Multi-Bracket Heat Exchanger Coil Mount for Varying Geometries
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Solution Overview
Problem
Heat exchanger coils with varying geometries due to manufacturing imperfections and the need for a secure yet damage-free mounting system that accommodates different materials between the coil and its cover or shroud are not adequately addressed by existing technologies.
Innovation Solution
A multi-bracket coil mount comprising a flexible plastic bracket for securing the heat exchanger coil to a base and a rigid metallic bracket for coupling the shroud, allowing for a flexible connection without using fasteners that could damage the plastic bracket, thereby ensuring secure mounting and protection from contaminants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single rigid bracket is used to mount the heat exchanger coil, then the mounting structure is simple, but it cannot accommodate varying coil geometries caused by manufacturing imperfections
Solution Approach 1:
The mounting bracket is divided into two distinct segments: a flexible plastic bracket that directly contacts the coil and a rigid metallic bracket that provides structural support. This segmentation allows each part to perform its specialized function - the flexible portion adapts to geometry variations while the rigid portion maintains structural integrity
Solution Approach 2:
The bracket assembly combines two different materials with complementary properties: plastic (flexible, compliant) and metal (rigid, strong). This composite approach allows the system to simultaneously achieve adaptability to manufacturing tolerances and structural stability for mounting the heat exchanger coil
2Reliability
If fasteners are used to secure the plastic bracket, then the mounting is secure, but the plastic bracket may be damaged
Solution Approach 1:
The rigid metallic bracket serves as an intermediary between the plastic bracket and the mounting holes. Fasteners are inserted through the rigid metal bracket to secure the assembly, preventing direct contact between fasteners and the plastic bracket, thereby eliminating the risk of damaging the plastic material
Solution Approach 2:
The bracket is segmented into a flexible plastic portion for mounting the coil and a rigid metallic portion for fastener engagement. This segmentation allows the plastic portion to be protected from fasteners while still achieving secure mounting through the rigid metal section
3Device complexity
If the heat exchanger coil is directly coupled to the shroud, then the structure is simplified, but damage may occur due to different materials
Solution Approach 1:
The flexible plastic bracket acts as an intermediary between the heat exchanger coil and the shroud or base pan. This intermediate component provides a compliant mounting interface that prevents direct contact between potentially incompatible materials, eliminating damage risks while maintaining structural connection
Data Source
AI summary
A bracket system includes a first bracket configured to couple a heat exchanger coil to a base of a heat exchanger via engagement of a mounting surface of the base, where the first bracket has a recessed member and a fastening tab, and a second bracket configured to couple the heat exchanger coil to a shroud of the heat exchanger via engagement of a fastener, where the second bracket has a protruding member and a protruding ridge. The recessed member is configured to receive the protruding member such that the first bracket and the second bracket are coupled to one another in a first configuration of the bracket system, and where the fastening tab is configured to receive the protruding ridge such that the first bracket and the second bracket are coupled to one another in a second configuration of the bracket system.