Splash guard with fastener-free attachment for multi-poise furnace coils
Condensate formed on a horizontally oriented multi-poise evaporator coil is directed to a condensate pan located under a bottom coil slab using a splash guard having a top member configured to be attachable to a back end of the bottom coil slab and a guard member configured to be attachable to a side of the bottom coil slab.
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The following application is filed on the same day as the following co-pending applications: “METHOD AND SYSTEM FOR HORIZONTAL COIL CONDENSATE DISPOSAL” by inventors Arturo Rios, Floyd J. Frenia, Jason Michael Thomas, Michael V. Hubbard, and Thomas K. Rembold (attorney docket number U75.12-003); “CASING ASSEMBLY SUITABLE FOR USE IN A HEAT EXCHANGE ASSEMBLY” by inventors Floyd J. Frenia, Arturo Rios, Thomas K. Rembold, Michael V. Hubbard, Jason Michael Thomas, and Stephen R. Carlisle (attorney docket number U75.12-004); “CONDENSATE PAN INSERT” by inventors Jason Michael Thomas, Floyd J. Frenia, Thomas K. Rembold, Arturo Rios, Michael V. Hubbard, and Dale R. Bennett (attorney docket number U75.12-005); “METHOD AND SYSTEM FOR VERTICAL COIL CONDENSATE DISPOSAL” by inventors Thomas K. Rembold, Arturo Rios, Jason Michael Thomas, and Michael V. Hubbard (attorney docket number U75.12-006); “CASING ASSEMBLY SUITABLE FOR USE IN A HEAT EXCHANGE ASSEMBLY” by inventors Arturo Rios, Thomas K. Rembold, Jason Michael Thomas, Stephen R. Carlisle, and Floyd J. Frenia (attorney docket number U75.12-007); “LOW-SWEAT CONDENSATE PAN” by inventors Arturo Rios, Floyd J. Frenia, Thomas K. Rembold, Michael V. Hubbard, and Jason Michael Thomas (attorney docket number U75.12-008); “CONDENSATE PAN INTERNAL CORNER DESIGN” by inventor Arturo Rios (attorney docket number U75.12-009); “VERTICAL CONDENSATE PAN WITH NON-MODIFYING SLOPE ATTACHMENT TO HORIZONTAL PAN FOR MULTI-POISE FURNACE COILS” by inventor Arturo Rios (attorney docket number U75.12-010); and “CONDENSATE SHIELD WITH FASTENER-FREE ATTACHMENT FOR MULTI-POISE FURNACE COILS” by inventor Arturo Rios (attorney docket number U75.12-011), which are incorporated herein by reference.
BACKGROUND OF THE INVENTIONThe present invention relates generally to a system for disposing of condensation formed on an evaporator coil. More particularly, the invention relates to a system for catching the condensation from a top coil slab of a multi-poise coil oriented horizontally, and directing the condensation to a condensate pan.
In a conventional refrigerant cycle, a compressor compresses a refrigerant and delivers the compressed refrigerant to a downstream condenser. From the condenser, the refrigerant passes through an expansion device, and subsequently, to an evaporator. The refrigerant from the evaporator is returned to the compressor. In a split system heating and/or cooling system, the condenser may be known as an outdoor heat exchanger and the evaporator as an indoor heat exchanger, when the system operates in a cooling mode. In a heating mode, their functions are reversed.
In the split system, the evaporator is typically a part of an evaporator assembly coupled with a furnace. However, some cooling systems are capable of operating independent of a furnace. A typical evaporator assembly includes an evaporator coil (e.g., a coil shaped like an “A”, which is referred to as an “A-frame coil”) and a condensate pan disposed within a casing. An A-frame coil is typically referred to as a “multi-poise” coil because it may be oriented either horizontally or vertically in the casing of the evaporator assembly. During a cooling mode operation, a furnace blower circulates air into the casing of the evaporator coil assembly, where the air cools as it passes over the evaporator coil. The blower then circulates the air to a space to be cooled.
Refrigerant is enclosed in piping that is used to form the evaporator coil. If the temperature of the evaporator coil surface is lower than the dew point of air passing over it, the evaporator coil removes moisture from the air. Specifically, as air passes over the evaporator coil, water vapor condenses on the evaporator coil. The condensate pan of the evaporator assembly collects the condensed water as it drips off of the evaporator coil. The collected condensation then typically drains out of the condensate pan through a drain hole in the condensate pan.
