WO2014101215A1

WO2014101215A1 - Coil end plate for a heat exchanger coil assembly

Info

Publication number: WO2014101215A1
Application number: PCT/CN2012/088104
Authority: WO
Inventors: Shunhua Wang; Wenhu YANG; Duhui ZHOU
Original assignee: Trane Air Conditioning Systems (China) Co., Ltd.
Priority date: 2012-12-31
Filing date: 2012-12-31
Publication date: 2014-07-03
Also published as: CN105008847A

Abstract

Embodiments of coil end plate of a heat exchange coil assembly are disclosed. The coil end plate can be configured to include a raised surface feature(s) that can provide structural support to a header cover of the heat exchange coil assembly, so that the header cover can resist deformation caused, for example, by an external force. The raised surface features can also help retain the header cover on the surface of the coil end plate. The raised surface feature(s) of the coil end plate may be made by deforming (such as crimping or punching) a portion of the coil end plate from a back of the coil end plate, so that the back of the coil end plate remains to be flat. During assembly, the flat back of the coil end plate can engage a side panel of an indoor unit.

Description

COIL END PLATE FOR A HEAT EXCHANGER COIL ASSEMBLY

Field

The disclosure herein generally relates to a heating, ventilation, and air-conditioning ("HVAC") system, and more particularly to a heat exchanger coil assembly of the HVAC system. Generally, methods, systems, and apparatuses are described that are directed to a coil end plate of the heat exchanger coil assembly.

Background

Heat exchanger coil assemblies have been used in a HVAC system. The heat exchanger coil assembly can be configured to include a plurality of heat exchange tubes. The heat exchange tubes are generally configured to carry a fluid internally, such as a refrigerant or a process fluid (such as water conditioned by the HVAC system). When air is moved across the heat exchange tubes, the air and the fluid in the heat exchange tubes can form a heat exchange relationship to help exchange heat between the fluid and the air.

The heat exchanger coil assembly sometimes can be configured to include coil end plates. The coil end plates may be configured to include a plurality of holes configured to receive the heat exchange tubes. The coil end plates can provide structural support to the heat exchange tubes, thus help increase a structural integrity of the heat exchanger coil assembly.

Summary

Embodiments of a coil end plate of a heat exchange coil assembly are disclosed to provide structural support to a header cover engaging the coil end plate, so that the header cover can resist deformation by an external force.

In some embodiments, the coil end plate may be configured to include a plurality of raised surface features, such as tabs or flanges. In some embodiments, the raised surface features may be configured to engage an inner surface of a header cover of the heat exchange coil assembly, so as to provide structural support to the header cover. In some embodiments, the coil end plate may also include a plurality of raised sides along a profile of the coil end plate. In some embodiments, for example, the profile of the coil end plate is generally rectangular box-like, the raised sides may be configured to be along some or all of the four sides of the general rectangular shaped profile.

In some embodiments, a wing of the header cover may be positioned between one of the raised sides and one of the corresponding raised surface features. In some embodiments, the wing of the header cover may be configured to engage the raised surface feature and the corresponding raised side of the coil end plate, and be retained by the raised surface feature and the corresponding raised side. In some embodiments, a distance between the raised surface feature and the corresponding raised side may be configured to be about the same as a width of a wing of the header cover of the heat exchange coil assembly.

In some embodiments, the raised surface features may be configured to be made by deforming a portion of the coil end plate from a back of the coil end plate. In some

embodiments, the back of the coil end plate may remain flat after the raised surface features being made. In some embodiments, the flat back of the coil end plate may be configured to engage a side panel of an indoor unit.

In some embodiments, the raised surface features are flanges or tabs, which may be made by punching the back of the coil end plate.

In some embodiments, the coil end plate of a heat exchange coil assembly may include a plurality of raised surface features configured to engage and retain a header cover on a surface of the coil end plate; and a back of the coil end plate configured to engage a side panel of an indoor unit.

