Drain Systems and Methods for Heater Assemblies

Abstract

A drain assembly is provided for a heater assembly. The heater assembly has a tankless water heater. The drain assembly includes a stand having a base and a support portion extending from the base. The support portion is configured to be coupled to the tankless water heater. The drain assembly further includes a drain pan provided at the base. The drain pan has an outlet. The drain pan is configured to direct liquid from the tankless water heater to the outlet.

Claims

1. A drain assembly for a heater assembly, the heater assembly comprising a tankless water heater, the drain assembly comprising: a stand comprising a base and a support portion extending from the base, the support portion being configured to be coupled to the tankless water heater; and a drain pan provided at the base, the drain pan having an outlet, wherein the drain pan is configured to direct liquid from the tankless water heater to the outlet.

2. The drain assembly according to claim 1, wherein the drain pan has a first end, a second disposed opposite the first end, and a body extending from the first end to the second end, wherein the outlet is disposed at the second end, and wherein the body is inclined at the first end, with respect to the second end.

3. The drain assembly according to claim 2, wherein the body is inclined at the first end at an angle of between two and fifteen degrees, with respect to the second end.

4. The drain assembly according to claim 3, wherein the outlet comprises a conduit extending from the second end away from the first end.

5. The drain assembly according to claim 4, wherein the drain pan is removably coupled to the base.

6. The drain assembly according to claim 4, wherein the drain pan and the base are a unitary component made from a single piece of material.

7. The drain assembly according to claim 4, further comprising a controller and a leak detection sensor electrically connected to the controller, wherein the controller is associated with the tankless water heater, and wherein the leak detection sensor is configured to detect a leak in the tankless water heater.

8. The drain assembly according to claim 7, wherein the leak detection sensor is disposed on the tankless water heater.

9. The drain assembly according to claim 7, wherein the leak detection sensor is disposed on the drain pan.

10. The drain assembly according to claim 4, wherein the conduit is a pipe made of a material selected from the group consisting of a monomer, a polymer, or a mixture thereof.

11. A heater assembly comprising: a tankless water heater; and a drain assembly comprising: a stand comprising a base and a support portion extending from the base, the support portion being coupled to the tankless water heater, and a drain pan provided at the base, the drain pan having an outlet, wherein the drain pan is configured to direct liquid from the tankless water heater to the outlet.

12. The heater assembly according to claim 11, wherein the tankless water heater is a first tankless water heater, wherein the drain assembly is a first drain assembly, wherein the heater assembly further comprises a second tankless water heater and a second drain assembly each configured and coupled together the same as the first tankless water heater and the first drain assembly, respectively, wherein the first and second tankless water heaters are positioned adjacent one another, and wherein the first and second drain assemblies are positioned adjacent one another.

13. The heater assembly according to claim 12, wherein the drain pan of the first drain assembly and the drain pan of the second drain assembly are a unitary component made from a single piece of material.

14. The heater assembly according to claim 11, wherein the drain pan has a first end, a second disposed opposite the first end, and a body extending from the first end to the second end, wherein the outlet is disposed at the second end, wherein the body is inclined at the first end, with respect to the second end, wherein the tankless water heater is a first tankless water heater, wherein the drain assembly is a first drain assembly, wherein the heater assembly further comprises a second tankless water heater and a second drain assembly each configured and coupled together the same as the first tankless water heater and the first drain assembly, respectively, wherein the first and second tankless water heaters are positioned adjacent one another, and wherein the first and second drain assemblies are positioned adjacent one another.

15. The heater assembly according to claim 14, wherein the body of the first drain assembly is inclined at the first end of the first drain assembly at an angle of between two and fifteen degrees, with respect to the second end of the first drain assembly, and wherein the body of the second drain assembly is inclined at the first end of the second drain assembly at an angle of between two and fifteen degrees, with respect to the second end of the second drain assembly.

