GB2566743A

GB2566743A - An apparatus for controlling airflow within a vehicle, a vehicle and a method

Info

Publication number: GB2566743A
Application number: GB1715552.4A
Authority: GB
Inventors: Richard Hutchins William
Original assignee: Jaguar Land Rover Ltd
Current assignee: Jaguar Land Rover Ltd
Priority date: 2017-09-26
Filing date: 2017-09-26
Publication date: 2019-03-27
Also published as: GB201715552D0; DE102018216090A1

Abstract

An apparatus for controlling airflow within a vehicle comprises a cowl 106 for a fan 108 and a heat exchanger assembly 102 which define an aperture 203 between them, and a flap 204 moveable between at least one open position allowing airflow through the aperture and a closed position wherein the flap covers at least a portion of the aperture. The flap may be an elastic material, such as natural or synthetic rubber, configured to resiliently move to or from the closed position. It may be connected by a living hinge, and may open/close based on a pressure differential between inner and outer faces. The apparatus prevents hot air expelled by the fan from recirculating back into the cowl through the aperture, thus increasing fan efficiency and improving engine cooling. A method comprises mounting a fan cowl relative to a heat exchanger assembly to define an aperture between them, and mounting a flap to be moveable between open positions enabling airflow through the aperture and a closed position in which the flap covers the aperture.

Description

TECHNICAL FIELD

The present disclosure relates to an apparatus for controlling airflow within a vehicle, a vehicle and a method. In particular, but not exclusively it relates to an apparatus for controlling airflow within a vehicle, a vehicle and a method in a road vehicle such as a car.

Aspects of the invention relate to an apparatus, a vehicle and a method.

BACKGROUND

A liquid coolant is circulated around the internal combustion engine of vehicles and the coolant is cooled by passing it through a radiator that is air-cooled. When the vehicle is moving, the motion of the vehicle can be sufficient to cause the required movement of air through the radiator. When the vehicle is stationary an electric fan is switched on to draw air through the radiator. The fan resides in a cowl mounted adjacent to the radiator. Typically, one or more gaps of variable width exist between the cowl and the radiator. Consequently hot air blown out by the fan is able to recirculate back into the cowl through the gaps. This recirculation is unwanted because it reduces the efficiency of the fan to provide the required cooling.

It is an aim of the present invention to address this disadvantage of the prior art.

SUMMARY OF THE INVENTION

Aspects and embodiments of the invention provide an apparatus, a vehicle and a method as claimed in the appended claims.

According to an aspect of the invention there is provided an apparatus for controlling airflow within a vehicle, the apparatus comprising: a cowl for a fan; a heat exchanger assembly positioned relative to the cowl to define an aperture between the heat exchanger assembly and the cowl; and a flap configured to be moveable between at least one open position allowing a flow of air through the aperture and a closed position, in which the flap covers at least a portion of the aperture.

This provides the advantage that air may pass through the aperture when the flap is in the open position to facilitate movement of air in the cowl in the vicinity of the aperture when the vehicle is travelling quickly, while enabling the flap to be closed to prevent an unwanted recirculation of air at low speeds.

In some embodiments the flap is moveable from the closed position to an open position by an increase in pressure within the cowl. This provides the advantage that air forced into the cowl by movement of the vehicle may be used to open the flap to allow a flow of air through the aperture.

In some embodiments the flap comprises an elastic material configured to resiliently bend to move to, or from, the closed position. This provides the advantage of a simple construction for the flap that allows for variations in the relative positions of the cowl and the heat exchanger assembly. It also enables abrasion of components by the flap to be avoided.

In some embodiments the flap comprises a polymeric material. The polymeric material may comprise natural rubber or synthetic rubber.

In some embodiments the flap forms a part of a flap member comprising a mounting portion and the flap is connected to the mounting portion by a living hinge.

In some embodiments the flap has an inner face facing the aperture and an outer face facing away from the aperture and the flap is configured to reside in a first open position in dependence on a pressure on the inner face being equal to a pressure on the outer face. This provides the advantage that the flap remains open to enable air to flow through the aperture unless the air pressure inside the cowl is below the ambient air pressure.

