Patent Publication Number: US-2023151976-A1

Title: Heat exchanger assembly

Description:
TECHNOLOGICAL FIELD 
     The present disclosure relates generally to an improved heat exchanger assembly, particularly an HVAC heat exchanger assembly. 
     BACKGROUND 
     Heating, ventilation, and/or air conditioning (HVAC) systems may generally be used in residential and/or commercial areas for heating and/or cooling to create comfortable temperatures inside those areas. As part of these systems, heat exchanger(s) may be used to transfer heat between air and a working fluid, and typically, these heat exchangers include a coil assembly. 
     These coil assemblies attempt to maximize heat transfer between the various fluids while at the same time optimizing costs, efficiencies, and other factors. As part of these systems, a baffle may be used to cap a portion of the coil assembly, protecting the coils from condensate and directing air flow. Generally, the baffle is attached via screws by puncturing a portion of the baffle. However, puncturing the coil assembly walls may reduce the overall performance of the heat exchanger, particularly over time. 
     As a result, there exists a need for an improved heat exchanger assembly, which enables easy alignment of the baffle with the coil assembly, while also capping the coil assembly. The improved heat exchanger assembly should also reduce a number of parts needed to couple the baffle with the coil assembly. 
     BRIEF SUMMARY 
     The present disclosure relates to a heat exchanger designed to overcome one or more of these existing issues. This assembly utilizes an improved baffle configured to utilize apertures that interact with tube sheets to address these deficiencies in the prior art. 
     The present disclosure thus includes, without limitation, the following example implementations. 
     Some example implementations provide an improved heat exchanger comprising a coil assembly comprising a pair of heat exchanger coil slabs, each slab comprising a first tube sheet and a second tube sheet, the first and second tube sheets each including a first end located proximate a first end of the coil assembly, the first end of each tube sheet having a hook; and a baffle comprising: a plurality of apertures located on the baffle, wherein each aperture of the plurality of apertures is detachably engaged with the hook located on the first end of the first and second tube sheets such that the plurality of apertures couple the baffle to the first end of the first tube sheet and the first end of the second tube sheet of each coil slab, wherein the baffle caps the coil assembly to minimize airflow through the first end of the coil assembly. 
     In some example implementations of the heat exchanger of any example implementation, or any combination of any preceding example implementations, the baffle includes a v-shaped panel, wherein the v-shaped panel is shaped at a first angle. 
     In some example implementations of the heat exchanger of any example implementation, or any combination of any preceding example implementations, the first end of the coil assembly comprises a v-shaped end, wherein the v-shaped end is shaped at a second angle that is different from the first angle when the baffle is uncoupled from the coil assembly. 
     In some example implementations of the heat exchanger of any example implementation, or any combination of any preceding example implementations, a difference between the first angle and the second angle is at least five degrees. 
     In some example implementations of the heat exchanger of any example implementation, or any combination of any preceding example implementations, a force created when the v-shaped panel deforms to allow the first angle on the v-shaped panel to more closely align with the second angle on the v-shaped end helps secure the baffle to the coil assembly. 
     In some example implementations of the heat exchanger of any example implementation, or any combination of any preceding example implementations, the baffle includes two side flanges extending from the v-shaped panel on opposite sides, wherein the apertures are located on at least one of the side flanges. 
     In some example implementations of the heat exchanger of any example implementation, or any combination of any preceding example implementations, each of the side flanges includes two apertures of the plurality of apertures, such that when the v-shaped panel of the baffle is arranged over the coil assembly, each of the hooks engages a corresponding aperture. 
     In some example implementations of the heat exchanger of any example implementation, or any combination of any preceding example implementations, the baffle further comprises an outer flange extending outward from each of the side flanges for flexing the v-shaped panel during assembly. 
     In some example implementations of the heat exchanger of any example implementation, or any combination of any preceding example implementations, the hook comprises an inner engagement edge and an outer curved edge, wherein the inner engagement edge engages a respective one of the plurality of apertures, and the outer curved edge is configured to engage the outer flange for deflecting the respective side flange. 
