Multi-position condensation kit and bracket
11725888 · 2023-08-15
Assignee
Inventors
Cpc classification
F25D21/14
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F28F17/005
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24F13/222
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F28F17/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24F13/22
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A mounting bracket for mounting a condensate trap to a heating, venting, and air conditioning (HVAC) system that can be mounted in multiple orientations such that the condensate trap receives condensate fed by gravity.
Claims
1. A mounting bracket configured to mount a condensate trap to a heating, ventilating, and air conditioning (HVAC) system, wherein the condensate trap is configured to mount to the HVAC system in multiple orientations relative to the HVAC system and to receive a flow of condensate into an inner cavity of the condensate trap induced by gravity in each orientation of the multiple orientations, wherein the inner cavity is configured to retain condensate from the HVAC system independently of the mounting bracket, and wherein the mounting bracket comprises: a mounting portion comprising a first flat surface; and a unit mounting portion comprising a second flat surface extending cross-wise to the first flat surface, wherein the unit mounting portion comprises a through hole, the mounting bracket is configured to be mounted to a surface of the HVAC system via a fitting extending through the through hole and coupled to a condensate outlet of the HVAC system, and the fitting is configured to direct the flow of condensate from the condensate outlet of the HVAC system to the inner cavity of the condensate trap.
2. The mounting bracket of claim 1, wherein the first flat surface is a condensate trap mounting surface, wherein the mounting portion comprises a mounting receiving portion configured to receive a fastener to mount the condensate trap to the condensate trap mounting surface and wherein the second flat surface is a unit mounting surface that is substantially perpendicular to the condensate trap mounting surface, wherein the unit mounting surface is configured to abut the surface of the HVAC system when the unit mounting portion is mounted to the HVAC system.
3. The mounting bracket of claim 2, wherein the unit mounting surface defines the through hole, wherein the through hole of the unit mounting portion is configured to receive a threaded portion of the fitting, wherein the mounting bracket is configured to mount to the HVAC system via the threaded portion of the fitting extending through the through hole and threading into receiving threads at the condensate outlet of the HVAC system.
4. A kit for managing condensate of a heating, ventilating, and air conditioning (HVAC) system, comprising: a condensate trap having an inlet port formed in a surface of the condensate trap and an outlet port formed in an additional surface of the condensate trap, wherein the inlet port and the outlet port are in fluid communication with a cavity within the condensate trap, wherein the condensate trap is configured to retain a volume of the condensate received from the HVAC system; a mounting bracket comprising: a mounting portion with a condensate trap mounting surface configured to have the condensate trap mounted thereto, wherein the condensate trap mounting surface is a first flat surface; and a unit mounting portion having a unit mounting surface that is substantially perpendicular to the condensate trap mounting surface, wherein the unit mounting surface is a second flat surface, and wherein the cavity of the condensate trap is defined by the condensate trap independent of the mounting bracket; and a conduit configured to create a fluid communication path between the inlet port of the condensate trap and an outlet of the HVAC system, wherein the condensate trap is configured to be installed in a vertical orientation with the outlet port of the condensate trap facing a downward direction with respect to gravity and the inlet port of the condensate trap facing an upward direction with respect to gravity in a first configuration of the kit with the HVAC system and in a second configuration of the kit with the HVAC system, wherein the HVAC system is oriented vertically in the first configuration of the kit, and the HVAC system is oriented horizontally in the second configuration of the kit.
5. The kit of claim 4, wherein the conduit comprises: a straight fitting having a threaded portion configured to be threaded into the outlet of the HVAC system; and a tube configured to be affixed to the straight fitting at a first end of the tube and to the inlet port of the condensate trap at a second end of the tube in the second configuration of the kit.
6. The kit of claim 5, further comprising: a bent fitting having an additional threaded portion configured to be threaded into the outlet of the HVAC system and forming a bent passage, wherein the tube is configured to be affixed to the bent fitting at the first end and to the inlet port of the condensate trap at the second end in the first configuration of the kit.
7. The kit of claim 6, wherein the bent fitting is configured to be threaded into the outlet of the HVAC system in the first configuration of the kit.
8. The kit of claim 5, wherein the unit mounting portion of the mounting bracket includes a through hole, wherein the mounting bracket is configured to be mounted to a first surface of the HVAC system by passing the threaded portion of the straight fitting through the through hole and threading the straight fitting into the outlet of the HVAC system.
