Patent Publication Number: US-2022235980-A1

Title: Condensate block for v-coil heat exchanger

Description:
CROSS REFERENCE TO A RELATED APPLICATION 
     The application claims the benefit of U.S. Provisional Application No. 63/199,768 filed Jan. 23, 2021 and U.S. Provisional Application No. 63/200,838 filed Mar. 31, 2021, the contents of which are hereby incorporated in their entirety. 
    
    
     BACKGROUND 
     The disclosed embodiments relate to heating and cooling systems and more specifically to a condensate block for a heat exchanger (e.g., an evaporator coil of an HVAC system) that is configured in a v-shaped arrangement (v-coil). 
     An evaporator coil is commonly used within HVAC systems. In certain instances, the evaporator coil may be a microchannel heat exchanger (MCHX), which may be configured in a v-coil arrangement. The evaporator coil may be mounted vertically in a housing (e.g., of a furnace, etc.), which may be connected in line with the ductwork of, for example, a home. The evaporator coil is designed to become cold when the unit operates. When the system is on, air flows through the coil and the cold air is distributed throughout the home. This air is commonly forced through the coil using a blower (which may be referred to as a fan assembly). This HVAC system may either be in an upflow configuration or in a downflow configuration. When in upflow configuration the blower forces air upwards through the housing toward the bottom of the ‘V’ (when the heat exchanger is configured in a v-shaped arrangement). When in downflow configuration the blower forces air downwards through the housing toward the open, top portion of the ‘V’ (when the heat exchanger is configured in a v-shaped arrangement). As can be assumed, when the air is cooled moisture in the air drops out and forms condensate. This condensate is commonly collected using a condensate receptor, which is commonly placed at the bottom of the ‘v-coil.’ Due to the open nature of the bottom of the ‘V’ (i.e., to allow the heat exchanger to be bent in the v-coil arrangement) and the open nature of the condensate receptor, there is potential that condensate may blow through the HVAC system and into the ductwork when in a downflow configuration. 
     Accordingly, there remains a need for an invention that mitigates the potential of condensate blowing through the HVAC system and into the ductwork when the HVAC system is in a downflow configuration. 
     BRIEF DESCRIPTION 
     According to one embodiment, an evaporator assembly for a heating, ventilation, and air conditioning (HVAC) system is provided. The evaporator assembly including a housing, a fan assembly disposed within the housing, a v -coil heat exchanger mounted within the housing, downstream of the fan assembly, and a condensate block disposed adjacent to the v-coil heat exchanger. The v-coil heat exchanger defines a v-coil bend angle. The condensate block has a body made of a malleable, flame-resistant material. The body defining at least one upward facing surface and opposing outward facing surfaces. The opposing outward facing surfaces are configured at an apex angle, the apex angle being complimentary to the v -coil bend angle. 
     In accordance with additional or alternative embodiments, the v-coil bend angle is defined by a bend section of the v-coil heat exchanger, the bend section being disposed between a first leg and a second leg of the v-coil heat exchanger, each of the first leg and the second leg being closer to the fan assembly than the bend section. 
     In accordance with additional or alternative embodiments, the first leg and the second leg each include one or more fins disposed between heat exchange tube segments, and the bend section is devoid of any fins. 
     In accordance with additional or alternative embodiments, the upward facing surface of the condensate block spans between the fins of first leg and the fins of the second leg. 
     In accordance with additional or alternative embodiments, the apex angle is greater than the v-coil bend angle. 
     In accordance with additional or alternative embodiments, the apex angle is at least 5° greater than the v-coil bend angle. 
     In accordance with additional or alternative embodiments, the evaporator assembly further includes a condensate receptor positioned downstream of the bend section, the condensate receptor configured to receive the bend section of the v-coil heat exchanger. 
     In accordance with additional or alternative embodiments, the condensate receptor includes a first channel with a length defined between a first end of the first channel and a second end of the first channel, the condensate block including a length defined between a first end of the condensate block and a second end of the condensate block, the length of the condensate block being complimentary to the length of the first channel. 
     In accordance with additional or alternative embodiments, the length of the condensate block is at least  90 % of the length of the first channel. 
     In accordance with additional or alternative embodiments, the malleable, flame-resistant material comprises at least one of: a non-porous foam, and a malleable plastic. 
     In accordance with additional or alternative embodiments, the malleable, flame-resistant material is non-permeable to water. 
     According to another aspect of the disclosure, a condensate block for a vertically mounted v-coil heat exchanger is provided. The condensate block including a body made of a malleable, flame-resistant material. The body defining at least one upward facing surface and opposing outward facing surfaces. The outward facing surfaces configured at an apex angle. The apex angle being complimentary to a v-coil bend angle defined by the v-coil heat exchanger. 
