GB2569016A - A mounting system for mounting an electrical module in a vehicle - Google Patents

Abstract

The present application relates to a mounting system 34 for mounting an electrical module (23, see fig. 7) to an internal support of a vehicle. The mounting system has a support block 40 that defines a recess 41 configured to push-fit receive an electrical module. The mounting system has an air inlet 47, an air outlet 48, and an air duct (46) between the inlet and outlet 48. The air duct has a first flow portion (46a), and a second flow portion (46b), the recess being between the first and second flow portions and the air duct intersects with the recess. The block portion may comprise two block portions and may be joined by a live hinge. The support block may also define an air channel which is isolated in the support block from the recess and the air duct. The present application also relates to a vehicle sub-assembly 33 and a vehicle.

Description

A MOUNTING SYSTEM FOR MOUNTING AN ELECTRICAL MODULE IN A VEHICLE

TECHNICAL FIELD

The present disclosure relates to a mounting system for mounting an electrical module in a vehicle. In particular, the present disclosure relates to a mounting system for mounting an electrical module to an internal support of a vehicle. Aspects of the invention relate to a mounting system for mounting an electrical module to an internal support of a vehicle, a vehicle sub-assembly, and a vehicle.

BACKGROUND

Vehicles, and in particular automobiles or cars, typically include multiple electrical modules. Such electrical modules are mounted in a vehicle, and are used to control and or operate different systems within the vehicle. The electrical modules are mounted to a body of the vehicle by different mounting arrangements, and may be directly or indirectly mounted. Typically a bracket, such as a metal flange, is used to hold an electrical module on the body.

In such an arrangement, the electrical module is fixed to the bracket via fixings, and the bracket itself is then fixed to the body by further fixings. Such fixings may include studs, bolts, and mounting apertures. Typically, separate brackets are used for each electrical module. A problem with these arrangements is that it can be time consuming and complex to assemble and mount the electrical modules to the body of the vehicle. Furthermore, multiple fixings are required to secure the modules to the brackets, and the brackets to the body of the vehicle itself.

The electrical modules are typically mounted on an internal side of the body of the vehicle, and then internal body panels, also known as trims, are mounted over the electrical modules. Such an arrangement provides protection for the electrical modules, and restricts access to the electrical modules. This arrangement also provides a void between the body and the internal body panels in which the electrical modules are mounted. The internal body panels and body itself may be provided with vents in order to vent the void in which the electrical modules are mounted to aid cooling of the electrical modules. However, the ducting of airflow is complicated and may be inefficient.

At least in certain embodiments, the present invention seeks to overcome or ameliorate at least some of the shortcomings associated with the prior art.

SUMMARY OF THE INVENTION

Aspects and embodiments of the invention provide a mounting system for mounting an electrical module to an internal support of a vehicle, a vehicle sub-assembly, and a vehicle.

According to an aspect of the present invention, there is provided a mounting system for mounting an electrical module to an internal support of a vehicle, the mounting system defining a recess configured to receive an electrical module; and the mounting system comprising an air inlet; an air outlet; and an air duct between the inlet and outlet, wherein the air duct intersects with the recess.

As such, the cooling of electrical modules to a vehicle may be simplified. Electrical modules may be straightforwardly received by the mounting system and cooled by air flowing through a duct in the mounting system.

The recess may be a mounting slot configured to at least substantially receive and hold the electrical module.

As such, the fixing arrangement required to mount electrical modules to a vehicle may be minimized.

The air duct and the recess may together define a flow path between the air inlet and air outlet.

With this arrangement, a straightforward flow path is formed by the mounting system.

The air duct may comprise a first flow portion and a second flow portion. The recess may be between the first and second flow portions.

The air inlet and the air outlet may be spaced from each other.

With this arrangement air flowing from the air duct is at least restricted from contaminating air flowing into the air duct.

The mounting system comprises a support block defining the recess.

The support block may comprise at least two block portions, the at least two portions may be attached to one another, for example by a hinge or flexible portion.

As such, assembly of the mounting system may be simplified.

The support block may be an expanded polymer block.

The support block may be an expanded polypropylene block.

The air inlet and air outlet may be on one side of the support block.

The recess may be configured to substantially encompass the electrical module when the electrical module is received in the recess.

The term ‘encompass’ is intended to refer to an object or objects holding another object within. The another object should be held within the boundary of the object or objects. However, it is not intended that the another object must be surrounded on all sides by the object holding it. Reference to ‘substantially encompass’ refers to an object that at least predominantly holds another object within its boundary, but may have a minor exposed portion.

According to an aspect of the present invention, there is provided a vehicle sub-assembly comprising a mounting system, and a panel section configured to be supported on the support block.

The panel section may be a seat support panel.

The panel section may comprise a first vent arranged to be aligned with the air inlet of the mounting system and a second vent arranged to be aligned with the air outlet of the mounting system.

The support block may define an airflow channel.

The air flow channel may extend along a surface of the support block.

An underside of the seat support panel may enclose the air flow channel.

The air flow channel may be isolated in the support block from the recess and the air duct.

According to an aspect of the present invention, there is provided a mounting system for mounting an electrical module to an internal support of a vehicle, the mounting system comprising a support block defining a recess configured to receive and hold an electrical module; and an air flow channel.

As such, the configuration for mounting electrical modules and providing air flow may be simplified. As such, the number of components required may be reduced and the provision of electrical modules and air flow made more compact.

The air flow channel may extend along a surface of the support block.

The air flow channel may be elongate.

The air flow channel may be isolated in the support block from the recess. As such, the temperature of any electrical module in the recess will not affect the temperature of the air flow.

The recess may be configured to at least substantially encompass the electrical module.

