Drain pan assembly

Abstract

A drain assembly of a heat exchanger system of an air handling unit or an evaporator coil is provided. The drain assembly includes a drain pan having a drain channel configured to receive condensate from an evaporator coil disposed above the drain pan. The drain assembly also includes tubing configured to receive refrigerant from a condenser and supply subcooled liquid refrigerant to an evaporator. The tubing includes at least one segment disposed within the drain channel, and the at least one segment is configured to be at least partially submerged in the condensate from the evaporator coil when condensate collects within the drain channel.

Description

DRAIN PAN ASSEMBLYCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of US provisional application No. 63 / 594,124, filed October 30, 2023, which is hereby incorporated by reference herein in its entirety.FIELD

[0002] This application relates to air-conditioning (“AC”) systems and more particularly to drip pan assemblies for collecting condensate from heat exchangers of AC systems.BACKGROUND

[0003] Indoor heat exchanger coils in residential split air-conditioning (“AC”) systems are typically configured as an N-coil, an A-coil, or a V-coil. Present day indoor heat exchanger coils generally include a drain pan at a base of the AC system to collect condensate formed on, and dripping from, the coil. Typically, the center of the base of the coil, and hence the drain pan, is disposed proximal to a heat exchanger.

[0004] Drain pans are typically configured to collect and dispose of collected condensate from the evaporator coils. For example, a drain pan may be angled or fitted with an outlet so that collected condensate is expelled from the drain pan in a direction away from the AC system. Moreover, although collected condensate is frequently expelled, drain pans are often susceptible to undesirable microbial growth as a result of the constant moisture therein.BRIEF DESCRIPTION OF THE DRAWINGS

[0005] The detailed description is set forth with reference to the accompanying drawings. The use of the same reference numerals may indicate similar or identical items. Various embodiments may utilize elements and / or components other than those illustrated in the drawings, and some elements and / or components may not be present in various embodiments. Elements and / or components in the figures are not necessarily drawn to scale.

[0006] FIG. 1 is a perspective view of a portion of a heat exchanger system, according to one or more embodiments of the present disclosure.

[0007] FIG. 2 is a perspective view of the evaporator and drain assembly of the heat exchanger system of FIG. 1A, according to one or more embodiments of the present disclosure.

[0008] FIG. 3A is a perspective view of a drain assembly of the heat exchanger system, according to one or more embodiments of the present disclosure.

[0009] FIG. 3B is a top view of the drain assembly of FIG. 2A, according to one or more embodiments of the present disclosure.

[0010] FIG. 3C is a bottom view of the drain assembly of FIG. 2A, according to one or more embodiments of the present disclosure.DETAILED DESCRIPTION

[0011] The disclosure will be described more fully hereinafter with reference to the accompanying drawings, in which example embodiments of the disclosure are shown. This disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein.

[0012] Unless otherwise defined herein, all technical and scientific terms used herein have meanings commonly understood by those of ordinary skill in the art to which the present invention belongs. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments, and is not intended to be limiting. In describing an claiming the present invention, the following terminology will be used in accordance with the definitions set out below.

[0013] As used herein, the singular forms "a", "an", and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a component" can include a combination of two or more components.

[0014] The term "about", as used herein, indicates the value of a given quantity can include quantities ranging within 10% of the stated value, or optionally within 5% of the stated value, or in some embodiments, within 1% of the value.

[0015] Ranges may be expressed herein as from “about” or “approximately” or “substantially” one particular value and / or to “about” or “approximately” or “substantially” another particular value. When such a range is expressed, the disclosed technology can include from the one particular value and / or to the other particular value. Further, ranges described as being between a first value and a second value are inclusive of the first and second values.Likewise, ranges described as being from a first value and to a second value are inclusive of the first and second values.

[0016] In certain embodiments, a drain assembly for use with an indoor heat exchanger coil of an air-conditioning system is disclosed herein. According to a preferred embodiment, the heat exchanger coil is a V-coil. However, it would be understood that the drain pan assemblies disclosed herein may be adapted for use with other coil types, such as N-coils or A-coils. In a cooling mode of operation, the indoor heat exchanger coil may act as an evaporator coil in a heat pump system. The indoor heat exchanger coil is positioned within a structure where conditioned air is circulated. For example, the indoor heat exchanger coil may be positioned in a flow of air circulated within the structure. The drain assembly may be used with any suitable heat exchanger coil. In some aspects, the drain assembly includes a drain pan having an elongated base. Side walls may be disposed about a periphery of the elongated base and extend upward to form a drain basin for collecting condensate from the heat exchanger coil. An elongated deflector may be disposed within the drain basin. The elongated deflector may project upward from a central area of the elongated base in a manner to define a drain channel bounded by the elongated base, the side walls, and the elongated deflector.

