Air Conditioner Condensate Collection System

Abstract

In one embodiment, an auxiliary condensate collection system for an air conditioner includes a guide sheet and a drain pan. The guide sheet is positioned under an air handler of the air conditioner to collect condensate overflow and direct the condensate to a drain pan. The guide sheet is large, but flexible, so that it can be rolled up to fit through an attic access hole. The drain pan is small enough that it fits through the attic access hole also. In other embodiments, the auxiliary condensate collection system includes two or more drain pans that can fit through an attic access hole and a bridge that spans a seam formed between the edges of the drain pans arranged side-by-side or end-to-end to seal the seam and direct condensate into the side-by-side or end-to-end drain pans. In other embodiments, each drain pan has an integral overlapping flange so that a matrix of drain pans can be connected together both side-by-side and/or end-to-end.

Description

CROSS REFERENCE TO RELATED PATENT APPLICATIONS

This invention claims priority from U.S. Provisional Patent Application No. 62/054,240, filed Sep. 23, 2014, which is hereby incorporated by reference.

FIELD OF THE INVENTION

This invention relates to air conditioners and specifically to an auxiliary condensate collection system for the air handler and attached plenums of an air conditioner.

BACKGROUND OF THE INVENTION

The cooling coils in the air handler of an air conditioner cause condensation, resulting in condensate dripping from the cooling coils. Air handlers have a condensate collection pan, but they are not very large and fit inside the air handler. Traditionally, auxiliary condensate collection pans are positioned external to the air handler to collect condensate overflow from the air handler. The auxiliary condensate collection pans have an area that is large enough to encompass the entire footprint of the air handler and the air plenums at either end of the air handler. Consequently, the auxiliary condensate collection pans can collect condensate from anywhere underneath the air handler, as well as from the air plenums at either end of the air handler.

When an air handler is installed in the attic of a house, the air handler and the auxiliary condensate collection pan are placed in the attic before the ceilings and walls of the house are finished. Auxiliary condensate collection pans deteriorate and leak over time. Unfortunately, a traditional replacement auxiliary condensate collection pan is too large to fit through an attic access hole. Consequently, the original auxiliary pan is often repaired instead of being replaced. Repaired pans are not as reliable as the original. Over time, the condensate collection pans may leak, often causing damage to ceilings and walls in houses.

Accordingly, what is needed is an auxiliary condensate collection pan that can fit through an attic access hole, and yet be large enough to collect condensate overflow from underneath a large air handler.

SUMMARY OF THE INVENTION

The present invention addresses the need to replace the original auxiliary condensate collection pan where access to the air handler is only available through a small attic access hole. The present invention is an auxiliary condensate collection system with components that will fit through a small attic access hole and yet when assembled is large enough to collect condensate from anywhere underneath the air handler and the air plenums.

In one embodiment of the present invention, the auxiliary condensate collection system of the present invention is a two-part condensate collection system that includes a guide sheet and a drain pan. The guide sheet is positioned under the air handler and receives condensate from an air handler of the air conditioner, and in turn the drain pan receives the condensate from the guide sheet. The guide sheet directs the flow of condensate across the guide sheet to the drain pan. The guide sheet is flexible so that is can be rolled up to fit through attic access holes and other small access ports. The drain pan is small enough to fit through the attic access holes and access ports. The guide sheet includes a guide sheet first end and a guide sheet second end. In some aspects of the first embodiment, the guide sheet first end is removeably coupled to the air handler. In some other aspects of the first embodiment, the guide sheet second end is removeably coupled to the drain pan. In some additional aspects of the first embodiment, the drain pan includes a guide sheet coupler bar. In another aspect of the first embodiment, the guide sheet includes a hook at the guide sheet first or second end. The hook cooperates with the guide sheet coupler bar to couple the guide sheet to the drain pan. In additional aspects of the first embodiment, the guide sheet is stored in a rolled-up state. In some more aspects of the first embodiment, the guide sheet is stored in a rolled-up state inside the drain pain.

The first embodiment of the present invention enables a method of collecting condensate from an air handler that includes positioning the flexible guide sheet to collect the condensate from the air handler and positioning the drain pan to receive the condensate from the guide sheet. The method also includes coupling the guide sheet to the air handler, coupling the guide sheet to the air handler with a flexible cord, coupling the guide sheet to the drain pan, and coupling a hook of the guide sheet to a coupler bar of the drain pan.

In a second embodiment of the present invention, the condensate collection system includes two small drain pans placed side-by-side or end-to-end with a guide sheet in the form of a bridge extending across the joint between the two side-by-side or end-to-end small drain pans. The two small drain pans are sized so that each small drain pan individually will fit through an attic access hole, but when placed side-by-side or end-to-end, the two drain pans have a combined area that is large enough to encompass the entire area of the footprint of the air handler, as well as air plenums at either end of the air handler. While two small drain pans usually have sufficient area to encompass the entire area of the footprint of the air handler and air plenums, the condensate collection system of the present invention may be implemented by more than two small drain pans placed side-by-side or end-to-end with multiple bridges extending across the joints between the additional side-by-side or end-to-end small drain pans. The small drain pans of the second embodiment of further have risers on which the air handler may be supported.

