Coil locator for an outdoor unit of a climate control system

Outdoor units for climate control systems and related methods are disclosed. In an embodiment, the outdoor unit includes a base pan including an upper surface, a lower surface opposite the upper surface, and at least one receptacle, wherein the at least one receptacle comprises an aperture. Additionally, the outdoor unit includes at least one coil locator coupled to the at least one receptacle of the base pan wherein the at least one coil locator comprises a tongue which extends through the aperture and a pair of horizontally spaced feet separate and distinct from the tongue and which are received in the aperture. Further, the outdoor unit includes a heat exchanger coil, and an outdoor fan configured to produce an airflow across the heat exchanger coil.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not applicable.

Not applicable.

BACKGROUND

Heat exchangers are used in a variety of commercial and residential settings for a variety of purposes. For example, a climate control system for circulating a refrigerant through a refrigerant loop so as to exchange heat between an indoor space (e.g., a house, office, commercial store, etc.) and an outdoor ambient environment surrounding the indoor space may include an outdoor unit positioned in the outdoor ambient environment. The outdoor unit of the climate control system may comprise a heat exchanger coil. The heat exchanger coil of the outdoor unit may transfer heat between refrigerant flowing through the heat exchanger coil and an airflow passing over the heat exchanger coil. In some applications, the heat exchanger coil may be physically supported by a base pan of the outdoor unit.

BRIEF SUMMARY

Some embodiments disclosed herein are directed to an outdoor unit of a climate control system. In an embodiment, the outdoor unit includes a base pan comprising an upper surface, a lower surface opposite the upper surface, and at least one receptacle, wherein the at least one receptacle comprises an aperture extending entirely through the base pan from the upper surface to the lower surface. Additionally, the outdoor unit includes at least one coil locator coupled to the at least one receptacle of the base pan wherein the at least one coil locator comprises a tongue which extends through the aperture, and a pair of horizontally spaced feet separate and distinct from the tongue and which are received in the aperture, wherein the pair of feet are aligned along a horizontal axis which extends through the pair of feet and wherein the pair of feet restrict the at least one coil locator from pivoting about a pivot axis extending vertically and orthogonal to the horizontal axis. Further, the outdoor unit includes a heat exchanger coil having an upper end and a lower end opposite the upper end, and wherein the lower end of the heat exchanger coil is positioned on the at least one coil locator, and a fan configured to produce an airflow across the heat exchanger coil.

Other embodiments disclosed herein are directed to an outdoor unit of a climate control system that includes a base pan comprising an upper surface, a lower surface opposite the upper surface, and at least one receptacle, wherein the at least one receptacle comprises an aperture extending entirely through the base pan from the upper surface to the lower surface. In addition, the outdoor unit includes at least one coil locator coupled with the receptacle of the base pan, wherein the at least one coil locator comprises a pair of horizontally spaced feet and a tongue separate and distinct from the pair of feet, wherein the tongue extends through the aperture and beneath the lower surface of the base pan whereby a vertical axis extending orthogonal to the lower surface of the base pan and intersects both the lower surface and the tongue. Further, the outdoor unit includes a heat exchanger coil having an upper end and a lower end opposite the upper end, and wherein the lower end of the heat exchanger coil is positioned on the at least one coil locator, and a fan configured to produce an airflow across the heat exchanger coil.

Still other embodiments disclosed herein are directed to a method for assembling an outdoor unit of a climate control system. In an embodiment, the method includes contacting an upper surface of a base ban of the outdoor unit with a support surface of a coil locator of the outdoor unit, wherein the coil locator comprises a pair of horizontally spaced feet and a tongue separate and distinct from the pair of feet. In addition, the method includes inserting the tongue of the coil locator through an aperture of a receptacle of the base pan and beneath a lower surface of the base pan whereby a vertical axis extending parallel to the lower surface intersects both the lower surface and the tongue. Further, the method includes lowering a heat exchanger coil onto the coil locator.

Embodiments described herein comprise a combination of features and characteristics intended to address various shortcomings associated with certain prior devices, systems, and methods. The foregoing has outlined rather broadly the features and technical characteristics of the disclosed embodiments in order that the detailed description that follows may be better understood. The various characteristics and features described above, as well as others, will be readily apparent to those skilled in the art upon reading the following detailed description, and by referring to the accompanying drawings. It should be appreciated that the conception and the specific embodiments disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes as the disclosed embodiments. It should also be realized that such equivalent constructions do not depart from the spirit and scope of the principles disclosed herein.

DETAILED DESCRIPTION

The following discussion is directed to various exemplary embodiments. However, one of ordinary skill in the art will understand that the examples disclosed herein have broad application, and that the discussion of any embodiment is meant only to be exemplary of that embodiment, and not intended to suggest that the scope of the disclosure, including the claims, is limited to that embodiment.