[0017] In some instances, copper tubing may be at least partially disposed within the drain channel. The copper tubing may be configured to receive liquid refrigerant from an outdoor heat exchanger coil, which operates as a condenser in a cooling mode of operation and supply subcooled liquid refrigerant to an expansion valve and subsequently to the indoor heat exchanger coil, which operates as an evaporator in the cooling mode of operation. In some instances, the copper tubing may be bypassed in a heating mode of operation. In some instances, the drain channel may be configured to receive condensate from an evaporator coil disposed above the drain pan. At least some of the condensate may be directed into the drain channel by the elongated deflector, and at least one segment of the copper tubing disposed within the drain channel may be at least partially submerged within the condensate when condensate collects within the drain channel. In this manner, the at least partially submerged segment of the copper tubing may act as a subcooling segment of the copper tubing. For example, as the liquid refrigerant passes through the at least partially submerged segment of the copper tubing, the refrigerant may be cooled by the condensate surrounding the copper tubing. Cooling the refrigerant prior to introducing it to the expansion valve, and subsequently the evaporator coilmay therefore improve the cooling capacity of the air conditioning system. Generally, the more a high pressure liquid refrigerant is cooled before being introduced to the system, the lower an inlet enthalpy will be for a given mass flowrate, thereby increasing the capacity of the air conditioning system.

[0018] FIGS. 1-2 depict a portion of a heat exchanger system 100 that may be configured for use with a drain assembly, such as drain assembly 200 disclosed herein. The heat exchanger system 100 may be part of a heating, ventilation, and / or air conditioning (HVAC) system. 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 an expansion valve, 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.

[0019] In some embodiments, the heat exchanger system 100 is an air handler or an AC furnace coil having a V-shaped evaporator 102 housed within a cabinet 104, as shown in FIG. 1. In other embodiments, the air handler or AC furnace coil may have a N-shaped or an A-shaped evaporator. In some embodiments, as shown in FIG. 2, the evaporator 102 is disposed above a drain assembly 200. The drain assembly 200 may be configured to collect condensate from the evaporator 102. For example, as air passes through the cabinet and across the evaporator coils 106, condensate may form on the evaporator coils 106 of the evaporator 102. The condensate may collect and fall (or drip) from the evaporator coils 106. As condensate falls from the evaporator coils 106, the condensate may be collected within the drain assembly 200. The condensate is typically expelled from the drain assembly 200 to a drain or the like.

[0020] The drain assembly 200 is shown in greater detail in FIGS. 3A-3C. In some embodiments, the drain assembly 200 includes a drain pan 202 for collecting the condensate from the evaporator coils 106. The drain pan assembly also includes copper tubing 204. In certain embodiments, the copper tubing 204 may be at least partially disposed within the drain pan 202, such that any condensate collected within the drain pan 202 at least partially contacts or covers the copper tubing 204.

[0021] In some embodiments, the drain pan 202 includes an elongated base 206. The drain pan 202 may also include side walls 208 disposed around a perimeter of the elongated base 206. The drain pan 202 and the side walls 208 may collectively form a drain basin for collecting the condensate from the evaporator coils 106. The drain pan 202 may be sized and shaped to fit beneath the base of the evaporator coils 106. For example, for use with a V-coil, the elongate base 206 of the drain pan 202 may be between about 2 inches to about 6 inches wide, such as between about 3 inches and about 5 inches wide, or about 4 inches. The elongate base 206 may also be between about 15 inches and 25 inches long, such as between about 16 inches and 24 inches, between about 18 inches and about 22 inches, or about 20 inches. In other embodiments, where the drain pan is used with a different coil type, the drain pan and elongate base may have a different shape and / or different dimensions than those described with respect to the exemplary embodiments disclosed herein.

[0022] In some instances, the drain pan 202 may also include an elongated deflector 210 projecting upward from the center of the drain basin. In some instances, the elongated deflector 210 may form a dome-like structure positioned about the center of the drain basin. For example, the elongated deflector 210 may be formed by a number of side walls forming an arch. In other instances, the arch may be a single curved wall. The elongated deflector 210 may be any suitable size, shape, or configuration. For example, the elongated deflector 210 may be between about 1 inch and about 5 inches wide, such as between about 1 inch and about 4 inches wide, about 1 inch and about 3 inches wide, or about 2 inches wide. In other embodiments, the drain pan may not include an elongate deflector to accommodate use with a different coil type.

