Air Handler

This application is a continuation of U.S. application Ser. No. 18/312,294, filed May 4, 2023, which claims the benefit of U.S. Application No. 63/364,144, filed May 4, 2022, the entireties of which are hereby incorporated by reference.

The present disclosure relates, in general, to heat exchangers and, more specifically, relates to removable fixtures for an evaporator coil.

Known air handlers employ delta plates on both sides of an evaporator coil, such as a V-coil, to prevent air from bypassing the evaporator coil. In cases where return air or air from surrounding is forced through the evaporator coil for long period of time, an upstream portion of the evaporator coil is subjected to deposition of dust. Presence of the delta plates prevents access to the upstream portion of the evaporator coil and requires removal of the evaporator coil from a cabinet of the air handler to perform cleaning and maintenance activities. As such, presence of the delta plates prolongs the maintenance activity besides increasing an overall weight and cost of the air handler.

According to an aspect of the present disclosure, an air handler is disclosed. The air handler includes a cabinet, a V-shaped round tube plate fin evaporator coil disposed within the cabinet, a first coil extension coupled to a first tube sheet at a first arm of the V-shaped round tube plate fin evaporator coil, and a second coil extension coupled to a second tube sheet at a second arm of the V-shaped round tube plate fin evaporator coil. Each of the first coil extension and the second coil extension extends along a transverse direction of the V-shaped round tube plate fin evaporator coil. The air handler also includes a door disposed on a front portion of the cabinet to provide access to the V-shaped round tube plate fin evaporator coil. In such an arrangement, the first coil extension, the second coil extension, and the door are together configured to achieve an air-tight seal.

In an embodiment, the first coil extension is removably coupled to the first tube sheet and the secondly coil extension is removably coupled to the second tube sheet.

In an embodiment, the door is detachably coupled to the cabinet via tooled fasteners.

In an embodiment, the air handler further includes a first sealing member attached to a first peripheral surface of the first coil extension, and a second sealing member attached to a second peripheral surface of the second coil extension. The first sealing member and the second sealing member are configured to achieve the air-tight seal with an inner surface of the door.

In an embodiment, each of the first sealing member and the second sealing member of the air handler includes a compressive material.

In some embodiments, each of the first sealing member and the second sealing member is one of compressible closed cell foam, silicone, latex rubber, butyl rubber, or a resin-based sealant.

In some embodiments, a thickness of each of the first sealing member and the second sealing member is in a range of about 0.125 inch to about 0.75 inch.

In an embodiment, each of the first coil extension and the second coil extension includes a flat longitudinal surface configured to direct condensate towards a drain pan of the V-shaped round tube plate fin evaporator coil.

In an embodiment, the air handler further includes a first insulation strip attached to a bottom surface of the first coil extension and a second insulation strip attached to a bottom surface of the second coil extension. Each of the first insulation strip and the second insulation is configured to prevent dripping of condensate from corresponding bottom surfaces of the first coil extension and the second coil extension.

In some embodiments, each of the first insulation strip and the second insulation strip includes foam.

In some embodiments, a thickness of each of the first insulation strip and the second insulation strip is in a range of about 1/16inch to about ⅛inch.

In an embodiment, the first tube sheet defines a first slit and the second tube sheet defines a second slit. Further, the first coil extension includes a first tab to engage with the first slit, and the second coil extension includes a second tab to engage with the second slit.

In an embodiment, the first tube sheet includes a first flange, and the second tube sheet includes a second flange. Further, the first coil extension defines a first locating hole to engage with the first flange, and the second coil extension defines a second locating hole to engage with the second flange.

In another embodiment, each of the first coil extension and the second coil extension includes a root member to engage with a drain pan of the V-shaped round tube plate fin evaporator coil.

In some embodiments, each of the first coil extension and the second coil extension is made of one of aluminum, steel, or galvanized steel.

In some embodiments, a length of each of the first coil extension and the second coil extension is in a range of about 18 inches to about 40 inches.

In some embodiments, the air handler further includes a third coil extension coupled to a rear portion of a first arm of the V-shaped round tube plate fin evaporator coil and a fourth coil extension coupled to a rear portion of a second arm of the V-shaped round tube plate fin evaporator coil. Each of the third coil extension and the fourth coil extension extends along the transverse direction of the V-shaped round tube plate fin evaporator coil. The third coil extension, the fourth coil extension, and a rear panel of the cabinet are together configured to achieve an air-tight seal.

According another aspect of the present disclosure, a method of assembling a V-shaped round tube plate fin evaporator coil of an air handler is disclosed. The method includes disposing a first tube sheet at a first arm of the V-shaped round tube plate fin evaporator coil; disposing a second tube sheet at a second arm of the V-shaped round tube plate fin evaporator coil; engaging a first tab of a first coil extension with a first slit defined in the first tube sheet; engaging a second tab of a second coil extension with a second slit defined in the second tube sheet; and locking the first coil extension and the second coil extension in position based on the engagement of the first tab with the first slit and the second tab with the second slit.

