Condensate liquid pumping system

Abstract

A condensate liquid pumping system pumps from a reservoir outlet condensate liquid received from an air-handling apparatus. A filter located upstream of the reservoir outlet filters the condensate liquid. A filter blockage sensor located upstream of the filter senses a predetermined liquid level upstream of the filter which is indicative of blockage of the filter. The filter and the filter blockage sensor may be disposed inside the reservoir. The filter may be a removable filter that can be easily withdrawn for service or replacement without disassembling the reservoir or disconnecting or disturbing any of the tubing or other components of the reservoir or the condensate liquid pumping system.

Description

BACKGROUND

The present invention relates to condensate liquid pumping systems for use with air cooling systems, and in particular to condensate liquid pumping systems that include a filter between the source of condensate and a pump used to pump that condensate out of the system.

As a fundamental part of the physics of cooling, all air conditioners extract water from the air when they are in the cooling mode. An air cooling system, such as an air conditioner or a heat pump, typically has heat exchange coils that produce water as the system cools the air in a building. This water, known as condensate, is typically collected in a drain pan usually placed below the heat exchange coils, and is transported away through a drain line connected to the drain pan. The overflow of condensate can cause damage to structures within the building, such as dry walls, ceilings, wooden supports, etc. The overflow also can provide ideal conditions for the growth of mold in those areas that are continually wetted and can seriously compromise the air quality inside the building, as well as possibly have adverse effects on the health of the occupants.

Thus, condensate must be removed from the air conditioning unit and piped to outside the building. If this is not adequately or correctly done, the condensate will overflow the drain pan of the air conditioner and cause extensive water damage and/or pose health risks. Some systems for preventing condensate overflow are described in U.S. Pat. No. 5,069,042 and U.S. Pat. No. 5,522,229, the disclosures of which are incorporated herein by reference in their entireties.

U.S. Pat. No. 5,069,042 discloses a condensate trap that includes a mechanical switch and a float. When the condensate accumulates in the trap due to a blockage, the float rises with the rising level of the condensate. Eventually, the float activates the mechanical switch to shut off the air cooling system to prevent further condensate from being produced by the system.

U.S. Pat. No. 5,522,229 discloses a drain tube that includes an inlet end for attaching to a drain pan, and an outlet end for transporting condensate out of the drain pan. The drain tube includes a sensor probe that extends from the drain tube inlet end and into the drain pan when attached to the drain pan. The sensor probe detects excess condensate in the drain pan due to a blockage. When the excess condensate is detected, the sensor probe triggers a control circuit that generates an output signal to sound an alarm and/or turn off the air cooling system.

One type of air cooling system is a “minisplit” air conditioner. A minisplit air conditioner is similar to a wall unit air conditioner, except that it is split into two parts. The first part is the cooling/blowing part which is mounted in the wall of the room to be cooled. The second part is the condenser which is mounted outside of the building. The two parts are connected to each other by wire cables and pipes that conduct the cooling fluid (for example, Freon). There may be up to four cooling/blowing parts (e.g., for up to four different rooms) for each condenser.

The “minisplit” system often requires specialized pumps to pump the condensate liquid out of the cooling/blowing part, as the system may not always be able to rely on gravity for condensate drainage. For example, if the cooling/blowing unit is mounted in an internal wall of the building, the condensate often must be led upward through the internal wall and out of the building. A pump is thus used to pump the water upward. The pump may be relatively small, for example, having a flow line diameter of about 1 mm. The pump is connected to an outlet of a reservoir. The reservoir receives condensate flow from the drain pan in the wall-mounted portion of the air conditioning unit. The reservoir contains a sensing mechanism, such as a float switch, that activates the pump when an increase in the condensate level is sensed, and that deactivates the pump once the condensate level decreases. One example of a pump that is used in such minisplit systems is described in U.S. Pat. No. 5,562,003, the disclosure of which is incorporated herein by reference in its entirety.

SUMMARY

The invention is directed to condensate liquid pumping systems that can be used with various air cooling systems, such as air conditioners (as used herein “air conditioner” refers to standard air conditioners, heat pumps and to any type of de-humidifying unit) and refrigeration units. For example, the invention is directed to condensate liquid pumping systems that can be used with miniature condensate pumps, such as those used in minisplit air conditioners.

Because the condensate water is dirty (i.e., contains particles of dirt or biological masses), a filter is required to prevent the flow line of the pump from becoming blocked when a pump is provided to pump the condensate liquid from the cooling unit. This is particularly important in minisplit systems because the pump flow lines are often very small, for example, 1 mm in diameter. Current designs of minisplit pumps have the filter disposed at the inlet of the reservoir that receives liquid from a drain pan. When condensate reaches a predetermined level in the reservoir (determined by the sensing mechanism), the pump is activated. However, if the filter becomes clogged, condensate does not flow into the reservoir. Instead, the condensate backs up in the drain hose and the drain pan until it overflows and causes water damage. Further, if a blockage occurs in the drain pan outlet or in the drain pan hose which connects the drain pan to the reservoir, the condensate backs up in the drain pan until it overflows and causes water damage. Moreover, in these systems, there is no warning mechanism available which will indicate that a potential flooding problem exists and will alert the owner to this possibility. Nor is there a way of disabling these types of air conditioners when flooding occurs so that the air conditioner cannot continue operating and creating further condensate water to exacerbate the problem. Additionally, there is no way of easily cleaning the filter on a regular basis. The filter is generally in an inaccessible place inside the air conditioning unit's evaporator, and disassembly of the reservoir unit is required to provide access to the filter. Further, disconnection of the tubing may be required to allow the filter to be removed for inspection and cleaning.