According to an aspect of the present invention, there is provided a vehicle sub-assembly comprising a mounting system as set out above and a panel section configured to define a side of the air flow channel.

As such, the air flow channel may be easily formed.

The panel section may be a seat support panel.

The air flow channel may have an inflow and an outflow, the inflow being defined in a sidewall of the support block, and the outflow being defined in the panel section.

The mounting system may further comprise a connector for fixedly mounting the support block to the internal support of a vehicle, wherein the connector comprises a locating part on the support block configured to be received by an attachment configuration of the internal support; and a locking part movable relative to the locating part between a non-engaging configuration and an engaging configuration, wherein, in the engaging configuration, the locking part is inserted into the locating part, the locking part being configured to act on the locating part and restrict movement of the locating part relative to the internal support.

The connector may comprise a locating part on the support block configured to receive a protruding feature of the internal support, and a locking part movable relative to the locating part between a non-engaging configuration and an engaging configuration, wherein, in the engaging configuration, the locking part is configured to engage with the protruding feature to restrict movement of the locating part relative to the protruding feature.

The locating part may be integrally formed with the support block.

The locking part may be integrally formed with the support block.

According to an aspect of the present invention, there is provided a mounting system for mounting an electrical module to an internal support of a vehicle, the mounting system defining a recess configured to receive an electrical module.

According to an aspect of the present invention, there is provided a mounting system for mounting an electrical module to an internal support of a vehicle, the mounting system comprising a support block defining a recess configured to receive and hold an electrical module.

According to an aspect of the present invention, there is provided a vehicle comprising a mounting system as set out above.

According to an aspect of the present invention, there is provided a vehicle sub-assembly as set out above.

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:

Figure 1 is a schematic side elevation cut-away view of a vehicle showing an under seat panel and a void space;

Figure 2 is a partial cut-away view of a known arrangement of mounting an electrical module in the void space shown in Figure 1;

Figure 3 is a partial cut-away view of a known arrangement of mounting an air duct in the void space shown in Figure 1;

Figure 4 is a partial cut-away view of the known arrangement of Figure 3, perpendicular to the air duct axis;

Figure 5 is a partial cut-away perspective view of a mounting system mounting an electrical module in the void space shown in Figure 1;

Figure 6 is a partial cut-away side view of the mounting system shown in Figure 6;

Figure 7 is an exploded view of the mounting system shown in Figure 6;

Figure 8 is a partial cut-away side view of the mounting system shown in Figure 6 showing an air duct;

Figure 9 is partial cut-away view of the mounting system shown in Figure 8 showing the air duct, perpendicular to the air duct axis;

Figure 10 is a schematic cross-sectional view of part of a block and internal support, and a connector in a non-engaging configuration;

Figure 11 is a schematic perspective view of the part of the block and internal support, and the connector shown in Figure 10 in a non-engaging configuration;

Figure 12 is a schematic cross-sectional view showing the connector of Figure 10 in an engaging configuration;

Figure 13 is a schematic perspective view of the connector of Figure 10 in an engaging configuration;

Figure 14 is a schematic cross-sectional view of part of a block and internal support, and a connector in an engaging configuration;

Figure 15 is a schematic cross-sectional of the part of the block and internal support, and an alternative connector shown in a non-engaging configuration;

Figure 16 is a schematic perspective view of the alternative connector of Figure 15 in a nonengaging configuration;

Figure 17 is a schematic cross-sectional view of the alternative connector of Figure 15 in an engaging configuration; Figure 18 is schematic perspective view of the alternative connector of Figure 15 in an engaging configuration;

Figure 19 shows an embodiment ofthe invention in an open position;

Figure 20 shows the embodiment of Figure 19 in a part closed position;

Figure 21 shows the embodiment of Figure 19 in a nearly closed position;

Figure 22 shows the embodiment of Figure 19 in a fully closed position;

Figure 23 shows a perspective view of the embodiment of Figure 19

Figure 24 shows a section of “A”-“A” of Figure 23;

Figure 25 shows a section of of Figure 23; and

Figure 26 shows a section of “C”-“C” of Figure 23.

DETAILED DESCRIPTION

An example of a vehicle 10 is shown in Figure 1.

In the following description front refers to components towards the front of the vehicle and the term rear refers to components towards the rear of the vehicle. The terms forward and rearward shall be construed accordingly. The position of features may be construed relative to other components, for example a forward component may be disposed on a forward side of another component, towards the rear of the vehicle. The term horizontal is used herein to mean a plane which extends parallel to the plane of the surface on which a vehicle is located in normal operation.

The vehicle 10 comprises a vehicle body 11. The vehicle body 11 defines a passenger cabin 12 and a load space 13. The vehicle 10 has a front end 14 and a rear end 15. Access doors are defined in the vehicle body 11.

The load space 13 of the vehicle 10 is also typically known as the boot or trunk of the vehicle 10. The load space 13 is at the rear end 15 of the vehicle 10. The vehicle 10 has a row of passenger seating 16. The row of passenger seating 16 may comprising seating for a driver of the vehicle 10. Typically, the row 16 has two seats in a parallel arrangement. A rearward row (not shown) may be disposed rearwards of the row 16. The load space 13 is defined from the passenger cabin 12 by the rearward passenger seating (not shown). However, it will be understood that an alternative feature may separate the load space 13 and the passenger cabin 12. The load space 13 and passenger cabin 12 are typically connected with each other.

The passenger cabin 12 and load space 13 are defined by the vehicle body 11. The vehicle body 11 forms a shell and may be a monocoque construction. The vehicle body 11 provides a support to which other components can be mounted. Herein an internal support refers to an element of the body 11 which is able to provide some support to a component within the body 11, either directly or indirectly.

