Patent Grant
10215507
The embodiments disclosed herein relate generally to a component within a unit of an air conditioning system or unit and/or HVAC unit or system and in particular, a component that supports an outdoor coil and has condensate drainage functionality.
In typical outdoor units of an air conditioning system, plastic injected coil support pads are installed to support an outdoor coil. The pads are generally designed to sit on top of embossments in the base pan. Some pads are secured in place by a machine screw, with a clearance hole on a tab on the side of the pad, and an engagement hole in the base pan. Other pads are not screwed into place, and simply rely on the compressive force of the coil to stay in place. Additional plastic pads can be added along the length of the coil to minimize coil deformation during transportation and installation. For these additional pads for which there are no corresponding embosses in the base pan or engagement hole for a screw, an adhesive-backed foam block is used to keep the pad in place. The adhesive side of the pad is affixed to the base pan, and the plastic pad sits on top of the foam block.
The embodiments described herein are directed to a coil support pad for condensate drainage and a method of manufacturing the coil support pad. The coil support pad generally functions to provide support for outdoor coils and facilitates the drainage of condensate away from the coils.
In general, the coil support can be used in a unit within an air conditioning system, e.g., an outdoor unit. In some examples, the outdoor unit can include a case, a condenser, a fan, an outdoor coil, and a coil support pad.
In some examples, the case can include a front plate, a rear plate, a lateral plate, a top cover and a bottom pan.
In some examples, the outdoor coil can be a microchannel coil that may include a plurality of microchannel tubes with one or more microchannels therein. In some examples, a refrigerant flows through the microchannels. In some examples, the microchannel tubes generally extend from one or more headers. In some examples, the headers generally extend vertically and are horizontally spaced apart from each other for example by a predetermined distance. In some examples, the microchannels or the headers may be in fluid communication with each other and with the overall air-conditioning system.
In some embodiments, the coil support pad can be incorporated as part of the outdoor unit by being installed onto the base pan prior to the outdoor coil installation. In general, the coil support pad has one or more mating features that mate, for example, with one or more corresponding mating features on the base pan, facilitate in securing the outdoor coil on the coil support pad and/or directs liquid such as condensate and rain water away from the coils, thereby preventing the coils from being submerged in the liquid.
In some embodiments, the coil support pad is shaped so that the coil support pad as viewed in top view generally follows the outline of the outdoor coil. In some examples, the coil support pad is substantially continuous. The term “substantially continuous” means that the coil support pad is a single integrated unit so that there are no spaces that would separate the coils support pad into multiple units. In some examples, the coil support provides substantially continuous support for the outdoor coil. The term “substantially continuous support” means that the coil support pad is configured so that when the outdoor coil is provided on the coil support pad, a pressure applied on the coil support pad is evenly distributed across the coil support pad so as to reduce and/or eliminate point loads on the coil support pad.
In one embodiment, the coil support pad includes a base having a central portion, a first arm portion and a second arm portion. In some examples, the first arm portion extends outwardly along a first axis from a first end of the central portion and the second arm portion extends outwardly along a second axis from a second end of the central portion. In some examples, the first and second axes are substantially perpendicular to one another.
In some examples, the base has top and bottom principal surfaces. In some examples, the bottom principal surface includes a mating feature. In some examples, the mating feature is an emboss feature or a deboss feature. The bottom principal surface further includes slotted features. The slotted features are configured to allow debris, condensation, rain water, etc. to escape from an outdoor section of the outdoor unit.
In some examples, the top principal surface is sloped relative to a vertex. In some examples, the top principal surface is patterned with a plurality of support protrusions. In some instances, the sloped surface and/or the plurality of support protrusions are configured to provide continuous support and/or facilitate the drainage of liquid, for example, condensate, away from the outdoor coils.
In some examples, the top principal surface has one or more support features. In some examples, the support feature is generally configured to position the outdoor coil during installation and/or facilitate in securing the outdoor coil during assembly of the outdoor unit.
