Seal assembly for heat exchanger of HVAC system

Abstract

A heat exchanger assembly for an HVAC system includes a heat exchanger and a seal assembly configured to couple to the heat exchanger. The heat exchanger includes a plurality of tubes configured to direct a working fluid therethrough, wherein the plurality of tubes defines a first section, a second section, and an intermediate section extending from the first section to the second section, and the first section and the second section extend crosswise relative to one another. The seal assembly includes a mounting bracket configured to mount the seal assembly between the first section and the second section and in alignment with the intermediate section along a direction of air flow across the heat exchanger and a gasket configured to couple to the mounting bracket, wherein the gasket is configured to bias against the first section and the second section and block air flow across the intermediate section.

Description

BACKGROUND

[0001] This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure and are described below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be noted that these statements are to be read in this light, and not as admissions of prior art.

[0002] Heating, ventilation, and / or air conditioning (HVAC) systems are utilized in residential, commercial, and industrial environments to control environmental properties, such as temperature and humidity, for occupants of the respective environments. An HVAC system may control the environmental properties by conditioning a supply air flow delivered to the environment. For example, the HVAC system may include a heat exchanger configured to place the supply air flow in a heat exchange relationship with a working fluid (e.g., a refrigerant) of a vapor compression system to condition the supply air flow. Some heat exchangers may include certain sections with different features relative to other sections of the heat exchanger. In some instances, performance and / or efficiency of the heat exchanger may be affected by relative amounts of air flow that are directed across the various sections of the heat exchanger.SUMMARY

[0003] A summary of certain embodiments disclosed herein is set forth below. It should be noted that these aspects are presented merely to provide the reader with a brief summary of these certain embodiments and that these aspects are not intended to limit the scope of this disclosure. Indeed, this disclosure may encompass a variety of aspects that may not be set forth below.

[0004] In one embodiment, a heat exchanger assembly for a heating, ventilation, and / or air conditioning (HVAC) system may include a heat exchanger including a plurality of tubes configured to direct a working fluid therethrough, wherein the plurality of tubes defines a first section, a second section, and an intermediate section extending from the first section to the second section, and the first section and the second section extend crosswise relative to one another, and a seal assembly configured to couple to the heat exchanger, wherein the seal assembly includes a mounting bracket configured to mount the seal assembly between the first section and the second section and in alignment with the intermediate section along a direction of air flow across the heat exchanger and a gasket configured to couple to the mounting bracket, wherein the gasket is configured to bias against the first section and the second section and block air flow across the intermediate section

[0005] In another embodiment, a heat exchanger assembly for a heating, ventilation, and / or air conditioning (HVAC) system includes a heat exchanger comprising a plurality of tubes configured to direct a working fluid therethrough and a seal assembly configured to couple to the heat exchanger. The plurality of tubes defines a first section, a second section, and an intermediate section, the first second, the second section, and the intermediate section define a space configured to receive an air flow. The first section includes a first plurality of fins extending between the plurality of tubes, and the second section includes a second plurality of fins extending between the plurality of tubes. The seal assembly includes a mounting bracket configured to mount the seal assembly within the space and a gasket configured to couple to the mounting bracket, wherein the gasket is configured to overlap with the intermediate section, relative to a direction of the air flow through the space and across the heat exchanger, and to block air flow across the at least one non-finned section.

[0006] In a further embodiment, a heat exchanger assembly for a heating, ventilation, and / or air conditioning (HVAC) system includes a heat exchanger comprising a plurality of tubes defining a first panel section, a second panel section, and an arcuate section extending from the first panel section to the second panel section. The first panel section comprises a first plurality of fins extending between the plurality of tubes, the second panel section comprises a second plurality of fins extending between the plurality of tubes, and the arcuate section is without fins extending between the plurality of tubes. The HVAC system also includes a seal assembly mounted to the heat exchanger within a space defined by the first panel section, the second panel section, and the arcuate section. The seal assembly includes a mounting bracket and a gasket coupled to the mounting bracket. The gasket overlaps with the arcuate section along a direction of an air flow across the heat exchanger and is configured to block air flow across the arcuate section.DESCRIPTION OF DRAWINGS

[0007] Various aspects of this disclosure may be better understood upon reading the following detailed description and upon reference to the drawings in which:

[0008] FIG. 1 is a perspective view of an embodiment of a heating, ventilation, and / or air conditioning (HVAC) system for environmental management that may employ one or more HVAC units, in accordance with an aspect of the present disclosure;

[0009] FIG. 2 is a perspective view of an embodiment of a packaged HVAC unit that may be used in an HVAC system, in accordance with an aspect of the present disclosure;

[0010] FIG. 3 is a cutaway perspective view of an embodiment of a residential, split HVAC system, in accordance with an aspect of the present disclosure;

[0011] FIG. 4 is a schematic of an embodiment of a vapor compression system that may be used in an HVAC system, in accordance with an aspect of the present disclosure;

[0012] FIG. 5 is a perspective view of an embodiment of a heat exchanger assembly for an HVAC system, in accordance with an aspect of the present disclosure;

[0013] FIG. 6 is a side view of an embodiment of a heat exchanger assembly for an HVAC system, in accordance with an aspect of the present disclosure;

[0014] FIG. 7 is an exploded view of an embodiment of a seal assembly for a heat exchanger of an HVAC system, in accordance with an aspect of the present disclosure;

[0015] FIG. 8 is a perspective view of an embodiment of a seal assembly for a heat exchanger of an HVAC system, in accordance with an aspect of the present disclosure; and

[0016] FIG. 9 is an expanded perspective view of a portion of an embodiment of a heat exchanger assembly for an HVAC system, in accordance with an aspect of the present disclosure.DETAILED DESCRIPTION

[0017] One or more specific embodiments will be described below. In an effort to provide a concise description of these embodiments, not all features of an actual implementation are described in the specification. It should be noted that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be noted that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

[0018] When introducing elements of various embodiments of the present disclosure, the articles “a,”“an,” and “the” are intended to mean that there are one or more of the elements. The terms “comprising,”“including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Additionally, it should be noted that references to “one embodiment” or “an embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.

[0019] As used herein, the terms “approximately,”“generally,” and “substantially,” and so forth, are intended to convey that the property value being described may be within a relatively small range of the property value, as those of ordinary skill would understand. For example, when a property value is described as being “approximately” equal to (or, for example, “substantially similar” to) a given value, this is intended to mean that the property value may be within + / −5%, within + / −4%, within + / −3%, within + / −2%, within + / −1%, or even closer, of the given value. Similarly, when a given feature is described as being “substantially parallel” to another feature, “generally perpendicular” to another feature, and so forth, this is intended to mean that the given feature is within + / −5%, within + / −4%, within + / −3%, within + / −2%, within + / −1%, or even closer, to having the described nature, such as being parallel to another feature, being perpendicular to another feature, and so forth. Further, it should be understood that mathematical terms, such as “planar,”“slope,”“perpendicular,”“parallel,” and so forth are intended to encompass features of surfaces or elements as understood to one of ordinary skill in the relevant art, and should not be rigidly interpreted as might be understood in the mathematical arts. For example, a “planar” surface is intended to encompass a surface that is machined, molded, or otherwise formed to be substantially flat or smooth (within related tolerances) using techniques and tools available to one of ordinary skill in the art. Similarly, a surface having a “slope” is intended to encompass a surface that is machined, molded, or otherwise formed to be oriented at an angle (e.g., incline) with respect to a point of reference using techniques and tools available to one of ordinary skill in the art.

[0020] The present disclosure is directed to a heating, ventilation, and / or air conditioning (HVAC) system. The HVAC system may be configured to condition (e.g., heat, cool) an air flow and deliver the conditioned air flow to a space, such as a room, to condition the space. For example, the HVAC system may include a heat exchanger configured to place the air flow in a heat exchange relationship with a working fluid, such as a refrigerant, to change a temperature of the air flow. The air flow may then be delivered to the space as a supply air flow to adjust the temperature of the space, such as toward a target or set point temperature of the space.

[0021] As will be appreciated, heat exchangers may be manufactured in various configurations. For example, a heat exchanger may include tubes or coils configured to circulate a working fluid therethrough, and an air flow may be directed across the tubes or coils to place the working fluid in a heat exchange relationship with the air flow. In some instances, the heat exchanger may also include fins attached to the tubes. For example, fins may extend between and couple to adjacent tubes of the heat exchanger. The fins may increase a heat transfer surface area of the heat exchanger and may therefore enable increased and / or more efficient transfer of heat between the working fluid and the air flow. Heat exchangers having tubes and fins may include one or more sections including the fins extending between the coils (e.g., finned sections) and one or more sections that do not include fins extending between the coils (e.g., non-finned sections). As the fins enable increased heat transfer between the working fluid and the air flow, it may be beneficial to direct (e.g., divert) air flow across sections of the heat exchanger having the fins (e.g., finned sections) to enable increased heat transfer between the working fluid and the air flow.

