AIR HANDLER ASSEMBLY INCLUDING V-SHAPED BAFFLE

Description

TECHNICAL FIELD

The disclosed apparatuses and systems relate generally to an air handler assembly that cools or heats air. The air handler assembly includes a blower and a heat-exchanging coil. The blower causes air to move through the heat-exchanging coil. A baffle is located upstream of the heat-exchanging coil with respect to an airflow direction in which air is discharged from the outlet of the blower.

BACKGROUND

An air handler assembly generally includes a blower and a heat exchanger, which may include coils through which refrigerant flows. The blower may be located at an airflow inlet of the heat exchanger such that it blows air through the coils of the heat exchanger, or the blower may be located at an airflow outlet of the heat exchanger such that it draws air through the coils of the heat exchanger. When air is moved through the coils of the heat exchanger by the blower, the airflow may have a high velocity and may contact the coils of the heat exchanger with excessive force.

In this case, condensate blow-off may occur. Specifically, high-velocity airflow passing through the heat exchanger may cause drops of water formed on the coils due to condensation to blow off of the heat exchanger and into duct areas or other small and narrow areas of the air handler assembly. This may cause mold and odor to form, resulting in a possible health hazard for occupants of the building at which the air handler is located.

Furthermore, when the airflow passing through the heat exchanger is concentrated on a center portion of the heat exchanger instead of being evenly distributed across the heat-transfer regions of the heat exchanger, the efficiency of the heat exchanger may be reduced.

Therefore, it is desirable to provide an air handler assembly that evenly distributes the airflow to the coils of the heat exchanger.

SUMMARY OF THE INVENTION

According to one or more embodiments, an air handler assembly is provided, including: a heat-exchanging coil; a blower configured to move air through the heat-exchanging coil; and a baffle positioned upstream of the heat-exchanging coil in an airflow direction in which air is discharged from an outlet of the blower. The baffle includes a first inclined plate and a second inclined plate, and a distance between the first inclined plate and the second inclined plate increases from an edge of the first inclined plate that is furthest upstream in the airflow direction to an edge of the first inclined plate that is furthest downstream in the airflow direction.

The first inclined plate and the second inclined plate of the baffle may be connected at a portion of the baffle that is furthest upstream in the airflow direction.

The baffle may be V-shaped in cross-section.

The portion of the baffle that is furthest upstream in the airflow direction may be curved.

A flat plate may connect the first inclined plate and the second inclined plate at a portion of the baffle that is furthest upstream in the airflow direction.

An angle between the first inclined plate and the second inclined plate may be between 45° and 135°.

The baffle may be formed of metal.

The baffle may be formed of plastic.

A distance between the edge of the first inclined plate that is furthest upstream in the airflow direction and the edge of the first inclined plate that is furthest downstream in the airflow direction may be between 1 inch and 4 inches, and a distance between an edge of the second inclined plate that is furthest upstream in the airflow direction and an edge of the second inclined plate that is furthest downstream in the airflow direction may be between 1 inch and 4 inches.

The air handler assembly may further comprise a housing which surrounds the blower, the heat-exchanging coil, and the baffle.

The heat-exchanging coil may include a plurality of heat transfer tubes configured to convey fluid. Each heat transfer tube of the plurality of heat transfer tubes may be positioned such that a flow direction of the fluid is substantially perpendicular to the airflow direction.

The heat-exchanging coil may include two coil plates. The two coil plates may be inclined such that a distance between the two coil plates increases from a position of the heat-exchanging coil that is furthest downstream in the airflow direction to a position of the heat-exchanging coil that is furthest upstream in the airflow direction. The two coil plates may be joined at the position of the heat-exchanging coil that is furthest downstream in the airflow direction.

The air handler assembly may further comprise a first side plate and a second side plate. The first side plate may cover a first side of the heat-exchanging coil such that it contacts a first side of each of the two coil plates. The second side plate may cover a second side of the heat-exchanging coil such that it contacts a second side of each of the two coil plates. The first side plate may extend from the position at which the two coil plates are joined to an end of each coil plate that is furthest upstream in the airflow direction, and the second side plate may extend from the position at which the two coil plates are joined to the end of each coil plate that is furthest upstream in the airflow direction.

The baffle may overlap with the position at which the two coil plates are joined when viewed in the airflow direction.

The air handler assembly may further comprise a side drain pan located below the heat-exchanging coil when the air handler is in a horizontal position in which the first inclined plate is positioned vertically above the second inclined plate. The entire baffle may be located above the side drain pan.

