present invention, an air vent 100 comprises a control stem 130, permitted to selectively slide axially within the housing 20 along an inner stem 134. The inner stem 134 is pivotably mounted within the housing 20 via the co-operation of the ball 36 and cup 25 arrangement used in the other embodiments.

Figure 4a shows the alternative embodiment with an open air vent lOOa.

When air flow is required, the axial position of a control knob 135 and control stem 130 relative to the housing 20 is set to a first (open) position 135a. In this position, the vanes are formed as two portions, the directing portion of the vanes and a folding portion of the vane 155. In the example shown in Figure 4a, the folding portion of the vane 155 is shown stretched axially between the outlet side of the vent 21, between the control stem 130 and housing 20, and a movable support member 136 shown in the open position 136a. The movable support member 136 is slidably mounted onto the inner stem 134 or may be threaded via a threaded portion 132 as shown in Figure 4. Moving the control knob 135 towards from the air vent 100 stretches both portions of the vanes 150 and 155 and opens the passageways to allow air to flow freely through the air vent 1 OOa.

However, if it is desirable to restrict or close-off the air flow through the air vent altogether, then the axial position of the control knob 1 35b control stem 130 relative to the housing 20 is slid to a second (closed) position shown in Figure 4b.

In this example, the control knob 135b has been moved away from the air vent 100. This brings the support member 136 to a closed position 136b where it is moved towards the outlet 21 of the air vent 100. Moving the support member to a closed position 136b will compress the folding portion 155b of the vanes 150, obstructing the passageways and restricting the airflow through the air vent 1 OOb.

In the second or closed position, a proportion of the axial length of the vanes is in compression. This compression causes the vanes to fold over between the control stem and the housing member which restricts the air flow down the passageways. The adjustment of the control stem in the axial direction may be achieved by sliding the control stem in and out of the housing member or by rotating the knob of the control stem. In the case of a rotating type control stem, the stem may be formed from two or more pieces which co-operate to form a telescopic control stem so as to affect the compression from the back of the vane towards the knob. In this way, the position of the knob relative to the user does not change, regardless of the compression of the flexible vanes.

It will be appreciated by one skilled in the art that such an air vent may be employed in a variety of locations around the vehicle to help improve the circulation of air.

Sharing common parts between two or more vehicle models is highly desirable to increase purchasing volumes to reduce the piece part cost. Sharing common parts between vehicles also serves to reduce the likelihood of accidental assembly of the wrong part to the vehicle as it reduces the variation of parts on the side of the vehicle assembly line.

It will be appreciated by one skilled in the art that such an air vent may be employed in a variety applications unrelated to vehicles without deviating from the inventive concept of the present invention.

Other advantage will be apparent to one skilled in the art and the present examples and embodiments are to be considered illustrative and not restrictive.

The invention is not to be limited to the details given herein, but may be modified within the scope and equivalence of the appended claims.

Claims

CLAIMS1. An air-vent for directing airflow into a vehicle comprising: a control stem; a plurality of generally flexible vanes extending generally radially from the control stem between the first and second ends thereof the control stem; and a housing member at least partially surrounding the vanes and control stem, wherein the direction of airflow from the air-vent is adjusted by deforming the vanes between the control stem and the housing member in response to relative movement therebetween.
2. An air-vent according to Claim 1, comprising: an adjustment knob at a first end of the control stem, and a ball joint arranged to pivotably connect the control stem to the housing member, wherein the orientation of the control stem relative to the housing member may be adjusted by the user grasping the adjustment knob and moving the control stem about to the ball joint.
3. An air-vent according to Claim 1 or Claim 2, wherein the housing member comprises: a first end through which the airflow is directed into the vehicle, and a second end configured to secure an air-vent tube in fluid communication with the air-vent.
4. An air-vent according to any of the preceding claims, wherein the vanes are formed with a profiled section arranged to control the airflow through the air-vent.
5. An air-vent according to any of the preceding claims, wherein the vanes are formed as a unitary moulding of a flexible rubber or rubber-like polymer.
6. An air-vent according to any of the preceding claims, wherein the flexible vanes are formed as an over-moulding flexibly securing the control stem and the housing member together.
7. An air-vent according to claim 5 or claim 6, wherein surface features are formed along the control stem between first and second ends thereof, the surface features being arranged to support the flexible vanes.
8. An air-vent according to any of claims 5 to 7, wherein surface features are formed along the inner surface of the housing member between first and second end thereof, the surface features being arranged to support the vanes.
9. An air-vent according to any of the preceding claims, wherein the housing member is arranged to be mounted within a co-operating feature provided in an instrument panel of a vehicle.
10. An air-vent according to claim 9, wherein relative movement between the housing member and the instrument panel is permitted by the co-operating feature of the instrument panel.
11. A vehicle comprising an air-vent according to any of the preceding claims.
12. A method of controlling airflow into the interior of a vehicle comprising: directing air through a duct comprising a plurality of deformable vanes and, deforming at least some of the vanes so as to alter the flow properties through the duct.