[0023] The elongated base 206, side walls 208, and elongated deflector 210 together may define a drain channel 212 configured to collect and drain condensate produced by the evaporator coil 106 disposed above the drain pan 202. For example, the drain channel 212 may have a generally U-shaped cross-section and extend about and around the perimeter of theelongated base 206. In some embodiments, the drain channel 212 includes a first side section 214 and a second side section 216 extending parallel to one another on opposing sides of the elongated deflector 208. The drain channel 212 may include a back section 218 and a front section 220 opposing the back section 216. The back section 218 and the front section 220 may be fluidly connected with the first side section 214 and the second side section 216, such that the drain channel 212 forms a continuous loop around the elongated deflector 208. For example, the drain channel 212 may form a continuous loop about the perimeter of the drain pan 202. In some instances, the drain channel 212 may be substantially the same width and depth about the entire length of the drain channel 212. For example, the first side section 214 and the second side section 216 of the drain channel 212 may be between about 0.5 and about 2 inches, such as between about 0.5 inches and 1 about inch, or about 0.8375 inches. The back section 218 of the drain pan may be between about 1 inch and about 2 inches, such as about 1.25 inches. The drain pan 202 may be made of any suitable material, such as a plastic or polymer, and may be manufactured according to suitable methods known within the art. According to a preferred embodiment, the drain pan 202 is made from a molded plastic. In other embodiments, the drain channel may be uninterrupted, i.e., not obstructed by an elongate deflector disposed therein.

[0024] In some embodiments, the side wall 208 defining the front section 220 of the drain channel may include one or more drain apertures 222 extending therethrough. The drain apertures 222 may be positioned to maintain a predefined condensate level within the drain channel 212. For example, the drain apertures 222 may be positioned so that the level of condensate maintained within the drain channel 212 at least partially covers the portion of the copper tubing 204 disposed within the drain pan 202. That is, condensate collected within the drain channel 212 may pool within the channel and rise to a particular level before it can exit the drain channel 212 by way of the apertures 222. In some instances, the level of the condensate may correspond to an upper height of the copper tubing 204 disposed within the drain channel 212. In other instances, the level of the condensate may correspond to an upper height that is configured to at least partially submerge a portion of the copper tubing 204 disposed within the drain channel 212 in the condensate. In some instances, the drain apertures 222 are round. The drain apertures 222 may be between about 0.5 and about 1.5 inches, such as between about 0.75 inches and about 1.25 inches, or about 1 inch. In other instances, the drain apertures 222 may be have any suitable size, shape, or configuration.

[0025] In some embodiments, the drain pan 202 may also include a lateral arm 224 extending laterally from the front section 220 of the drain channel 212. That is, the lateral arm 224 may extend in a direction that is substantially perpendicular to the first side section 214 and the second side section 216 of the drain channel 212, and to the elongate deflector 210. While the lateral arm 224 is shown in FIGS. 1-3C as extending from the front section 220 of the drain channel 212 to the left, it would be understood that the lateral arm could also extend to the right, or in both directions (i.e., to the left and to the right, forming a T-shaped drain pan). In some instances, the lateral arm 224 may extend from the front section 220 of the drain channel 212 to the cabinet 104. That is, the lateral arm 224, including the front section 220, may have a length of between about 2 inches and about 6 inches, such as between about 3 inches and about 5 inches, or about 4 inches. In other instances, the lateral arm 224 may extend only a part of the distance between the front section 220 of the drain channel 212 and the cabinet 104.

[0026] The lateral arm 224 may also have side walls 208 disposed around the perimeter of the lateral arm 224, defining a secondary channel 225 therebetween for collecting condensate from the evaporator coils 106 that cannot be contained within the primary drain channel 212. That is, the secondary channel 225 of the lateral arm 224 may be fluidly connected with the drain channel 212, such that condensate is free to flow between the drain channel 212 and the secondary channel 225. In some embodiments, the secondary channel 225 may have similar width and depth to the drain channel 212. In other instances, the secondary drain channel 225 may have different dimensions from the drain channel 212. For example, the secondary drain channel 225 may have a width that is greater than that of the drain channel 212, or a width that is less than that of the drain channel 212.