BRIEF SUMMARY OF THE INVENTIONA condensate formed on a horizontally oriented multi-poise evaporator coil is directed to a condensate pan located under a bottom coil slab using a splash guard having a top member configured to be attachable to a back end of the bottom coil slab and a guard member configured to be attachable to a side of the bottom coil slab. The splash guard is configured to be attachable to the bottom coil slab without the use of any fasteners.
BRIEF DESCRIPTION OF THE DRAWINGS
When evaporator assembly 2 is integrated into a heating and/or cooling system, evaporator assembly 2 is typically mounted above or adjacent to an air handler, depending on whether evaporator assembly 2 is in a vertical or horizontal configuration. In
Coil 6, condensate pan 14, and condensate pan 16 are disposed within casing 4, which is preferably a substantially airtight space for receiving and cooling air. That is, casing 4 is preferably substantially airtight except for openings 4A and 4B (shown in
Coil brace 8 is connected to air seal 28 and helps support coil 6 when coil 6 is in its horizontal orientation, as shown in
In the embodiment shown in
As discussed in the Background section, if the temperature of coil 6 surface is lower than the dew point of the air moving across coil 6, water vapor condenses on coil 6. If coil 6 is horizontally oriented, condensation from coil 6 drips into condensate pan 14, and drains out of condensate pan 14 through drain holes 15, which are typically located at the bottom of condensate pan 14. If coil 6 is vertically oriented, condensate pan 16 collects the condensed water from coil 6, and drains the condensation through drain holes 17, which are typically located at the bottom of condensate pan 16.
Because evaporator assembly 2 includes horizontal condensate pan 14 and vertical condensate pan 16, evaporator assembly 2 is configured for applications involving a horizontal or vertical orientation of coil 6. See the above cross-referenced applications relating to the features of a vertically-oriented evaporator assembly.
Horizontal and vertical condensate pans 14 and 16 are typically formed of a plastic, such as polyester, but may also be formed of any material that may be casted, such as metal (e.g., aluminum). Horizontal condensate pan 14 slides into casing 4 and is secured in position by pan supports 46. Tabs 46A of pan supports 46 define a space for condensate pan 14 to slide into. Coil 6 is positioned above horizontal condensate pan 14 so that condensation flows from coil 6 into horizontal condensate pan 14. Air splitter 44 and splash guards 45A and 45B guide condensation from coil 6 into horizontal condensate pan 14. Air splitter 44 and splash guards 45A and 45B are described in further detail in reference to
Condensation that accumulates in horizontal condensate pan 14 eventually drains out of horizontal condensate pan 14 through drain holes 15. Gasket 52A is positioned around drain holes 15 prior to positioning first cover 18 over drain holes 15 in order to help provide a substantially airtight seal between drain holes 15 and first cover 18. First cover 18 includes opening 53A, which corresponds to and is configured to fit over drain holes 15 and gasket 52A. The substantially airtight seal helps prevent air from escaping from casing 4, and thereby increases the efficiency of evaporator assembly 2. Caps 56A may be positioned over one or more drain holes 15, such as when evaporator assembly 2 is used in an application in which coil 6 is vertically oriented.
Vertical condensate pan 16 slides into casing 4 and is supported, at least in part, by flange 48, which is formed by protruding sheet metal on three-sides of casing 4 and top surface 39A of front deck 39. Specifically, bottom surface 16A of condensate pan 16 rests on flange 48 and top surface 39A of front deck 39. Condensate pan 16 has an open center portion; and thus, air is able to pass through openings 4A and 4B, when evaporator assembly 2 is in either a horizontal or vertical configuration.
If coil 6 were oriented vertically, condensation that accumulates in vertical condensate pan 16 eventually drains out of vertical condensate pan 16 through drain holes 17. Gasket 52B is positioned around drain holes 17 prior to positioning first cover 18 over drain holes 17 in order to help provide a substantially airtight seal between drain holes 17 and first cover 18. First cover 18 includes opening 53B, which corresponds to and is configured to fit over drain holes 17 and gasket 52B. The airtight seal helps prevent air from escaping from casing 4, and thereby increases the efficiency of evaporator assembly 2. Cap 56B may be positioned over one or more drain holes 17.