     In accordance with additional or alternative embodiments, the v-coil bend angle is defined by a bend section of the v-coil heat exchanger, the bend section being disposed between a first leg and a second leg of the v-coil heat exchanger, each of the first leg and the second leg being closer to the fan assembly than the bend section. 
     In accordance with additional or alternative embodiments, the first leg and the second leg each include one or more fins disposed between heat exchange tube segments, the bend section devoid of any fins, the upward facing surface of the condensate block spanning between the fins of first leg and the fins of the second leg. 
     In accordance with additional or alternative embodiments, the apex angle is greater than the v-coil bend angle. 
     In accordance with additional or alternative embodiments, the apex angle is at least 5° greater than the v-coil bend angle. 
     In accordance with additional or alternative embodiments, the bend section is configured to be received by a drain pan, the condensate receptor includes a first channel with a length defined between a first end of the first channel and a second end of the first channel, the condensate block has a length defined between a first end of the condensate block and a second end of the condensate block, the length of the condensate block being complimentary to the length of the first channel. 
     In accordance with additional or alternative embodiments, the length of the condensate block is at least  90 % of the length of the first channel. 
     In accordance with additional or alternative embodiments, the malleable, flame-resistant material comprises at least one of: a non-porous foam, and a malleable plastic. 
     In accordance with additional or alternative embodiments, the malleable, flame-resistant material is non-permeable to water. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The subject matter, which is regarded as the disclosure, is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The following descriptions of the drawings should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike. 
         FIG. 1  is a perspective view of an exemplary heating, ventilation, and air conditioning (HVAC) system with an evaporator assembly in downflow configuration in accordance with one aspect of the disclosure. 
         FIGS. 2A  is a front view of a portion of the evaporator assembly including a heat exchanger in a v-shaped arrangement (v-coil) and a condensate receptor within a housing in accordance with one aspect of the disclosure. 
         FIG. 2B  is a side view of the portion of the evaporator assembly shown in  FIG. 2A  in accordance with one aspect of the disclosure. 
         FIG. 2C  is a perspective view of the portion of the evaporator assembly shown in  FIG. 2A  in accordance with one aspect of the disclosure. 
         FIG. 3A  is a front view of the condensate receptor shown in  FIG. 2A  in accordance with one aspect of the disclosure. 
         FIG. 3B  is a perspective view of the condensate receptor shown in  FIG. 2A , the condensate receptor including a first channel and a second channel, in accordance with one aspect of the disclosure. 
         FIG. 3C  is a cross-sectional view of the first channel of the condensate receptor shown in  FIG. 3B  in accordance with one aspect of the disclosure. 
         FIG. 4  is a perspective view of the condensate receptor shown in  FIG. 2A , illustrating the opposing ends of the first channel and the second channel in accordance with one aspect of the disclosure. 
         FIG. 5  is a perspective top view of an exemplary heat exchanger in accordance with one aspect of the disclosure. 
         FIG. 6  is a perspective side view of an exemplary condensate block disposed adjacent to a heat exchanger in a v-shaped arrangement (i.e., a v-coil heat exchanger) in accordance with one aspect of the disclosure. 
         FIG. 7  is a perspective top view of an exemplary condensate block disposed adjacent to a v-coil heat exchanger in accordance with one aspect of the disclosure. 
         FIG. 8  is a perspective view of an exemplary condensate block in accordance with one aspect of the disclosure. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  illustrates an exemplary heating, ventilation, and air conditioning (HVAC) system  10 . As shown, the HVAC system  10  may include a condenser assembly  20  and an evaporator assembly  100  (which may also be referred to as an air handler). The evaporator assembly  100  may include a housing  120  (e.g., made of sheet metal, etc.), a fan assembly  45  disposed within the housing, and a heat exchanger  130 , which, as shown, may be configured into a v-shaped arrangement. It should be understood that the terms ‘upstream’ and ‘downstream’ are in relationship to the flow of air, which may be directed by the fan assembly  45 . For example, the v-coil heat exchanger  130  depicted in  FIG. 1  is downstream of the fan assembly  45 . It should be appreciated that the v-shaped coil arrangement shown in  FIG. 1  may present challenges for effectively managing condensate without the use of a condensate block (described below), due, at least in part, to the downflow configuration. For example, when in downflow configuration the fan assembly may blow condensate out of the condensate receptor and through the HVAC system and into the ductwork if no condensate block is present (which may not be ideal). This is largely due to the open nature of the bottom of the v-coil heat exchanger  130  (to allow the heat exchanger to be bent in the v-coil arrangement) and the open nature of the condensate receptor (to allow the flow and collection of the condensate). 