It is therefore desirable to have a condensate liquid pumping system that includes a filter blockage sensor located upstream of a filter, the filter located upstream of a reservoir outlet, that senses a predetermined condensate level upstream of the filter, indicating if the filter is blocked or clogged. The filter and the filter blockage sensor may both be disposed inside the reservoir. The condensate liquid pumping system also may include a drainage pan coupled to a reservoir inlet, and a drainage pan liquid level sensor disposed in the drainage pan.

It is also desirable to have a condensate liquid removal system that includes a filter that can be easily removable for service or replacement. The removable filter can be disposed in a reservoir and filters the condensate that enters the reservoir. The reservoir includes a sealable opening by which the removable filter can be easily installed and removed from the reservoir without disassembling the reservoir or disconnecting/disturbing any tubing or other connecting components.

According to one aspect of the invention, there is provided a condensate liquid pumping system for pumping liquid received from an air-handling apparatus. The pumping system includes a reservoir having an inlet and an outlet, the inlet receiving condensate liquid from the air-handling apparatus, and a pump communicating with the reservoir outlet to pump the condensate liquid out of the reservoir. The pumping system also includes a filter to filter the condensate liquid. The filter is located upstream of the reservoir outlet. The pumping system further includes a filter blockage sensor disposed upstream of the filter to sense a predetermined liquid level upstream of the filter which is indicative of blockage of the filter.

According to some embodiments, the filter is disposed inside the reservoir. The filter blockage sensor can be disposed in the reservoir upstream of the filter. According to further embodiments, the filter is disposed upstream of the reservoir inlet.

According to some embodiments, the filter blockage sensor is disposed in a drain line connecting the reservoir to a drainage pan located upstream of and coupled to the reservoir inlet. According to some embodiments, the filter blockage sensor is disposed in the drainage pan located upstream of and coupled to the reservoir inlet. According to further embodiments, a second filter blockage sensor is disposed in a drain line connecting the reservoir to the drainage pan.

According to some embodiments, the condensate liquid pumping system further includes a liquid level sensor disposed in the reservoir downstream of the filter, the pump being activated when the liquid level sensor detects a predetermined liquid level. According to further embodiments, the liquid level sensor senses a second, higher predetermined level of liquid in the reservoir downstream of the filter indicative of a pump abnormality condition.

According to some embodiments, the liquid level sensor includes a float coupled to a switch that activates the pump when the float, which is located in the reservoir, reaches the predetermined level.

According to some embodiments, the filter blockage sensor includes a float coupled to a switch.

According to some embodiments, the filter blockage sensor includes at least one electrode. According to further embodiments, the electrode is adjustably disposed.

According to some embodiments, the filter blockage sensor includes at least one infrared level detector.

According to some embodiments, the filter blockage sensor includes at least one contact molded onto a wall of the reservoir.

According to some embodiments, the filter blockage sensor communicates with a controller utilizing at least one of a dedicated cable, electronic impulses, infrared signal, ultraviolet signal, and fiber optic cable.

According to some embodiments, the pump includes an alarm circuit triggered when the second, higher predetermined level of liquid is detected.

According to some embodiments, the filter blockage sensor also is connected to the alarm circuit. According to further embodiments, the alarm circuit shuts off the air-handling apparatus and deactivates the pump so as to prevent overheating damage to the pump and/or overflow of condensate liquid. According to further embodiments, the alarm circuit generates an audible or visual signal.

According to some embodiments, there is provided a minisplit air conditioner that includes the pumping systems described above.

According to some embodiments, the filter blockage sensor is disposed inside the reservoir, and the condensate liquid pumping system further includes a drainage pan coupled to the reservoir inlet, and a drainage pan liquid level sensor disposed in the drainage pan. In further embodiments, a second filter blockage sensor is disposed in a drain line connecting the reservoir to the drainage pan.

According to another aspect of the invention, a condensate liquid removal system includes a reservoir having an inlet and an outlet, the inlet receives liquid generated by an air cooling apparatus, and a removable filter disposed in the reservoir and that filters the liquid that enters the reservoir. The reservoir can include a sealable opening by which the removable filter can be installed and removed from the reservoir.

According to some embodiments, the filter is formed of at least one of metal, plastic mesh, a slotted plate, a fiber cartridge and a plastic cartridge.

According to some embodiments, the sealable opening is a slot in a wall of the reservoir through which the removable filter is slidable.

According to some embodiments, the sealable opening is an end of the reservoir, the system further including a removable end cap that sealably fits into the end, the removable end cap having the reservoir inlet and holding the removable filter.

According to some embodiments, the condensate liquid removal system further includes a pump coupled to the reservoir outlet to pump liquid out of the reservoir through the outlet.