Piping system 62 fluidically connects piping 30A of first slab 6A and piping 30B of second slab 6B. Refrigerant flows through piping 30A and 30B, and is recirculated from and to a compressor through inlet and outlet tubes 20 and 22, respectively. Specifically, refrigerant is introduced into piping 30A and 30B through inlet 20 and exits piping 30A and 30B through outlet 22. As known in the art, refrigerant outlet 22 includes rubber plug 64, and refrigerant inlet 20 includes strainer 66 and rubber plug 68. Inlet 20 protrudes through opening 70 in first cover 18 and outlet 22 protrudes through opening 72 in first cover 18. By protruding through first cover 18 and out of casing 4, inlet 20 and outlet 22 may be connected to refrigerant lines that are fed from and to the compressor, respectively. Gasket 74 is positioned around inlet 20 in order to provide a substantially airtight seal around opening 70. Similarly, gasket 76 is positioned around outlet 22.
First cover 18 is attached to casing 4 with screws 78. However, in alternate embodiments, other means of attachment are used, such as welding, an adhesive or rivets. Further covering a front face of evaporator assembly 2 is access cover 38, which is abutted with first cover 18. Again, in order to help increase the efficiency of evaporator assembly 2, it is preferred that joint 81 between first cover 18 and access cover 38 is substantially airtight. A substantially airtight connection may be formed by, for example, placing a gasket at joint 81.
Access cover 38 is attached to casing 4 with screws 82. However, in alternate embodiments, any means of removably attaching access cover 38 to casing 4 are used. Access cover 38 is preferably removably attached in order to provide access to coil 6, condensate pan 16, and other components inside casing 4 for maintenance purposes. One or more labels 84, such as warning labels, may be placed on first cover 18 and/or access cover 38.
As air is passing over coil 6, condensation forms on first slab 6A and second slab 6B. When coil 6 is oriented horizontally, it is difficult to drain the condensation to condensate pan 14 located below second slab 6B. To overcome this obstacle, splitter 44 is inserted between first slab 6A and second slab 6B, and is configured to catch the condensation that forms on first slab 6A and direct it to condensate pan 14 to prevent the condensation from being blown-off by air passing over coil 6. As explained in more detail below, once the condensation is caught in splitter 44, the condensation then flows to ends 44A and 44B, and through second coil slab 6B, onto splash guards 45A and 45B (not shown in
Although splash guard 45B is not shown in
Air seal 28 is used to position splitter 44 and splash guards 45A and 45B on coil 6. Air seal 28 also functions to prevent condensation that forms on coil 6 from being blown-off into the air stream passing either from right to left, or left to right across coil 6. Air seal 28 includes top portion 98 and bottom portion 100. Air seal 28 is configured such that top portion 98 is fixed across back face 102A of first slab 6A, and bottom portion 100 is fixed across back face 102B of second slab 6B. Top member 104 of splitter 44 is fixed between top portion 98 of air seal 28 and back face 102A of first slab 6A. As such, fold 106 of splitter 44 is positioned at junction 108 (see
Splash guard 45A includes top portion 110 and guard portion 112 and is configured to be attachable to coil 6. Guard portion 112 tapers inward towards end 118. Top portion 110 of splash guard 45A is fixed to bottom portion 100 of air seal 28, and guard portion 112 is configured to rest under second slab 6B. Splash guard 45A will be discussed in more detail below in reference to
It is recognized that air seal 28, splitter 44 and splash guards 45A and 45B may be configured and attached to one another in alternative manners and still be within the scope of the present invention. In a preferred embodiment, air seal 28, splitter 44 and splash guards 45A and 45B are each formed out of sheet metal. However, it is recognized that other materials may be substituted and are within the scope of the invention.
Evaporator assembly 2 is configured such that tube sheets 29A and 29B both include tabs (not shown) that are configured to be received into slots (not shown) on top portion 98 and bottom portion 100 of air seal 28. As shown in
In
In a preferred embodiment of splash guard 45A shown in
As shown in
Splash guard 45B, shown in
It is beneficial to use the same splash guard for opposing sides of the bottom coil slab to avoid the extra costs associated with having to manufacture two oppositely configured splash guards. However, in an alternative embodiment, splash guard 45B is a mirror image of splash guard 45A and is configured to coil 6 in the same manner as described above under
When air is passing over coil 6, there is a constant draining of water into splitter 44. As the water or condensation builds up within splitter 44, subsequent condensation that is drained into splitter 44 forces the water to flow away from the center of splitter 44 and towards either end 44A or 44B (see
Because splash guard 45A and second slab 6B are configured at an angle, once the condensation drops onto splash guard 45A, the condensation is directed down splash guard 45A to end 118 of guard 45A, as indicated by arrows 160C. Wire 90A is connected at one end to end 118 of guard 45A and at another end to protrusion 92A of condensate pan 14. Wire 90A is used to prevent or minimize splashing of water as the condensate travels from end 118 of splash guard 45A and into condensate pan 14, as indicated by arrows 160D.