In a third embodiment of the present invention, the condensate collection system includes two small drain pans placed side-by-side or end-to-end with a guide sheet in the form of a bridge extending across the joint between the two side-by-side or end-to-end small drain pans. The two small drain pans are sized so that each small drain pan individually will fit through an attic access hole, but when placed side-by-side or end-to-end, the two drain pans have a combined area that encompasses the entire area of the footprint of the air handler, as well as air plenums at either end of the air handler. While two small drain pans usually have sufficient area to encompass the entire area of the footprint of the air handler and air plenums, the condensate collection system of the present invention may be implemented by more than two small drain pans placed side-by-side or end-to-end with multiple bridges extending across the joints between the additional side-by-side or end-to-end small drain pans. Further, the small drain pans of the third embodiment have elongated and rib reinforced risers on which the air handler may be supported. The bridge also includes a riser with a connecting slot that engages the sides of the side-by-side or end-to-end small drain pans and positively locks the small drain pans together.

In a fourth embodiment of the present invention, the condensation collection system includes a matrix of individual drain pans with overlapping sidewall flange sections and overlapping end wall sections. The condensate collection system is installed in an attic under an air handler and plenums by passing two or more of the drain pans through the attic opening into the space in the attic occupied by the air handler and plenums. The drain pans are then placed on a support surface side-by-side and/or end-to-end. As configured, the overlapping sidewall flange of one of the drain pans overlaps the sidewall of an adjacent drain pan to thereby form a matrix of drain pans.

The foregoing and other features and advantages of the invention will be apparent to those of ordinary skill in the art from the following more particular description of the invention and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side elevation view of a first embodiment of an auxiliary condensate collection system including a guide sheet and a drain pan in accordance with the present invention.

FIG. 2 is a front elevation view of the auxiliary condensate collection system of FIG. 1 in accordance with the present invention.

FIG. 3 is an enlarged side elevation view of internal structure of the condensate collection system of FIG. 1 in accordance with the present invention.

FIGS. 4a, 4b, and 4c is a side elevation schematic view illustrating the sequential steps for attaching the guide sheet to the drain pan of FIG. 1 by means of a hook and a coupler bar all in accordance with the present invention.

FIG. 5a is an end elevation view of the drain pan of FIG. 1 in accordance with the present invention.

FIG. 5b is a side elevation view of the drain pan of FIG. 1 in accordance with the present invention.

FIG. 5c is top plan view of the drain pan of FIG. 1 in accordance with the present invention.

FIG. 6a is an end elevation view of another drain pan in accordance with the present invention.

FIG. 6b is a side elevation view of the drain pan of FIG. 6a in accordance with the present invention.

FIG. 6c is top plan view of the drain pan of FIG. 6a in accordance with the present invention.

FIG. 7a is a top plan view of the guide sheet of FIG. 1 in accordance with the present invention.

FIG. 7b is a side elevation view of the guide sheet of FIG. 1 in accordance with the present invention.

FIG. 7c is a front elevation view of the guide sheet of FIG. 1 in accordance with the present invention.

FIG. 8a is a side elevation view of the guide sheet of FIG. 1 being rolled up in accordance with the present invention.

FIG. 8b is a side elevation view and an end elevation view of guide sheet of FIG. 1 after it is rolled up in accordance with the present invention.

FIG. 8c is a top plan view of drain pan of FIG. 1 with the rolled up guide sheet inside in accordance with the present invention.

FIG. 9a is a side, front, and back elevation view of a drain pan coupler in accordance with the present invention.

FIG. 9b is a side elevation view of the drain pan of FIG. 1 coupled to a support member using two drain pan couplers in accordance with the present invention.

FIG. 10 is a top perspective view of a second embodiment of an auxiliary condensate collection system including two drain pans and a guide sheet in the form of a bridge spanning a gap between the two drain pans in accordance with the present invention.

FIG. 11 is a top plan view of the auxiliary condensate collection system of FIG. 10 in accordance with the present invention.

FIG. 12 is a side elevation view of the auxiliary condensate collection system of FIG. 10 in accordance with the present invention.

FIG. 13 is a front elevation view of the auxiliary condensate collection system of FIG. 10 in accordance with the present invention.

FIG. 14 is a bottom plan view of the auxiliary condensate collection system of FIG. 10 in accordance with the present invention.

FIG. 15 is an assembled top perspective view of a third embodiment of an auxiliary condensate collection system including two drain pans and a guide sheet in the form of a bridge spanning a joint between the two drain pans in accordance with the present invention.

FIG. 16 is an exploded top perspective view of the auxiliary condensate collection system of FIG. 15 in accordance with the present invention.

FIG. 17 is a top plan view of the auxiliary condensate collection system of FIG. 15 in accordance with the present invention.

FIG. 18 is a side elevation view of the auxiliary condensate collection system of FIG. 15 in accordance with the present invention.

FIG. 19 is front elevation view of the auxiliary condensate collection system of FIG. 15 in accordance with the present invention.

FIG. 20 is a bottom plan view of the auxiliary condensate collection system of FIG. 15 in accordance with the present invention.

FIG. 21 is a top perspective view of a fourth embodiment of an auxiliary condensate collection system with nine drain pans in accordance with the present invention.