According to another aspect of the invention, a condensate liquid removal system includes a reservoir having an inlet and an outlet, the inlet receiving condensate liquid generated by an air cooling apparatus, and a filter that is removably attached to the inlet.

According to some embodiments, the filter is disposed in a tube that is removably attached to the reservoir inlet by a quick-connect coupling.

According to some embodiments, the filter is formed of at least one of metal, plastic mesh, a slotted plate, a fiber cartridge and a plastic cartridge.

According to some embodiments, the condensate liquid removal system further includes a pump coupled to the reservoir outlet to pump liquid out of the reservoir through the outlet.

These and other features and advantages of the invention are described in, or are apparent from, the following description of various exemplary embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Various exemplary embodiments of the invention are described in detail with reference to the following figures wherein:

FIG. 1 is a simplified view of an air cooling system incorporating a condensate liquid pumping system according to some embodiments of the present invention;

FIGS. 2A-D illustrate exemplary embodiments of a reservoir in a condensate liquid pumping system that includes a filter blockage sensor and a liquid level sensor;

FIGS. 3A-D illustrate exemplary embodiments of a drainage pan in a condensate liquid pumping system that can include a filter blockage sensor; and

FIGS. 4A-D illustrate exemplary embodiments of a condensate liquid removal system that includes a removable filter.

DETAILED DESCRIPTION OF EMBODIMENTS

FIG. 1 illustrates an air cooling system 1 including a drainage system 14 that includes a condensate liquid pumping system 3 according to an exemplary embodiment of the present invention. The air cooling system 1 includes an air conditioner 2 coupled to an air handling apparatus 4. The air conditioner 2 circulates and cools a coolant passing through the air conditioner 2. The air handling apparatus 4 contains heat exchange coils 6 through which the cold coolant circulates. Warm air is conveyed to the air handling apparatus 4 through an inlet duct 10. The warm air is cooled as it makes contact with the exchange coils 6. The cool air is then transported away from air handling apparatus 4 through an outlet duct 8. When the warm air is cooled, moisture in the air condenses on the heat exchange coils 6 as liquid droplets or condensate.

The drainage system 14 includes a drainage pan 12, a drain line 16 and the condensate liquid pumping system 3. The drainage system 20 also may include a condensate trap 5. The condensate produced by the heat exchange coils 6 drips into the drain pan 12, which is placed below the heat exchange coils 6. The drain pan 12 is coupled to a drain line 16 which transports the condensate to a drain (not shown).

The condensate liquid pumping system 3 includes a reservoir 18 having an inlet 20 and an outlet 22, and a pump 24. According to some embodiments, the reservoir 18 includes a filter blockage sensor 30 (shown in FIGS. 2A-D and discussed below) that communicates with a controller 21 (shown in FIG. 2A and discussed below) in the pump utilizing, for example, a dedicated cable 26. The condensate liquid pumping system 3 can be attached to the drain line 16 or to the condensate trap 5, as shown in FIG. 1. That is, the condensate liquid pumping system 3 may be installed in any location in the drainage system 14. The air cooling system can be a minisplit air conditioner or other type of air cooling system. In a minisplit system, the flow lines 16 and the pump flow path within the pump 24 typically have a diameter of about 1 mm.

FIG. 2A illustrates the reservoir 18 and the pump 24 in a condensate liquid pumping system 3 according to an exemplary embodiment of the invention. The reservoir 18 includes a hollow body with a top cover 36. The top cover 36 may be a removable cover that detachably connects to the upper end of the reservoir 18. The reservoir 18 may be of a multi-sided rectangular, triangular (such as an “elbow” shape), trapezoidal or circular structure. The reservoir 18 may be made of plastic, such as polyvinyl chloride (PVC), thermoplastic, etc.; metal, such as brass, aluminum, steel, etc.; or ceramic, etc. In various embodiments, the hollow body of the reservoir 18 is transparent to allow a person to see (inspect) the interior of the reservoir 18.

The reservoir 18 includes the inlet 20 and the outlet 22 disposed at different ends of the reservoir 18 so that condensate liquid from the air-handling apparatus 4 is received at the inlet 20, passes through the body of the reservoir 18 and exits via the outlet 22. The cross-sectional shape of the inlet 20 and outlet 22 may vary, as long as the inlet 20 can be attachable to the drain line 16 to receive the condensate liquid. In the exemplary embodiment, the inlet 20 and the outlet 22 protrude from respective walls of the hollow body of the reservoir 18. However, either one or both of the inlet 20 and the outlet 22 may be flush with the respective wall of the hollow body of the reservoir 18 so as to provide a more compact configuration. The inlet 20 may be adapted to snap fit with an end of the drain line 16. In another example, the inner surface of the inlet 20 may be smooth or roughened, glued and slip fitted to the end of the drain line 16. Various methods of attaching the inlet 20 to the drain line 16 can be used. For example, in another embodiment, the inlet 20 is threaded to mate with an end of the drain line 16, which also may be threaded.

