Compact dual-zone console HVAC system for automobiles

A multi-zone climate control system for electrically-powered vehicles having a passenger compartment and a front row of seats including left and right front seats defining first and second front zones of the passenger compartment, a second row of seats behind the left and right front seats defining at least one rear zone of the passenger compartment, a center console extending in a fore-aft direction between the left and right front seats, and a high voltage traction battery disposed below at least a portion of the center console, the multi-zone climate control system comprising:

• a front HVAC unit configured to be mounted in a forward portion of the vehicle, wherein the front HVAC unit includes an auxiliary air passage, a first air passage, and a heat exchanger that is configured to selectively heat air flowing through the first air passage, the front HVAC unit further including an evaporator that is adapted to selectively cool air flowing through the first air passage and through the auxiliary air passage, wherein the front HVAC unit does not include an air mix door or an air mix space associated with the auxiliary air passage, such that air flowing through the auxiliary air passage cannot be mixed with air that has been heated by the heat exchanger, wherein air flowing through the first air passage is supplied to left and right front air outlets to provide heated and cooled air to first and second front zones, respectively, of the vehicle, and wherein the auxiliary air passage of the front HVAC unit is fluidly connected to a cold air outlet such that the front HVAC unit is incapable of providing air that has been heated by the heat exchanger to the cold air outlet;
• a powered blower fluidly connected to the cold air and positioned in the center console behind the front HVAC unit;
• and
• a heater core fluidly connected to the powered blower whereby cold air from the cold air outlet of the front HVAC unit passes through the powered blower and enters the heater core, the heater core including a liquid-to-air heat exchanger that is configured to be fluidly connected to a source of heated liquid to selectively heat cold air entering the heater core, and wherein the heater core includes a control system that is configured to control a temperature of air exiting the heater core, the heat control system comprising at least one of:
• 1) a liquid-based heat control that is configured to adjust at least one of a temperature and a volume flow rate of heated liquid flowing through the liquid-to-air heat exchanger, and 2) an air blender having a blend door that is configured to selectively mix cold air from the front HVAC unit with air that has been heated by the liquid-to-air heat exchanger to control the temperature of air exiting the heater core, the heater core further including at least one air outlet configured to supply heated air from the heater core to the at least one rear zone of the passenger compartment.

A method of controlling air temperature in multiple zones of a passenger compartment of an electrically-powered motor vehicle, the method comprising:

• providing an electrically-powered vehicle having a passenger compartment and a front row of seats including left and right front seats defining first and second front zones of the passenger compartment, a second row of seats behind the left and right front seats defining at least one rear zone of the passenger compartment, a center console extending in a fore-aft direction between the left and right front seats, and a high voltage traction battery disposed below at least a portion of the center console, the electrically-powered vehicle further including a multi-zone climate control system comprising:
• providing a front HVAC unit mounted in a forward portion of the electrically-powered vehicle forward of the left and right front seats, wherein the front HVAC unit includes a first air passage and a heat exchanger wherein the heat exchanger is adapted to selectively heat air flowing through the first air passage, the front HVAC unit further including an evaporator that is adapted to selectively cool air flowing through the first air passage and through an auxiliary air passage of the front HVAC unit, wherein air flowing through the auxiliary air passage does not flow through the heat exchanger such that air flowing through the auxiliary air passage cannot be heated by operation of air flowing through the heat exchanger, the front HVAC unit including left and right front air outlets that are fluidly connected to the first air passage to provide heated and cooled air having non-equal first and second temperatures to the first and second front zones, respectively, and wherein the auxiliary air passage of the front HVAC unit is fluidly connected to a cold air outlet such that the front HVAC unit is incapable of providing air that has been heated by the heat exchanger to the cold air outlet;
• providing a powered blower fluidly connected to the cold air outlet and positioned in the center console behind the front HVAC unit;
• and
• providing a heater core that is fluidly connected to the powered blower whereby cold air from the cold air outlet of the front HVAC unit passes through the powered blower and enters the heater core, the heater core including a liquid-to-air heat exchanger that is fluidly connected to a source of heated liquid to selectively heat cold air entering the heater core, and wherein the heater core includes a heat control system that is configured to control a temperature of air exiting the heater core, the heat control system comprising at least one of:
• 1) a liquid-based heat control that is configured to adjust at least one of a temperature and a volume flow rate of heated liquid flowing through the liquid-to-air heat exchanger, and 2) an air blender having a blend door that is configured to selectively mix cold air from the front HVAC unit with air that has been heated by the liquid-to-air heat exchanger to control the temperature of air exiting the heater core, the heater core further including at least one air outlet configured to supply heated air from the heater core to the at least one rear zone of the passenger compartment;
• utilizing the front HVAC unit to provide independently-controlled conditioned air to the first and second front zones of the passenger compartment;
• causing cold air from the cold air outlet of the front HVAC unit to flow rearwardly through the center console of the electrically-powered motor vehicle to the heater core;
• using the liquid-to-air heat exchanger of the heater core to heat the cold air from the front HVAC unit;
• and
• distributing air that has been heated by the liquid-to-air heat exchanger to a rear zone of the passenger compartment that is located behind the first and second front zones of the passenger compartment.