FIG. 22 is a top perspective view of the fourth embodiment of an auxiliary condensate collection system with two drain pans in accordance with the present invention.

FIG. 23 is a top perspective view of a drain pan for use in the fourth embodiment of the auxiliary condensate collection system in accordance with the present invention.

FIG. 24 is a bottom perspective view of the drain pan of FIG. 23 in accordance with the present invention.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

As discussed above, embodiments of the present invention relate to air conditioners and specifically to an auxiliary condensate collection system for the air handler including associated plenums of an air conditioner. In a first embodiment, the condensate collection system includes a guide sheet and a drain pan. The guide sheet receives condensate from an air handler of the air conditioner, and the drain pan receives the condensate from the guide sheet. The guide sheet directs the flow of condensate across the guide sheet to the drain pan. The guide sheet is flexible so that it can be rolled up to fit through attic access holes and other small access ports. The drain pan is small enough to also fit through the attic access holes and access ports.

The cooling coil of an air conditioner causes condensation as it operates. The product of the condensation is liquid water condensate, which drips from the cooling coil as the air handler and the air conditioner operate. Each air handler has a drain pan to collect condensate, but the drain pans in the air handlers are usually not large enough to collect all the condensate from an air handler. An auxiliary condensate overflow collection drain pan is used exterior to the air handler to collect condensate that overflows from the drain pan within the air handler. The auxiliary condensate overflow collection drain pan is large enough to collect condensate that drips from anywhere on the air handler including the input and output plenums on either end of the air handler. Auxiliary drain pans have overflow pipes coupled to them that direct water from the auxiliary drain pan to outside the house or to a nearby sewer or septic drain.

Issues arise when the auxiliary drain pan leaks. The most common cause of drain pan leaks is corrosion of the metal of the drain pain. But they can also leak due to damage to the drain pan for other reasons. A drain pan leak can cause severe damage to ceilings and walls, including collapse of a ceiling into the house. When an auxiliary drain pan leaks, it is desirable to replace it. But, unfortunately, drain pains are commonly much larger than an access hole to the attic. Thus replacing the auxiliary drain pan on an air handler in the attic or other space that has limited access requires enlarging the attic access hole, or, more often, repairing the auxiliary drain pan. Repairs to an auxiliary drain pan tend to have limited durability before the drain pan begins to leak again.

What is needed is an auxiliary drain pan that fits through an attic access hole and can be deployed under the air handler to catch condensate overflow. FIG. 1 shows a side elevation view of a condensate collection system 110 in accordance with the present invention. The condensate collection system 110 collects condensate overflow from an air handler 118 of an air conditioning system (some portions of the air conditioning system are not shown). The condensate collection system 110 includes a guide sheet 112 and a drain pan 114. Guide sheet 112 receives condensate 116 from air handler 118. Condensate 116 is often water that is the product of condensation on a cooling coil inside air handler 118, but this is not meant to be limiting. Condensate 116 can be any liquid that drips or flows from air handler 118. Guide sheet 112 is flexible and is shaped and positioned to receive and direct the flow of condensate 116 across guide sheet 112 to drain pan 114. Guide sheet 112 also collects any water that drips from a source air plenum 140 or a return air plenum 142 as shown in FIG. 1. Guide sheet 112 is large enough to receive condensate from any of air handler 118 or plenums 140 or 142.

Drain pan 114 receives condensate 116 from guide sheet 112. Condensate 116 gathers and flows across guide sheet 112 to drain pan 114. Guide sheet 112 is shaped and positioned such that condensate 116, which drips anywhere on guide sheet 112, flows into the drain pan 114. Guide sheet 112 has a first end 132 that is positioned higher than a guide sheet second end 134, so that condensate flows towards drain pan 114. Drain pan 114 has drain holes 126 that can be coupled to drain pipes or drain pipe fittings, for draining the condensate out of drain pan 114, as is known in the art of condensate drain pans. Drain pan 114 can also have an overflow detector (not shown) inside of drain pan 114 to detect when the water level gets too high in drain pan 114, as is also known in the art of condensate drain pans.

FIG. 2 shows a front elevation view of condensate collection system 110 of FIG. 1. Guide sheet 112 has top surface 148 and bottom surface 150 (see FIG. 1). Condensate 116 is received by top surface 148 of guide sheet 112. In the embodiment of condensate collection system 110 shown in FIG. 1 and FIG. 2, guide sheet 112 extends from source air plenum 140 coupled to an air handler back end 128 to an air handler front end 130, which is coupled to return air plenum 142, and beyond plenum 142 to drain pan 114. It is to be understood that guide sheet 112 can also extend sideways from air handler 118 if this configuration is more convenient for the positioning of air handler 118 and guide sheet 112. In some situations, air handlers are positioned such that one or more sides have limited access. Thus guide sheet 112 is capable of being positioned such that it accepts condensate 116 from air handler 118 and directs the flow of condensate 116 to drain pan 114 in any direction away from air handler 118. Alternatively, the ends of the guide sheet 112 can be attached to each end of the air handler 118. The guide sheet 112 has a drain (not shown) positioned at its center section. The drain pan 114 is then positioned under and attached to the center of the guide sheet 112. The condensate is directed from either end of the air handler 118 to the center drain and into the drain pan 114 positioned under the center section of the guide sheet 112.

