ARRANGEMENT FOR HEAT EXCHANGER

Info

Publication number: 20230228496
Type: Application
Filed: Jan 19, 2023
Publication Date: Jul 20, 2023
Inventors: Amit R. Chothave (Pune), Karan Garg (Jagadhri), Anthony J. Reardon (Norman, OK)
Application Number: 18/099,189

Abstract

A heating, ventilation, and air conditioning (HVAC) system includes a housing and a heat exchanger disposed within the housing. The heat exchanger includes a plurality of tubes where the plurality of tubes extends from a first end to a second end of the heat exchanger. The heat exchanger also includes a plurality of fins coupled to and extending between the plurality of tubes. The heat exchanger further includes a first end sheet disposed at the first end of the heat exchanger and a second end sheet disposed at the second end of the heat exchanger. The heat exchanger also includes a plurality of intermediate sheets disposed between the first end sheet and the second end sheet, where the plurality of tubes extends through each intermediate sheet of the plurality of intermediate sheets, and each intermediate sheet of the plurality of intermediate sheets is coupled to the housing.

Description

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority from and the benefit of U.S. Provisional Application No. 63/300,983, entitled “ARRANGEMENT FOR A HEAT EXCHANGER COIL,” filed Jan. 19, 2022, which is hereby incorporated by reference in its entirety for all purposes.

BACKGROUND

This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure, which are described below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.

HVAC systems are utilized in residential, commercial, and industrial environments to control environmental properties, such as temperature and humidity, for occupants of the respective environments. An HVAC system may control environmental properties by controlling a supply air flow delivered to the environment. For example, the HVAC system may place the supply air flow in a heat exchange relationship with a working fluid of a vapor compression circuit to condition the supply air flow. Typically, vapor compression circuits include one or more heat exchangers configured to place the working fluid in a heat exchange relationship with one or more additional fluids, such as water or air. In some instances, the heat exchangers of HVAC systems may be disposed within a housing of the HVAC system, and the heat exchangers may be mounted within the housing. For example, ends of the heat exchanger may be mounted to the housing. In some HVAC systems, the heat exchanger may be have a bent or curved configuration. Unfortunately, heat exchangers may be inadequately mounted within housing of existing HVAC systems. For example, the heat exchanger may be susceptible to shifting and/or deformation within the housing, such as during operation, during transportation, and/or during maintenance of the HVAC system.

SUMMARY

A summary of certain embodiments disclosed herein is set forth below. It should be understood that these aspects are presented merely to provide the reader with a brief summary of these certain embodiments and that these aspects are not intended to limit the scope of this disclosure. Indeed, this disclosure may encompass a variety of aspects that may not be set forth below.

The present disclosure relates to a heating, ventilation, and air conditioning (HVAC) system which includes a housing and a heat exchanger disposed within the housing. The heat exchanger includes a plurality of tubes configured to direct a working fluid therethrough, where the plurality of tubes extends from a first end to a second end of the heat exchanger. The heat exchanger also includes a plurality of fins coupled to and extending between the plurality of tubes. The heat exchanger further includes a first end sheet disposed at the first end of the heat exchanger, where the plurality of tubes extends through the first end sheet, and a second end sheet disposed at the second end of the heat exchanger, where the plurality of tubes extends through the second end sheet. The heat exchanger also includes a plurality of intermediate sheets disposed between the first end sheet and the second end sheet, where the plurality of tubes extends through each intermediate sheet of the plurality of intermediate sheets, and each intermediate sheet of the plurality of intermediate sheets is coupled to the housing.

The present disclosure also relates to a heat exchanger for a heating, ventilation, and air conditioning (HVAC) system which includes a plurality of heat exchange tubes configured to direct a working fluid therethrough, where the plurality of heat exchange tubes extends from a first end to a second end of the heat exchanger, and the plurality of heat exchange tubes is curved between the first end and the second end. The heat exchanger also includes a plurality of fins coupled to and extending between the plurality of heat exchanger tubes. The heat exchanger further includes a first end sheet disposed at the first end of the heat exchanger, where the plurality of heat exchange tubes extends through the first end sheet, and a second end sheet disposed at the second end of the heat exchanger, where the plurality of heat exchange tubes extends through the second end sheet. The heat exchanger also includes a plurality of intermediate sheets disposed between the first end sheet and the second end sheet, where the plurality of heat exchange tubes extends through each intermediate sheet of the plurality of intermediate sheets, and each intermediate sheet of the plurality of intermediate sheets is configured to mount to a housing of the HVAC system.

The present disclosure further relates to a heating, ventilation, and air conditioning (HVAC) system which includes a housing. The housing includes a frame, a base panel, and a top panel. The HVAC system also includes a heat exchanger disposed within the housing, where the heat exchanger includes a plurality of tubes configured to direct a working fluid therethrough, where the plurality of tubes extends from a first end to a second end of the heat exchanger, and the plurality of tubes defines a curved profile of the heat exchanger between the first end and the second end. The heat exchanger also includes a plurality of fins coupled to and extending between the plurality of tubes. The heat exchanger further includes a plurality of intermediate sheets disposed between the first end and the second end, wherein the plurality of tubes extends through each intermediate sheet of the plurality of intermediate sheets, each intermediate sheet of the plurality of intermediate sheets is secured to the housing, and the plurality of intermediate sheets is spaced apart from one another between the first end and the second end.

BRIEF DESCRIPTION OF THE DRAWINGS

Various aspects of this disclosure may be better understood upon reading the following detailed description and upon reference to the drawings in which:

FIG. 1 is a perspective view of an embodiment of a building incorporating a heating, ventilation, and/or air conditioning (HVAC) system in a commercial setting, in accordance with an aspect of the present disclosure;

FIG. 2 is a perspective view of an embodiment of a packaged HVAC unit, in accordance with an aspect of the present disclosure;

FIG. 3 is a perspective view of an embodiment of a split, residential HVAC system, in accordance with an aspect of the present disclosure;

FIG. 4 is a schematic diagram of an embodiment of a vapor compression system used in an HVAC system, in accordance with an aspect of the present disclosure;

FIG. 5 is a perspective view of an embodiment of an HVAC system with a heat exchanger, in accordance with an aspect of the present disclosure;

FIG. 6 is a schematic side view of an embodiment of an HVAC system with a heat exchanger, in accordance with an aspect of the present disclosure;

FIG. 7 is a schematic top view of an embodiment of an HVAC system having a heat exchanger, in accordance with an aspect of the present disclosure;

FIG. 8 is a schematic axial view of an embodiment of a heat exchanger, in accordance with an aspect of the present disclosure;

FIG. 9 is a perspective view of an embodiment of a bracket of a mounting bracket assembly for a heat exchanger of an HVAC system, in accordance with an aspect of the present disclosure;

FIG. 10 is a perspective view of an embodiment of a second bracket of a mounting bracket assembly for a heat exchanger of an HVAC system, in accordance with an aspect of the present disclosure;

FIG. 11 is a perspective view of an embodiment of a mounting bracket assembly for a heat exchanger of an HVAC system, illustrating a first bracket and a second bracket in an assembled configuration, in accordance with an aspect of the present disclosure;

FIG. 12 is a perspective view of an embodiment of a clamping assembly with a mounting bracket assembly for a heat exchanger of an HVAC system, in accordance with an aspect of the present disclosure;

FIG. 13 is a schematic side view of an embodiment of a clamping assembly and a mounting bracket assembly for a heat exchanger of an HVAC system, in accordance with an aspect of the present disclosure;

FIG. 14 is a perspective view of an embodiment of a mounting bracket for a heat exchanger of an HVAC system, in accordance with an aspect of the present disclosure; and

FIG. 15 is a schematic side view of an embodiment of a clamping assembly with a mounting bracket for a heat exchanger of an HVAC system, in accordance with an aspect of the present disclosure.

DETAILED DESCRIPTION

One or more specific embodiments of the present disclosure will be described below. These described embodiments are examples of the presently disclosed techniques. Additionally, in an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

When introducing elements of various embodiments of the present disclosure, the articles “a,” “an,” and “the” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Additionally, it should be understood that references to “one embodiment” or “an embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.

As used herein, the terms “approximately,” “generally,” and “substantially,” and so forth, are intended to convey that the property value being described may be within a relatively small range of the property value, as those of ordinary skill would understand. For example, when a property value is described as being “approximately” equal to (or, for example, “substantially similar” to) a given value, this is intended to mean that the property value may be within +/−5%, within +/−4%, within +/−3%, within +/−2%, within +/−1%, or even closer, of the given value. Similarly, when a given feature is described as being “substantially parallel” to another feature, “generally perpendicular” to another feature, and so forth, this is intended to mean that the given feature is within +/−5%, within +/−4%, within +/−3%, within +/−2%, within +/−1%, or even closer, to having the described nature, such as being parallel to another feature, being perpendicular to another feature, and so forth. Further, it should be understood that mathematical terms, such as “planar,” “slope,” “perpendicular,” “parallel,” and so forth are intended to encompass features of surfaces or elements as understood to one of ordinary skill in the relevant art, and should not be rigidly interpreted as might be understood in the mathematical arts. For example, a “planar” surface is intended to encompass a surface that is machined, molded, or otherwise formed to be substantially flat or smooth (within related tolerances) using techniques and tools available to one of ordinary skill in the art. Similarly, a surface having a “slope” is intended to encompass a surface that is machined, molded, or otherwise formed to be oriented at an angle (e.g., incline) with respect to a point of reference using techniques and tools available to one of ordinary skill in the art.

As briefly discussed above, a heating, ventilation, and/or air conditioning (HVAC) system may be used to regulate environmental parameters (e.g., temperature, humidity) within a space to be conditioned, such as a building, home, storage space, or other suitable structure. For example, the HVAC system may include a vapor compression circuit configured to transfer thermal energy between a working fluid, such as a refrigerant, and a fluid to be conditioned, such as air. The vapor compression circuit includes heat exchangers, such as a condenser and an evaporator, which are fluidly coupled to one another via one or more conduits of a working fluid loop or circuit. A compressor of the vapor compression circuit may be used to circulate the working fluid through the conduits and other components of the vapor compression circuit (e.g., an expansion device, the heat exchangers) and, thus, enable the transfer of thermal energy between components of the vapor compression circuit (e.g., between the condenser and the evaporator) and one or more thermal loads (e.g., an environmental air flow, a supply air flow).