16. The heater assembly according to claim 15, wherein the outlet of the first drain assembly comprises a first conduit extending from the second end of the first drain assembly away from the first end of the first drain assembly, wherein the outlet of the second drain assembly comprises a second conduit extending from the second end of the second drain assembly away from the first end of the second drain assembly, and wherein the first and second conduits are disposed parallel to one another.

17. The heater assembly according to claim 11, wherein the drain assembly further comprises a controller and a leak detection sensor electrically connected to the controller, wherein the controller is associated with the tankless water heater, and wherein the leak detection sensor is configured to detect a leak in the tankless water heater.

18. A method of using a drain assembly with a tankless water heater, the method comprising the steps of: providing the tankless water heater; providing the drain assembly with a stand and a drain pan, the stand comprising a base and a support portion extending from the base; positioning the tankless water heater on the support portion; positioning the drain pan at the base of the stand and providing the drain pan with an outlet; and collecting liquid from the tankless water heater at the outlet.

19. The method according to claim 18, wherein the drain assembly further comprises a controller and a leak detection sensor electrically connected to the controller, and wherein the method further comprises the steps of: associating the controller with the tankless water heater; and detecting a leak in the tankless water heater with the leak detection sensor.

20. The method according to claim 19, wherein the drain pan has a first end, a second disposed opposite the first end, and a body extending from the first end to the second end, wherein the outlet is disposed at the second end, wherein the body is inclined at the first end, with respect to the second end, wherein the body is inclined at the first end at an angle of between two and fifteen degrees, with respect to the second end, and wherein the outlet comprises a conduit extending from the second end away from the first end.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0004] The detailed description is set forth with reference to the accompanying drawings. The use of the same reference numerals may indicate similar or identical items. Various embodiments may utilize elements and/or components other than those illustrated in the drawings, and some elements and/or components may not be present in various embodiments.

[0005] Elements and/or components in the figures are not necessarily drawn to scale. Throughout this disclosure, depending on the context, singular and plural terminology may be used interchangeably.

[0006] FIG. 1A is a perspective view of a heater assembly and drain assembly therefor in accordance with one or more embodiments of the present disclosure.

[0007] FIG. 1B is a partial exploded view of the heater assembly and drain assembly therefor of FIG. 1A, shown without the leak detection sensor and the controller, in accordance with one or more embodiments of the present disclosure.

[0008] FIG. 2 is a perspective view of a heater assembly and drain assembly therefor in accordance with one or more embodiments of the present disclosure.

[0009] FIG. 3 is a perspective view of a plurality of heater assemblies and corresponding drain assemblies therefor in accordance with one or more embodiments of the present disclosure.

[0010] FIG. 4 is a schematic view of the heater assembly and drain assembly therefor of FIG. 1A in accordance with one or more embodiments of the present disclosure.

[0011] FIG. 5 is a schematic view of a heater assembly and drain assembly therefor in accordance with one or more embodiments of the present disclosure.

[0012] FIG. 6 is a flow chart corresponding to an example method in accordance with one or more embodiments of the present disclosure.

DETAILED DESCRIPTION

[0013] The systems and methods disclosed herein may assist at least in part in directing liquid (e.g., condensate) away from tankless water heaters that are mounted to a stand or a wall. For example, a heater assembly in accordance with the disclosed embodiments may include a tankless water heater and a drain assembly coupled to the tankless water heater. In some instances, the drain assembly may include a stand having a base and a support portion extending from the base. The support portion may be coupled to the tankless water heater to maintain at least a portion of the tankless water heater above a support surface (e.g., a floor). The drain assembly may further include a drain pan provided at the base of the stand. In this manner, the drain pan may be positioned below at least a portion of the tankless water heater. For example, the drain pan may be disposed about the base adjacent to the support surface (e.g., floor) in order to collect liquid (e.g., condensate) that may drip or otherwise flow from the tankless water heater. The drain pan may include an outlet configured to direct the liquid away from the drain pan and the tankless water heater.