     Some example implementations provide an HVAC system comprising a housing; and a blower arranged within the housing, wherein the heat exchanger of any example implementation, or any combination of any preceding implementations, arranged within the housing to receive pressurized air from the blower. 
     In some example implementations of the HVAC system of any example implementation, or any combination of any preceding example implementations, the heat exchanger further including a fastener cap coupled to at least one aperture and configured to seal the aperture. 
     In some example implementations of the HVAC system of any example implementation, or any combination of any preceding example implementations, the first end of the coil assembly of the heat exchanger comprises a v-shaped end, wherein the v-shaped end is shaped at a second angle that is different from the first angle when the baffle is uncoupled from the coil assembly. 
     In some example implementations of the HVAC system of any example implementation, or any combination of any preceding example implementations, a force created when the v-shaped panel deforms to allow the first angle on the v-shaped panel to more closely align with the second angle on the v-shaped end helps secure the baffle to the coil assembly. 
     In some example implementations of the HVAC system of any example implementation, or any combination of any preceding example implementations, the HVAC system further comprises an auxiliary heat exchanger arranged within the housing. 
     Some example implementations provide a method for assembling a heat exchanger baffle with a coil assembly comprising a pair of heat exchanger coil slabs each including a first tube sheet and a second tube sheet, the method comprising: orienting the baffle comprising a plurality of apertures located on the baffle relative to a first end of the first tube sheet and the first end of the second tube sheet, the first ends of the first and second tube sheets being located proximate a first end of the coil assembly; and detachably engaging each aperture of the plurality of apertures with a hook located on the first end of one of the first tube sheet or the second tube sheet so as to couple the baffle to the first end of the first tube sheet and the first end of the second tube sheet and thereby cap the coil assembly to minimize airflow through the first end of the coil assembly. 
     In some example implementations of the method of any example implementation, or any combination of any preceding example implementations, the baffle includes a v-shaped panel defining a first angle and the first end of the coil assembly comprises a v-shaped end defining a second angle that is different from the first angle when the baffle is uncoupled from the coil assembly, and wherein orienting the baffle comprises orienting the baffle so the v-shaped panel is positioned within the v-shaped end of the coil assembly. 
     In some example implementations of method of any example implementation, or any combination of any preceding example implementations, detachably engaging each of the plurality of apertures comprises deforming the v-shaped panel to allow the first angle on the v-shaped panel to align more closely with the second angle on the v-shaped end when each aperture of the plurality of apertures is detachably engaged with the corresponding hook. 
     In some example implementations of the method of any example implementation, or any combination of any preceding example implementations, the baffle includes two side flanges extending from the v-shaped panel on opposite sides, and the apertures are located on at least one of the side flanges, and wherein orienting the baffle comprises orienting the side flanges so the apertures located on the at least one side flange is arranged proximate to the corresponding hook. 
     In some example implementations of the method of any example implementation, or any combination of any preceding example implementations, there are four hooks located on the first end of each of the first and second tube sheets and the plurality of apertures comprises four apertures, each of the side flanges including two of the four apertures, and wherein orienting the baffle comprises orienting the side flanges so that each of the four apertures is arranged proximate to the corresponding hook. 
     In some example implementations of the method of any example implementation, or any combination of any preceding example implementations, the hook comprises an inner engagement edge and an outer curved edge, and wherein detachably engaging each aperture comprises engaging the outer curved edge to an outer flange extending outward from each of the side flanges of the baffle to guide the at least one aperture to detachably engage with the inner engagement edge. 