In an embodiment, the method further includes aligning a first locating hole defined in the first coil extension with a first flange of the first tube sheet; aligning a second locating hole defined in the second coil extension with a second flange of the second tube sheet; and engaging the first flange with the first locating hole and the second flange with the second locating hole.

In some embodiments, the method includes attaching a first sealing member to a first peripheral surface of the first coil extension and a second sealing member to a second peripheral surface of the second coil extension.

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.

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.

Although various aspects of the disclosed technology are explained in detail herein, it is to be understood that other aspects of the disclosed technology are contemplated. Accordingly, it is not intended that the disclosed technology is limited in its scope to the details of construction and arrangement of components expressly set forth in the following description or illustrated in the drawings. The disclosed technology can be implemented and practiced or carried out in various ways. In particular, the presently disclosed subject matter is described in the context of being removable fixtures for an evaporator coil. The present disclosure, however, is not so limited, and can be applicable in other contexts such as air filtration systems, industrial process systems, or other contexts. Accordingly, when the present disclosure is described in the context of removable fixtures for an evaporator coil, it will be understood that other implementations can take the place of those referred to.

It should also be noted that, as used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. References to a composition containing “a” constituent is intended to include other constituents in addition to the one named.

Also, in describing the disclosed technology, terminology will be resorted to for the sake of clarity. It is intended that each term contemplates its broadest meaning as understood by those skilled in the art and includes all technical equivalents which operate in a similar manner to accomplish a similar purpose.

Ranges may be expressed herein as from “about” or “approximately” or “substantially” one particular value and/or to “about” or “approximately” or “substantially” another particular value. When such a range is expressed, the disclosed technology can include from the one particular value and/or to the other particular value. Further, ranges described as being between a first value and a second value are inclusive of the first and second values. Likewise, ranges described as being from a first value and to a second value are inclusive of the first and second values.

It is also to be understood that the mention of one or more method steps does not preclude the presence of additional method steps or intervening method steps between those steps expressly identified. Moreover, although the term “step” can be used herein to connote different aspects of methods employed, the term should not be interpreted as implying any particular order among or between various steps herein disclosed unless and except when the order of individual steps is explicitly required. Further, the disclosed technology does not necessarily require all steps included in the methods and processes described herein. That is, the disclosed technology includes methods that omit one or more steps expressly discussed with respect to the methods described herein.

Herein, the use of terms such as “having,” “has,” “including,” or “includes” are open-ended and are intended to have the same meaning as terms such as “comprising” or “comprises” and not preclude the presence of other structure, material, or acts. Similarly, though the use of terms such as “can” or “may” are intended to be open-ended and to reflect that structure, material, or acts are not necessary, the failure to use such terms is not intended to reflect that structure, material, or acts are essential. To the extent that structure, material, or acts are presently considered to be essential, they are identified as such.

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.

The components described hereinafter as making up various elements of the disclosed technology are intended to be illustrative and not restrictive. Many suitable components that would perform the same or similar functions as the components described herein are intended to be embraced within the scope of the disclosed technology. Such other components not described herein can include, but are not limited to, similar components that are developed after development of the presently disclosed subject matter.

Referring to, a perspective view of an air handleris illustrated. The air handlerincludes a cabinet, a V-shaped round tube plate fin evaporator coil(hereinafter referred to as “the coil”) disposed within the cabinet, and a drain pandetachably coupled to a base of the coil. The coilincludes a first arm, a second arm, a first tube sheetmounted to the first arm, and a second tube sheetmounted to the second arm. The coilincludes a distributor (not shown) to distribute fluid, such as a refrigerant, through the tubes thereof. According to an aspect of the present disclosure, the air handlerincludes a first coil extensionremovably coupled to the first tube sheet, and a second coil extensionremovably coupled to the second tube sheet. Each of the first coil extensionand the second coil extensionextends along a transverse direction “T” of the coil. As used herein, the term “transverse direction” corresponds to a direction in which a width of the coilis measured. Condensate formed on return bendsof refrigerant pipes drips on the first coil extensionand the second coil extensionand flows towards the drain pan.

As shown in, the air handlerincludes a doordisposed on a front portion of the cabinetto provide access to the coil. In an embodiment, the dooris detachably coupled to the cabinetvia tooled fasteners (not shown). As used herein, the term “tooled fasteners” refers to fasteners which requires tools to disengage them from a structure. In a non-limiting example, the tooled fasteners may be one of screws or bolts.

illustrates a perspective view of the first coil extension. In an embodiment, each of the first coil extensionand the second coil extensionis made of one of aluminum, steel, or galvanized steel. In some embodiments, a length of each of the first coil extensionand the second coil extensionis in a range of about 18 inches to about 40 inches. In an embodiment, the first coil extensionincludes a flat longitudinal surfaceconfigured to direct the condensate towards the drain pan.