The pump 24 communicates with the reservoir outlet 22 via a line (not shown in FIG. 2A) similar to drain line 16 to pump the condensate liquid out of the reservoir 18. The outlet 22 may have similar properties as those of the inlet 20 with respect to attaching to the line connected to the pump 24. The pump 24 includes a controller 21 and an alarm circuit 23, each of which is discussed below. The pump 24 may be a self priming pump, and may operate automatically on when the condensate liquid level rises. The pump 24 may include push-in electrical terminals for quick connection of power and alarm wires. The pump 24 may operate on a battery, a 6 volt, a 12 volt, a 24 volt, a 120 volt, a 220 volt, or any other voltage AC or DC, which may prove to be practical, for example, for the purpose of connecting into an electrical building monitoring system or meeting current or future building codes.

The reservoir 18 further includes a filter 28 that filters the condensate liquid received from the air handling apparatus 4. The filter 28 is located upstream of the reservoir outlet 22. The filter 28 may be formed of metal, plastic mesh, a slotted plate, a fiber cartridge or a plastic cartridge.

As shown in FIGS. 2A-2D, the reservoir 18 includes a liquid level sensor 31 disposed in the reservoir 18 downstream of the filter 28. The liquid level sensor 31 is used to activate/deactivate the pump 24. The liquid level sensor 31 is formed of a float 33 disposed within the hollow body of the reservoir 18, and is connected to a switch 27′ which is external to the hollow body via a shaft 35. The switch 27′ need not necessarily be external to the reservoir 18. In other embodiments, the switch 27′ is disposed within the reservoir 18. The float 33, which may include a magnet 33′, can ascend and descend (i.e., move up and down) within the reservoir 18 such that as the condensate liquid flows from the filter 28, the float 33 elevates with the level of condensate liquid in the reservoir 18 downstream of the filter 28. As the float 33 elevates, the float 33 urges the shaft 35 towards the switch 27′. When the float 33 elevates to a predetermined level, the shaft 35 has moved sufficiently to activate the switch 27′. The float 33 may be suspended initially at a fixed position, thereby the predetermined level in which the float 33 activates the switch 27′ may be fixed or the initial position of the float 33 may be adjustable such that the installer can set the desired condensate level which would activate the switch 27′. Thus, when sensor 31 detects a predetermined level of liquid downstream of the filter 28, the pump 24 is activated.

The switch 27′ of the liquid level sensor 31 is electrically coupled to the pump 24, or the controller 21 of the pump 24, utilizing, for example, dedicated cable 26. In other embodiments, the switch 27′ communicates with the controller 21 utilizing at least one of electronic impulses, infrared signal, ultraviolet signal, and fiber optic cable. The pump 24 is, in turn, in fluid communication with the interior of the reservoir 18 through the outlet 22 via a line similar to drain line 16. When the switch 27′ is activated, the switch 27′ activates the pump 24 to pump the condensate liquid out of the reservoir 18 and into the line in fluid communication with the pump 24. The pump 24 will continue to pump the condensate liquid out of the reservoir 18 until the float 33 descends to a lower level that deactivates the switch 27′ or the pump 24 is shut off. For example, the pump 24 may be fitted with a secondary sensor 60 or a time delay relay 62 or a combination of both to ensure that the pump 24 does not continue to operate after the condensate level has receded. The time delay can be electronically varied at the time of manufacture and electronically reprogrammed, if necessary, before triggering anything to eliminate the possibility of false alarms due to air pressure induced surges in the condensate liquid level in the reservoir 18. In some embodiments, the liquid level sensor 31 senses a second, higher predetermined level of condensate liquid in the reservoir 18 downstream of the filter 28 indicative of a pump abnormality condition. In these embodiments, an alarm circuit 23 in the pump 24 is triggered when the second, higher predetermined level of condensate liquid is detected. The alarm circuit 23 sends an audible and/or visual alarm and/or shuts off the air cooling system to prevent further production and build-up of condensate.

However, if the filter 28 becomes blocked, the sensor 31 will indicate that no condensate is present, the pump 24 will not be activated and a condensate overflow condition may occur. Thus, in accordance with some aspects of the invention, a filter blockage sensor 30 is provided upstream of the filter 28 to sense a predetermined liquid level upstream of the filter 28 which is indicative of a blockage of the filter 28. In the exemplary embodiment of FIG. 2A, the filter 28 is disposed inside the reservoir 18, and the filter blockage sensor 30 is disposed in the reservoir 18 upstream of the filter 28. In some embodiments, the filter 28 is disposed upstream of the reservoir inlet 20. In the embodiment of FIG. 2A, the filter blockage sensor 30 is formed of a float 32 disposed within the hollow body of the reservoir 18, and is connected to a switch 27 which is external to the hollow body via a shaft 34. However, the switch 27 need not necessarily be external to the hollow body of the reservoir 18, and in other embodiments, the switch 27 is disposed within the hollow body. The float 32, which may include a magnet 32′, can ascend and descend (i.e., move up and down) within the reservoir 18 such that as the condensate liquid flows from the inlet 20, the float 32 elevates with the level of condensate liquid in the reservoir 18. As the float 32 elevates, the float 32 urges the shaft 34 towards the switch 27. When the float 32 elevates to a predetermined level, the shaft 34 has moved sufficiently to activate the switch 27. The float 32 may be suspended initially at a fixed position, thereby the predetermined level in which the float 32 activates the switch 27 may be fixed or the initial position of the float 32 may be adjustable such that the installer can set the desired condensate level which would activate the switch 27.