When the air handler is in the horizontal position, the entire baffle may be located within an outer wall of the side drain pan when viewed from above.

The baffle may be positioned between the outlet of the blower and the heat-exchanging coil.

The blower may be located downstream of the heat-exchanging coil in the airflow direction.

The blower may be located upstream of the heat-exchanging coil in the airflow direction.

According to one or more embodiments, an air handler assembly is provided, including: a heat-exchanging coil; a blower configured to move air through the heat-exchanging coil; and a baffle positioned upstream of the heat-exchanging coil in an airflow direction in which air is discharged from an outlet of the blower. The baffle may include a first inclined plate and a second inclined plate. A distance between the first inclined plate and the second inclined plate may increase from an edge of the first inclined plate that is furthest upstream in the airflow direction to an edge of the first inclined plate that is furthest downstream in the airflow direction. The heat-exchanging coil may include two coil plates. The two coil plates may be inclined such that a distance between the two coil plates increases from a position of the heat-exchanging coil that is furthest downstream in the airflow direction to a position of the heat-exchanging coil that is furthest upstream in the airflow direction, and the two coil plates may be joined at the position of the heat-exchanging coil that is furthest downstream in the airflow direction. A first side plate may cover a first side of the heat-exchanging coil such that it contacts a first side of each of the two coil plates. A second side plate may cover a second side of the heat-exchanging coil such that it contacts a second side of each of the two coil plates. A first side of the baffle may be attached to the first side plate, and a second side of the baffle may be attached to the second side plate.

The first side plate may extend from the position at which the two coil plates are joined to an end of each coil plate that is furthest upstream in the airflow direction. The second side plate may extend from the position at which the two coil plates are joined to the end of each coil plate that is furthest upstream in the airflow direction.

The baffle may include at least one first flange positioned on the first side of the baffle and extending in the airflow direction, and the baffle may include at least one second flange positioned on the second side of the baffle and extending in the airflow direction. The at least one first flange may be configured to be attached to the first side plate. The at least one second flange may be configured to be attached to the second side plate. The baffle may be positioned such that at least a portion of the baffle extends further upstream in the airflow direction than the first side plate and the second side plate.

The first side of the baffle may be attached to the first side plate by at least one first fastener, and the second side of the baffle may be attached to the second side plate by at least one second fastener.

The at least one first fastener may include at least one of a bolt, a screw, or a rivet, and the at least one second fastener may include at least one of a bolt, a screw, or a rivet.

The first inclined plate and the second inclined plate of the baffle may be connected at a portion of the baffle that is furthest upstream in the airflow direction.

The baffle may be V-shaped in cross-section.

The portion of the baffle that is furthest upstream in the airflow direction may be curved.

A flat plate may connect the first inclined plate and the second inclined plate at a portion of the baffle that is furthest upstream in the airflow direction.

An angle between the first inclined plate and the second inclined plate may be between 45° and 135°.

The baffle may be formed of metal.

The baffle may be formed of plastic.

A distance between the edge of the first inclined plate that is furthest upstream in the airflow direction and the edge of the first inclined plate that is furthest downstream in the airflow direction may be between 1 inch and 4 inches, and a distance between an edge of the second inclined plate that is furthest upstream in the airflow direction and an edge of the second inclined plate that is furthest downstream in the airflow direction may be between 1 inch and 4 inches.

The air handler assembly may further comprise a housing which surrounds the blower, the heat-exchanging coil, and the baffle.

The baffle may overlap with the position at which the two coil plates are joined when viewed in the airflow direction.

The air handler assembly may further comprise a side drain pan located below the heat-exchanging coil when the air handler is in a horizontal position in which the first inclined plate is positioned vertically above the second inclined plate. The entire baffle may be located above the side drain pan.

When the air handler is in the horizontal position, the entire baffle may be located within an outer wall of the side drain pan when viewed from above.

The baffle may be positioned between the outlet of the blower and the heat-exchanging coil.

The blower may be located downstream of the heat-exchanging coil in the airflow direction.

The blower may be located upstream of the heat-exchanging coil in the airflow direction.