The drawing figures are not necessarily to scale. Certain features and components herein may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in interest of clarity and conciseness.

In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . .” Also, the term “couple” or “couples” is intended to mean either an indirect or direct connection. Thus, if a first device couples to a second device, that connection may be through a direct connection of the two devices, or through an indirect connection that is established via other devices, components, nodes, and connections. In addition, as used herein, the terms “axial” and “axially” generally mean along or parallel to a given axis (e.g., central axis of a body or a port), while the terms “radial” and “radially” generally mean perpendicular to the given axis. For instance, an axial distance refers to a distance measured along or parallel to the axis, and a radial distance means a distance measured perpendicular to the axis. Further, when used herein (including in the claims), the words “about,” “generally,” “substantially,” “approximately,” and the like mean within a range of plus or minus 10%.

As used herein, a “climate control system” refers to any system, component, or collection of components that is used to circulate a fluid (e.g., a refrigerant) so as to alter or affect the climate conditions (e.g., temperature, relative humidity, etc.) within a defined space (e.g., an interior space of a home, office, retail store, etc.). The term “climate control system” specifically includes (but is not limited to) air conditioning systems, heat pump systems, dehumidification systems, heating ventilation and air-conditioning (HVAC) systems, etc.

As described above, an outdoor unit of a climate control system may include a heat exchanger coil physically supported by a base pan of the outdoor unit. The outdoor unit may comprise a fan generally configured to produce an airflow over a plurality of tubes of the heat exchanger coil whereby heat is transferred between the airflow and refrigerant circulating through the plurality of tubes.

During assembly of the outdoor unit, the heat exchanger coil may be lowered onto the base pan such that a lower end of the heat exchanger coil is positioned near the base pan. Unless positively located by a coil locator of the outdoor unit, the heat exchanger coil of the conventional outdoor unit may be permitted to move horizontally or slide upon the base pan, such as when the outdoor unit is in transport, which may damage the heat exchanger coil. Damage to the heat exchanger coil may have a negative impact on performance because deformation of the heat exchanger coil can impact the ability for the heat exchanger coil to transfer thermal energy during operation of the outdoor unit.

Additionally, in some applications, water within the air of the ambient environment may condense during operation of the outdoor unit. Water condensed during the operation of the outdoor unit may collect or pool on surfaces of the base pan.

Accordingly, embodiments disclosed herein include coil locators for positively locating a heat exchanger coil of an outdoor unit relative to a base pan of the outdoor unit whereby relative horizontal movement between the heat exchanger coil and the base pan is prevented. Particularly, coil locators disclosed herein are configured to lock to the base pan using a tongue and/or one or more feet of the coil locator to prevent relative movement between the coil locator and the base pan. By preventing relative movement between the coil locator and the base pan, relative movement between the heat exchanger coil (located by the coil locators) and the base pan may be prevented. Additionally, coil locators disclosed herein also ensure the lower end of the heat exchanger coil is elevated from the base pan whereby the heat exchanger coil is not exposed to water collected on surfaces of the base pan.

Referring now toFIGS. 1-3, an outdoor unit100for a climate control system according to some embodiments is shown. In this embodiment, outdoor unit100has a longitudinal axis105and generally includes an outdoor heat exchanger coil102, a base pan120, a protective shroud150, and a plurality of coil locators200. Outdoor unit100may include additional components not shown inFIGS. 1-3in the interest of clarity, such as a fan for providing an airflow over heat exchanger coil102. Additionally, in the interest of clarity, shroud150is not shown inFIG. 2.

The heat exchanger coil102of outdoor unit100may generally be configured to promote heat exchange between refrigerant carried within tubing104(not shown in detail inFIGS. 1-3) of the heat exchanger coil102and an airflow (e.g., generated by a fan of outdoor unit100not shown inFIGS. 1-3) that may contact the heat exchanger coil102but that is segregated from the refrigerant. Heat exchanger coil102may be formed generally from aluminum and may comprise a spine-fin coil where a plurality of spine-fins (not shown inFIGS. 1-3) extend radially outwards from the tubing104of heat exchanger coil102. However, in other embodiments, heat exchanger coil102may comprise a plate-fin heat exchanger coil, a microchannel heat exchanger coil, or any other suitable type of heat exchanger coil.

In some embodiments, heat exchanger coil102has a central or longitudinal axis parallel with longitudinal axis105, a longitudinal first or upper end106, a longitudinal second or lower end108opposite upper end106, a radially outer (relative to longitudinal axis105) end110, and a radially inner end112that forms a central passage or opening114of the heat exchanger coil102through which longitudinal axis105extends. As will be described further below, in some embodiments, heat exchanger coil102may include an inlet for receiving refrigerant from a compressor of a climate control system positioned in the central opening114of heat exchanger coil102, and an outlet for conveying refrigerant from the heat exchanger coil102to an indoor unit of a climate control system comprising outdoor unit100.