9. The kit of claim 4, further comprising: first instructions to mount the condensate trap directly to a first surface of the HVAC system in the first configuration of the kit; and second instructions to mount the condensate trap to the first surface of the HVAC system via the mounting bracket in the second configuration of the kit.
10. The kit of claim 9, wherein the second instructions further comprise instructions to mount the unit mounting portion of the mounting bracket to the first surface of the HVAC system and to mount the condensate trap to the condensate trap mounting surface of the mounting bracket in the second configuration of the kit with the HVAC system.
11. The kit of claim 9, wherein the first instructions further comprise instructions to connect the outlet of the HVAC system to the inlet port of the condensate trap via a bent fitting in the first configuration of the kit; and wherein the second instructions further comprise instructions to connect the outlet of the HVAC system to the inlet port of the condensate trap via a straight fitting in the second configuration of the kit.
12. The kit of claim 4, further comprising: a fastener configured to pass through a first hole of the condensate trap and into a second hole of the condensate trap mounting surface of the mounting portion of the mounting bracket to affix the condensate trap to the mounting bracket in the second configuration of the kit.
13. The kit of claim 12, wherein the fastener is further configured to pass through the first hole of the condensate trap, through the second hole in the condensate trap mounting surface of the mounting portion of the mounting bracket, and into a third hole in a first surface of the HVAC system to affix the condensate trap to the HVAC system in the second configuration of the kit.
14. A kit for managing condensate of a heating, ventilating, and air conditioning (HVAC) system, comprising: a condensate trap having an inlet port formed in a surface of the condensate trap and an outlet port formed in an additional surface of the condensate trap, wherein the inlet port and the outlet port are in fluid communication with a cavity within the condensate trap, wherein the condensate trap is configured to retain a volume of the condensate received from the HVAC system, wherein the inlet port faces an upward direction with respect to gravity and the outlet port faces a downward direction with respect to gravity in each mounted orientation of a plurality of mounted orientations of the condensate trap with the HVAC system; a mounting bracket having a mounting portion with a condensate trap mounting surface configured to have the condensate trap mounted thereto, and a unit mounting portion having a unit mounting surface that is substantially perpendicular to the condensate trap mounting surface, wherein the condensate trap mounting surface is a flat surface, wherein the cavity is defined by the condensate trap independently of the mounting bracket; and a fitting having a threaded portion configured to be threaded into an outlet of the HVAC system, wherein the fitting is configured to provide a communication path between the inlet port of the condensate trap and the outlet of the HVAC system.
15. The kit of claim 14, further comprising: an instruction sheet comprising first instructions to mount the condensate trap directly to a first surface of the HVAC system in a first configuration of the kit with the HVAC system, wherein the HVAC system is in a vertical orientation in the first configuration of the kit, and second instructions to mount the condensate trap to the condensate trap mounting surface of the mounting bracket and to mount the unit mounting portion of the mounting bracket to the first surface of the HVAC system in a second configuration of the kit with the HVAC system, wherein the HVAC system is in a horizontal orientation in the second configuration of the kit.
16. The kit of claim 14, wherein the fitting is a straight fitting, wherein the unit mounting portion of the mounting bracket includes a through hole, wherein the mounting bracket is configured to be mounted to a first surface of the HVAC system by passing the threaded portion of the straight fitting through the through hole and threading the straight fitting into the outlet of the HVAC system with the HVAC system in a horizontal orientation.
17. The kit of claim 14, wherein the fitting is a bent fitting having a threaded portion configured to be threaded into the outlet of the HVAC system and forming a bent passage, and wherein the condensate trap is configured to be mounted directly to a first surface of the HVAC system by threading the bent fitting into the outlet of the HVAC system with the HVAC system in a vertical orientation.
18. The kit of claim 14, further comprising: a tube configured to connect to the fitting at a first end of the tube and to the inlet port of the condensate trap at a second end of the tube to provide fluid communication between the outlet of the HVAC system and the inlet port of the condensate trap.