The switch 27 is electrically coupled to the pump 24, or the controller 21 of the pump 24, utilizing, for example, the dedicated cable 26 to activate the alarm circuit 23 when a blockage of filter 28 is detected. In other embodiments, the switch 27 of the filter blockage sensor 30 communicates with the controller 21 utilizing at least one of electronic impulses, infrared signal, ultraviolet signal, and fiber optic cable. In various embodiments, the switch 27 can be mechanical, and can be a single or multiple electronic probe or sensor, reed type, ultrasonic, optical, light fiber, pneumatic or can use any other known switching method, or any combination of the above, all of which can be capable of single or multiple pole switching for the purpose of carrying out simultaneous multi-switching operations without the necessity of any extra relays.

Switch 27 activates the alarm circuit 23 when a filter blockage occurs. The alarm circuit 23 may be coupled to a visual alarm signal such as a warning light or LED, and/or an audio alarm signal, such as a buzzer on the body of the pump 24 or reservoir 18 or mounted remotely by means of wired and/or wireless communication. When the switch 27 is activated by the float 32 at a predetermined level, the switch 27 activates the alarm circuit 23 to alert service personnel or an owner that there is a blockage of the filter 28. Preferably, the alarm circuit 23 shuts off the air-handling apparatus 4 and deactivates the pump 24 so as to prevent production of more condensate and to prevent overheating damage to the pump 24. The alarm circuit 23 can also communicate directly with the air cooling system 1 and/or an external alarm by means of wiring, wireless RF frequency, infrared, ultraviolet, ultrasonic or any of the known communication technology or any combination of the above. Further, the alarm circuit 23 can incorporate a physical method of adjusting the triggering point of a triggering mechanism or it can incorporate an electronic method of adjusting this prior to or after installation.

In an alternative embodiment shown in FIG. 2B, the filter blockage sensor 30, instead of relying on a float and a switch, includes one or multiple probes or electrodes 38 to sense excess condensate in the reservoir 18. As shown in FIG. 2B, the probes or electrodes 38 are disposed at a predetermined level within the reservoir 18 upstream of the filter 28, which is indicative of blockage of filter 28. The probes or electrodes 38 may be made of metal such as copper, aluminum, etc. The predetermined level of the probes or electrodes 38 may be fixed or may be adjustable such that the installer can set the required condensate level which would cause an electrical connection between the probes or electrodes 38. When the condensate liquid flows from the inlet 20 into the reservoir 18 and the filter 28 is blocked, the level of the condensate liquid rises within the reservoir 18 upstream of the filter 28. When the condensate liquid contacts the probes or electrodes 38, the probes or electrodes 38 conduct electricity. This activates the alarm circuit 23 and the air-handling apparatus 4 is shut off and the pump 24 is deactivated. In some embodiments, the material of the filter 28 disposed in the reservoir 18 is metallic, and the filter blockage sensor 30 utilizes the metallic material of the filter 28 to act as an electrode or probe to sense a high condensate liquid level indicative of a filter blockage. The probes or electrodes 38 also can be disposed downstream of filter 28 and used as the pump-activating liquid level sensor 31.

In another embodiment shown in FIG. 2C, the filter blockage sensor 30 includes one or multiple contacts 40 molded onto a wall of the reservoir 18. The contacts 40 may be made of metal such as copper, aluminum, etc. The contacts 40 may directly activate the alarm circuit 23. When the condensate liquid flows from the inlet 20 into the reservoir 18 and filter 28 is blocked, the level of the condensate liquid rises within the reservoir 18 upstream of filter 28. When the condensate liquid reaches the contacts 40, the contacts 40 conduct electricity. This activates the alarm circuit 23, and preferably the air-handling apparatus 4 is shut off and the pump 24 is deactivated.

In another embodiment shown in FIG. 2D, the filter blockage sensor 30 includes an infrared level detector 42, which also may be disposed on a wall of the reservoir 18. When the infrared level detector 42 detects a predetermined condensate liquid level, the infrared level detector 42 activates the alarm circuit 23, and preferably shuts off the air-handling apparatus 4 and deactivates the pump 24.

FIG. 3A illustrates the drainage pan 12 of a condensate liquid pumping system 3 according to an exemplary embodiment of the invention. Usually, the condensate liquid that drips into the drainage pan 12 flows away into the drain line 16 connected to the drainage pan 12. However, if a blockage occurs in the drain line 16, or in the drainage pan 12 adjacent to the inlet of the drain line 16, for example, due to accumulation of debris, algae, mold, etc., the condensate liquid starts to accumulate and eventually fills the drainage pan 12. If such a condition is not corrected, the condensate liquid may overflow out of the drainage pan 12 and cause water damage. Therefore, according to this exemplary embodiment, a blockage sensor 44 is disposed in a drainage pan 12 located upstream of and coupled to the reservoir inlet 20. For example, the blockage sensor 44 may be disposed in the drainage pan 12, as shown in FIG. 3A. This blockage sensor also would be effective at sensing a blockage in filter 28 because filter 28 is located downstream of the drainage pan 12. Additionally, a blockage sensor 66 may be disposed in the drain line 16 connecting the reservoir 18 to the drainage pan 12. Blockage sensor 66 would be effective at sensing a blockage in filter 28 because filter 28 also is located downstream of the drain line 16. Alternatively, the blockage sensor 66 may be disposed in the drain line 16 and there is no blockage sensor disposed in the drainage pan 12.