Additionally or alternatively, the HVAC system may include a heat pump (e.g., a heat pump system) having a first heat exchanger (e.g., a heating and/or cooling coil, an indoor coil, an evaporator) that may be fluidly coupled to the space to be conditioned, a second heat exchanger (e.g., a heating and/or cooling coil, an outdoor coil, a condenser) that may be positioned in or otherwise fluidly coupled to an ambient environment (e.g., the atmosphere), and a pump (e.g., a compressor) configured to circulate the working fluid (e.g., refrigerant) between the first and second heat exchangers to enable heat transfer between the thermal load and the ambient environment, for example. The heat pump may be operable in different modes to selectively provide cooling and heating to the space to be conditioned (e.g., a room, zone, or other region within a building) by adjusting a flow (e.g., a direction of flow) of the working fluid through the vapor compression circuit. For example, the heat pump may be a central HVAC system configured to generate and discharge a conditioned air flow to be distributed to a conditioned space or a plurality of conditioned spaces (e.g., rooms, zones) via an air distribution system, such as ductwork.

As mentioned above, the first heat exchanger, the second heat exchanger, or both may be disposed within a housing (e.g., a frame, walls, posts, plates) of the HVAC system. In some instances, the heat exchangers of the HVAC system may be mounted to the housing. Unfortunately, existing HVAC systems may include heat exchangers that are disposed within a housing but are not adequately secured or mounted within the housing. In such systems, the heat exchangers may be susceptible to undesired movement within the housing, such as during transportation and/or installation of the HVAC system. Undesired movement of the heat exchanger may result in warping and/or distortion of the heat exchanger, as well as undesired contact between the heat exchanger and other components of the HVAC system, which may cause wear and degradation of the heat exchanger. For example, undesired or unintended movement or positional adjustment of the heat exchanger may cause fins of the heat exchanger to contact or interfere with other components of the HVAC system. Such contact may alter a configuration of the fins and reduce efficient operation of the heat exchanger.

Accordingly, embodiments of the present disclosure are directed to heating, ventilation, and/or air conditioning (HVAC) systems with improved heat exchanger support. More particularly, embodiments of the present disclosure are directed to heat exchangers configured to mount to and/or within a housing with improved security and retention of a position of the heat exchanger within the housing. Thus, the heat exchangers may be mounted within the housing, and unintended movement of heat exchangers, such as during transportation and/or operation of the HVAC system, may be avoided. For example, heat exchangers having a bent or curved configuration may be mounted within the housing of the HVAC system and may be retained in a desired position within the housing during transportation of the HVAC system.

As will be appreciated, existing heat exchangers may be mounted within a housing of an HVAC system at a first end and at a second end of the heat exchanger. For example, a heat exchanger may have first and second end sheets configured to enable attachment of the heat exchanger to the housing of the HVAC system. However, mounting certain heat exchangers at the ends of the heat exchanger may not adequately retain the heat exchanger in a desired position. In some instances, a remainder of the heat exchanger (e.g., extending between the first and second ends) may be susceptible to undesired movement, deformation, and/or other positional adjustment within the housing. Accordingly, in addition to being configured to mount to a housing at first and second ends of the heat exchanger, heat exchangers incorporating the present techniques may also be configured to be mounted to the housing at one or more locations along the heat exchanger between the first and second ends. In other words, the first and second ends of the heat exchanger may be mounted to and/or within a housing, and intermediate locations of the heat exchanger between the first and second ends may also be mounted and/or within the housing.

For example, a heat exchanger incorporating the present techniques may include a plurality of intermediate sheets (e.g., mounting sheets) disposed between the first end and the second end of the heat exchanger. End sheets may also be disposed at the first end and the second end of the heat exchanger. Similar to the end sheets, the intermediate sheets may extend along a length or height of the heat exchanger. As discussed further below, the intermediate sheets may be fastened to the housing of the HVAC system to provide additional mounting points between the heat exchanger and the housing of the HVAC system. For example, each intermediate sheet may include one or more flanges that extend beyond a main body of the intermediate sheet, and the flanges may be secured to the housing (e.g., via fasteners, welds, brazes, adhesives). The end sheets at the first and second ends of the heat exchanger may also be secured to the housing. Thus, the heat exchanger may be retained in place within the housing at the first and second ends of the heat exchanger, as well as at multiple locations along the heat exchanger (e.g., between the first end and the second end). As a result, unintended movement of the heat exchanger may be restricted, limited, or avoided, and the heat exchanger may maintain a desired shape and position within the housing, such as during transportation or other movement of the HVAC system. In this way, undesired contact between the heat exchanger and other components of the HVAC system may be avoided, which may thereby reduce wear and degradation of the heat exchanger, extend a useful life of the heat exchanger, and improve operational efficiency of the heat exchanger.

Turning now to the drawings, FIG. 1 illustrates an embodiment of a heating, ventilation, and/or air conditioning (HVAC) system for environmental management that employs one or more HVAC units in accordance with the present disclosure. As used herein, an HVAC system includes any number of components configured to enable regulation of parameters related to climate characteristics, such as temperature, humidity, air flow, pressure, air quality, and so forth. For example, an “HVAC system” as used herein is defined as conventionally understood and as further described herein. Components or parts of an “HVAC system” may include, but are not limited to, all, some of, or individual parts such as a heat exchanger, a heater, an air flow control device, such as a fan, a sensor configured to detect a climate characteristic or operating parameter, a filter, a control device configured to regulate operation of an HVAC system component, a component configured to enable regulation of climate characteristics, or a combination thereof. An “HVAC system” is a system configured to provide such functions as heating, cooling, ventilation, dehumidification, pressurization, refrigeration, filtration, or any combination thereof. The embodiments described herein may be utilized in a variety of applications to control climate characteristics, such as residential, commercial, industrial, transportation, or other applications where climate control is desired.

In the illustrated embodiment, a building 10 is air conditioned by a system that includes an HVAC unit 12 in accordance with present embodiments. The building 10 may be a commercial structure or a residential structure. As shown, the HVAC unit 12 is disposed on the roof of the building 10; however, the HVAC unit 12 may be located in other equipment rooms or areas adjacent the building 10. The HVAC unit 12 may be a single package unit containing other equipment, such as a blower, integrated air handler, and/or auxiliary heating unit. In other embodiments, the HVAC unit 12 may be part of a split HVAC system, such as the system shown in FIG. 3, which includes an outdoor HVAC unit 58 and an indoor HVAC unit 56.

The HVAC unit 12 is an air cooled device that implements a refrigeration cycle to provide conditioned air to the building 10. Specifically, the HVAC unit 12 may include one or more heat exchangers across which an air flow is passed to condition the air flow before the air flow is supplied to the building. In the illustrated embodiment, the HVAC unit 12 is a rooftop unit (RTU) that conditions a supply air stream, such as environmental air and/or a return air flow from the building 10. After the HVAC unit 12 conditions the air, the air is supplied to the building 10 via ductwork 14 extending throughout the building 10 from the HVAC unit 12. For example, the ductwork 14 may extend to various individual floors or other sections of the building 10. In certain embodiments, the HVAC unit 12 may be a heat pump that provides both heating and cooling to the building with one refrigeration circuit configured to operate in different modes. In other embodiments, the HVAC unit 12 may include one or more refrigeration circuits for cooling an air stream and a furnace for heating the air stream.

A control device 16, one type of which may be a thermostat, may be used to designate the temperature of the conditioned air. The control device 16 also may be used to control the flow of air through the ductwork 14. For example, the control device 16 may be used to regulate operation of one or more components of the HVAC unit 12 or other components, such as dampers and fans, within the building 10 that may control flow of air through and/or from the ductwork 14. In some embodiments, other devices may be included in the system, such as pressure and/or temperature transducers or switches that sense the temperatures and pressures of the supply air, return air, and so forth. Moreover, the control device 16 may include computer systems that are integrated with or separate from other building control or monitoring systems, and even systems that are remote from the building 10.

FIG. 2 is a perspective view of an embodiment of the HVAC unit 12. In the illustrated embodiment, the HVAC unit 12 is a single package unit that may include one or more independent refrigeration circuits and components that are tested, charged, wired, piped, and ready for installation. The HVAC unit 12 may provide a variety of heating and/or cooling functions, such as cooling only, heating only, cooling with electric heat, cooling with dehumidification, cooling with gas heat, or cooling with a heat pump. As described above, the HVAC unit 12 may directly cool and/or heat an air stream provided to the building 10 to condition a space in the building 10.

As shown in the illustrated embodiment of FIG. 2, a cabinet 24 (e.g., a housing) encloses the HVAC unit 12 and provides structural support and protection to the internal components from environmental and other contaminants. In some embodiments, the cabinet 24 may be constructed of galvanized steel and insulated with aluminum foil faced insulation. Rails 26 may be joined to the bottom perimeter of the cabinet 24 and provide a foundation for the HVAC unit 12. In certain embodiments, the rails 26 may provide access for a forklift and/or overhead rigging to facilitate installation and/or removal of the HVAC unit 12. In some embodiments, the rails 26 may fit into “curbs” on the roof to enable the HVAC unit 12 to provide air to the ductwork 14 from the bottom of the HVAC unit 12 while blocking elements such as rain from leaking into the building 10.

The HVAC unit 12 includes heat exchangers 28 and 30 in fluid communication with one or more refrigeration circuits. Tubes within the heat exchangers 28 and 30 may circulate refrigerant, such as R-410A, through the heat exchangers 28 and 30. The tubes may be of various types, such as multichannel tubes, conventional copper or aluminum tubing, and so forth. Together, the heat exchangers 28 and 30 may implement a thermal cycle in which the refrigerant undergoes phase changes and/or temperature changes as it flows through the heat exchangers 28 and 30 to produce heated and/or cooled air. For example, the heat exchanger 28 may function as a condenser where heat is released from the refrigerant to ambient air, and the heat exchanger 30 may function as an evaporator where the refrigerant absorbs heat to cool an air stream. In other embodiments, the HVAC unit 12 may operate in a heat pump mode where the roles of the heat exchangers 28 and 30 may be reversed. That is, the heat exchanger 28 may function as an evaporator and the heat exchanger 30 may function as a condenser. In further embodiments, the HVAC unit 12 may include a furnace for heating the air stream that is supplied to the building 10. While the illustrated embodiment of FIG. 2 shows the HVAC unit 12 having two of the heat exchangers 28 and 30, in other embodiments, the HVAC unit 12 may include one heat exchanger or more than two heat exchangers.