In the illustrated embodiment, the vehicle 10 comprises internal body panels 17. The internal body panels 17 comprise panel sections mounted to the body 11. The internal body panels 17 cover internal sides of the body 11. The internal body panels 17 define accessible regions of the passenger cabin 12 and the load space 13. The internal body panels 17 may comprise a support panel 18, a load floor (not shown), ceiling panels (not shown), and side panels (not shown). One such support panel, an under seat support panel 19, is shown in Figure 1. The under seat support panel 19 extends between cross-members 20a, 20b. Cross-members 20a, 20b are part of the vehicle body 11.

The under seat support panel 19 is mounted to and spaced from an internal base 21 of the vehicle body 11. As such, a void is created between the under seat support panel 19 and the vehicle body 11. A void space 22 is defined between the vehicle body 11 and the under seat support panel 19. Components may be disposed in this and other similarly formed voids.

Multiple void spaces may be defined in the vehicle 10. Reference will be made to the specific void space formed below the under seat support panel 19 in Figure 1, although it will be understood that the following description may be applied to different void spaces.

An electrical module 23 is disposed in the void space 22. The void space 22 is vented. As components, such as electrical modules 23, are disposed in the void space 22, the void space 22 is vented to allow a flow of air through the void space 22 to assist in the cooling of the electrical modules 23.

An air flow pathway 30 may be defined though the void space 22 and isolated from the void space 22. In the illustrated examples the air flow pathway 30 extends from a forwards region of the vehicle 10 to a rearwards region. The air flow pathway 30 has an inflow 31 and an outflow 32. The inflow 31, in the present examples, communicates with the HVAC system (not shown). The outflow 32 vents to the passenger cabin 12.

Referring to Figure 2, a cross-sectional view from front to back through a known arrangement of mounting the electrical module 23 in the void space 22 is shown. The arrangement shown in Figure 2 does not form part of the present invention. In Figure 2, the electrical module 23 is shown mounted in the void space 22. The void space 22 is shown bounded by an internal base 21, forward and rearward cross-members 20a, 20b, and the under seat support panel 19.

The electrical module 23 is mounted to the internal base 21 by a bracket 24. The bracket 24 is mounted to the vehicle body by fixings 25. Such fixings 25 are typically studs and bolts. Other fixings 26 are used to mount the electrical module 23 to the bracket 24. Such brackets are conventional and usually take the form of a metal flange. Use of such brackets and fixings can be fiddly and time consuming.

An air vent 27 is formed in the under seat support panel 19. Air is allowed to flow into and out of the void space 22 through the air vent 27. Grille shutters 28 extend over the air vent 27. The grille shutters 28 direct a flow of air into the air vent 27.

Figure 3 illustrates a further cross-sectional view from front to back through a different of the known arrangement of Figure 2 is shown. This view shows the void space 22 with ducting 29 extending therethrough. Figure 4 illustrates a cross-sectional view from side-to-side of the ducting 29. The ducting 29 defines the air flow pathway 30 through the void space 22. The ducting 29 is received below the under seat support panel 19 and is spaced away from the electrical module 23, bracket 24 and under seat support panel 19. Flanges 29a are used to mount the ducting 29.

Referring now to Figures 1 and 5 to 9, some embodiments of the present invention will now be described. A vehicle sub-assembly 33 is shown. The vehicle sub-assembly 33 comprises a mounting system 34 and the under seat support panel 19.

The mounting system 34 is received in the void space 22. The mounting system 34 is configured to mount one or more electrical modules in the vehicle 10. One such electrical module 23 is shown in Figure 5. The type and arrangement of the electrical modules 23 may vary. The electrical module 23 may be, for example, a control module, a power module, an entertainment unit, or an operating module.

In the present arrangement, the mounting system 34 is configured to mount to the internal base 21 acting as an internal support of the vehicle 10. However, it will be understood that the mounting system 34 may be connected to alternative features of the vehicle 10 acting as an internal support. The connecting arrangement for connecting the mounting system 34 to the internal support includes a connector 60. Further details of the connecting arrangement will be described below.

The mounting system 34 is configured to be received in the void space 22. The void space 22 is defined in the present embodiment by the cross-members 20a, 20b and internal base 21 forming a body sub-assembly.

The mounting system 34 comprises a block 40. A recess 41 is defined in the block 40. The recess 41 is configured to receive the electrical module 23. The recess 41 is configured to act as a mounting slot for receiving and holding the electrical module 23.

The block 40 may be formed as one or more unitary blocks. In the illustrated example, the block 40 comprises a lower body 40a and an upper body 40b, acting as first and second bodies. Each of the lower body 40a and the upper body 40b may be formed as a one-piece component. In the illustrated example the lower and upper bodies 40a, 40b together form the recess 41. Alternatively, the block 40 is formed as a one-piece component defining the recess 41.

The lower and upper bodies 40a, 40b may have secondary components mounted thereto. The block 40 may be resiliently deformable. In some embodiments, the block 40 is formed from expanded polypropylene. However, the block 40 may be formed from alternative materials, such as another type of expanded polymer. In some embodiments compressed polypropylene regions may be formed in the block 40.

The lower and upper bodies 40a, 40b may be are rigidly mountable to each other. Referring to Figure 7, the lower and upper bodies 40a, 40b of the illustrated example are mounted to each other by a clip arrangement 42. The clip arrangement 42 comprises clips 42a and corresponding clip apertures 42b. The clips arrangement 42 is releasable to aid removal of the electrical module 23. Alternatively, the clip arrangement 42 fixedly mounts the bodies 40a, 40b. Although one clip arrangement 42 is shown, it will be understood that the clip arrangement 42 may differ. In embodiments, the clip arrangement comprises an arrangement corresponding to the connector 60. Further details of the connector 60 will be described below.