[0014] During use, liquid (e.g., condensation) may be expelled from the tankless water heaters and fall into the drain pan. In some instances, the liquid may be condensate that forms about the tankless water heater and drips down into the drain pan positioned about the base of the stand below the tankless water heater. In other instances, the liquid may be from a leak in the tankless water heater. In certain embodiments, the drain pan may include a lip about a perimeter of the drain pan. The drain pan may also be inclined at a first end with respect to a second end.

[0015] In some instances, the incline may be at an angle of between about two and fifteen degrees. The incline may be any suitable angle. In this manner, liquid which falls from the tankless water heater may be directed by the incline from the first end of the body of the drain pan towards the opposing second end. In some instances, the outlet of the drain pan may be in the form of a conduit (e.g., a PVC pipe or the like) that extends from the second end of the drain pan generally away from the first end of the drain pan and through the lip. The outlet may provide a passageway by which the liquid from the tankless water heater, after having fallen into the drain pan, may be directed away from the drain pan and the tankless water heater.

[0016] In certain embodiments, the drain pan and the base of the stand may be removably coupled to each other. For example, the drain pan and the base of the stand may be removably coupled via coupling members or fasteners, such as nuts, bolts, adhesives, etc.). Any suitable coupling device or system may be used. In another example, the drain pan and the base of the stand may be a unitary component made from a single piece of material (e.g., an injection molded piece).

[0017] Heater assemblies in accordance with the disclosed concept may also be free standing or may be positioned against a wall. In some instances, the heater assemblies may be unitary structures (e.g., one heater assembly positioned in isolation) or include multiple heater assemblies positioned adjacent one another and connected in parallel. In instances with multiple heater assemblies positioned adjacent one another, multiple stands and drain pans may be used to direct liquid away from the heater assemblies.

[0018] In certain embodiments, the drain assemblies in accordance with the disclosed embodiments may include leak detection sensors and controllers. In some instances, the controllers may be located at the tankless water heaters and/or include the controller of the tankless water heaters. The leak detection sensors may be located in or about the drain pans and/or on the tankless water heaters. In certain embodiments, the leak detection sensors may be configured to detect leaks in the tankless water heaters and communicate such information to the controllers, which may communicate with external devices (e.g., mobile devices) in order to alert users of such leaks.

[0019] As employed herein, the term coupled shall mean connected together either directly or via one or more intermediate parts or components. As employed herein, the term number shall mean one or an integer greater than one (i.e., a plurality).

[0020] Turning now to the drawings, FIG. 1A shows a heater assembly 2 and drain assembly 3 therefor in accordance with one or more embodiments of the present disclosure. The example heater assembly 2 may include a tankless water heater 98, such as a tankless water heater manufactured by Rheem Manufacturing Company of Atlanta, Georgia. Any suitable tankless water heater may be used herein. The tankless water heater may employ any suitable heating system to heat water therein. For example, the tankless water heater may utilize a gas heating system, an electric heating element, and/or a heat pump or the like to provide instant hot water. The tankless water heater may be used in residential, commercial, or industrial settings. Any number of tankless water heaters may be used herein.

[0021] Although described as a tankless water heater, in other embodiments, the heater assembly 2 may be any suitable heater assembly or combination of heater assemblies. For example, the heater assembly 2 may be a tank-based water heater or the like, which utilizes a gas heating system, an electric heating element, and/or a heat pump or the like to provide heated water. More so, although described as heating water, the heater assembly 2 may be configured to heat any liquid depending on the application.

[0022] The drain assembly 3 may include a stand 10 and a drain pan 60 having an outlet 68. The drain pan 60 may be made of metallic materials, monomeric materials, polymeric materials, or materials that are a mixture of a monomer and a polymer. The drain pan 60 may be any suitable material. In some instances, the stand 10 may be formed of metal, and the drain pain 60 may be plastic. As will be discussed below, the drain pan 60 is configured to direct liquid from the tankless water heater 98 to the outlet 68. In this manner, liquid from the tankless water heater 98 is advantageously able to be directed in a controlled manner.