The heat exchanger 30 is located within a compartment 31 that separates the heat exchanger 30 from the heat exchanger 28. Fans 32 draw air from the environment through the heat exchanger 28. Air may be heated and/or cooled as the air flows through the heat exchanger 28 before being released back to the environment surrounding the HVAC unit 12. A blower assembly 34, powered by a motor 36, draws air through the heat exchanger 30 to heat or cool the air. The heated or cooled air may be directed to the building 10 by the ductwork 14, which may be connected to the HVAC unit 12. Before flowing through the heat exchanger 30, the conditioned air flows through one or more filters 38 that may remove particulates and contaminants from the air. In certain embodiments, the filters 38 may be disposed on the air intake side of the heat exchanger 30 to prevent contaminants from contacting the heat exchanger 30.

The HVAC unit 12 also may include other equipment for implementing the thermal cycle. Compressors 42 increase the pressure and temperature of the refrigerant before the refrigerant enters the heat exchanger 28. The compressors 42 may be any suitable type of compressors, such as scroll compressors, rotary compressors, screw compressors, or reciprocating compressors. In some embodiments, the compressors 42 may include a pair of hermetic direct drive compressors arranged in a dual stage configuration 44. However, in other embodiments, any number of the compressors 42 may be provided to achieve various stages of heating and/or cooling. As may be appreciated, additional equipment and devices may be included in the HVAC unit 12, such as a solid-core filter drier, a drain pan, a disconnect switch, an economizer, pressure switches, phase monitors, and humidity sensors, among other components.

The HVAC unit 12 may receive power through a terminal block 46. For example, a high voltage power source may be connected to the terminal block 46 to power the equipment. The operation of the HVAC unit 12 may be governed or regulated by a control board 48. The control board 48 may include control circuitry connected to a thermostat, sensors, and alarms. One or more of these components may be referred to herein separately or collectively as the control device 16. The control circuitry may be configured to control operation of the equipment, provide alarms, and monitor safety switches. Wiring 49 may connect the control board 48 and the terminal block 46 to the equipment of the HVAC unit 12.

FIG. 3 is a perspective view of an embodiment of a residential heating and cooling system 50, in accordance with present techniques. The residential heating and cooling system 50 may provide heated and cooled air to a residential structure, as well as provide outside air for ventilation and provide improved indoor air quality (IAQ) through devices such as ultraviolet lights and air filters. In the illustrated embodiment, the residential heating and cooling system 50 is a split HVAC system. In general, a residence 52 conditioned by a split HVAC system may include refrigerant conduits 54 that operatively couple an indoor unit 56 to an outdoor unit 58. The indoor unit 56 may be positioned in a utility room, an attic, a basement, and so forth. The outdoor unit 58 is typically situated adjacent to a side of residence 52 and is covered by a shroud to protect the system components and to prevent leaves and other debris or contaminants from entering the unit. The refrigerant conduits 54 transfer refrigerant between the indoor unit 56 and the outdoor unit 58, typically transferring primarily liquid refrigerant in one direction and primarily vaporized refrigerant in an opposite direction.

When the system shown in FIG. 3 is operating as an air conditioner, a heat exchanger 60 in the outdoor unit 58 serves as a condenser for re-condensing vaporized refrigerant flowing from the indoor unit 56 to the outdoor unit 58 via one of the refrigerant conduits 54. In these applications, a heat exchanger 62 of the indoor unit functions as an evaporator. Specifically, the heat exchanger 62 receives liquid refrigerant, which may be expanded by an expansion device, and evaporates the refrigerant before returning it to the outdoor unit 58.

The outdoor unit 58 draws environmental air through the heat exchanger 60 using a fan 64 and expels the air above the outdoor unit 58. When operating as an air conditioner, the air is heated by the heat exchanger 60 within the outdoor unit 58 and exits the unit at a temperature higher than it entered. The indoor unit 56 includes a blower or fan 66 that directs air through or across the indoor heat exchanger 62, where the air is cooled when the system is operating in air conditioning mode. Thereafter, the air is passed through ductwork 68 that directs the air to the residence 52. The overall system operates to maintain a desired temperature as set by a system controller. When the temperature sensed inside the residence 52 is higher than the set point on the thermostat, or the set point plus a small amount, the residential heating and cooling system 50 may become operative to refrigerate additional air for circulation through the residence 52. When the temperature reaches the set point, or the set point minus a small amount, the residential heating and cooling system 50 may stop the refrigeration cycle temporarily. The outdoor unit 58 includes a reheat system in accordance with present embodiments.

The residential heating and cooling system 50 may also operate as a heat pump. When operating as a heat pump, the roles of heat exchangers 60 and 62 are reversed. That is, the heat exchanger 60 of the outdoor unit 58 will serve as an evaporator to evaporate refrigerant and thereby cool air entering the outdoor unit 58 as the air passes over the outdoor heat exchanger 60. The indoor heat exchanger 62 will receive a stream of air blown over it and will heat the air by condensing the refrigerant.

In some embodiments, the indoor unit 56 may include a furnace system 70. For example, the indoor unit 56 may include the furnace system 70 when the residential heating and cooling system 50 is not configured to operate as a heat pump. The furnace system 70 may include a burner assembly and heat exchanger, among other components, inside the indoor unit 56. Fuel is provided to the burner assembly of the furnace 70 where it is mixed with air and combusted to form combustion products. The combustion products may pass through tubes or piping in a heat exchanger, separate from heat exchanger 62, such that air directed by the blower 66 passes over the tubes or pipes and extracts heat from the combustion products. The heated air may then be routed from the furnace system 70 to the ductwork 68 for heating the residence 52.

FIG. 4 is an embodiment of a vapor compression system 72 that can be used in any of the systems described above. The vapor compression system 72 may circulate a refrigerant through a circuit starting with a compressor 74. The circuit may also include a condenser 76, an expansion valve(s) or device(s) 78, and an evaporator 80. The vapor compression system 72 may further include a control panel 82 that has an analog to digital (A/D) converter 84, a microprocessor 86, a non-volatile memory 88, and/or an interface board 90. The control panel 82 and its components may function to regulate operation of the vapor compression system 72 based on feedback from an operator, from sensors of the vapor compression system 72 that detect operating conditions, and so forth.

In some embodiments, the vapor compression system 72 may use one or more of a variable speed drive (VSDs) 92, a motor 94, the compressor 74, the condenser 76, the expansion valve or device 78, and/or the evaporator 80. The motor 94 may drive the compressor 74 and may be powered by the variable speed drive (VSD) 92. The VSD 92 receives alternating current (AC) power having a particular fixed line voltage and fixed line frequency from an AC power source, and provides power having a variable voltage and frequency to the motor 94. In other embodiments, the motor 94 may be powered directly from an AC or direct current (DC) power source. The motor 94 may include any type of electric motor that can be powered by a VSD or directly from an AC or DC power source, such as a switched reluctance motor, an induction motor, an electronically commutated permanent magnet motor, or another suitable motor.

The compressor 74 compresses a refrigerant vapor and delivers the vapor to the condenser 76 through a discharge passage. In some embodiments, the compressor 74 may be a centrifugal compressor. The refrigerant vapor delivered by the compressor 74 to the condenser 76 may transfer heat to a fluid passing across the condenser 76, such as ambient or environmental air 96. The refrigerant vapor may condense to a refrigerant liquid in the condenser 76 as a result of thermal heat transfer with the environmental air 96. The liquid refrigerant from the condenser 76 may flow through the expansion device 78 to the evaporator 80.

The liquid refrigerant delivered to the evaporator 80 may absorb heat from another air stream, such as a supply air stream 98 provided to the building 10 or the residence 52. For example, the supply air stream 98 may include ambient or environmental air, return air from a building, or a combination of the two. The liquid refrigerant in the evaporator 80 may undergo a phase change from the liquid refrigerant to a refrigerant vapor. In this manner, the evaporator 80 may reduce the temperature of the supply air stream 98 via thermal heat transfer with the refrigerant. Thereafter, the vapor refrigerant exits the evaporator 80 and returns to the compressor 74 by a suction line to complete the cycle.

In some embodiments, the vapor compression system 72 may further include a reheat coil. In the illustrated embodiment, the reheat coil is represented as part of the evaporator 80. The reheat coil is positioned downstream of the evaporator heat exchanger relative to the supply air stream 98 and may reheat the supply air stream 98 when the supply air stream 98 is overcooled to remove humidity from the supply air stream 98 before the supply air stream 98 is directed to the building 10 or the residence 52.

It should be appreciated that any of the features described herein may be incorporated with the HVAC unit 12, the residential heating and cooling system 50, or other HVAC systems. Additionally, while the features disclosed herein are described in the context of embodiments that directly heat and cool a supply air stream provided to a building or other load, embodiments of the present disclosure may be applicable to other HVAC systems as well. For example, the features described herein may be applied to mechanical cooling systems, free cooling systems, chiller systems, or other heat pump or refrigeration applications.

As noted above, HVAC systems may include one or more heat exchangers disposed within a housing of the HVAC system. For example, the heat exchanger may be mounted to the housing of the HVAC system. Unfortunately, conventional heat exchangers may be mounted inadequately within housings of HVAC systems and may be susceptible to undesired movement or deformation, such as during transportation of the HVAC system. Accordingly, present embodiments are directed to systems that enable improved mounting of a heat exchanger within an HVAC system. In particular, embodiments include a heat exchanger configured to mount within a housing of an HVAC system at multiple locations along the heat exchanger, including at a first end of the heat exchanger, at a second end (e.g., opposite the first end) of the heat exchanger, and at one or more intermediate locations (e.g., between the first end and the second end) of the heat exchanger. To this end, a heat exchanger may include a plurality of intermediate sheets disposed along the heat exchanger between a first end and a second end of the heat exchanger. The heat exchanger may also include end sheets disposed at the first and second ends of the heat exchanger. The heat exchanger may be mounted to and/or within the housing via the end sheets and the plurality of intermediate sheets, such that the heat exchanger may be mounted to the housing at multiple locations along a length or contour of the heat exchanger and between the ends of the heat exchanger.