Referring toFIGS. 4-6, detailed views of the base pan120of outdoor unit100are shown. The base pan120of outdoor unit100physically supports the other components of outdoor unit100including the heat exchanger coil102and protective shroud150. In embodiments where outdoor unit100forms part of an outdoor unit of a climate control system, base pan120may also physically support, directly or indirectly, an outdoor fan and a compressor of the outdoor unit. In some embodiments, base pan120includes an upper surface122and an opposing lower surface123(shown inFIGS. 14, 15). Upper surface122of base pan120may face opposite the ground or surface upon which outdoor unit100is positioned following the installation of outdoor unit100. Base pan120may also include an outer lip130extending about the longitudinal axis105of outdoor unit100along an outer perimeter of base pan120.

The upper surface122of base pan120may comprise a generally planar coil support surface124extending circumferentially about the longitudinal axis105of outdoor unit100. Additionally, coil support surface124may be positioned adjacent the outer perimeter of base pan120and may extend radially inwards (relative longitudinal axis105) from outer lip130. In some embodiments, the coil support surface124comprises a plurality of coil locator receptacles140spaced circumferentially about the longitudinal axis105of outdoor unit100, each coil locator receptacle140being configured to matingly receive one of the plurality of coil locators200of outdoor unit100. In the embodiment shown inFIGS. 4-6, base pan120includes four coil locator receptacles140spaced equidistantly (e.g., ninety degrees apart) about the longitudinal axis105of outdoor unit100; however, in other embodiments, the number of coil locator receptacles140of base pan120may vary.

As shown particularly inFIGS. 5, 6, in some embodiments, each coil locator receptacle140comprises an elongated aperture142extending entirely through the base pan120between upper surface122and lower surface123and having a generally rounded rectangle cross-section. Additionally, the aperture142of each coil locator receptacle140comprises a pair of reliefs144positioned at opposing longitudinal ends of aperture142and extending radially towards the outer lip130of base pan120. Further, each coil locator receptacle140may include an elongated tab146extending substantially orthogonally from the coil support surface124of base pan120and comprising a planar outer contact surface147. Additionally, tab146may extend longitudinally between the pair of reliefs144of aperture142such that a plane148(shown inFIG. 6) extending orthogonal to coil support surface124may extend through both tab146and aperture142. Further, the tab146of each coil locator receptacle140may be positioned along a lateral side of aperture142proximal outer lip130of base pan120such that tab146is positioned radially between (relative longitudinal axis105) outer lip130and at least a portion of aperture142.

Referring toFIGS. 1, 3, protective shroud150of outdoor unit100at least partially surrounds heat exchanger coil102to protect coil102from the ambient environment surrounding outdoor unit100and provide structural strength to the outdoor unit100. Protective shroud150, also commonly referred to as a wrapper, may extend longitudinally along longitudinal axis105of outdoor unit100and may have a first or upper end151and a second or lower end153, opposite upper end151, supported by the coil support surface124of base pan120. Additionally, at least a portion of the lower end153of protective shroud150may be positioned adjacent the outer lip130of base pan120. In some embodiments, a plurality of fasteners spaced along the perimeter of base pan120may extend through apertures formed in outer lip130and protective shroud150to couple protective shroud150with base pan120.

Additionally, in some embodiments, shroud150may encircle or surround the entire perimeter of heat exchanger coil102. Shroud150may comprise a plurality of angled panels152, and a control panel154upon which a controller of outdoor unit100may be mounted. Panels152,154of protective shroud150may be coupled together via a plurality of fasteners and at least some of the angled panels152may include openings formed therein to allow airflow to pass through protective shroud150and flow across the tubing104of heat exchanger coil102. In some embodiments, the protective shroud150and/or the base pan120may be formed from sheet metal; however, in other embodiments, protective shroud150and base pan120may be formed from various materials.

Referring toFIGS. 7-13, detailed views of one of the plurality of coil locators200of outdoor unit100are shown. As shown particularly inFIG. 7, outdoor unit100includes four coil locators200spaced equidistantly (ninety degrees apart) about the longitudinal axis105of outdoor unit100; however, in other embodiments, the number of coil locators200of outdoor unit100may vary. Coil locators200are configured to couple with the plurality of coil locator receptacles140of base pan120to secure or lock coil locators200with base pan120such that relative movement between coil locators200and base pan120is prevented. As described further below, each coil locator200may be secured or locked to base pan120such that, once installed, relative movement between the coil locator200and the base pan120vertically, extending parallel to the longitudinal axis105of outdoor unit100, as well as horizontally (e.g., in horizontal directions extending parallel to orthogonally extending horizontal X and Y axes shown inFIGS. 2, 7), is prevented.

