Patent Publication Number: US-7708052-B2

Title: Coil support

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
   None. 
   BACKGROUND 
   The present invention relates to a coil support. More particularly, the present invention relates to a coil support configured to support a coil and limit movement of the coil in at least one direction. 
   A split system heating and/or cooling system includes an outdoor unit, such as a condensing unit, and an indoor unit such as an evaporator unit. The condensing unit typically includes a protective cover (e.g., an inlet grill), a condenser coil, and a base pan for containing the condensing unit and receiving condensation that drips from the coil. The coil and base pan are disposed within the protective cover. During operation, condensation may accumulate on the coil, such as during a defrost cycle of the condensing unit. The condensation typically drips downward into the base pan. 
   A coil support is often used to lift the coil off the base pan, rather than resting the coil directly in the base pan. The coil support separates the coil from the base pan, and therefore, any condensation that collects in the base pan. By lifting the coil up off of the bottom of the base pan, the coil support helps prevent corrosion between the base pan and the coil. Furthermore, using a coil support provides room for condensation to drip away from the coil and into the base pan. 
   BRIEF SUMMARY 
   The present invention is a coil support suitable for supporting a coil in a condensing unit of a split system heating and/or cooling system. The coil support includes a surface configured to engage with the coil, and the surface includes a protrusion extending therefrom. The protrusion is configured to limit movement of the coil. In one embodiment, the protrusion is a wall, while in another embodiment, the surface of the coil support includes a plurality of protrusions configured to engage with the coil. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of a condensing unit. 
       FIG. 2  is a plan view of a base pan and coil assembly, which is supported and separated from the base pan by a plurality of coil supports. 
       FIG. 3  is a plan view of the coil assembly, base pan, and coil support of  FIG. 2 . 
       FIG. 4  is a perspective view of a first embodiment of a coil support, which includes a surface and a wall extending from the surface. 
       FIG. 5  is a perspective view of a second embodiment of a coil support, which includes a surface with a plurality of protrusions, and a wall extending from the surface. 
       FIG. 6  is a plan view of the coil support of  FIG. 5 , where a coil assembly is engaged with the protrusions on the coil support. 
       FIG. 7  is a perspective view of a third embodiment of a coil support, which includes a surface with a plurality of protrusions. 
       FIG. 8  is a perspective view of a fourth embodiment of a coil support, which includes a surface with a plurality of ribs. 
   

   DETAILED DESCRIPTION 
   The present invention is a coil support suitable for use in a condensing unit to support a coil and limit movement of the coil. In particular, a surface of a coil support in accordance with the present invention includes at least one protrusion that limits and discourages movement of a coil. In one embodiment, the protrusion is a wall that is configured to act as a stop and limit movement of the coil in at least one direction (e.g., helping to prevent the coil from contacting a protective cover of the condensing unit). In another embodiment, a coil support includes a plurality of protrusions arranged in a matrix, where the protrusions are configured to engage with a coil to discourage movement of the coil in a generally horizontal direction (i.e., movement along the x-y plane, where orthogonal x-y-z coordinates are shown in  FIG. 1 ). In yet another embodiment, a coil support includes a plurality of ribs configured to engage with the coil. 
     FIG. 1  is a perspective view of a general condensing unit  10  of an air conditioning or heat pump system. Condensing unit  10  is shown to aid in the description of the present invention and is not intended to limit the scope of the present invention. Condensing unit  10  includes condenser coil assembly  12 , base pan  14 , condenser  16 , fan  18 , and orifice assembly  20 . Other components of condensing unit  10 , such as a coil pad, have been removed from  FIG. 1  for clarity of illustration. Coil assembly  12  is protected by inlet grill  22 , which, together with base pan  14 , also defines the shape of condensing unit  10 . Although condensing unit  10  is shown in  FIG. 1  to be generally square with rounded corners in cross-section, in alternate embodiments, condensing unit  10  may be any suitable cross-section, such as a circular or rectangular. 
   Coil assembly  12  is supported by a coil support (shown in  FIG. 2 ) in accordance with the present invention, which is attached to base pan  14  using any suitable fastening mechanism, such as an adhesive, screw, or another mechanical attachment means. As discussed in the Background section, lifting coil assembly  12  off the bottom of base pan  14  helps prevent corrosion between coil assembly  12  and base pan  14 , and provides room for condensation to drip away from coil assembly  12  and into base pan  14 . The coil support will be discussed in further detail in reference to  FIGS. 2-5 . 