[0022] Thus, it is presently recognized that forcing air flow across finned sections of a heat exchanger may improve performance of various operations related to the heat exchanger. More specifically, diverting air flow to flow across the finned sections instead of across non-finned sections of the heat exchanger may enable increased heat transfer between the air flow and a working fluid circulated through the heat exchanger. Accordingly, embodiments of the present disclosure are directed to a heat exchanger assembly that includes features configured to direct and / or divert an air flow across finned sections of a heat exchanger instead of non-finned sections of the heat exchanger. The heat exchanger may include tubes through which a working fluid may flow. The tubes may define a first section, a second section, and an intermediate section of the heat exchanger. The intermediate section may extend between the first section and the second section of the heat exchanger. The first section and the second section may each include fins extending between the tubes in the first section and the second section. Therefore, the first section and the second section may be described as finned sections of the heat exchanger. However, the intermediate section may not include fins extending between tubes in the intermediate section and may therefore be described as a non-finned section.

[0023] To enable improved operation of the heat exchanger, the heat exchanger assembly includes a seal assembly configured to direct air flow across sections (e.g., first section and second section) of the heat exchanger having fins coupled to tubes of the heat exchanger. More specifically, the seal assembly may be configured to block air flow across one or more sections (e.g., intermediate section) of the heat exchanger that do not include fins and to divert and / or redirect the air flow to flow across sections of the heat exchanger that include fins. In this way, the seal assembly may direct the air flow across portions or sections of the heat exchanger having a greater heat transfer surface area, which may improve (e.g., increase) heat transfer between the air flow and a working fluid directed through the heat exchanger.

[0024] In some embodiments, the seal assembly may include a mounting bracket and a gasket. The mounting bracket may be configured to mount the seal assembly between the first section and the second section of the heat exchanger and in alignment with the intermediate section of the heat exchanger (e.g., along a direction of air flow across the heat exchanger). In this way, the seal assembly may block air flow across the intermediate section of the heat exchanger and diver the air flow toward the first section and / or the second section of the heat exchanger. The gasket may be coupled to the mounting bracket, and in an installed configuration of the seal assembly with the heat exchanger, the gasket may be biased against the first section and the second section of the heat exchanger. The gasket may therefore establish a sealing interface or engagement with the first section and the second section to improve blockage of air flow across the intermediate section and diversion of the air flow toward the first section and / or the second section of the heat exchanger.

[0025] Turning now to the drawings, FIG. 1 illustrates an embodiment of a heating, ventilation, and / or air conditioning (HVAC) system for environmental management that may employ one or more HVAC units. As used herein, an HVAC system includes any number of components configured to enable regulation of parameters related to climate characteristics, such as temperature, humidity, air flow, pressure, air quality, and so forth. For example, an “HVAC system” as used herein is defined as conventionally understood and as further described herein. Components or parts of an “HVAC system” may include, but are not limited to, all, some of, or individual parts such as a heat exchanger, a heater, an air flow control device, such as a fan, a sensor configured to detect a climate characteristic or operating parameter, a filter, a control device configured to regulate operation of an HVAC system component, a component configured to enable regulation of climate characteristics, or a combination thereof. An “HVAC system” is a system configured to provide such functions as heating, cooling, ventilation, dehumidification, pressurization, refrigeration, filtration, or any combination thereof. The embodiments described herein may be utilized in a variety of applications to control climate characteristics, such as residential, commercial, industrial, transportation, or other applications where climate control is desired.

[0026] In the illustrated embodiment, a building 10 is air conditioned by a system that includes an HVAC unit 12. The building 10 may be a commercial structure or a residential structure. As shown, the HVAC unit 12 is disposed on the roof of the building 10; however, the HVAC unit 12 may be located in other equipment rooms or areas adjacent the building 10. The HVAC unit 12 may be a single package unit containing other equipment, such as a blower, integrated air handler, and / or auxiliary heating unit. In other embodiments, the HVAC unit 12 may be part of a split HVAC system, such as the system shown in FIG. 3, which includes an outdoor HVAC unit 58 and an indoor HVAC unit 56.

[0027] The HVAC unit 12 is an air cooled device that implements a refrigeration cycle to provide conditioned air to the building 10. Specifically, the HVAC unit 12 may include one or more heat exchangers across which an air flow is passed to condition the air flow before the air flow is supplied to the building. In the illustrated embodiment, the HVAC unit 12 is a rooftop unit (RTU) that conditions a supply air stream, such as environmental air and / or a return air flow from the building 10. After the HVAC unit 12 conditions the air, the air is supplied to the building 10 via ductwork 14 extending throughout the building 10 from the HVAC unit 12. For example, the ductwork 14 may extend to various individual floors or other sections of the building 10. In certain embodiments, the HVAC unit 12 may be a heat pump that provides both heating and cooling to the building with one working fluid circuit configured to operate in different modes. In other embodiments, the HVAC unit 12 may include one or more working fluid circuits for cooling an air stream and a furnace for heating the air stream.

[0028] A control device 16, one type of which may be a thermostat, may be used to designate the temperature of the conditioned air. The control device 16 also may be used to control the flow of air through the ductwork 14. For example, the control device 16 may be used to regulate operation of one or more components of the HVAC unit 12 or other components, such as dampers and fans, within the building 10 that may control flow of air through and / or from the ductwork 14. In some embodiments, other devices may be included in the system, such as pressure and / or temperature transducers or switches that sense the temperatures and pressures of the supply air, return air, and so forth. Moreover, the control device 16 may include computer systems that are integrated with or separate from other building control or monitoring systems, and even systems that are remote from the building 10.

[0029] FIG. 2 is a perspective view of an embodiment of the HVAC unit 12. In the illustrated embodiment, the HVAC unit 12 is a single package unit that may include one or more independent working fluid circuits and components that are tested, charged, wired, piped, and ready for installation. The HVAC unit 12 may provide a variety of heating and / or cooling functions, such as cooling only, heating only, cooling with electric heat, cooling with dehumidification, cooling with gas heat, or cooling with a heat pump. As described above, the HVAC unit 12 may directly cool and / or heat an air stream provided to the building 10 to condition a space in the building 10.

[0030] As shown in the illustrated embodiment of FIG. 2, a cabinet 24 encloses the HVAC unit 12 and provides structural support and protection to the internal components from environmental and other contaminants. In some embodiments, the cabinet 24 may be constructed of galvanized steel and insulated with aluminum foil faced insulation. Rails 26 may be joined to the bottom perimeter of the cabinet 24 and provide a foundation for the HVAC unit 12. In certain embodiments, the rails 26 may provide access for a forklift and / or overhead rigging to facilitate installation and / or removal of the HVAC unit 12. In some embodiments, the rails 26 may fit onto “curbs” on the roof to enable the HVAC unit 12 to provide air to the ductwork 14 from the bottom of the HVAC unit 12 while blocking elements such as rain from leaking into the building 10.

[0031] The HVAC unit 12 includes heat exchangers 28 and 30 in fluid communication with one or more working fluid circuits. Tubes within the heat exchangers 28 and 30 may circulate a working fluid (e.g., refrigerant), such as R-410A, through the heat exchangers 28 and 30. The tubes may be of various types, such as multichannel tubes, conventional copper or aluminum tubing, and so forth. Together, the heat exchangers 28 and 30 may implement a thermal cycle in which the working fluid undergoes phase changes and / or temperature changes as it flows through the heat exchangers 28 and 30 to produce heated and / or cooled air. For example, the heat exchanger 28 may function as a condenser where heat is released from the working fluid to ambient air, and the heat exchanger 30 may function as an evaporator where the working fluid absorbs heat to cool an air stream. In other embodiments, the HVAC unit 12 may operate in a heat pump mode where the roles of the heat exchangers 28 and 30 may be reversed. That is, the heat exchanger 28 may function as an evaporator, and the heat exchanger 30 may function as a condenser. In further embodiments, the HVAC unit 12 may include a furnace for heating the air stream that is supplied to the building 10. While the illustrated embodiment of FIG. 2 shows the HVAC unit 12 having two of the heat exchangers 28 and 30, in other embodiments, the HVAC unit 12 may include one heat exchanger or more than two heat exchangers.

[0032] The heat exchanger 30 is located within a compartment 31 that separates the heat exchanger 30 from the heat exchanger 28. Fans 32 draw air from the environment through the heat exchanger 28. Air may be heated and / or cooled as the air flows through the heat exchanger 28 before being released back to the environment surrounding the HVAC unit 12. A blower assembly 34, powered by a motor 36, draws air through the heat exchanger 30 to heat or cool the air. The heated or cooled air may be directed to the building 10 by the ductwork 14, which may be connected to the HVAC unit 12. Before flowing through the heat exchanger 30, the conditioned air flows through one or more filters 38 that may remove particulates and contaminants from the air. In certain embodiments, the filters 38 may be disposed on the air intake side of the heat exchanger 30 to prevent contaminants from contacting the heat exchanger 30.

[0033] The HVAC unit 12 also may include other equipment for implementing the thermal cycle. Compressors 42 increase the pressure and temperature of the working fluid before the working fluid enters the heat exchanger 28. The compressors 42 may be any suitable type of compressors, such as scroll compressors, rotary compressors, screw compressors, or reciprocating compressors. In some embodiments, the compressors 42 may include a pair of hermetic direct drive compressors arranged in a dual stage configuration 44. However, in other embodiments, any number of the compressors 42 may be provided to achieve various stages of heating and / or cooling. Additional equipment and devices may be included in the HVAC unit 12, such as a solid-core filter drier, a drain pan, a disconnect switch, an economizer, pressure switches, phase monitors, and humidity sensors, among other things.

