Modular Heat Exchanger Mounting Rails for Easy HVAC Coil Replacement
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Solution Overview
Problem
The existing mounting systems for heat exchangers in residential HVAC systems are cumbersome and costly to service and replace, as they often require new housings for heat exchangers of different dimensions, leading to increased consumer costs and time-consuming installation processes.
Innovation Solution
A modular heat exchanger assembly with adjustable mounting rails and support members that can be secured to any two interior parallel walls of a housing using fasteners or welding, allowing for easy installation and removal of heat exchangers of varying sizes, and incorporating features like thermal breaks and seals to enhance efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heat exchangers are fixedly attached to a foundation or base plate within a housing, then the heat exchanger is securely mounted, but servicing, removal or replacement becomes difficult and time consuming
Solution Approach 1:
The mounting system is divided into separate components: a base plate that remains fixed in the housing, and a heat exchanger assembly that can be independently removed. This segmentation allows the heat exchanger to be securely mounted during operation but easily removed for servicing by detaching from the base plate.
Solution Approach 2:
The mounting system transitions from a static fixed attachment to a dynamic removable connection. The heat exchanger can be securely fixed during operation but becomes easily detachable when servicing is needed, providing adaptability between operational security and maintenance accessibility.
2Adaptability or versatility
If heat exchangers of different dimensions are installed, then various coil configurations can be accommodated, but replacement may require replacement of the entire housing
Solution Approach 1:
The system separates the housing structure from the heat exchanger mounting components. The base plate and mounting rails are designed as independent elements that can be retained in the existing housing while accommodating different heat exchanger sizes and configurations, eliminating the need to replace the entire housing.
Solution Approach 2:
The base plate and mounting rail system is designed to universally accommodate multiple heat exchanger configurations and dimensions. This multi-functional mounting structure allows different coil arrangements (A-coil, N-coil, etc.) to be installed using the same housing components, providing versatility without increasing housing complexity.
3Stability of the object's composition
If traditional fixed mounting methods are used, then the heat exchanger is stable in position, but installation and servicing costs increase due to time consumption
Solution Approach 1:
The heat exchanger is pre-assembled with mounting attachments (flanges, brackets, or integrated mounting structures) that align with the base plate and mounting rails. This preliminary preparation enables quick connection and disconnection during installation and servicing, reducing on-site time while maintaining operational stability.
Solution Approach 2:
The mounting system provides dynamic characteristics that allow rapid transition between installed and removed states. During operation, the heat exchanger maintains stable positioning through the base plate and rail connection, but can be quickly removed for servicing by disconnecting these same components, thereby reducing time loss.
Data Source
AI summary
A heat exchanger mounting assembly for use in an HVAC system includes a frame for mounting a heat exchanger operably coupled to at least two sides of a heat exchanger housing, the frame having at least two mounting rails, each mounting rail having a first mounting rail side, and second mounting rail side, a proximate end and a distal end; and at least two coil support members extending from the first mounting rail side; and at least one connection member located on the second mounting rail side; and at least one support rail configured to engage the second mounting rail side of the at least two mounting rails; and at least two cross rails operably coupled to each of the at least two coil support members; and a heat exchanger, comprising at least one coil header operably coupled to at least two coil support members.