Multi-zone control module for a heating, ventilation, and air conditioning system

1. A control module for a heating, ventilating, and air conditioning system comprising:

a housing forming an air flow conduit therein, the housing having an inlet providing fluid communication between a supply of air and the air flow conduit and a center wall forming a first flow path and a second flow path in the air flow conduit;

an evaporator disposed in the housing assembly downstream of the inlet;

a heater core disposed in the housing assembly downstream of the evaporator;

at least one divider disposed in the housing assembly to partition the air flow conduit into a first sub-passage and a second sub-passage;

at least one blend door disposed in the air flow conduit, the at least one blend door selectively positionable between a first position and a second position, wherein the at least one blend door permits a flow of air through the first flow path and militates against the flow of air through the second flow path when positioned in the first position, and permits the flow of air through the second flow path and militates against the flow of air through the first flow path when positioned in the second position, the at least one blend door permitting the flow of air through the first flow path and the second flow path when positioned intermediate the first position and the second position, wherein a third flow path is formed between the at least one blend door and the center wall when the at least one blend door is positioned intermediate the first position and the second position to provide fluid communication between the first flow path and the second flow path downstream of the heater core and upstream of the at least one blend door;

a first mode door disposed in the first sub-passage, the first mode door selectively positionable between a first position and a second position, wherein the first mode door permits a flow of conditioned air through a first outlet of the first sub-passage and militates against the flow of conditioned air through a second outlet of the first sub-passage when positioned in the first position, and permits the flow of conditioned air through the second outlet of the first sub-passage and militates against the flow of conditioned air through the first outlet of the first sub-passage when positioned in the second position, and the first mode door permitting the flow of conditioned air through the first outlet of the first sub-passage and the second outlet of the first sub-passage when positioned intermediate the first position and the second position, wherein only the first mode door directs the flow of conditioned air into the first outlet of the first sub-passage and the second outlet of the first sub-passage, and wherein the first mode door is spaced from a wall of the housing forming a gap between a cross-member of the first mode door and the wall when positioned intermediate the first position and the second position;

a second mode door disposed in the second sub-passage, the second mode door selectively positionable between a first position and a second position, wherein the second mode door permits a flow of conditioned air through a first outlet of the second sub-passage and militates against the flow of conditioned air through a second outlet of the second sub-passage when positioned in the first position, and permits the flow of conditioned air through the second outlet of the second sub-passage and militates against the flow of conditioned air through the first outlet of the second sub-passage when positioned in the second position, and the second mode door permitting the flow of conditioned air through the first outlet of the second sub-passage and the second outlet of the second sub-passage when positioned intermediate the first position and the second position, wherein only the second mode door directs the flow of conditioned air into the first outlet of the second sub-passage and the second outlet of the second sub-passage, and wherein the second mode door is spaced from a wall of the housing forming a gap between a cross-member of the second mode door and the wall when positioned intermediate the first position and the second position; and

a plurality of volume doors, one of the volume doors disposed in at least one of the first outlet and the second outlet of the first sub-passage and another of the volume doors disposed in at least one of the first outlet and the second outlet of the second sub-passage, each of the volume doors selectively positionable between a first position and a second position, wherein each of the volume doors permits the flow of a volume of conditioned air through the at least one of the first outlet and the second outlet of at least one of the first sub-passage and the second sub-passage in the first position and militates against the flow of a volume of conditioned air through the at least one of the first outlet and the second outlet of at least one of the first sub-passage and the second sub-passage when positioned in the second position, and each of the volume doors when positioned intermediate the first position and the second position permitting the flow of a volume of conditioned air less than the volume of conditioned air permitted to flow through the at least one of the first outlet and the second outlet of at least one of the first sub-passage and the second sub-passage when positioned in the first position.

2. The control module according to claim 1 , wherein the housing includes a first housing and a second housing.

3. The control module according to claim 2 , wherein the at least one divider is disposed between the first housing and the second housing.

4. The control module according to claim 3 , wherein the divider separates the first outlet and the second outlet of the first housing from the first outlet and the second outlet of the second housing.

5. The control module according to claim 4 , wherein the first housing is configured to supply the conditioned air to a driver side of a passenger compartment of a vehicle.

6. The control module according to claim 4 , wherein the second housing is configured to supply the conditioned air to a passenger side of the passenger compartment of the vehicle.