As shown particularly inFIGS. 8-13, each coil locator200may have an inner end201, an outer end203opposite the inner end201, and a pair of opposing lateral sides205. Each coil locator200may comprise a non-metallic, corrosion resistant material. For example, each coil locator200may comprise a polymeric material. In some embodiments, each coil locator200may comprise a composite material. Each coil locator200may comprise a material resistant to ultraviolet (UV) light and/or a fire retardant material.

The coil locator200may include a horizontal support member202and a vertical support member204. Horizontal support member202may comprise a generally planar horizontal support surface207and the vertical support member204may comprise a generally planar vertical support surface209. The coil locator200may also include a skirt206extending from the horizontal support member202to a lower support surface208of the coil locator200. The coil locator200may also include a pair of side panels210extending from opposing ends of vertical support member204to the outer end203of the coil locator200. Additionally, each side panel210may extend from the lower support surface208of coil locator200to an upper surface212of coil locator200. Skirt206of the coil locator200may extend along a periphery of the horizontal support member202to the pair of side panels210, where each lateral side205of coil locator200may be defined by one of the side panels210and a portion of the skirt206. As shown particularly inFIG. 11, skirt206of the coil locator200extends a first non-zero distance206D between lower support surface208and horizontal support surface207. Additionally, each side panel210of the coil locator200extends a second non-zero distance210D between lower support surface208and upper surface212, where second distance210D may be greater than first distance206D.

In some embodiments, each coil locator200may include a tongue220extending both vertically and horizontally from a lower end (opposite upper surface212) of vertical support member204below the lower support surface208of coil locator200. Particularly, the tongue220of coil locator200may include a pair of lateral sides221, an inclined portion222extending both horizontally and vertically from the lower end of vertical support member204, and a horizontal portion224extending horizontally from the inclined portion222to a terminal end226of the tongue220. The inclined portion222of tongue220may extend at a non-zero angle relative to the lower end of the vertical support member204. Tongue220may vertically extend a third non-zero distance220D (shown inFIG. 11) below the lower support surface208of the coil locator200. Tongue220may also include an upper contact surface228which, as will be described further herein, may contact the lower surface123of base pan120following the assembly of outdoor unit100. Upper contact surface228may overlap a horizontally extending plane227(shown inFIG. 11) defined by the lower support surface208such that a vertically extending plane229(also shown inFIG. 11) may extend through upper contact surface228and horizontal plane227.

Each coil locator200may also include one or more feet242each extending fourth non-zero distance242D (shown inFIG. 11) below the lower support surface208of coil locator200. Particularly, in some embodiments, each coil locator200may include a rear member or panel240extending from the vertical support member204to the outer end203of the coil locator200. The rear panel240extends vertically from upper surface212to a pair of the feet242which are horizontally-spaced and aligned such that a horizontal axis243(shown inFIG. 10) extends through each foot242. In some embodiments, the distance between upper surface212and either a lower surface of each foot242or a lower surface of tongue220may be greater than the distance between the upper surface212and the lower support surface208. Although feet242are shown inFIGS. 11-13extending from rear panel240, in other embodiments, feet242may be positioned at various locations on the coil locator200. For example, in some embodiments, one or more feet242of each coil locator200may extend from lower support surface208of the coil locator200.

In some embodiments, a recess244(shown inFIG. 10) may extend into rear panel240from a lower end of the rear panel240proximal feet242. Recess244may include a planar inner contact surface246which may extend in a direction substantially orthogonal lower support surface208of the coil locator200. As will be described further herein, the inner contact surface246of recess244may contact the tab146of one of the coil locator receptacles140of base pan120following the assembly of outdoor unit100.

Referring toFIGS. 14, 15, following assembly of outdoor unit100, each coil locator200may be matingly received in one of the coil locator receptacles140of the base pan120of outdoor unit100such that each coil locator200is locked to the base pan120. Following the assembly of the outdoor unit100, lower support surface208of the coil locator200contacts coil support surface124of the upper surface122of base pan120. Additionally, tongue220of the coil locator200extends through aperture142of the coil locator receptacle140whereby upper contact surface228of the tongue220of coil locator200contacts and is positioned directly beneath the lower surface123of the base pan120such that a first pivot axis (e.g., axis231shown inFIG. 15) extending vertically and orthogonal to horizontal axis243and the lower surface123of base pan120intersects both the lower surface123of base pan120and the horizontal portion224of tongue220. Contact between lower support surface208of coil locator200and coil support surface124of base pan120, and contact between upper contact surface228of coil locator200and lower surface123of base pan120prevent relative movement between coil locator200and base pan120in each opposing axial direction along an axis parallel the longitudinal axis105of outdoor unit100.