With the foregoing in mind, FIG. 5 is a perspective view of a portion of an embodiment of an HVAC system 100, such as the HVAC unit 12 of FIG. 1, the split, residential HVAC system 50 of FIG. 3, and/or the vapor compression system 72 of FIG. 4. Indeed, it should be noted that the HVAC system 100 may include embodiments and/or components of the HVAC unit 12, embodiments or components of the split, residential HVAC system 50, a rooftop unit (RTU), an air handler or air handling unit, an outdoor unit, and indoor unit, or any other suitable HVAC system. To facilitate discussion, the HVAC system 100 and its components may be described with reference to a longitudinal axis 106, a vertical axis 104, which is oriented relative to a direction of gravity, and a lateral axis 102.

In the illustrated embodiment, the HVAC system 100 includes a housing 108 and a heat exchanger 110 disposed within the housing 108. The heat exchanger 110 may be a condenser or heat exchanger coil configured to place a working fluid circulated through the heat exchanger 110 in a heat exchange relationship an air flow (e.g., ambient air) directed across the heat exchanger 110. In the illustrated embodiment, the heat exchanger 110 includes a plurality of tubes 112 (e.g., heat exchanger tubes) configured to direct a working fluid (e.g., refrigerant) throughout the heat exchanger 110. The heat exchanger 110 also includes a plurality of fins 114 coupled to and disposed along the plurality of tubes 112 to further enable heat transfer between the air flow directed across the heat exchanger 110 and the working fluid directed throughout the plurality of tubes 112. For example, the plurality of fins 114 may extend between (e.g., from and to) adjacent tubes 112 of the plurality of tubes 112. As will be appreciated, the plurality of fins 114 may increase the surface area of the heat exchanger 110 exposed to the air flow to improve heat transfer between the air flow and the working fluid. In some embodiments, the plurality of fins 114 is separated into fin sheets extending from an external side 115 (e.g., outward facing side, external boundary, outer perimeter) of the heat exchanger 110 to an internal side 116 (e.g., inward facing side, internal boundary, inner perimeter) of the heat exchanger 110. As such, the plurality of fins 114 may extend at least partially in or along a vertical direction (e.g., along the vertical axis 104) between a top edge 117 of the heat exchanger 110 and a bottom edge 118 of the heat exchanger 110.

In some embodiments, the heat exchanger 110 may at least partially define or include a curved or bent configuration. For example, the heat exchanger 110 (e.g., the plurality of tubes 112) may be bend or curve along at least a portion of the heat exchanger 110 (e.g., along a portion of a length of the heat exchanger 110). In the illustrated embodiment, the heat exchanger 110 includes or defines a first bend 120 (e.g., first curved portion) and a second bend 122 (e.g., second curved portion) to define a curved or bent configuration of the heat exchanger 110. For example, the curved configuration may generally define a U-shape, a J-shape, a C-shape, or any other shape having a bent or curved contour, profile, or geometry. Accordingly, the plurality of tubes 112 may also include one or more bends along respective lengths of each tube 112 to define the curved geometry or configuration of the heat exchanger 110.

In certain applications, a curved profile or geometry of the heat exchanger 110 may be selected to achieve a desired operation of the HVAC system 100. For example, the heat exchanger 110 may have a U-shaped configuration to enable flow of air across the heat exchanger 110 via a plurality of sides of the housing 108 (e.g., three sides). That is, air flow may enter the housing 108 via a plurality of sides and may be directed across the heat exchanger 110 to enable transfer of thermal energy between the air flow and the working fluid directed through the plurality of tubes 112. Accordingly, the curved configuration of the heat exchanger 110 may be mounted within the housing 108 in a desired arrangement to achieve desired air flow across the heat exchanger 110.

The plurality of tubes 112 extends from a first end 124 (e.g., distal end) of the heat exchanger 110 to a second end 126 (e.g., distal end) of the heat exchanger 110. As will be appreciated, the plurality of tubes 112 may extend to and from the first end 124 and second end 126 in a coiled, circuitous, and/or serpentine arrangement. The heat exchanger 110 also includes a first end sheet 128 disposed at (e.g., extending along) the first end 124 of the heat exchanger 110 and a second end sheet 130 disposed at (e.g., extending along) the second end 126 of the heat exchanger 110. Each end sheet 128, 130 may include an end sheet body 132 and one or more end sheet flanges 134 extending from the end sheet body 132. In some embodiments, the plurality of tubes 112 may extend the end sheet body 132 of each end sheet 128, 130. The heat exchanger 110 may secured to the housing 108 via the one or more end sheet flanges 134 of the end sheets 128, 130.

The housing 108 may include a frame 136 (e.g., support structure), a base panel 138, and a top panel 140 (shown in outline for illustrative legibility). The frame 136 may include a top rail 142, a base rail 144, and a plurality of support members 146 (e.g., upright supports, vertical supports) oriented along the vertical axis 104 and connecting the top rail 142 to the base rail 144. The top panel 140 may be disposed along the top rail 142 and may be secured to the top rail 142 via any suitable mechanism or method, such as mechanical fasteners, adhesives, welds, brazes, or any combination thereof. The top panel 140 may include a top panel flange 148, which may extend cross-wise from the top panel 140 (e.g., along vertical axis 104). For example, the top panel flange 148 may extend laterally outward relative to the top rail 142 and may extend along lateral sides of the top rail 142. In this way, the top panel 140 may be more easily secured to the top rail 142, such as via fasteners extending through the top panel flange 148 and the top rail 142. Similarly, the base panel 138 may be disposed along the base rail 144 and secured to the base rail 144 via any suitable mechanism, such as those described above.

The heat exchanger 110 may also include a plurality of intermediate sheets 150 (e.g., mounting panels, reinforcing sheets, etc.) disposed along the heat exchanger 110. Specifically, the intermediate sheets 150 may be arrayed or positioned along a length of the heat exchanger 110 (e.g., along lengths of the tubes 112) between the first end 124 and the second end 126 (e.g., between the end sheets 128, 130). As described in further detail below, the intermediate sheets 150 are also configured to enable mounting or coupling (e.g., securement) of the heat exchanger 110 to the housing 108. In this way, a position and/or arrangement of the heat exchanger 110 within the housing 108 may be more desirable retained and/or maintained, such as during transportation of the HVAC system 100. The intermediate sheets 150 may be manufactured from a material (e.g., steel, sheet metal) that is different from that of the heat exchanger 110. More specifically, the intermediate sheets 150 may be formed from a material that is different than that utilized to form the tubes 112 and/or the fins 114.

The plurality of intermediate sheets 150 may extend along the heat exchanger 110 from the top edge 117 to the bottom edge 118 and from the external side 115 to the internal side 116. Each intermediate sheet 150 of the plurality of intermediate sheets 150 includes a main body 152 and a flange 154. As mentioned above, each intermediate sheet 150 is also disposed between the first end sheet 128 and the second end sheet 130 (e.g., relative to a length of the tubes 112). The plurality of tubes 112 may extend through each intermediate sheet 150 of the plurality of intermediate sheets 150. In some embodiments, the tubes 112 extend through the main body 152 of each intermediate sheet 150. For example, the main body 152 of the intermediate sheet 150 may include a plurality of holes formed therethrough, and each hole may receive one of the tubes 112. In this way, the working fluid may be directed through the heat exchanger tubes 112 without interference from the intermediate sheets 150. The intermediate sheets 150 may also be disposed along the tubes 112 in an alternating arrangement with subsets of the fins 114 coupled to the tubes 112 (e.g., a first subset of fins 114, one intermediate sheet 150, a second subset of fins 114, another intermediate sheet 150, a third subset of fins 114, and so forth).

In some embodiments, the plurality of intermediate sheets 150 is spaced apart from one another between the first end sheet 128 and the second end sheet 130. For example, the intermediate sheets 150 may be substantially evenly spaced across the heat exchanger 110 (e.g., across a length of the tubes 112 extending from the first end 124 to the second end 126). However, the intermediate sheets 150 may be spaced from one another in any desired arrangement (e.g., based on the dimensions of the heat exchanger 110, a desired contour of the heat exchanger 110 once installed, mounting locations of the housing 108 corresponding to the intermediate sheets 150, and so forth). In some embodiments, the flanges 154 of each intermediate sheet 150 extend generally along (e.g., parallel to) a length of the heat exchanger tubes 112 extending through the intermediate sheet 150. However, the flanges 154 may extend from the main body 152 in any desired direction or orientation to facilitate ease of securing the flange 154 to the housing 108 (e.g., the frame 136, the base panel 138, the top panel 140, etc.).

The housing 108 may further include one or more mounting brackets 156 (e.g., mounting bracket assemblies) configured to enable mounting of the heat exchanger 110 within the housing 108 in a desired arrangement, configuration, or position. As shown, the mounting brackets 156 may be disposed on the base panel 138. In some embodiments, the mounting brackets 156 may be disposed along the base panel 138 and/or along the heat exchanger 110 with similar spacing intervals as the plurality of intermediate sheets 150. In this way, each intermediate sheet 150 corresponds to one of the mounting brackets 156. The mounting brackets 156 may be positioned beneath the heat exchanger 110 (e.g., relative to vertical axis 104) in an assembled configuration of the HVAC system 100. In some applications, the mounting brackets 156 may support at least a portion of the weight of the heat exchanger 110.

As mentioned above, the intermediate sheets 150 are components of the heat exchanger 110 that enable additional securement of the heat exchanger 110 to and/or within the housing 108. In some embodiments, one or more of the intermediate sheets 150 may be coupled to one or more of the mounting brackets 156. The mounting brackets 156 may be modular and/or adjustable in order to enable adjustable positioning of the mounting brackets 156 within the housing 108. For example, one or more the mounting brackets 156 may be positioned within the housing 108 to align with one of the intermediate sheets 150 in an assembled configuration of the HVAC system 100. The mounting brackets 156 may rest on the base panel 138 and may be mechanically fastened or otherwise attached to the base panel 138, such as via mechanical fasteners, an interference fit (e.g., a prong of the mounting bracket 156 extending through an aperture formed in the base panel 138), an adhesive, or other coupling technique. In this way, the mounting brackets 156 may provide additional points of securement to which one or more of the intermediate sheets 150 may be mounted.

As discussed in further detail below, each intermediate sheet 150 is configured to be mounted and/or secured to one or more components of the housing 108, such as the frame 136, the top rail 142, the top panel 140 (e.g., the top panel flange 148), the base rail 144, the base panel 138, the mounting bracket 156, or any combination thereof. Indeed, in some embodiments, each intermediate sheet 150 may be mounted to one or more components of the housing 108 at two or more mounting locations. For example, one of the flanges 154 of one of the intermediate sheets 150 may be secured to the top panel flange 148 adjacent the top edge 117 of the heat exchanger 110 and may be secured to one of the mounting brackets 156 adjacent the bottom edge 118 of the heat exchanger 110. The flange 154 of the intermediate sheets 150 may be secured to one or more components of the housing 108 via a mechanical fastener, an adhesive, a weld, a braze, or any combination thereof. As a result, the heat exchanger 110 may be mounted to the housing 108 at an increased number of mounting points, which may facilitate retention of the heat exchanger 110 in a desired arrangement within the housing 108, thereby reducing unintended movement of the heat exchanger 110 within the housing 108.

FIG. 6 is a schematic side view of a portion of the HVAC system 100, illustrating the housing 108 having the frame 136, top panel 140, and the base panel 138 with the heat exchanger 110 disposed within the housing 108. As discussed above, the frame 136 of the housing 108 may include the support members 146, the base rail 144, and the top rail 142. The top panel flange 148 is illustrated as extending along and outward from (e.g., relative to an interior of the housing 108) the top rail 142. In some embodiments, the top panel flange 148 may not fully overlap with the top rail 142 (e.g., along the vertical axis 104). In other embodiments, the top panel flange 148 may overlap with and extend beyond the top rail 142 (e.g., along vertical axis 104), such that a distal portion of the top panel flange 148 may not contact the top rail 142. In an assembled configuration, one or more flanges 154 of one or more intermediate sheets 150 may overlap with the top panel flange 148 (e.g., along vertical axis 104). For example, one of the flanges 154 may extend beyond an uppermost tube 112 and/or uppermost fin 114 of the heat exchanger 110 (e.g., relative to vertical axis 104) and may overlap with the top panel flange 148. In this way, the flange 154 of the intermediate sheet 150 may be fastened to the top panel flange 148 (e.g., via a mechanical fastener extending through the flange 154 and top panel flange 148). In other embodiments, the flange 154 of the intermediate sheet 150 may extend to overlap with the top rail 142 (e.g., along vertical axis 104), and the intermediate sheet 150 may be fastened to the top rail 142 (e.g., via a mechanical fastener). In this way, the intermediate sheet 150 of the heat exchanger 110 may be secured to the housing 108 of the HVAC system 100 adjacent the top edge 117 of the heat exchanger 110.

The base panel 138 may be coupled to the frame 136 of the housing 108 along the base rail 144. In some embodiments, one or more of the mounting brackets 156 may be disposed along the base panel 138 and/or along the base rail 144 of the frame 136. For example, the mounting brackets 156 may be secured to the base panel 138 and/or the base rail 144 such that at least a portion of each mounting bracket 156 extends toward the heat exchanger 110 (e.g., along vertical axis 104). For example, a portion of each mounting bracket 156 positioned laterally outward from the heat exchanger 110 (e.g., relative to an interior of the housing 108) may extend along the heat exchanger 110, such that the portion of the mounting bracket 156 overlaps with the heat exchanger 110 along the vertical axis 104. As mentioned above and as illustrated in FIG. 6, one or more mounting brackets 156 may also be aligned with one or more intermediate sheets 150 (e.g., along longitudinal axis 106). More specifically, one or more mounting brackets 156 may overlap with and extend along one or more flanges 154 of the intermediate sheets 150 in an assembled configuration. In this way, intermediate sheets 150 may be secured to mounting brackets 156 of the housing 108, such as via fasteners extending through corresponding flanges 154 and mounting brackets 156. In some embodiments, one or more flanges 154 of one or more intermediate sheets 150 may be directly mounted to the base panel 138, the base rail 144, or both instead of mounting to the mounting bracket 156. In other words, one or more flanges 154 may be fastened directly to the housing 108. The intermediate sheet 150 may be secured to the housing 108 of the HVAC system 100 via the frame 136 (e.g., the base rail 144), the base panel 138 (e.g., the mounting brackets 156), or both.

FIG. 7 is a schematic top view of an embodiment of a portion of the HVAC system 100, illustrating the heat exchanger 110 having the intermediate sheets 150 secured to the housing 108. Specifically, the illustrated embodiment shows securement of the flanges 154 of the intermediate sheets 150 to the top panel 140 (e.g., the top panel flange 148) adjacent to the top edge 117 of the heat exchanger 110. For example, one of the flanges 154 of each intermediate sheet 150 may be secured to the top panel flange 148 at one or more points along the heat exchanger 110. In some embodiments, the heat exchanger 110 may be secured to the housing 108 via the intermediate sheets 150 on one or both sides of the first bend 120, the second bend 122, or both (e.g., relative to a length of the tubes 112 from the first end 124 to the second end 126). In this way, movement, warping, and/or distortion in the heat exchanger 110, such as during transportation of the HVAC system 100 in an assembled configuration.

The heat exchanger 110 may also be secured to the HVAC system 100 (e.g., the housing 108) via the end sheets 128, 130 disposed at and/or along the first end 124 and the second end 126. For example, the end sheets 128, 130 may be secured to a support structure or other structural component of the HVAC system 100 (e.g., the housing 108). For example, one or both of the end sheets 128, 130 may be secured (e.g., mounted) to a post 158 of the frame 136 and/or housing 108, a flange 160 (e.g., mounting flange) of the frame 136 and/or housing 108, or another suitable component of the HVAC system 100. In some embodiments, the post 158 may be one of the plurality of support members 146 of the frame 136. In some embodiments, the flange 160 may be an extension of the top panel 140 or an extension of a component of the frame 136. Indeed, one or both of the end sheets 128, 130 may be secured to any suitable component of the housing 108 to enable a fixed and/or rigid connection between the end sheets 128, 130 and the housing 108. Thus, movement of the first end 124 and the second end 126 may be restricted, to enable retention of the heat exchanger 110 within the housing 108 in a desired position, configuration, and/or arrangement.

As shown, the top panel flange 148 may extend about the heat exchanger 110 (e.g., laterally outward from the heat exchanger 110 relative to an interior of the housing 108). Thus, the top panel flange 148, which extends from the top panel 140 (e.g., from a main body of the top panel 140, along the vertical axis 104), may physically contact one or more of the flanges 154 of the intermediate sheets 150. Indeed, in some embodiments, the top panel flange 148 may abut one of the flanges 154 of each intermediate sheet 150 of the heat exchanger 110. The intermediate sheets 150 may be fastened to the top panel flange 148 via any suitable securement technique. For example, respective fasteners 162 (e.g., mechanical fasteners, bolts, rivets, screws, etc.) may extend through the top panel flange 148 and one of the flanges 154 of each intermediate sheet 150. Similarly, mechanical fasteners 162 may be utilized to secure the end sheets 128, 130 to the HVAC system 100 (e.g., the frame 136, support member 146, post 158, flange 160, and so forth). However, it should be appreciated other suitable fastening features, such as welds, adhesives, brazes, etc. may be utilized to secure the flanges 154 of the intermediate sheets 150 and the end sheet flanges 134 of the end sheets 128, 130 to corresponding components (e.g., mounting points) of the HVAC system 100.

FIG. 8 is a schematic axial view of an embodiment of a portion of the HVAC system 100, illustrating the heat exchanger 110 having the intermediate sheets 150 secured to the housing 108. Specifically, the illustrated embodiment shows securement of the flanges 154 of the intermediate sheets 150 to the mounting brackets 156 adjacent the bottom edge 118 of the heat exchanger 110. For example, one of the flanges 154 of each intermediate sheet 150 being secured to a corresponding one of the mounting brackets 156 (e.g., positioned on the base panel 138) adjacent the bottom edge 118 of heat exchanger 110. As previously discussed, the mounting brackets 156 may be components of the housing 108 and/or may be rigidly secured to the housing 108. Thus, securement between the intermediate sheets 150 and the mounting brackets 156 may facilitate retention of the heat exchanger 110 in a desired configuration or position within the housing 108.

The heat exchanger 110 may also be secured to the HVAC system 100 (e.g., the housing 108) via the end sheets 128, 130 disposed at and/or along the first end 124 and the second end 126 of the heat exchanger 110. For example, as discussed above with reference to FIG. 7, the end sheets 128, 130 may be secured to one or more components of the housing 108 adjacent the top edge 117 of the heat exchanger 110. In some embodiments, the end sheets 128, 130 may also be secured to one or more components of the housing 108 adjacent the bottom edge 118 of the heat exchanger 110. Further, in some embodiments, the end sheets 128, 130 may be secured to one or more components of the housing 108 along a height or length (e.g., a dimension extending along vertical axis 104) of the end sheets 128, 130 of the heat exchanger 110, such as between the top edge 117 and the bottom edge 118 along the vertical axis 104. As discussed above, the end sheets 128, 130 may be secured to a component of the housing 108, such as the post 158, the flange 160, another component of the frame 136, and/or another portion of the HVAC system 100.

As shown, the mounting brackets 156 may be disposed adjacent the heat exchanger 110, such that at least a portion of each mounting bracket 156 is disposed laterally outward from the heat exchanger 110 (e.g., relative to an interior of the housing 108, along lateral axis 102 and/or longitudinal axis 106). One or more of the mounting brackets 156 may also be disposed adjacent to one of the flanges 154 of one or more intermediate sheets 150 along the length of the heat exchanger 110. That is, one or more mounting brackets 156 may be aligned with a corresponding one of the flanges 154 along the lateral axis 102 or longitudinal axis 106. Thus, the intermediate sheets 150 may be fastened to the mounting brackets 156 via one or more fastening techniques, such as mechanical fasteners (e.g., fasteners 162), welds, adhesives (e.g., metal glues, chemical bonding agents), or another suitable technique. The mounting brackets 156 may have any suitable configuration configured to enable securement of the heat exchanger 110 to the housing 108 and are discussed in further detail below.

FIG. 9 is a perspective view of an embodiment of a portion of the mounting bracket 156 (e.g., mounting bracket assembly), illustrating a first bracket 200 of the mounting bracket 156. The first bracket 200 includes a first bracket base 202 and a first bracket arm 204 (e.g., extension, flange) extending from the first bracket base 202 at a first bracket joint 206. In some embodiments, the first bracket arm 204 may extend perpendicularly from the first bracket base 202. The first bracket 200 may be formed from a single piece of material (e.g., sheet metal), such that the first bracket base 202 and the first bracket arm 204 are integrally formed with one another as one piece. In an assembled or installed configuration, the first bracket base 202 may be disposed along the base panel 138 (e.g., extend along lateral axis 102 and/or longitudinal axis 106), and the first bracket arm 204 may extend away from the base panel 138 (e.g., along vertical axis 104).

In some embodiments, one or more first bracket holes 208 (e.g., apertures) are formed in the base 202 of the first bracket 200. The holes 208 may be configured to direct fluid away from the heat exchanger 110 and/or out of the housing 108. For example, the fluid may be rain water or liquid condensation (e.g., water) that may enter or accumulate within the housing 108 during operation of the HVAC system 100. In some embodiments, the first bracket holes 208 are spaced evenly apart in order to enable desired drainage of liquid from the housing 108. However, any suitable shape, size, and/or arrangement of the first bracket holes 208 may be selected to facilitate desirable drainage of fluids from the HVAC system 100. In some embodiments, the first bracket base 202 may have one or more inclined surfaces or contours (e.g., relative to a horizontal direction, in an installed configuration) to enable flow of fluid towards the first bracket holes 208.

The first bracket 200 includes an inner surface 210 and an outer surface 212. For example, in an installed configuration of the first bracket 200 with the heat exchanger 110, the inner surface 210 may generally face the heat exchanger 110, while the outer surface 212 may face away from the heat exchanger 110. Further, in some embodiments, the heat exchanger 110 may be positioned above (e.g., relative to vertical axis 104) the first bracket base 202. For example, the heat exchanger 110 may contact the inner surface 210 of the first bracket 200 along the first bracket base 202. In an assembled configuration, a portion of the heat exchanger 110 (e.g., one of the intermediate sheets 150) may also contact the inner surface 210 along the first bracket arm 204.

The first bracket arm 204 extends from the first bracket base 202 along a first bracket arm height 214. The first bracket arm height 214 may correspond to a distance or dimension from the bottom edge 118 of the heat exchanger 110 to a lowermost tube 112 of the heat exchanger 110. For example, a distal edge 216 of the first bracket arm 204 may be disposed beneath (e.g., relative to vertical axis 104) the lowermost tube 112 in an assembled configuration of the first bracket 200 with the heat exchanger 110. As a result, the plurality of fins 114 disposed along the plurality of tubes 112 may not physically contact the first bracket 200. However, the inner surface 210 of the first bracket 200 (e.g., the first bracket arm 204) may contact one of the intermediate sheets 150 of the heat exchanger 110 in an assembled configuration. More specifically, the inner surface 210 of the first bracket arm 204 may overlap with and contact one of the flanges 154 of one of the intermediate sheets 150. In this way, the first bracket arm 204 may be secured to a corresponding one of the intermediate sheets 150, such as via a mechanical fastener (e.g., fastener 162) extending through the first bracket arm 204 and one of the flanges 154.

FIG. 10 is a perspective view of an embodiment of a portion of the mounting bracket 156 (e.g., mounting bracket assembly), illustrating a second bracket 250 of the mounting bracket 156. As described further below, the second bracket 250 may be coupled to the first bracket 200 discussed above with reference to FIG. 9 to form one of the mounting brackets 156. The second bracket 250 includes a second bracket base 252 and a plurality of second bracket legs 254. Each second bracket leg 254 extends from the second bracket base 252 at a respective second bracket joint 256. In some embodiments, the second bracket legs 254 may extend perpendicularly from the second bracket base 252. The second bracket 250 may be formed from any suitable material, such as metal, a polymer (e.g., plastic), or other material. In some embodiments, the second bracket 250 is formed as a single piece component having the second bracket base 252 and the plurality of second bracket legs 254. For example, the second bracket 250 may be formed via an injection molding process.

One or more second bracket holes 258 may be formed in and/or disposed along the second bracket base 252. The holes 258 may be configured to direct fluid away from the heat exchanger 110 and/or out of the housing 108. For example, the fluid may be rain water or liquid condensation (e.g., water) that may enter or accumulate within the housing 108 during operation of the HVAC system 100. In some embodiments, the second bracket holes 258 are spaced evenly apart in order to enable desired drainage of liquid from the housing 108. However, any suitable shape, size, and/or arrangement of the second bracket holes 258 may be selected to facilitate desirable drainage of fluids from the HVAC system 100. In some embodiments, the second bracket base 252 may be have one or more inclined surfaces or contours (e.g., relative to a horizontal direction, in an installed configuration) to enable flow of fluid towards the second bracket holes 258.

The second bracket 250 includes an inner surface 260 and an outer surface 262. In an installed configuration of the second bracket 250 with the heat exchanger 110, the inner surface 260 may generally face the heat exchanger 110, while the outer surface 262 may face away from the heat exchanger 110. As mentioned above, the first bracket 200 and the second bracket 250 may be coupled to one another to form one of the mounting brackets 156. For example, the first bracket 200 and the second bracket 250 may be assembled such that the inner surface 260 of the second bracket 250 abuts the outer surface 212 of the first bracket 200. In such an embodiment, the heat exchanger 110 may be positioned above (e.g., relative to vertical axis 104) the first bracket 200 coupled to the second bracket 250, such that the heat exchanger 110 abuts the inner surface 210 of the first bracket 200.

The first bracket 200 and the second bracket 250 may be manufactured from of any suitable material. In some embodiments, the first bracket 200 and the second bracket 250 may be formed from different materials. For example, the first bracket 200 may be formed from a metallic material (e.g., steel, sheet metal), and the second bracket 250 may be formed from plastic. In some embodiments, the first bracket 200 may be manufactured from a similar material as the plurality of intermediate sheets 150 (e.g., sheet metal). In this way, the first bracket 200 and the intermediate sheets 150 (e.g., flanges 154) may be readily attached to one another, such as via mechanical fasteners, adhesives, welding, brazing, and so forth. As mentioned above, the second bracket 250 may be manufactured from a plastic. In this way, the second bracket 250 may more readily absorb external forces applied to the second bracket 250 (e.g., mounting bracket 156) without plastic or lasting deformation. Further, the second bracket 250 formed from plastic may more readily resist corrosion that may otherwise be induced by contact with fluids (e.g., water residing along the base panel 138 adjacent the second bracket 250).

FIG. 11 is a perspective view of an embodiment of a mounting bracket assembly 300 of the HVAC system 100. The mounting bracket assembly 300 may be an embodiment of the mounting bracket 156 discussed above and may be incorporated with the HVAC system 100. That is, the mounting bracket assembly 300 may be positioned within the housing 108 and/or may be a component of the housing 108. In an installed configuration, the mounting bracket assembly 300 may be coupled to the frame 136 (e.g., the base panel 138) and may at least partially support a weight of the heat exchanger 110 positioned on the mounting bracket assembly 300. As shown, the mounting bracket assembly 300 is an assembly of an embodiment of the first bracket 200 and an embodiment of the second bracket 250 discussed above.

The first bracket 200 and the second bracket 250 may be coupled together via a suitable coupling technique, such as mechanical fasteners, adhesives, an interference fit, interlocking features, and so forth. For example, the second bracket 250 may include hollow extensions and/or prongs sized to fit within the holes 208 of the first bracket 200, such that the first bracket 200 and the second bracket 250 interlock together. In an assembled configuration, the first bracket holes 208 and the second bracket holes 258 may overlap with one another (e.g., along vertical axis 104) to enable drainage of fluid through the mounting bracket assembly 300 (e.g., from the inner surface 210 of the first bracket 200 to the outer surface 262 of the second bracket 250). In this way, the mounting bracket assembly 300 may direct fluid therethrough and away from the heat exchanger 110.

The second bracket 250 may support the first bracket 200 in an installed configuration of the mounting bracket assembly 300, such that the mounting bracket assembly 300 may structurally support the heat exchanger 110 when the heat exchanger 110 is disposed against the inner surface 210 of the first bracket 200. In some embodiments, the second bracket 250 and/or the first bracket 200 may include one or more features configured to enable attachment of the mounting bracket assembly 300 to the housing 108 (e.g., base panel 138) of the HVAC system 100. For example, the mounting bracket assembly 300 may include hooks, holes to receive fasteners, fixtures, clamps, vices, magnets, prongs, extensions, or other suitable features configured to enable securement of the mounting bracket assembly 300 to the housing. In some embodiments, the mounting bracket assembly 300 may include one or more support legs extending from the second bracket 250 to the base panel 138 of the housing 108 to facilitate attachment of the mounting bracket assembly 300 to the housing 108 of the HVAC system 100. For example, one or more support legs of the second bracket 250 may extend from the second bracket base 252 in a direction opposite the second bracket legs 254 and may extend into slots formed in the base panel 138 to enable an interference fit between the mounting bracket assembly 300 and the base panel 138.

FIG. 12 is a perspective view of an embodiment of a clamping assembly 350 configured to enable retention of the heat exchanger 110 in a desired position or configuration within the housing 108 of the HVAC system 100. As shown in the illustrated embodiment, the clamping assembly 350 may be disposed along the base panel 138 of the housing 108. The clamping assembly 350 may also be incorporated with an embodiment of the mounting bracket assembly 300. The clamping assembly 350 includes one or more support legs 352 configured to abut the base panel 138 and support the mounting bracket assembly 300. In some embodiments, the support legs 352 may be attached to the second bracket 250 and/or may be components of the second bracket 250 (e.g., integrally formed with the second bracket 250). In some embodiments, the mounting bracket assembly 300 may be attached directly to the base panel 138 without the support legs 352.

The clamping assembly 350 also includes a clamp 354 (e.g., clamping member, gripping member, abutment surface) that is adjustably positioned relative to the mounting bracket assembly 300. The clamp 354 may be configured to cooperatively capture the heat exchanger 110 with the mounting bracket assembly 300. To this end, the clamp 354 may be adjusted to be closer or further away from the mounting bracket assembly 300 to accommodate a size (e.g., width, depth) of the heat exchanger 110 and to enable retention of the heat exchanger 110 therebetween. The clamp 354 includes a clamp base 356 and a clamp arm 358. In some embodiments, the clamp base 356 may be configured to slide across the base panel 138, such as during positional adjustment of the clamp 354 relative to the mounting bracket assembly 300. Additionally or alternatively, the clamp base 356 may be configured to rest against and/or abut the base panel 138 to provide structural support for the heat exchanger 110 in an installed configuration. The clamp base 356 may include one or more surface features applied to an underside of the clamp base 356 to enable more efficient positional adjustment of the clamp 354.

The clamping assembly 350 may include one or more mechanisms configured to enable adjustment of the clamp 354 relative to the mounting bracket assembly 300. For example, the clamping assembly 350 may include an adjustment device 360 (e.g., adjuster, translation mechanism, adjustment system, adjusting mechanism) configured to adjust a magnitude of a gap 359 extending between the mounting bracket assembly 300 (e.g., the inner surface 210 of the first bracket 200) and the clamp arm 358. The gap 359 may be adjusted in order to accommodate heat exchangers 110 of varying sizes. For example, the size or dimension of the gap 359 may be adjusted to accommodate and secure heat exchangers 110 having different numbers of rows of tubes 112. In some embodiments, the adjustment device 360 may be configured to retain the mounting bracket assembly 300 in a desired position (e.g., relative to the base panel 138) and to adjust a position of the clamp 354 relative to the mounting bracket assembly 300. In other embodiments, the adjustment device 360 may retain the clamp 354 in a desired position (e.g., relative to the base panel 138) and to adjust a position of the mounting bracket assembly 300 relative to the clamp 354.

In the illustrated embodiment, the adjustment device 360 includes a retention member 362 (e.g., retention panel, retention plate) and one or more threaded rods 364 (e.g., bolts, screws, etc.). The retention member 362 may be disposed along the base panel 138 and/or may be attached to the housing 108 of the HVAC system 100. The threaded rod 364 may extend through the retention member 362, the support legs 352, and the clamp 354 and may actuated (e.g., rotated) to adjust a position of the mounting bracket assembly 300, the clamp 354, or both. That is, the threaded rod 364 may be actuated to adjust positions of the mounting bracket assembly 300 and the clamp 354 relative to one another to adjust a size of the gap 359 extending therebetween. In some embodiments, rotation of the threaded rod 364 in a clockwise direction may cause the gap 359 to decrease in size, and rotation of the threaded rod 364 in a counterclockwise direction may cause the gap 359 to increase in size. In some embodiments, an operator may rotate the threaded rod 364 by hand or with a tool (e.g., a screwdriver) in order to adjust the position of the clamp 354.

FIG. 13 is a side view of an embodiment of the clamping assembly 350 in an installed configuration with the heat exchanger 110. Specifically, FIG. 13 illustrates a lower portion 382 (e.g., base portion) of the heat exchanger 110 supported and retained by the mounting bracket assembly 300 and the clamping assembly 350. As previously discussed, the adjustment device 360 (e.g., threaded rods 364) may be actuated to a gap size 384 of the gap 359 extending between the inner surface 210 of the first bracket arm 204 and the clamp arm 358. For example, the adjustment device 360 may be actuated to translate the clamp 354 closer to or further away from the mounting bracket assembly 300 in order to accommodate a width 386 of the lower portion 382 of the heat exchanger 110.

As shown, the heat exchanger 110 may be positioned to rest on the mounting bracket assembly 300 within the gap 359. With the heat exchanger 110 positioned as shown, the adjustment device 360 may be actuated to draw the clamp 354 toward the mounting bracket assembly 300 to capture the lower portion 382 of the heat exchanger 110 therebetween. For example, the threaded rod 364 may be actuated to adjust the clamp 354 towards the heat exchanger 110, such that the clamp arm 358 contacts or abuts a first side 388 the heat exchanger 110 and biases a second side 390 of the heat exchanger 110 against the first bracket arm 204. In this way, the clamping assembly 350 may be utilized to retain the heat exchanger 110 in a desired position within the housing 108. Further, it should be appreciated that the HVAC system 100 may include any suitable or desirable number of clamping assemblies 350 with mounting bracket assemblies 300 to enable desirable retention of the heat exchanger 110 within the housing 108.

FIG. 14 is a perspective view of an embodiment of a mounting bracket 400 configured to enable mounting of the heat exchanger 110 within the housing 108 of the HVAC system 100, in accordance with the present techniques. For example, the mounting bracket 400 may be utilized in addition to, or instead of, the mounting bracket 156 and/or the mounting bracket assembly 300 discussed above. In other words, the mounting bracket 400 may be positioned within the housing 108 (e.g., on the base panel 138), and the heat exchanger 110 may be disposed on and/or may couple to the mounting bracket 400. The mounting bracket 400 may therefore support at least a portion of a weight of the heat exchanger 110 in an installed configuration. As similarly discussed above, multiple mounting brackets 400 may be incorporated with the housing 108 to support the heat exchanger 110 and/or to enable mounting and securement of the heat exchanger 110 within the housing. 108. As discussed further below, the mounting bracket 400 may also be utilized with an embodiment of the clamping assembly 350 to enable retention of the heat exchanger 110 within the housing 108 in a desired configuration or arrangement.

The mounting bracket 400 includes a mounting bracket base 402 and a mounting bracket arm 404 (e.g., extension, flange) extending from the mounting bracket base 402 at a bracket joint 406. In some embodiments, the mounting bracket arm 404 may extend perpendicularly from the mounting bracket base 402. The mounting bracket 400 may be formed from a single piece of material (e.g., sheet metal), such that the mounting bracket base 402 and the mounting bracket arm 404 are integrally formed with one another as one piece. Indeed, the mounting bracket 400 may be formed from a single piece of material (e.g., sheet metal) including some or all of the components of the mounting bracket 400 discussed below.

In some embodiments, one or more bracket holes 408 (e.g., apertures) are formed in the mounting bracket base 402 of the mounting bracket 400. The bracket holes 408 may be configured to direct fluid away from the heat exchanger 110 and/or out of the housing 108. For example, the fluid may be rain water or liquid condensation (e.g., water) that may enter or accumulate within the housing 108 during operation of the HVAC system 100. In some embodiments, the bracket holes 408 are spaced evenly apart in order to enable desired drainage of liquid from the housing 108. However, any suitable shape, size, and/or arrangement of the bracket holes 408 may be selected to facilitate desirable drainage of fluids from the HVAC system 100. In some embodiments, the mounting bracket base 402 may have one or more inclined surfaces or contours (e.g., relative to the horizontal direction, in an installed configuration) to enable flow of fluids toward the bracket holes 408

The mounting bracket 400 includes a mounting surface 410 (e.g., inner surface). In an assembled configuration of the mounting bracket 400 with the heat exchanger 110, the heat exchanger 110 may generally rest upon and/or abut the mounting surface 410. In other words, in some embodiments, the heat exchanger 110 may be positioned above (e.g., relative to vertical axis 104) the bracket base 402, and the mounting surface 410 may engage with the heat exchanger 110 to support a portion of a weight of the heat exchanger 110. In an assembled configuration, a portion of the heat exchanger 110 (e.g., one of the intermediate sheets 150) may also contact the mounting bracket arm 404. As similarly discussed above, the one or more intermediate sheets 150 (e.g., one or more flanges 154) may be secured to the mounting bracket arm 404 to enable securement and retention of the heat exchanger 110 within the housing in a desired arrangement or configuration.

The mounting bracket 400 also includes one or more mounting bracket legs 412 extending from edges 414 of the mounting bracket base 402. The mounting bracket legs 412 may extend from the mounting bracket base 402, such as in a direction generally opposite the mounting bracket arm 404 (e.g., the mounting bracket arm 404 may extend in a generally upward direction along the vertical axis 104, and the mounting bracket legs 412 extend in a generally downward direction along the vertical axis 104). Each of the mounting bracket legs 412 includes a leg base 416 (e.g., extension, flange) and a leg arm 418 (e.g., extension, flange). In an assembled or installed configuration, the leg bases 416 may be disposed along the base panel 138 (e.g., extend along lateral axis 102 and/or longitudinal axis 106), and the leg arms 418 may extend away from the base panel 138 (e.g., along vertical axis 104). In some embodiments, the mounting bracket legs 412 may have one or more bracket leg holes 420 formed in the mounting bracket leg bases 416. The leg holes 420 may be configured to receive a mechanical fastener (e.g., a bolt, a screw, a nail, a rod, etc.) to secure the mounting bracket 400 to the housing 108 (e.g., the base panel 138).

In some embodiments, the mounting bracket 400 may also include a bracket support leg 422 extending from one of the edges 414 of the mounting bracket base 402. For example, the bracket support leg 422 may extend from the mounting bracket base 402 on a side of the mounting bracket base 402 opposite that of the mounting bracket arm 404. In an assembled configuration with the housing 108, a distal end of the bracket support leg 422 may abut the base panel 138 of the housing 108. The bracket support leg 422 may also extend in a direction generally opposite that of the mounting bracket arm 404. As shown, the bracket support leg 422 and the leg arms 418 extend in a generally common direction (e.g., generally downward along the vertical axis 104). In some embodiments, the bracket support leg 422 may also include one or more support holes 424 formed therein. One or more of the support holes 424 may be configured to receive a respective mechanical fastener (e.g., an embodiment of the threaded rod 364, a bolt, a nail, etc.). For example, the mechanical fastener(s) may be components of an embodiment of the clamping assembly 350. Thus, the mounting bracket 400 may be configured for use in cooperation with the clamping assembly 350 (e.g., to support and/or retain the heat exchanger 110 within the housing 108.

FIG. 15 is a schematic side view of an embodiment of a clamping assembly 450 in an installed configuration with the heat exchanger 110 and the mounting bracket 400. The clamping assembly 450 and the mounting bracket 400 may be configured to cooperatively retain the heat exchanger 110 in a desired configuration or arrangement within the housing 108. In particular, the clamping assembly 450 and the mounting bracket 400 may be configured to capture a portion of the heat exchanger 110 therebetween, as similarly discussed above.