According to one or more embodiments, an air handler assembly is provided, including: a heat-exchanging coil; a blower configured to move air through the heat-exchanging coil; a bottom drain pan positioned upstream of the heat-exchanging coil in an airflow direction in which air is discharged from an outlet of the blower, and a baffle. The baffle may include a first inclined plate and a second inclined plate. A distance between the first inclined plate and the second inclined plate may increase from an edge of the first inclined plate that is furthest upstream in the airflow direction to an edge of the first inclined plate that is furthest downstream in the airflow direction. The bottom drain pan may include an outer wall surrounding a periphery of the drain pan, an aperture formed in a center of the drain pan, and an interior wall surrounding a periphery of the aperture. The baffle may be mounted to the interior wall of the bottom drain pan.

The baffle may be positioned in the aperture of the bottom drain pan.

The baffle may cover 10 to 20 percent of the aperture of the bottom drain pan.

The heat-exchanging coil may include two coil plates. The two coil plates may be inclined such that a distance between the two coil plates increases from a position of the heat-exchanging coil that is furthest downstream in the airflow direction to a position of the heat-exchanging coil that is furthest upstream in the airflow direction. The two coil plates may be joined at the position of the heat-exchanging coil that is furthest downstream in the airflow direction. A first side plate may cover a first side of the heat-exchanging coil such that it contacts a first side of each of the two coil plates. A second side plate may cover a second side of the heat-exchanging coil such that it contacts a second side of each of the two coil plates. The first side plate may extend for an entire length of each of the two coil plates. The second side plate may extend for an entire length of each of the two coil plates. The first side plate may be fixed to the outer wall of the bottom drain pan, and the second side plate may be fixed to the outer wall of the bottom drain pan.

The baffle may overlap with the position at which the two coil plates are joined when viewed in the airflow direction.

The first inclined plate and the second inclined plate of the baffle may be connected at a portion of the baffle that is furthest upstream in the airflow direction.

The baffle may be V-shaped in cross-section.

The portion of the baffle that is furthest upstream in the airflow direction may be curved.

A flat plate may connect the first inclined plate and the second inclined plate at a portion of the baffle that is furthest upstream in the airflow direction.

An angle between the first inclined plate and the second inclined plate may be between 45° and 135°.

The baffle may be formed of metal.

The baffle may be formed of plastic.

A distance between the edge of the first inclined plate that is furthest upstream in the airflow direction and the edge of the first inclined plate that is furthest downstream in the airflow direction may be between 1 inch and 4 inches, and a distance between an edge of the second inclined plate that is furthest upstream in the airflow direction and an edge of the second inclined plate that is furthest downstream in the airflow direction may be between 1 inch and 4 inches.

The air handler assembly may further comprise a housing which surrounds the blower, the heat-exchanging coil, and the baffle.

The heat-exchanging coil may include a plurality of heat transfer tubes configured to convey fluid. Each heat transfer tube of the plurality of heat transfer tubes may be positioned such that a flow direction of the fluid is substantially perpendicular to the airflow direction.

The air handler assembly may further comprise a side drain pan located below the heat-exchanging coil when the air handler is in a horizontal position in which the first inclined plate is positioned vertically above the second inclined plate. The entire baffle may be located above the side drain pan.

When the air handler is in the horizontal position, the entire baffle may be located within an outer wall of the side drain pan when viewed from above.

The baffle may be positioned between the outlet of the blower and the heat-exchanging coil.

The blower may be located downstream of the heat-exchanging coil in the airflow direction.

The blower may be located upstream of the heat-exchanging coil in the airflow direction.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying figures, where like reference numerals refer to identical or functionally similar elements and which together with the detailed description below are incorporated in and form part of the specification, serve to further illustrate an exemplary embodiment and to explain various principles and advantages in accordance with the present disclosure.

FIG. 1A is a schematic view of an air handler assembly according to disclosed embodiments.

FIG. 1B is a schematic view of an air handler assembly according to disclosed embodiments.

FIG. 2 is a side view of a heat exchanger assembly according to disclosed embodiments.

FIG. 3 is an isometric view of a baffle according to disclosed embodiments.

FIG. 4 is a side view of the baffle according to disclosed embodiments.

FIG. 5 is an exploded view of the air handler assembly according to disclosed embodiments.

FIG. 6 is a cross-sectional view of the heat exchanger assembly according to disclosed embodiments.

FIG. 7 is an isometric view of a baffle according to alternate disclosed embodiments.

FIG. 8 is a side view of a baffle according to alternate disclosed embodiments.

FIG. 9 is a cross-sectional view of a heat exchanger assembly according to alternate disclosed embodiments.

FIGS. 10A-10C are schematic drawings of a cross-sectional shape of a baffle.