The first coil extensionincludes a first peripheral surfacethat is configured to face an inner surface of the doorwhen removably coupled to the first tube sheet.also illustrates an enlarged view of a portion “A” and portion “B” of the first coil extension. In an embodiment, as seen in the enlarged view of portion “A”, the first coil extensiondefines a first locating holeand, as seen in the enlarged view of portion “B”, includes a first tab(clearly illustrated in). Further, the first coil extensionincludes a root memberconfigured to engage with the drain pan. The root memberis inclined at a predefined angle with respect to the flat longitudinal surface. For the purpose of brevity, only the first coil extensionis described. The second coil extensionincludes corresponding features described with respect to the first coil extension. In an embodiment, the second coil extensiondefines a second locating hole and includes a second tab and a root member.

illustrates a sequence of assembly stages of assembling the coil. Specifically,illustrates a first assembly stage of assembling the coil, according to an aspect of the present disclosure. A rear surface “R” of the first coil extensionincludes the first tab. In the illustrated embodiment, the first tabis formed from a cut portion of the rear surface of the first coil extension. The surface opposite to the first peripheral surface, with respect to a width of the first coil extension, is referred to as “the rear surface”. As such, the rear surface “R” of the first coil extensionremains distal from the inner surface of the door.

The first tube sheetdefines a first slitextending along a width thereof as shown in. The first slithas a narrow portionand a broad portion. According to an aspect, the first tabis configured to engage with the first slit, to removably couple the first coil extensionwith the first tube sheet. Particularly, the first slitis configured to receive the first tabtherein. The first tabincludes an arcuate portionand a planar portion. The arcuate portion of the first tabpositions the planar portionat a distance “X” from the rear surface “R” of the first coil extension. The distance “X” is preset to be greater than a thickness “Y” of the first tube sheet. Additionally, a width of the narrow portionof the first slitis designed to be greater than a thickness of the first tab. In the first assembly stage, the arcuate portionof the first tabis aligned with the narrow portionof the first slit.

illustrates a second assembly stage of assembling the coil, according to an aspect of the present disclosure. In the second assembly stage, the first coil extensionis moved towards the first tube sheet, such that the arcuate portionof the first tabis received within the narrow portionof the first slit. Further movement of the first coil extensioninto the first slitallows the first tabto be completely received within the first slit, as shown in.

illustrates a third assembly stage of assembling the coil, according to an aspect of the present disclosure. The first coil extensionis moved in a direction along a length of the first tube sheetto lock the first tabwithin the broad portionof the first slit. Such an arrangement prevents the first coil extensionfrom being detached through the narrow portionof the first slit. Therefore, the first coil extensionis removably coupled to the first tube sheet. Following these steps in a reverse order allows detachment of the first coil extensionfrom the first tube sheet.

andillustrates another set of sequential stages of assembling the coil. Specifically,illustrates a fourth assembly stage andillustrates a fifth assembly stage of assembling the coil, according to an aspect of the present disclosure. The first tube sheetincludes a first protrusion. The first locating holedefined in the first coil extensionis aligned with the first protrusion. As shown in, the first coil extensionis moved towards the first tube sheetuntil the first protrusionis received in the first locating hole. In some embodiments, the first locating holemay get aligned with the first protrusionsimultaneously when the first tabis locked within the first slit. In some embodiments, the assembly stages described with respect toandmay be performed separately after the assembly stages described with respect to. In some embodiments, the first tube sheetmay define another hole instead of the first protrusion, to be aligned with the first locating holedefined in the first coil extension. Once the two holes are aligned, a fastener may be used to couple the first coil extensionto the first tube sheet.

The terms “first assembly stage”, “second assembly stage”, “third assembly stage”, “fourth assembly stage”, and “fifth assembly stage” used herein are merely for the purpose of clarity in description and do not represent the initial steps in order of assembling the coil.