Additionally, contact between upper contact surface228of the coil locator200and the lower surface123of base pan120may prevent the coil locator200from “rocking” towards the outer lip130of base pan120in response to contact between heat exchanger coil102and the coil locator200. For instance, varying forces may be applied to the outdoor unit100during transport of outdoor unit100to a location where the outdoor unit100will be installed (e.g., a home), urging the relatively heavy heat exchanger coil102to shift relative other components of outdoor unit100.

As shown particularly inFIG. 15, contact between heat exchanger coil102and the coil locator200(e.g., due to movement of outdoor unit100during transportation, etc.) may result in the application of a radially outwards (relative longitudinal axis105of outdoor unit100) directed force (indicated by arrow250inFIG. 15) from heat exchanger coil102against the vertical support surface209of coil locator200. The radially outwards force250may apply a torque to coil locator200, urging the inner end201of coil locator200to rock or pivot about a second pivot axis252(extending out of the page inFIG. 15) in a first rotational direction, where second pivot axis252may comprise a lateral axis oriented orthogonal longitudinal axis105. However, contact between the upper contact surface228of coil locator200and the lower surface123of base pan120applies a counter-acting force (indicated by arrow254inFIG. 15) to the coil locator200. The counter-acting force254may also apply a torque to coil locator200, urging the inner end201of coil locator200to pivot about second pivot axis252(shown inFIG. 15) in a second rotational direction opposite the first rotational direction. Thus, the torque resulting from counter-acting force254may cancel out the torque applied to coil locator200from radially outwards force250, thereby preventing coil locator200from pivoting about second pivot axis252.

Further, following the assembly of outdoor unit100, tab146of the coil locator receptacle140is received in recess244of the coil locator200and the inner contact surface246of coil locator200contacts the outer contact surface147of tab146. Further, feet242of the coil locator200may be received in the reliefs144of the aperture142of coil locator receptacle140whereby coil locator200is prevented from pivoting relative base pan120about the first pivot axis231. Contact between the inner contact surface246of coil locator200and the outer contact surface147of tab146as well as contact between feet242of coil locator200and reliefs144of the coil locator receptacle140may prevent relative movement between the coil locator200and the base pan120in each opposing axial direction along orthogonal axes parallel with the X and Y axes shown inFIGS. 2, 7.

In some embodiments, a lateral width242W (shown inFIG. 10) of each foot242of the coil locator200may be as great, or slightly greater than, a lateral width144W (shown inFIG. 6) of each relief144of the coil locator receptacle140. In some embodiments, each foot242may be configured to flex to reduce the lateral width144W of the foot242as the foot is inserted into a corresponding relief144to provide a snap-fit between the foot242of the coil locator200and the relief144of the coil locator receptacle140. The snap-fit may prevent feet242from releasing from the reliefs144of coil locator receptacle140, thereby locking coil locator200to the base pan120. For example, the snap-fit between feet242of coil locator200and the reliefs144of aperture140may prevent the outer end203of coil locator200from pivoting about a second pivot axis256(extending out of the page inFIG. 15) in response to a radially directed force applied to coil locator200. In some embodiments, mechanisms other than a snap-fit between feet242and reliefs144of receptacle140may be employed to lock the coil locator200to the base pan120.

In some embodiments, a space or channel156between the outer end203of the coil locator200and the outer lip130of the base pan120may be provided in which the lower end of the protective shroud150may be positioned. In other words, coil locator200is radially spaced (relative longitudinal axis105of the outdoor unit100) from outer lip130of base pan120.

Following the assembly of outdoor unit100, the lower end108of the heat exchanger coil102contacts the horizontal support surface207of each coil locator200of outdoor unit100whereby the lower end108of the heat exchanger coil102is spaced or elevated from the coil support surface124of the base pan120. The lower end108of the heat exchanger coil102may be vertically spaced (along longitudinal axis105of outdoor unit100) from the base pan120by at least the first distance206D. Thus, heat exchanger coil102may be elevated or vertically spaced from any standing moisture collected on coil support surface124or any other surface of base pan120.

Additionally, following the assembly of outdoor unit100, the radially outer end110of heat exchanger coil102contacts the vertical support surface209of each coil locator200of the plurality of coil locators200, restricting relative movement between the heat exchanger coil102and the base pan120in each opposing axial direction along the X and Y axes shown inFIGS. 2, 7. Particularly, the heat exchanger coil102may be positioned between a first pair of the plurality of coil locators200positioned along the X axis shown inFIGS. 2, 7whereby contact between the vertical support members204of the first pair of coil locators200and the heat exchanger coil102restrict relative movement between the heat exchanger coil102and the base pan120in each opposing direction along the X axis. Similarly, the heat exchanger coil102may be positioned between a second pair of the plurality of coil locators200positioned along the Y axis shown inFIGS. 2, 7whereby contact between the vertical support members204of the second pair of coil locators200and the heat exchanger coil102restrict relative movement between the heat exchanger coil102and the base pan120in each opposing direction along the Y axis.

