Heat Exchanger System

Abstract

A heat exchanger system and a method of assembly is provided for a gas appliance such as a furnace. The heat exchanger system includes an attachment plate having at least one recess sized to receive an inlet of a heat exchanger. The heat exchanger has a first flange disposed at the inlet that is positioned in the recess. A second flange in the attachment plate recess is crimped onto the inlet flange to couple the heat exchanger to the attachment plate. The attachment plate may also include a pair of slots that extend from the recess that are sized to receive a pair of third flanges on the heat exchanger.

1 . A heat exchanger system comprising:
 an attachment plate having at least one recess and a pair of slots extending from said at least one recess; and,   a heat exchanger member having an inlet, the inlet having a first flange coupled within said at least one recess and a pair second flanges disposed within said pair of slots.   
     
     
         2 . The heat exchanger system of  claim 1  wherein said attachment plate further includes a third flange within said at least one recess, wherein said first flange is coupled to said at least one recess by said third flange. 
     
     
         3 . The heat exchanger system of  claim 2  wherein said third flange includes a plurality of projections. 
     
     
         4 . The heat exchanger system of  claim 3  wherein:
 said heat exchanger member includes a first half coupled to a second half which define a gap in said inlet; and, 
 said plurality of projections includes a first projection adjacent one of said pair of slots and a second projection adjacent a second of said pair of slots. 
 
     
     
         5 . The heat exchanger system of  claim 4  wherein:
 said inlet includes an inner wall; and, 
 said first projection and said second projection are arranged parallel to said inner wall. 
 
     
     
         6 . The heat exchanger system of  claim 4  wherein said plurality of projections includes a plurality of curved projections defining a plurality of peak portions and a plurality of trough portions. 
     
     
         7 . A heat exchanger system for a gas appliance having a combustion chamber, said heat exchanger system comprising:
 an attachment plate coupled to said combustion chamber, said attachment plate having at least one recess, a first slot extending from one side of said at least one recess and a second slot extending from said at least one recess opposite said first slot; and,   a heat exchanger member having an inlet fluidly coupled to receive a combustion gas from said combustion chamber, said inlet having a first flange about an opening and fixedly disposed in said at least one recess, and a pair of second flanges arranged adjacent and substantially perpendicular to said first flange, said pair of second flanges being disposed in said first slot and said second slot.   
     
     
         8 . The heat exchanger system of  claim 7  wherein said attachment plate further includes a third flange within said at least one recess, wherein said first flange is coupled to said at least one recess by said third flange. 
     
     
         9 . The heat exchanger system of  claim 8  wherein said third flange includes a plurality of projections. 
     
     
         10 . The heat exchanger system of  claim 9  wherein:
 said heat exchanger member includes a first half coupled to a second half which define a gap in said inlet; and, 
 said plurality of projections includes a first projection said first slot and a second projection adjacent said second slot. 
 
     
     
         11 . The heat exchanger system of  claim 10  wherein said first projection and said second projection are arranged parallel to a flow direction of said combustion gas. 
     
     
         12 . The heat exchanger system of  claim 11  wherein:
 said inlet includes an inner wall; and, 
 said first projection and said second projection are arranged parallel to said inner wall. 
 
     
     
         13 . The heat exchanger system of  claim 12  wherein said plurality of projections includes a plurality of curved projections defining a plurality of peak portions and a plurality of trough portions. 
     
     
         14 . A method of assembling a heat exchanger system to a combustion chamber comprising:
 providing an attachment plate having at least one recess and a pair of slots extending from said at least one recess;   providing a heat exchanger member having an inlet with a first flange disposed about an opening and a pair of second flanges adjacent said first flange;   disposing said first flange in said at least one recess;   disposing said pair of second flanges in said pair of slots; and,   coupling said heat exchanger member to said attachment plate in said at least one recess; and,   supporting said inlet with said at least one recess when said heat exchanger member is coupled to said attachment plate.   
     
     
         15 . The method of  claim 14  further comprising:
 providing said attachment plate with a third flange disposed within said at least one recess; and, 
 bending said third flange about said first flange to couple said heat exchanger member to said attachment plate. 
 
     
     
         16 . The method of  claim 15  further comprising providing a radial crimping force said third flange on said first flange to form a seal. 
     
     
         17 . The method of  claim 16  wherein said third flange includes a plurality of projections and said plurality of projections includes a first projection aligned with one of said pair of slots and a second projection aligned with a second of said pair of slots. 
     
     
         18 . The method of  claim 17  wherein:
 said inlet has an inner wall; and, 
 said bending of said third flange bends said first projection and said second projection such that a portion of said first projection and said second projection are arranged substantially parallel to said inner wall. 
 
     
     
         19 . The method of  claim 17  wherein:
 said heat exchanger member includes a first heat exchanger half and a second heat exchanger half and a gap disposed in said inlet between said first heat exchanger half and said second heat exchanger half; and, 
 said bending of said first projection and said second projection includes bending said first projection and said second projection over said gap. 
 
     
     
         20 . The method of  claim 19  wherein said supporting of said inlet prevents an increase in a size of said gap when said first projection and said second projection are bent over said gap.