19. A mounting bracket configured to mount a condensate trap to a heating, ventilating, and air conditioning (HVAC) system, comprising: a mounting portion comprising a first flat surface defining a condensate trap mounting surface, wherein the mounting portion comprises a mounting receiving portion for receiving a fastener therethrough to mount the condensate trap to the condensate trap mounting surface; and a unit mounting portion comprising a second flat surface defining a unit mounting surface that is substantially perpendicular to the condensate trap mounting surface, wherein the unit mounting surface is configured to abut a surface of the HVAC system and extend substantially parallel with the surface of the HVAC system to mount the unit mounting portion to the HVAC system, wherein the condensate trap is configured to mount to the HVAC system in a vertical orientation of the HVAC system and in a horizontal orientation of the HVAC system, and wherein the condensate trap is configured to receive a flow of condensate induced by gravity in the vertical orientation of the HVAC system and the horizontal orientation of the HVAC system wherein the unit mounting surface defines a through hole, wherein the through hole is configured to receive a threaded portion of a fitting, wherein the mounting bracket is configured to mount to the HVAC system via the threaded portion of the fitting extending through the through hole and threading the threaded portion of the fitting into receiving threads of a condensate outlet of the HVAC system.
20. The mounting bracket of claim 19, wherein the unit mounting portion comprises a cut-out formed in an edge of the unit mounting portion.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The features believed to be characteristic of aspects of the disclosure are set forth in the appended claims. In the description that follows, like parts are marked throughout the specification and drawings with the same numerals, respectively. The drawing figures are not necessarily drawn to scale and certain figures may be shown in exaggerated or generalized form in the interest of clarity and conciseness. The disclosure itself, however, as well as a preferred mode of use, further objects and advantages thereof, will be best understood by reference to the following detailed description of illustrative aspects of the disclosure when read in conjunction with the accompanying drawings, wherein:
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DETAILED DESCRIPTION
(7) The following includes definitions of selected terms employed herein. The definitions include various examples and/or forms of components that fall within the scope of a term and that may be used for implementation. The examples are not intended to be limiting. Further, it will be obvious to one skilled in the art that the present invention may be practiced without these specific details. In other instances, well-known methods, procedures, and components have not been described in detail so as to not unnecessarily obscure aspects of the present invention.
(8) Throughout the disclosure the term substantially may be used as a modifier for a geometric relationship between elements or for the shape of an element or component. While the term substantially is not limited to a specific variation and may cover any variation that is understood by one of ordinary skill in the art to be an acceptable variation, some examples are provided as follows. In one example, the term substantially may include a variation of less than 10% of the dimension of the object or component. In another example, the term substantially may include a variation of less than 5% of the object or component. If substantially is used to define the angular relationship of one element to another element, one non-limiting example of the term substantially may include a variation of 5 degrees or less. These examples are not intended to be limiting and may be increased or decreased based on the understanding of acceptable limits to one of ordinary skill in the art.
(9) For purposes of the disclosure, directional terms are expressed generally with relation to a standard frame of reference when the system and apparatus described herein is installed and in an in-use orientation.
(10) In order to provide context to the current disclosure, a broad overview of the discovered deficiencies of various systems and an example implementation of the current disclosure and the advantages provided by the disclosure are described below. Further details of example implementations of the current disclosure are described detail with reference to the figures below.
(11) Heating, ventilating and air conditioning (HVAC) systems often include a furnace and heat exchanger to heat the air circulated by the system. As air flows through the system, condensation can form. Further, in some HVAC systems, water may condense from the flue gas within the heat exchanger and may be collected in a condensate pan and drained separately from the flue gas. An example HVAC system may be referred to throughout the disclosure. It is noted that while one example may be discussed as an example, the current disclosure may relate to any type of system that provides heating or cooling in a commercial or residential context and requires the removal or drainage of condensation or condensate. Some examples may include one or more of a condensate furnace or high efficiency furnace, a furnace, a gas or electric furnace, a heat exchanger, or an air conditioner. Further, the system disclosed may be usable with any type of system that requires the drainage of condensation or condensate.
(12) A condensate trap may be provided external to the condensate pan and fixed to an external surface of the HVAC system. One example of the disclosed condensate trap allows for fluid flow from the condensate pan to an outlet or drain separate from the system despite pressure changes within the HVAC system. For example, a condensate trap may prevent or slow the intake of air or gas external to the unit, or prevent the blockage of flow of condensate water from the condensate pan to the outlet or drain when the inside of the HVAC system is in vacuum or at a negative pressure with relation to an outside atmosphere. Further a condensate trap may prevent air or gasses from the inside of the HVAC system from escaping to an outside atmosphere. The condensate trap may also prevent blockage of a passage from the condensate pan to the outlet or drain. In a system where gravity provides the force necessary for water or condensate to drain from the condensate pan, the condensate trap may need to be positioned in a certain orientation in order for proper operation of the condensate trap. For example, in order for the condensate trap to properly function, the condensate trap may be required to be oriented vertically (e.g., with the condensate trap intake pointing upwards with respect to gravity and the drain pointing downward with respect to gravity) regardless of the orientation of the HVAC unit.
