Abstract: A modular door for a vehicle HVAC system includes a door plate, a first shaft, and a second shaft. The door plate has a front surface extending between an upper edge surface and a lower edge surface. The upper edge surface defines a first array of keyed orifices. The lower edge surface defines a second array of keyed orifices. The first shaft has a first keyed protrusion that is disposed within a first keyed orifice of the first array of keyed orifices. The second shaft has a second keyed protrusion that is disposed within a first keyed orifice of the second array of keyed orifices. The first keyed orifice of the first array of keyed orifices and the first keyed orifice of the second array of keyed orifices form a pair of axially aligned keyed orifices.

Abstract: A modular door kit for a vehicle HVAC system includes first, second, and third subcomponents. The first subcomponent defines a receptacle and is configured to be standardized for first and second door configurations. The second subcomponent has a first protrusion and is configured to be standardized for the first door configuration but not the second door configuration. The first protrusion is configured to engage the receptacle to rigidly affix the position of the second subcomponent relative to the first subcomponent to form the first door configuration. The third subcomponent has a second protrusion and is configured to be standardized for the second door configuration but not the first door configuration. The second protrusion is configured to engage the receptacle to rigidly affix the position of the third subcomponent relative to the first subcomponent to form the second door configuration.

Abstract: A modular door for a vehicle HVAC system includes a door plate, a first shaft, and a second shaft. The door plate has a front surface extending between an upper edge surface and a lower edge surface. The upper edge surface defines a first array of keyed orifices. The lower edge surface defines a second array of keyed orifices. The first shaft has a first keyed protrusion that is disposed within a first keyed orifice of the first array of keyed orifices. The second shaft has a second keyed protrusion that is disposed within a first keyed orifice of the second array of keyed orifices. The first keyed orifice of the first array of keyed orifices and the first keyed orifice of the second array of keyed orifices form a pair of axially aligned keyed orifices.

Abstract: A modular door for a vehicle HVAC system includes a first subcomponent, a second subcomponent, and a customized subcomponent. The first subcomponent forms a first portion of the modular door and is configured to be standardized for first and second vehicle HVAC systems. The second subcomponent forms a second portion of the modular door and is configured to be standardized for the first and second vehicle HVAC systems. The customized subcomponent is configured to separate the first subcomponent from the second subcomponent. The customized subcomponent is also configured to connect the first subcomponent to the second subcomponent such that the modular door is configured for the first vehicle HVAC system.