     These and other features, aspects, and advantages of the disclosure will be apparent from a reading of the following detailed description together with the accompanying drawings, which are briefly described below. The disclosure includes any combination of two, three, four, or more of the above-noted embodiments as well as combinations of any two, three, four, or more features or elements set forth in this disclosure, regardless of whether such features or elements are expressly combined in a specific embodiment description herein. This disclosure is intended to be read holistically such that any separable features or elements of the disclosed disclosure, in any of its various aspects and embodiments, should be viewed as intended to be combinable unless the context clearly dictates otherwise. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURE(S) 
       In order to assist the understanding of aspects of the disclosure, reference will now be made to the appended drawings, which are not necessarily drawn to scale. The drawings are provided by way of example to assist in the understanding of aspects of the disclosure, and should not be construed as limiting the disclosure. 
         FIG.  1    is a schematic of an air handling unit including a heat exchanger according to an example embodiment of the present disclosure; 
         FIG.  2    is a schematic of a heat exchanger according to an example embodiment of the present disclosure; 
         FIG.  3    is a close-up schematic of a heat exchanger including a baffle uncoupled from a coil assembly thereof, according to an example embodiment of the present disclosure; 
         FIG.  4    is a detailed view of  FIG.  2    with the baffle uncoupled from the coil assembly, according to an example embodiment of the present disclosure; 
         FIG.  5    is a detailed view of  FIG.  2    with the baffle coupled to the coil assembly, according to an example embodiment of the present disclosure; 
         FIG.  6    is an is an angled view of a baffle, according to an example embodiment of the present disclosure; 
         FIG.  7    is a front view of a baffle, which when rotated 180 degrees to a rear view is the same, according to an example embodiment of the present disclosure; 
         FIG.  8    is a top view of a baffle, according to an example embodiment of the present disclosure; 
         FIG.  9    is a bottom view of a baffle, according to an example embodiment of the present disclosure; 
         FIG.  10    is a left side view of a baffle, according to an example embodiment of the present disclosure; 
         FIG.  11    is a right side view of a baffle, according to an example embodiment of the present disclosure; and 
         FIG.  12    is a method flow diagram showing a method for assembling a heat exchanger baffle with a coil assembly, according to an example embodiment of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Some implementations of the present disclosure will now be described more fully hereinafter with reference to the accompanying figures, in which some, but not all implementations of the disclosure are shown. Indeed, various implementations of the disclosure may be embodied in many different forms and should not be construed as limited to the implementations set forth herein; rather, these example implementations are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. 
     For example, unless specified otherwise or clear from context, references to first, second or the like should not be construed to imply a particular order. A feature described as being above another feature (unless specified otherwise or clear from context) may instead be below, and vice versa; and similarly, features described as being to the left of another feature may instead be to the right, and vice versa. Also, while reference may be made herein to quantitative measures, values, geometric relationships or the like, unless otherwise stated, any one or more if not all of these may be absolute or approximate to account for acceptable variations that may occur, such as those due to engineering tolerances or the like. 
     As used herein, unless specified otherwise, or clear from context, the “or” of a set of operands is the “inclusive or” and thereby true if and only if one or more of the operands is true, as opposed to the “exclusive or” which is false when all of the operands are true. Thus, for example, “[A] or [B]” is true if [A] is true, or if [B] is true, or if both [A] and [B] are true. Further, the articles “a” and “an” mean “one or more,” unless specified otherwise or clear from context to be directed to a singular form. Like reference numerals refer to like elements throughout. 
     As used herein, the terms “bottom,” “top,” “upper,” “lower,” “upward,” “downward,” “rightward,” “leftward,” “interior,” “exterior,” and/or similar terms are used for ease of explanation and refer generally to the position of certain components or portions of the components of embodiments of the described disclosure. It is understood that such terms are not used in any absolute sense. 
     Example implementations of the present disclosure relate generally to an improved heat exchanger for use in an HVAC device. Example implementations will be primarily described in conjunction with air handling units used in HVAC applications, but it should be understood that example implementations may be utilized in conjunction with a variety of other applications. For example, other HVAC devices include but are not limited to cased coils, uncased coils, indoor units, outdoor units, packaged units, furnaces, heaters (electric or otherwise) as well as other devices generally including water heaters, kitchen appliances, and the like may utilize the assembly described herein. 