[0034] The HVAC unit 12 may receive power through a terminal block 46. For example, a high voltage power source may be connected to the terminal block 46 to power the equipment. The operation of the HVAC unit 12 may be governed or regulated by a control board 48. The control board 48 may include control circuitry connected to a thermostat, sensors, and alarms. One or more of these components may be referred to herein separately or collectively as the control device 16. The control circuitry may be configured to control operation of the equipment, provide alarms, and monitor safety switches. Wiring 49 may connect the control board 48 and the terminal block 46 to the equipment of the HVAC unit 12.

[0035] FIG. 3 illustrates a residential heating and cooling system 50, also in accordance with present techniques. The residential heating and cooling system 50 may provide heated and cooled air to a residential structure, as well as provide outside air for ventilation and provide improved indoor air quality (IAQ) through devices such as ultraviolet lights and air filters. In the illustrated embodiment, the residential heating and cooling system 50 is a split HVAC system. In general, a residence 52 conditioned by a split HVAC system may include working fluid conduits 54 that operatively couple the indoor unit 56 to the outdoor unit 58. The indoor unit 56 may be positioned in a utility room, an attic, a basement, and so forth. The outdoor unit 58 is typically situated adjacent to a side of the residence 52 and is covered by a shroud to protect the system components and to block leaves and other debris or contaminants from entering the unit. The working fluid conduits 54 transfer working fluid (e.g., refrigerant) between the indoor unit 56 and the outdoor unit 58, typically transferring primarily liquid working fluid in one direction and primarily vaporized working fluid in an opposite direction.

[0036] When the system shown in FIG. 3 is operating as an air conditioner, a heat exchanger 60 in the outdoor unit 58 serves as a condenser for re-condensing vaporized working fluid flowing from the indoor unit 56 to the outdoor unit 58 via one of the working fluid conduits 54. In these applications, a heat exchanger 62 of the indoor unit 56 functions as an evaporator. Specifically, the heat exchanger 62 receives liquid working fluid, which may be expanded by an expansion device, and evaporates the working fluid before returning it to the outdoor unit 58.

[0037] The outdoor unit 58 draws environmental air through the heat exchanger 60 using a fan 64 and expels the air above the outdoor unit 58. When operating as an air conditioner, the air is heated by the heat exchanger 60 within the outdoor unit 58 and exits the unit at a temperature higher than it entered. The indoor unit 56 includes a blower or fan 66 that directs air through or across the indoor heat exchanger 62, where the air is cooled when the system is operating in air conditioning mode. Thereafter, the air is passed through ductwork 68 that directs the air to the residence 52. The overall system operates to maintain a desired temperature as set by a system controller. When the temperature sensed inside the residence 52 is higher than the set point on the thermostat, or the set point plus a small amount, the residential heating and cooling system 50 may become operative to cool additional air for circulation through the residence 52. When the temperature reaches the set point, or the set point minus a small amount, the residential heating and cooling system 50 may stop the refrigeration cycle temporarily.

[0038] The residential heating and cooling system 50 may also operate as a heat pump. When operating as a heat pump, the roles of heat exchangers 60 and 62 are reversed. That is, the heat exchanger 60 of the outdoor unit 58 will serve as an evaporator to evaporate working fluid and thereby cool air entering the outdoor unit 58 as the air passes over the heat exchanger 60. The heat exchanger 62 of the indoor unit 56 will receive a stream of air blown over it and will heat the air by condensing the working fluid.

[0039] In some embodiments, the indoor unit 56 may include a furnace system 70. For example, the indoor unit 56 may include the furnace system 70 when the residential heating and cooling system 50 is not configured to operate as a heat pump. The furnace system 70 may include a burner assembly and heat exchanger, among other components, inside the indoor unit 56. Fuel is provided to the burner assembly of the furnace 70 where it is mixed with air and combusted to form combustion products. The combustion products may pass through tubes or piping in a heat exchanger, separate from heat exchanger 62, such that air directed by the blower 66 passes over the tubes or pipes and extracts heat from the combustion products. The heated air may then be routed from the furnace system 70 to the ductwork 68 for heating the residence 52.

[0040] FIG. 4 is a schematic of an embodiment of a vapor compression system 72 that can be used in any of the systems described above. The vapor compression system 72 may circulate a working fluid through a circuit starting with a compressor 74. The circuit may also include a condenser 76, an expansion valve(s) or device(s) 78, and an evaporator 80. The vapor compression system 72 may further include a control panel 82 that has an analog to digital (A / D) converter 84, a microprocessor 86, a non-volatile memory 88, and / or an interface board 90. The control panel 82 and its components may function to regulate operation of the vapor compression system 72 based on feedback from an operator, from sensors of the vapor compression system 72 that detect operating conditions, and so forth.

[0041] In some embodiments, the vapor compression system 72 may use one or more of a variable speed drive (VSDs) 92, a motor 94, the compressor 74, the condenser 76, the expansion valve or device 78, and / or the evaporator 80. The motor 94 may drive the compressor 74 and may be powered by the variable speed drive (VSD) 92. The VSD 92 receives alternating current (AC) power having a particular fixed line voltage and fixed line frequency from an AC power source, and provides power having a variable voltage and frequency to the motor 94. In other embodiments, the motor 94 may be powered directly from an AC or direct current (DC) power source. The motor 94 may include any type of electric motor that can be powered by a VSD or directly from an AC or DC power source, such as a switched reluctance motor, an induction motor, an electronically commutated permanent magnet motor, or another suitable motor.

[0042] The compressor 74 compresses a working fluid vapor and delivers the vapor to the condenser 76 through a discharge passage. In some embodiments, the compressor 74 may be a centrifugal compressor. The working fluid vapor delivered by the compressor 74 to the condenser 76 may transfer heat to a fluid passing across the condenser 76, such as ambient or environmental air 96. The working fluid vapor may condense to a working fluid liquid in the condenser 76 as a result of thermal heat transfer with the environmental air 96. The liquid working fluid from the condenser 76 may flow through the expansion device 78 to the evaporator 80.

[0043] The liquid working fluid delivered to the evaporator 80 may absorb heat from another air stream, such as a supply air stream 98 provided to the building 10 or the residence 52. For example, the supply air stream 98 may include ambient or environmental air, return air from a building, or a combination of the two. The liquid working fluid in the evaporator 80 may undergo a phase change from the liquid working fluid to a working fluid vapor. In this manner, the evaporator 80 may reduce the temperature of the supply air stream 98 via thermal heat transfer with the working fluid. Thereafter, the vapor working fluid exits the evaporator 80 and returns to the compressor 74 by a suction line to complete the cycle.

[0044] In some embodiments, the vapor compression system 72 may further include a reheat coil in addition to the evaporator 80. For example, the reheat coil may be positioned downstream of the evaporator 80 relative to the supply air stream 98 and may reheat the supply air stream 98 when the supply air stream 98 is overcooled to remove humidity from the supply air stream 98 before the supply air stream 98 is directed to the building 10 or the residence 52.

[0045] Any of the features described herein may be incorporated with the HVAC unit 12, the residential heating and cooling system 50, or other HVAC systems. Additionally, while the features disclosed herein are described in the context of embodiments that directly heat and cool a supply air stream provided to a building or other load, embodiments of the present disclosure may be applicable to other HVAC systems as well. For example, the features described herein may be applied to mechanical cooling systems, free cooling systems, chiller systems, or other heat pump or refrigeration applications.

[0046] The present disclosure is directed to a heat exchanger assembly including a heat exchanger and a seal assembly configured to enable improved heat transfer between an air flow directed across the heat exchanger and a working fluid (e.g., refrigerant) directed through the heat exchanger. As described in further detail below, the heat exchanger may include tubes configured to circulate a working fluid therethrough, and the tubes may define a first section, a second section, and an intermediate section extending between the first section and the second section. In accordance with present embodiments, the first section and the second section may each include fins extending between the tubes (e.g., tube segments, tube sections) in the first section and the second section to increase a heat transfer surface area of the first section and the second section. However, the tubes (e.g., tube segments, tube sections) in the intermediate section may not include fins. As a result, heat transfer between the working fluid and air flow directed across the intermediate section may be limited compared to heat transfer between the working fluid and air flow directed across the first section and / or the second section. Accordingly, present embodiments also include the seal assembly configured to block air flow across the intermediate section and to divert air flow toward the first section and / or the second section. In this way, the seal assembly may enable increased air flow across the first section and / or the second section, which may improve heat transfer (e.g., heat transfer efficiency) of the heat exchanger.

[0047] With the foregoing in mind, FIG. 5 is a perspective view of an embodiment of a heat exchanger assembly 150 for an HVAC system 152, which may include the HVAC unit 12, the residential heating and cooling system 50, or any other suitable HVAC system. In general, the heat exchanger assembly 150 is configured to place a working fluid in a heat exchange relationship with a flow of air directed across the heat exchanger assembly 150. For example, the heat exchanger assembly 150 may be configured to condition (e.g., heat, cool, dehumidify) a flow of air (e.g., supply air) directed across the heat exchanger assembly 150 before the flow of air is provided to a conditioned space. In accordance with the present techniques, the heat exchanger assembly 150 may include a heat exchanger 154 and a seal assembly 156 configured to enable improved heat transfer (e.g., heat transfer efficiency) via the heat exchanger 154 during operation of the HVAC system 152. In some embodiments, the heat exchanger assembly 150 may also include one or more end plates 158 (e.g., delta plates) configured to couple to the heat exchanger 154.

