PORTABLE AIR CONDITIONER CONDENSATE HANDLING ASSEMBLY
A condensate overflow handling apparatus having a condensate drain reservoir housing positioned at a first elevation. The reservoir housing has an inlet that is adapted to be fluidly connected to at least one drain pan of an air cooling appliance positioned at a second elevation above the reservoir housing. A fluid level sensor is mounted to the reservoir housing for sensing a fluid level within the reservoir housing which activates a pump to pump fluid from the reservoir housing through an exit conduit into a discharge assembly. The discharge assembly comprises at least one discharge hose and a stepped expansion fitting mounted to the at least one discharge hose.
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STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENTNot applicable.
REFERENCE TO SEQUENCE LISTING, A TABLE OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIXNone.
BACKGROUND OF THE INVENTION 1. Field of InventionThe present invention relates to a condensate overflow handling apparatus for use with a portable air conditioning device, heat pump or dehumidifier and includes a kit providing a condensate overflow assembly which can be attached to a preexisting condensate pan or pans on an air conditioning device, heat pump or dehumidifier to discharge condensate to a remote location.
2. Description of the Prior ArtAn air cooling appliance such as a portable air conditioner, heat pump or dehumidifier is generally provided with heat exchange coils that produce condensate taken from the surrounding atmosphere. This condensate collects in a drain pan or pans of the appliance as the device cools the air in the room or space around the device. Condensate in the form of water drops are formed on the surface of an evaporator during heat exchange between the room air and the refrigerant at the evaporator because the surface temperature of the evaporator is very low compared to the room temperature with the evaporator cooling down the room air in contact with the evaporator below the dew point of the air. In humid conditions, the appliance drain pan must be regularly removed and drained as water in excess of a gallon a day may be generated in areas having moderate to high humidity. Prior art cooling devices require constant maintenance and checking to make sure that the drain pan does not overflow causing damage to the dry walls, the wood framing, floors and the ceilings beneath the floors of the building in addition to the carpeting, tiling and furniture. Sometimes in the case of condensate spillage, water may go unnoticed for days. As will be appreciated, the overflowing water may cause considerable property damage or cause an electrical short. Furthermore, when the drain pan of the appliance is connected to a pump and drain line for removing the collected liquid and depositing the same in a sump pump or outside the building, blockage can occur in the drain line and in winter the outside connection to the drain line can freeze causing the drain line to crack or break allowing water held therein or pumped there through to pour into the base structure causing damage and a buildup of mold and potentially harmful biological organisms.
Many attempts have been used or suggested to solve the aforenoted problems and the prior art has attempted to solve these problems in a number of different ways.
U.S. Pat. No. 5,069,042 issued Dec. 3, 1991 discloses a condensate trap that includes a mechanical switch and a float. When the condensate accumulates in the trap due to a blockage in the discharge line, the float rises with the rising level of the condensate. At a set liquid level height point, the float activates a mechanical switch to shut off the air cooling system to prevent further condensate from being produced.
U.S. Pat. No. 5,522,229 issued Jun. 4, 1996 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.
U.S. Pat. No. 6,976,367 issued Dec. 20, 2005 discloses a condensate overflow prevention assembly for an air cooling system using a fluid level sensor and a pump activated by the fluid level sensor to pump the condensate away from a drainage system when a blockage occurs in the drainage system.
There is a need for a means to extract condensate (water) from small portable air conditioners, dehumidifiers and heat pumps that are used to regulate temperature or humidity in small indoor areas. There are presently no condensate pump assemblies designed to deal with the special demands encountered by these small units placed in the odd environments that they are commonly utilized in.
The teachings of the prior art do not aid in the resolution of a number of practical difficulties that are resolved by the present invention. Furthermore, the prior art did not contemplate portable air conditioners which can be wheeled around to various areas of the structure being cooled. Therefore, there is a need for an assembly that will prevent condensate overflows and can be economically installed. There is also a need for the exterior drain lines leading to the outside be constructed to prevent the line from freezing.
Therefore, the present condensate collection and disposal assembly allows the use of a local space cooling air conditioner or a small sized portable air conditioner which is convenient and simple in installation and utility.
