Patent ID: 12188694

DETAILED DESCRIPTION

FIG.1illustrates an exemplary heating, ventilation, and air conditioning (HVAC) system10. As shown, the HVAC system10may include a condenser assembly20and an evaporator assembly100(which may also be referred to as an air handler). The evaporator assembly100may include a housing120(e.g., made of sheet metal, etc.), a fan assembly45disposed within the housing, and a heat exchanger130, 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 assembly45. For example, the v-coil heat exchanger130depicted inFIG.1is downstream of the fan assembly45. It should be appreciated that the v-shaped coil arrangement shown inFIG.1may 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 exchanger130(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 inFIGS.2A-2C, the evaporator assembly100may include a v-coil heat exchanger130(which may define a v-coil bend angle Θ1) vertically mounted within the housing120. It should be appreciated that the v-coil heat exchanger130may be configured from a microchannel heat exchanger or a round tube plate fin constructions in certain instances. As shown, a condensate receptor140may be mounted within the housing120, downstream of the v-coil heat exchanger130, and may be configured to receive the bend section135(shown inFIG.5) of the v-coil heat exchanger130. As shown inFIG.5, the v-coil bend angle Θ1may be defined by a bend section135of the v-coil heat exchanger130. For example, the v-coil heat exchanger130may be viewed to have a first leg132and a second leg133, each of which may be closer to the fan assembly45than the bend section135when installed. As mentioned above, the bottom of the v-shaped heat exchanger130(i.e., the bend section135) may be open to allow the heat exchanger130to be bent in the v-coil arrangement. Being ‘open’ may be interpreted to mean that the bend section135may be devoid of any fins. As shown inFIG.5, each of the first leg132and the second leg133may include one or more fins136disposed between heat exchange tube segments131. As shown inFIG.6, the condensate block300may span between the fins136of the first leg132and the fins136of the second leg133when installed.

Turning back to the condensate receptor140, as shown inFIGS.2C and3B, the condensate receptor140may include a first channel150having a length L1defined between a first end145aand a second end145bof the first channel150. It is envisioned that the length L1of the first channel150may be complimentary (i.e., approximately the same length, width, etc.) to the v-coil heat exchanger130(to enable the bend section135to be received by the first channel150). As shown, the condensate receptor140may include a second channel160, in certain instances, which may be viewed to have a second length L2defined between opposing ends165a,165b. The second channel160may be perpendicular to the first channel150. The second channel160may include a first orifice170illustrated schematically intermediate the second opposing ends165for receiving condensate from the first channel150.

Turning toFIGS.3A-3C, the first orifice170may be fluidly connected to one end of the first opposing ends145a,145band specifically the downstream end145b, at a junction180which substantially defines a T-shape. For example the downstream end145bmay open into the second channel160to allow condensate to flow substantially unobstructed from the first channel150to the second channel160. The second channel160may include a fluid drain port190at one or both of the second opposing ends165a,165b. The fluid drain port190may include a pair of ports190a,190bthat may be together disposed at the one or both of the second opposing ends165a,165b. Each port190may have a circular profile for condensate drainage therethrough. As can be appreciated providing drain ports at both of the second opposing ends165a,165bmay increase an ability to drain condensate from the receptor140. In addition, the drain ports190may be configured to protrude from the housing120(FIG.2B) to enable removing of the condensate from the assembly100.

In an embodiment the first channel150may have a bottom surface200(shown inFIG.2B) that is sloped between the first end145aand the second end145b. From this configuration a first depth D1of the first channel150, located at the junction180, may be deeper than a second depth D2of the first channel150located at the other end of the first channel150, which may assist with condensate removal.

In an embodiment the first channel150may include a first internal cross section210referenced inFIG.3Band illustrated, for example, inFIG.3C. The cross section210may include a top portion210athat is arcuate, for example, semicircular, and a bottom portion210bthat is frustoconical. That is, in the bottom portion210b, side surfaces150a,150bof the first channel150may converge toward the bottom surface200of the first channel150. A converging angle A between the surfaces150a,150bmay 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 portion210aof the first internal cross section210may be constant between the first opposing ends145a,145bin certain instances.