[0023] Continuing to refer to FIG. 1A, the stand 10 may include a base 20 and a support portion 30 extending from the base 20. In some instances, the base 20 may be disposed on a support surface (e.g., a floor or the ground), and the support portion 30 may extend generally upward from the base 20. In one example, the support portion 30 may be coupled to the tankless water heater 98 via coupling members (e.g., screws, bolts, fasteners, etc.) so as to position the tankless water heater 98 above the support surface (e.g., the floor). For example, the support portion 30 may include a pair of opposing/parallel legs 32,34 and a number of lateral struts (e.g., one example strut 36 is shown in FIG. 1A) extending between and being located substantially or entirely perpendicular to the legs 32,34. It will, however, also be appreciated that the tankless water heater 98 may be coupled to the support portion 30 or a suitable alternative support portion via alternative mechanisms including tongue and groove connections, separate straps extending through or around the tankless water heater 98 and the support portion 30, and the like.

[0024] FIG. 1B depicts a partial exploded view of the heater assembly 2 of FIG. 1A. As depicted, the base 20 of the stand 10 may include a first base assembly 21 and a second base assembly 22 each coupled to a corresponding one of the first and second legs 32,34. For ease of illustration and economy of disclosure, only the first base assembly 21 will be discussed in detail, although it will be appreciated that the first and second base assemblies 21,22 can be structured the same. As shown in FIG. 1B, the first base assembly may include a first base member 23 and second/third base members 24,26 each extending from and coupling the first base member 23 to the leg 32. The first, second, and third base members 23,24,26 may each be planar members (e.g., metal or plastic bars or the like). The second/third base members 24,26 may act as support structures for maintaining the leg 32 in a generally upright orientation relative to the first base member 23, which may be positioned on the surface and be generally perpendicular to the leg 32. For example, in one embodiment, the leg 32 is located perpendicular to the first base member 23 such that the leg 32 and the first base member 23 form a T-shaped junction of the stand 10.

[0025] In certain embodiments, as depicted in FIG. 2B, the leg 32 may include a thru hole that is configured to receive a coupling member (e.g., bolt 28) therethrough in order to removably couple the drain pan 60 to the base 20. In other words, the bolt 28 extends through the leg 32 and the drain pan 60 and removably couples the two components together via a nut 29. In this manner, the drain pan 60 may quickly and easily be removed from the base 20 for cleaning and/or during transport of the drain assembly 3. However, in suitable alternative arrangements, other mechanisms for coupling the legs 32,34 drain pan 60 and/or to the first and second base assemblies 21,22, or the first and second base assemblies 21,22 to drain pan 60, may be provided.

[0026] Continuing to refer to FIGS. 1A and 1B, the drain pan 60 may have a first end 62, a second end 64 located opposite the first end 62, and a body 66 extending from the first end 62 to the second end 64. Additionally, as depicted, the outlet 68 is located at the second end 64, and the body 66 is inclined at the first end 62 with respect to the second end 64. In addition, the drain pan 60 may include a lip 63 about a perimeter of the drain pan 60. The lip 63 may extend upward from the body 66. The outlet 68 may pass through the lip 63. As such, liquid from the tankless water heater 98 that is captured by the drain pan 60 can advantageously be directed down the incline of the body 66 between the lip 63 toward the outlet 68, where it can then be collected in an efficient manner. In some instances, the outlet 68 may be in fluid communication with a drain or the like via one or more conduits.

[0027] In certain embodiments, as depicted in FIG. 1B, the body 66 may be inclined at the first end 62 at an angleof between about two and fifteen degrees with respect to the second end 64 (e.g., the body 66 is parallel to a top edge 67 of the drain pan 60 extending between the first and second ends 62,64). Furthermore, the outlet 68 may be in the form of a conduit 68 extending from the second end 64 away from the first end 62. The conduit 68, in one example, is a pipe made of a monomeric material, a polymeric material, or a mixture thereof (e.g., polyvinylchloride) and may optionally be integrally formed with the rest of the drain pan 60 such that the drain pan 60 is a unitary component made from a single piece of material.