[0048] An air flow 160 may be directed across the heat exchanger assembly 150, and a working fluid (e.g., a refrigerant) may be directed (e.g., circulated) through the heat exchanger 154 during operation of the HVAC system 152. For example, the heat exchanger 154 may include an inlet 162 (e.g., inlet port, first port) through which the working fluid may be directed into the heat exchanger 154, and the heat exchanger 150 may include an outlet 164 (e.g., outlet port, second port) through which the working fluid may be discharged from the heat exchanger 154. The heat exchanger 154 may further include one or more tubes 166 (e.g., coils, channels, microchannels) configured to direct the working fluid therethrough and from the inlet 162 to the outlet 164. Thus, the working fluid may flow through the heat exchanger 154 by flowing into the inlet 162, through the tubes 166, and out of the outlet 164. In some embodiments, the tubes 166 may include microchannel tubes, but the tubes 166 may include any suitable tubes, conduits, or other flow passages in additional or alternative embodiments to direct working fluid therethrough.

[0049] The air flow 160 (e.g., a supply air flow, a return air flow, an ambient air flow) may be directed across the tubes 166 during operation of the heat exchanger 154. The tubes 166 may enable heat transfer between the air flow 160 directed across the tubes 166 and the working fluid flowing through the tubes 166, thereby changing a characteristic (e.g., temperature, humidity) of the air flow 160. As an example, the heat exchanger 154 may operate as an evaporator, whereby heat may transfer from the air flow 160 to the tubes 166 and to the working fluid, thereby cooling the air flow 160 and heating the working fluid. As another example, the heat exchanger 154 may operate as a condenser, whereby heat may transfer from the working fluid to the tubes 166 and to the air flow 160, thereby heating the air flow 160 and cooling the working fluid. To enable flow of the air flow 160 across the heat exchanger 154, each tube 166 may be offset from one another along a first axis 170 (e.g. lateral axis, first lateral axis) to form spaces between adjacent tubes 166. The air flow 160 may therefore be directed across the tubes 166 via the spaces to place the air flow 160 in a heat exchange relationship with the working fluid via the tubes 166. For example, the air flow 160 may be directed from the heat exchanger 154 to a space serviced by the HVAC system 152 to condition the space. Furthermore, the working fluid may be directed from the heat exchanger 154 to another component of the HVAC system 152, such as to a compressor (e.g., compressor 42, compressor 74), to circulate through a vapor compression system (e.g., vapor compression system 72) of the HVAC system 152.

[0050] In the illustrated embodiment, the heat exchanger 154 includes a first section 176 (e.g., first panel section, first slab, first finned section, first linear section), a second section 178 (e.g., second panel section, second slab, second finned section, second linear section), and an intermediate section 180 (e.g., bent section, curved section, non-finned section, arcuate section) defined by the tubes 166 (e.g., microchannel tubes). In other words, each tube 166 may extend within and / or form a portion of the first section 176, the second section 178, and the intermediate section 180. As shown, portions of the tubes 166 within the intermediate section 180 fluidly couple corresponding portions of the tubes 166 in the first section 176 and the second section 178. The first section 176 and the second section 178 may be positioned crosswise to one another. For example, each of the first section 176 and the second section 178 may have a generally planar or flat (e.g., a rectangular) geometry. The first section 176 and the second section 178 may be oriented to form an angle 182 (e.g., acute angle, oblique angle) therebetween. As such, the first section 176 and the second section 178 may extend crosswise relative to one another to form a V-shape configuration and / or an A-shape configuration of the heat exchanger 154 defining a space 184 (e.g., air flow path) between the first section 176 and the second section 178.

[0051] As mentioned above, each tube 166 may form a portion of the first section 176, the second section 178, and the intermediate section 180. More specifically, each tube 166 may include a first portion 185 (e.g., first linear portion) disposed within the first section 176, a second portion 187 (e.g., second linear portion) within the second section 178, and a bent portion 189 (e.g., curved portion, arcuate portion) disposed within the intermediate section 180. The bent portion 189 may extend from the first portion 185 to the second portion 187 and may be curved to enable orientation of the first section 176 and the second section 178 in a crosswise arrangement with the angle 182 formed therebetween. The first portion 185, the second portion 187, and the bend portion 189 are fluidly coupled to one another to define one or more flow paths (e.g., microchannels) of the tube 166 to enable flow of working fluid through the tube 166.

[0052] The heat exchanger 154 may also include a first manifold 186 (e.g., an inlet manifold, intake manifold) and a second manifold 188 (e.g., outlet manifold, discharge manifold). The first manifold 186 is fluidly coupled to the inlet 162 and to each of the tubes 166. In particular, the first manifold 186 is fluidly coupled to the first portion 185 of each tube 166 to enable flow of working fluid from the inlet 162 and into each tube 166 of the heat exchanger 154. Similarly, the second manifold 188 is fluidly coupled to the outlet 164 and to the second portion 187 of each tube 166 to enable flow of the working fluid from the tubes 166 to the outlet 164. In certain embodiments, the heat exchanger 154 may include more than two manifolds.

[0053] Each tube 166 may extend from the first manifold 186 to the second manifold 188. In the illustrated embodiment, the first portion 185 of each tube 166 may extend along a first dimension 190 (e.g., first length, first width) of the first section 176, and the second portion 187 of each tube 166 may extend along a second dimension 192 (e.g., a second length, a second width) of the second section 178. Thus, each tube 166 may direct working fluid sequentially from the first manifold 186, through the first portion 185 (e.g., first section 176), through the bent portion 189 (e.g., intermediate section 180), and through the second portion 187 (e.g., second section 178) to the second manifold 188. In certain embodiments, the working fluid may flow multiple times through the first section 176, the intermediate section 180, and / or the second section 178 (e.g., along dimensions 190, 192) before being discharged from the heat exchanger 154. For example, the working fluid may flow through one of the tubes 166 from the first section 176 through the intermediate section 180 to the second section 178, then along another one of the tubes 166 from the second section 178 through the intermediate section 180 to the first section 176, and subsequently along yet another one of the tubes 166 from the first section 176 through the intermediate section 180 to the second section 178 toward the outlet 164. In such embodiments, the first manifold 186, the second manifold 188, or both may include one or more partitions (e.g., dividers) to provide a multi-pass configuration of the heat exchanger 154. Accordingly, the working fluid may flow through multiple passes of the heat exchanger 154, and sets of the tubes 166 may be positioned in series with one another with respect to the flow of working fluid through the tubes 166. Additionally or alternatively, working fluid may flow in parallel through sets of the tubes 166. By way of example, working fluid may flow through the inlet 162, and the working fluid may be split or divided into multiple working fluid flows within the first manifold 186 to flow through multiple sets of tubes 166 (e.g., through the first section 176, the intermediate section 180, and the second section 178) in parallel with one another. The working fluid flows may combine (e.g., within the second manifold 188) before flowing to the outlet 164 via the second manifold 188. Although the inlet 162 and the outlet 164 are positioned at different sections 176, 178 in the illustrated embodiment, other embodiments of the heat exchanger 154 may include the inlet 162 and the outlet 164 positioned at the same section (e.g., at the first section 176, at the second section 178) of the heat exchanger 154. In this manner, the working fluid may enter and exit the heat exchanger 154 via a common manifold and / or proximate the same section (e.g., end) of the heat exchanger 154.

[0054] The first section 176 and the second section 178 of the heat exchanger 154 may each include a plurality of fins extending between respective portions of the tubes 166 within the first section 176 and the second section 178. For example, in the illustrated embodiment, the first section 176 includes a first plurality of fins 191 extending between adjacent first portions 185 of the tubes 166 within the first section 176. Similarly, the second section 178 includes a second plurality of fins 193 extending between adjacent second portions 187 of the tubes 166 within the second section 178. The first section 176 and the second section 178 may therefore be considered or described as finned sections of the heat exchanger 154. It should be appreciated that the first plurality of fins 191 may extend between adjacent first portions 185 of the tubes 166 along the first dimension 190 (e.g., an entirety of the first dimension 190, a substantial entirety of the first dimension 190) of the first section 176, and the second plurality of fins 193 may extend between adjacent second portions 187 of the tubes 166 along the second dimension 192 (e.g., an entirety of the second dimension 192, a substantial entirety of the second dimension 192) of the second section 178. The first plurality of fins 191 may increase a heat transfer surface area of first section 176, and the second plurality of fins 193 may increase a heat transfer surface area of second section 178. The additional heat transfer surface area provided by the first plurality of fins 191 and the second plurality of fins 193 may enable increased heat transfer (e.g., improved heat transfer efficiency) between the working fluid circulated through the heat exchanger 154 and the air flow 160 directed across the heat exchanger 154.