In the embodiment, the blockage sensor 44 includes a float 45 disposed within the drainage pan 12, and is connected to a switch 47 via a shaft 46. The float 45, which may include a magnet 45′, can ascend and descend (i.e., move up and down) within the drainage pan 12 such that the float 45 elevates with the level of condensate liquid in the drainage pan 12. As the float 45 elevates, the float 45 urges the shaft 46 towards the switch 47. When the float 45 elevates to a predetermined level, the shaft 46 has moved sufficiently to activate the switch 47. Like the filter blockage sensor 32 described in above embodiments, the float 45 may be suspended initially at a fixed position, thereby the predetermined level in which the float 45 activates the switch 47 may be fixed or the initial position of the float 45 may be adjustable such that the installer can set the desired condensate level which would activate the switch 47.

The switch 47 can be electrically coupled to the alarm circuit 23 utilizing, for example, the dedicated cable 48. In other embodiments, the switch 47 communicates with the alarm circuit 23 utilizing at least one of electronic impulses, infrared signal, ultraviolet signal, and fiber optic cable. When the switch 47 is activated, the switch 47 activates the alarm circuit 23 and preferably shuts off the air-handling apparatus 4 and deactivates the pump 24 so as to prevent overheating damage to the pump 24. In this manner, the condensate is prevented from overflowing out of the drainage pan 12.

In an alternative embodiment shown in FIG. 3B, the blockage sensor 44, instead of relying on a float and a switch, includes one or multiple probes or electrodes 52 to sense excess condensate in the drainage pan 12. As shown in FIG. 3B, the probes or electrodes 52 are disposed at a predetermined level within the drainage pan 12. The probes or electrodes 52 may be made of metal such as copper, aluminum, etc. The predetermined level of the probes or electrodes 52 may be fixed or may be adjustable such that the installer can set the required condensate level which would cause an electrical connection between the probes or electrodes 52. The probes or electrodes 52 may directly activate the alarm circuit 23, and preferably shuts off the air-handling apparatus 4 and deactivates the pump 24. The probes or electrodes 52 in these embodiments are electrically coupled to the pump 24, or the controller 21 of the pump 24, utilizing at least one of a dedicated cable 48, electronic impulses, infrared signal, ultraviolet signal, and fiber optic cable. In this manner, the condensate is prevented from overflowing out of the drainage pan 12. This embodiment also may include blockage sensor 66 disposed in the drain line 16.

In an alternative embodiment shown in FIG. 3C, the blockage sensor 44 includes one or multiple contacts 50 molded onto a wall of the drainage pan 12. The contacts 50 may be made of metal such as copper, aluminum, etc. The contacts 50 may directly activate the alarm circuit 23, and preferably shut off the air-handling apparatus 4 and deactivate the pump 24. The contacts 50 in these embodiments are electrically coupled to the pump 24, or the controller 21 of the pump 24, utilizing at least one of a dedicated cable 48, electronic impulses, infrared signal, ultraviolet signal, and fiber optic cable. In this manner, the condensate is prevented from overflowing out of the drainage pan 12. This embodiment also may include blockage sensor 66 disposed in the drain line 16.

In an alternative embodiment shown in FIG. 3D, the blockage sensor 44 includes an infrared level detector 54, which also may be disposed on a wall of the drainage pan 12. When the infrared level detector 54 detects a predetermined condensate liquid level, the infrared level detector 54 activates the alarm circuit 23, and preferably shuts off the air-handling apparatus 4 and deactivates the pump 24. The blockage sensor 44 in this embodiment is electrically coupled to the pump 24, or the controller 21 of the pump 24, utilizing at least one of a dedicated cable 48, electronic impulses, infrared signal, ultraviolet signal, and fiber optic cable. In this manner, the condensate is prevented from overflowing out of the drainage pan 12. This embodiment also may include blockage sensor 66 disposed in the drain line 16.

In some embodiments, the condensate liquid pumping system 3 includes the blockage sensor 44 disposed in the drainage pan 12 in addition to the filter blockage sensor 32 associated with the reservoir 18. In further alternative embodiments, the condensate liquid pumping system 3 includes the liquid level sensor 31 in the reservoir 18 downstream of the filter 28 in addition to the blockage sensor 44 in the drainage pan 12 and the filter blockage sensor 32 associated with the reservoir 18. In other embodiments, the liquid level sensor 31 may be used with either the blockage sensor 44 in the drainage pan 12 or the filter blockage sensor 32 associated with the reservoir 18.