Other features and aspects of the embodiments will become apparent by consideration of the following detailed description and accompanying drawings.

Brief Description of the Drawings

Reference is now made to the drawings in which like reference numbers represent corresponding parts throughout. FIG. 1 is a perspective view of an indoor unit of a HVAC system.

FIGS. 2A and 2B illustrate perspective views of a heat exchanger coil assembly of the indoor unit as shown in FIG. 1.

FIGS. 3 A to 3C illustrate different perspective views of a coil end plate and a header cover of the indoor unit as shown in FIG. 1. FIG. 3A illustrates a perspective view of the coil end plate and the attached header cover. FIG. 3B illustrates a perspective view of the coil end plate. FIG. 3C illustrates a side view of the coil end plate.

FIG. 4 illustrates an enlarged front view of the indoor unit as shown in FIG. 1. The engagement of the coil end plate to a side panel of the indoor unit is shown.

FIGS. 5 A to 5D illustrate a partial perspective view of coil end plates, showing different embodiments of raised surface features of the coil end plates.

FIG. 6 illustrates a partial perspective view of a coil end plate and a header cover.

Detailed Description

Various heat exchanger coil assemblies have been used in HVAC systems. The heat exchanger coil assembly can be configured to have a plurality of heat exchange tubes configured to form a heat exchange relationship, such as, between air moving across outer surfaces of the heat exchange tubes and a fluid (such as a refrigerant or water) carried in the heat exchange tubes. When the air moves across the outer surfaces of the heat exchange tubes, the air can be conditioned (cooled or heated) by the fluid in the heat exchange tubes. In the heat exchanger coil assembly, the heat exchange tubes are often configured to extend between two coil end plates. The coil end plates can be configured to have holes that are configured to receive the heat exchange tubes. The heat exchange tubes can pass through the holes of the coil end plates, and the coil end plates can provide structural support for the heat exchange tubes.

The heat exchange tubes may be connected to coil headers that are configured to distribute the fluid into the heat exchange tubes or collect the fluid flowing out of the heat exchange tubes. In some embodiments, the coil headers may be at least partially covered and protected by a header end cover, which is often configured to be attached to a surface of the coil end plate. The header end cover sometimes may be deformed by an external force, such as for example during transportation, causing damages to the coil headers and/or the heat exchange tubes.

Embodiments disclosed herein relates to raised surface features of a coil end plate of a heat exchanger coil assembly that are configured to provide structural support to a coil header cover so as to help prevent the coil header cover from deformation. In some embodiments, the coil end plate is configured to have a plurality of raised surface features (such as flanges or tabs) rising out of a surface of the coil end plate. In some embodiments, the plurality of raised surface features can be configured to engage an inner surface of the header end cover and provide structural support to the header end cover, so as to prevent the header end cover from

deformation by an external force. In some embodiments, the plurality of raised surface features can also help retain the coil header cover on the surface of the coil end plate. The raised surface features can be made by deforming (such as crimping or punching) a portion of the coil end plate from a back of the coil end plate. Deforming a portion of the coil end plate is a relatively easy manufacturing process.

References are made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration of the embodiments in which the embodiments may be practiced. It is to be understood that the terms used herein are for the purpose of describing the figures and embodiments and should not be regarding as limiting the scope of the present application.

Fig. 1 illustrates a HVAC indoor unit 100 that includes a heat exchanger coil assembly

110, according to one embodiment. The indoor unit 100 includes a housing 115 configured to accommodate the heat exchanger coil assembly 1 10. A fan 120 is attached to the housing 115 and is configured to move air across the heat exchanger coil assembly 110, so that the air can be conditioned by the heat exchanger coil assembly 110. The housing 115 includes a side panel 150.

The heat exchanger coil assembly 110 includes a coil end plate 112. A plurality of heat exchange tubes 1 13 of the heat exchanger coil assembly 110 extending out of the coil end plate 112. The coil end plate 1 12 can be configured to provide structural support to the heat exchange tubes 113. It is to be understood that the heat exchange tubes 1 13 extend in a longitudinal direction that is defined by a length LI inside the housing 115. (The extension of the heat exchange tubes inside the housing 115 is not shown.)