[0055] The intermediate section 180 including the bent portions 189 of the tubes 166 may not include fins extending between adjacent bent portions 189 of the tubes 166. Accordingly, the intermediate section 180 may be considered or described as a non-finned section of the heat exchanger 154. The intermediate section 180 may not include fins to facilitate and / or simplify manufacturing of the heat exchanger 154, to reduce costs of the heat exchanger 154, to facilitate adjustability of the heat exchanger 154, and / or for any other suitable purpose. For example, the tubes 166 of the heat exchanger 154 may be manufactured in an initial, linear configuration, and the first section 176 and the second section 178 may rotated relative to one another to form the intermediate section 180. In any case, omission of fins between adjacent bent portions 189 of the tubes 166 may reduce a heat transfer efficiency and / or effectiveness of the intermediate section 180 relative to the first section 176 and the second section 178 of the heat exchanger 154. Therefore, it may be more desirable to direct the air flow 160 across the first section 176 and the second section 178.

[0056] Accordingly, present embodiments include the seal assembly 156 configured to couple to the heat exchanger 154 and to block air flow (e.g., air flow 160) across the intermediate portion 180 of the heat exchanger 154 and to divert the air flow to flow across the first section 176 and the second section 178 instead of the intermediate section 180. In this way, the seal assembly 156 enables additional flow of the air flow 160 across the first section 176 and / or the second section 178, which facilitates improved (e.g., additional, more efficient) heat transfer between the air flow 160 and the working fluid circulated through the tubes 166 of the heat exchanger 154. The seal assembly 156 may include a mounting bracket 194 (e.g., support structure, mounting rail, support rail, retention bracket) and a gasket 196 (e.g., seal, sealing member, plug, wedge, cover) configured to couple to the mounting bracket 194. In some embodiments, the mounting bracket 194 may be configured to mount to the end plates 158 in an installed configuration of the heat exchanger assembly 150, as described in further detail below.

[0057] The end plates 158 (e.g., delta plates) may be coupled to the heat exchanger 154 to enable flow of the air flow 160 across the tubes 166 in a desired manner. More specifically, in an assembled configuration of the heat exchanger assembly 150, the end plates 158 may be configured to guide or direct the air flow 160 across the tubes 166 and block bypass of the air flow 160 around the tubes 166 (e.g., external to the space 184). The end plates 158 may be configured to couple to end sheets (e.g., end panels, cap sheets, side panels) attached to the heat exchanger 154. For example, in the illustrated embodiment and on a first side 195 (e.g., first end) of the heat exchanger 154 and / or the heat exchanger assembly 150, the heat exchanger 154 includes a first end sheet 197 coupled to the first section 176 and extending along the first dimension 190 and a second end sheet 199 coupled to the second section 178 and extending along the second dimension 192. The first end sheet 197 and the second end sheet 199 may be secured to any suitable components of the heat exchanger 154, such as one or more of the tubes 166, the first manifold 186, the second manifold 188, another component, or any combination thereof. The first end sheet 197 and the second end sheet 199 each include one or more respective flanges 198. Each flange 198 may include a corresponding aperture 201 (e.g., hole, opening) formed therethrough. A first end plate 203 of the end plates 158 may also include a plurality of apertures 205 (e.g., holes, openings) formed therethrough. In an assembled configuration, the first end plate 203 may be mounted or attached to the first end sheet 197 and the second end sheet 199 via mechanical fasteners (e.g., rivets, screws, bolts) extending through corresponding apertures 201 of the flanges 198 and apertures 205 of the first end plate 203. However, in other embodiments, the first end plate 203 may be attached to the heat exchanger 154 (e.g., first end sheet 197, second end sheet 199, flanges 198) via another suitable technique, such as a weld, an adhesive, a punch, and so forth. In this way, the first end sheet 203 may extend from the first section 176 to the second section 178 (e.g., along a second axis 172) on the first side 195 of the heat exchanger assembly 150 and may guide the air flow 160 through the space 184 and across the tubes 166. In other words, the first end plate 203 may block the air flow 160 from flowing external to the space 184 and bypassing the tubes 166. It should be appreciated that a second side 207 (e.g., second end) of the heat exchanger 154 and / or the heat exchanger assembly 150, opposite the first side 195, may also include end sheets similar to the first end sheet 197 and the second end sheet 199 to enable securement of a second end plate 209 of the end plates 158 to the heat exchanger 154 on the second side 207 of the heat exchanger assembly 150.

[0058] As shown, the air flow 160 may be directed into the space 184 defined by the heat exchanger 154 along a third axis 174 (e.g., longitudinal axis, vertical axis, air flow direction) and in a first direction 211 (e.g., upward direction). Thus, the heat exchanger assembly 154 may be described as arranged in an upflow configuration. However, in other embodiments, the heat exchanger assembly 150 may arranged in other orientations and / or the heat exchanger assembly 150 may be configured to receive the air flow 160 directed in another direction. For example, the heat exchanger assembly 150 be oriented as illustrated, and the air flow 160 may be directed across the heat exchanger 154 along the third axis 174 in a second direction 213 (e.g., downward direction, downflow configuration), opposite the first direction 211. The heat exchanger assembly 150 may also be oriented in other arrangements, such as a horizontal left or horizontal right configuration, and configured to receive the air flow 160 directed along the second axis 172 or the first axis 170.

[0059] In any case, in an assembled configuration, the seal assembly 156 is configured to overlap with the intermediate section 180, relative to a direction of the air flow 160 directed across the heat exchanger 154 (e.g., first direction 211). As a result, the seal assembly 156 may block the air flow 160 from flowing across the intermediate section 180 (e.g., non-finned section) and may diver the air flow 160 to flow across the first section 176 and / or the second section 178 (e.g., finned sections). As described in further detail below, the gasket 196 may be configured engage with (e.g., abut, bias against) the first section 176, the second section 176, the intermediate section 180, or any combination thereof, in the assembled configuration to create a sealing engagement and / or sealing interface therebetween and improve blockage of the air flow 160 across the intermediate section 180.

[0060] FIG. 6 is a side view of a portion of an embodiment of the heat exchanger assembly 150, illustrating the seal assembly 156 in an installed or assembled configuration with the heat exchanger 154. As discussed above, the heat exchanger 154 includes the tubes 166 defining the first section 176, the second section 178, and the intermediate section 180 extending between the first section 176 and the second section 178. The first section 176 includes the first plurality of fins 191 extending between the tubes 166, and the second section 178 includes the second plurality of fins 193 extending between the tubes 166. Thus, the first section and the second section 178 are finned sections of the heat exchanger 154. The intermediate section 180 does not include fins extending between the tubes 166, and the intermediate section 180 is therefore a non-finned section of the heat exchanger 154. The first section 176 and the second section 178 of the heat exchanger 154 are arranged to form the angle 182 therebetween. Additionally, the intermediate section 180 may include a bend extending between the first section 176 and the second section 178. That is, the tubes 166 may include the bent portions 189 extending within the intermediate section 180.

[0061] As described above, the seal assembly 156 is configured to couple to the heat exchanger 154 to block the air flow 160 from flowing across the intermediate section 180 (e.g., non-finned section of the heat exchanger 154) and to direct (e.g., divert, redirect) a greater amount of the air flow 160 to flow across the first section 176 and the second section 178 (e.g., finned sections of the heat exchanger 154). The seal assembly 156 also includes the mounting bracket 194 and the gasket 196 described above. The gasket 196 may be coupled to the mounting bracket 194 (e.g., via fasteners, via adhesive), and the mounting bracket 194 may be attached to one or more components of the heat exchanger 154 and / or heat exchanger assembly 150 (e.g., end plates 158) to retain the seal assembly 156 in an installed and / or assembled orientation with the heat exchanger 154.

[0062] In the assembled configuration, the seal assembly 156 may be disposed between the first section 176 and the second section 178 of the heat exchanger 154 (e.g., along the second axis 172) and within the space 184 defined by the heat exchanger 154. The seal assembly 156 may also be mounted in alignment with the intermediate section 180 along a direction of the air flow 160 (e.g., first direction 211) across the heat exchanger 154 (e.g., along the third axis 174, along a central axis 200 of the heat exchanger 154). Thus, the seal assembly 156 (e.g., gasket 196) may overlap with the intermediate section 180 of the heat exchanger 154 (e.g., along the third axis 174). The seal assembly 156 may be also disposed upstream of the intermediate section 180 relative to the direction of the air flow 160 across the heat exchanger 154. Therefore, the seal assembly 156 may block the air flow 160 from flowing across the intermediate section 180 and may divert and / or redirect at least a portion of the air flow 160 to flow across the first section 176 and / or the second section 178.

[0063] To enable and / or improve blockage of the air flow 160 across the intermediate section 180 of the heat exchanger 154, the gasket 196 may engage with (e.g., contact, abut) one or more portions of the heat exchanger 154. For example, the gasket 196 may abut the first section 176 and / or the intermediate section 180 to define a first sealing interface 215 between the gasket 196 and the heat exchanger 154, and the gasket 196 may abut the second section 178 and / or the intermediate section 180 to define a second sealing interface 217 between the gasket 196 and the heat exchanger 154 (e.g., opposite the first sealing interface 215, relative to the central axis 200). In some embodiments, the gasket 196 may abut the heat exchanger 154 and create the first sealing interface 215 at a first interface 177 (e.g., connection, joint, transition) between the first section 176 and the intermediate section 180. Similarly, the gasket 196 may abut the heat exchanger 154 and create the second sealing interface 217 at a second interface 179 (e.g., connection, joint) between the second section 178 and the intermediate section 180. Therefore, in some embodiments, the gasket 196 may abut the first section 176, the second section 178, and the intermediate section 180 in the assembled configuration. In this way, the gasket 196 may block the air flow 160 from flowing through and / or across the intermediate section 180.