[0027] In some instances, the lateral arm 224 also includes one or more additional drain apertures 222 extending therethrough. That is, the drain pan 202 may include a second set of one or more drain apertures 222, the second set of drain apertures 222 of the lateral arm 224 being laterally spaced from the drain apertures 222 positioned on the front section 222 of the drain channel 212. In some instances, the drain apertures 222 positioned on the lateral arm 224 may have a similar size, shape, and configuration as the drain apertures positioned on the front section 220 of the drain channel 212. In other instances, the drain apertures 222 positioned on lateral arm 224 may have a different, size, shape, and / or configuration as the drain apertures 222 positioned on the front section 220 of the drain channel 212. For example, the lateral arm 224 drainapertures 222 may be positioned at a lower or higher level along the sidewall 308 to maintain a higher or lower level, respectively, of condensate within the secondary channel 225 as compared to the drain channel 212. In some other instances, the lateral arm 224 does not include any additional drain apertures.

[0028] In some embodiments, the bottom of the drain pan 202 is supported by a bracket 226, as shown in FIG. 3C. The bracket 226 may include an elongate body portion 238 and at least one attachment portion 230 configured to secure the drain assembly 200 within the cabinet 104 of the heat exchanger system 100. In some instances, the elongate body portion 238 of the bracket 226 may extend at least partially along the length of the elongate base 206 of the drain pan 202. In some preferred instances, the elongate body portion 238 of the bracket 226 extends along the entire length of the drain pan 202 and may include an attachment portion 230 at each end thereof for securing the bracket 226 to both the front and back sides of the cabinet 104. In some instances, the at least one attachment portion 230 may be secured to the cabinet 104 by screws, however other means of attachment are possible. For example, the at least one attachment portion 230 could be welded or more permanently secured to the cabinet 104.

[0029] In some instances, the elongate body portion 238 of the bracket 226 is at least partially disposed underneath the elongate deflector 210. That is, the upward projection of the elongate deflector 210 may define a reciprocal depression 232 underneath the drain pan 202. The elongate body portion 238 of the bracket 226 may be disposed with depression 232 so that the drain pan 202 may still rest flatly within the cabinet 104 when the bracket 226 is attached. The depression 232 of the drain pan 202 may also include a plurality of support structures 234 which may contact the elongate body portion 238 of the bracket 226 to secure the bracket to the drain pan 202. For example, the elongate body portion 238 of the bracket 226 may form an interference fit with a gap defined within each support structure 234, thereby securing the bracket 226 to the drain pan 202. In some instances, the bracket 226 may be made of any suitable material possessing the necessary strength to support the drain assembly 200 and exchanger 102, such as a suitable metal material.

[0030] In embodiments, the copper tubing 204 is configured to supply a liquid refrigerant to the expansion valve, and subsequently the evaporator heat exchanger coil 102. The copper tubing 204 may include an inlet portion 234 through which the refrigerant is supplied and an outlet portion 236 through which the refrigerant is delivered to the evaporator 102. Between the inletportion 234 and the outlet portion 236 is an intermediate portion 232 at least partially disposed within the drain channel 212 of the drain pan 202. For example, the refrigerant may be forced through the inlet portion 234, through the intermediate portion 232 disposed within the drain channel 212, and out of the copper tubing 204 via the outlet portion 236. Because the intermediate portion 232 is at least partially disposed within the drain channel 212, the intermediate portion 232 may be contacted by any condensate that is collected within the drain channel 212. As the liquid refrigerant passes through the intermediate portion 232, it may be cooled as a result of the indirect contact (i.e., thermal communication) with the condensate through the copper tubing 204. That is, the contact between the condensate collected in the drain channel 212 and the copper tubing 204 disposed at least partially therein may be effective to cool the liquid refrigerant passing through the intermediate portion 232 of the copper tubing 204.