       FIG.  1    shows a schematic of the components that may comprise an example air handling unit or a HVAC system  10 . In this example, these components are located within a housing  15  of the air handling unit  10  and the conditioned air path is indicated by arrow  11 . The air path flows through the air handling unit  10 , passing through the various components. As indicated by arrows  12  the air is directed through the heat exchanger  20 , often in a manner that ensures sufficient heat transfer between the coils within the heat exchanger and the air. Return air  13  from a conditioned space and/or outdoor air are directed to the air handling unit via return air duct  14 . In this example, the air first passes through a mechanical filter  16 , before entering an inlet of a blower or fan  18  arranged within the housing  15 . The blower  18  pressurizes the air and directs it to a heat exchanger  20  arranged within the housing  15  to receive the pressurized air from the blower  18 . The heat exchanger  20  includes a baffle  17  as contemplated by the present disclosure that is capable of capping coils of the heat exchanger  20  to minimize airflow through a first end of a coil assembly of the heat exchanger  20 . For example, the baffle  17  may include additional features such as an aperture, which will be described in more detail below. The depicted embodiment also includes a heating element  22  located downstream from the heat exchanger. The conditioned air is then directed into the supply air duct  24 , which directs the air into a conditioned space (not shown). 
     In other implementations, the air handling unit  10  may be located horizontally with heat exchanger  20  and/or the heating element  22  disposed on one side of the blower  18 . The heating element  22  may be an electric heating element, and in some embodiments, potentially embodiments where the HVAC system is a heat pump,  22  could be an auxiliary heat exchanger arranged within the housing  15 . In other examples, the blower is located down stream of either the heat exchanger or the heating element. In still other examples, the heat exchanger and/or the heating element may be disposed within a fluid duct of the air handling unit and may also be selectively removable from the air handling unit. It is appreciated that more or less of these components may be utilized, and that they may be arranged in different configurations provided they provide the functionality described herein. In some embodiments, the heat exchanger may be used in combination with a furnace (not shown). In these examples, the furnace may include some or all of the elements shown in  FIG.  1   . 
       FIGS.  2  and  3    show example embodiments of a heat exchanger assembly  100 , which may be utilized in an air handler unit located within a structure, such as a residence.  FIG.  2    shows a heat exchanger  100 .  FIG.  3    shows an exploded close up of a first end of the heat exchanger  100 . The heat exchanger  100  comprises a coil assembly  102  comprising a pair of heat exchanger coil slabs  104 , each slab  104  comprising a first tube sheet  106  and a second tube sheet  108 . In some example embodiments, and as depicted in  FIGS.  2  and  3   , the first tube sheets  106  are connected to each other and the second tube sheets  108  are connected to each other. As shown, an end baffle  110  is arranged between the first tube sheets  106  and another end baffle  110  is arranged between the second tube sheets  108 . The end baffles  110  and the respective tube sheets  106 ,  108  may be integrally connected to one another or may be joined together via one or more fastener, welding, adhering, or the like. 
     The slabs  104  may be arranged relative to one another so that the heat exchanger  100  forms an “A” shape (or an inverted “V” shape) when viewed from the front. Each of the slabs  104  may be arranged such that coils extend between the first and second tube sheets  106 ,  108 . Although the slabs  104  of the coil assembly  102  are illustrated in an A-frame configuration in  FIGS.  2  and  3   , the coil assembly  102  may be slightly different than what is shown therein. For example, the coil assembly  102  may comprise additional or fewer groupings of coils and/or tube sheets arranged in other configurations, as well as fewer or any additional or different components not shown in  FIGS.  2  and  3   . Accordingly, some of the components shown in  FIGS.  2  and  3    will not be described in detail and are known to those of skill in the art. 