As mentioned above, the first channel150may be configured so as to receive the bend section135of the v-coil heat exchanger130. For example, when installing the v-coil heat exchanger130, a bend section135(which may be viewed as a bottom apex, of the v-coil heat exchanger130) may be positioned against at least part of the bottom surface200of the first channel150(FIGS.2A-2B). This may steady the v-coil heat exchanger130during installation and, in addition, the shape of the converging orientation of the side surface150a,150bmay provide for vertical (upright) alignment of the v-coil heat exchanger130during installation.

In an embodiment the upstream end145aof the first channel150includes an upstream end wall250(FIG.3C) having a shape that conforms with the first internal cross section210. The upstream end wall250may include an upstream mounting hole260, which may be a set of holes260a,260b, configured to mount the receptor140to the housing120. The downstream end145bmay include a downstream end wall270that is a partial end wall having a shape that conforms with at least the top portion210aof the first internal cross section210. Below the downstream end wall270, the first orifice170provides for flow into the second channel160, as indicated, to allow condensate to flow to the second channel160. The downstream end wall270may include a downstream mounting hole280(FIG.3A), which may be another set of holes280a,280b, configured to mount the condensate receptor140to the housing120.

Turning toFIG.4, in at least one embodiment, the receptor140may have each of the features of the embodiment illustrated inFIGS.3A-3Cexcept for the downstream end wall270in the first channel150. Thus, the first channel150and second channel160may be opened at a top thereof between the first opposing ends145, the second opposing ends165and at the junction180. In comparison, as shown in the embodiment ofFIGS.3A-3C, the first channel150and second channel160may be opened at the top thereof between the first opposing ends145, the second opposing ends165, but the downstream end wall270may provide an effective cover at the junction180.

As mentioned above, due to the open nature of the bend section131of the ‘V’ (i.e., to allow the heat exchanger130to be bent in the v-coil arrangement) and the open nature of the condensate receptor140, there is potential that condensate may blow through the HVAC system10and into the ductwork when in a downflow configuration. It should be appreciated that the HVAC system10may either be in an upflow configuration or in a downflow configuration. When in upflow configuration the fan assembly45forces air upwards through the housing80toward the bottom of the ‘V’ (when the heat exchanger130is configured in a v-shaped arrangement). When in downflow configuration the fan assembly45forces air downwards through the housing80toward the open, top portion of the ‘V’ (when the heat exchanger130is configured in a v-shaped arrangement). In certain instances, the condensate block300described herein may only be used when the HVAC system10is in a downflow configuration. As shown inFIGS.6-8, to mitigate the potential of condensate blowing through the HVAC system10and into the ductwork when the HVAC system10is in a downflow configuration, a condensate block300may be disposed adjacent to the v-coil heat exchanger130(e.g., directly above the bend section131). The condensate block300may be viewed to include a body310made 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 body310may be made of a closed or open cell foam, or a malleable plastic in certain instances. In either case the body310may be viewed to be non-permeable to water (e.g., meaning that the body310may not absorb condensate). The body310may be viewed to define at least one upward facing surface311and opposing outward facing surfaces313. The outward facing surfaces313may be configured at an apex angle Θ2. The apex angle Θ2may be complimentary to (e.g., equal to or greater than) the bend angle Θ1of the v-coil heat exchanger130(i.e., so as to be able to be wedged into the bottom portion (i.e., the bend section131) of the ‘V’ to prevent, or at least mitigate, the air from blowing condensate through the HVAC system10). In certain instances the v-coil bend angle Θ1may be between 15° and 50° (as shown inFIG.2A), and the apex angle Θ2may be at least 5° greater (up to 15° greater in certain instances) than the v-coil bend angle Θ1. For example, the apex angle Θ2may be between 20° and 55° in certain instances. It should be appreciated that the condensate block300may span the entire bend section131to effectively prevent, or at least mitigate, the condensate from being blown through the HVAC system10and into the ductwork. As shown inFIGS.6-8, the length LCBof the condensate block300(defined between a first end312and second end314of the condensate block300) may be complimentary to the length L1of the first channel150. For example the length LCBof the condensate block300may be at least 90% to the length L1of the first channel150.

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.