In some embodiments the flap is configured to move to the closed position in dependence on a pressure on the inner face being lower than a pressure on the outer face. This provides the advantage that the flap prevents air being drawn through the aperture when the air pressure inside the cowl is below ambient air pressure.

In some embodiments the flap is configured to reside in a second open position that is less resistant to airflow than the first open position in dependence on a pressure on the inner face being greater than a pressure on the outer face.

In some embodiments the flap is mounted on the cowl.

In some embodiments the flap is mounted on the heat exchanger assembly.

In some embodiments the heat exchanger assembly is mounted alongside a further component of the vehicle, and the flap is mounted on the further component.

In some embodiments the further component comprises a heat insulating component configured to maintain heat within an engine compartment of a vehicle.

In some embodiments the apparatus comprises a fan configured to operate to reduce pressure within the cowl, and the flap is configured to move to the closed position in dependence on the operation of the fan. This provides the advantage that air is prevented from being recirculated through the cowl via the aperture when the fan is operated.

According to another aspect of the invention there is provided a vehicle comprising the apparatus of any one of the previous paragraphs.

In some embodiments of the vehicle, the flap is configured to move from a first position to a second position in dependence on increased pressure within the cowl produced by movement of the vehicle, and the second position provides less resistance to airflow through the aperture than the first position.

According to a further aspect of the invention there is provided a method of assembly, the method comprising: mounting a cowl for a fan relative to a heat exchanger assembly to define an aperture between the heat exchanger assembly and the cowl; and mounting a flap to be moveable between open positions enabling a flow of air through the aperture and a closed position, in which the flap covers the aperture.

According to another aspect of the invention there is provided an apparatus for controlling airflow within a vehicle, the apparatus comprising: a cowl for a fan; a heat exchanger assembly positioned relative to the cowl to define an aperture between the heat exchanger assembly and the cowl; and an air blocking means configured to be moveable between open positions allowing a flow of air through the aperture and a closed position, in which the air blocking means covers the aperture.

This provides the advantage that air may pass through the aperture when the air blocking means is in the open position to facilitate movement of air in the cowl in the vicinity of the aperture when the vehicle is travelling quickly, while enabling the air blocking means to be closed to prevent an unwanted recirculation of air at low speeds.

Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.

BRIEF DESCRIPTION OF THE DRAWINGS

One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

Fig. 1 shows a plan view of a vehicle embodying the present invention;

Fig. 2 shows an enlarged view of apparatus for controlling airflow within the vehicle;

Fig. 3 shows a flap, which extends alongside an aperture between an edge of a cowl and a heat exchanger assembly;

Fig. 4 shows flap member comprising a flap;

Fig. 5 shows a portion of an alternative apparatus embodying the present invention;

Fig. 6 shows a portion of another alternative apparatus embodying the present invention;

Fig. 7 shows a portion of yet another alternative apparatus embodying the present invention; Fig. 8 shows the apparatus of Fig. 2 at a time when the vehicle is moving forwards at high speed and the fan is not operating;

Fig. 9 shows the apparatus of Fig. 2 at a time when the vehicle is stationary or moving slowly and the fan is switched on; and

Fig. 10 shows a flowchart illustrating a method of assembly.

DETAILED DESCRIPTION

A vehicle 100 embodying the present invention is shown in a plan view in Fig. 1, and an enlarged view of apparatus 200 at the front of the vehicle 100, for controlling airflow within the vehicle, is shown in Fig. 2. The vehicle 100 comprises an internal combustion engine 101 (referred to below simply as an “engine”). During operation, the engine 101 is cooled by a liquid coolant, which is circulated through the engine 101. The vehicle 100 also comprises a heat exchanger assembly 102 comprising a radiator 103 through which the liquid coolant is circulated in order to cool the liquid coolant with air blown through the radiator 103.