FIG. 11 is a schematic showing airflow near a heat-exchanging coil according to disclosed embodiments.

FIG. 12 is a schematic showing airflow near a heat-exchanging coil according to a comparative example.

DETAILED DESCRIPTION

The instant disclosure is provided to further explain in an enabling fashion the best modes of performing one or more embodiments of the present invention. The disclosure is further offered to enhance an understanding and appreciation for the inventive principles and advantages thereof, rather than to limit the invention in any manner. The invention is defined solely by the appended claims including any amendments made during the pendency of this application and all equivalents of those claims as issued.

It is further understood that the use of relational terms such as first and second, and the like, if any, are used solely to distinguish one from another entity, item, or action without necessarily requiring or implying any actual such relationship or order between such entities, items or actions. It is noted that some embodiments may include a plurality of processes or steps, which can be performed in any order, unless expressly and necessarily limited to a particular order; i.e., processes or steps that are not so limited may be performed in any order.

FIGS. 1A and 1B are schematic views of an air handler assembly 100 including a heat exchanger assembly 200, a blower 300, and a housing 400. The air handler assembly 100 may be positioned vertically or horizontally. In particular, the air handler assembly 100 may be positioned so that the heat exchanger assembly 200 is located vertically above or below the blower 300. Alternatively, the air handler assembly 100 may be positioned horizontally such that the blower 300 and the heat exchanger assembly 200 are aligned in a horizontal direction.

As illustrated in FIGS. 1A, 1B, and 5, a housing 400 is configured to form an outer wall of the air handler assembly 100 and to enclose the components of the air handler assembly 100. The housing 400 surrounds the blower 300 and the heat exchanger assembly 200.

The blower 300 is configured to draw air in through an inlet and discharge the air from an outlet 310. The blower 300 may be, for example, a centrifugal fan or an axial fan.

The blower 300 is configured to move air through the heat exchanger assembly 200. As shown in FIG. 1A, the air handler assembly 100 may have a “blow through” configuration in which the blower 300 is located upstream of the heat exchanger assembly 200 in an airflow direction 110 in which air is discharged from the outlet 310 of the blower 300. In this case, the outlet 310 of the blower 300 faces the heat exchanger assembly 200. In particular, the blower 300 is configured to blow air toward a heat-exchanging coil 220 of the heat exchanger assembly 200.

As shown in FIG. 1B, the air handler assembly 100 may instead have a “draw-through” configuration in which the blower 300 is located downstream of the heat exchanger assembly 200 in the airflow direction 110 in which air is discharged from the outlet 310 of the blower 300. In this case, the outlet 310 of the blower 300 faces away from the heat exchanger assembly 200. In particular, the blower 300 is configured to draw air through the heat-exchanging coil 220 of the heat exchanger assembly 200.

The heat exchanger assembly 200 includes a baffle 210, a heat-exchanging coil 220, a side drain pan 230, a bottom drain pan 240, and a top drain pan 250.

The heat-exchanging coil 220 is configured to facilitate heat exchange between air and a heat-exchange medium flowing in the heat-exchanging coil 220. The heat-exchanging coil 220 includes at least one coil plate 221. The at least one coil plate 221 has a plurality of heat transfer tubes 222 that are configured to convey fluid such as refrigerant or another heat-transfer medium. Each of the heat transfer tubes 222 may be positioned such that a flow direction of the fluid is substantially perpendicular to the airflow direction 110 at the outlet 310 of the blower 300.

The heat-exchanging coil 220 may include two coil plates 221. The two coil plates 221 are inclined such that a distance between the two coil plates 221 increases from a position of the heat-exchanging coil 220 that is furthest downstream in the airflow direction 110 to a position of the heat-exchanging coil 220 that is furthest upstream in the airflow direction 110. In the blow-though configuration illustrated in FIG. 1A, the two coil plates 221 are furthest apart at a point that is closest to the outlet 310 of the blower 300 and closest together at a point that is furthest away from the outlet 310 of the blower 300. In the draw-through configuration illustrated in FIG. 1B, the two coil plates 221 are furthest apart at a point that is furthest away from the outlet 310 of the blower 300 and closest together at a point that is closest to the outlet 310 of the blower 300.

The two coil plates 221 are joined at the position of the heat-exchanging coil 220 that is furthest downstream in the airflow direction 110. Thus, the two coil plates 221 form an “A coil” shape.