Similar to
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.
Claims
1. A splash guard configured to be attachable to a bottom coil slab of a horizontally oriented A-frame evaporator coil for catching and directing a condensate to a condensate pan, the splash guard comprising:
- a top member configured to be attachable to a back end of the bottom coil slab;
- a guard member configured to be attachable to a side of the bottom coil slab, the guard member comprising: a bottom portion having a first end and a second end, wherein the bottom portion is connected to the top member at the first end of the bottom portion; a first side wall extending from the bottom portion; and a second side wall extending from the bottom portion.
2. The splash guard of claim 1 wherein the first side wall includes a slit configured to engage with a tube sheet attached to the bottom coil slab.
3. The splash guard of claim 1 wherein the first side wall includes a tab configured to be received in a notch on a tube sheet attached to the bottom coil slab.
4. The splash guard of claim 1 wherein the guard member includes an extension at a second end of the bottom portion, wherein the extension is configured to be attachable to a wire.
5. The splash guard of claim 1 wherein the top member includes at least one slot configured to receive a tab formed on a tube sheet attached to the bottom coil slab.
6. The splash guard of claim 5 wherein the splash guard is configured to be attachable to a two-row coil slab or a three-row coil slab.
7. The splash guard of claim 5 wherein the top member is configured to attach to a bottom portion of an air seal attached across a back end of a top coil slab and the back end of the bottom coil slab.
8. The splash guard of claim 7 wherein the at least one slot on the top member is configured to align with a slot on the bottom portion of the air seal, and the tab formed on the tube sheet is configured to pass through both the slot on the bottom portion of the air seal and the slot on the top member to secure the splash guard to the evaporator coil.
9. A system for disposing of a condensate formed on an evaporator coil, the system comprising:
- a multi-poise evaporator coil configurable horizontally, the evaporator coil comprising a top coil slab and a bottom coil slab;
- a condensate pan located under the bottom coil slab; and
- a splash guard attached to a side of the bottom coil slab for catching the condensate formed on the top coil slab and directing the condensate to the condensate pan.
10. The system of claim 9 further comprising a splitter positioned between the top coil slab and the bottom coil slab for catching the condensate formed on the top coil slab and directing the condensate to a first end or a second end of the splitter, and then through the bottom coil slab onto the splash guard.
11. The system of claim 9 further comprising an air seal having a top portion and a bottom portion, wherein the top portion is configured to attach across an end of the top coil slab, and the bottom portion is configured to attach across an end of the bottom coil slab.
12. The system of claim 11 further comprising:
- a first gasket located between the top portion of the air seal and the end of the top coil slab; and
- a second gasket located between the bottom portion of the air seal and the end of the bottom coil slab.
13. The system of claim 9 further comprising:
- a wire having a first end coupled to the splash guard and a second end coupled to the condensate pan.
14. The system of claim 9 further comprising:
- a second splash guard positioned on a second side of the bottom coil slab.
15. The system of claim 14 further comprising:
- a second wire having a first end coupled to the second splash guard and a second end coupled to the condensate pan.
16. The system of claim 9 wherein the splash guard comprises:
- a top member attached to a back end of the bottom coil slab;
- a bottom member having a first end and a second end, wherein the bottom member is connected to the top member at the first end;
- a first side wall extending from the bottom member, the first side wall attached to a tube sheet on the bottom coil slab; and
- a second side wall extending from the bottom member.
17. The system of claim 16 wherein the first side wall includes a slit configured to attach the first side wall to the tube sheet of the bottom coil slab.
18. The system of claim 16 wherein the first side wall includes a tab configured to be received into a notch on the tube sheet of the bottom coil slab.
19. The system of claim 16 wherein the top member is attached to a bottom portion of an air seal.
20. The system of claim 19 wherein the top member includes a slot configured to align with a slot on the bottom portion of the air seal, and a tab on the tube sheet of the bottom coil slab is configured to be received through both the slot on the bottom portion of the air seal and the slot on the top member of the splash guard.
Type: Application
Filed: Jan 20, 2006
Publication Date: Jul 26, 2007
Applicant: United Technologies Corporation (Hartford, CT)
Inventor: Arturo Rios (Avon, IN)
Application Number: 11/336,651
International Classification: F25D 21/14 (20060101);