[0064] In some embodiments, the gasket 196 may be configured to deform (e.g., elastically deform) to establish the first sealing interface 215 and the second sealing interface 217 with the heat exchanger 154 in the installed configuration of the seal assembly 156 with the heat exchanger 154. To this end, the gasket 196 may be at least partially formed from a flexible and resilient material, such as foam (e.g., foam material), rubber, leather, a polymer, another suitable material, or any combination thereof. During installation of the seal assembly 156, the gasket 196 may flex or bend to enable positioning of the seal assembly 156 in an installed position between the first section 176 and the second section 178. To this end, an undeformed width (e.g., resting width, natural width, relaxed dimension, dimension along the second axis 172) of the gasket 196 may be greater than an internal width 219 of the heat exchanger 154 extending between the first interface 177 and the second interface 179 (e.g., between ends of the first section 176 and the second section 178 coupled to the intermediate section 180) along the second axis 172. Therefore, in the installed configuration, lateral ends 221 (e.g., end portions, distal ends, lateral portions) of the gasket 196 may bend or flex (e.g., along the third axis 174) to enable positioning of the seal assembly 156 in a desired or installed orientation. As a result, the lateral ends 221 of the gasket 196 may be biased against the heat exchanger 154 (e.g., first interface 177, second interface 179), such as due to elastic and / or resilience properties of a material of the gasket 196, in the installed configuration of the seal assembly 156. The gasket 196 may therefore define a generally convex geometry or surface facing the intermediate section 180 in the installed configuration. The mounting bracket 194 may be attached to components (e.g., end plates 158) of the heat exchanger assembly 150 to retain the gasket 196 in biased engagement with the heat exchanger 154 and to maintain the first sealing interface 215 and the second sealing interface 217 created therebetween.

[0065] As mentioned above, certain embodiments of the heat exchanger 154 may include the first section 176 and the second section 178 configured to move (e.g., pivot, rotate) relative to one another. For example, the first section 176 and the second section 178 may rotate or pivot relative to one another and generally about the intermediate section 180. In some embodiments, the intermediate section 180 may be configured to flex or bend to enable adjustable relative positioning of the first section 176 and the second section 178. For instance, the first section 176 and the second section 178 may be rotated in inward directions 223 (e.g., toward one another, toward the space 184, toward the central axis 200) to reduce a magnitude of the angle 182, reduce a size of the space 184, and / or reduce a size (e.g., dimension) of the heat exchanger 154 along the second axis 172 (e.g., decrease a width of the heat exchanger 154). Additionally or alternatively, the first section 176 and the second section 178 may be pivoted and / or rotated in outward directions 225 (e.g., away from one another, away from the space 184, away from the central axis 200) to increase a magnitude of the angle 182, increase a size of the space 184, and / or increase a size (e.g., dimension) of the heat exchanger 154 along the second axis 172 (e.g., increase a width of the heat exchanger 154). In such embodiments, the first section 176 and the second section 178 of the heat exchanger 154 may be adjustable (e.g., rotatable, pivotable, positionally adjustable) such that the heat exchanger 154 may be arranged in each orientation of a plurality of orientations (e.g., first angular orientation and / or first overall width, second angular orientation and / or second overall width, etc.), where each orientation corresponds to a different magnitude of the angle 182, a different size (e.g., volume) of the space 184, and / or a different overall width of the heat exchanger 154. A common embodiment of the heat exchanger 154 may therefore be utilized in different HVAC systems (e.g., indoor units, air handlers, rooftop units) having different characteristics (e.g., dimensions, capacities, operating parameters), and an orientation of the heat exchanger 154 (e.g., angular arrangement of the first section 176 and the second section 178) may be selected based on one or more characteristics of a particular HVAC system with which the heat exchanger 154 is implemented.

[0066] In accordance with the present techniques, a common embodiment of the seal assembly 156 may be configured to engage with embodiments of the heat exchanger 154 configured to enable positional adjustment (e.g., pivoting, rotation) of the first section 176 and the second section 178 relative to one another. That is, a common embodiment of the seal assembly 156 may be configured to sealingly engage with the heat exchanger 154 in each orientation (e.g., angular orientation) of the first section 176 and the second section 178 relative to one another. More specifically, the gasket 196 may be configured to engage with the heat exchanger 154 (e.g., in contact with the first section 176, the second section 178, and / or the intermediate section 180) in each orientation of the plurality of orientations of the heat exchanger 154. For example, in different relative orientations of the first section 176 and the second section 178 (e.g., different magnitudes of the angle 182 formed via the first section 176 and the second section 178), the internal width 219 of the heat exchanger 154 may be less than an overall, relaxed width (e.g., undeformed width, resting width) of the gasket 196. The gasket 196 may therefore engage with (e.g., contact, abut) the first section 176, the second section 178, and / or the intermediate section 180 in the different orientations of the heat exchanger 154 in the installed configuration of the seal assembly 156. In each orientation of the heat exchanger 154, the gasket 196 may extend between the first section 176, the second section 178, and / or the intermediate section 180 (e.g., along the second axis 172) and at least partially deform to engage with the heat exchanger 154 (e.g., first interface 177, second interface 179) to establish the first sealing interface 215 and the second sealing interface 217. For example, as discussed further below, the gasket 196 may be a panel having a generally rectangular shape or profile in an undeformed (e.g., natural, resting, relaxed) state. Upon installation of the seal assembly 156 with the heat exchanger 154, the lateral ends 221 of the gasket 196 may contact and / or engage with one or more sections of the heat exchanger 154 and may bend or otherwise deform to accommodate a particular orientation (e.g., angle 182) of the first section 176 and the second section 178 relative to one another. As will be appreciated, an amount or extent by which the lateral ends 221 of the gasket 196 bend or deform may depend on the particular orientation of the first section 176 and the second section 178 relative to one another.

[0067] FIG. 7 is an exploded perspective view of an embodiment of the seal assembly 156, illustrating embodiments of the mounting bracket 194 and the gasket 196. As discussed above, the gasket 196 is configured to couple (e.g., attach) to the mounting bracket 194, and the mounting bracket 194 is configured to enable securement of the seal assembly 156 to the heat exchanger 154 (e.g., heat exchanger assembly 150) and retention of the gasket 196 in a desired position in an installed configuration of the seal assembly 156. The mounting bracket 194 may be formed from any suitable material, such as a rigid and / or heat-resistant material (e.g., steel, aluminum). In some embodiments, the mounting bracket 194 may be formed from a single piece of material (e.g., sheet metal), which may be cut, bent, formed, punched, and / or otherwise manipulated to form features of the mounting bracket 194.

[0068] As shown, the mounting bracket 194 may include and / or define a support rail 202, a first mounting flange 204, and a second mounting flange 206. The support rail 202 may include a base portion 220 (e.g., mounting portion, platform, mounting surface, support surface), a first side flange 222 (e.g., first support flange), and a second side flange 224 (e.g., second support flange). Alternatively, the first side flange 222 and the second side flange 224 may be considered components of the mounting bracket 194 coupled to the support rail 202 (e.g., base portion 220). The base portion 220 may be a generally planar portion of the support rail 202 and may be configured to support the gasket 196 in an installed configuration of the seal assembly 156 with the heat exchanger 154. As described further below, in an assembled configuration of the seal assembly 156, the gasket 196 may be coupled to (e.g., via adhesive, via mechanical fasteners) and may extend along the base portion 220 of the support rail 202. The first side flange 222 and the second side flange 224 each extend from opposite lateral edges 226 of the base portion 220. The mounting bracket 194 (e.g., support rail 202) may have a length 228 (e.g., extending along the first axis 107), and the first side flange 222 and the second side flange 224 may each extend along the base portion 220 (e.g., lateral edges 226, along the first axis 170) for an entirety or a substantial entirety (e.g., at least 90 percent, at least 95 percent) of the length 228. As will be appreciated, the first side flange 222 and the second side flange 224 may increase a structural rigidity of the mounting bracket 194 and enable improved retention of the seal assembly 156 in an installed position with the heat exchanger 154. For example, the improved structural rigidity of the mounting bracket 194 may enable establishment and preservation of a sealing engagement between the gasket 196 and the heat exchanger 154 (e.g., first sealing interface 215, second sealing interface 217).

[0069] The mounting bracket 194 also includes the first mounting flange 204 and the second mounting flange 206, which are configured to enable securement of the seal assembly 156 to the heat exchanger 154 and / or heat exchanger assembly150. As shown, the first mounting flange 204 extends from the support rail 202 (e.g., base portion 220) at a first end 230 (e.g., first longitudinal end) of the support rail 202, and the second mounting flange 206 extends from the support rail 202 (e.g., base portion 220) at a second end 232 (e.g., second longitudinal end) of the support rail 202, opposite the first end 230 (e.g., along the first axis 170). Each of the first mounting flange 204 and the second mounting flange 206 may be configured to couple to a corresponding one of the end plates 158 of the heat exchanger assembly 150. For example, the first mounting flange 204 and the second mounting flange 206 may each be configured to receive a corresponding fastener 208 (e.g., mechanical fastener, rivet, bolt, screw, pin) configured to extend therethrough (e.g., via a respective aperture or opening of the first mounting flange 204 or the second mounting flange 206) and into the corresponding end plate 158 to attach (e.g., mount, secure) the seal assembly 156 to the heat exchanger assembly 150.