The heat exchanger assembly 200 may further include side plates 223 that cover the sides of the heat-exchanging coil 220. In particular, the side plates 223 may fully cover the sides of the heat-exchanging coil 220 and extend for the entire length of each coil plate 221. The side plates 223 may be fixed to the bottom drain pan 240. The side plates 223 may be triangular in shape so as to correspond to a shape made by the gap between the two coil plates 221. However, the side plates 223 may have a rectangular shape or another polygonal or non-polygonal shape. The side plates 223 may be formed of, e.g., metal or plastic.

A first side plate 223 may cover a first side of the heat-exchanging coil 220 such that the side plate 223 contacts a first side of each of the two coil plates 221. A second side plate 223 may cover a second side of the heat-exchanging coil 220 such that the side plate 223 contacts a second side of each of the two coil plates 221. Each side plate 223 extends from the position at which the two coil plates 221 are joined to an end of each coil plate 221 that is furthest upstream in the airflow direction 110.

In this manner, the side plates 223 can direct airflow toward the heat transfer tubes 222 of the coil plates 221. The side plates 223 prevent air from escaping out of the side of the heat-exchanging coil 220, thus improving the efficiency of the heat-exchanging coil 220.

The baffle 210 is positioned upstream of the heat-exchanging coil 220 in the airflow direction 110. In the blow-through configuration of the air handler assembly 100 illustrated in FIG. 1A, the baffle 210 is located between the outlet 310 of the blower 300 and the heat-exchanging coil 220. In the draw-through configuration of the air handler assembly 100 illustrated in FIG. 1B, the heat-exchanging coil 220 is located between the blower 300 and the baffle 210. The baffle 210 is configured to redirect airflow away from narrow regions of the heat-exchanging coil 220 at which localized high-velocity airflows occur. The baffle 210 is formed of, for example, metal or plastic.

The baffle 210 includes a first inclined plate 211 and a second inclined plate 212. As illustrated in FIGS. 3 and 4, the first inclined plate 211 and the second inclined plate 212 are inclined with respect to each other. The first inclined plate 211 and the second inclined plate 212 are connected to each other at a portion of the baffle 210 that is furthest upstream in the airflow direction 110. In the blow-through configuration of the air handler assembly 100 illustrated in FIG. 1A, the first inclined plate 211 and the second inclined plate 212 are connected to each other at a portion of the baffle 210 that is closest to an outlet 310 of the blower 300. In the draw-through configuration of the air handler assembly 100 illustrated in FIG. 1B, the first inclined plate 211 and the second inclined plate 212 are connected to each other at a portion of the baffle 210 that is furthest from an outlet 310 of the blower 300.

A distance between the first inclined plate 211 and the second inclined plate 212 increases from an edge of the first inclined plate 211 that is furthest upstream in the airflow direction 110 to an edge of the first inclined plate 211 that is furthest downstream in the airflow direction 110. The first inclined plate 211 and the second inclined plate 212 may form a V-shape when viewed from the side. In particular, an angle between the first inclined plate 211 and the second inclined plate 212 may be between 45° and 135°, and particularly may be between 75° and 110°. When the air handler assembly 100 is in the horizontal position, the first inclined plate 211 is positioned vertically above the second inclined plate 212.

A distance between a first edge of the first inclined plate 211 that is furthest upstream in the airflow direction 110 and a second edge of the first inclined plate 211 that is furthest downstream in the airflow direction 110 is between 1 inch and 4 inches. A distance between a first edge of the second inclined plate 212 that is furthest upstream in the airflow direction 110 and a second edge of the second inclined plate 212 that is furthest downstream in the airflow direction 110 is between 1 inch and 4 inches. In other words, the widths of each of the first inclined plate 211 and the second inclined plate 212 are between 1 inch and 4 inches. Specifically, the widths of each of the first inclined plate 211 and the second inclined plate 212 may be between 1.5 inches and 2.5 inches. The baffle 210 may extend the entire distance from one side plate 223 to the other side plate 223. Alternatively, the baffle 210 may extend between 75% and 100% of the distance from one side plate 223 to the other side plate 223.

The baffle 210 is located such that it overlaps with the position at which the two coil plates 221 are joined when viewed in the airflow direction 110 in which air is discharged from the outlet 310 of the blower 300. In this manner, the baffle 210 can redirect airflow passing through the heat-exchanging coil 220 away from the narrow regions formed in the area at which the two coil plates 221 are joined. In particular, the baffle 210 may redirect high velocity airflow away from the top drain pan 250.