SUMMARY OF THE INVENTIONMany of the above described prior art devices switch off the air cooling system and/or activate an alarm when a condensate level in the drain pan rises due to a blockage in the drain line or the drain pan. However, simple notice of a product problem does not prevent the air cooling device from producing additional condensate and eventually the rising condensate will overflow from the drain pan causing water damage.
The present invention provides an advantage in that the inventive assembly can be sold as an accompanying kit for a new air conditioner unit, heat pump or dehumidifier. Another advantage includes the capability of installing the inventive assembly with previously installed existing air conditioner units.
It is an object of the invention to provide an assembly for disposing of condensate from a small sized portable air conditioner, humidifier or the like allowing the air conditioner or humidifier to be easily installed and moved to desired locations.
It is another object of the invention to provide an assembly connected to the drain pan of the air treating unit which directs condensate generated by the air treating unit into a pump reservoir and discharges the same away from the inside of the building.
It is still another object of the invention to provide a condensate discharge assembly for air treating units which can be connected to any shape or height reservoir that the air treating unit is provided with and still be able to function.
The inventive condensate discharge assembly includes drainage and disposal lines, a tee connector connecting same, a pump, a condensate reservoir, formed rigid window insulation blocks and flexible insulation strips and a stepped expander pipe.
These and other objects, advantages, and novel features of the present invention will become apparent when considered with the teachings contained in the detailed disclosure along with the accompanying drawings herein.
The present invention will be described with reference to the appended Figures. Further objects and advantages of the invention will become apparent from the following detailed description and the accompanying drawings forming a part thereof in which like reference characters designate like parts throughout the views and wherein:
The preferred embodiments and best mode of the invention is shown in
The present invention is directed toward a condensate overflow prevention apparatus or kit for attachment to an air conditioner appliance, heat pump, humidifier or the like to prevent condensate overflow from the appliance and drainage discharge line freezing.
The condensate handling apparatus 30, as shown in
The terms hose, line and conduit are used interchangeably throughout this specification and refer to the same numbered part.
It should be noted that the hoses, lines or conduits noted above are flexible and can be constructed of clear plastic, opaque plastic, rubber or other suitable material.
Some units that function as an air conditioner use a method to re-evaporate water using the hot coil and then direct the hot humid air out the window or to an associated duct. This system works until conditions become unfavorable (mostly due to high humidity) at which point, the air conditioner cannot keep up with the water that is accumulating and the unit will shut off or overflow. To prevent this from happening, the upper hose 32 is additionally formed with a pee trap 34 which holds air pressure around the upper coil and allows the condensate to run down to the condensate collector housing reservoir 50. A second lower drainage hose or line 36 is mounted to the lower outlet fitting 28 of the lower drain pan with the distal end 38 of hose 36 being mounted into an inlet or fitting 39 of the condensate collection housing container 50. The outlet fitting 39 is shown in
A second bypass hose or line 46 has its distal end 47 mounted to the perpendicular stem 67 of the tee connector 62 and its proximal end 48 is mounted in condensate pump housing 50. The design of the system is thus able to expel water outside of a building or resident without water freezing in a hose or piping system between cycles (in the heat pump or dehumidifier mode). As water is pumped out by the condensate pump 60, it will have substantial momentum. The water will go straight to the outside through hose 72 and fitting 77 and reduce air pressure in hose 46. When the pump 60 stops, check valve 44 will make all water momentum in line or hose 42 stop up to the tee connector 62. The water flowing past the tee connector 62 will continue as it has momentum and air will come from line or hose 46 thus evacuating hose 72 that connects to tee connector end 65 and discharge assembly 70.
