Coil Support Protrusions to Prevent Condenser Coil Movement
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Solution Overview
Problem
Condensing unit coils in split system heating and cooling systems are prone to movement during handling, which can result in damage, such as piercing by sharp edges or assembly screws, compromising system operation and leading to corrosion between the coil and base pan due to direct contact.
Innovation Solution
A coil support with a surface featuring protrusions, such as walls or ribs, that engage with the coil to limit its movement, preventing contact with protective covers and base pans, thereby securing the coil in place and preventing corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the coil is allowed to rest directly in the base pan for simplicity, then the device complexity is reduced, but the coil becomes prone to movement and direct contact with the base pan causing corrosion
Solution Approach 1:
The coil support is divided into multiple individual support elements (legs or protrusions) that are distributed across the base pan surface. Each support element independently engages with the coil, providing stable positioning without requiring a complex continuous support structure. This segmentation allows the coil to be elevated and secured through multiple discrete contact points.
Solution Approach 2:
The coil support acts as an intermediary element positioned between the base pan and the coil. It provides a stable interface that prevents direct contact between the coil and base pan, thereby preventing corrosion while maintaining simplicity. The support structure mediates the interaction between these components, ensuring proper positioning and separation.
2Manufacturing precision
If a simple flat support surface is used, then the manufacturing precision required is reduced, but the coil can still move and contact sharp edges or protective covers
Solution Approach 1:
Instead of requiring the entire support surface to be precisely flat, the invention applies localized engagement features (protrusions or legs) at specific critical points. These localized features provide precise positioning and contact prevention where needed, while the rest of the support surface can be manufactured with lower precision requirements. The protrusions are strategically positioned to engage with the coil and prevent movement toward harmful edges.
Solution Approach 2:
The coil support structure is designed to pre-position the coil in a safe location before any harmful contact can occur. The protrusions are configured to engage with the coil and establish its position in advance, preventing the coil from moving into contact with sharp edges or protective covers during operation or handling.
3Reliability
If the coil support provides extensive movement restriction, then the coil stability is improved, but the device complexity and number of protrusions increases
Solution Approach 1:
The coil support uses a minimal number of strategically positioned protrusions that provide sufficient stabilization without over-engineering the system. Rather than distributing many protrusions across the entire support surface, only the critical minimum number needed to prevent harmful movement is implemented. This partial action approach achieves adequate coil stability while maintaining simplicity.
Data Source
AI summary
A coil support suitable for supporting a coil in a condensing unit includes a body and a protrusion extending from the body. The protrusion is configured to limit movement of the coil in at least one direction.