In a disclosed embodiment, the baffle 210 is mounted to the side plates 223 of the heat exchanger assembly 200. A first side of the baffle 210 is attached to a first side plate 223, and a second side of the baffle 210 that is opposite to the first side of the baffle 210 is attached to a second side plate 223. The first side of the baffle 210 may be attached to the first side plate 223 with at least one fastener 216. The second side of the baffle 210 may be attached to the second side plate 223 with at least one fastener 216. Fasteners 216 may include, for example, bolts, screws, and/or rivets. Alternatively, the baffle 210 may be attached to the side plates 223, for example, by an adhesive or by welding. The baffle 210 may be integrally formed with the side plates 223.

The baffle 210 may include two or more flanges 214. In particular, the baffle 210 includes at least one flange 214 positioned on the first side of the baffle 210 and at least one flange 214 positioned on the second side of the baffle 210.The baffle 210 may include two flanges 214 on the first side of the baffle 210 and two flanges 214 on the second side of the baffle 210. On the first side of the baffle 210, a first flange 214 may extend from the first inclined plate 211, and a second flange 214 may extend from the second inclined plate 212. Likewise, on the second side of the baffle, a first flange 214 may extend from the first inclined plate 211, and a second flange 214 may extend from the second inclined plate 212.

Each of the flanges 214 is configured to be attached to a side plate 223. Specifically, the at least one flange 214 positioned on the first side of the baffle 210 is attached to a first side plate 223, and the at least one flange 214 positioned on the second side of the baffle 210 is attached to a second side plate 223. Each flange 214 may include a mounting hole 215. Each flange 214 may be attached to a side plate 223 with at least one fastener 216. The at least one fastener 216 includes, for example, at least one of a bolt, a screw, or a rivet. The at least one fastener 216 may be secured in the mounting hole 215 and in a corresponding hole formed in the side plate 223.

As illustrated in FIG. 6, each of the flanges 214 extends from the baffle 210 in the airflow direction 110 when the baffle 210 is mounted in the heat exchanger assembly 200. In particular, in the blow-through configuration of the air handler assembly 100 illustrated in FIG. 1A, each of the flanges 214 extend from the baffle 210 in a direction away from the blower 300 when the baffle 210 is mounted in the heat exchanger assembly 200. In the draw-through configuration of the air handler assembly 100 illustrated in FIG. 1B, each of the flanges 214 extend from the baffle 210 in a direction toward the blower 300 when the baffle 210 is mounted in the heat exchanger assembly 200.

As such, the baffle 210 can be offset from the side plates 223. At least a portion of the baffle 210 may extend further upstream in the airflow direction 110 than the side plates 223. An entirety of the first inclined plate 211 and an entirety of the second inclined plate 212 may extend further upstream in the airflow direction 110 than the side plates 223. In particular, the baffle 210 may extend such that a portion of it is located within an aperture 242 of the bottom drain pan 240.

Each flange 214 includes a strip 217 and a tab 218. The mounting hole 215 is formed in the tab 218. Each strip 217 extends from an edge of the first inclined plate 211 or the second inclined plate 212 in the airflow direction 110. The strips 217 each have a length between 0.5 inches and 4 inches.

A tab 218 extends from an end portion of each strip 217. The end portion of the strip 217 is opposite to the portion of the strip 217 that is connected to the first inclined plate 211 or the second inclined plate 212. A face of the tab 218 is substantially perpendicular to a face of the strip 217. The face of the tab 218 extends substantially parallel to a surface of the side plate 223 to which the flange 214 is attached. To attach the flange 214 to the side plate 223, a fastener 216 such as a screw, a bolt, or a rivet may be secured in the mounting hole 215 and in a corresponding hole formed in the side plate 223. Alternatively, the flange 214 may be attached to the side plate 223, for example, by an adhesive or welding.

The baffle 210 may have a variety of cross-sectional shapes. In particular, the baffle 210 may have any of the cross-sectional shapes illustrated in FIGS. 10A-10C, or may have another shape.

As illustrated in FIG. 10A, the first inclined plate 211 and the second inclined plate 212 may form a V-shape when viewed from the side. In other words, a point may be formed at the position where the first inclined plate 211 and the second inclined plate 212 are connected to each other.