Ends of the heat exchange tubes 113 extend out of the coil end plate 112, and are configured to be connected to headers 130a and 130b. The header 130a is configured to, for example, collect the fluid flowing back to the header 130a through the heat exchange tubes 1 13, and the header 130b is configured to, for example, distribute a fluid (e.g. refrigerant or water) to the heat exchange tubes 113.

A header cover 140 is configured to at least partially cover the portion of the heat exchange tubes 113 extending out of the coil end plate 1 12 and/or the headers 130a and 130b. In the illustrated embodiments, the header cover 140 is configured to have a generally rectangular box shape, with two side panels 142a and 142b, and an end panel 144, and is configured to bracket the heat exchange tubes 113 and the headers 130a and 130b. The two side panels 142a and 142b are connected by the end panel 144. The header cover 140 may have mounting apertures 155 that are configured to receive, for example, screws. The header cover 140 can provide some protection for the heat exchange tubes 113 and/or the headers 130a and 130b from, for example, external forces or objects. In some embodiments, the header cover 140 may be made of sheet metal.

It is to be appreciated that the general rectangular box shaped header cover 140 is exemplary. The header cover 140 can be configured to have other shapes. Generally, the header cover 140 is configured to provide some protection to the heat exchange tubes 1 13 and/or the headers 130a and 130b.

Figs. 2 A and 2B further illustrate the heat exchanger coil assembly 110, which includes the heat exchange tubes 113, the coil end plates 1 12, the header cover 140 and headers 130a and 130b. As shown in Figs. 2A and 2B, the heat exchanger coil assembly 1 10 has two coil end plates 1 12. The heat exchange tubes 1 13 are configured to extend between the two coil end plates 112. (The portions of the heat exchange tubes 1 13 that extend between the two coil end plates 112 are not shown in the figures.) The coil end plates 112 are configured to have a plurality of holes 116 configured to accommodate the heat exchange tubes 1 13. Each of the holes 116 may typically be configured to accept one heat exchange tube 113. Because the holes 116 can retain the heat exchange tubes 113, the coil end plates 1 12 can provide structural support to the heat exchange tubes 113 in the heat exchanger coil assembly 110.

The header cover 140 is configured to engage the coil end plate 112. The header cover 140 is generally configured to at least partially cover the headers 130a, 130b and portions of the heat exchange tubes 113, thus provide protection to the headers 130a and 130b and/or the heat exchange tubes 113.

Referring to Figs. 1, 2A and 2B, when the heat exchanger coil assembly 110 is assembled to the indoor unit 100, the coil end plate 112 is configured to engage the side panel 150 of the housing 1 15. The coil end plate 112 and the header cover 140 can be mounted to the side panel 150 by, for example, screws through the mounting apertures 155.

Referring to Figs. 3A to 3C, more details of the coil end plate 112 and the header cover 140 are illustrated. As illustrated in Fig. 3A, the coil end plate 1 12 and the header cover 140 are typically configured to attach to or engage each other. The coil end plate 1 12 has raised sides 162 along a circumferential profile of the coil end plate 112. The coil end plate 112 also has holes 116 that are configured to accommodate the heat exchange tubes 113 (as shown in, for example, Fig. 1).

The coil end plate 112 has a plurality of raised surface features 166, such as flanges or tabs, rising out of a surface 170 of the coil end plate 1 12. The raised surface features 166 can have a distance from the corresponding raised sides 162. For example, as shown in Fig. 3B, the raised surface feature 166b has a distance D3 from the corresponding raised side 162b.

Similarly, the raised surface feature 166a can also have a similar distance as D3 from the corresponding raised side 162a. The corresponding raised side (such as 162b) is generally the raised side 162 that is situated close to the raised surface feature (such as 166b), and the corresponding raised side and the raised surface feature generally extend in the same direction.