     As shown in  FIGS. 2A-2C , the evaporator assembly  100  may include a v-coil heat exchanger  130  (which may define a v-coil bend angle Θ 1 ) vertically mounted within the housing  120 . It should be appreciated that the v-coil heat exchanger  130  may be configured from a microchannel heat exchanger or a round tube plate fin constructions in certain instances. As shown, a condensate receptor  140  may be mounted within the housing  120 , downstream of the v-coil heat exchanger  130 , and may be configured to receive the bend section  135  (shown in  FIG. 5 ) of the v-coil heat exchanger  130 . As shown in  FIG. 5 , the v-coil bend angle Θ 1  may be defined by a bend section  135  of the v-coil heat exchanger  130 . For example, the v-coil heat exchanger  130  may be viewed to have a first leg  132  and a second leg  133 , each of which may be closer to the fan assembly  45  than the bend section  135  when installed. As mentioned above, the bottom of the v-shaped heat exchanger  130  (i.e., the bend section  135 ) may be open to allow the heat exchanger  130  to be bent in the v-coil arrangement. Being ‘open’ may be interpreted to mean that the bend section  135  may be devoid of any fins. As shown in  FIG. 5 , each of the first leg  132  and the second leg  133  may include one or more fins  136  disposed between heat exchange tube segments  131 . As shown in  FIG. 6 , the condensate block  300  may span between the fins  136  of the first leg  132  and the fins  136  of the second leg  133  when installed. 
     Turning back to the condensate receptor  140 , as shown in  FIGS. 2C and 3B , the condensate receptor  140  may include a first channel  150  having a length L 1  defined between a first end  145   a  and a second end  145   b  of the first channel  150 . It is envisioned that the length L 1  of the first channel  150  may be complimentary (i.e., approximately the same length, width, etc.) to the v-coil heat exchanger  130  (to enable the bend section  135  to be received by the first channel  150 ). As shown, the condensate receptor  140  may include a second channel  160 , in certain instances, which may be viewed to have a second length L 2  defined between opposing ends  165   a,    165   b.  The second channel  160  may be perpendicular to the first channel  150 . The second channel  160  may include a first orifice  170  illustrated schematically intermediate the second opposing ends  165  for receiving condensate from the first channel  150 . 
     Turning to  FIGS. 3A-3C , the first orifice  170  may be fluidly connected to one end of the first opposing ends  145   a,    145   b  and specifically the downstream end  145   b,  at a junction  180  which substantially defines a T-shape. For example the downstream end  145   b  may open into the second channel  160  to allow condensate to flow substantially unobstructed from the first channel  150  to the second channel  160 . The second channel  160  may include a fluid drain port  190  at one or both of the second opposing ends  165   a,    165   b.  The fluid drain port  190  may include a pair of ports  190   a,    190   b  that may be together disposed at the one or both of the second opposing ends  165   a,    165   b.  Each port  190  may have a circular profile for condensate drainage therethrough. As can be appreciated providing drain ports at both of the second opposing ends  165   a,    165   b  may increase an ability to drain condensate from the receptor  140 . In addition, the drain ports  190  may be configured to protrude from the housing  120  ( FIG. 2B ) to enable removing of the condensate from the assembly  100 . 
     In an embodiment the first channel  150  may have a bottom surface  200  (shown in  FIG. 2B ) that is sloped between the first end  145   a  and the second end  145   b.  From this configuration a first depth D 1  of the first channel  150 , located at the junction  180 , may be deeper than a second depth D 2  of the first channel  150  located at the other end of the first channel  150 , which may assist with condensate removal. 
     In an embodiment the first channel  150  may include a first internal cross section  210  referenced in  FIG. 3B  and illustrated, for example, in  FIG. 3C . The cross section  210  may include a top portion  210   a  that is arcuate, for example, semicircular, and a bottom portion  210   b  that is frustoconical. That is, in the bottom portion  210   b,  side surfaces  150   a,    150   b  of the first channel  150  may converge toward the bottom surface  200  of the first channel  150 . A converging angle A between the surfaces  150   a,    150   b  may be between 50° and  90 °, which may be optimized to limit impact on the airflow. Other angle configurations, below 50° and above 90°, are within the scope of the disclosed embodiments so as to optimize performance. It should be appreciated that the shape of the top portion  210   a  of the first internal cross section  210  may be constant between the first opposing ends  145   a,    145   b  in certain instances. 
     As mentioned above, the first channel  150  may be configured so as to receive the bend section  135  of the v-coil heat exchanger  130 . For example, when installing the v-coil heat exchanger  130 , a bend section  135  (which may be viewed as a bottom apex, of the v-coil heat exchanger  130 ) may be positioned against at least part of the bottom surface  200  of the first channel  150  ( FIGS. 2A-2B ). This may steady the v-coil heat exchanger  130  during installation and, in addition, the shape of the converging orientation of the side surface  150   a,    150   b  may provide for vertical (upright) alignment of the v-coil heat exchanger  130  during installation. 