   When condensing unit  10  is used as a part of an air conditioning unit, fan  18  draws air from outside condensing unit  10  across coil assembly  12 . Refrigerant is enclosed in piping that is used to form coil  15  (shown in  FIG. 3 ) of coil assembly  12 . As the refrigerant passes through coil  15  of coil assembly  12  and the cooler air from outside condensing unit  10  passes across coil assembly  12 , the air absorbs heat from coil assembly  12 , which causes the refrigerant to condense. Orifice assembly  20  is used to direct air out of condensing unit  10 . The resulting liquid refrigerant then flows to an evaporator, which utilizes the refrigerant to cool air. As those skilled in the art recognize, when condensing unit  10  is used as a part of a heat pump system, coil assembly  12  acts as an evaporator coil to extract heat from the surrounding air. 
   It has been found that during the handling (e.g., shipping, installation, etc.) of condensing unit  10 , coil assembly  12  of condensing unit  10  may shift, and damage may result. For example, coil assembly  12  may be pierced by a sharp edge of inlet grill  22  or by a screw that is used to assemble condensing unit  10 . The operation of condensing unit  10  may be compromised if coil assembly  12  is damaged. 
     FIGS. 2-8  illustrate embodiments of a coil support in accordance with the present invention, where the coil support is configured to limit movement of coil assembly  12 . In a first embodiment shown in  FIGS. 2-4 , a coil support includes a wall that limits movement of coil assembly  12  in at least one direction. The wall is positioned between coil assembly  12  and inlet grill  22  and acts as a stop to help prevent coil assembly  12  from contacting inlet grill  22 . In some situations, the wall of the coil support also limits movement of coil assembly  12  the z-axis direction. In a second embodiment shown in  FIG. 5 , a coil support includes a wall and a plurality of protrusions configured to engage coil assembly  12 . The protrusions help to discourage movement of coil assembly  12  along the x-y plane. In a third embodiment shown in  FIG. 7 , a coil support includes a plurality of protrusions (but no wall) that are configured to engage a coil assembly and help secure the coil assembly in a fixed position. In a fourth embodiment shown in  FIG. 8 , a coil support includes a wall and a plurality of ribs, which are configured to engage a coil assembly. 
   A coil support in accordance with the present invention may be formed of any suitable material, such as, but not limited to, a polymeric or a co-polymeric material. 
     FIG. 2  is a plan view of base pan  14  and coil assembly  12 , which is supported and separated from base pan  14  by a plurality of coil supports  24  in accordance with a first embodiment. Coil supports  24  are positioned about a perimeter of base pan  14 . Each coil support  24  includes surface  26 , which engages with coil assembly  12 , and wall  28 , which extends from surface  26 . 
     FIG. 3  is a plan view of coil assembly  12 , base pan  14 , and coil support  24 , and illustrates the relationship therebetween. Coil assembly  12  is engaged with surface  26  of coil support  24 , while second surface  27  of coil support  24  is engaged with base pan  14 . Second surface  27  of coil support  24  is positioned on an opposite side of coil support  24  from surface  26 . As shown in  FIG. 3 , surfaces  26  and  27  are generally parallel to one another. However, in alternate embodiments, surface  26  and/or surface  27  may be sloped in order to help condensation move from surface  26  into base pan  14 . 
   Coil assembly  12  is typically a part of a plate-fin coil assembly (or a “plate-fin coil”), which, as known in the art, is comprised of a serpentine shaped coil  15  extending between two parallel end plates (not shown) with a series of thin, parallel fins  13  mounted on coil  15 . Fins  13  run along a vertical direction (i.e., the z-axis direction) and are oriented generally perpendicular to surface  26  of coil support  24 . Fins  13  are commonly made of aluminum, and may be spaced apart from ⅛ inch to 3/32 inch. Fins  13  engage with surface  26  of coil support  24 . 
   As  FIG. 3  illustrates, wall  28  of each coil support  24  extends from and is generally perpendicular to surface  26 . However, in alternate embodiments, wall  28  may be oriented at any suitable angle A less than 180° with respect to surface  26 . Furthermore, wall  28  may be integral with surface  26 . 