The recess 41 is configured to receive the electrical module 23. The recess 41 may be configured to encompass the electrical module 23 when the electrical module 23 is received in the recess 41. In embodiments, the recess 41 is configured to at least substantially encompass the electrical module 23 when the electrical module 23 is received in the recess 41. The recess 41 may define a chamber 43 configured to receive the electrical module 23, such a chamber 43 comprising a chamber base 43a and side faces 43b that define an interior surface of the recess 41.

In the illustrated example, mounting protrusions 44 extend from the interior surface into the recess 41. The mounting protrusions 44 are configured to space the electrical module 23 from the interior surface. The mounting protrusions 44 may space the electrical module 23 substantially entirely from the interior surface, or in some embodiments only from a part of the interior surface, for example from the base 43a and/ or one or more of the side faces 43b. The number of mounting protrusions 44 may vary, and may include a single mounting protrusion. In the present embodiment, the mounting protrusions 44 comprise ribs.

The recess 41 is configured to correspond substantially to the configuration of the electrical module 23. As such, the recess 41 is configured to push-fit receive the electrical module 23 therein. Therefore, the electrical module 23 may be held in the recess 41 without the need for further fixings. The mounting protrusions 44 as well as other portions of the block 40, may be resilient to allow the electrical module 23 to be push-fitted into the recess 41.

The block 40 is configured to support the under seat support panel 19. The block 40 has a panel mounting face 45. The panel mounting face 45 is configured to receive the under seat support panel 19 thereon. The under seat support panel 19 is mountable on the block 40. The block 40 and the under seat support panel 19 together form the vehicle sub-assembly 33.

An air duct 46 is formed in the block 40. The air duct 46 extends between an air inlet 47 and an air outlet 48. The air inlet 47 and air outlet 48 are defined by first and second openings on the exterior of the block 40. The air inlet 47 and air outlet 48 communicate with the recess 41. The air duct 46 intersects with the recess 41. The air duct 46 defines an air flow passage, acting as a flow path, between the air inlet 47 and the air outlet 48. In the illustrated example the air inlet 47 and air outlet 48 are on the panel mounting face 45. The air inlet 47 and air outlet 48 are spaced from each other.

In the illustrated example, the air duct 46 comprises a first flow portion 46a between the air inlet 47 and the recess 41. The air duct 46 of the illustrated example further comprises a second flow portion 46b between the recess 41 and the air outlet 48. In this manner, the recess 41 of the illustrated example is between the first and second flow portions 46a, 46b. The first flow portion 46a of the illustrated example communicates with the recess 41 in one of the side face 43b. The first flow portion 46a of the illustrated example is at a spaced position from the second flow portion 46b in the recess 41.

The first flow portion 46a of the illustrated example extends from the panel mounting face 45 to side face 43b. The first flow portion 46a has a substantially L-shaped arrangement. The second flow portion 46b extends from the upper end of the recess 41 to the panel mounting face 45. The panel mounting face 45 of the illustrated example defines a shoulder which restricts the electrical module 23 from sliding out of the recess 41 when the block 40 is assembled.

With the above arrangement, the air duct 46 defines a flow path from the panel mounting face 45 to the recess 41 with a return path to the panel mounting face 45. As such, the recess 41 communicates with the panel mounting face 45 at two spaced positions. There is a dedicated air flow path over the electrical module 23. The electrical module 23 may have a cooling path through and/or over the electrical module 23. In particular, the electrical module 23 may have a heat sink (not shown). As the first and second flow portions 46a, 46b communicate in a spaced arrangement in the recess 41, a dedicated air flow path through the recess 41 is defined. When the electrical module 23 is disposed in the recess 41 then air flow through the air duct 46 is forced to flow over and/or through the electrical module 23.

The under seat support panel 19 may comprise a panel section formed from polypropylene. The support panel 19 may be rigid. The under seat support panel 19 may be configured to be supported on the panel mounting face 45 of the block 40. In the illustrated example, the under seat support panel 19 has a first vent 49 and a second vent 50. In the vehicle, air flow over the under seat support panel 19 is typically in a rearwards direction. Accordingly in the illustrated example the first vent 49 is located forward of the second vent 50 on the under seat support panel 19. The first vent 49 and second vent 50 extend through the under seat support panel 19 between an upperside 19a and an underside 19b. The first vent 49 is arranged to be aligned with the air inlet 47 and the second vent 50 is arranged to be aligned with the air outlet 48. The first vent 49 locates over and may at least partially seal against the air inlet 47, and the second vent 50 locates over and may at least partially seal against the air outlet 48 when the under seat support panel 19 is mounted on the block 40.

Airflow through the first vent 49 is guided into the air inlet 47. Airflow from the air outlet 48 is fed through the second vent 50. In Figures 5 and 6, arrows show air flow directions. Grille shutters 50a extend over the second vent 50. The grille shutters 50a are inclined away from the first vent 49 towards the upper side 19a of the under seat support panel 19. The grille shutters 50a are configured to direct airflow from the air duct 46 away from the air inlet 47.

With the above arrangement, cool air flowing into the air duct 46 is separated from heated air from the electrical module 23, and as such recirculation of hot air may be prevented. As such, cooling of the electrical module 23 is maximized and heat generated by the electrical module 23 is more easily dispersed. Furthermore, the electrical module 23 is securely held by the mounting system 34 without the need for dedicated fixings. The block is also able to limit vibrations transferred to the electrical module 23.

The mounting system 34 may additionally comprise an air flow channel, such as the example air flow channel 51 of the illustrated embodiment. The air flow channel 51 may be provided in the block 40. The air flow channel 51 may be defined in an exposed face of the block 40. The air flow channel 51 extends along a surface of, in the shown embodiment, the panel mounting face 45 of the block 40. The air flow channel 51 is configured to guide a flow of air through the void space 22.

