Vehicle air system assemblies with aircap assemblies

1. An air system assembly for a vehicle, the air system assembly comprising:

a carpet module;

an HVAC unit above the carpet module;

a floor aircap assembly attached to the carpet module and comprising a hardsheet affixed to a back of the carpet module and an aircap affixed to the hardsheet to define an enclosure for receiving conditioned air from the HVAC unit and provide a load bearing structure for the carpet module, the floor aircap assembly having a vertical portion extending upwardly above the carpet module and a horizontal portion extending below the carpet module; and

a duct that connects the floor aircap assembly to the HVAC unit,

wherein the hardsheet of the floor aircap assembly is formed of a first material, the back of the carpet module is formed of a second material that is different from the first material, and the duct is formed of a third material that is harder than the first material, the first material having a noise insulating property greater than the third material.

2. The air system assembly of claim 1 , wherein the first material is a polypropylene and fiber blend.

3. The air system assembly of claim 1 , wherein the aircap has a flange that provides a seating surface for the hardsheet, the flange of the aircap being attached to the hardsheet with an adhesive or by welding.

4. The air system assembly of claim 1 , wherein the HVAC unit is located at a rear of the vehicle.

5. The air system assembly of claim 1 , wherein the floor aircap assembly has a first end that is closed and a second end that is open.

6. The air system assembly of claim 1 , wherein the vertical portion of the floor aircap assembly extends upwardly through an opening in the carpet module.

7. A vehicle including an air system assembly, the vehicle comprising:

a carpet module;

a rear HVAC unit above the carpet module;

a floor aircap assembly affixed to a back of the carpet module to provide a load bearing structure for the carpet module, the floor aircap assembly comprising a hardsheet affixed to the back of the carpet module and an aircap affixed to the hardsheet to define an enclosure for receiving conditioned air from the HVAC unit; and

a duct connecting the HVAC unit and the floor aircap assembly;

wherein the hardsheet of the floor aircap assembly is formed of a first material, the back of the carpet module is formed of a second material that is different from the first material, and the duct is formed of a third material that is harder than the first material, the first material having a noise insulating property greater than the third material.

8. The vehicle of claim 7 , wherein the second material is a polypropylene and fiber blend.

9. The vehicle of claim 7 , wherein the floor aircap assembly has a vertical portion extending upwardly above the carpet module and a horizontal portion extending below the carpet module.

10. The vehicle of claim 7 , wherein the aircap has a flange that provides a seating surface for the hardsheet the flange of the aircap being attached to the hardsheet with an adhesive or by welding.

11. The vehicle of claim 10 , wherein the hardsheet has a plurality of openings extending therethrough over a broad surface of the hardsheet positioned proximate to the back of the carpet module.

12. A method of providing a floor aircap assembly for a vehicle, the method comprising:

forming a hardsheet for a floor aircap assembly;

affixing the hardsheet to a back of a carpet module at a location remote from a vehicle assembly location thereby providing a single hardsheet/carpet module assemblage for installation in a vehicle;

at a time subsequent to affixing the hardsheet to the back of the carpet module, affixing an aircap to the hardsheet to define an enclosure for receiving conditioned air from the HVAC unit and providing a load bearing structure for the carpet module; and

at a time subsequent to affixing the aircap to the hardsheet, connecting the HVAC unit to the aircap with a duct, wherein the hardsheet of the floor aircap assembly is formed of a first material, the back of the carpet module is formed of a second material that is different from the first material, and the duct is formed of a third material that is harder than the first material, the first material having a noise insulating property greater than the third material.

13. The method of claim 12 , wherein the step of forming the hardsheet comprises forming the hardsheet with a vertical portion and a horizontal portion, the step of affixing the hardsheet to the back of the carpet module including locating the vertical portion of the hardsheet at least partially above the carpet module.

14. The method of claim 12 , wherein the hardsheet is affixed to the back of the carpet module using an adhesive.

15. The method of claim 12 further comprising providing the hardsheet with a plurality of openings.

16. The method of claim 12 , further comprising at a time subsequent to affixing the aircap to the hardsheet, transporting the carpet module, the hardsheet, and the aircap to a vehicle assembly location for installation into a vehicle.

17. The method of claim 12 , wherein the aircap is affixed to the hardsheet by welding or adhering.