[0070] In an installed configuration of the seal assembly 156 with the heat exchanger 154, the support rail 202 may extend along the first axis 170, and the first mounting flange 204 and the second mounting flange 206 may extend from the support rail 202 (e.g., base portion 220) generally along the third axis 174. The first side flange 222 and the second side flange 224 may also extend from the support rail 202 (e.g., base portion 220, lateral edges 226) along the third axis 174 in the installed configuration of the seal assembly 156. Therefore, in some embodiments, the first mounting flange 204, the second mounting flange 206, the first side flange 222, and the second side flange 224 may extend from the support rail 202 (e.g., base portion 220) in a common direction. As mentioned above, the support rail 202 may be formed from a single piece of material, such as a single piece of sheet metal. For example, the support rail 202 may be cut, stamped, or otherwise formed to create the single piece structure, and the support rail 202 may be bent to form the first mounting flange, 204, the second mounting flange 206, the first side flange 222, and the second side flange 224.

[0071] FIG. 8 is a perspective view of an embodiment of the seal assembly 156, illustrating an assembled configuration of the seal assembly 156. As described above, the seal assembly 156 includes the mounting bracket 194 and the gasket 196. In the assembled configuration, the gasket 196 is coupled to the support rail 202 (e.g., base portion 220). The gasket 196 and the mounting bracket 194 may be assembled together such that the gasket 196 and the mounting bracket 194 are generally centered along the third axis 174. Thus, the seal assembly 156 may include and / or define a central axis 240. In an installed configuration of the seal assembly 156 with the heat exchanger 154, the central axis 240 of the seal assembly 156 may be generally aligned (e.g., coaxial) with the central axis 200 of the heat exchanger 154.

[0072] As mentioned above, the gasket 196 may be formed from a flexible, pliable, and / or resilient material, such as foam, to enable engagement (e.g., sealing engagement, interference fit) between the gasket 196 and the heat exchanger 154 (e.g., first section 176, second section 178, and / or intermediate section 180) in the installed configuration of the seal assembly 156 with the heat exchanger 154. Indeed, the material of the gasket 196 may enable establishment of a sealing engagement between the gasket 196 and the heat exchanger 154 in each orientation (e.g., angular orientation) of a plurality of orientations of the first section 176 and the second section 178 relative to one another. To this end, the gasket 196 includes a main body 212 (e.g., central portion, seal, core), which may be formed from the flexible, pliable, and / or resilient material (e.g., foam, rubber, polymer, leather, high-temperature-rated foam, ultraviolet-rated foam). The illustrated embodiment also depicts an undeformed width 242 (e.g., resting width, natural width, relaxed dimension, dimension along the second axis 172) of the gasket 196. As described above, the undeformed width 242 may be greater than the internal width 219 of the heat exchanger 154 extending between the first interface 177 and the second interface 179 (e.g., between ends of the first section 176 and the second section 178 coupled to the intermediate section 180) along the second axis 172. Thus, the gasket 196 may be configured to engage with the heat exchanger 154 to form the first sealing interface 215 and the second sealing interface 217 therebetween in the installed configuration of the seal assembly 156. Additionally, in the installed configuration, the material of the gasket 196 (e.g., main body 212) may enable deformation of the gasket 196, such as bending of the lateral ends 221 of the gasket 196, to establish and maintain the first sealing interface 215 and the second sealing interface 217 with the heat exchanger 154.

[0073] Some embodiments of the gasket 196 may also include additional components and / or elements. For example, the gasket 196 may include a first layer 210 (e.g., insulative layer, outer layer, external layer, protective layer) coupled to (e.g., attached, applied, and / or overlaid) and / or disposed on a first base surface 244 (e.g., first side, first surface) of the main body 212. The first layer 210 may include a material configured to protect and / or insulate the main body 212 of the gasket 196 (e.g., from elevated temperatures). The first layer 210 may be formed from any suitable material, such as an insulating and / or heat-resistant material. In some embodiments, the first layer 210 may be a foil layer. The first layer 210 may be attached to the main body 212 (e.g., first base surface 244) in any suitable manner, such as via an adhesive or a molding process. In some embodiments, the first layer 210 may also extend along and / or be attached to lateral surfaces 246 of the main body 212. In the installed configuration of the seal assembly 156 (e.g., an assembled configuration of the heat exchanger assembly 150), the first layer 210 may be arranged to face the intermediate section 180 of the heat exchanger 154 (e.g., in a downstream direction, relative to a direction of the air flow 160 across the heat exchanger 154).

[0074] Additionally or alternatively, the gasket 196 may include a second layer 214 (e.g., attachment layer, adhesive layer, outer layer, external layer) applied to a second base surface 248 of the main body 212, opposite the first base surface 244 (e.g., relative to the third axis 174). The second layer 214 may be configured to enable attachment of the gasket 196 to the support rail 202 (e.g., base portion 220) of the mounting bracket 194. For example, the second layer 214 may be an adhesive (e.g., glue, bonding, paste) configured to bind the gasket 196 to the support rail 202. In some embodiments, in an unassembled configuration of the seal assembly 156, a protective layer 250 (e.g., film, plastic, paper, third layer) may overlay the second layer 214 (e.g., opposite the main body 212). As an example, the protective layer 250 may be formed with the same material as the first layer 210 (e.g., foil). To assemble the seal assembly 156, a portion of the protective layer 250 may be removed to reveal and / or expose at least a portion of the second layer 214 (e.g., adhesive) to enable attachment of the gasket 196 to the mounting bracket 194. For example, the protective layer 250 may be scored or precut, such that a portion (e.g., central portion) of the protective layer 250 may be removed from the second layer 214 to reveal a section 252 of the second layer 214 having an area and / or dimension (e.g., along the first axis 170, along the third axis 174) approximately equal to or less than that of the base portion 220 of the support rail 202. In this manner, a process of assembling the seal assembly 156 may be improved and / or simplified by facilitating proper alignment of the gasket 196 and the mounting bracket 194 (e.g., along the central axis 240) in the assembled configuration. Unremoved portions (e.g., lateral portions) of the protective layer 250 may remain adhered to the second layer 214 in the assembled configuration of the seal assembly 156. Thus, during installation of the seal assembly 156 with the heat exchanger 154, inadvertent contact (e.g., adhesion) between the second layer 214 and the first side flange 222 and / or second side flange 224 (e.g., via flexing or bending of the lateral portions 221) may be blocked by the unremoved portions of the protective layer 250.

[0075] In the illustrated embodiment, the first mounting flange 204 includes an aperture 254 (e.g., mounting aperture, fastener aperture) formed therethrough (e.g., along the first axis 170). The second mounting flange 206 may similarly include an aperture formed therethrough. The aperture 254 of the first mounting flange 204 and the aperture of the second mounting flange 206 are configured to enable securement of the seal assembly 156 to the heat exchanger 154 and / or heat exchanger assembly 150, as discussed in further detail below.

[0076] FIG. 9 is an expanded perspective view of a portion of an embodiment of the heat exchanger assembly 150, illustrating the heat exchanger 154 and the seal assembly 156 in an assembled configuration. The illustrated embodiment also includes the first end plate 203 of the end plates 158 in the assembled configuration with the heat exchanger assembly 150. As described above, the seal assembly 156 may be coupled the end plates 158 to position and retain the seal assembly 156 in a desired orientation relative to the heat exchanger 154. The mounting bracket 194 may be coupled to the end plates 158 via any suitable technique (via mechanical fasteners, via adhesive). For example, in the illustrated embodiment, the first mounting flange 204 of the mounting bracket 194 is secured to the first end plate 203 via one of the fasteners 208. The fastener 208 may extend through the aperture 254 formed in the first mounting flange 204 and may also extend through one of the apertures 205 formed in the first end plate 203.

[0077] To facilitate desired positioning of the seal assembly 156 relative to the heat exchanger 154 (e.g., intermediate section 180), the mounting bracket 194 (e.g., support rail 202) may extend (e.g., along the first axis 170) external to the space 184 defined by the heat exchanger 154 and across an edge 260 (e.g., upper edge, apex edge, longitudinal edge) of the first end plate 203, and the first mounting flange 204 may extend along an outer surface 262 of the first end plate 203 (e.g., along the third axis 174). Therefore, the first mounting flange 204 and the aperture 254 may be disposed external to the space 184 defined by the heat exchanger 154, which may enable improved and / or simplified securement of the seal assembly 156 to the first end plate 203 via the fastener 208. The fastener 208 may remain exposed with the heat exchanger assembly 150, which may facilitate streamlined uninstallation and / or removal of the seal assembly 156 from the heat exchanger 154. It should be appreciated that the second mounting flange 206 and the second end plate 209 may be arranged similarly.

[0078] As described above, the end plates 158 may be coupled to the heat exchanger 154 in the assembled configuration of the heat exchanger assembly 150. For example, the first end plate 203 may be coupled to (e.g., attached via mechanical fasteners) to the flanges 198 of the first end sheet 197 and the second end sheet 199 on the first side 195 of the heat exchanger assembly 150, and the second end plate 209 may be similarly coupled to corresponding flanges of end sheets on the second side 207 of the heat exchanger assembly 150. In this way, the seal assembly 156 may be arranged in a sealing engagement with the heat exchanger 154 to enable blockage of the air flow 160 across the intermediate section 180 (e.g., non-finned section) and to redirect and / or divert an increased amount of the air flow 160 across the first section 176 and the second section 178 (e.g., finned sections) of the heat exchange 154.