Alternatively, as illustrated in FIG. 10B, a flat plate 213 may connect the first inclined plate 211 and the second inclined plate 212 at a portion of the baffle 210 that is furthest upstream in the airflow direction 110. In other words, the portion of the baffle 210 that is furthest upstream in the airflow direction may be flat. A height of the flat plate 213 is less than 25% of a total height of the baffle 210 measured from an edge of the first inclined plate 211 that is furthest downstream in the airflow direction 110 to an edge of the second inclined plate 212 that is furthest downstream in the airflow direction 110.

As illustrated in FIG. 10C, the portion of the baffle 210 that is furthest upstream in the airflow direction may be curved. In particular, the baffle 210 may be curved at a position at which the first inclined plate 211 and the second inclined plate 212 are connected to each other.

The baffle 210 is configured to reduce or eliminate condensate blow-off in the heat exchanger assembly 200. During the course of operation of the air handler assembly 100, droplets of condensate may form on the heat-exchanging coil 220 and the top drain pan 250. Condensate blow-off occurs when high-velocity airflow carries droplets of water off of the heat-exchanging coil 220 and the top drain pan 250. The condensate subsequently travels into a duct area beyond the heat exchanger assembly 200 or into other narrow areas of the air handler assembly 100 where it may cause mold and odor. This produces an unpleasant environment and a possible health hazard for occupants of the building at which the air handler assembly 100 is installed. Additionally, when airflow is concentrated on a small section of the heat-exchanging coil 220, the efficiency of the heat-exchanging coil 220 is reduced.

The baffle 210 is configured to decrease a velocity of the airflow that reaches the heat-exchanging coil 220. Therefore, condensate blow-off caused by high-velocity air blowing across the heat-exchanging coil 220 and the top drain pan 250 is reduced or eliminated, and mold and odor can be avoided in duct areas. Furthermore, the baffle 210 is configured to redirect airflow away from narrow regions at which there are localized high velocity airflows, such as the top drain pan 250. In particular, the baffle 210 redirects airflow away from the center of the heat-exchanging coil 220 and creates a more even distribution of airflow across the heat-exchanging coil 220. This improves the efficiency of the heat-exchanging coil 220. These functions of the baffle 210 are most effective when the air handler assembly 100 is in the horizontal position.

A comparative example in which no baffle is provided is illustrated in FIG. 12. As seen in FIG. 12, high velocity airflow 500 is directed at the center of the heat-exchanging coil 220. This high velocity airflow 500 may blow condensate off of the heat-exchanging coil 220 and into duct areas of an air-conditioning system. This can cause mold and odor to occur. Additionally, the airflow 500 is not distributed evenly throughout the heat-exchanging coil 220 but is concentrated at the center of the heat-exchanging coil 220.

In contrast, FIG. 11 illustrates an example of an airflow distribution when a baffle 210 is provided. The baffle 210 reduces the velocity of the airflow 500 approaching the heat-exchanging coil 220. Additionally, the baffle 210 redirects the airflow 500 so that the airflow 500 is more evenly distributed along the heat-exchanging coil 220. Thus, the airflow 500 is not concentrated in the center of the heat-exchanging coil 220. In particular, a low-velocity flow area 510 may be formed between the baffle 210 and the center of the heat-exchanging coil 220. Thus, the efficiency of the heat-exchanging coil 220 may be improved.

The side drain pan 230 is configured to collect condensate that forms on the heat-exchanging coil 220. When the air handler assembly 100 is in a vertical position, the side drain pan 230 is positioned along a side of the heat-exchanging coil 220. When the air handler assembly 100 is in a horizontal position, the bottom drain pan 240 is positioned below the heat-exchanging coil 220. The side drain pan 230 may include a pipe or conduit that is configured to drain condensate collected at the side drain pan 230 to the outside of the heat exchanger assembly 200.

The entire baffle 210 is located above the side drain pan 230 when the air handler assembly 100 is in the horizontal position. In other words, when viewed from above, the entire baffle 210 is located within an outer wall 231 of the side drain pan 230. As such, any condensate that may form on the baffle 210 can drip into the side drain pan 230 when the air handler assembly 100 is in the horizontal position.

The bottom drain pan 240 is configured to collect condensate that forms on the heat-exchanging coil 220. When the air handler assembly 100 is in a vertical position, the bottom drain pan 240 is positioned below the heat-exchanging coil 220. When the air handler assembly 100 is in a horizontal position, the bottom drain pan 240 is positioned on a side of the heat-exchanging coil 220. The ends of the coil plates 221 that are furthest upstream in the airflow direction 110 may be positioned inside of the bottom drain pan 240. The bottom drain pan 240 may include a pipe or conduit that is configured to drain the collected condensate to the outside of the heat exchanger assembly 200.