FIG. 4A illustrates a removable filter 28 in a condensate liquid pumping system 3 according to an exemplary embodiment of the invention. In the embodiment, the reservoir 18 includes a sealable opening 37 at the upper end of the reservoir 18 by which the removable filter 28 can be easily installed and removed from the reservoir 18. As shown in FIG. 3A, the sealable opening 37 may be a slot in the top of the reservoir 18 through which the removable filter 28 is slidable. The reservoir 18 may also include a guide 29 to secure the removable filter 28 into a predetermined location within the reservoir 18. The guide 29 serves to fit the removable filter 28 in such a way within the reservoir 18 that the removable filter 28 cannot inadvertently be reversed or installed incorrectly. A removable end cap 39 is provided to sealably close the sealable opening 37. The removable filter 28 can be installed in such a way that it incorporates one or more of many different types of sealing mechanisms to ensure that there is no leakage once the removable filter 28 has been inserted into place. In some embodiments, the removable filter 28 can be installed in the reservoir 18 with a quick release mechanism which will enable the removable filter 28 to be removed and replaced easily without tools.

In this configuration, the removable filter 28 can be easily withdrawn for service or replacement without disassembling the reservoir 18 or disconnecting or disturbing any of the tubing or other components of the reservoir 18 or the condensate liquid pumping system 3, thus eliminating the possibility of damaging or loosening the components and potentially causing condensate water leakage. Further, the removable filter 28 is fitted such that the removal and/or replacement of the removable filter 28 can be done without applying any torque to the reservoir 18, the pump 24 or the various lines or hoses in the condensate liquid pumping system 3. As discussed above, the removable filter 28 may be formed of a metal or plastic mesh, a slotted plate, a cartridge of fiber or plastic material or any other material or combination of materials in any form which can be used for the purpose of filtering the condensate liquid water which passes through it. Further, the removable filter 28 may take the form of a washable reusable material or it can be a disposable cartridge which is simply replaced when it becomes clogged.

In an alternative embodiment shown in FIG. 4B (which is a plan view of the reservoir 18), the removable filter 28 is easily installed and removed from a side wall of the reservoir 18 through a sealable opening 37′. As shown in FIG. 4B, the sealable opening 37′ may be a slot in a wall of the reservoir 18 through which the removable filter 28 is slidable. The reservoir 18 may also include a guide 29′ to secure the removable filter 28 into a predetermined location within the reservoir 18. The guide 29′ serves to fit the removable filter 28 in such a way within the reservoir 18 that the removable filter 28 cannot inadvertently be reversed or installed incorrectly. A removable end cap 39′ is provided to sealably close the sealable opening 37′. The removable filter 28 may be formed of a metal or plastic mesh, a slotted plate, a cartridge of fiber or plastic material or any other material or combination of materials in any form which can be used for the purpose of filtering the condensate liquid water which passes through it. Further, the removable filter 28 may take the form of a washable reusable material or it can be a disposable cartridge which is simply replaced when it becomes clogged. The embodiment illustrated in FIG. 4B provides all of the benefits associated with easily withdrawing the removable filter 28 for service or replacement discussed above in the embodiment of FIG. 4A.

In an alternative embodiment shown in FIG. 4C, the sealable opening into which the filter 28 is installed is an end of the reservoir 18, and a removable end cap sealably closes the end. In the embodiment, the removable end cap forms the reservoir inlet 20 and also holds the removable filter 28. The removable filter 28 may be formed of a metal or plastic mesh, a slotted plate, a cartridge of fiber or plastic material or any other material or combination of materials in any form which can be used for the purpose of filtering the condensate liquid water which passes through it. Further, the removable filter 28 may take the form of a washable reusable material or it can be a disposable cartridge which is simply replaced when it becomes clogged. The embodiment illustrated in FIG. 4C provides all of the benefits associated with easily withdrawing the removable filter 28 for service or replacement discussed above in the embodiments of FIGS. 4A and 4B.

In an alternative embodiment shown in FIG. 4D, the removable filter 28 is remotely mounted from the reservoir 18, and is disposed in a tube 58 that is removably attached to the reservoir inlet 20 by a quick-connect coupling (not shown). The removable filter 28 includes a housing 56 and may be formed of a metal or plastic mesh, a slotted plate, a cartridge of fiber or plastic material or any other material or combination of materials in any form which can be used for the purpose of filtering the condensate liquid water which passes through it. Further, the removable filter 28 may take the form of a washable reusable material or it can be a disposable cartridge which is simply replaced when it becomes clogged.

Some embodiments of the condensate liquid pumping system 3 have been described above. In some embodiments, the pump 24 can be directly mounted on the body of the reservoir 18 so that the pump 24 drains directly from the reservoir 18 itself. Alternatively, the pump 24 can be connected via a flexible tube to the outlet 22 of the reservoir, as discussed above. The pump 24 may be positioned on any part of the surface of the body of the reservoir 18, which provides for a desirable drain of the reservoir 18. The pump 24 also can be connected via a flexible tube to a specially placed inlet inside the drainage pan 12 which can be integrated into the drainage pan structure, or the pump 23 can be retrofitted to the drainage pan after installation of the air cooling system 1.

