Patent Application
20080142525
This invention relates to a one step designed emergency drain pan which catches condensate overflow from an HVAC air handler. It also can be used as a pan for heat pump condensing units that are in concrete court yards or platforms that utilize the space below them for storage. Many owners in southern states in the United States do not like water buildup on their concrete which causes algae growth. Also, these owners do not like water dripping on their storage under the condensing units when they are elevated.
As to the pan being utilized as an air handler emergency drain pan, wherein it allows for the installing dealers to have a one step, one product pan assembly. With standard installation practices, a galvanized pan is set onto plywood or a stand is built of wood to give the unit a little elevation. After the pan is set, the installer has to cut treated 2×4 wood planks the length of the pan, stack two together and nail, and then make one more set and place in the pan. Then the installer sets four rubber vibration isolators on the 2×4's and in turn sets the air handler. Another method is to use foam blocks placed in the pan which take place of the wood. The drain line exiting the galvanized pan has no pitch if placed on the rafters, or the installer has to build a platform to get elevation. One other method is to hang the air handler from a cradle made of threaded rods, 2×4's and angle iron. Once again, the installer has to cut wood to support the secondary drain pan and air handler and continue using previous described methods to set the air handler. The plastic molded drain pan has an elevated bottom and a pitched bottom panel with for example 4.5″ support risers extending upward to allow a level unit. The pitch of the panels ensures no standing water beneath the unit. The older style design using galvanized pans causes about 3-5 gallons of water to sit under the unit as it drains. This in turn causes algae growth, rust and potential problems for a service technician trying to remove the water with vacuums or other means of removal. One type of secondary drain pan is shown in U.S. Pat. No. 6,895,770 to Kaminski filed on Sep. 24, 2003 and issued on May 24, 2005, the disclosure of which is hereby incorporated herein by reference.
The present invention allows for easier installation of air handling equipment, a durable long life design, and greater peace of mind for home owners. Because of the one piece design made of injection molded plastic material, the pan has a longer life span than a galvanized pan. Molded plastic also allows for noise reduction transmitting into the structure without using rubber vibration pads. The sloped bottom panel ensures condensate water drains to its lowest place in the pan. At that position, which is in the front middle portion of the pan, water funnels down into the threaded hole which accommodates standard pvc fittings. The threaded hole is designed into a block of plastic below the front edge of the pan. This allows for improved strength so that if someone applies too much pressure to the drain line, the pvc will break and not the side of the pan. A channel leads from the bottom panel down into the block, thus allowing no water to stand at its connection. The four risers built into the pan allow the air handler or condensing unit to sit level above the base support and sloped bottom panel. A four inch base, which is accommodating the solid plastic block for the pvc connection, is made under the bottom panel. The base has perpendicular and parallel ribs running from side to side giving support. Solid blocks are at each line parallel with the four risers allowing a threaded connection to be made accommodating a bolt such as a ½″ bolt. These connections allow for “L” shaped brackets to be installed in front and back panels to hang the pan.
Other objects and features of the present invention will become apparent from the following detailed description considered in connection with the accompanying drawings. It should be understood, however, that the drawings are designed for the purpose of illustration only and not as a definition of the limits of the invention.
In the drawings, wherein similar reference characters denote similar elements throughout the several views:
Referring in detail to the drawings,
In addition, there are also a plurality of panels 15, including a first panel 15a, a second panel 15b and a third panel 15c. These panels 15 extend at different angles relative to each other. Extending up from these panels are a plurality of risers 14 wherein these risers 14 allow unit to sit level in this pan 1. These panels 15a 15b and 15c are all angled so that they allow water to flow down through the pan to outlet channel 16 and on to female threaded connection 4. For example, panel 15a is angled at least 1 degree down from back lip 13 to front lip 3. In addition, panel 15b is angled at least 1 degree down from a side lip 23 to angled connection region 24. Similarly, panel 15c is angled at least 1 degree down from side lip 33 to angled connection region 34. These different angled panels, cause the funneling of the water into channel 16, that allows water to drain unimpeded through to threaded connection 4.
These risers 14 are also positioned so that they extend up from the sloped panels 15 to support elements above the pan 1. In that way, an element or device can be stacked on top so that it would sit level on these risers 14.
Accordingly, while a few embodiments of the present invention have been shown and described, it is to be understood that many changes and modifications may be made thereunto without departing from the spirit and scope of the invention as defined in the appended claims.