[0031] In some instances, the intermediate portion 232 of the copper tubing 204 has a first portion 232a and a second portion 232b, both of which may be disposed within the drain channel 212. For example, in some instances, the intermediate portion 232 of the coper tubing 204 is long enough to be wrapped around the perimeter of the deflector 210 twice so that the first portion 232a and the second portion 232b are disposed side-by-side within the drain channel 212. That is, the intermediate portion 232 of the copper tubing 204 may form two loops within the drain channel 212, the first loop being the first portion 232a and the second loop being the second portion 232b. Looping the intermediate portion 232 around the deflector 210 provides twice as much copper tubing 204 within the drain channel 212, which may improve the subcooling capacity of the intermediate portion 232. That is, exposing a larger portion of the copper tubing 204 to the condensate within the drain pan 212 may have a more significant cooling effect on the liquid refrigerant passing through the tubing 204 because the liquid refrigerant is indirectly exposed to (i.e., in thermal communication with) and cooled by the condensate for twice as long. This may beneficially improve the cooling capacity without unnecessarily burdening the system 100. According to a preferred embodiment, the intermediate portion(s) 232 of the copper tubing 204 are fully submerged in condensate within the drain channel 212. That is, it is preferred that the condensate level in the drain channel 212 is sufficient to completely cover the copper tubing 204. Fully covering the copper tubing 204 may help to further cool the refrigerant passing through the copper tubing 204. It would be understood that the arrangement of the copper tubing within the drain channel may be dependent on the size and / or shape of the drain channel. That is,where the drain channel does not extend around an elongate deflector portion to accommodate a V-coil, the copper tubing may have a different configuration within the drain channel.

[0032] In other instances, the copper tubing 204 does not have segment that is looped around the deflector 210, but instead includes two distinct pieces of copper tubing 204 disposed within the drain channel 212. That is, the copper tubing 204 may not be a single piece of tubing with three distinct segments as previously described. The copper tubing 204 may have an inlet piece and an outlet piece, where the inlet piece includes an inlet for the refrigerant and the outlet piece includes an outlet for the refrigerant. The inlet piece and the outlet piece may each have a drain channel portion, where the respective drain channel portions of the inlet and outlet pieces are fluidly connected within the drain tube. In some instances, the drain channel portions of the inlet and outlet pieces may be hairpin tubes configured to fit beside one another within the drain pan. That is, one of either the inlet or outlet hairpin tube may be larger than and able to fit around the other so that the tubes may lay side-by-side within the drain channel 212.

[0033] In embodiments, the copper tubing 204 may have any diameter suitable for use with the drain assembly 200 disclosed therein. That is, the copper tubing 204 may have a diameter that is small enough that the copper tubing 204 may fit within the drain channel 212. However, as previously described it may be preferable to loop the copper tubing around the deflector 210, in which case the copper tubing 204 should have a diameter small enough so that the twice- looped tubing 204 may fit within the drain channel. For example, the diameter of the copper tubing 204 may be between 0.125 inches and 1 inch, 0.125 inches and 0.75 inches, 0.25 inches and 0.75 inches, 0.125 to 0.5 inches, 0.25 to 0.5 inches, or preferably, 0.375 inches.

[0034] While the drain assembly 200 has been described herein as utilizing copper tubing, it would be understood that other materials (i.e., metals, plastics, etc.) may be used for the tubing. However, copper tubing may be preferred because of the unique advantages that the use of copper provides in this context. For example, copper may have inherent anti-microbial, antiviral, or anti-bacterial properties, which may combat the high levels of microbial growth that may occur within the drain pan as a result of the constant presence of moisture therein. That is, the copper ions released from the surface of the copper tubing will be present in any residual condensate that is collected. These copper ions may therefore prevent, or quickly eliminate, any microbial growth caused by this residual condensate.

[0035] In some embodiments, the drain assembly may include a bypass line to bypass the copper tubing when the heat exchanger system is operating in certain modes of operation. For example, the copper tubing may be bypassed in a heating mode of operation, where providing additional cooling to the system is unnecessary or undesirable.

[0036] While the present disclosure has been described in connection with a plurality of exemplary aspects, as illustrated in the various figures and discussed above, it is understood that other similar aspects can be used, or modifications and additions can be made to the described subject matter for performing the same function of the present disclosure without deviating therefrom. In this disclosure, methods and compositions were described according to aspects of the presently disclosed subject matter. But other equivalent methods or compositions to these described aspects are also contemplated by the teachings herein. Therefore, the present disclosure should not be limited to any single aspect, but rather construed in breadth and scope in accordance with the appended claims.

Claims

CLAIMSThat which is claimed is:

1. A drain assembly of a heat exchanger system of an air handling unit or an evaporator coil, the drain assembly comprising: a drain pan comprising a drain channel configured to receive condensate from an evaporator coil disposed above the drain pan; and tubing configured to receive refrigerant from a condenser and supply subcooled liquid refrigerant to an evaporator, wherein the tubing comprises at least one segment disposed within the drain channel, and wherein the at least one segment is configured to be at least partially submerged in the condensate from the evaporator coil when condensate collects within the drain channel.