Guide sheet 112 is removeably coupled to both air handler 118 and drain pan 114 in this embodiment. Guide sheet 112 has a first end 132 and a second end 134. In this embodiment guide sheet first end 132 is removeably coupled to air handler 118 and guide sheet second end 134 is removeably coupled to drain pan 114. Guide sheet 112 in this embodiment is coupled to air handler 118 with a cord 120. Cord 120 is coupled to cord holes 138 (see FIG. 7a) on guide sheet 112 first end 132. Cord 120 extends around air handler 118 and/or plenum 140.

Guide sheet 112 in this embodiment is coupled to drain pan 114 with a hook 124 and a coupler bar 122, as shown in FIG. 3. FIG. 3 shows an expanded view of area 136 of FIG. 1. FIG. 3 shows hook 124 coupled to second end 134 of guide sheet 112. Hook 124 is a J-shaped flexible curve in the flexible material of guide sheet 112, as shown in FIG. 3 and FIG. 7b. Coupler bar 122 is a bar that runs across the inside of drain pan 114 as shown in FIGS. 3, 4a-c, and 5c. Hook 124 is slid in a downward direction 144 between the wall of drain pain 114 and coupler bar 122, as shown in FIG. 4a through FIG. 4c. Once hook 124 is past coupler bar 122, hook 124 catches on coupler bar 122 to removeably couple hook 122 and second end 134 of guide sheet 112 to drain pan 114. It is to be understood that guide sheet 112 can be coupled to drain pan 114 in many different ways, the illustrations shown are examples only.

FIGS. 5a-c show views of drain pan 114. FIG. 5a shows an end elevation view of drain pan 114. Drain pan 114 has height Hd. Height Hd can be any value, but is often about 2 inches to about 5 inches, and more specifically height Hd can be about 3 inches. Drain pan 114 has a width Wd. Width Wd can be any value, but is often in the range of 2 inches to about 6 inches. More specifically, width Wd is often in the range of about 3 inches to about 4 inches.

FIG. 5b shows a side elevation view of drain pan 114. Drain pan 114 has a length Ld. Length Ld can be any value, but is often in the range of about 37 inches to about 43 inches. FIG. 5c shows a top plan view of drain pan 114. FIG. 5c shows coupler bar 122 extending across length Ld of drain pan 114 inside of drain pan 114.

FIG. 6a, FIG. 6b, and FIG. 6c shows views of a drain pan 214. Drain pan 214 is similar to drain pan 114, except that drain pan 214 has a drain pan floor 146 that slopes towards the front of drain pan 214 so that water runs to the front of drain pan 214 and out drain hole 126. FIG. 6a shows an end view of drain pan 214. FIG. 6b shows a side view of drain pan 214. FIG. 6c shows a top view of drain pan 214. FIG. 5c shows coupler bar 122 extending across length Ld of drain pan 214 inside of drain pan 214. A sloping drain pan floor 146 helps keep water from puddling on the floor of drain pan 214, avoiding rusting and damage to drain pan 214.

FIG. 7a, FIG. 7b, and FIG. 7c show views of guide sheet 112. FIG. 7a shows a top view of guide sheet 112, showing guide sheet 112 top surface 148, which extends from first end 132 to second end 134 with guide sheet length Lg. Guide sheet length Lg can be any value, but is often in the range of about 50 to about 80 inches, more specifically often about 60 inches. Cord holes 138 are used to couple cord 120 to guide sheet 112. Guide sheet 112 has a width Wg. Width Wg can be any value, but is often in the range of about 36 inches to about 42 inches. Guide sheet 112 has lip 152 on either side of guide sheet 112. Lip 152 can be better seen in FIG. 7b and FIG. 7c. Hook 124 is on second end 134 of guide sheet 112 in this embodiment. It is to be understood that hook 124 can be on any edge of guide sheet 112. It is to be understood that lip 152 can be on any edge of guide sheet 112. Lip 152 helps direct condensate 116 to drain pan 114. Hook 124 is used to couple guide sheet 112 to drain pan 114.

FIG. 7b shows a side elevation view of guide sheet 112. FIG. 7b shows how lip 152 has a thickness tg. Thickness tg can be any value, but is often in the range of about ¼ inch to about ¾ inch, more specifically, tg is often about ½ inch. FIG. 7b shows hook 124 coupled to second end 134 of guide sheet 112. In this embodiment hook 124 is formed integral to guide sheet 112 and is the same flexible material as guide sheet 112. Having hook 124 be flexible allows hook 124 to flex as it is squeezed between coupler bar 122 and the wall of drain pan 114, as shown in FIG. 4. Once hook 124 gets past coupler bar 122, hook 124 resumes its shape and catches coupler bar 122 to couple guide sheet 112 to drain pan 114, as shown in FIG. 4a, FIG. 4b, and FIG. 4c. FIG. 7c shows a front elevation view of guide sheet 112, showing how hook 124 extends across the entire width Wg of guide sheet 112 in this embodiment. In some embodiments, hook 124 extends across a portion of width Wg of guide sheet 112.