Referring toFIG. 16, a method300for assembling an outdoor unit is shown. In some embodiments, method300may be practiced with outdoor unit100shown inFIGS. 1-15. However, it should be appreciated that embodiments of method300may be practiced with other systems, assemblies, and devices other than those described above. One or more of the steps of method300may be performed manually by a user of the outdoor unit, such as an assembler of the outdoor unit, an installer of the outdoor unit, a technician equipped to service the outdoor unit, etc.

Initially, method300includes forming a base pan of an outdoor unit to include a coil locator receptacle at method block302. Method block302may include forming the base pan to include a plurality of the coil locator receptacles, each coil locator receptacle including an aperture extending entirely through the base pan. The aperture of each coil locator receptacle may comprise a pair of reliefs positioned at opposing longitudinal ends of the aperture and each relief may extend radially towards an outer lip of the base pan. Additionally, each coil locator receptacle of the base pan may also include a tab extending substantially orthogonally from a surface of the base pan. For example, method block302may include forming the plurality of coil locator receptacles140in base pan120, where each coil locator receptacle140includes aperture142and tab146. In some embodiments, the base pan may be stamped or pressed to include the plurality of coil locator receptacles; however, the base pan may be formed to include the plurality of coil locator receptacles through a variety of manufacturing processes.

Method300continues by coupling a coil locator to the coil locator receptacle of the base pan. Method block304may include coupling the coil locator to the coil locator receptacle of the base pan whereby the relative movement between the coil locator and the base pan is prevented. For example, method block304may include preventing the coil locator200from rocking or pivoting about a pivot axis relative the base pan120. Additionally, method block304may include restricting relative movement between the coil locator and the base pan in each opposing direction along three orthogonal axes including a vertical axis and a pair of orthogonal horizontal axes, where the vertical axis may be parallel with a longitudinal axis of the outdoor unit.

Method block304may include coupling a plurality of the coil locators to the base pan of the outdoor unit. In some embodiments, method block304may include coupling the plurality of coil locators200to the base pan120of outdoor unit100shown inFIGS. 1-15. For example, referring briefly toFIG. 17, first the tab146of one of the coil locator receptacles140of base pan120may be inserted into the recess244of one of the coil locators200. Second, with the tab146of the coil locator receptacle140received in the recess244of the coil locator200, the tongue220of one of the coil locators200may be inserted (indicated by arrow305inFIG. 17) through the aperture142of one of the corresponding coil locator receptacles140whereby the upper contact surface228contacts and slides against the lower surface123of base pan120while the lower support surface208of the coil locator200contacts and slides against the coil support surface124of the base pan120. Once the terminal end226of the tongue220is inserted through and into the aperture142of the coil locator receptacle140, the coil locator200may be displaced radially inwards towards the longitudinal axis105of outdoor unit100until the outer contact surface147of tab146contacts or is disposed adjacent the inner contact surface246of the coil locator200, restricting further radially inward travel of coil locator200relative to the base pan120. Contact between upper contact surface228of coil locator200and the lower surface123of base pan120may prevent the inner end201of coil locator200from pivoting about a pivot axis (e.g., first pivot axis252shown inFIG. 15) relative base pan120.

Referring briefly toFIG. 18, following the insertion of the tongue220of coil locator200through the aperture142of the corresponding coil locator receptacle140, feet242of the coil locator200may each be inserted into reliefs144of the aperture142of the coil locator receptacle140. Particularly, the outer end203of the coil locator200may be pivoted (indicated by arrow307inFIG. 18) towards the coil support surface124whereby each foot242of the coil locator200is inserted into one of the reliefs144of the coil locator receptacle140. In some embodiments, feet242of the coil locator200may audibly pop or snap into reliefs144of the coil locator receptacle140to form a snap-fit between the coil locator200and the base pan120. The popping sound made in response to the snapping of the feet242of coil locator200into the reliefs144of coil locator receptacle140may provide confirmation to the user/assembler of outdoor unit100(e.g., assembler or installer of the outdoor unit, etc.) that the coil locator200is locked to the base pan120. Additionally, the snap-fit formed between feet242of coil locator200and reliefs144of aperture142may prevent the outer end203of coil locator200from pivoting about a pivot axis (e.g., second pivot axis256shown inFIG. 15) relative base pan120.