7. The control module according to claim 1 , wherein at least one of the at least one blend door, the first mode door, the second mode door, and the volume doors is selectively positioned by an actuator.

8. The control module according to claim 1 , further comprising a motor coupled to the housing, wherein the motor is capable of controlling a rate of air flow through the air flow conduit by selectively increasing and decreasing a rotational motion of a blower wheel disposed in the housing.

9. The control module according to claim 8 , wherein the position of each of the at least one blend door, the first mode door, the second mode door, and the volume doors together with the motor selectively increasing and decreasing the rotational motion of the blower wheel, provide the first outlet and the second outlet of the first sub-passage and the first outlet and the second outlet of the second sub-passage with a desired temperature and volume of air flow.

10. The control module according to claim 1 , wherein the first outlet of at least one of the first sub-passage and the second sub-passage is configured to supply the conditioned air to a floor area of a passenger compartment of a vehicle.

11. The control module according to claim 1 , wherein the second outlet of at least one of the first sub-passage and the second sub-passage is configured to supply the conditioned air to a headliner area of a passenger compartment of a vehicle.

12. The control module according to claim 1 , wherein the first outlet of at least one of the first sub-passage and the second sub-passage is configured to supply the conditioned air to a rear area of a passenger compartment of a vehicle.

13. The control module according to claim 1 , wherein the second outlet of at least one of the first sub-passage and the second sub-passage is configured to supply conditioned air to a rear area of the passenger compartment.

14. A control module for a heating, ventilating, and air conditioning system for a vehicle comprising:

a housing assembly having a first housing and a second housing forming an air flow conduit therein, the housing assembly having an inlet providing fluid communication between a supply of air and the air flow conduit and a center wall forming a first flow path and a second flow path in the air flow conduit, wherein the first housing is configured to supply conditioned air to a driver side of a passenger compartment and the second housing is configured to supply the conditioned air to a passenger side of the passenger compartment;

an evaporator disposed in the housing assembly downstream of the inlet;

a heater core disposed in the housing assembly downstream of the evaporator;

at least one divider disposed between the first housing and the second housing to partition the air flow conduit into a first sub-passage and a second sub-passage;

at least one blend door disposed in the air flow conduit, the at least one blend door selectively positionable between a first position and a second position, wherein the at least one blend door permits a flow of air through the first flow path and militates against the flow of air through the second flow path when positioned in the first position, and permits the flow of air through the second flow path and militates against the flow of air through the first flow path when positioned in the second position, the at least one blend door permitting the flow of air through the first flow path and the second flow path when positioned intermediate the first position and the second position, wherein a third flow path is formed between the at least one blend door and the center wall when the at least one blend door is positioned intermediate the first position and the second position to provide fluid communication between the first flow path and the second flow path downstream of the heater core and upstream of the at least one blend door;

a first mode door disposed in the first sub-passage, the first mode door selectively positionable between a first position and a second position, wherein the first mode door permits a flow of conditioned air through a first outlet of the first sub-passage configured to supply the conditioned air to a floor area of the passenger compartment and militates against the flow of conditioned air through a second outlet of the first sub-passage configured to supply the conditioned air to a headliner area of the passenger compartment when positioned in the first position, and permits the flow of conditioned air through the second outlet of the first sub-passage and militates against the flow of conditioned air through the first outlet of the first sub-passage when positioned in the second position, and the first mode door permitting the flow of conditioned air through the first outlet of the first sub-passage and the second outlet of the first sub-passage when positioned intermediate the first position and the second position, wherein only the first mode door directs the flow of conditioned air into the first outlet of the first sub-passage and the second outlet of the first sub-passage, and wherein the first mode door is spaced from a wall of the housing forming a gap between a cross-member of the first mode door and the wall when positioned intermediate the first position and the second position;

a second mode door disposed in the second sub-passage, the second mode door selectively positionable between a first position and a second position, wherein the second mode door permits a flow of conditioned air through a first outlet of the second sub-passage configured to supply the conditioned air to a floor area of the passenger compartment and militates against the flow of conditioned air through a second outlet of the second sub-passage configured to supply the conditioned air to a headliner area of the passenger compartment when positioned in the first position, and permits the flow of conditioned air through the second outlet of the second sub-passage and militates against the flow of conditioned air through the first outlet of the second sub-passage when positioned in the second position, the second mode door permitting the flow of conditioned air through the first outlet of the second sub-passage and the second outlet of the second sub-passage when positioned intermediate the first position and the second position, wherein only the second mode door directs the flow of conditioned air into the first outlet of the second sub-passage and the second outlet of the second sub-passage, and wherein the second mode door is spaced from a wall of the housing forming a gap between a cross-member of the second mode door and the wall when positioned intermediate the first position and the second position;

