Embodiments disclosed herein relate generally to a heat exchange system. Specifically, the embodiments disclosed herein relate to an evaporator and a case for the evaporator wherein a horizontal V-coil with vertical fins has drain pans allowing for multiple configurations of the coil.
HVACR systems, such as home furnaces with air conditioning units, are used to cool airflow distributed within a structure. Some HVACR systems, for example those for smaller buildings such as residences, cool the airflow using a refrigeration coil such as an evaporator coil.
Current evaporator coil designs are installed in HVACR systems in a particular orientation, such as “horizontal left,” “horizontal right,” or vertical orientations, with the direction of airflow with respect to a front side having the refrigerant line connecting the coil to the rest of a compressor system. The shape of the coil may be a V-shape, which may be referred to as a V-coil or an A-coil depending on the orientation of the coil.
When the airflow being cooled is humid, water may condense on the evaporator coil. The condensate may drip or pool, and contact the support structures or the duct system, possibly damaging the structure or components of the structure. To capture and direct the condensate, a drain pan may be included, positioned below the evaporator coil when the coil is installed.
Coil designs may be optimized for particular orientations and directions of airflow, or designed to offer consistent though less efficient performance in a variety of orientations. Where a coil is optimized for a particular type of airflow, installers may be limited in the placement and orientation of a furnace in order to install the coil in its optimal configuration while connecting to the refrigeration line. In addition to reduced efficiency compared to airflow-specific dedicated coil designs, multi-position coil designs may require additional swapping of components or parts or use of different installation kits for each orientation, making their use more complex and costly for installers.
Convertible-cased refrigeration coil and drain pan assemblies may include refrigeration coils for dedicated airflow directions, and drain pans which allow the assembly to be installed in multiple positions while collecting condensate. The refrigeration coil and drain pan assembly is such that the assembly may be switched between a horizontal-left dedicated coil or a horizontal-right dedicated coil by rotating the assembly about an axis parallel to the direction of airflow through the installed assembly. This enables the use of efficient designs for the refrigeration coil while allowing embodiments to be installed in a variety of configurations.
An HVACR refrigeration coil and drain pan assembly, including two drain pans, opposite one another, each having at least one drain connection, and a coil comprising a plurality of fins, the fins running in a direction from a first drain pan towards a second drain pan.
In an embodiment, a refrigerant line is connected to the refrigeration coil. The refrigerant line may exit the drain pan assembly on a side of the drain pan assembly between the two drain pans. The refrigerant line may be vertically biased towards one of the drain pans. In an embodiment, the refrigerant line exits the refrigeration coil and drain pan assembly on a side of the assembly and at a point equidistant from the two drain pans. In an embodiment, there is a removable access door on the side of the refrigeration coil and drain pan assembly that the refrigerant line exits the assembly.
In an embodiment, the fins run perpendicular to the plane of the drain pans.
In an embodiment, one or more of the drain pans comprises multiple levels.
In an embodiment, the refrigeration coil is a dedicated horizontal refrigeration coil.
An HVACR unit includes a blower providing an airflow and a refrigeration coil and drain pan assembly downstream from the blower with respect to the airflow, and the refrigeration coil and drain pan assembly includes first and second drain pans, located opposite one another and each having one or more drain connections, a refrigeration coil having fins running in a direction from one drain pan to the other, and a refrigerant line exiting the heat exchanger and drain pan assembly on a side.
In an embodiment, the refrigeration coil and drain pan assembly is installed in the HVACR unit such that a drain pan is at the bottom of the assembly.
In an embodiment, the airflow enters the refrigeration coil and drain pan assembly at an open end of the refrigeration coil side and travels towards a converged end of the refrigeration coil.
In an embodiment, the refrigeration coil and drain pan assembly may be installed in a horizontal-left position or a horizontal-right position with respect to the direction of the airflow from the perspective of the refrigerant line side of the assembly.
In an embodiment, there is a removable access door on the side of the refrigeration coil and drain pan assembly that the refrigerant line exits the assembly.
In an embodiment, the fins run perpendicular to the plane of the drain pans.
In an embodiment, one or more of the drain pans comprises multiple levels.
These refrigeration coil and drain pan assemblies and HVACR systems including these assemblies may allow installers more freedom in orienting and placing the HVACR systems within buildings, particularly where the systems must be in tight spaces such as closets or crawl spaces, while still enabling the use of refrigeration coils which are designed for superior performance in a particular orientation.