The vehicle 100 comprises a grille 104 positioned in front of the radiator 103. The grille 104 has apertures to enable air external to the vehicle 100 to flow in through the grille 104 and through apertures in the radiator 103. When the vehicle 100 is moving forwards at high speed, the motion of the vehicle 100 causes air to be blown through the grille 104 and the radiator 103, to provide cooling to the radiator 103. To provide sufficient cooling of the radiator 103 when the vehicle 100 is stationary or moving relatively slowly, the vehicle 100 comprises a fan 105 positioned to the rear of the radiator 103 which is arranged to draw air through the radiator 103. The fan 105 may be electrically powered and arranged to operate in dependence on a measured temperature, as is known.

The vehicle 100 also comprises a cowl 106 that has a first opening which faces the radiator 103 and a smaller second opening 107 in which the fan 105 is mounted. When the vehicle 100 is stationary or moving relatively slowly, operation of the fan 105 generates a negative pressure, i.e. a pressure that is below ambient air pressure, within the cowl 106, so that the higher ambient air pressure blows air through the radiator 103 into the cowl 106.

To improve the efficiency of the engine 101, the vehicle 100 of Fig. 1 also makes use of engine encapsulation. Thus, the vehicle 100 comprises a heat insulating component 108 configured to maintain heat within an engine compartment 109 during periods in which the engine is switched off. The heat insulating component 108 comprises a sheet of material that extends around the engine 101, and the radiator 103 is located within an opening in the heat insulating component 108.

One or more rear walls 201 of the cowl 106 may be provided with slots and associated ram flaps that are configured to open under forces applied by air pressure generated within the cowl 106. Alternatively, as shown in the embodiment of Fig. 2, the rear walls 201 of the cowl 106 may be free of any such slots and ram flaps.

As shown in Fig. 2, the heat exchanger assembly 102 may comprise one or more mounting brackets 202 configured to support the radiator 103 in a required position within the engine compartment 109. The one or more mounting brackets 202 may also be configured to enable the cowl 106 to be fixed to it, for example by screws, at several different positions spaced around the cowl 106. At some positions, the cowl 106 may butt against the heat exchanger assembly 102. However, as illustrated in Fig. 2, one or more apertures 203 exist between the heat exchanger assembly 102 and a neighbouring edge of the cowl 106.

The apertures 203 have a length extending alongside the edge of the cowl 106 and a width between the heat exchanger assembly 102 and the neighbouring edge of the cowl 106. In some embodiments the apertures 203 have a width from the heat exchanger assembly 203 to the neighbouring edge of the cowl 106 which may vary from about 0.1mm and 4mm. Alternatively, at least some of the apertures 203 may be provided with a larger width of between about 5mm and 20mm to enable a required flow of air during use.

The apertures 203 may extend vertically up one or both of the sides of the heat exchanger assembly 102 and/or along one or both of the top and the bottom of the heat exchanger assembly 102.

An air blocking means comprising one or more flaps 204 is provided, and each flap 204 covers at least a respective portion of an aperture 203 when the one or more flaps 204 are in a closed position. That is, when a flap 204 is in its closed position, it extends completely across the width of an aperture 203 along at least a portion of the length of the aperture 203. The one or more flaps 204 are moveable between their closed positions and one or more open positions, such as the open positions illustrated in Fig. 2, to enable a flow of air through the respective aperture 203.

One of the flaps 204, which extends alongside an aperture 203 between an edge 301 of the cowl 106 and the heat exchanger assembly 102, is shown in Fig. 3. For the purposes of the present specification the word “edge” refers to a line separating two surfaces or to a relatively narrow surface separating two surfaces, as is the case in Fig. 3.