     In some example implementations, and as illustrated in  FIG.  2   , the first and second tube sheets  106 ,  108  may each include a first end or edge  112  located proximate a first end or edge  114  of the coil assembly  102  and an opposing second end or edge  113  of each of the first and second tube sheets  106 ,  108  located proximate a second end  115  of the coil assembly  102 . Side edges of each of the first and second tube sheets  106 ,  108  may be arranged between the opposing first and second ends. The first and second tube sheets  106 ,  108  may thus be oriented so that when an air handling unit (such as that shown in  FIG.  1   ) is in a vertical orientation, the first ends  112  of each of the tube sheets  106 ,  108  are arranged more proximate toward an apex or top of the converging A-configuration, while the opposing seconds ends  113  are arranged more proximate to the ground. 
     Based on an arrangement of the first and second tube sheets  106 ,  108  (such as, e.g., in the converging A-configuration), an interior angle θ is formed between the first ends  112  of adjacent tube sheets, i.e., such as between the first ends  112  of the first tube sheets  106  and between the first ends  112  of the second tube sheets  108 . Thus, and as a result of the angle θ formed between the first ends  112  of adjacent tube sheets, the first end  114  of the coil assembly  102  comprises a v-shaped end, though the end may be of another shape. 
     Each of the first ends  112  of each tube sheet  106 ,  108  may also have at least one tab or hook  122  located on the first end  112  thereof. In some example embodiments, the first and second tube sheets  106 ,  108  each comprise one hook  122  located proximate the first end  112  (four hooks total), although two, three, four hooks may be arranged proximate the first end  112  of all of the tube sheets or just one, two, or three of the tube sheets. The hook  122  may be arranged at an outer corner of the first end  112 , as shown in  FIG.  3   , for example, though it may also be inset therefrom. In some further example embodiments, and as shown in  FIG.  4   , the hook  122  comprises an inner engagement edge  124  and an outer curved edge  126 . 
     The heat exchanger  100  may further comprise a baffle  116  comprising a panel  118  and two side flanges  130  extending from the panel  118  on opposite sides. The side flanges  130  may approximate a right angle with respect to the adjacent portion of the panel  118 . Additionally, each side flange  130  may include an outer flange  128  extending outward from each of the side flanges  130  for flexing the v-shaped panel  118  during assembly. The outer flange  128  may be bent 45 degrees relative to the adjacent side flange  130 . The baffle  116  may be shaped to complementarily couple to (e.g., combine or connect) or be received by the coil assembly  102 . In the depicted embodiment, where the coil assembly  102  is in the A-configuration, with the angle θ at the apex thereof, the panel  118  of the baffle  116  may be or include a v-shaped panel, where the v-shaped panel is shaped at an angle α (referred to herein as the first angle). In other embodiments, the baffle  116  may comprise a panel  118  of a different shape or with a different curvature, such as, for example, a flat panel, a rounded panel, etc. 
     In some embodiments, the first angle α may correspond to the angle θ (hereinafter referred to the second angle) when the baffle  116  is coupled to the coil assembly  102 . For example, where the second angle θ is 160 degrees, the first angle α may correspondingly be about 160 degrees when the baffle  116  is coupled to the coil assembly  102 . In some embodiments, the v-shaped end may be shaped at the second angle θ, which may be different from the first angle α when the baffle  116  is uncoupled from the coil assembly  102 . For example, the first angle α may be smaller than the second angle θ when the baffle  116  is uncoupled from the coil assembly  102 . In one example, a difference between the first angle α and the second angle θ is at least five degrees. In this example, the first angle α may be an angle ranging from five to ten degrees less than the second angle θ. More particularly, the panel  118  may be formed of a material (e.g., carbon steel, alloy steel, stainless steel, aluminum, a nonferrous material, etc.) that enables the baffle  116  to deflect from its original shape (for example expanding the first angle α) to couple to the coil assembly  102 . The baffle  116  may then return to its original shape (and the first angle α) upon uncoupling of the baffle  116  from the coil assembly  102 . 