[0028] In certain embodiments, the disassembled stand 10 may fit within the body 66 of the drain pan 60. That is, the legs 32,34, the first and second base assemblies 21, 22, and the first, second, and third base members 24,26 (as well as any additional struts or the like) may fit within the body 66 of the drain pan 60. This may be advantageous for packaging, storage, and shipping purposes.

[0029] FIG. 2 shows another heater assembly 102 and drain assembly 103 therefor in accordance with one or more embodiments of the present disclosure. As depicted in FIG. 2, the drain pan 160 and the base 120 are a unitary component made from a single piece of material (e.g., an injection-molded piece). In some instances, the drain pan 160 forms the base 120 (i.e., the drain pan 160 and base 120 are one in the same) such that the first and second legs 32,34 may be attached to and extend up from the drain pan 160. In this manner, assembly of the drain assembly 103 may be simplified.

[0030] In addition to the embodiments of FIGS. 1A-2, which provide for freestanding heater assemblies 2,102 (e.g., those that need not be leaned up against or coupled to a wall), it is also contemplated that heater assemblies in accordance with one or more embodiments of the present disclosure may be mounted to a wall. See FIG. 3, for example, which shows a plurality of heater assemblies 202,302,402 mounted to a wall 200. The heater assemblies 202,302,402 may be mounted, e.g., coupled, to the wall 200 via coupling members (e.g., screws, bolts, straps, and the like). In the example of FIG. 3, all of the heater assemblies 202,302,402 are structured the same, although only the heater assembly 402 will be described in detail for ease of illustration and economy of disclosure. In other embodiments, the heater assemblies 202,302,402 may all be different styles and types of heater assemblies. For example, the heater assemblies 202,302,402 may all be tankless, tank-based, or a combination thereof.

[0031] As shown, the drain pan 460 may include a first end 462 pressed up against and abutting the wall 200, a second end 464 located opposite the first end 462, and a body 466 (e.g., is structured similar to the drain pan 60 (FIG. 1A)). The body 466 may be surrounded by a lip 470. In some instances, the first end 462 may be coupled to the wall 200 via screws, fasteners, or the like or alternatively may be disposed against the wall 200 without being coupled thereto. Additionally, the leg 432 may be coupled to the first base member 423 via a second base member 426 such that the leg 432 and the first base member 423 form an L-shaped junction that is pressed up against the wall 200. In this manner, the heater assemblies 202,302,402 may be configured to be mounted to the wall 200 by having the first ends of the drain pans 260,360,460 extend between legs 432 of the stands (e.g., as compared to the drain pan 60 of FIGS. 1A and 1B wherein a middle of the drain pan 60 extends between the legs 32,34) and by having the leg 432 and the base member 423 form an L-shaped junction (e.g., in order to be mounted against the wall 200, and as compared to the T-shaped junction of the free standing heater assembly 2 of FIG. 1A).

[0032] Accordingly, the heater assemblies 202,302,402 in accordance with the disclosed concept may be located against a wall 200. Moreover, as depicted, the tankless water heaters 298,398,498 of the heater assemblies 202,302,402 may be positioned adjacent one another, and the drain assemblies therefor may be positioned adjacent one another. In other words, heater assemblies 202,302,402 may be aligned the same (e.g., may have similar components facing the same direction) and, in one example, may engage one another. It is also contemplated that the drain pans 260,360,460 of the adjacent drain assemblies may be unitary components made from single pieces of material (e.g., a single injection molded piece comprising the three drain pans 260,360,460). Moreover, the outlets (e.g., the conduits 268,368,468) of the drain pans 260,360,460 may be located parallel to one another. In this manner, liquid from the tankless water heaters 298,398,498 may be collected in a relatively streamlined manner.