a first volume door disposed in the first outlet of the first sub-passage, the first volume door selectively positionable between a first position and a second position, wherein the first volume door permits the flow of a volume of conditioned air through the first outlet of the first sub-passage in the first position and militates against the flow of a volume of conditioned air through the first outlet of the first sub-passage when positioned in the second position, the first volume door when positioned intermediate the first position and the second position permitting the flow of a volume of conditioned air less than the volume of conditioned air permitted to flow through the first outlet of the first sub-passage when positioned in the first position;

a second volume door disposed in the first outlet of the second sub-passage, the second volume door selectively positionable between a first position and a second position, wherein the second volume door permits the flow of a volume of conditioned air through the first outlet of the second sub-passage in the first position and militates against the flow of a volume of conditioned air through the first outlet of the second sub-passage when positioned in the second position, the second volume door when positioned intermediate the first position and the second position permitting the flow of a volume of conditioned air less than the volume of conditioned air permitted to flow through the first outlet of the second sub-passage when positioned in a first position; and

a motor coupled to the housing, the motor capable of controlling a rate of air flow through the air flow conduit by selectively increasing and decreasing a rotational motion of a blower wheel disposed in the housing.

15. The control module according to claim 14 , wherein at least one of the at least one blend door, the first mode door, the second mode door, the first volume door, and the second volume door is selectively positioned by an actuator.

16. The control module according to claim 14 , wherein the position of each of the at least one blend door, the first mode door, the second mode door, the first volume door, and the second volume door together with the motor selectively increasing and decreasing the rotational motion of the blower wheel, provide the first outlet and the second outlet of the first sub-passage and the first outlet and the second outlet of the second sub-passage with a desired temperature and volume of air flow.

17. The control module according to claim 14 , wherein the first outlet of at least one of the first sub-passage and the second sub-passage is configured to supply the conditioned air to a rear area of the passenger compartment.

18. The control module according to claim 14 , wherein the second outlet of at least one of the first sub-passage and the second sub-passage is configured to supply the conditioned air to a rear area of the passenger compartment.

19. A rear control module for a heating, ventilating, and air conditioning system for a vehicle comprising:

a housing assembly having a first housing and a second housing forming an air flow conduit therein, the housing assembly having a cold air inlet providing fluid communication between a supply of cold air and the air flow conduit and a center wall forming a hot air flow path and a cold air flow path in the air flow conduit, wherein the first housing is configured to supply conditioned air to a driver side of a passenger compartment and the second housing is configured to supply the conditioned air to a passenger side of the passenger compartment;

an evaporator disposed in the housing assembly downstream of the cold air inlet;

a heater core disposed in the housing assembly downstream of the evaporator;

at least one divider disposed between the first housing and the second housing to partition the air flow conduit into a first sub-passage and a second sub-passage;

at least one blend door disposed in the air flow conduit, the at least one blend door selectively positionable between a first position and a second position, wherein the at least one blend door permits a flow of hot air through the hot air flow path and militates against a flow of cold air through the cold air flow path when positioned in the first position, and permits the flow of cold air through the cold air flow path and militates against the flow of hot air through the hot air flow path when positioned in the second position, the at least one blend door permitting the flow of hot air through the hot air flow path and the flow of cold air through the cold air flow path when positioned intermediate the first position and the second position, wherein a secondary cold air flow path is formed between the at least one blend door and the center wall when the at least one blend door is positioned intermediate the first position and the second position to provide fluid communication between the hot air flow path and the cold flow path downstream of the heater core and upstream of the at least one blend door;

