Residential outdoor heat exchanger unit

Abstract

An outdoor coil unit of a residential heating, ventilation, and air conditioning system includes a frame and a heat exchanger assembly mounted within the frame. The heat exchanger assembly includes at least one heat exchanger coil having a first header, a second header, and a plurality of heat exchange tube segments extending between and fluidly coupling the first header and the second header. The heat exchanger assembly is formed into a shape including at least one apex. A fan assembly is mounted to the frame and includes at least one fan operable to draw air into the outdoor coil unit through the at least one heat exchanger coil and discharge the a qr outside of the outdoor coil unit.

What is claimed is: 
     
         1 . An outdoor coil unit of a residential heating, ventilation, and air conditioning system, comprising:
 a frame;   a heat exchanger assembly mounted within the frame, the heat exchanger assembly including at least one heat exchanger coil having a first header, a second header, and a plurality of heat exchange tube segments extending between and fluidly coupling the first header and the second header, the heat exchanger assembly being formed into a shape including at least one apex; and   a fan assembly mounted to the frame and including at least one fan operable to draw air into the outdoor coil unit through the at least one heat exchanger coil and discharge the air outside of the outdoor coil unit.   
     
     
         2 . The outdoor coil unit according to  claim 1 , wherein the heat exchanger assembly is generally V-shaped. 
     
     
         3 . The outdoor coil unit according to  claim 1 , wherein the heat exchanger assembly is generally W-shaped. 
     
     
         4 . The outdoor coil unit according to  claim 1 , wherein the first header and the second header are oriented generally horizontally, and the plurality of heat exchange tube segments is oriented generally vertically. 
     
     
         5 . The outdoor coil unit according to  claim 1 , wherein the first header and the second header are oriented generally vertically, and the plurality of heat exchange tube segments is oriented generally horizontally. 
     
     
         6 . The outdoor coil unit according to  claim 1 , wherein the heat exchanger assembly formed into a shape including at least one apex includes a first heat exchanger coil and a second heat exchanger coil fluidly coupled via an intermediate header. 
     
     
         7 . The outdoor coil unit according to  claim 1 , wherein the heat exchanger assembly formed into a shape including at least one apex includes a first heat exchanger coil and a second heat exchanger coil, the first heat exchanger coil and second heat exchanger coil being fluidly separate from one another. 
     
     
         8 . The outdoor coil unit according to  claim 1 , wherein the heat exchanger assembly is oriented vertically within the frame. 
     
     
         9 . The outdoor coil unit according to  claim 1 , wherein the heat exchanger assembly is oriented horizontally within the frame. 
     
     
         10 . The outdoor coil unit according to  claim 1 , wherein the at least one heat exchanger coil is a microchannel heat exchanger coil such that each heat exchange tube segment includes a plurality of discrete flow channels. 
     
     
         11 . The outdoor coil unit according to  claim 1 , further comprising a base pan positioned within the frame, wherein an interface between the heat exchanger assembly and the base plan stabilizes a position of the heat exchanger assembly within the frame. 
     
     
         12 . The outdoor coil unit according to  claim 11 , wherein the base pan includes a raceway having a contour generally complementary to a portion of the heat exchanger assembly such that when the portion of the heat exchanger is mounted therein, the heat exchanger is offset from a floor of the base pan. 
     
     
         13 . The outdoor coil unit according to  claim 11 , wherein one or more openings are formed in a portion of the base pan. 
     
     
         14 . The outdoor coil unit according to  claim 13 , wherein the one or more openings are positioned adjacent an area of the heat exchanger assembly where condensate accumulates. 
     
     
         15 . The outdoor coil unit according to  claim 13 , wherein at least one of a size and location of the one or more openings is optimized to provide maximum drainage during a defrost cycle of the outdoor coil unit. 
     
     
         16 . The outdoor coil unit according to  claim 13 , wherein the one or more openings are positioned adjacent an area of the heat exchanger assembly to provide an optimized airflow path. 
     
     
         17 . The outdoor coil unit according to  claim 1 , wherein the fan assembly includes a first fan and a second fan, the first fan and the second fan being operably independent. 
     
     
         18 . The outdoor coil unit according to  claim 1 , wherein a plurality of heat exchanger fins are mounted to the plurality of heat exchange tube segments and the plurality of heat exchanger fins do not extend beyond a leading edge or a trailing edge of the plurality of heat exchange tube segments. 
     
     
         19 . The outdoor coil unit according to  claim 1 , wherein a plurality of heat exchanger fins are mounted to the plurality of heat exchange tube segments and the plurality of heat exchanger fins extend beyond at least one of a leading edge and a trailing edge of the plurality of heat exchange tube segments. 
     
     
         20 . The outdoor coil unit according to  claim 1 , wherein the residential heating, ventilation, and air conditioning system has a capacity of less than or equal to 65,000 Btuh. 
     
     
         21 . The outdoor coil unit according to  claim 1 , wherein the apex of the heat exchanger assembly includes an opening to define a flow path there between. 
     
     
         22 . The outdoor coil unit according to  claim 1 , wherein at least a portion of the heat exchanger assembly is sealed with a cover such the fan assembly draws air through only an intended portion of the heat exchanger assembly. 
     
     
         23 . An outdoor coil unit, comprising:
 a frame; and   a heat exchanger assembly mounted within the frame, the heat exchanger assembly including a first heat exchanger coil and a second heat exchanger coil, each heat exchanger coil having a first header, a second header, and a plurality of heat exchange tube segments extending between and fluidly coupling the first header and the second header, the first heat exchanger coil and the second heat exchanger coil are angled relative to one another to such that a first end of the first heat exchanger coil and a first end of the second heat exchanger coil form an apex, the first end of the first heat exchanger coil and the first end of the second heat exchanger coil being separated from one another by a distance to allow a flow path for at least one of debris, airflow, and condensate there between; and   a fan assembly including at least one fan being mounted to the frame, the fan assembly being located adjacent a second end of the first heat exchanger coil and a second end of the second heat exchanger coil.   
     
     
         24 . An outdoor coil unit comprising:
 a frame;   a heat exchanger assembly mounted within the frame, the heat exchanger assembly including at least one heat exchanger coil having a first header, a second header, and a plurality of heat exchange tube segments extending between and fluidly coupling the first header and the second header, the heat exchanger assembly being formed into a shape including at least one apex;   a fan assembly mounted to the frame and including at least one fan operable to draw air into the outdoor coil unit through the at least one heat exchanger coil and discharge the air outside of the outdoor coil unit; and   at least one cover positioned adjacent a portion of the heat exchanger assembly to seal the portion of the heat exchanger assembly against air flow there through.