The air flow channel 51 of the illustrated example comprises a profiled channel in the block 40. Such a channel may be formed during moulding of the block 40, or by a subsequent manufacturing action. It will be understood that the manufacturing method may vary. The air flow channel 51 may be elongate and extend in a forwards-rearwards direction. The airflow channel 51 of the illustrated example is enclosed by the under seat support panel 19. In this manner, the under seat support panel 19, acting as a panel section, is configured to define a side of the air flow channel 51. For example, and as illustrated, a section of the underside 19b of the under seat support panel 19 abuts against the block 40 to enclose the air flow channel 51.

In the illustrated example, the air flow channel 51 has a channel base 52 and channel side walls 53. The under seat support panel 19 extends across and encloses the upper end of the channel side walls 53. The support panel 19 may at least partially seal with the upper end of the channel side walls 53. As such the air flow pathway 30 is defined.

In the illustrated example, the air flow channel 51 defines the inflow 31 and the outflow 32. The inflow 31 is configured to connect with a flow 57 from the HVAC system (not shown). The outflow 32 may comprise an internal vent of the passenger cabin 12. As such the air flow pathway 30 is defined though the void space 22. The enclosed air flow pathway 30 is isolated from the void space 22. The air flow pathway 30 extends from a forwards region of the vehicle 10 to a rearwards region. The outflow 32 vents to the passenger cabin 12.

The air flow channel 51 is isolated from the recess 40. As such, there is no pathway in the block between the airflow channel 51 and either of the recess 40 and the air duct 46. The mounting system 34 for the electrical module 23 and the air flow channel 51 are therefore combined into an integral part. As such, the number of components is minimised. There is no requirement to fix an air flow channel 51 separately from the electrical module 23. The arrangement also minimizes space requirements, by using the under seat support panel 19 as a side of a flow passageway. The block 40 received in the void space 22 may thus act to control multiple flows of air in the void space 22. Carpet 55 may be disposed on the under seat support panel 19.

The connecting arrangement for connecting the mounting system to the vehicle including connecter 60 will now be described in more detail. It will be understood that the connector 60 may take different arrangements. In embodiments, the connector 60 is integrally formed with the block 40. In alternative arrangements part of the connector 60 is integrally formed with the block 40, or is separably formed.

An embodiment of one such connector 60 will now be described with reference to Figures 10 to 13. The connector 60 releasably couples the block 40 to the internal base 21 acting as the internal support of the vehicle 10. Alternative features of the vehicle 10 may act as the internal support.

A portion of the block 40 and a portion of the internal base 21 is shown in the figures. In the illustrated embodiment, the connector 60 is on the block 40, and may be integrally formed with the block 40. The connector 60 comprises a locating means in the form of a locating part 61. The locating part 61 is configured to be received in an aperture 21a formed in the internal base 21. The aperture 21a acts as an attachment configuration. The attachment configuration may have a different arrangement. For example, the attachment configuration may be a cavity, or a through hole in a plate portion of the internal base 21 (as shown). The locating part 61 is inserted through the aperture 21a of the attachment configuration.

In the illustrated embodiment, the connector 60 comprises a locking means in the form of a locking part 70. The illustrated locking part 70 is a male locking part, and 70 is configured to be inserted into the locating part 61 to act on and lock the locating part 61 as will be described in detail below. The locking part 70 in the illustrated embodiment is movable about the locating part 61. For example, the locking part 70 may be pivotably connected to pivot about the locating part 61. The locking part 70 and the locating part 61 are integrally formed in the present embodiment.

The locating part 61 comprises a connector base 63. The connector base 63, in the present embodiment, is a section of reduced thickness of the block 40, and is formed by a recessed portion of the block 40. The locating part 61 has a dowel 64, acting as a protruding element, upstanding from the connector base 63.

The dowel 64 is integrally formed with the connector base 63 in the illustrated embodiment, and is elongate with a free end 66 distal to the connector base 63. In the illustrated embodiment, the dowel 64 has an expanded region 65 of increased thickness in a direction perpendicular to a longitudinal axis of the dowel 64. The expanded region 65 may comprise a circumferentially extending protruding band, although alternative arrangements are possible. The expanded region 65 is spaced from the connector base 63, and in the present embodiment is disposed between the connector base 63 and the free end 66. In this manner, the exterior surfaces of the dowel 64 diverge from the connector base 63 to the expanded region 65, and converge from the expanded region 65 to the free end 66.

The dowel 64 has a bore 67 extending axially along the dowel 64. The bore 67 acts as a locking cavity for receiving the locking part 70. The bore 67 shall hereafter be referred to as the locking cavity 67. The locking cavity 67 extends axially through the length of the dowel 64. In other embodiments, the locking cavity may extend part-way through the dowel 64. The locking cavity 67 comprises a receiving opening 68. The receiving opening 68 is on an opposing side of the connector base 63 to the dowel 64. As such, the locking cavity 67 extends through the connector base 63. The inner face of the locking cavity 67 is defined by a locking cavity wall 67a. A circumferentially extending groove 69, acting as an interacting element, is formed in the locking cavity wall 67a.

The locking part 70 of the illustrated embodiment has a locking base 71 and an elongate rod 72. The elongate rod 72 acts as a locking element. The elongate rod 72 protrudes from the locking base 71. The elongate rod 72 has a tip 73 at a distal end to the locking base 71.The locking base 71 is configured to be received in the recessed portion of the block 40. The elongate rod 72 may be tapered, for example such that it converges from the locking base 71 to the tip 73. In other embodiments, the elongate rod 72 may have a uniform diameter along its length. The elongate rod 72 is configured to conform to the locking cavity 67. The locking part 70 in the illustrated embodiment comprises an engaging element 75 on the elongate rod 72. The engaging element 75 extends circumferentially about the elongate rod 72. The engaging element 75 in the illustrated embodiment is in the form of an annular band. In other embodiments, the engaging element 75 may be in any other suitable form.