Refrigeration coils in HVACR units require a refrigerant line to be connected to a refrigerant circuit, for example by brazing. The position of the refrigerant line, in conjunction with the design of the refrigeration coil and the airflow direction required by the refrigeration coil design can constrain the options of HVACR system installers by requiring particular positions for the furnace and other HVACR system components to connect a refrigerant line to a refrigerant circuit and to have the proper airflow through the refrigeration coil. The furnace position required by the refrigeration coil may conflict with the limitations of small spaces such as, for example, basements or crawlspaces. A dedicated horizontal refrigeration coil assembly that provides adjustability and reversibility of the refrigerant line connection allows installers more options without having to compromise efficiency with a multi-position refrigeration coil design. The assembly may include two drain pans located opposite one another, allowing condensate to drain regardless of a 180 degree rotation of the assembly to present the refrigerant line on a particular side of the refrigeration coil assembly.
Refrigeration coils may be arranged in various configurations. These configurations include, for example, V-shaped coil assemblies (V-coils), A-shaped coil assemblies (A-coils) and horizontal coils which may be tilted V- or A-shapes. The evaporator coil configuration may be selected based on a direction of airflow to be directed through it, for example to optimize heat transfer to an airflow traveling through the coil in a particular direction. For example, the evaporator coil may be in a dedicated horizontal configuration which is similar to a V-shape laid down onto its back. V-shaped coil assemblies may have a converged end corresponding to the vertex of the V, and may have an open end corresponding to the open top of a V.
Refrigeration coil and drain pan assemblies which present a refrigerant line on a side of the refrigeration coil and drain pan assembly may be designed to have vertical or horizontal orientations, defined by the direction of the airflow through the refrigeration coil. The horizontal orientations may further have a direction, such as horizontal-left or horizontal-right, based on the direction of airflow from the perspective facing the refrigerant line.
The refrigerant circuit 2 can generally be applied in a variety of systems used to control an environmental condition (e.g., temperature, humidity, air quality, or the like) in a space (generally referred to as a conditioned space). Examples of such systems include, but are not limited to, HVACR systems.
The compressor 10, condenser 4, expansion device 6, and evaporator 8 are fluidly connected. The refrigerant circuit 2 can operate according to generally known principles. The refrigerant circuit 2 can be configured to heat or cool a process fluid such as air, such as in an air conditioner or heat pump.
In operation, the compressor 10 compresses a working fluid (e.g., a heat transfer fluid such as a refrigerant or the like) from a relatively lower pressure gas to a relatively higher-pressure gas. The relatively higher-pressure gas is also at a relatively higher temperature, which is discharged from the compressor 10 and flows through the condenser 4. The working fluid flows through the condenser 4 and rejects heat to a process fluid (e.g., air or the like), thereby cooling the working fluid. The cooled working fluid, which is now in a liquid form, flows to the expansion device 6. The expansion device 6 reduces the pressure of the working fluid. As a result, a portion of the working fluid is converted to a gaseous form. The working fluid, which is now in a mixed liquid and gaseous form flows to the evaporator 8. The working fluid flows through the evaporator 8 and absorbs heat from a process fluid such as air, heating the working fluid, and converting it to a gaseous form. The gaseous working fluid then returns to the compressor 10. The above-described process continues while the refrigerant circuit is operating, for example, in a cooling mode (e.g., while the compressor 10 is enabled).
Evaporator 8 may be a refrigeration coil located in the path of an airflow, for example located within an HVACR system such as a residential furnace assembly. In an embodiment, the airflow is a process fluid, and heat is transferred from the process fluid to a working fluid within the refrigeration coil such as a refrigerant, cooling the airflow. The airflow may then be distributed within a structure such as a home, providing air conditioning to the structure.
Refrigeration coil 34 may be a dedicated horizontal V-coil, arranged such that it appears as a V lying on a flat plane. The refrigeration coil 34 includes fins 28. The fins 28 may run in a direction from one drain pan to another. Where the drain pans are parallel to one another, the fins 28 may run in a direction perpendicular to the plane of each drain pan 24. For example, the fins 28 may run vertically when the refrigeration coil and drain pan assembly 22 is installed with the HVACR unit. This orientation allows condensate to run down the fins 28 into the drain pans 24, and the condensate may leave the drain pans via drain connections 26.