[0079] The present disclosure may provide one or more technical effects useful in the operation of an HVAC system. For example, the HVAC system may include a heat exchanger with tubes through which a working fluid may flow. The HVAC system may also direct an air flow across the tubes of the heat exchanger, and the heat exchanger may place the air flow in a heat exchange relationship with the working fluid to condition the air flow. The tubes may define a first section, a second section, and an intermediate section extending between the first section and the second section of the heat exchanger. The first section and the second section may each include fins extending between portions of the tubes within the first section and the second section, while the intermediate section may not include fins extending between portions of the tubes within the intermediate section. A seal assembly may be installed with the heat exchanger in an orientation to block air flow across the intermediate section (e.g., non-finned section) and to force an increase amount of air flow across the first section and the second section of the heat exchanger (e.g., finned sections). In this manner, the seal assembly enables greater and more efficient heat transfer between the air flow and the working fluid circulated through the tubes of the heat exchanger.

[0080] The seal assembly may include a mounting bracket and a gasket. The mounting bracket may be configured to mount the seal assembly between the first section and the second section of the heat exchanger and in alignment with the intermediate section of the heat exchanger along a direction of air flow across the heat exchanger. In an installed configuration, the gasket may be biased against the first section, the second section, and / or the intermediate section to enable blockage of air flow across the intermediate section. The technical effects and technical problems in the specification are examples and are not limiting. It should be noted that the embodiments described in the specification may have other technical effects and can solve other technical problems.

[0081] While only certain features and embodiments of the disclosure have been illustrated and described, many modifications and changes may occur to those skilled in the art, such as variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, including temperatures and pressures, mounting arrangements, use of materials, colors, orientations, and so forth without materially departing from the novel teachings and advantages of the subject matter recited in the claims. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the disclosure.

[0082] Furthermore, in an effort to provide a concise description of the exemplary embodiments, all features of an actual implementation may not have been described, such as those unrelated to the presently contemplated best mode of carrying out the disclosure, or those unrelated to enabling the claimed disclosure. It should be noted that in the development of any such actual implementation, as in any engineering or design project, numerous implementation specific decisions may be made. Such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure, without undue experimentation.

[0083] The techniques presented and claimed herein are referenced and applied to material objects and concrete examples of a practical nature that demonstrably improve the present technical field and, as such, are not abstract, intangible or purely theoretical. Further, if any claims appended to the end of this specification contain one or more elements designated as “means for [perform]ing [a function] . . . ” or “step for [perform]ing [a function] . . . ”, it is intended that such elements are to be interpreted under 35 U.S.C. 112(f). However, for any claims containing elements designated in any other manner, it is intended that such elements are not to be interpreted under 35 U.S.C. 112(f).

Claims

1. A heat exchanger assembly for a heating, ventilation, and / or air conditioning (HVAC) system, comprising:a heat exchanger comprising a plurality of tubes configured to direct a working fluid therethrough, wherein the plurality of tubes defines a first section, a second section, and an intermediate section extending from the first section to the second section, and the first section and the second section extend crosswise relative to one another; anda seal assembly configured to couple to the heat exchanger, wherein the seal assembly comprises:a mounting bracket configured to mount the seal assembly between the first section and the second section and in alignment with the intermediate section along a direction of air flow across the heat exchanger; anda gasket configured to couple to the mounting bracket, wherein the gasket is configured to bias against the first section and the second section and block air flow across the intermediate section.

2. The heat exchanger assembly of claim 1, wherein the gasket comprises a foam material.

3. The heat exchanger assembly of claim 2, wherein the gasket comprises a foil layer attached to the foam material, and the foil layer is configured to face the intermediate section in an assembled configuration of the heat exchanger assembly.

4. The heat exchanger assembly of claim 3, wherein the gasket comprises an adhesive layer coupled to a surface of the foam material opposite the foil layer, and the gasket is configured to couple to the mounting bracket via the adhesive layer.

5. The heat exchanger assembly of claim 1, wherein the mounting bracket comprises:a support rail configured to couple to the gasket;a first mounting flange extending from a first end of the support rail; anda second mounting flange extending from a second end of the support rail, opposite the first end of the support rail;wherein the first mounting flange and the second mounting flange are configured to mount the seal assembly to the heat exchanger assembly.

6. The heat exchanger assembly of claim 5, comprising:a first end plate configured to couple to the first section and the second section at a first end of the heat exchanger; anda second end plate configured to couple to the first section and the second section at a second end of the heat exchanger, opposite the first end of the heat exchanger,wherein the first mounting flange is configured to mount to the first end plate, and the second mounting flange is configured to mount to the second end plate.

7. The heat exchanger assembly of claim 1, wherein the first section comprises a first plurality of fins extending between the plurality of tubes, the second section comprises a second plurality of fins extending between the plurality of tubes, and the intermediate section is a non-finned section of the heat exchanger.

8. The heat exchanger assembly of claim 7, each tube of the plurality of tubes extends within the first section, the second section, and the intermediate section, each tube of the plurality of tubes forms a bend, and the bend extends within the intermediate section.

9. The heat exchanger assembly of claim 8, wherein the first section and the second section are pivotable, via the intermediate section, relative to one another across a plurality of orientations, the first section and the second section extend crosswise relative to one another at a respective angle in each orientation of the plurality of orientations, and the gasket is configured to create sealing interfaces with the first section and the second section in each orientation of the plurality of orientations.

10. The heat exchanger assembly of claim 1, wherein the first section and the second section extend crosswise relative to one another to define an angle, and the gasket is configured to extend across the angle and deform to abut and sealingly engage with the first section and the second section.

11. The heat exchanger assembly of claim 1, wherein the mounting bracket comprises a support rail, a first side flange extending along the support rail and crosswise to the support rail, and a second side flange extending along the support rail and crosswise to the support rail, and wherein the gasket is configured to be attached to the support rail.

12. A heat exchanger assembly for a heating, ventilation, and / or air conditioning (HVAC) system, comprising:a heat exchanger comprising a plurality of tubes configured to direct a working fluid therethrough, wherein the plurality of tubes defines a first section, a second section, and an intermediate section, the first second, the second section, and the intermediate section define a space configured to receive an air flow, the first section comprises a first plurality of fins extending between the plurality of tubes, and the second section comprises a second plurality of fins extending between the plurality of tubes; anda seal assembly configured to couple to the heat exchanger, wherein the seal assembly comprises:a mounting bracket configured to mount the seal assembly within the space; anda gasket configured to couple to the mounting bracket, wherein the gasket is configured to overlap with the intermediate section, relative to a direction of the air flow through the space and across the heat exchanger, and the gasket is configured to block air flow across the intermediate section.

13. The heat exchanger assembly of claim 12, wherein each tube of the plurality of tubes comprises an arcuate portion, and the arcuate portion extends within the intermediate section and between the first section and the second section.

14. The heat exchanger assembly of claim 13, wherein the intermediate section does not include fins extending between the arcuate portions of the plurality of tubes.

15. The heat exchanger assembly of claim 12, wherein the gasket comprises a main body, the main body comprises foam, and the foam is deformable to bias the gasket against the first section, the second section, the intermediate section, or a combination thereof in an installed configuration of the seal assembly.

16. The heat exchanger assembly of claim 15, wherein the gasket comprises an insulative layer coupled to a surface of the main body, and the insulative layer is configured to face the intermediate section in the installed configuration of the seal assembly.

17. A heat exchanger assembly for a heating, ventilation, and / or air conditioning (HVAC) system, comprising:a heat exchanger comprising a plurality of tubes defining a first panel section, a second panel section, and an arcuate section extending from the first panel section to the second panel section, wherein the first panel section comprises a first plurality of fins extending between the plurality of tubes, the second panel section comprises a second plurality of fins extending between the plurality of tubes, and the arcuate section is without fins extending between the plurality of tubes; anda seal assembly mounted to the heat exchanger within a space defined by the first panel section, the second panel section, and the arcuate section, wherein the seal assembly comprises:a mounting bracket; anda gasket coupled to the mounting bracket, wherein the gasket is configured to deform and bias against the first section and the second section, the gasket overlaps with the arcuate section along a direction of an air flow across the heat exchanger, and the gasket is configured to block flow of the air flow across the arcuate section.

18. The heat exchanger assembly of claim 17, wherein the gasket comprises:a main body comprising a foam material;a first layer disposed on a first surface of the main body, wherein the first layer comprises an insulating material; anda second layer disposed on a second surface of the main body, opposite the first surface, wherein the second layer comprises an adhesive.

19. The heat exchanger assembly of claim 17, wherein the mounting bracket comprises:a support rail configured to couple to the gasket;a first mounting flange extending from a first end of the support rail and crosswise to the support rail; anda second mounting flange extending from a second end of the support rail, opposite the first end, and crosswise to the support rail;wherein the first mounting flange and the second mounting flange are configured to mount the seal assembly within the space.

20. The heat exchanger assembly of claim 17, wherein each tube of the plurality of tubes is a microchannel tube.

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