In the illustrated example, the locking part 70 is connected to the locating part 61 by means of a live hinge 78, which is integrally formed with the locating part 61 and the locking part 70. A live hinge is thin flexible hinge or flexure bearing made from one of the same materials as the adjacent hinged sections, such as polypropylene in this case. Live hinges connect two adjacent generally rigid sections. Live hinges are typically a thinned or partially cut region which allows the rigid sections to bend along the line of the hinge.

Alternatively, the locking part 70 may be formed separately from the locating part 61 and the locking part 70 may be connected to the locating part 61 using any other suitable means. In a further alternative, the locking part 70 and the locating part 61 may be unconnected.

The locking part 70 is pivotable about the locating part 61. The locking part 70 is configured to pivot between a non-engaging configuration, wherein the elongate rod 72 is absent from the locking cavity 67, and an engaging configuration, wherein the elongate rod 72 is inserted into the locking cavity 67.

In other embodiments, the elongate rod 72 may be translatable between the non-engaging configuration and the engaging configuration.

When the elongate rod 72 is in the non-engaging configuration, the locating part 61 is configured to be inserted into and removed from the aperture 21a, acting as an attachment configuration, on the internal base 21. A locating edge acting as a locating surface, is defined at a distal end of the aperture 21a. The locating surface may be a face. The attachment configuration may be a channel, an aperture or any other suitable configuration.

The dowel 64 is resiliently deformable and is configured to distend inwardly upon the application of a radial compressive force. As such, the dowel 64 forms a resiliently deformable section of the locating part 61. In the distended configuration, the diameter of the dowel 64 is less than the diameter of the aperture 21a. The aperture 21a of the internal base 21 is configured to permit the insertion and removal of the dowel 64 when the dowel 64 is in the distended configuration. In other embodiments, the dowel 64 may be insertable and removable in the distended configuration.

The dowel 64 is configured to revert back to the non-distended configuration after the dowel 64 has been received within the aperture 21a. The expanded region 65 of the dowel 64 is configured to locate within the aperture 21a, forming a snap fit connection, which secures the dowel 64 within the aperture 21a. The locating face 21b acts against a corresponding surface of the dowel 64, thereby preventing withdrawal of the dowel 64 from the aperture 21a when the dowel 64 is in the non-distended configuration.

Referring now to Figures 12 and 13, the locking cavity 67 is configured to receive the elongate rod 72 of the locking part 70 via the receiving opening 68. Upon insertion, the engaging element 75 of the locking part 70 is received within the circumferentially extending groove 69 of the locking cavity 67. The engaging element 75 forms a snap-fit connection with the circumferentially extending groove 69 which deters the locking part 70 from becoming dislodged from the locking cavity 67 once the locking part has been placed in the engaging configuration.

When the connector 60 is placed in the engaging configuration, the elongate rod 72 abuts against the locking cavity walls 67a which substantially restricts any inward distention of the dowel 64, thereby securing the dowel 64 within the aperture 21a. Alternatively, the elongate rod 72 may have a diameter that is greater than a diameter of the locking cavity 67, the elongate rod 72 being configured to expand the dowel 64 when the connector 60 is placed in the engaging configuration.

Referring now to Figure 14, an alternate embodiment is described in which the first component further comprises a locking recess 79. The base 71 ofthe locking part 70 comprises a locking projection 76. The base 71 is formed from a resiliently deformable material. Alternatively, the base 71 may be substantially rigid and the first component may be resiliently deformable or both the base 71 and the first component may be resiliently deformable. The locking recess 79 and locking projection 76 are substantially angular. However, in other embodiments the locking recess 79 and the locking projection 76 may be any form of suitable connection.

When the locking part 70 ofthe alternate embodiment is placed in the engaging configuration, the locking projection 76 interfaces with the locking recess 79 to form a snap-fit connection between the locking projection 76 and the locking recess 79, thereby deterring the locking part 70 from becoming dislodged from within the locking cavity 67. In this alternative embodiment, the engaging element 75 and/or the circumferentially extending groove 69 of the locking cavity 67 may be omitted.

Referring back to Figure 13, the base 71 of the locking part 70 fits substantially flush within the recessed portion of the block 40 when the locking part 70 is in the engaging configuration.

The base 71 of the illustrated embodiment further comprises a base recess 77 in the form of a semi-circular groove providing a release mechanism for enabling a user to disengage the locking part 70 from the locking cavity 67. Alternatively, the groove may be any other suitable form. However, the release mechanism may instead be in the form of a pull tab, a lever or any other suitable mechanism.

The locking part 70 is configured to be removable from the locking cavity 67 by, for example, inserting a tool (not shown) and applying a force to the base 71 of the locking part 70 in a direction away from the locating part 61. It shall be appreciated that a tool in this case may be a human digit or may be a tool in a more traditional sense, such as a hook.

Referring to Figures 15 to 18 an alternative connector 110 is provided for releasably coupling the block 40 to the internal base 21 acting as the internal support of the vehicle 10.

The connector 110 comprises a locating part 80 in the form of a locating aperture 81. The locating aperture 81 is a through hole which extends through the block 40. The locating aperture 81 is configured to receive a protruding feature in the form of a stud 100 located on the internal base 21. The thickness of the block 40 in the region of the locating aperture 81 is substantially less than a length of the stud 100, which thereby permits a protruding end 102 of the stud 100 to protrude from the block 40 when the locating aperture 81 is inserted onto the stud 100. In this embodiment, the protruding feature, in this arrangement the stud 100, acts as the attachment arrangement. In the illustrated embodiment, the locating aperture 81 is provided within a recessed portion 82 of the block 40.