Referring again toFIG. 16, method300continues by lowering a heat exchanger coil of the outdoor unit onto the coil locator at method block306. Method block306may include lowering the heat exchanger coil onto a plurality of the coil locators coupled to the base pan of the outdoor unit. In some embodiments, relative lateral movement between the heat exchanger coil and the base pan may be prevented once the heat exchanger coil is landed on the plurality of coil locators. For instance, relative movement between the heat exchanger coil and the base pan may be prevented in each opposing direction along a pair of lateral axes each extending orthogonal a longitudinal axis of the outdoor unit following the landing of the heat exchanger coil on the plurality of coil locators. Additionally, the heat exchanger coil may be spaced or elevated from the base pan following the lowering of the heat exchanger coil onto the plurality of coil locators. For instance, the lower end of the heat exchanger coil may be vertically spaced from a coil support surface upon which the coil locator is positioned. In this configuration, the coil locator may be positioned vertically between the lower end of the heat exchanger coil and the coil support surface.

In some embodiments, method block306may include lowering heat exchanger coil102onto the plurality of coil locators200of the outdoor unit100shown inFIGS. 1-15. For example, heat exchanger coil102may be lowered onto the plurality of coil locators200whereby the lower end108of heat exchanger coil102contacts the horizontal support surface207of each coil locator200, restricting further downward travel of the heat exchanger coil102relative base pan120. Additionally, as the heat exchanger coil102is lowered onto the plurality of coil locators200the radially outer end110of the heat exchanger coil102may contact the vertical support surface209of each coil locator200, preventing relative movement between heat exchanger coil102and the base pan120in each opposing direction along a pair of lateral axes (e.g., the X and Y axes shown inFIGS. 2, 7) each extending orthogonal the longitudinal axis105of outdoor unit100. Further, the lower end108of the heat exchanger coil102may be spaced or elevated from the base pan120following the lowering of the heat exchanger coil102onto the plurality of coil locators200. In this manner, the lower end108of the heat exchanger coil102may be vertically spaced from or elevated above any moisture collected or pooled on surfaces of base pan120(e.g., on coil support surface124).

Method300continues by coupling a protective shroud of the outdoor unit to the base pan at method block308. Method block308may include positioning the protective shroud radially (relative to a longitudinal axis of the outdoor unit) between the coil locator and an outer lip of the base pan. For example, method block308may include positioning protective shroud150in the channel156formed between the outer end203of each coil locator200and outer lip130of the base pan120of outdoor unit100. In this position, protective shroud150may extend about the entire perimeter of the heat exchanger coil102supported by coil locators200. Method block308may additionally include extending one or more fasteners through the outer lip130to couple the protective shroud150with the base pan120.

In addition to the method blocks302-308described above, method300may include additional steps such as, for example, coupling an outdoor fan to the protective shroud and/or other member of the outdoor unit. Method300may also include coupling a controller and/or other accessories to the outdoor unit. Additionally, in embodiments where the outdoor unit comprises an outdoor unit of a climate control system, method300may include coupling a compressor of the climate control system to the base pan of the outdoor unit.

Referring toFIG. 19, a schematic diagram of a climate control system400according to some embodiments is shown and which comprises the outdoor unit100described above. In this embodiment, climate control system400is a vapor compression air conditioning system that is configured to circulate a refrigerant through a refrigerant loop so as to provide a cooling functionality for an indoor space (e.g., such as an interior or a house, office, retail store, etc.). The climate control system400generally comprises an indoor unit402, outdoor unit100, and a refrigerant loop430extending between and through the indoor unit402and outdoor unit100.

Indoor unit402generally comprises an indoor air handling unit comprising an indoor heat exchanger408, an indoor fan410, and an indoor metering device412. The indoor heat exchanger408may generally be configured to promote heat exchange between refrigerant carried within tubing of the indoor heat exchanger408and an airflow (e.g., generated by the indoor fan410) that may contact the indoor heat exchanger408but that is segregated from the refrigerant. In some embodiments, the indoor heat exchanger408may comprise a plate-fin heat exchanger; however, in other embodiments, indoor heat exchanger408may comprise a microchannel heat exchanger and/or any other suitable type of heat exchanger.

The indoor fan410may generally comprise a centrifugal blower comprising a blower housing, a blower impeller at least partially disposed within the blower housing, and a blower motor configured to selectively rotate the blower impeller. The indoor fan410may generally be configured to provide airflow through the indoor unit402and/or the indoor heat exchanger408to promote heat transfer between the airflow and a refrigerant flowing through the indoor heat exchanger408. The indoor fan410may also be configured to deliver temperature-conditioned air from the indoor unit402to one or more areas and/or zones of an indoor space. The indoor fan410may generally comprise a mixed-flow fan and/or any other suitable type of fan.

The indoor metering device412may generally comprise an electronically-controlled motor-driven electronic expansion valve (EEV). In some embodiments, however, the indoor metering device412may comprise a thermostatic expansion valve, a capillary tube assembly, and/or any other suitable metering device.