Refrigerant line 30 carries cooled working fluid, such as a refrigerant, into the refrigeration coil 34, where it transfers heat to an airflow 32 flowing through the refrigeration coil 34. A refrigerant return line 36 may return working fluid heated in the refrigeration coil 34 to continue flowing through the refrigerant circuit. The refrigerant line 30 may include an opening located near where the refrigerant line leaves the refrigeration coil assembly. The opening may be brazed to a line from a compressor system to put the refrigerant line 30 in fluid communication to receive a working fluid of the compressor system. In an embodiment, the refrigerant line 30 may be positioned proximate to an end of the refrigeration coil 34 and drain pan assembly 22 along an axis 46 in the direction of the airflow (e.g. arrow 32 shown in
The orientation of the refrigeration coil and drain pan assembly 22 may be defined based on the perspective of the side that the refrigerant line 30 leaves the assembly 22 and the direction of airflow 32 when the refrigeration coil and drain pan assembly 22 is viewed from that side. In the embodiment shown in
In the embodiment shown in
An access door 38 may be located on the side of the refrigeration coil and drain pan assembly 22 where the refrigerant line 30 exits the refrigeration coil and drain pan assembly 22. The access door 38 may be moved or removed from the refrigeration coil and drain pan assembly 22 to provide access to the interior of the assembly, including access to the refrigeration coil 34 for maintenance and the refrigerant line 30 for installation. In the embodiment shown in
The refrigeration coil and drain pan assembly 22 may be placed following furnace 20 with respect to the direction of airflow 32 through the HVACR unit. The airflow 32 may be driven by a blower 42, such as a fan, included in furnace 20. In the embodiment and position shown in
Aspects:
It is to be appreciated that any of aspects 1-10 may be combined with any of aspects 11-19.
Aspect 1: A refrigeration coil and drain pan assembly, comprising:
Aspect 2: The refrigeration coil and drain pan assembly according to aspect 1, further comprising a refrigerant line connected to the refrigeration coil.
Aspect 3: The refrigeration coil and drain pan assembly according to aspect 2, wherein the refrigerant line exits the refrigeration coil and drain pan assembly at a point equidistant from the first drain pan and the second drain pan.
Aspect 4: The refrigeration coil and drain pan assembly according to any of aspects 2-3, further comprising a removable access door disposed on a side of the refrigeration coil and drain pan assembly where the refrigerant line exits the refrigeration coil and drain pan assembly.
Aspect 5: The refrigeration coil and drain pan assembly according to any of aspects 1-4, wherein the first drain pan and the second drain pan are parallel to one another.
Aspect 6: The refrigeration coil and drain pan assembly according to aspect 5, wherein the fins run in a direction perpendicular to the planes of both the first drain pan and the second drain pan.
Aspect 7: The refrigeration coil and drain pan assembly according to any of aspects 1-6, wherein at least one of the first drain pan and the second drain pan comprises at least two levels.
Aspect 8: The refrigeration coil and drain pan assembly according to any of aspects 1-7, wherein the refrigeration coil is a dedicated horizontal refrigeration coil.
Aspect 9: The refrigeration coil and drain pan assembly according to any of aspects 1-8, wherein the refrigeration coil is configured for an airflow to enter the refrigeration coil from a specific direction.
Aspect 10: The refrigeration coil and drain pan assembly according to any of aspects 1-9, wherein the refrigeration coil has an open end and a converged end and an airflow enters the refrigeration coil at the open end and travels in a direction towards the converged end.
Aspect 11: An HVACR unit, comprising:
Aspect 12: The HVACR unit according to aspect 11, wherein the refrigeration coil and drain pan assembly is oriented such that one of the first drain pan and the second drain pan is located at the bottom of the refrigeration coil and drain pan assembly.
Aspect 13: The HVACR unit according to any of aspects 11-12, wherein the refrigeration coil has an open end and a converged end and the airflow enters the refrigeration coil at the open end and travels in a direction towards the converged end.
Aspect 14: The HVACR unit according to aspect 13, The HVACR unit of claim 13, wherein the refrigeration coil and drain pan assembly is installed in one of:
Aspect 15: The HVACR unit according to any of aspects 11-14, wherein the refrigeration coil and drain pan assembly further comprises a removable access door disposed on a side of the refrigeration coil and drain pan assembly where the refrigerant line exits the refrigeration coil and drain pan assembly.
Aspect 16: The HVACR unit according to any of aspects 11-15, wherein at least one of the first drain pan and the second drain pan comprises at least two levels.
Aspect 17: The HVACR unit according to any of aspects 11-16, wherein the refrigerant line exits the refrigeration coil and drain pan assembly at a point equidistant from the first drain pan and the second drain pan.
Aspect 18: The HVACR unit according to any of aspects 11-17, wherein the first drain pan and the second drain pan are parallel to one another.
Aspect 19: The HVACR unit according to aspect 18, wherein the fins run in a direction perpendicular to the planes of both the first drain pan and the second drain pan.
The examples disclosed in this application are to be considered in all respects as illustrative and not limitative. The scope of the invention is indicated by the appended claims rather than by the foregoing description; and all changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein.