Heat Exchanger System and Insulation Therefor

Abstract

A heat exchanger system including a cabinet, a V-shaped round tube plate fin heat exchanger disposed within the cabinet, and an axial fan housing disposed within the cabinet and located downstream of the V-shaped round tube plate fin heat exchanger. The heat exchanger system also includes a first insulation disposed along a first portion of an inner periphery of the cabinet, a second insulation disposed along a second portion of the inner periphery of the cabinet, and a connecting member disposed along an abutment of the first insulation and the second insulation. The first portion located upstream of the V-shaped round tube plate fin heat exchanger and the second portion located downstream of the V-shaped round tube plate fin heat exchanger. A temperature of the air flowing through the second portion is less than a temperature of the air flowing through the first portion.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and benefit of U.S. Provisional Patent Application No. 63/404,411, filed Sep. 7, 2022, which is incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates, in general, to heat exchanger system and, more specifically relates, to insulation provided at an inner surface of a cabinet of the heat exchanger system.

BACKGROUND

Conventional air handlers include a single insulation material, such as fiberglass, throughout an inner periphery of a cabinet thereof. Typically, air handlers include A-type or N-type evaporator coils, where a larger surface of the cabinet located downstream of the evaporator coil is exposed to conditioned cold air. A foil provided on fiberglass insulation is known to tear over a period of usage of the air handler. Due to such tearing of the foil, air can leak through the fiberglass insulation. In humid conditions, when such fiberglass insulation is provided on a downstream portion of the evaporator coil that is in contact with the conditioned cold air, any leakage of the conditioned cold air through the fiberglass insulation may result in condensation (sweating) of the air handler on an outer surface thereof. Collection of such condensate around the air handler may cause damage to a region at which the air handler is located. In order to address such problems, the inner periphery of the cabinet of the air handlers are known to include foam insulation throughout, which renders the air handlers costly due to high cost of the foam insulation.

SUMMARY

According to one aspect, a heat exchanger system is disclosed that includes a cabinet, a V-shaped round tube plate fin heat exchanger disposed within the cabinet, and an axial fan housing disposed within the cabinet and located downstream of the V-shaped round tube plate fin heat exchanger. The heat exchanger system also includes a first insulation disposed along a first portion of an inner periphery of the cabinet, a second insulation disposed along a second portion of the inner periphery of the cabinet, and a connecting member disposed along an abutment of the first insulation and the second insulation. The first portion located upstream of the V-shaped round tube plate fin heat exchanger and the second portion located downstream of the V-shaped round tube plate fin heat exchanger. In operation, a temperature of the air flowing through the second portion is less than a temperature of the air flowing through the first portion.

In an embodiment, the connecting member is a mesh tape. In an embodiment, the connecting member is configured to conceal the abutment.

In an embodiment, the first insulation comprises fiberglass and the second insulation comprises foam.

In some embodiments, a thickness of each of the first insulation and the second insulation is in a range of 0.5 inch to 1.5 inch. In some embodiments, the thickness of each of the first insulation and the second insulation is in a range of 0.55 inch to 1.25 inch. In some embodiments, the thickness of each of the first insulation and the second insulation is in a range of 0.6 inch to 1 inch.

In an embodiment, the first insulation overlaps with the second insulation at the abutment.

In an embodiment, the heat exchanger system further includes a foil configured to conceal the first insulation.

According to another aspect, a heating, ventilation, and air conditioning (HVAC) system is disclosed that includes a heat exchanger system including a cabinet, a V-shaped round tube plate fin heat exchanger disposed within the cabinet, an axial fan housing disposed within the cabinet and located downstream of the V-shaped round tube plate fin heat exchanger, and a plurality of refrigerant tubes located in the V-shaped round tube plate fin heat exchanger. The HVAC system further includes a first insulation disposed along a first portion of an inner periphery of the cabinet, a second insulation disposed along a second portion of the inner periphery of the cabinet, and a connecting member disposed along an abutment of the first insulation and the second insulation. The first portion located upstream of the V-shaped round tube plate fin heat exchanger, the second portion located downstream of the V-shaped round tube plate fin heat exchanger, and, in operation, a temperature of air flowing through the second portion is less than a temperature of the air flowing through the first portion. The connecting member is configured to conceal the abutment.

In an embodiment, the heat exchanger system is one of an air handler or a gas furnace.

In an embodiment, the first insulation comprises fiberglass and the second insulation comprises foam.

These and other aspects and features of non-limiting embodiments of the present disclosure will become apparent to those skilled in the art upon review of the following description of specific non-limiting embodiments of the disclosure in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

A better understanding of embodiments of the present disclosure (including alternatives and/or variations thereof) may be obtained with reference to the detailed description of the embodiments along with the following drawings, in which:

FIG. 1 is a perspective view of an air handler, according to an embodiment of the present disclosure;

FIG. 2A is a perspective view of a portion of the air handler of FIG. 1, according to an embodiment of the present disclosure;

FIG. 2B illustrates a cross-sectional view of the air handler of FIG. 1, according to an embodiment of the present disclosure;

FIG. 2C is an illustration of an inner periphery of a door of the air handler, according to an embodiment of the present disclosure;

FIG. 2D is an illustration of a rear cover of the air handler, according to an embodiment of the present disclosure; and

FIG. 3 is an enlarged view of a portion “A” in FIG. 2, according to an embodiment of the present disclosure.

DETAILED DESCRIPTION

Reference will now be made in detail to specific embodiments or features, examples of which are illustrated in the accompanying drawings. Wherever possible, corresponding, or similar reference numbers will be used throughout the drawings to refer to the same or corresponding parts. Moreover, references to various elements described herein, are made collectively or individually when there may be more than one element of the same type. However, such references are merely exemplary in nature. It may be noted that any reference to elements in the singular may also be construed to relate to the plural and vice-versa without limiting the scope of the disclosure to the exact number or type of such elements unless set forth explicitly in the appended claims.

As used herein, the terms “a”, “an” and the like generally carry a meaning of “one or more,” unless stated otherwise. Further, the terms “approximately”, “approximate”, “about”, and similar terms generally refer to ranges that include the identified value within a margin of 20%, 10%, or preferably 5%, and any values therebetween.

Referring to FIG. 1, a perspective view of a heat exchanger system 100 (hereinafter referred to as “the system 100”) is illustrated. The system 100 includes a cabinet 102 and a cabinet cover 104 is shown detached from the cabinet 102 to illustrate few internal components of the system 100. In some embodiments, the system 100 may be implemented as one of an air handler or a gas furnace. In an implementation, the system 100 may be a part of a heating, ventilation, and air conditioning (HVAC) system. A lower portion of the cabinet 102 houses a V-shaped round tube plate fin heat exchanger 106 (hereinafter referred to as “the coil 106”). The system 100 includes an axial fan housing 108 disposed within the cabinet 102. Particularly, the axial fan housing 108 is disposed vertically above and downstream of the coil 106 with respect to an airflow passage. A support plank 110 fastened to edges of the body 102 is configured to support the axial fan housing 108 within the cabinet 102. The axial fan housing 108 is configured to house an axial fan 112.

FIG. 2A illustrates a perspective view of the lower portion of the cabinet 102. The coil 104 includes a first arm 202, a second arm 204, and a plurality of refrigerant tubes 206 directed through each of the first arm 202 and the second arm 204. Typically, during operation of the air handler, warm or hot air from a living space of a house is suctioned through a return duct (not shown) and directed towards the coil 106. The warm or hot air passes through the first arm 202 and the second arm 204 of the coil 106, where heat is lost to the refrigerant supplied through the refrigerant tubes 206. As a result of such heat exchange, cold air exits the coil 106 and is supplied to the living space. As such, a first portion 208 of an inner periphery 210 of the cabinet 102 is subjected to the warm or hot air at an upstream location of the coil 106 and a second portion 212 of the inner periphery 210 of the cabinet 102 is subjected to the cold air at a downstream location of the coil 106. As such, a temperature of the second portion 212 is less than a temperature of the first portion 208. According to the present disclosure, a first insulation 214 is disposed along the first portion 208 of the cabinet 102 and a second insulation 216 is disposed along the second portion 212 of the cabinet 102.

FIG. 2B illustrates a cross-sectional view of the system 100 of FIG. 1. The first insulation 214 is provided along inner periphery of two opposite walls of the cabinet 102 as shown in FIG. 2B. Particularly, the first insulation 214 extends along the inner periphery of the two opposite walls up to a region where the arms of the coil 106 abut the inner periphery. Further, portions of the cabinet 102 downstream of the coil 106 is provided with the second insulation 216 as shown in FIG. 2B.

FIG. 2C is an illustration of an inner periphery of a door 220 of the system 100. The door 220 is configured to conceal the coil 106 when fastened to the cabinet 102. A portion of the door 220 exposed to the warm air flowing through the upstream portion of the coil 106 is provided with the first insulation 214 and another portion of the door 220 exposed to the conditioned air flowing downstream of the coil 106 is provided with the second insulation 216 as illustrated in FIG. 2C. Additionally, yet another portion (illustrated as V-shape) of the door 202 that abuts the coil 106 to form an interference fit is free from the insulations.

FIG. 2D is an exemplary illustration of a rear cover 222 of the cabinet 102 as seen from an end of the cabinet 102 configured to receive the door 220. As used herein, the “rear cover” refers a part of the cabinet 102 located opposite to the door 220 along a breadth of the cabinet 102. Similar to the configuration of the door 220, a portion of the rear cover 222 exposed to the warm air flowing through the upstream portion of the coil 106 is provided with the first insulation 214 and another portion of the rear cover 222 exposed to the conditioned air flowing downstream of the coil 106 is provided with the second insulation 216 as illustrated in FIG. 2D.

FIG. 3 illustrates details of a portion “A” in FIG. 2. In an embodiment, the first insulation 214 includes fiberglass and the second insulation 216 includes one of a rubber, a foam (e.g., a closed cell foam or an open cell foam), or a combination thereof. In one embodiment, the second insulation 216 is U723 closed-cell foam. In some embodiments, the second insulation 216 may be one of ArmaFlex Class-O closed-cell Nitrile rubber insulation, synthetic rubber insulation such as ethylene propylene diene monomer (EPDM), polyethylene anti-condensation soundproof foam, polyurethane foam, or an open-cell foam. In an embodiment, a thickness of each of the first insulation 214 and the second insulation 216 is in a range of 0.5 inch to 1.5 inch. In another embodiment, the thickness of each of the first insulation 214 and the second insulation 216 is in a range of 0.55 inch to 1.25 inch. In yet another embodiment, the thickness of each of the first insulation 214 and the second insulation 216 is in a range of 0.6 inch to 1 inch. In some embodiments, the system 100 may further include foils (not shown) configured to individually conceal the first insulation 214 and the second insulation 216.

In certain embodiments, the system 100 further includes a connecting member 218 disposed along an abutment of the first insulation 214 and the second insulation 216. In an embodiment, the first insulation 214 overlaps with the second insulation 216 at the abutment. The connecting member 218 may be embodied as a mesh or other suitable tape or flashing material and is configured to conceal the abutment. Additionally, in some embodiments, an inner surface (not shown) of the cabinet cover 104 may include the two insulation materials corresponding to the first portion 208 and the second portion 212 of the cabinet 102. When the cabinet cover 104 is fastened to the cabinet 102 to conceal the coil 106, a tight sealing may be established between the inner surface of the cabinet cover 104 and each of the first arm 202 and the second arm 204 of the coil 106. As such, portions of the inner surface of the cabinet cover 104 corresponding to first portion 208 and the second portion 212 of the cabinet 102 may include the first insulation 214 and the second insulation 216, respectively.

To this end, the present disclosure provides two material type insulation, such as the fiberglass or other insulation for the warm or hot side of the cabinet 102 and the foam or other insulation only for the cold side of the cabinet 102. As such, the foam insulates portions of the inner periphery 210 of the cabinet 102 that is exposed to the conditioned cold air and prevents condensation on an outer surface of the cabinet 102. With a marginal increase in cost of insulating the inner periphery 210 of the cabinet 102 due to the foam, a sweat-free heat exchanger system 100, such as the air handler, may be achieved. Therefore, the combination of fiberglass insulation in the warm or hot side of the cabinet 102 and the foam insulation only for the cold side of the cabinet 102 results in a non-sweat, low cost cabinet for the heat exchanger system 100.

While aspects of the present disclosure have been particularly shown and described with reference to the embodiments above, it will be understood by those skilled in the art that various additional embodiments may be contemplated by the modification of the disclosed methods without departing from the spirit and scope of what is disclosed. Such embodiments should be understood to fall within the scope of the present disclosure as determined based upon the claims and any equivalents thereof.

Claims

1. A heat exchanger system comprising:

a cabinet;

a V-shaped round tube plate fin heat exchanger disposed within the cabinet;

an axial fan housing disposed within the cabinet and located downstream of the V-shaped round tube plate fin heat exchanger;

a first insulation disposed along a first portion of an inner periphery of the cabinet, the first portion located upstream of the V-shaped round tube plate fin heat exchanger;

a second insulation disposed along a second portion of the inner periphery of the cabinet, the second portion located downstream of the V-shaped round tube plate fin heat exchanger, wherein, in operation, a temperature of air flowing through the second portion is less than a temperature of the air flowing through the first portion; and

a connecting member disposed along an abutment of the first insulation and the second insulation.

2. The heat exchanger system of claim 1, wherein the connecting member is a mesh tape.

3. The heat exchanger system of claim 1, wherein the connecting member is configured to conceal the abutment.

4. The heat exchanger system of claim 1, wherein the first insulation comprises fiberglass.

5. The heat exchanger system of claim 1, wherein the second insulation comprises one of a foam, a rubber, or a combination thereof.

6. The heat exchanger system of claim 1, wherein a thickness of each of the first insulation and the second insulation is in a range of 0.5 inch to 1.5 inch.

7. The heat exchanger system of claim 6, wherein the thickness of each of the first insulation and the second insulation is in a range of 0.55 inch to 1.25 inch.

8. The heat exchanger system of claim 7, wherein the thickness of each of the first insulation and the second insulation is in a range of 0.6 inch to 1 inch.

9. The heat exchanger system of claim 1, wherein the first insulation overlaps with the second insulation at the abutment.

10. The heat exchanger system of claim 1, further comprising a foil configured to conceal the first insulation.

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

a heat exchanger system comprising: a cabinet; a V-shaped round tube plate fin heat exchanger disposed within the cabinet; an axial fan housing disposed within the cabinet and located downstream of the V-shaped round tube plate fin heat exchanger; a plurality of refrigerant tubes located in the V-shaped round tube plate fin heat exchanger; a first insulation disposed along a first portion of an inner periphery of the cabinet, the first portion located upstream of the V-shaped round tube plate fin heat exchanger; a second insulation disposed along a second portion of the inner periphery of the cabinet, the second portion located downstream of the V-shaped round tube plate fin heat exchanger, wherein, in operation, a temperature of air flowing through the second portion is less than a temperature of the air flowing through the first portion; and a connecting member disposed along an abutment of the first insulation and the second insulation, wherein the connecting member is configured to conceal the abutment.

12. The HVAC system of claim 11, wherein the heat exchanger system is one of an air handler or a gas furnace.

13. The HVAC system of claim 11, wherein the first insulation comprises fiberglass.

14. The HVAC system of claim 11, wherein the second insulation comprises foam.

15. A heat exchanger system comprising:

a cabinet;

a V-shaped, round tube plate fin heat exchanger disposed within the cabinet;

an axial fan housing disposed within the cabinet and located downstream of the V-shaped round tube plate fin heat exchanger;

a first insulation disposed along a first portion of an inner periphery of the cabinet, the first portion located upstream of the V-shaped round tube plate fin heat exchanger;

a second insulation disposed along a second portion of the inner periphery of the cabinet, the second portion located downstream of the V-shaped round tube plate fin heat exchanger, wherein, in operation, a temperature of air flowing through the second portion is less than a temperature of the air flowing through the first portion; and

a connecting member disposed along, and configured to conceal, an abutment of the first insulation and the second insulation.

16. The heat exchanger system of claim 15, wherein the connecting member is a mesh tape.

17. The heat exchanger system of claim 15, wherein the first insulation comprises fiberglass having a thickness from 0.5 inch to 1.5 inch, and wherein the second insulation comprises a foam, a rubber, or a combination thereof, having a thickness from 0.5 inch to 1.5 inch.

18. The heat exchanger system of claim 17, further comprising a foil configured to conceal the first insulation.

19. The heat exchanger system of claim 15, wherein the first portion of the inner periphery along which the first insulation is disposed comprises at least part of a door of the cabinet and/or at least part of a rear cover of the cabinet.

20. The heat exchanger system of claim 19, wherein the second portion of the inner periphery along which the second insulation is disposed comprises at least part of a door of the cabinet and/or at least part of a rear cover of the cabinet.