Although not illustrated through figures, as mentioned earlier, the second coil extensionand the second tube sheetinclude features corresponding to those described with respect to the first coil extensionand the first tube sheet, respectively. In an embodiment, the second tube sheetdefines a second slit and the second coil extensionincludes a second tab configured to engage with the second slit. Additionally, the second tube sheetincludes a second protrusion and the second coil extensiondefines a second locating hole configured to receive the second protrusion. To this end, the first coil extensionand the second coil extensionmay be removably coupled to the first tube sheetand the second tube sheet, respectively. From the description herein, other methods of removably coupling the first coil extensionwith the first tube sheetand the second coil extensionwith the second tube sheetmay be apparent to a person skilled in the art.

illustrates a cross-sectional top view of the air handler. In an embodiment, the air handlermay include a first sealing memberattached to the first peripheral surfaceof the first coil extensionand a second sealing memberattached to the second peripheral surface(see) of the second coil extension. In an embodiment, each of the first sealing memberand the second sealing memberincludes a compressive material. In some embodiments, the first sealing memberand the second sealing memberis one of compressible closed cell foam, silicone, latex rubber, butyl rubber, or a resin-based sealant. In some embodiments, a thickness of each of the first sealing memberand the second sealing memberis in a range of about 0.125 inch to about 0.75 inch. According to an aspect of the present disclosure, the first peripheral surfaceof the of the first coil extension, the second peripheral surfaceof the second coil extension, and the inner surfaceof the doorare together configured to achieve an air-tight seal. Particularly, the first sealing memberattached to the first peripheral surfaceof the first coil extensionand the second sealing memberattached to the second peripheral surfaceof the second coil extensionaid in achieving the air-tight seal between the coiland the door. In an embodiment, a rear portion of the coilmay include coil extensions similar to those described herein, and additional sealing members may be used to achieve an air-tight seal between such coil extensions and rear wall of the cabinet.

As such, a first air flow region(see) that is in fluid communication with the first armof the coiland a second air flow region(see) that is in fluid communication with the second armof the coilmay be free from openings through which the air escapes from the flow regions. Therefore, in a draw-through application, it may be ensured that the suctioned air passes wholly through the arms,of the coil. Typically, a temperature difference between the air flowing across the arms,of the coiland the condensate flowing along the coil extensions,may result in formation of condensation droplets on a bottom surface of the coil extensions,. Accumulation of such droplets may cause dripping of the condensate from the coil.

In an embodiment, the air handlermay include a first insulation strip (not shown) attached to a bottom surface(see) of the first coil extensionand a second insulation strip (not shown) attached to a bottom surface (not shown) of the second coil extension. Each of the first insulation strip and the second insulation strip is configured to prevent dripping of condensate from corresponding bottom surfaces of the first coil extensionand the second coil extension, respectively. In some embodiments, each of the first insulation strip and the second insulation strip includes foam. In some embodiments, a thickness of each of the first insulation strip and the second insulation strip is in a range of about 1/16inch to about ⅛inch. In some embodiments, each of the first insulation strip and the second insulation strip may include copper dispersed therein, so that copper ions are added to the condensate to kill viruses therein and prevent growth of bacteria.

illustrates a rear portion of the coil. In some embodiments, the coilincludes a third coil extensionremovably coupled to a rear portion of the first armof the coiland a fourth coil extensionremovably coupled to a rear portion of the second armof the coil. Each of the third coil extensionand the fourth coil extensionextends along the transverse direction “T” of the coil. The third coil extension, the fourth coil extension, and a rear panel (not shown) of the cabinet are configured to together achieve an air-tight seal. Structurally, the third coil extensionand the fourth coil extensioninclude features already described with respect to the first coil extensionand the second coil extension. Additionally, a manner in which the third coil extensionand the fourth coil extensionare coupled to rear portions of the first armand the second arm, respectively, is the same described with respect to that of the first coil extensionand the second coil extension.

To this end, the present disclosure provides the air handlerthat effectively drains the condensate and prevents bypass of air within the cabinet. Particularly, presence of the first sealing memberand the second sealing memberbetween the respective coil extensions,and the inner surfaceof the doorensures the bypass of the air is prevented. As such, requirement of delta plates is overcome. Therefore, a service personnel may easily access an upstream portion of the coilto perform the maintenance activity without the need to remove the coilfrom the cabinet. Such provision reduces the overall time required to execute the maintenance of the coiland reduces the overall cost and weight of the air handler due to absence of the delta plates. Additionally, presence of the tabs on the coil extensions and slits in the tube sheets eliminates need for tools, thereby easing the assembly process. The coil extensions may be embodied as sheet metal parts, and hence the tabs may be formed therein with minimum time and effort. Although the coil extensions herein are described with respect to the V-coil, in some embodiments, the coil extensions of the present disclosure may be used in A-coil, N-coil, and the like.

illustrates a flowchart of a methodandillustrates a flowchart of methodof assembling the coil, according to aspects of the present disclosure. The methodis described in conjunction withthrough. The order in which the methodsandare described is not intended to be construed as a limitation, and any number of the described method blocks can be combined in any order to implement the methodsand, or an alternative method. Additionally, individual blocks may be deleted from the methodsandwithout departing from the scope of the subject matter described herein.