In some examples, the support feature protrudes upwardly from the top principal surface. In some examples, the support feature has a shape as viewed in top view that generally follows an outline of a cross-section of a coil header as viewed in side view. In some examples, the support feature is U-shaped as viewed in top view.
In some examples, during assembly, gasketing is applied to the top of the outdoor coil before the top cover is installed. Once the top cover is installed, a compressive force maintains substantially continuous support for the outdoor coil along the length of the outdoor coil.
In one embodiment, the disclosed method of manufacturing the outdoor unit involves assembling the coil support pad on the base pan by mating the mating features on the coil support with the corresponding mating features on the base pan, securing the outdoor coil on the coil support pad by securing the outdoor coil to the support feature of the coil support pad, applying a gasket on a top of the outdoor coil, and installing the top cover on the outdoor coil so that a compressive force maintains substantially continuous support for the outdoor coil along the length of the outdoor coil.
Referring now to the drawings in which like reference numbers represent corresponding parts throughout.
The embodiments described herein are directed to a coil support pad for condensate drainage and a method of manufacturing the coil support pad. In some examples, the coil support pad is included in a unit, for example, an outdoor unit of an air conditioning system. In some examples, the outdoor unit can be used on a stationary or mobile structure.
In general, the coil support pad generally is configured to provide support for outdoor coils and facilitate the drainage of condensate away from the outdoor coils.
In general, the compressor 31 is suitable for compressing a refrigerant. The compression of the refrigerant results in refrigerant being heated. The heated refrigerant then is sent through the condenser coil 48 via an inlet 4a where the heat is dissipated. The fan 36 generally functions to discharge air that is passed through the outdoor coil 48. The compressor 31 utilized can be any type of compressor suitable for use in an air conditioning system. In some examples, the unit 10 can include an evaporator (not shown). In this instance, a lower pressure line (not shown) can receive refrigerant from the evaporator, which passes to the compressor 31.
In some examples, the outdoor coil 48 can be a microchannel coil that may include a plurality of microchannel tubes with one or more microchannels therein. In some examples, a refrigerant enters through the inlet 4a, flows across the microchannels, and flows out through an outlet 4b. In some examples, the microchannel tubes generally extend from a first header 21a to a second header 21b. In some examples, the headers 21a, 21b generally extend vertically and are horizontally spaced apart from each other. In some examples, the headers 21a, 21b may be in communication with the overall air-conditioning system via the inlet 4a and the outlet 4b.
In some embodiments, the outdoor unit 10 is assembled such that the coil support pad 41 is provided on the base pan 12, the outdoor coil 48 is provided on the coil support pad 41, and the top cover 15 is provided on the outdoor coil 48.
Details of the outdoor coil 48 will now be discussed with reference to
Referring to
In the example illustrated, the coil support pad 41 includes three mating features 92 which are shown to be deboss features. However, it is to be appreciated that any number and/or any type of mating feature that is suitable for attaching the coil support pad 41 to the bottom pan 12 can be utilized. For instance, the coil support pad 41 can include one or more emboss features, while the bottom pan 12 can include one or more corresponding deboss features.
The bottom principal surface 89 further includes slotted features 95. The slotted features 95 are openings that are configured to allow debris, condensation, rain water, etc. to escape from an outdoor section of the outdoor unit 10.
Referring to
Referring to
Referring again to
In some examples, the coil support pad 41 can be patterned with a plurality of support protrusions 111 that protrude upwardly along a vertical axis D-D from the top principal surface 86. In some examples, the support protrusions 111 are generally configured to provide substantially continuous support for the outdoor coil 48 and/or facilitate drainage of liquid away from the outdoor coils 148 due to spaces between the support protrusions 111 which create drainage paths for condensate liquid, etc. to pass, for instance, together with the sloped features of the top principal surface 86. In some examples, the distance that the support protrusions 111 protrude from the top principal surface 86 is less than the distance that the support features 69, 73 protrude from the top principal surface 86.