In the present embodiment, the flaps 204 are moveable from the closed position to an open position by an increase in air pressure within the cowl 106. Similarly, the flaps 204 are moveable from an open position to the closed position by a decrease in air pressure within the cowl 106. The flaps 204 have an inner surface 302 that faces towards the aperture 203 and an outer surface 303 that faces away from the aperture 203. In the present embodiment the flaps 204 are configured to reside in a first open position in dependence on a pressure on the inner face 302 being greater than or equal to a pressure on their outer face 303. I.e. when the air pressure on the inside of the cowl is greater than or equal to the air pressure outside of the cowl 106, the flaps 204 are in an open position. The flaps 204 are configured to move to the closed position in dependence on a pressure on the inner face 302 being lower than a pressure on the outer face 303. The first open position is close to the closed position, being at an angle of about 10^e from the closed position. Consequently, the forces required to close a flap 204 from the first open position is sufficiently small to enable the low pressure caused by air flowing under the inner surface 302 into the cowl 106 to cause the flap 204 to close.

In the present embodiment the flaps 204 are arranged to open to an angle that depends on the difference in pressure between the air inside the cowl 106 and the air outside of the cowl 106. For example, the flaps 204 are arranged to move from the first open position to a second open position that provides less restriction to airflow, in dependence on the air pressure on the inner face 302 of the flap 204 being greater than the air pressure on the outer face 303.

In an alternative embodiment, the flaps 204 are configured to be in their closed position when the pressure of air on their inner surface 302 is less than or equal to the pressure of air on their outer surface 303. I.e. when the air pressure on the inside of the cowl 106 is less than or equal to the air pressure outside of the cowl, the flaps 204 are in their closed position. Such flaps are configured to open only when the air pressure on their inner surface 302 is greater than the air pressure on their outer surface 303.

In the embodiment of Figs. 2 and 3, the flap 204 forms a part of a flap member 304, which also comprises a mounting portion 305. The flap member 304 is shown in a perspective view in Fig. 4. The flap member 304 is formed of an elastic material so that the flap 204 is configured to resiliently bend to move to, or from, the closed position. In the present embodiment the flap 204 comprises a polymeric material, which may comprise a natural or synthetic rubber. The flap 204 is formed with a sufficiently thin cross-section to enable the flap 204 to move from an open to the closed position or from the closed position to an open position in dependence on the air pressure differences between the inner surface 302 and the outer surface 303 that are generated by motion of the vehicle 100 and/or operation of the fan 105.

The mounting portion 305 may be provided with attachment features such as holes to facilitate attachment to a component, such as the cowl 106. Alternatively, attachment of the mounting portion 305 to a component may be made by a glue or adhesive.

In the embodiment shown in Fig. 3, the mounting portions 305 of the flaps 204 are attached to an outer surface 306 of the cowl 106 adjacent to the edge 301. In alternative embodiments, the mounting portions 305 may be attached to an inner surface 307 of the cowl 106. In the closed position, the flaps 204 rest against the heat exchanger assembly 102. Depending upon the design of the mounting bracket(s) 202, the flaps 204 may rest against the mounting bracket(s) and/or the radiator 103 and/or a seat member fixed to the radiator for providing a suitable surface for enabling the flap 204 to seal against.

In some alternative embodiments, the flaps 204 may be formed of a relatively rigid material such as a metal plate which is mounted to pivot around one of its edges. Such a flap may be arranged to move to its closed position by gravity and/or a spring mechanism and moved to its open position in dependence on a greater pressure of air on its inner surface 302 than its outer surface 303.

A portion of an alternative apparatus 200A is shown in the partial view of Fig. 5. The apparatus 200A is identical to the previously described apparatus 200 of Fig. 2, except that a groove 501 extends along the length of the flap member 304 (i.e. into the page as shown in Fig. 5) between the flap 204 and the mounting portion 305, so that the flap 204 is connected to the mounting portion 305 by a living hinge 502. Thus, the flap 204 pivots about the living hinge 502 during use.

A portion of another alternative apparatus 200B is shown in the partial view of Fig. 6. The apparatus 200B is identical to the previously described apparatus 200 of Fig. 2, except that the mounting portion 305 of the flap member 304 is mounted on the heat exchanger assembly 102, rather than the cowl 106. The flap 204 is shown in its open position in Fig. 6. However, the flap member 304 is positioned so that, when the flap 204 is in its closed position, the flap 204 rests against the cowl 106 to cover at least a portion of the aperture

203 between the cowl 106 and the heat exchanger assembly 102.