The bottom drain pan 240 includes an outer wall 231 that surrounds an outer periphery of the bottom drain pan 240 and that is configured to keep the condensate water contained in the bottom drain pan 240. As illustrated in FIG. 2, an aperture 242 is formed in a center of the bottom surface of the bottom drain pan 240. Airflow that is generated by the operation of the blower 300 passes through the aperture 242 to reach the heat-exchanging coil 220. Thus, the air can exchange heat with the fluid flowing in the heat-exchanging coil 220. An interior wall 243 of the bottom drain pan 240 surrounds the aperture 242 and is configured to keep the condensate water contained in the bottom drain pan 240.

The top drain pan 250 is located at a portion of the heat-exchanging coil 220 at which the coil plates 221 are joined. The top drain pan 250 is configured to collect condensate that forms on the heat-exchanging coil 220. When the air handler assembly 100 is in a horizontal position, condensate collected by the top drain pan 250 may flow into the side drain pan 230 via a conduit 251.

Alternate Embodiment

FIG. 9 is a cross-sectional view of a heat exchanger assembly 600. The embodiment of FIG. 9 is similar to the embodiment of FIG. 6, except that the baffle 210 is replaced by the baffle 610. The following discussion will omit descriptions of portions of this embodiment that directly correspond to those of FIG. 6 for ease of disclosure.

As illustrated in FIGS. 7 and 8, the baffle 610 includes the first inclined plate 211 and the second inclined plate 212, which are configured as described above in relation to the baffle 210. The baffle 610 has generally the same function as the baffle 210 described above.

The baffle 610 is configured to be mounted to the interior wall 243 of the bottom drain pan 240. In particular, the baffle 610 differs from the baffle 210 because it includes flanges 614 instead of flanges 214. The flanges 614 are formed as tabs that protrude from the baffle 610. The baffle 610 may include two or more flanges 614.

Specifically, the baffle 610 may include at least one flange 614 positioned on a first side of the baffle 610 and at least one flange 614 positioned on a second side of the baffle 610. The baffle 610 may include two flanges 614 on the first side of the baffle 610 and two flanges 614 on the second side of the baffle 610. On the first side of the baffle 610, a first flange 614 may extend from the first inclined plate 211, and a second flange 614 may extend from the second inclined plate 212. Likewise, on the second side of the baffle 610, a first flange 614 may extend from the first inclined plate 211, and a second flange 614 may extend from the second inclined plate 212.

A face of each flange 614 is substantially parallel to a face of the interior wall 243 of the bottom drain pan 240 onto which the flange 614 is mounted. Each of the flanges 614 is configured to be attached to the interior wall 243 of the bottom drain pan 240. Each flange 614 may include a mounting hole 215. Each flange 614 may be attached to the interior wall 243 with at least one fastener 216. The at least one fastener 216 may include at least one of a bolt, a screw, or a rivet. Alternatively, the baffle 210 may be mounted to the interior wall 243 of the bottom drain pan 240 by, for example, an adhesive or welding. Furthermore, the baffle 210 may be integrally formed with the bottom drain pan 240.

Each of the flanges 614 may extend from the first inclined plate 211 or the second inclined plate 212 in a direction that is substantially opposite to the airflow direction 110, as illustrated in FIGS. 7-9. However, the baffle 610 may be configured such that one or more of the flanges 614 extend from the first inclined plate 211 or the second inclined plate 212 substantially in the airflow direction 110.

The baffle 610 is positioned within the aperture 242 of the bottom drain pan 240. The baffle 610 covers or blocks 10 to 20 percent of the aperture 242 of the bottom drain pan 240. Specifically, the baffle 610 may cover 15 percent of the aperture 242 of the bottom drain pan 240. As such, airflow can pass through the aperture 242 while being redirected by the baffle 610.

Conclusion

This disclosure is intended to explain how to fashion and use various embodiments in accordance with the invention rather than to limit the true, intended, and fair scope and spirit thereof. The foregoing description is not intended to be exhaustive or to limit the invention to the precise form disclosed. Modifications or variations are possible in light of the above teachings. The embodiment(s) was chosen and described to provide the best illustration of the principles of the invention and its practical application, and to enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims, as may be amended during the pendency of this application for patent, and all equivalents thereof, when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled. The various circuits described above can be implemented in discrete circuits or integrated circuits, as desired by implementation.