Application of Foam Packing in Sealing Doors and Reducing Fluid Leakage in Automotive HVAC of the Climate Control System 2022-28-0457

The heating, ventilation and air conditioning system is one of the complex systems installed inside the cabin of an automobile vehicle. Each HVAC discipline has specific design requirements in terms of packaging space, performance targets, etc. Technical specifications such as airflow, noise, air distribution, allowable leakage rate vary as per vehicle segment and interior design accordingly. While maintaining the design parameters of HVAC, design engineers often face challenges related to water leakage, air leakage, water infiltration, etc. Controlling these parameters becomes crucial for customer satisfaction and for safety features.

Several studies on seal proof technology have been conducted and continue to be conducted, whether for air-based applications, water-based applications, or any other fluid material.The application of sealing technology is spread almost everywhere, from domestic purposes to industrial applications. Similarly, in automotive HVAC, the application of foam packing for sealing doors or reducing leakage plays a crucial role. Different types of material with different cell structures are being used as per application requirements.

This study will give insight regarding the application of foam packing, whether for the sealing of doors or the sealing of txv areas. Apart from this, a study was done on defrost leakage, which is a very prominent issue in HVAC. Defrost leakage leads to mist formation during certain climate conditions. The mist issue is mainly related to safety while driving the vehicle. Study on sealing and further detailed study of defrost sealing will give a brief guide to the design engineer in the selection of foam packing according to application within HVAC and surroundings. The application of foam packing in different forms and shapes with the results is presented in this study. Controlling the defrost leakage due to variation in parts is also captured in the study and bench test results provide a fair idea about the selection of foam packing at critical areas like the defrost outlet.