The header cover 140 can have two wings 164a and 164b that are configured to engage the raised sides 162 and/or the corresponding raised surface features 166 of the coil end plate 112. The wings 164a and 164b are generally outwardly extending portions of the header cover 140.

As shown in Fig. 3 A, the wings 164a and 164b of the header cover 140 can be configured to be positioned between one of the raised surface features 166 and one of the corresponding raised sides 162. For example, the wing 164a can be positioned between the raised surface feature 166a and the corresponding raised side 162a; and the wing 164b can be positioned between the raised surface feature 166b and the corresponding raised side 162b. The distance D3 between, for example, the raised surface feature 166b to the corresponding raised side 162b, may be configured to be about the same as a width W3 of the wing 164a or 164b. Consequently, the wings 164a and 164b can be positioned between the raised surface features 166a, 166b and the corresponding raised sides 162a, 162b respectively. The raised surface features 166 are configured to also engage an internal surface 172 of the header cover 140 when the wings 164a and 164b are positioned between the raised surface features 166a, 166b and the corresponding raised sides 162a, 162b respectively.

In some embodiments, the engagement of the raised sides 162 and the raised surface features 166 with the header cover 140 can help retain the header cover 140 on the surface 170 of the coil end plate 112.

It is to be appreciated that the wings 164a and 164b are exemplary. The header cover 140 is typically configured to include a feature (such as a fiat surface) that is configured to engage the surface 170 of the coil end plate 1 12. It is also appreciated that in some embodiments, the wing 164a or 164b may not engage the raised side 162a or 162b. The wing 164a or 164b may be retained on the surface 170 of the coil end plate 112 solely by raised surface features. (See, for example, Figs. 5D and 6.)

The raised surface features 166, such as flanges as illustrated in Figs 3 A and 3B, can be made by deforming (such as crimping or punching) a portion of the coil end plate 112 from a back 180 of the coil end plate 112, which is relatively easy to make during manufacturing processes. As shown in Fig. 3C, since the raised surface features 166 can be made by deforming a portion of the coil end plate 112 from the back 180 of the coil end plate 112, the back 180 remains to be essentially flat after the raised surface features 166 being made.

Referring to Fig. 4, when the heat exchange assembly 110 is assembled to the indoor unit 100, the flat back 180 of the coil end plate 112 is configured to engage the side panel 150 of the housing 1 15. The flat back 180 can engage the side panel 150. This can help maintain a good engagement between the coil end plate 1 12 and the side panel 150, and may help prevent air leakage between the coil end plate 1 12 and the side panel 150 and/or increase structural integrity of the indoor unit 100.

Referring back to Fig. 3 A, the raised surface features 166 engage the inner surface 172 of the header cover 140. When the header cover 140 is pushed, for example, by a lateral external force F, the raised surface features 166 can provide a support to the header cover 140 against the lateral external force F, so that the header cover 140 can resist deformation that otherwise would be caused by the lateral external force F. The raised surface features 166 therefore provide structural support to the header cover 140.

The raised surface feature can have various shapes and forms. Figs. 5A to 5D illustrate other embodiments of raised surface features 566a, 566b, 566c and 566d respectively. As illustrated in Fig. 5A, the raised surface feature 566a can be a break-away piece, such as a louver-like piece, from surface 570a of a coil end plate 512a.

As illustrated in Fig. 5B, the raised surface feature 566b can be a half-dome like structure on surface 570b of a coil end plate 512b. As illustrated in Fig. 5C, the raised surface feature 566c can be a bridge-like structure on surface 570c of a coil end plate 512c.