A portion of another alternative apparatus 200C is shown in the partial view of Fig. 7. The apparatus 200C is identical to the previously described apparatus 200 of Fig. 2, except that the flap 204 is attached to the heat insulating component 108 adjacent to the heat exchanger assembly 102. In the embodiment of Fig. 7, the flap member 304 is similar to that of Figs. 3 and 4, and the mounting portion 305 is attached to the heat insulating component 108 so that the flap 204 extends from an edge 701 of the heat insulating component 108. The flap 204 is shown in its open position in Fig. 7. However, the flap member 304 is positioned so that, when the flap 204 is in its closed position, the flap 204 rests against the cowl 106 to cover at least a portion of the aperture 203 between the cowl 106 and the heat exchanger assembly 102.

The operation of the apparatus 200 of Fig. 2 is illustrated in Figs. 8 and 9. However, it should be noted that the apparatus 200A, 200B and 200C may operate in a similar manner.

The apparatus 200 comprising the heat exchanger assembly 102, the cowl 106 and the flaps

204 are shown in Fig. 8 at a time when the vehicle 100 is moving forwards at high speed,

e.g. 70 miles per hour (or 31ms¹) and the fan 105 is not operating. Air is forced through the grille 104 to the radiator 103 by the movement of the vehicle 100. Air is able to pass through apertures (not shown) in the radiator 102 to generate a positive pressure within the cowl 106. Consequently, a portion of the air in the cowl 106 is forced through the opening 107, around the fan 105, towards the engine 101. Other portions of the air in the cowl 106 are forced through the apertures 203 between the cowl 106 and the heat exchanger assembly 102 past the flaps 204 which are in an open position.

The apparatus 200 comprising the heat exchanger assembly 102, the cowl 106 and the flaps 204 are shown in Fig. 9 at a time when the vehicle 100 is stationary or moving slowly and the fan 105 is switched on. Air passes through the radiator 103 due to the fan 105 causing a negative pressure in the cowl 106. That is, air pressure within the cowl 106 is reduced to below ambient air pressure by the fan 105. The air passing through the radiator 103 is heated as it cools the liquid coolant in the radiator 103. Air is drawn out of the cowl 106 by the fan 105 and blown against the engine 101, which further heats up the air. If the flaps 204 were not present, the hot air blown against the engine 101 by the fan 105 could re-enter the cowl 106 through the apertures 203 between the cowl 106 and the heat exchanger assembly 102. However, the negative air pressure within the cowl 106 has caused the flaps 204 to move to their closed position and consequently the flaps 204 prevent the hot air blown against the engine 101 by the fan 105 from re-entering the cowl 106 through the apertures 203.

A flowchart illustrating a method 1000 of assembly is shown in Fig. 10. The method comprises, at block 1001, mounting a cowl 106 for a fan 105 relative to a heat exchanger assembly 102 to define an aperture 203 between the heat exchanger assembly 102 and the cowl 106. The heat exchanger assembly 102, including a radiator 103 for a vehicle 101, may be provided with one or more mounting brackets 202 defining holes and/or slots at spaced positions for receiving fasteners. The cowl 106 may therefore be attached to the heat exchanger assembly 102 at each of the holes and/or slots and at these positions there may be no gap between the cowl 106 and the heat exchanger assembly 102. However, one or more apertures 203 are formed between the cowl 106 and the heat exchanger assembly 102 at at least one position.

The method 1000 also comprises, at block 1002, mounting a flap 204 to be moveable between open positions enabling a flow of air through the aperture 203 and a closed position, in which the flap 204 covers the aperture 203. The flap 204 may be mounted on the cowl 106, the heat exchanger assembly 102 or a component adjacent to the cowl 106 and the heat exchanger assembly 102, when located within the vehicle 101, as discussed above. The flap 204 may be fixed in position using glue, adhesive, fasteners or by having a mounting portion 305 that is configured to engage with features provided on the cowl 106 or on the heat exchanger assembly 102.