In the illustrated embodiment, the clamping assembly 450 is disposed along the base panel 138 of the housing 108 adjacent the mounting bracket 400. For example, the mounting bracket 400 may be disposed along the base panel 138 such that the mounting bracket arm 404 is aligned with the base rail 144 (e.g., along the vertical axis 104). The mounting bracket 400 may be coupled and/or secured to the base panel 138 (e.g., the frame 136) via a suitable technique, such as mechanical fasteners extending through the leg holes 420 and the base panel 138.

The clamping assembly 450 includes an embodiment of the clamp 354, which is configured to be adjustably positioned relative to the mounting bracket 400 and the heat exchanger 110. Similar to the clamping assembly 350 discussed above, the clamping assembly 450 may include an embodiment of the adjustment device 360 that is configured to adjust a position of the clamp 354 relative to the mounting bracket 400. To this end, the adjustment device 360 includes one or more of the threaded rods 364, each of which may extend through one of the support holes 424 formed in the bracket support leg 422. The clamping assembly 450 further includes the retention member 362, which may be disposed along the base rail 144 and/or the mounting bracket 400, as shown. The one or more threaded rods 364 may extend through the retention member 362 and the bracket support leg 422 and may couple to the clamp 354. An operator may rotate the one or more threaded rods 364 of the clamping assembly 450 to adjust the gap size 384 between the mounting bracket arm 404 and the clamp arm 358. In this way, the heat exchanger 110 positioned on the mounting bracket 400 (e.g., the mounting bracket base 402) may be captured and retained between the clamp arm 358 and the mounting bracket arm 404 to retain a desired configuration or arrangement of the heat exchanger 110 within the housing 108.

In some embodiments, a shape, geometry, profile, and/or structure of the clamp 354 may be selected based on a configuration of the HVAC system 100 in which the clamp 354 is implemented. For example, in the illustrated embodiment, the clamp 354 of the clamping assembly 450 includes the clamp base 356 and the clamp arm 358 via a clamp bend 452 or joint (e.g., a single clamp bend 452) to define a generally L-shaped configuration. In other embodiments, the clamp 354 may include multiple clamp bends 452, such that the clamp 354 defines other shapes or configurations (e.g., based on an arrangement of the clamping assembly 450 within the housing 108, a size, dimension, or shape of the heat exchanger 110, an arrangement of the clamping assembly 450 relative to the mounting bracket 400, and so forth

As discussed in detail above, embodiments of the present disclosure include an HVAC system having a heat exchanger with intermediate sheets disposed or arrayed along tubes of the heat exchanger. The intermediate sheets are configured to enable improved securement of the heat exchanger within a housing of the HVAC system in a desired position or configuration. Indeed, presently disclosed embodiments are configured to enable retention of the heat exchanger within the housing in a desired position during transportation, installation, and/or operation of the HVAC system. In this way, unintended shifts or positional adjustments of the heat exchanger within the housing may be reduced, which may thereby reduce inadvertent deformation or degradation of the heat exchanger, such as via contact between the heat exchanger and other components of the HVAC system.

The intermediate sheets may be disposed (e.g., arrayed, spaced) along the length of the heat exchanger, such as along lengths of tubes of the heat exchanger, between a first end and a second end of the heat exchanger. The intermediate sheets may be incorporated in addition to end sheets disposed at the first end and the second end that also enable mounting of the heat exchanger to the housing of the HVAC system. Thus, the intermediate sheets are configured to provide additional mounting points between the heat exchanger and the housing. Indeed, the intermediate sheets may provide additional mounting points at a top of the heat exchanger, a base of the heat exchanger, and at locations between the top and the base. The additional mounting locations provided by the intermediate sheets decrease the potential of unintended movement of the heat exchanger within the housing, which may otherwise cause wear or degradation on the heat exchanger. Therefore, the improved systems of the present disclosure may increase a useful of the heat exchanger, reduce unscheduled maintenance, and improve efficient performance of the heat exchanger.

While only certain features and embodiments of the disclosure have been illustrated and described, many modifications and changes may occur to those skilled in the art (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters (e.g., temperatures, pressures, etc.), mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited in the claims. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the present disclosure.

Furthermore, in an effort to provide a concise description of the exemplary embodiments, all features of an actual implementation may not have been described, such as those unrelated to the presently contemplated best mode, or those unrelated to enablement. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation specific decisions may be made. Such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure, without undue experimentation.

The techniques presented and claimed herein are referenced and applied to material objects and concrete examples of a practical nature that demonstrably improve the present technical field and, as such, are not abstract, intangible or purely theoretical. Further, if any claims appended to the end of this specification contain one or more elements designated as “means for [perform]ing [a function] . . . ” or “step for [perform]ing [a function] . . . ”, it is intended that such elements are to be interpreted under 35 U.S.C. 112(f). However, for any claims containing elements designated in any other manner, it is intended that such elements are not to be interpreted under 35 U.S.C. 112(f).

Claims

1. A heating, ventilation, and air conditioning (HVAC) system, comprising:

a housing; and

a heat exchanger disposed within the housing, wherein the heat exchanger comprises: a plurality of tubes configured to direct a working fluid therethrough, wherein the plurality of tubes extends from a first end to a second end of the heat exchanger; a plurality of fins coupled to and extending between the plurality of tubes; a first end sheet disposed at the first end of the heat exchanger, wherein the plurality of tubes extends through the first end sheet; a second end sheet disposed at the second end of the heat exchanger, wherein the plurality of tubes extends through the second end sheet; and a plurality of intermediate sheets disposed between the first end sheet and the second end sheet, wherein the plurality of tubes extends through each intermediate sheet of the plurality of intermediate sheets, and each intermediate sheet of the plurality of intermediate sheets is coupled to the housing.

2. The HVAC system of claim 1, wherein the plurality of tubes forms a bend between the first end and the second end of the heat exchanger.

3. The HVAC system of claim 1, wherein each intermediate sheet of the plurality of intermediate sheets comprises a main body and a flange extending from the main body.

4. The HVAC system of claim 3, wherein the plurality of tubes extends through the main body, and the flange is secured to the housing.

5. The HVAC system of claim 3, wherein the housing comprises a frame, and the flange of an intermediate sheet of the plurality of intermediate sheets is secured to the frame.

6. The HVAC system of claim 5, wherein the housing comprises a top panel coupled to the frame, and the flange of an additional intermediate sheet of the plurality to intermediate sheets is secured to the top panel.

7. The HVAC system of claim 3, wherein the plurality of tubes extends through the main body, the housing comprises a base panel and a bracket disposed on the base panel, the bracket supports the heat exchanger, and the flange of an intermediate sheet of the plurality of intermediate sheets is secured to the bracket.

8. The HVAC system of claim 7, wherein the flange and the bracket are secured to one another via a mechanical fastener, an adhesive, a weld, a braze, or any combination thereof.

9. The HVAC system of claim 1, wherein the plurality of intermediate sheets is spaced apart from one another along the plurality of tubes, and the plurality of fins is disposed between the plurality of intermediate sheets.

10. The HVAC system of claim 1, wherein an intermediate sheet of the plurality of intermediate sheets is secured to the housing at a base of the heat exchanger and at a top of the heat exchanger.

11. The HVAC system of claim 1, wherein the first end sheet and the second end sheet are coupled to the housing.

12. A heat exchanger for a heating, ventilation, and air conditioning (HVAC) system, comprising:

a plurality of heat exchange tubes configured to direct a working fluid therethrough, wherein the plurality of heat exchange tubes extends from a first end to a second end of the heat exchanger, and the plurality of heat exchange tubes is curved between the first end and the second end;

a plurality of fins coupled to and extending between the plurality of heat exchanger tubes;

a first end sheet disposed at the first end of the heat exchanger, wherein the plurality of heat exchange tubes extends through the first end sheet;

a second end sheet disposed at the second end of the heat exchanger, wherein the plurality of heat exchange tubes extends through the second end sheet; and

a plurality of intermediate sheets disposed between the first end sheet and the second end sheet, wherein the plurality of heat exchange tubes extends through each intermediate sheet of the plurality of intermediate sheets, and each intermediate sheet of the plurality of intermediate sheets is configured to mount to a housing of the HVAC system.

13. The heat exchanger of claim 12, wherein the plurality of heat exchange tubes defines a first bend and a second bend between the first end and the second end.

14. The heat exchanger of claim 12, wherein each intermediate sheet of the plurality of intermediate sheets is configured to mount to a frame of the housing, a panel of the housing, a bracket of the housing, or any combination thereof.

15. The heat exchanger of claim 12, wherein each intermediate sheet of the plurality of intermediate sheets comprises a main body and a flange extending from the main body, the plurality of heat exchange tubes extends through the main body, and the flange is configured to mount to the housing.

16. The heat exchanger of claim 15, wherein each intermediate sheet of the plurality of intermediate sheets extends from a base of the heat exchanger to a top of the heat exchanger.

17. The heat exchanger of claim 12, wherein the plurality of intermediate sheets is spaced apart from one another between the first end and the second end, and the plurality of fins is disposed between the plurality of intermediate sheets.

18. A heating, ventilation, and air conditioning (HVAC) system, comprising:

a housing comprising a frame, a base panel, and a top panel; and

a heat exchanger disposed within the housing, wherein the heat exchanger comprises: a plurality of tubes configured to direct a working fluid therethrough, wherein the plurality of tubes extends from a first end to a second end of the heat exchanger, and the plurality of tubes defines a curved profile of the heat exchanger between the first end and the second end; a plurality of fins coupled to and extending between the plurality of tubes; and a plurality of intermediate sheets disposed between the first end and the second end, wherein the plurality of tubes extends through each intermediate sheet of the plurality of intermediate sheets, each intermediate sheet of the plurality of intermediate sheets is secured to the housing, and the plurality of intermediate sheets is spaced apart from one another between the first end and the second end.

19. The HVAC system of claim 18, wherein each intermediate sheet of the plurality of intermediate sheets is secured to the top panel of the housing.

20. The HVAC system of claim 19, wherein the housing comprises a plurality of brackets coupled to the base panel, the heat exchanger is disposed on top of the plurality of brackets, and each intermediate sheet of the plurality of intermediate sheets is secured to the frame, the base panel, a respective bracket of the plurality of brackets, or a combination thereof.