The connector 110 has a locking means in the form of a locking part 90. The locking part 90 is a female locking part. The locking part 90 is configured to receive the stud 100 of the internal base 21. The locking part 90 is moveable about the stud 100. The locking part is pivotally connected to the locating part 80. In the present embodiment, the locking part 90 and the locating part 80 are integrally formed. However, the locating part 80 and the locking part 90 may be adjoined components.

The locking part 90 is connected to the locating part 80 by a live hinge 84. The live hinge 84 is integrally formed with the locating part 80 and the locking part 90. It shall be appreciated that the living live hinge 84 is equivalent to the live hinge 78 referenced in Figures 10-13. Means for connecting the locking part 90 and the locating part 80 have already been described with reference to Figures 10 to 13 and shall not be described in any further detail with reference to Figures 15 to 18.

The locking part 90 comprises a locking body 91. The locking body 91 may be resiliently deformable and may be made from, for example, an expanded polypropylene block. Alternatively, the locking body 91 may be formed from any other suitable material such as rubber. The locking body 91 has a lower face 97 and an upper face 98. The lower face 97 corresponds substantially to the shape of the recessed portion 82 of the block 40 in the illustrated embodiment. A grip element 92, for example in the form of a star washer, may be integrally formed within the locking body 91. The grip element 92 is configured to form an interference fit with the protruding end 102 of stud 100. The locking part 90 may comprise any other suitable kind of grip element, such as a clamp or a screw.

The grip element 92 is located within an opening 94 of a channel 93 which extends partially through the thickness ofthe locking body 91. Alternatively, and as illustrated in Figure 15, the channel 93 may extend through the entire thickness of the locking body 91. The opening 94 of the channel 93 is located on the lower face 97 of the locking body 91. The channel 93 in the illustrated embodiment has a generally frusto-conical cross section defined by channel walls 95. The channel walls 95 are tapered and diverge towards the opening 94 in which the grip element 92 is located. The channel walls 95 may form a plurality of teeth within the channel 93. Alternatively, the channel 95 may comprise a high-friction surface disposed on the channel walls 95.

The locking part 90 is pivotable about the locating part 80. The locking part 90 is configured to pivot between a non-engaging configuration, wherein the the stud 100 is absent from the channel 93 of the locking part 90 as illustrated in Figures 15 and 16, and an engaging configuration, wherein the stud 100 is received within the channel 93 of the locking part 90 as illustrated in Figures 17 and 18.

The stud 100 of the internal base 21 is configured to be inserted into and removed from the locating aperture 81. In the illustrated embodiment, the stud 100 is upstanding from the internal base 21 and comprises an elongate shaft 101 with a substantially uniform diameter. The stud 100 may be formed as a separate component and adjoined to the internal base 21. The stud

100 may be attached to the internal base 21 via any suitable means. Alternatively, the stud 100 may be integrally formed with the internal base 21.

The locking part 90 is configured to locate on the protruding end 102 of stud 100 when the stud is inserted into the locating aperture 81. Referring to Figure 17, the connector 110 is placed in the engaging configuration when the locking part 90 is located on the stud 100. When the locking part 90 is placed in the engaging configuration, the lower face 97 of the locking part 90 abuts with the block 40.

In the engaging configuration, the channel walls 95 bias against the elongate shaft 101 of the stud 100 to form an interference fit between the grip element 92 and the stud 100. The interference fit between the grip element 92 and the stud 100 deters the stud 100 from being removed from the locating part 80.

Referring now to Figure 18, the locking part 90 may further comprise a tab 99. The tab 99 is integrally formed within the upper face 98 the locking part body 91. The tab 99 is configured to receive, for example, a human digit in order to facilitate removal of the locking part 90 from the stud 100. However, in other embodiments, the tab 99 may be omitted.

Referring now to Figures 19 to 26 an alternative embodiment of the invention is shown.

A vehicle sub-assembly 133 is shown which comprises a mounting system. The mounting system 134 is received in the void space 22 as described hereinabove. The mounting system 134 is configured to mount one or more electrical modules, in this case two electric modules 23 in the vehicle 10.

The mounting system 134 comprises a support block 140. Two recesses 141 are defined in the support block 140. The recesses 141 are configured to receive the electrical modules 23. The recesses 141 are configured to act as a mounting slot for receiving and holding the electrical module 23.

The block 140 may be formed as a unitary block. In the illustrated example, the block 140 comprises a lower body 140a and an upper body 140b, the lower body 140a and the upper body 140b are formed as a single component joined to one another by a live hinge 200. The block 140 including the live hinge 200 is formed from substantially from expanded polypropylene as a single molding in a known manner. However, the block 140 may be formed from alternative materials, such as another type of expanded polymer. In some embodiments compressed polypropylene regions may be formed in the block 140.

Between the two recesses 141 a pass through air flow channel 151 is provided which allows a flow of air from one side of the block 140 to the other side of the block, without passing through the recesses. The air flow channel 151 may, in use, form part of a vehicle HVAC system and may be used to duct HVAC warm or cool air from a front area of the seating compartment to a rear area of the seating compartment as described above in relation to Figures 7 and 8.