     In an embodiment the upstream end  145   a  of the first channel  150  includes an upstream end wall  250  ( FIG. 3C ) having a shape that conforms with the first internal cross section  210 . The upstream end wall  250  may include an upstream mounting hole  260 , which may be a set of holes  260   a,    260   b,  configured to mount the receptor  140  to the housing  120 . The downstream end  145   b  may include a downstream end wall  270  that is a partial end wall having a shape that conforms with at least the top portion  210   a  of the first internal cross section  210 . Below the downstream end wall  270 , the first orifice  170  provides for flow into the second channel  160 , as indicated, to allow condensate to flow to the second channel  160 . The downstream end wall  270  may include a downstream mounting hole  280  ( FIG. 3A ), which may be another set of holes  280   a,    280   b,  configured to mount the condensate receptor  140  to the housing  120 . 
     Turning to  FIG. 4 , in at least one embodiment, the receptor  140  may have each of the features of the embodiment illustrated in  FIGS. 3A-3C  except for the downstream end wall  270  in the first channel  150 . Thus, the first channel  150  and second channel  160  may be opened at a top thereof between the first opposing ends  145 , the second opposing ends  165  and at the junction  180 . In comparison, as shown in the embodiment of  FIGS. 3A-3C , the first channel  150  and second channel  160  may be opened at the top thereof between the first opposing ends  145 , the second opposing ends  165 , but the downstream end wall  270  may provide an effective cover at the junction  180 . 
     As mentioned above, due to the open nature of the bend section  131  of the ‘V’ (i.e., to allow the heat exchanger  130  to be bent in the v-coil arrangement) and the open nature of the condensate receptor  140 , there is potential that condensate may blow through the HVAC system  10  and into the ductwork when in a downflow configuration. It should be appreciated that the HVAC system  10  may either be in an upflow configuration or in a downflow configuration. When in upflow configuration the fan assembly  45  forces air upwards through the housing  80  toward the bottom of the ‘V’ (when the heat exchanger  130  is configured in a v-shaped arrangement). When in downflow configuration the fan assembly  45  forces air downwards through the housing  80  toward the open, top portion of the ‘V’ (when the heat exchanger  130  is configured in a v-shaped arrangement). In certain instances, the condensate block  300  described herein may only be used when the HVAC system  10  is in a downflow configuration. As shown in  FIGS. 6-8 , to mitigate the potential of condensate blowing through the HVAC system  10  and into the ductwork when the HVAC system  10  is in a downflow configuration, a condensate block  300  may be disposed adjacent to the v-coil heat exchanger  130  (e.g., directly above the bend section  131 ). The condensate block  300  may be viewed to include a body  310  made of a malleable, flame-resistant material (e.g., non-porous foam that meets the requirement of UL  1995  or UL  60335 - 2 - 40 ). It should be appreciated that the body  310  may be made of a closed or open cell foam, or a malleable plastic in certain instances. In either case the body  310  may be viewed to be non-permeable to water (e.g., meaning that the body  310  may not absorb condensate). The body  310  may be viewed to define at least one upward facing surface  311  and opposing outward facing surfaces  313 . The outward facing surfaces  313  may be configured at an apex angle Θ 2 . The apex angle Θ 2  may be complimentary to (e.g., equal to or greater than) the bend angle Θ 1  of the v-coil heat exchanger  130  (i.e., so as to be able to be wedged into the bottom portion (i.e., the bend section  131 ) of the ‘V’ to prevent, or at least mitigate, the air from blowing condensate through the HVAC system  10 ). In certain instances the v-coil bend angle Θ 1  may be between 15° and 50° (as shown in  FIG. 2A ), and the apex angle Θ 2  may be at least  5 ° greater (up to 15° greater in certain instances) than the v-coil bend angle Θ 1 . For example, the apex angle Θ 2  may be between 20° and 55° in certain instances. It should be appreciated that the condensate block  300  may span the entire bend section  131  to effectively prevent, or at least mitigate, the condensate from being blown through the HVAC system  10  and into the ductwork. As shown in  FIGS. 6-8 , the length L CB  of the condensate block  300  (defined between a first end  312  and second end  314  of the condensate block  300 ) may be complimentary to the length L 1  of the first channel  150 . For example the length L CB  of the condensate block  300  may be at least  90 % to the length L 1  of the first channel  150 . 
     The use of the terms “a” and “and” and “the” and similar referents, in the context of describing the invention, are to be construed to cover both the singular and the plural, unless otherwise indicated herein or cleared contradicted by context. The use of any and all example, or exemplary language (e.g., “such as”, “e.g.”, “for example”, etc.) provided herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed elements as essential to the practice of the invention. 
     While the present disclosure has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the essential scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this present disclosure, but that the present disclosure will include all embodiments falling within the scope of the claims.