In addition to the heat exchanger coil102described above, outdoor unit100may comprise a compressor416, and an outdoor fan418. As described above, heat exchanger coil102may generally be configured to promote heat transfer between a refrigerant carried within the internal tubing104of the heat exchanger coil102and an airflow that contacts the heat exchanger coil102but that is segregated from the refrigerant.

The compressor416of outdoor unit100may generally comprise a variable speed scroll-type compressor that may generally be configured to selectively pump refrigerant at a plurality of mass flow rates through the indoor unit402, the outdoor unit100, and/or between the indoor unit402and the outdoor unit100. In some embodiments, the compressor416may comprise a rotary type compressor configured to selectively pump refrigerant at a plurality of mass flow rates. In some embodiments, however, the compressor416may comprise a modulating compressor that is capable of operation over a plurality of speed ranges, a reciprocating-type compressor, a single speed compressor, and/or any other suitable refrigerant compressor and/or refrigerant pump. In some embodiments, compressor416may be positioned within the central opening114(shown inFIGS. 1-3) of heat exchanger coil102and mounted to the base pan120(shown inFIGS. 1-5) of outdoor unit100.

The outdoor fan418of outdoor unit100may generally comprise an axial fan comprising a fan blade assembly and fan motor configured to selectively rotate the fan blade assembly. The outdoor fan418may generally be configured to provide airflow through the outdoor unit100to promote heat transfer between the airflow and a refrigerant flowing through the indoor heat exchanger408. The outdoor fan418may generally be configured as a modulating and/or variable speed fan capable of being operated at a plurality of speeds over a plurality of speed ranges. In other embodiments, the outdoor fan418may comprise a mixed-flow fan, a centrifugal blower, and/or any other suitable type of fan and/or blower, such as a multiple speed fan capable of being operated at a plurality of operating speeds by selectively electrically powering different multiple electromagnetic windings of a motor of the outdoor fan418. In some embodiments, outdoor fan418may be suspended above heat exchanger coil102and coupled to the protective shroud150(shown inFIG. 1) of outdoor unit100.

As shown inFIG. 19, during operations of the climate control system400refrigerant may be circulated through the refrigerant loop430so that heat is generally absorbed by the refrigerant at the indoor heat exchanger408and rejected from the refrigerant at the heat exchanger coil102of outdoor unit100. As a result, operation of the climate control system400may generally reduce a temperature (and potentially a relative humidity) of an indoor space (not shown). Starting at the compressor416, the compressor416may be operated to compress refrigerant and pump the relatively high temperature and high pressure compressed refrigerant to the heat exchanger coil102of outdoor unit100, where the refrigerant may transfer heat to an airflow that is passed through and/or into contact with the heat exchanger coil102by the outdoor fan418. After exiting the heat exchanger coil102, the refrigerant may flow to the indoor metering device412, which may meter the flow of refrigerant through the indoor metering device412, such that the refrigerant downstream of the indoor metering device412is at a lower pressure than the refrigerant upstream of the indoor metering device412. From the indoor metering device412, the refrigerant may enter the indoor heat exchanger408. As the refrigerant is passed through the indoor heat exchanger408, heat may be transferred to the refrigerant from an airflow that is passed through and/or into contact with the indoor heat exchanger408by the indoor fan410. Refrigerant leaving the indoor heat exchanger408may flow to the compressor416, where the refrigeration cycle may begin again.

Embodiments disclosed herein include coil locators for outdoor units and methods for assembling an outdoor unit of a climate control system. In some embodiments, a coil locator may couple with a receptacle of a base pan of the outdoor unit whereby movement between the coil locator and the base pan is prevented. Particularly, a snap-fit may be formed between the coil locator and the base pan to lock the coil locator with the base pan. Additionally, a tongue of the coil locator may be positioned beneath a lower surface of the base pan whereby an axis extending parallel to a longitudinal axis of the outdoor unit intersects both the base pan and the tongue. By locking the coil locator to the base pan, a heat exchanger coil of the outdoor unit may be lowered onto to the coil locator to positively locate the heat exchanger coil relative to the base pan whereby horizontal movement between the heat exchanger coil and the base pan is prevented.

By locking the coil locator to the base pan upon assembly of the outdoor unit, the coil locator is prevented from becoming dislodged or decoupled from the base pan (thereby permitting relative movement between the heat exchanger coil and the base pan), such as during transportation of the outdoor unit when varying forces may be applied to the heat exchanger coil. In this manner, damage to the heat exchanger coil due to sliding of the coil relative to the base pan (due to dislodging of the coil locator) may be avoided. Further, the coil locator may vertically space or elevate a lower end of the heat exchanger coil from the base pan, thereby vertically spacing the lower end of the heat exchanger coil from any moisture collected or pooled on the base pan.