The discharge assembly 70 has a flexible conduit or hose 72 with expansion fitting 77 mounted thereto which are wrapped or covered with a cylindrical insulation member 74 which is covered by a fibrous plastic protection cover 76 as is shown in
The discharge assembly 170 has a flexible conduit or hose member 172 and reversed expansion fitting 177 which is wrapped or covered by a cylindrical insulation member 174 which is covered by a fibrous plastic protection cover 176 as is shown in
The window closure assembly 80/180 for both embodiments of the invention is formed of a plurality of different sized foamed flexible foam insulation strips 82 and rigid foam blocks 84, two of which are provided with a cut insert member of flexible foam 86 allowing the slide door member to be held therein. The strips 82 and blocks 84 are glued or fastened together to hold discharge assembly 70 in place as schematically shown in
The blocks 84 and strips 82 are meant to be placed inside the window frame 90 to span the window opening formed by the bottom of the window and sill of the window frame. If it is envisioned that the installation will be for a long period of time and not temporary, the blocks 84 and strips 82 can be fastened together with fast acting epoxy glue or with mechanical fasteners as previously described.
The foam blocks 84 are placed side by side to span the window opening and hold the door member 87 in place. Flexible strips 82 are placed on top of the blocks 84 and cover the top and the bottom of the door member 87 as seen in
Alternatively, as shown in
The design of the assembly is such that it is able to expel water outside a building or residence without water freezing in the discharge assembly 70/170 between cycles. As water is pumped out of the reservoir housing by the condensate pump 60/160, it has substantial momentum. As the water goes through the hose or conduit 42, 142, it passes through the tee connector 62 as shown in
The principles, preferred embodiments and modes of operation of the present invention have been described in the foregoing specification. However, the invention should not be construed as limited to the particular embodiments which have been described above. Instead, the embodiments described here should be regarded as illustrative rather than restrictive. Variations and changes may be made by others without departing from the scope of the present invention as defined by the following claims:
Claims
1. A condensate overflow handling apparatus for air conditioning appliances having at least one drain pan comprising a condensate drain reservoir housing horizontally positioned at a first elevation;
- said reservoir housing having an inlet means that is adapted to be fluidly connected by conduit means to at least one drain pan of said air conditioning appliance positioned at a second elevation, positioned above said reservoir housing;
- a fluid level sensor mounted to said reservoir housing within said reservoir housing, said sensor sensing a predetermined fluid level within said reservoir housing;
- a pump connected to said reservoir housing which is activated by said fluid level sensor to pump fluid from said reservoir housing when said fluid level sensor senses that fluid has reached a predetermined level within said reservoir housing into an exit conduit fluidly connected to said reservoir housing;
- means to selectively drive said pump in response to the activation of said fluid level sensor; and
- a discharge assembly fluidly connected to said exit conduit, said discharge assembly comprising a discharge hose and a stepped expansion fitting mounted to said discharge hose.
2. A condensate overflow handling apparatus as claimed in claim 1 wherein said pump is a diaphragm pump which is electrically driven.
3. A condensate overflow handling apparatus as claimed in claim 1 wherein said reservoir housing has a planar bottom and defines a mounting structure for said pump.
4. A condensate overflow handling apparatus as claimed in claim 1 wherein said discharge assembly includes an insulated cover member and a protective cover surrounding said insulated cover member.
5. A condensate overflow handling apparatus as claimed in claim 1 wherein said exit conduit has a one way check valve mounted therein.
6. A condensate overflow handling apparatus as claimed in claim 1 wherein said discharge assembly comprises a connector mechanism mounted to said discharge hose, a stepped expansion fitting mounted to said discharge hose and insulation means covering said discharge hose and expansion fitting.
7. A condensate overflow handling apparatus as claimed in claim 6 wherein said insulation means comprises an inner cylindrical hollow insulation member and a cylindrical protective cover engaging and positioned around said cylindrical hollow insulated member.
8. A condensate overflow handling apparatus as claimed in claim 6 including a second conduit mounted to said reservoir housing and said connector mechanism.
9. A condensate overflow handling apparatus as claimed in claim 1 wherein said condensate overflow handling apparatus includes a window mounting assembly for said discharge assembly.
10. A condensate overflow handling apparatus as claimed in claim 6 wherein said stepped expansion fitting is a stepped pipe having a larger diameter step chamber downstream from at least one smaller diameter step chamber.