The illustration of a particular order to the blocks in Fig. 10 does not necessarily imply that there is a required or preferred order for the blocks and the order and arrangement of the blocks may be varied, i.e. The flap 204 may be mounted, at block 1002, before the cowl 106 is mounted relative to the heat exchanger assembly 102 at block 1001.

Although embodiments of the present invention have been described in the preceding paragraphs with reference to various examples, it should be appreciated that modifications to the examples given can be made without departing from the scope of the invention as claimed.

Features described in the preceding description may be used in combinations other than the combinations explicitly described.

Although functions have been described with reference to certain features, those functions may be performable by other features whether described or not.

Although features have been described with reference to certain embodiments, those features may also be present in other embodiments whether described or not.

Whilst endeavoring in the foregoing specification to draw attention to those features of the invention believed to be of particular importance it should be understood that the Applicant claims protection in respect of any patentable feature or combination of features hereinbefore referred to and/or shown in the drawings whether or not particular emphasis has been placed thereon.

Claims

1. Apparatus for controlling airflow within a vehicle, the apparatus comprising: a cowl for a fan;

a heat exchanger assembly positioned relative to the cowl to define an aperture between the heat exchanger assembly and the cowl; and a flap configured to be moveable between at least one open position allowing a flow of air through the aperture and a closed position, in which the flap covers at least a portion of the aperture.

2. Apparatus according to claim 1, wherein the flap is moveable from the closed position to an open position by an increase in pressure within the cowl.

3. Apparatus according to claim 1 or claim 2, wherein the flap comprises an elastic material configured to resiliently bend to move to, or from, the closed position.

4. Apparatus according to any one of claims 1 to 3, wherein the flap comprises a polymeric material.

5. Apparatus according to claim 4, wherein the polymeric material comprises natural rubber or synthetic rubber.

6. Apparatus according to any one of claims 3 to 5, wherein the flap forms a part of a flap member comprising a mounting portion and the flap is connected to the mounting portion by a living hinge.

7. Apparatus according to any one of claims 1 to 6, wherein the flap has an inner face facing the aperture and an outer face facing away from the aperture and the flap is configured to reside in a first open position in dependence on a pressure on the inner face being equal to a pressure on the outer face.

8. Apparatus according to claim 7, wherein the flap is configured to move to the closed position in dependence on a pressure on the inner face being lower than a pressure on the outer face.

9. Apparatus according to claim 7 or claim 8, wherein the flap is configured to reside in a second open position that is less resistant to airflow than the first open position in dependence on a pressure on the inner face being greater than a pressure on the outer face.

10. Apparatus according to any one of claims 1 to 9, wherein the flap is mounted on the cowl.

11. Apparatus according to any one of claims 1 to 9, wherein the flap is mounted on the heat exchanger assembly.

12. Apparatus according to any one of claims 1 to 9, wherein the heat exchanger assembly is mounted alongside a further component of the vehicle, and the flap is mounted on the further component.

13. Apparatus according to claim 12, wherein the further component comprises a heat insulating component configured to maintain heat within an engine compartment of a vehicle.

14. Apparatus according to any one of claims 1 to 13, wherein the apparatus comprises a fan configured to operate to reduce pressure within the cowl, and the flap is configured to move to the closed position in dependence on the operation of the fan.

15. A vehicle comprising the apparatus of any one of claims 1 to 14.

16. A vehicle according to claim 15, wherein the flap is configured to move from a first position to a second position in dependence on increased pressure within the cowl produced by movement of the vehicle, and the second position provides less resistance to airflow through the aperture than the first position.

17. A method of assembly, the method comprising:

mounting a cowl for a fan relative to a heat exchanger assembly to define an aperture between the heat exchanger assembly and the cowl; and mounting a flap to be moveable between open positions enabling a flow of air through the aperture and a closed position, in which the flap covers the aperture.