(13) Some HVAC systems may for example be installed in various orientations or positions due to the design of the system. For example an HVAC system may be installed in an upflow position (with the heated and/or cooled air exiting vertical upwards), a downflow position (with the heated air and/or cooled air exiting vertically downwards), in a horizontal right or left position (with the heated and/or cooled air exiting in a corresponding horizontal direction). These variations may cause challenges when installing a condensate trap onto the HVAC unit.
(14) In order to overcome the aforementioned deficiencies, in one example, the disclosure relates to a condensate management kit and condensate trap bracket that allows an HVAC system to be vertically or horizontally in any one of four configurations—upflow, downflow, horizontal right or horizontal left without the need for additional components or modifications to the HVAC system or condensate trap. The disclosed condensate management kit and/or bracket provide improved efficiency when installing a condensate trap, especially for a technician installing the HVAC system on site. The condensate management kit and bracket further provides for improved simplicity of installation and prevents incorrect installation of the condensate trap when an HVAC system is installed in any one of the aforementioned positions. Other features and advantages will be made apparent from the present specification. The teachings disclosed extend to those embodiments that fall within the scope of the claims, regardless of whether they accomplish one or more of the aforementioned needs.
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(16) As combustion air 72 exchanges heat with supply air 74, a portion of the water vapor in combustion air 72 condenses to a liquid. A resultant liquid condensate 77 emerges from second heat exchanger 55 and falls into a condensate pan 59 and is eventually directed out of the condensing furnace 60 and through the condensate trap described below. Likewise, the uncondensed portion of combustion air 72 emerges from second heat exchanger 55 as exhaust 51 and is removed from furnace 60 by use of an exhaust blower, or inducer, 59 or similar air-moving device through a vent, such as vent pipe 65. Exhaust 52 may include air, water vapor and other combustion products.
(17) Liquid condensate 77 formed in second heat exchanger 55, in addition to water, may contain combustion products and other contaminants that can be acidic and/or corrosive. Thus, in one example, the second heat exchanger 55 and the areas in which the liquid condensate 77 forms and flows can be fabricated using corrosion resistant materials such as stainless steel or other heat resistant, corrosion resistant materials, such as plastic or fiberglass.
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(19) As shown in
(20) As shown in
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(22) The bracket 200 may further include a unit mounting portion 205 that may for example form a flat surface that is substantially perpendicular or perpendicular to the flat mounting portion 203. The unit mounting portion 204 may for example include a first opening 209 and a cut-out 212. The first opening 209 may for example be dimensioned so that threads 108 (
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(24) The condensate trap 100 may further include mounting features 101a and 101b that may be through holes configured to receive fasteners (e.g., 111a and 111b in
(25) The components and aspects mentioned throughout may be included as individual components of a kit that is provided for installation of an HVAC system. As noted above, the kit may further include instructions describing the installation of the components described above and providing instructions on how to install the components described above when the system is installed on an HVAC system to be installed in a vertical orientation and instructions on how to install the components described above when the system is installed on an HVAC system that is to be oriented in a horizontal orientation. For example, when the HVAC system is installed in the vertical orientation (e.g., as shown in
(26) The foregoing description of various aspects and examples have been presented for purposes of illustration and description. It is not intended to be exhaustive nor to limit the disclosure to the forms described. The embodiment(s) illustrated in the figures can, in some instances, be understood to be shown to scale for illustrative purposes. Numerous modifications are possible in light of the above teachings, including a combination of the abovementioned aspects. Some of those modifications have been discussed and others will be understood by those skilled in the art. The various aspects were chosen and described in order to best illustrate the principles of the present disclosure and various aspects as are suited to the particular use contemplated. The scope of the present disclosure is, of course, not limited to the examples or aspects set forth herein, but can be employed in any number of applications and equivalent devices by those of ordinary skill in the art. Rather, it is hereby intended the scope be defined by the claims appended hereto.