FIG. 8a and FIG. 8b show how guide sheet 112 can be rolled up. Guide sheet 112 is formed of flexible material so that guide sheet 112 can be rolled up into a roll as shown in FIG. 8b. FIG. 8a shows guide sheet 112 being rolled up. As shown in FIG. 8a, it is preferable to roll the guide sheet 112 from the end with a hook 124 to the other end of the flexible sheet 112 (in the direction of the arrow), with the bottom surface 150 being exposed. In other embodiments, the top surface 148 can be exposed, as well as the rolling beginning with the end opposite of the hook 124. FIG. 8b shows an end elevation view and a side elevation view of a rolled-up guide sheet 112. Making guide sheet 112 flexible allows guide sheet 112 to fit through small access holes, such as an attic access hole. Guide sheet 112 can be rolled up and stored/carried in drain pan 114, as shown in FIG. 8c, which shows drain pan 114 and guide sheet 112 in a rolled up state inside of drain pan 114.

Drain pan 114 is small enough to fit through an attic access hole or other small access port. Guide sheet 112 is flexible so that it can be rolled up or otherwise folded so that it fits through an attic access hole of other small access port. Thus, drain pan 114 and guide sheet 112 can easily be used to replace a defective auxiliary condensate collection pan in an attic, for example. Guide sheet 112 is flexible enough in this embodiment so that guide sheet 112 can be rolled up and placed inside drain pan 114, as shown in FIG. 8c. This makes it easy to position drain pan 114 and guide sheet 112 in an attic, for example. Once rolled-up guide sheet 112 and drain pan 114 are placed into the attic, guide sheet 112 is removed from drain pan 114, unrolled, and coupled to air handler 118 and drain pan 114.

FIG. 9a and FIG. 9b show how drain pan 114 can be mounted to a joist 162 using drain pan couplers 154. FIG. 9a shows a side, front, and back elevation views of a drain pan couplers 154. Drain pan coupler 154 includes a rigid hook portion 158, a flat portion 160, and a coupling device 156 which extends through a hole in flat portion 160 to couple drain pan coupler 154 to joist 162. Hook portion 158 is hooked over the top edge of drain pan 114 as shown in FIG. 9b. Drain pan coupler 154 is made long enough so that flat portion 160 sits against joist 162 when hook portion 158 is hooked on the top edge of drain pan 114. The coupling device 156 can be any type of fastener, including, but not limited to, a screw, bolt, nail or the like. The coupling device 156 is used to attach flat portion 160 of drain pan coupler 154 to joist 162. Once coupled to joist 162, drain pan coupler 154 keeps drain pan 114 in place on joist 162. Drain pan couplers 154 can be used on any top edge of drain pan 114 so that drain pan 114 can be positioned in any orientation for mounting on joist 162.

In order to install the condensate collection system 110, the drain pan 114 and the rolled up guide sheet 112 are brought into the attic through the attic access hole. The rolled up guide sheet 112 is unfolded, and the first end 132 of the guide sheet 112 is attached, for example, to the source air plenums 140. The drain pan 214 is then positioned on a joist 162 below the first end 132 of the guide sheet 112 and proximate to the second end 134 of the guide sheet 112. Installation is then completed by attaching the second end of the guide sheet 112 by means of the hook 124 and coupler bar 122 two drain pan 114.

A second embodiment of a condensate collection system 310 of the present invention is illustrated in FIGS. 10-14. The condensate collection system 310 includes a first drain pan 312 and a second drain pan 312′ positioned side-by-side as shown in FIGS. 10, 11, and 13 with a gap 320 between the first and second drain pans 312 and 312′. The first drain pan 312 and the second drain pan 312′ are operatively connected by a guide sheet in the form of a bridge 344. The three components, the first drain pan 312, the second drain pan 312′, and the bridge 344 are all sized to fit through an attic access hole.

As shown in FIG. 10, the first drain pan 312 and the second drain pan 312′ are identical. The drain pans 312 and 312′ have bases 314 and 314′, sidewalls 318 and 318′, and end walls 316 and 316′. The bases 314 and 314′, the sidewalls 318 and 318′, and end walls 316 and 316′ together form two containers for catching and retaining condensate that may drip from the air handler and plenums. Drain holes 340 and 340′ are provided in the end walls 316 and 316′ in order to install pipes (not shown) to drain away the collected condensate to a disposal location. When installed below the air handler and plenums, the drain pans 312 and 312′ should be installed so that the drain holes 340 and 340′ are located at the lowest point of the end walls 316 and 316′.

The drain pans 312 and 312′ also have frustoconical hollow risers 326 and 326′ that can support the air handler above the bases 314 and 314′. The risers 326 and 326′ are formed by conical riser sidewalls 328 and 328′, which extend upwardly and inwardly from the bases 314 and 314′, and terminate in top support surfaces 334 and 334′.

The bridge 344 is a curved surface that in FIG. 10 is a section of the circumference of a cylinder. The bridge 344 has a length that is approximately equal to the lengths of the drain pans 312 and 312′ and has a diameter or chord sufficient in length to bridge the gap 320 between the sidewalls 318 and 318′ of the first and second drain pans 312 and 312′. The bridge 344 may also be in the form of any curved surface or planar surfaces that will direct condensate from the surface of the bridge 344 into either the first drain pan 312 or the second drain pan 312′.

The condensate collection system 310 is installed by passing the drain pans 312 and 312′ and the bridge 344 through the attic access opening into the space in the attic occupied by the air handler and plenums. The drain pans 312 and 312′ are then placed on a support surface side-by-side as shown in FIG. 10. The support surface is adjusted so that the drain holes 340 and 340′ are at a low point. Next, the bridge 344 is fit over the side walls 318 and 318′ adjacent the gap 320 to cover the gap 320. Finally, the air handler is placed on the top support surfaces 334 and 334′ of the risers 326 and 326′. Further, the area defined by the dimensions of the first drain pan 312 and the second drain pan 312′, when positioned side-by-side as shown in FIGS. 10 and 13, is sufficient to encompass the area of the footprint of the air handler and plenums. As previously indicated, additional drain pans and additional bridges can be added to increase the area defined by the side-by-side positioning of the drain pans in order to accommodate larger sized air handlers and plenums. Moreover, the gap 320 between the drain pans 312 and 312′ can be adjusted to accommodate the dimensions of the air handler and plenums.

A third embodiment of a condensate collection system 410 of the present invention is illustrated in FIGS. 15-20. FIG. 15 shows the condensate collection system 410 as assembled, and FIG. 16 shows the condensate collection system 410 prior to final assembly. The condensate collection system 410 includes a first drain pan 412 and a second drain pan 412′ positioned side-by-side as shown in FIGS. 15 and 16. The first drain pan 412 and the second drain pan 412′ are operatively connected by a guide sheet in the form of a bridge 444. The bridge 444 is shown in FIG. 16 prior to assembly of the condensate collection system 410. The three components, the first drain pan 412, the second drain pan 412′, and the bridge 444 are all sized to fit through an attic access hole. Further, the area defined by the dimensions of the first drain pan 412 and the second drain pan 412′, when positioned side-by-side as shown in FIG. 16, is sufficient to encompass the area of the footprint of an air handler and plenums. As previously indicated, additional drain pans and additional bridges can be added to increase the area defined by the side-by-side positioning of the drain pans in order to accommodate larger sized air handlers and plenums.

As shown in FIGS. 15 and 16, the first drain pan 412 and the second drain pan 412′ are identical or may be mirror images of each other. The drain pans 412 and 412′ have bases 414 and 414′, end walls 416 and 416′, and sidewalls 418 and 418′. The bases 414 and 414′, the end walls 416 and 416′, and the sidewalls 418 and 418′ together form two containers for catching and retaining condensate that may drip from the air handler and plenums. Drain holes 440 and 440′ are provided in the end walls 416 and 416′ in order to install pipes (not shown) to drain away the collected condensate to a disposal location. When installed below the air handler and plenums, the drain pans 412 and 412′ should be installed so that the drain holes 440 and 440′ are located at the lowest point on the end walls 416 and 416′.

The bases 414 and 414′ of the drain pans 412 and 412′ have reinforcing ribs 417 and 417′ that stiffen the bases 414 and 414′. The sidewalls 418 and 418′ of the drain pans 412 and 412′ have top flanges 420 and 420′ that extend around the tops of the sidewalls 418 and 418′. Reinforcing ribs 424 and 424′ extend between the bases 414 and 414′ and the top flanges 420 and 420′ to stiffen the sidewalls 418 and 418′ of the drain pans 412 and 412′. Side-by-side sidewalls 421 and 421′ have top flanges sections 422 and 422′ that alternately overlap each other to form an elongated joint 442 as shown in FIGS. 16 and 20. The overlapping flange sections 422 and 422′ inhibit relative movement between the drain pans 412 and 412′ in a direction along the length of the joint 442.

The drain pans 412 and 412′ also have hollow risers 426 and 426′ that can support the air handler above the bases 414 and 414′. The risers 426 and 426′ have elongated sections 431 and 431′ and end sections 432 and 432′. The end sections 432 and 432′ are set at approximately 90° to the length of the elongated sections 431 and 431′. The risers 426 and 426′ are formed by riser sidewalls 428 and 428′ that extend upwardly and inwardly from the bases 414 and 414′ and terminate in top support surfaces 434 and 434′. The riser side walls 428 and 428′ have riser reinforcing ribs 430 and 430′ that extend along the side walls 428 and 428′ from the bases 414 and 414′ to the top support surfaces 434 and 434′. Where the riser reinforcing ribs 430 and 430′ end at the top support surfaces 434 and 434′, the top support surfaces 434 and 434′ are wider than the top support surfaces 434 and 434′ between the reinforcing ribs 430 and 430′. Top support beads 436 and 436′ extend around the periphery of the top support surfaces 434 and 434′ to reinforce the top support surfaces 434 and 434′ and to create a contact surface for the air handler and plenums. Weep holes 438 and 438′ are provided at various points along the lengths of the support beads 436 and 436′ in order to allow condensate to drain from the top support surfaces 434 and 434′ down the sidewalls 418 and 418′ and onto the bases 414 and 414′ of the drain pans 412 and 412′.

The bridge 444 comprises a bridge riser 445, end sections 464, and connecting slot 460. The bridge riser 445 includes a riser base flange 446, riser sidewalls 448, and top support surface 452. The sidewalls 448 extend upwardly and inwardly from the base flange 446 and terminate at top support surface 452. The riser sidewalls 448 have riser reinforcing ribs 450 that extend along the sidewalls 448 from the base flange 446 to the top support surface 452. Where the riser reinforcing ribs 450 end at the top support surface 452, the top support surface 452 is wider than the top support surface 452 between the reinforcing ribs 450. A top support bead 454 extends around the periphery of the top support surface 452 to reinforce the top support surface 452 and to create a contact surface for the air handler and plenums. Weep holes 456 are provided at various points along the length of the support bead 454 in order to allow condensate from the top support surface 452 to drain down the sidewalls 448, onto the base flange 446, and then onto the bases 414 and 414′ of the drain pans 412 and 412′.

Each end section 464 of the bridge 444 comprises a cowl 458 and an end wall 466 with a top flange 468. The cowl 458 is connected to the end of the riser 445 and slopes downwardly toward and terminates at the end wall 466.

The bridge 444 also has a connecting slot 460 formed by the sloped inner surfaces 462 of the riser sidewalls 448 and the sloped interior of the cowl 458. The connecting slot 460 fits over the sloped sidewalls 421 and 421′ of the drain pans 412 and 412′ to hold the drain pans 412 and 412′ together and to cover the joint 442. Consequently, any condensate that strikes the top surface 452 of the bridge 444 will drain down the sloped sidewalls 448 and into the drain pans 412 and 412′ and cannot reach the joint 442. The bridge 444 has return slots 470 in the base flange 446 located at four corners of the bridge 444. With the bridge 444 positioned over the sloped sidewalls 421 and 421′, the return slots 470 engage the riser end sections 432 and 432′ of the drain pans 412 and 412′ to further stabilize the connection between the drain pans 412 and 412′ created by the bridge 444.

The condensate collection system 410 is installed in an attic under an air handler and plenums by passing the drain pans 412 and 412′ and the bridge 444 through the attic opening into the space in the attic occupied by the air handler and plenums. The drain pans 412 and 412′ are then placed on a support surface side-by-side as shown in FIG. 16 with the flanges 422 and 422′ overlapping. The support surface is adjusted so that the drain holes 440 and 440′ are at a low point. Next, the connecting slot 460 of the bridge 444 is fit over the sidewalls 421 and 421′ to secure the drain pans 412 and 412′ together and to seal the joint 442. Finally, the air handler and plenums are placed on the top surfaces 434 and 434′ of the risers 426 and 426′ and on the top surface 452 of the bridge 444.

A fourth embodiment of a condensate collection system 510 of the present invention is illustrated in FIGS. 21-24. FIG. 21 shows the condensate collection system 510 assembled with nine identical small drain pans 512. The nine small drain pans 512 are arranged in a 3×3 matrix with overlapping sidewall flange sections 522 and overlapping end wall sections 523. FIG. 22 shows the condensate collection system assembled with two identical small drain pans 512 positioned end-to-end with an overlapping end wall section 523. FIGS. 23 and 24 show details of one of the small drain pans 512.

With reference to FIGS. 22-24, each drain pan 512 has a base 514, end walls 516 and sidewalls 518. The base 514, the end walls 516, and the sidewalls 518 together form a container for catching condensate that may drip from the air handler and plenums. Drain holes 540 in each of the end walls 516 are provided in order to install pipes (not shown) to connect drain pans 512 installed end-to-end and to drain away the collected condensate to a disposal location. When installed below the air handler and plenums, the drain pans 512 should be installed so that the drain holes 540 of the last drain pans 512 connected in series are located at the lowest point of the interconnected drain pans 512.

The base 514 of the drain pan 512 has reinforcing ribs 515 that stiffen the base 514. One of the sidewalls 518 of the drain pan 512 has a top sidewall flange 520, and the opposite sidewall 518 has an overlapping sidewall flange 522. Reinforcing ribs 519 extend between the base 514 and the top sidewall flange 520 and the overlapping sidewall flange 522 to stiffen the sidewalls 518 of the drain pan 512. One of the end walls 516 of the drain pan 512 has a top end wall flange 521, and the opposite end wall 516 has an overlapping end wall flange 523. Reinforcing ribs 517 extend between the base 514 and the top end wall flange 521 and the overlapping end wall flange 523 to stiffen the end walls 516 of the drain pan 512.

The condensate collection system 510 is installed in an attic under an air handler and plenums by passing two or more of the drain pans 512 through the attic opening into the space in the attic occupied by the air handler and plenums. The drain pans 512 are then placed on a support surface side-by-side and/or end-to-end as shown in FIGS. 21 and 22. As configured in FIGS. 21 and 22, the overlapping sidewall flange 522 of one of the drain pans 512 overlaps the sidewall flange 520 of an adjacent drain pan 512. Similarly the overlapping end wall flange 523 of one of the drain pans 512 overlaps the end wall flange 521 of an adjacent drain pan 512. The support surface is adjusted so that the drain holes 540 at the end of the series of drain pans 512 are at a low point. Finally, the air handler and plenums are placed on the top of the sidewall flanges 520, the end wall flanges 521, the overlapping sidewall flanges 522, and the overlapping end wall flanges 523 so that the air handler and plenums are supported by the reinforced end walls 516 and the reinforced sidewalls 518. Alternatively, the air handler and plenums may be suspended above the condensate collection system 510.

The embodiments and examples set forth herein were presented in order to best explain the present invention and its practical application and to thereby enable those of ordinary skill in the art to make and use the invention. However, those of ordinary skill in the art will recognize that the foregoing description and examples have been presented for the purposes of illustration and example only. The description as set forth is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the teachings above.

Claims

1. An auxiliary condensate collection system for collecting condensate from the combination of an air handler and attach plenums, the combination having a footprint area and wherein the combination is installed in an attic having an attic access hole with an opening having an opening area less than the footprint area, the condensate collection system comprising a guide sheet configured to fit through the attic access hole and a first drain pan sized to fit through the attic access hole wherein the guide sheet is positioned below the air handler and attach plenums for receiving condensate emitted from the air handler or attach plenums and for directing the condensate to the first drain pan.

2. The auxiliary condensate collection system of claim 1, wherein the guide sheet is flexible, has an open area equal to or greater than the area of the footprint area, and is foldable to fit through the attic access hole.

3. The auxiliary condensate collection system of claim 2, wherein the sheet has a first end connected to the air handler or the plenums and a second end attached to the first drain pan.

4. The auxiliary condensate collection system of claim 3, wherein the sheet has a center section, and the first end of the sheet and the second end of the sheet are connected to the air handler or the plenums and the center section is attached to and empties into the first drain pan.

5. The auxiliary condensate collection system of claim 1, wherein the sheet is flexible, has an open area equal to or greater than the area of the footprint area, and is rolled into a configuration that fits through the attic access hole.

6. The auxiliary condensate collection system of claim 5, wherein the sheet has a first end connected to the air handler or the plenums and a second end attached to the first drain pan.

7. The auxiliary condensate collection system of claim 1, further comprising a second drain pan sized to fit through the attic access hole, wherein the first drain pan has a side and an end and the second drain pan has a side and an end, and the first drain pan and second drain pan are aligned side-by-side or end-to-end with a joint between the sides or ends, and wherein the guide sheet forms a bridge spanning the joint and directing condensate into each drain pan.

8. The auxiliary condensate collection system of claim 7, wherein the joint is open.

9. The auxiliary condensate collection system of claim 7, wherein the joint is closed.

10. The auxiliary condensate collection system of claim 7, wherein the bridge is connected to the side of the first drain pan and overlaps the side of the second drain pan when the first drain pan and the second drain pan are aligned in a side-by-side relationship.

11. The auxiliary condensate collection system of claim 7, wherein the bridge is connected the end of the first drain pan and overlaps the end of the second drain pan when the first drain pan and the second drain pan are aligned in an end-to-end relationship.

12. The auxiliary condensate collection system of claim 7, wherein the bridge is connected to one end of the first drain pan and is connected to one side of the first drain pan, and the bridge overlaps an adjacent side or an adjacent end of the second drain pan when the first drain pan and the second drain pan are aligned in a side-by-side relationship or an end-to-end relationship.

13. The auxiliary condensate collection system of claim 7, wherein the first pan and the second pan have risers for supporting the air handler and attached plenums.

14. The auxiliary condensate collection system of claim 13, wherein the bridge includes a riser for supporting the air handler and attach plenums.

15. An auxiliary condensate collection system for collecting condensate from the combination of an air handler and attach plenums, the combination having a footprint area and wherein the combination is installed in an attic having an attic access hole with an opening having an opening area less than the footprint area, the condensate collection system comprising: wherein the sum of the bridge area, the first drain pan area, and the second drain pan area is equal to or greater than the footprint area of the air handler and attach plenums.

a. a first drain pan sized to fit through the attic access hole and having a side, an end, and a first drain pan area;

b. a second drain pan sized to fit through the attic access hole and having a side, an end, and a second drain pan area, wherein the first drain pan and second drain pan are aligned side-by-side or end-to-end with a joint between the sides or ends; and

c. a bridge having a bridge area and spanning the joint and directing condensate from the air handler and attach plenums into at least one of the drain pans,

16. The auxiliary condensate collection system of claim 15, wherein the joint is open.

17. The auxiliary condensate collection system of claim 15, wherein the joint is closed.

18. The auxiliary condensate collection system of claim 15, wherein the bridge is connected to the side of the first drain pan and overlaps the side of the second drain pan when the first drain pan and the second drain pan are aligned in a side-by-side relationship.

19. The auxiliary condensate collection system of claim 15, wherein the bridge is connected the end of the first drain pan and overlaps the end of the second drain pan when the first drain pan and the second drain pan are aligned in an end-to-end relationship.

20. The auxiliary condensate collection system of claim 15, wherein the bridge is connected to one end of the first drain pan and is connected to one side of the first drain pan, and the bridge overlaps an adjacent side or an adjacent end of the second drain pan when the first drain pan and the second drain pan are aligned in a side-by-side relationship or an end-to-end relationship.