     In some embodiments, the deformation of the baffle  116  is used to create a force between the baffle  116  and the coil assembly  102 . The force created when the v-shaped panel  118  deforms to allow the first angle α to more closely align with the second angle θ on the v-shaped end helps secure the baffle  116  to the coil assembly  102 . In some embodiments, this force is also used to secure other components (e.g., a gasket  132 ,  FIG.  3   ) between the baffle  116  and the coil assembly  102 , potentially providing a seal to direct air flow appropriately through the heat exchanger. For example, the first angle α may be smaller than second angle θ when the baffle  116  is uncoupled from the coil assembly  102 . When the baffle  116  is elastically deformed and aligns with the coil assembly  102  such that the first angle α corresponds more closely with the second angle θ, the deformation may create a spring force across the baffle, for example bowing each segment of the v-shaped panel  118 . In these examples, the spring force developed in the baffle  116  results in a normal force exerted downwards by the hook  122  of the tube sheets  106 ,  108  onto the baffle  116 , which directs an edge E 1  of the baffle  116  downwards towards the coil assembly  102 . A pressing contact point is created at a center Cl of the baffle  116 . 
     In some embodiments, the material associated with the baffle  116  and the angles α, θ are selected to encourage retention between the baffle  116  and the coil assembly  102 . For example, the attributes of the baffle may be designed based on the power associated with the circulation fan (e.g., fan  18  in  FIG.  1   ) used in the system. This fan may circulate an air flow through the heat exchanger at a given static pressure, e.g., 1 in water column, and the spring force of the baffle may be designed to force the center of the baffle  116  to abut the coil assembly  102  at a force greater than the air pressure at that point in the system. 
     In some example embodiments, the baffle  116  may also comprise a plurality of apertures  120  located on the baffle  116 . Each aperture  120  of the plurality of apertures is configured to detachably engage with a hook  122  located on the first end  112  of the first and second tube sheets  106 ,  108 . As illustrated in  FIG.  4   , for example, the apertures  120  are located on at least one of the side flanges  130 . As shown in  FIGS.  6 - 11   , one example embodiment of the present disclosure, each of the side flanges  130  includes two apertures  120  (four apertures total) of the plurality of apertures, such that when the v-shaped panel  118  is arranged over the coil assembly  102 , each of the hooks  122  engages a corresponding aperture  120 . However, there may be fewer or more apertures in different locations on the baffle  116 , such as on the panel  118 . 
     One example embodiment of the detachable engagement of the apertures  120  with the tube sheets  106 ,  108 , is shown in more detail in  FIGS.  4  and  5   . More particularly,  FIG.  4    illustrates the orientation/alignment of one of the apertures  120  relative to the first end  112  of the first tube sheet  106 .  FIG.  5    illustrates the engagement of this aperture  120  with the hook  122  to thereby couple the baffle  116  to the first ends  112  of the first tube sheet  106  (and the second tube sheet  108 ) of each coil slab  104 . In particular, when the panel  118  of the baffle  116  is arranged over the coil assembly  102 , each of the hooks  122  engages a corresponding aperture  120  via the various edges of the hooks  122 . For example, the inner engagement edge  124  of the hook  122  engages a respective one of the plurality of apertures  120  located on the baffle  116 , and the outer curved edge  126  of the hook  122  is configured to engage the outer flange  128  of the baffle  116  for deflecting the respective side flange  130 . 
     In some embodiments, the outer flange(s)  128  are designed to engage with the outer curved edge  126  of the hook  122 . For example, the outer flange  128  may be angled away from the side flange  130 , and the curved edge  126  may include a curve that mirrors the angle of the outer flange, at least in some portions. In these examples, the shape of the outer flange  128  and the outer curved edge  126  may assist in assembly of the baffle  116  with the coil assembly  102 . For example, the outer flange  128  may engage with the curved edge  126 , directing the connectors on the side flange  130  onto the inner engagement edge  124  of the hook  122 . Thus, the baffle  116  may be arranged to cap the coil assembly  102  when the plurality of apertures  120  are engaged (i.e., cooperates) with respective hooks  122 . 
