Condensate drain devices for heat exchanger coil and methods for making the same

Abstract

A condensate drain device includes an elongate base having a first end, a second end and side edges extending between the first and second ends; a plurality of teeth extending away from a side edge of the base; and a lip formed on the side edge of the base opposite from the teeth. Each tooth includes a free end and two side edges. The condensate drain device is configured to be attached to a microchannel coil to collect condensate including a plurality of tubes and a plurality of fins coupled to the tubes, with each tooth being received in a space formed between two adjacent fins.

1 . A heat exchanger coil assembly, comprising:
 a heat exchanger coil including:
 a first header; 
 a second header; 
 a plurality of tubes extending between the first and second headers; and 
 a plurality of fins coupled to the tubes, and 
   a condensate drain device including:
 an elongate base including a first end, a second end and side edges extending between the first and second ends; and 
 a plurality of teeth extending away from a side edge of the base, the plurality of teeth being disposed parallel with each other, 
   wherein the condensate drain device is attached to the heat exchanger coil at a location between the first and second headers and spaced away from both the first and second headers, and   wherein the elongate base is oriented such that an upper surface of the elongate base slopes from the first end toward the second end at an angle relative to a horizontal direction.   
     
     
         2 . The heat exchanger coil assembly of  claim 1 , wherein a height of the heat exchanger coil is greater than 30 inches. 
     
     
         3 . The heat exchanger coil assembly of  claim 1 , wherein each of the teeth is received in a space formed between two adjacent fins of the heat exchanger coil. 
     
     
         4 . The heat exchanger coil assembly of  claim 3 , wherein the teeth have a length smaller than a depth of the fin, so that when each of the teeth is received in the corresponding space, one of the side edges of the elongate base engages with a side edge of the corresponding flat tube. 
     
     
         5 . The heat exchanger coil assembly of  claim 3 , wherein each of the plurality of teeth has a width slightly smaller than a distance between the two respective adjacent tubes of the heat exchanger coil, thereby allowing side edges of each of the teeth to have an interference fit with corresponding side walls of the two respective adjacent tubes. 
     
     
         6 . The heat exchanger coil assembly of  claim 1 , wherein each of the plurality of teeth has a uniform width from the base to a respective free end of the respective tooth. 
     
     
         7 . The heat exchanger coil assembly of  claim 1 , wherein a height of the heat exchanger coil is greater than 30 inches. 
     
     
         8 . A condensate drain device, comprising:
 an elongate base including a first end, a second end and side edges extending between the first and second ends;   a plurality of teeth extending away from a side edge of the base, each tooth includes a free end and two side edges; and   a lip formed on the side edge of the base opposite from the teeth,   wherein the condensate drain device is configured to be attached to a heat exchanger coil to collect condensate including a plurality of tubes and a plurality of fins coupled to the tubes, with each tooth being received in a space formed between two adjacent fins.   
     
     
         9 . The condensate drain device of  claim 8 , wherein each of the plurality of teeth has a uniform width from the base to the respective free end of the respective tooth. 
     
     
         10 . The condensate drain device of  claim 8 , wherein the plurality of teeth are spaced apart by about the same distance and are generally parallel to each other. 
     
     
         11 . The condensate drain device of  claim 8 , further comprising an end wall attached to the second end of the base. 
     
     
         12 . The condensate drain device of  claim 8 , wherein the heat exchanger coil is a microchannel coil. 
     
     
         13 . A method for assembling a condensate drain device to a heat exchanger coil, the heat exchanger coil including a plurality of tubes and a plurality of fins coupled to the tubes, comprising:
 inserting a plurality of teeth of the condensate drain device in corresponding spaces formed between adjacent fins to allow the condensation drain device to be attached to the heat exchanger coil; and   securing the condensate drain device to the heat exchanger coil,   wherein the condensate drain device further includes an elongate base which has a first end and a second end, the elongate base being oriented such that an upper surface of the elongate base slopes from the first end toward the second end at an angle relative to a horizontal direction.   
     
     
         14 . The method of  claim 13 , wherein the condensate drain device comprises:
 an elongate base including a first end, a second end and side edges extending between the first and second ends;   a plurality of teeth extending away from a side edge of the base, each tooth includes a free end and two side edges; and   a lip formed on the side edge of the base opposite from the teeth.   
     
     
         15 . The method of  claim 14 , wherein each of the plurality of teeth has a uniform width from the base to the respective free end of the respective tooth. 
     
     
         16 . The method of  claim 14 , wherein the plurality of teeth are spaced apart by about the same distance and are generally parallel to each other.