a first mode door disposed in the first sub-passage, the first mode door selectively positionable between a first position and a second position, wherein the first mode door permits a flow of conditioned air through a floor outlet of the first sub-passage configured to supply the conditioned air to a floor area of the passenger compartment and militates against the flow of conditioned air through a headliner outlet of the first sub-passage configured to supply the conditioned air to a headliner area of the passenger compartment when positioned in the first position, and permits the flow of conditioned air through the headliner outlet of the first sub-passage and militates against the flow of conditioned air through the floor outlet of the first sub-passage when positioned in the second position, and the first mode door permitting the flow of conditioned air through the floor outlet of the first sub-passage and the headliner outlet of the first sub-passage when positioned intermediate the first position and the second position, wherein only the first mode door directs the flow of conditioned air into the floor outlet of the first sub-passage and the headliner outlet of the first sub-passage, and wherein the first mode door is spaced from a wall of the housing forming a gap between a cross-member of the first mode door and the wall when positioned intermediate the first position and the second position;

a second mode door, the second mode door selectively positionable between a first position and a second position, wherein the second mode door permits a flow of conditioned air through a floor outlet of the second sub-passage configured to supply the conditioned air to a floor area of the passenger compartment and militates against the flow of conditioned air through a headliner outlet of the second sub-passage configured to supply the conditioned air to a headliner area of the passenger compartment when positioned in the first position, and permits the flow of conditioned air through the headliner outlet of the second sub-passage and militates against the flow of conditioned air through the floor outlet of the second sub-passage when positioned in the second position, the second mode door permitting the flow of conditioned air through the floor outlet of the second sub-passage and the headliner outlet of the second sub-passage when positioned intermediate the first position and the second position, wherein only the second mode door directs the flow of conditioned air into the floor outlet of the second sub-passage and the headliner outlet of the second sub-passage, and wherein the second mode door is spaced from a wall of the housing forming a gap between a cross-member of the second mode door and the wall when positioned intermediate the first position and the second position;

a first volume door disposed in the floor outlet of the first sub-passage, the first volume door selectively positionable between a first position and a second position, wherein the first volume door permits the flow of a volume of conditioned air through the floor outlet of the first sub-passage in the first position and militates against the flow of a volume of conditioned air through the floor outlet of the first sub-passage when positioned in the second position, the first volume door when positioned intermediate the first position and the second position permitting the flow of a volume of conditioned air less than the volume of conditioned air permitted to flow through the floor outlet of the first sub-passage when positioned in the first position;

a second volume door disposed in the floor outlet of the second sub-passage, the second volume door selectively positionable between a first position and a second position, wherein the second volume door permits the flow of a volume of conditioned air through the floor outlet of the second sub-passage in the first position and militates against the flow of a volume of conditioned air through the floor outlet of the second sub-passage when positioned in the second position, the second volume door when positioned intermediate the first position and the second position permitting the flow of a volume of conditioned air less than the volume of conditioned air permitted to flow through the floor outlet of the second sub-passage when positioned in the first position; and

a motor coupled to the housing, the motor capable of controlling a rate of air flow through the air flow conduit by selectively increasing and decreasing a rotational motion of a blower wheel disposed in the housing, wherein the position of the at least one blend door, the mode doors, and the volume doors together with the motor selectively increasing and decreasing the rotational motion of the blower wheel, provide the floor outlet and the headliner outlet of the first sub-passage and the floor outlet and the headliner outlet of the second sub-passage with a desired temperature and volume of air flow.

20. The rear control module according to claim 19 , further comprising:

a first volume door disposed in the headliner outlet of the first sub-passage, the first volume door selectively positionable between a first position and a second position, wherein the first volume door permits the flow of a volume of conditioned air through the headliner outlet of the first sub-passage in the first position and militates against the flow of a volume of conditioned air through the headliner outlet of the first sub-passage when positioned in the second position, the first volume door when positioned intermediate the first position and the second position permitting the flow of a volume of conditioned air less than the volume of conditioned air permitted to flow through the headliner outlet of the first sub-passage when positioned in the first position;

a second volume door disposed in the headliner outlet of the second sub-passage, the second volume door selectively positionable between a first position and a second position, wherein the second volume door permits the flow of a volume of conditioned air through the headliner outlet of the second sub-passage in the first position and militates against the flow of a volume of conditioned air through the headliner outlet of the second sub-passage when positioned in the second position, the second volume door when positioned intermediate the first position and the second position permitting the flow of a volume of conditioned air less than the volume of conditioned air permitted to flow through the headliner outlet of the second sub-passage when positioned in the first position.