2. The drain pan assembly of claim 1, wherein the drain channel comprises a front channel section along one end of the drain channel, the front channel section comprising one or more drain apertures extending therethrough, wherein the one or more drain apertures are positioned and configured to provide a water level within the drain channel to at least partially submerge the at least one segment.

3. The drain assembly of claim 1, wherein the at least one segment is looped upon itself such that at least two segments are disposed side-by-side within the drain channel and configured to be at least partially submerged position when condensate collects within the drain channel.

4. The drain pan assembly of claim 1 , wherein the drain pan further comprises a base having side walls and a deflector projecting upward from the base to define the drain channel, wherein the drain channel is bounded by the base, the side walls, and the deflector.

5. The drain assembly of claim 1, wherein the drain channel comprises two primary straight sections extending parallel to one another on opposing sides of the deflector, and wherein the two primary sections of the drain channel are connected by a secondary section of thedrain channel at an end of the deflector, wherein the two primary straight sections are longer than the secondary section.

6. The drain pan assembly of claim 5, wherein the at least one segment of the tubing is disposed within the two primary sections and the secondary section of the drain channel.

7. The drain assembly of claim 5, wherein the drain pan further comprise an arm section in which the front channel section extends in a direction substantially perpendicular to the primary sections of the drain channel.

8. The drain assembly of claim 6, wherein the side walls of the arm section comprise one or more additional drain apertures extending therethrough.

9. The drain assembly of claim 1, wherein the tubing comprises first and second upwardly extending segments which are connected to opposing ends of the at least one segment.

10. The drain assembly of claim 9, wherein the first and second upwardly extending segments join the at least one segment in or around a front channel section of the drain channel.

11. The drain assembly of claim 1, further comprising a support bracket coupled to the base of the drain pan.

12. A heat exchanger system of an air handling unit or an evaporator coil, the heat exchanger system comprising: a heat exchanger comprising an evaporator and an evaporator coil; and a drain assembly comprising: a drain pan positioned below the evaporator coil, the drain pan comprising: a base having side walls; anda deflector projecting upward from the base to define a drain channel bounded by the base, the side walls, and the deflector, wherein the drain channel is configured to receive condensate from the evaporator coil; and a tubing configured to supply liquid refrigerant to the evaporator, wherein the tubing comprises at least one subcooling segment disposed within the drain channel, and wherein the at least one subcooling segment is configured to be at least partially submerged in condensate when condensate collects within the drain channel.

13. The heat exchanger system of claim 12, wherein the tubing is a copper tubing.

14. The heat exchanger system of claim 12, wherein the tubing comprises first and second upwardly extending segments which are connected to opposing ends of the subcooling segment.

15. The heat exchanger system of claim 14, wherein the first and second upwardly extending segments join the subcooling segment in or about a front channel section of the drain channel.

16. The heat exchanger system of claim 12, wherein the at least one subcooling segment is looped upon itself such that at least two subcooling segments are disposed side-by-side within the drain channel and configured to be in the at least partially submerged position when condensate collects within the drain channel.

17. The heat exchanger system of claim 12, wherein the drain channel comprises a front channel section, the front channel section comprising one or more drain apertures extending therethrough, the drain apertures being positioned and configured to provide a water level within the drain channel effective to maintain the at least one subcooling segment at least partially submerged in condensate within the drain channel.

18. A method of improving cooling efficiency of a heat exchanger system, the method comprising: providing a tubing configured to supply liquid refrigerant to an evaporator; placing at least one subcooling segment of the tubing within a drain channel of a drain pan disposed below an evaporator coil of the evaporator; and collecting condensate from the evaporator coil within the drain channel; wherein the at least one subcooling segment is configured to be at least partially submerged within the condensate when condensate collects within the drain channel; and wherein at least partially submerging the at least one subcooling segment within the condensate cools the liquid refrigerant in the tubing.

19. The method of claim 18, wherein the drain channel comprises a front channel section along one end of the drain channel, the front channel section comprising one or more drain apertures extending therethrough, wherein the one or more drain apertures are positioned and configured to provide a water level within the drain channel to at least partially submerge the at least one subcooling segment.

20. The method of claim 18, wherein the at least one subcooling segment is looped upon itself such that at least two segments are disposed side-by-side within the drain channel and configured to be at least partially submerged position when condensate collects within the drain channel.

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