While the invention has been described with reference to preferred embodiments thereof, it is to be understood that the invention is not limited to the preferred embodiments or constructions. To the contrary, the invention is intended to cover various modifications and equivalent arrangements. In addition, while the various elements of the preferred embodiments are shown in various combinations and configurations, which are exemplary, other combinations and configurations, including more, less or only a single light emitting element, are also within the spirit and scope of the invention.

Claims

1. A condensate liquid pumping system for pumping liquid received from an air-handling apparatus, the pumping system comprising:

a reservoir having an inlet and an outlet, the inlet receiving condensate liquid from the air-handling apparatus;

a pump communicating with the reservoir outlet to pump the condensate liquid out of the reservoir;

a filter to filter the condensate liquid, the filter located upstream of the reservoir outlet; and

a filter blockage sensor disposed upstream of the filter to sense a predetermined liquid level upstream of the filter which is indicative of blockage of the filter.

2. The system of claim 1, wherein the filter is disposed inside the reservoir.

3. The system of claim 2, wherein the filter blockage sensor is disposed in the reservoir upstream of the filter.

4. The system of claim 2, wherein the filter blockage sensor is disposed in a drainage pan located upstream of and coupled to the reservoir inlet.

5. The system of claim 1, wherein the filter is disposed upstream of the reservoir inlet.

6. The system of claim 5, wherein the filter blockage sensor is disposed in a drainage pan located upstream of and coupled to the reservoir inlet.

7. The system of claim 1, further comprising a liquid level sensor disposed in the reservoir downstream of the filter, the pump being activated when the liquid level sensor detects a predetermined liquid level.

8. The system of claim 7, wherein the liquid level sensor senses a second, higher predetermined level of liquid in the reservoir downstream of the filter indicative of a pump abnormality condition.

9. The system of claim 7, wherein the liquid level sensor includes a float coupled to a switch that activates the pump when the float, which is located in the reservoir, reaches the predetermined level.

10. The system of claim 1, wherein the filter blockage sensor includes a float coupled to a switch.

11. The system of claim 1, wherein the filter blockage sensor includes at least one electrode.

12. The system of claim 11, wherein the electrode is adjustably disposed.

13. The system of claim 1, wherein the filter blockage sensor includes at least one infrared level detector.

14. The system of claim 1, wherein the filter blockage sensor includes at least one contact molded onto a wall of the reservoir.

15. The system of claim 1, wherein the filter blockage sensor communicates with a controller utilizing at least one of a dedicated cable, electronic impulses, infrared signal, ultraviolet signal, and fiber optic cable.

16. The system of claim 8, wherein the pump includes an alarm circuit triggered when the second, higher predetermined level of liquid is detected.

17. The system of claim 16, wherein the filter blockage sensor also is connected to the alarm circuit.

18. The system of claim 17, wherein the alarm circuit shuts off the air-handling apparatus and deactivates the pump so as to prevent overheating damage to the pump.

19. The system of claim 17, wherein the alarm circuit generates an audible or visual signal.

20. A mini-split air conditioner comprising the pumping system of claim 1.

21. The system of claim 1, wherein the filter blockage sensor is disposed inside the reservoir, and further comprising:

a drainage pan coupled to the reservoir inlet; and

a drainage pan liquid level sensor disposed in the drainage pan.

22. A condensate liquid removal system comprising:

a reservoir having an inlet and an outlet, the inlet receives liquid generated by an air cooling apparatus; and

a removable filter disposed in the reservoir and that filters the liquid that enters the reservoir, wherein

the reservoir includes a sealable opening by which the removable filter can be installed and removed from the reservoir.

23. The system of claim 22, wherein the filter is comprised of at least one of metal, plastic mesh, a slotted plate, a fiber cartridge and a plastic cartridge.

24. The system of claim 22, wherein the sealable opening is a slot in a wall of the reservoir through which the removable filter is slidable.

25. The system of claim 22, wherein the sealable opening is an end of the reservoir, the system further comprising a removable end cap that sealably fits on the end, the removable end cap having the reservoir inlet and holding the removable filter.

26. The system of claim 22, further comprising a pump coupled to the reservoir outlet to pump liquid out of the reservoir through the outlet.

27. A condensate liquid removal system comprising:

a reservoir having an inlet and an outlet, the inlet receives condensate liquid generated by an air cooling apparatus; and

a filter that is removably attached to the inlet.

28. The system of claim 27, wherein the filter is disposed in a tube that is removably attached to the reservoir inlet by a quick-connect coupling.

29. The system of claim 27, wherein the filter is comprised of at least one of metal, plastic mesh, a slotted plate, a fiber cartridge and a plastic cartridge.

30. The system of claim 27, further comprising a pump coupled to the reservoir outlet to pump liquid out of the reservoir through the outlet.

31. The system of claim 2, wherein the filter blockage sensor is disposed in a drain line connecting the reservoir to a drainage pan that is located upstream of and coupled to the reservoir inlet.

32. The system of claim 4, wherein a second filter blockage sensor is disposed in a drain line connecting the reservoir to the drainage pan.

33. The system of claim 21, wherein a second filter blockage sensor is disposed in a drain line connecting the reservoir to the drainage pan.