     Because the hook  122  and the aperture  120  are detachably engaged, this allows the baffle  116  to be easily separated and removed from the first ends  112  of the tube sheets  106 ,  108  so as to allow for access to the heat exchanger  100  during maintenance, and then recoupled once the maintenance is done. The baffle  116  may thus be configured to be secured to the coil assembly  102  when the plurality of apertures  120  is engaged with a corresponding hook  122 . In particular, for example, the first angle α is smaller than the second angle θ when the baffle  116  is in its original shape. User manipulation of the baffle  116  to align the baffle  116  with the coil assembly  102  results in displacement of the edges E 1  of the baffle so that the apertures  120  align with and engage the hooks  122 . Conversely, to uncouple the baffle  116  from the coil assembly  102 , a user may grasp one or both of the outer flanges  128  and pull outwardly to move the outer curved edge  126  of each aperture  120  into/out of engagement with its respective hook  122 . In this manner, the baffle  116  is arranged to cap the coil assembly  102  when the plurality of apertures  120  are engaged. 
     A size and/or shape of the apertures  120  and the respective hooks  122  may be designed so as to simultaneously enable ease of assembly and secure retention of the baffle  116  to the coil assembly  102 . For example, an inner engagement edge  124  of the hook  122  may be between about 0.12 inches and about 0.16 inches in length, while the outer curved edge  126  of the hook  122  may be between about 0.365 inches and about 0.385 inches in length. Additionally, a width of the apertures  120  (front-to-back) may be between about 0.26 inches and about 0.32 inches in length. As such, with hooks  122  and apertures  120  sized and shaped as contemplated herein, secure engagement of the hooks  122  with the apertures  120  may be enabled, despite manufacturing process variations. 
     In some other example embodiments (not shown), an ‘integrated’ connector may be utilized rather than the aperture  120  and hook  122  or in addition to the aperture  120  and hook  122 . As used herein, an integrated connector is one that is so formed with the baffle  116  such that they are of one unit. Thus, the integrated connectors may be formed so that they do not require any additional hardware (e.g., screw fasteners) in order to detachably engage the tube sheets  106 ,  108 . However, and as otherwise contemplated, the integrated connectors may be separate from, but fixedly coupled to, the baffle  116  such that they are considered integrated therewith. Regardless, the integrated connector(s) may configured to cap the coil assembly  102  when the plurality of apertures are engaged (i.e., interconnected or joined) with the first ends  112  of the tube sheets  106 ,  108 . 
     In some example embodiments, and as shown for example in  FIG.  3   , a gasket  132  may be secured between the baffle  116  and the first end  112  of at least one of the first and second tube sheets  106 ,  108  when the apertures are engaged. In some embodiments, the gasket  132  is made from an elastic material, such as, for example, a deformable elastic (e.g., thermoplastic vulcanizate) material rated for temperatures at least as great as 135° C. The gasket  132  may substantially surround a perimeter formed at an intersection between the baffle  116  and at least one of the first and second tube sheets  106 ,  108 , or may only surround a portion of the perimeter therebetween. Regardless, the gasket  132  may be removable or remain coupled to one of the baffle  116  or the tube sheets  106 ,  108  when the baffle  116  is uncoupled from the coil assembly  102 . Notably, in some example embodiments, a height of each aperture  120  is designed to provide a small gap between the first end of the tube sheets and a bottom of the baffle  116  to allow for easier disassembly of the baffle  116  from the coil assembly  102 , and to provide a small tolerance to allow for installation of the gaskets  132 . 
     In some example embodiments, and as shown in  FIG.  2   , a fastener cap  134  may be coupled to at least one aperture  120  and be configured to seal the aperture  120 . The fastener cap  134  may be a waterproof or water resistant material that is able to partially or substantially cover the aperture  120  to prevent debris, water, and the like from entering the coil assembly  102  through the aperture  120 . In some other example embodiments, crimped on shielding may be utilized to cover the apertures  120  to prevent condensation from leaving the apertures  120  and/or a drain pan in the air handling unit  10 . 