11. A condensate overflow handling apparatus as claimed in claim 9 wherein said window mounting assembly comprises a plurality of flexible strips, a plurality of rigid blocks, at least two of said blocks having a flexible insert portion which holds an exit mechanism, and means to hold said flexible strips, rigid blocks and exit mechanism together.
12. A condensate overflow handling apparatus as claimed in claim 11 wherein said exit mechanism comprises a frame defining an opening and a slidable door mounted on said frame over said opening.
13. A condensate overflow handling apparatus as claimed in claim 11 wherein said rigid blocks are slotted on an exterior surface to present a uniform channel across a window opening and a linear adjustment bar is mounted in said channel with the ends of said linear adjustment bar being mounted to a window frame.
14. A condensate overflow handling apparatus for an air cooling apparatus comprising a condensate drain reservoir housing positioned at a first elevation;
- said reservoir housing having an inlet that is adapted to be fluidly connected to at least one drain pan of said air cooling apparatus positioned at a second elevation, positioned above said reservoir housing;
- a fluid level sensor mounted to said reservoir housing for sensing a fluid level within said reservoir housing;
- a pump connected to said reservoir housing which is activated by said fluid level sensor to pump fluid from said reservoir housing when said fluid level sensor senses that fluid has reached a predetermined level within said reservoir container into a discharge conduit;
- means to selectively drive said pump; and
- a discharge assembly mounted to said discharge conduit comprising at least one discharge hose and a stepped expansion fitting with a throughgoing bore defining a plurality of central chambers of different diameter sizes mounted to said at least one discharge hose.
15. A condensate overflow handling apparatus as claimed in claim 14 including a window mounting assembly, said window mounting assembly comprising a plurality of rigid blocks, a plurality of said blocks having a flexible portion for holding an exit mechanism and a plurality of flexible strips; said blocks, said exit mechanism and said flexible strips being capable of being assembled together to close an open window space.
16. A condensate overflow handling apparatus as claimed in claim 14 including a tee connector member mounted to said discharge conduit with said discharge assembly being mounted to tee connector member opposite said discharge conduit, said discharge assembly comprising a hose member mounted to said tee connector member, insulation means covering said discharge assembly.
17. A condensate overflow handling apparatus as claimed in claim 14 wherein said stepped expansion fitting is a stepped pipe having larger diameter step downstream from at least one smaller diameter step.
18. A kit for discharging condensate fluid from an air treatment device comprising a condensate drain reservoir housing horizontally positioned at a first elevation;
- said reservoir housing having an inlet that is adapted to be fluidly connected to at least one drain pan of said air treatment devices positioned at a second elevation, positioned above said reservoir housing;
- a fluid level sensor mounted to said reservoir housing within said reservoir housing, said sensor sensing a fluid level within said reservoir housing;
- a pump connected to said reservoir housing which is activated by said fluid level sensor to pump fluid from said reservoir housing when said fluid level sensor senses that fluid has reached a predetermined level within said reservoir housing;
- same pump being fluidly connected to an exit conduit;
- a distal end of said exit conduit being mounted to a fluid discharge assembly
- said discharge assembly comprising at least one discharge hose and a stepped expansion fitting having larger diameter chamber downstream from at least one smaller diameter chamber and a window mounting assembly, said window mounting assembly comprising a plurality of rigid blocks, at least two of said blocks being provided with a flexible portion holding an exit mechanism and a plurality of flexible strips, said window mounting assembly being adapted to fit into an open window space of a window frame and hold said discharge assembly.
19. A kit as claimed in claim 18 wherein said discharge assembly comprises an exit discharge hose assembly mounted to a tee connector opposite said exit conduit which is mounted to said tee connector, said exit discharge hose assembly comprising a stepped expansion fitting mounted to said exit discharge hose and insulation means covering said exit discharge assembly.
20. A kit as claimed in claim 18 wherein said rigid blocks are slotted on an exterior surface to present a uniform channel across on opening of a window frame and an adjustment bar is mounted in said channel and engages opposite sides of said window frame.
Type: Application
Filed: Jan 27, 2017
Publication Date: Aug 2, 2018
Inventor: Robert Potorti (Floyds Knobs, IN)
Application Number: 15/418,057