   A screw or other fastener may protrude through edge  14 A of base pan  14  or through inlet grill  22  (shown in  FIG. 1 ), which is adjacent to edge  14 A of base pan, in order to secure base pan  14  and inlet grill  22  together. In order to help prevent the screw from puncturing coil  15  of coil assembly  12 , wall  28  limits movement of coil assembly  12  in a direction toward side  25  of coil support  24 . Otherwise stated, wall  28  acts as a stop that helps discourage/limit movement of coil assembly  12  toward edge  14 A of base pan  14 , as well as toward inlet grill  22 . 
   Wall  28  also helps to discourage movement of coil assembly  12  when the movement also includes a z-direction component due to height H of wall  28 . Height H may be adjusted, depending upon the amount of z-direction movement of coil assembly  12  that is to be restricted. 
   When multiple coil supports  24  are used, as shown in  FIG. 2 , a confined space is defined for coil assembly  12 , thus further limiting movement of coil assembly  12 . The confined space helps ensure coil assembly  12  will remain in place during handling of condensing unit  10 . In an alternate embodiment, coil support  24  may also include a second wall on an opposite end of surface  26  from wall  28  to limit movement of coil assembly  12  away from edge  14 A of base pan  14 . 
     FIG. 4  is a perspective view of the first embodiment of coil support  24 . Length L S  of surface  26  of coil support  24  is greater than length L W  of wall  28 . Alternatively, length L S  may be equal to or less than L W . Coil support  24  includes recesses  30  and lips  32  for securing coil support  24  to base pan  14 . A fastener, such as a screw, may be threaded through recesses  30  and into base pan  14 . Of course, if an adhesive is used to attach coil support  24  to base pan  14 , coil support  24  may not include recesses  30 . Furthermore, in an alternate embodiment, lips  32  may be eliminated from coil support  24 . 
     FIG. 5  is a perspective view of a second embodiment of coil support  40 , which includes surface  42 , wall  44  extending from surface  42 , and a plurality of protrusions  46  on surface  42 . Coil support  40  is similar to coil support  24  of  FIG. 4 , except that surface  42  includes a plurality of diamond-shaped protrusions  46  that further aid in discouraging movement of coil assembly  12 . Protrusions  46  are arranged in a matrix (i.e., a plurality of rows and columns). However, in alternate embodiments, protrusions  46  are arranged in another suitable pattern or in a random arrangement. In one embodiment, protrusions  46  are integral with surface  42 , while in another embodiment, protrusions  46  are distinct units attached to surface  42 . 
     FIG. 6  is a plan view of coil support  40  disposed in base pan  14 , where coil assembly  12  is engaged with protrusions  46  on surface  42  of coil support  40 . Fins  13  of coil assembly  12  are formed of a deformable material, such as aluminum. When coil assembly  12  is positioned on surface  42  of coil support  40 , fins  13  engage with protrusions  46  on surface  42  and deform around protrusions  46 . By interfacing with fins  13 , protrusions  46  help discourage movement of coil assembly  12  along the x-y plane. Although  FIG. 5  illustrates protrusions  46  having a diamond shape, protrusions  46  may be modified in alternate embodiments to be of any suitable shape. 
     FIG. 7  illustrates a perspective view of a third embodiment of coil support  50 , which is similar to coil support  40  of  FIG. 5 , except that coil support  50  does not include a wall extending from surface  52 . Rather, as  FIG. 7  shows, a plurality of protrusions  54  (which are similar to protrusions  46  of  FIG. 4 ) on surface  52  of coil support discourage movement of coil assembly  12  generally along the x-y plane. 
     FIG. 8  is a fourth embodiment of coil support  60  in accordance with the present invention, which includes surface  62 , plurality of elongated ribs  64  extending from surface  62 , and wall  66 . In one embodiment, ribs  64  are integrally formed with surface  62 , while in another embodiment, ribs  64  are attached to surface  62 . Just as protrusions  46  ( FIG. 6 ) are configured to engage with fins  13  of coil assembly  12 , ribs  64  on surface  62  are configured to engage with coil assembly  12 . When coil assembly  12  is positioned on surface  62 , fins  13  deform around ribs  64  to discourage movement of coil assembly  12  in a generally horizontal direction. Coil support  60  may be modified to exclude wall  66 , as well as change the pattern of ribs  64  on surface  62 . 
   The terminology used herein is for the purpose of description, not limitation. Specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as bases for teaching one skilled in the art to variously employ the present invention. Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.