     Turning now to  FIGS.  6 - 11   , these figures show various views of the embodiment of a heat exchanger baffle, such as the baffle  116  illustrated in  FIGS.  2 - 5   . The embodiment of the baffle depicted in  FIGS.  6 - 11    may include many of the features discussed above and may be configured in a similar manner. 
       FIG.  12    illustrates a method flow diagram for a method for assembling a heat exchanger baffle with a coil assembly comprising a pair of heat exchanger coil slabs each including a first tube sheet and a second tube sheet. The method, generally designated  200 , includes orienting the baffle comprising a plurality of apertures located on the baffle relative to a first end of the first tube sheet and the first end of the second tube sheet, the first ends of the first and second tube sheets being located proximate a first end of the coil assembly, block  202 . The method  200  also comprises detachably engaging each aperture of the plurality of apertures with a hook located on the first end of one of the first tube sheet or the second tube sheet so as to couple the baffle to the first end of the first tube sheet and the first end of the second tube sheet and thereby cap the coil assembly to minimize airflow through the first end of the coil assembly, block  204 . 
     The method  200  further comprises, in some example embodiments, that the baffle includes a v-shaped panel defining a first angle and the first end of the coil assembly comprises a v-shaped end defining a second angle that is different from the first angle when the baffle is uncoupled from the coil assembly, and wherein orienting the baffle comprises orienting the baffle so the v-shaped panel is positioned within the v-shaped end of the coil assembly. In some example embodiments, detachably engaging each of the plurality of apertures comprises deforming the v-shaped panel to allow the first angle on the v-shaped panel to align more closely with the second angle on the v-shaped end when each aperture of the plurality of apertures is detachably engaged with the corresponding hook. In some still further example embodiments, the baffle includes two side flanges extending from the v-shaped panel on opposite sides, and the apertures are located on at least one of the side flanges, and wherein orienting the baffle comprises orienting the side flanges so the apertures located on the at least one side flange is arranged proximate to the corresponding hook. In still further example embodiments, there are four hooks located on the first end of each of the first and second tube sheets and the plurality of apertures comprises four apertures, each of the side flanges including two of the four apertures, and wherein orienting the baffle comprises orienting the side flanges so that each of the four apertures is arranged proximate to the corresponding hook. In even further example embodiments, the hook comprises an inner engagement edge and an outer curved edge, and wherein detachably engaging each aperture comprises engaging the outer curved edge to an outer flange extending outward from each of the side flanges of the baffle to guide the at least one aperture to detachably engage with the inner engagement edge. 
     Accordingly, the heat exchanger assemblies discussed herein can be used in multiple different devices and for various purposes. In some embodiments, as discussed herein, the heat exchanger is a refrigerant coil heat exchanger. Otherwise, the heat exchanger discussed herein may be used with a furnace, and in these embodiments, the heat exchanger may allow for an improved process for manufacturing and conducting maintenance on HVAC units, by reducing the number of parts needed to secure the baffle to the coil assembly and thus streamlining the process for installing the air handling unit. 
     Many modifications and other implementations of the disclosure set forth herein will come to mind to one skilled in the art to which the disclosure pertains having the benefit of the teachings presented in the foregoing description and the associated figures. Therefore, it is to be understood that the disclosure is not to be limited to the specific implementations disclosed and that modifications and other implementations are intended to be included within the scope of the appended claims. Moreover, although the foregoing description and the associated figures describe example implementations in the context of certain example combinations of elements and/or functions, it should be appreciated that different combinations of elements and/or functions may be provided by alternative implementations without departing from the scope of the appended claims. In this regard, for example, different combinations of elements and/or functions than those explicitly described above are also contemplated as may be set forth in some of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.