[0033] In certain embodiments, the outlet 468 is located at the second end 464, and the body 466 is inclined at the first end 462 with respect to the second end 464. In addition, the drain pan 460 may include the lip 470 about a perimeter of the drain pan 460. The lip 470 may extend upward from the body 466. The outlet 468 may pass through the lip 470. As such, liquid from the tankless water heater 498 that is captured by the drain pan 460 can advantageously be directed down the incline of the body 466 between the lip 470 toward the outlet 468, where it can then be collected in an efficient manner. In some instances, the outlet 468 may be in fluid communication with a drain or the like via one or more conduits. For example, all of the outlets may direct fluid to the same drain via the same or interconnected conduits.

[0034] FIG. 4 shows a simplified view of the heater assembly 2 and drain assembly 3 therefor of FIGS. 1A and 1B. As depicted in FIG. 4, the drain assembly 3 may include a controller 90 and a leak detection sensor 92 electrically (e.g., wired or wirelessly) connected to the controller 90. The controller 90 may be commercially available general-purpose controller. Additionally, the controller 90 may be associated with the tankless water heater 98, and the leak detection sensor 92 may be configured to detect a leak in the tankless water heater 98 and communicate (e.g., wire or wirelessly) with the controller 90. In the example of FIG. 4, the leak detection sensor 92 is located on, in, and/or about the drain pan 60.

[0035] FIG. 5 shows another example heater assembly 502 and drain assembly 503 therefor in accordance with one or more embodiments of the present disclosure. As depicted in FIG. 5, the leak detection sensor 592 and the controller 590 of the drain assembly 503 are each located on the tankless water heater 598. Accordingly, different arrangements of a controller and leak detection sensor are contemplated herein in order to perform the desired function of detecting leaks in the tankless water heaters 98,598 with the leak detection sensors 92,592 and communicating such detection to external devices (e.g., mobile devices or the like) with the controllers 90,590.

[0036] FIG. 6 shows an example method 600 of using the drain assembly 3 with the tankless water heater 98. The method 600 may include a first step 602 of providing the tankless water heater 98. The method 600 may include a second step 604 of providing the drain assembly 3 with a stand 10 and a drain pan 60. As noted above, the stand 10 may include the base 20 and the support portion 30 extending from the base 20. Additionally, the method 600 may include a third step 606 of positioning the tankless water heater 98 on the support portion 30. For example, the tankless water heater 98 may be attached to the support portion by one or more fasteners or the like. The method 600 may include a fourth step 608 of positioning the drain pan 60 at the base 20 of the stand 10 and providing the drain pan 60 with an outlet 68. In this manner, the drain pan 60 may be disposed beneath the tankless water heater 98. In some instances, the drain pan 60 and the base 20 may be two separate components that are attached to each other. In other instances, the drain pan 60 and the base 20 may be a single unitary structure.

[0037] The method 600 may include a fifth step 610 of collecting liquid from the tankless water heater 98 and disposing of the liquid via the outlet 68. The method 600 may also include additional steps of associating the controller 90,590 with the tankless water heater 98,598 and detecting a leak in the tankless water heater 98,598 with the leak detection sensor 92,592.

[0038] Accordingly, it will be appreciated that the disclosed concept provides for an improved liquid disposal system that is better able to direct liquid away from a tankless water heater.

[0039] It should be apparent that the foregoing relates only to certain embodiments of the present application and that numerous changes and modifications may be made herein by one of ordinary skill in the art without departing from the general spirit and scope of the disclosure.

[0040] Although specific embodiments of the disclosure have been described, numerous other modifications and alternative embodiments are within the scope of the disclosure. For example, any of the functionality described with respect to a particular device or component may be performed by another device or component. Further, while specific device characteristics have been described, embodiments of the disclosure may relate to numerous other device characteristics. Further, although embodiments have been described in language specific to structural features and/or methodological acts, it is to be understood that the disclosure is not necessarily limited to the specific features or acts described. Rather, the specific features and acts are disclosed as illustrative forms of implementing the embodiments. Conditional language, such as, among others, can, could, might, or may unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments could include, while other embodiments may not include, certain features, elements, and/or steps. Thus, such conditional language is not generally intended to imply that features, elements, and/or steps are in any way required for one or more embodiments.