In some examples, the pattern of the support protrusions 111 is uniform. The term “uniform” means that each of the support protrusions 111 has a shape and/or dimension that is substantially the same as one another and/or the number of support protrusions 111 and the relative positions of the support protrusions 111 are the same within a given area. In some examples, some or all of the support protrusions 111 can have a shape and/or dimension that is different from one another.
In some examples, the support protrusions 111 substantially cover a surface area of the top principal surface 86. In some examples, the support protrusions 111 substantially cover a surface area of the top principal surface 86 such that about 50% to about 90% of the surface area of the top principal surface 86 is covered with the support protrusions 111.
In some examples, each of the support protrusions 111 is substantially cylindrical in shape. In this instance, each of the support protrusions 111 has a top surface 109 that is substantially flat and is circular as viewed in top view. In some examples, each of the support protrusions 111 protrudes a distance so that the top surface 109 of each of the support protrusions 111 is substantially level on a plane that is parallel to the horizontal axis C-C.
In some examples, the shape of each of the support protrusions 111, the number of support protrusions 111 and the pattern of the support protrusions 111 can be any shape, any number and any pattern, respectively, that is suitable for facilitating the drainage of liquid, for example, condensate, away from the outdoor coils 48.
In some examples, the coil support pad 41 is substantially continuous. The term “substantially continuous” means that the coil support pad 41 is a single integrated unit so that there are no spaces that would separate the coils support pad 41 into multiple units.
In some instances, the coil support pad 41 is modular, and can be made of more than one unit as illustrated in
The material of the coil support pad 41 can be any material that is suitable for supporting an outdoor coil and/or preventing metal-to-metal corrosion of the aluminum coil, and/or has absorptive properties that help protect the outdoor coil, for example, during transportation and installation. In some examples, the material is Styrofoam, expanded polypropylene and the like, etc. In some examples, the coil support pad 41 is a molded expanded polypropylene.
Referring to
Advantageously, the disclosed coil support pad does not rely on the use of “teeth”, e.g., that are made of plastic, for supporting the outdoor coil. That is, conventional pads have “teeth” that extend above the flat surface on which the coil sits. The teeth often create point loads and cause coil damage both internally during coil install and externally during shipping and/or installation. Instead, the disclosed coil support pad utilizes a compressive force of the top cover to secure the outdoor coil in place. Additionally, the “U” shaped support feature helps hold the coil in place once installed by fixing the coil's header location. During outdoor coil installation, the coil support pad provides a larger surface area on which to install the coil with a manipulator so as to provide substantially continuous support for the coil, for example, via the support protrusions. Once the coil is on the pad, the operator can easily adjust the coil position into place.
Moreover, since the coil support pad can be a continuous piece, the risk of the support popping off of the bottom pan can be eliminated. In some examples, the debosses on the pads are press-fit onto the embossments of the bottom pan, securing the pad in place. Once the coil is installed, and even more so when the top cover is installed, there is a very minimal chance, if at all, that the pad can become dislodged. This makes the overall outdoor coil assembly less susceptible to imperfections in coil flatness, bend angle accuracy, and up-line dead tube deformation. This also can decrease the risk of galvanic corrosion of the coil by eliminating the risk of the pad becoming dislodged and the coil coming into contact with the other metal, e.g., the bottom pan.
Even further, in some examples, the continuous outdoor coil support pad can eliminate or at least reduce point loads on the outdoor coil. In this instance, the bottom of the coil is supported along the entire length of the coil, including around the coil bend (which laboratory testing has proven to be a particularly susceptible area or the most susceptible area for coil deformation).
Any of aspects 1-17 can be combined with one another.
With regard to the foregoing description, it is to be understood that changes may be made in detail, especially in matters of the construction materials employed and the shape, size and arrangement of the parts without departing from the scope of the present invention. It is intended that the specification and depicted embodiment to be considered exemplary only, with a true scope and spirit of the invention being indicated by the broad meaning of the claims.
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| Number | Date | Country | |
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| 20150292816 A1 | Oct 2015 | US |
| Number | Date | Country | |
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| 61979767 | Apr 2014 | US |