Referring to Figures 19 to 22 the process for forming the sub-assembly 133 is shown. First the electric modules 23 are placed in the recesses 141. And then the upper body 140b is folded over, by way of the live hinge, so that it closes the electric modules 23 within the body 140. The lower body 140a and upper body 140b have corresponding projections and recesses molded therein such that when the two parts are brought together there is an interference fit between the projections and the corresponding other part. As the body 140 is manufactured from expanded polypropylene it has a natural resilience which enables the projections to deform as the parts are brought together until they locate in the corresponding recesses, thereby retaining the parts together. If sufficient force is applied the parts may be separated without causing damage and allowing for re-closure, for example to enable the electric modules 23 to be replaced. Similarly, naturally resilient projections may be provided within the recesses 141 so that the electric module can be push fit into place and then retained within the recesses 141 by the molded projections.

The upper body 140b has, molded into its upper surface, a recess 204 that forms one half of the passthrough air flow channel 151. A second part of the pass through air flow channel 151, an air flow channel closure 202, is formed integrally with the block 140 and is attached thereto by a second live hinge 214. The airflow channel closure 202 is folded down so as to create the pass through air flow channel 151 between the closure 202 and the recess 204. It will be appreciated that the closure 202 may be folded to create the air flow channel either before or after the body has been enclosed. As can be seen the assembled sub-assembly 131 has an air flow channel inlet 206 and an air flow channel outlet 208 through which the HVAC air can flow. It will be understood that the closure 202 may be retained in place in the same manner as described above, i.e. using an interference with integrally molded projections. It will also be appreciated that other forms of attachment, for example clips may be used to retain the upper and lower body and the closure 202 in place.

It is an advantage of this embodiment that, by using live hinges in this manner, the body, including the airflow channel 151 can be created as a single mounding using a simple up and down tooling arrangement. In addition by using undercuts in the tooling the projections and recesses for attaching the parts together can be molded as part of the single up and down tooling, and the natural resilience of expanded polypropylene will allow the part to be removed from the tool without causing damage. It will, of course, be appreciated that the pass through airflow channel 151 may be molded into the upper body 140b, or the lower body 140a by use of removable cores in the tool, however the disclosed embodiment removes this necessity thereby allowing a simpler tooling process.

Referring to Figures 23 to 26, the block 140 is shown in more detail. Within the upper portion 140b, an upper passage 210 of two first flow portions 146a, each having an air inlet 147, is provided and within the lower portion 140a a lower passage 212 of two first flow portions 146a is provided, the first flow portion 146a providing a flow path for air through the block 140 and into the lower part of the recesses 141. In the upper portion 140b two second flow portions 146b, each having an outlet 148, are provided which create an outlet flow path for air from the recesses 141. In this way a good flow through of air through the recesses can be provided which, as it passes from one side of the recess 141 to the other, past or through the electric modules 23, good cooling of the electric modules is achieved.

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 endeavouring 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 (14)

1. A mounting system for mounting an electrical module to an internal support of a vehicle, the mounting system comprising a support block defining a recess configured to pushfit receive an electrical module; and the support block comprising:

an air inlet;

an air outlet; and an air duct between the inlet and outlet, wherein the air duct comprises a first flow portion and a second flow portion, the recess being between the first and second flow portions and the air duct intersects with the recess to define a flow path between the air inlet and air outlet.

2. The mounting system according to any preceding claim, wherein the recess is configured to substantially encompass the electrical module when the electrical module is received in the recess.

3. The mounting system according to claim 1 or claim 2, wherein the support block comprises at least two block portions.

4. The mounting system according to claim 3 wherein the at least two block portions are joined to one another by a live hinge integrally molded with the at least two block portions.

5. The mounting system according to claim 4 wherein the at least two block portions have a respective integral recess and resilient protrusion thereon and wherein when the two block portions are brought together the protrusion resiliently deforms to allow it to pass into the recess, wherein it resiliently recovers to hold the two block portions together.

6. The mounting system according to any one of the preceding claims, wherein the support block defines an airflow channel passing therethrough and wherein the air flow channel is isolated in the support block from the recess and the air duct.

7. The mounting system according to claim 6, wherein the air flow channel extends along a surface of the support block.

8. The mounting system according to claim 7, further comprising an air flow channel closure joined to the support block by a live hinge integrally molded therewith, wherein when said air flow channel closure is folded about said live hinge and secured to the support block, an underside of the air flow channel closure encloses the air flow channel.

9. The mounting system according to claim 7 wherein the air flow channel closure and the support block have a respective integral recess and resilient protrusion thereon and wherein when the air flow channel closure and the support block are brought together the protrusion resiliently deforms to allow it to pass into the recess, wherein it resiliently recovers to hold the air flow channel closure and the support block together.

10. The mounting system according to any one of the preceding claims, wherein the support block is an expanded polymer block, especially an expanded polypropylene block.

11. The mounting system according to any one of claims 1 to 10, comprising a connector for fixedly mounting the support block to the internal support of a vehicle, the connector comprises a locating part on the support block, and a locking part movable relative to the locating part between a non-engaging configuration and an engaging configuration, and wherein the locating part is either:

configured to be received by an attachment configuration of the internal support and in the engaging configuration, the locking part is inserted into the locating part, the locking part being configured to act on the locating part and restrict movement of the locating part relative to the internal support, or configured to receive a protruding feature of the internal support, and in the engaging configuration, the locking part is configured to engage with the protruding feature to restrict movement of the locating part relative to the protruding feature.

12. The mounting system according to claim 11, wherein the locating part and/or the locking part is integrally formed with the support block.

13. A vehicle sub-assembly comprising a mounting system according to any of claims 1 to 6, and a panel section configured to be supported on the support block, the panel section comprising a first vent arranged to be aligned with the air inlet of the mounting system and a second vent arranged to be aligned with the air outlet of the mounting system, optionally, wherein an underside of the panel section encloses the air flow channel.

14. A vehicle comprising a mounting system according to any of claims 1 to 12, or a vehicle sub-assembly according to claim 13.