As illustrated in Fig. 5D, the raised surface feature 566d can be a double bridge-like structure on surface 570d of a coil end plate 512d. The double bridge-like raised surface feature 566d has a gap G5 between the bridges 566d-l and 566d-2. The gap G5 may be configured to receive a wing of a header cover (such as the wing 164a or 164b of the header cover 140), so that the wing of the header cover can be positioned between the bridges 566d-l and 566d-2. In some embodiments, the header cover may be made of sheet metal. The gap G5 can be configured to be about a thickness of the sheet metal. The sheet metal can be positioned in the gap G5 directly, and the wing section may not be necessary.

As illustrated in Fig. 6, a wing 664 of a header cover 640 can include a slot 672 that is configured to receive raised surface feature 666, such as a flange or a tab, of coil end plate 612. The engagement of the raised surface feature 666 and the wing 664 can help provide structural support to the header cover 640 and/or help retain the header cover 640 on a surface 670 of the coil end plate 612.

It is to be understood that the embodiments as illustrated herein are exemplary. The general principle is to provide a raised surface feature(s) on a coil end plate that is configured to provide structural support to a header cover, so that the header cover can resist deformation that would otherwise be caused by an external force. The raised surface features(s) can also be configured to retain the header cover on a surface of the coil end plate. The raised surface features can be easily made, such as, by deforming (such as crimping or punching) a portion of the coil end plate from a back of the coil end plate, so that the coil end plate can also have a generally flat back. The flat back of the coil end plate can be attached to or engage a side panel of an indoor unit to achieve a good engagement between the side panel and the coil end plate.

With regard to the foregoing description, it is to be understood that changes may be made in detail, without departing from the scope of the present invention. It is intended that the specification and depicted embodiments are to be considered exemplary only, with a true scope and spirit of the invention being indicated by the broad meaning of the claims.

Claims

Claims What claimed is:

1. A coil end plate of a heat exchange coil assembly comprising:

a plurality of raised surface features, wherein the raised surface features are configured to engage an inner surface of a header cover of the heat exchange coil assembly.

2. The coil end plate of claim 1, further comprising:

a plurality of raised sides along a profile of the coil end plate, wherein a distance between the one of the plurality of raised surface features and the neighboring one of the plurality of raised sides is configured to be the same as a width of a wing of the header cover of the heat exchange coil assembly, wherein the wing of the header cover of the heat exchange coil is configured to be positioned between the one of the plurality of raised surface features and the neighboring one of the plurality of raised sides.

3. The coil end plate of claim 1, wherein the plurality of raised surface features are made by deforming the coil end plate from a back of the coil end plate.

4. The coil end plate of claim 1, wherein the plurality of raised surface features are flanges.

5. The coil end plate of claim 1, wherein a back of the coil end plate is configured to engage a side panel of an indoor unit when the indoor unit is assembled.

6. A coil end plate of a heat exchange coil assembly, comprising:

a plurality of raised surface features configured to engage a header cover on a surface of the coil end plate; and

a back of the coil end plate configured to engage a side panel of an indoor unit when it is assembled;

wherein the plurality of raised surface features are made by deforming a portion of the coil end plate from the back of the coil end plate so that the back of the coil end plate remains to be flat.

7. A heat exchanger coil assembly, comprising:

a first end plate and a second end plate;

a plurality of heat exchange tubes extending between the first end plate and the second end plate; and

a header cover, the header cover having a wing extending outwardly;

wherein the first end plate has a raised surface feature and a corresponding raised side, the wing is positioned between the raised surface feature and the corresponding raised side, and the raised surface feature engages an inner surface of the header cover.

8. The heat exchanger coil assembly of claim 7, wherein the raised surface feature is made by deforming the first end plate from a back of the end plate.

9. The heat exchanger coil assembly of claim 7, wherein the raised surface feature is a flange.

10. A method to make an indoor unit including a heat exchanger assembly, comprising:

deforming a back of a coil end plate of the heat exchange coil assembly to make a plurality of raised surface features on a surface of the coil end plate;

engaging an inner surface of a header cover with the raised surface features; and attaching the back of the coil end plate of the heat exchange coil assembly to a panel of the indoor unit, wherein the back of the coil end plate engages the panel of the indoor unit.