Abstract:
A mounting device for removably supporting an overflow safety switch in operable position within a condensation collecting drain pan in HVACR equipment. The mounting device includes a clip member that is secured to the drain pan side wall and locked in place by a non-penetrating thumb screw. A bracket removably attaches to the overflow safety switch at several adjusted positions and is slidably adjustable on the clip member for adjustably positioning the overflow safety switch relative to a bottom of the drain pan. The overflow safety switch is easily removed from the bracket for adjustment and replacement while the bracket remains fitted to the clip member. Moreover, the bracket is easily removed from the clip member without removing the clip member from the drain pan side wall.

Description:
[0001]    This patent application is a Continuation-In-Part of patent application Ser. No. 14/615,976 filed on Feb. 6, 2015, which is a Continuation-In-Part of patent application Ser. No. 14/451,589 filed on Aug. 5, 2014, which is a Continuation-In-Part of patent application Ser. No. 13/953,948 filed on Jul. 30, 2013, now U.S. Pat. No. 8,967,183 issued on Mar. 3, 2015, which is based on provisional patent application Ser. No. 61/716,238 filed on Oct. 19, 2012. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates generally to overflow safety switches for condensation producing equipment and, more particularly, to a device for installing an overflow safety switch to the side wall of a drain pan in HVACR equipment. 
         [0004]    2. Discussion of the Related Art 
         [0005]    In various systems and equipment, there is a need to transfer and/or drain liquid to another location. For example, in air conditioning and refrigeration systems, condensation naturally occurs as warm, humid air passes over the exterior of the evaporator coil. Typically, the condensation drips from the evaporator coil into a condensate collection pan positioned below the evaporator coil. From the collection pan, the liquid condensate is directed through a drain line that leads to a safe discharge location, such as the exterior of a building. 
         [0006]    Occasionally, problems can occur as a result of a failure in the normal liquid transfer or drainage system. For instance, the primary condensate collection pan in an air conditioner unit, usually made of metal materials, is susceptible to rust and corrosion. This can lead to a leak developing in the primary collection pan, causing water damage to the area below the unit. Additionally, mildew and other microbial growths, combined with dust and other particulate, accumulate in the condensate pool. Over time, this accumulation can eventually cause the drain line to become clogged. When this happens, the continually produced condensate fills within the primary condensate collection pan and eventually overflows. The overflow of condensate from a continuously running HVAC unit can cause extensive and costly damage to the interior of a building or home. This is a common problem that is well known in the industry. 
         [0007]    To prevent overflow of the primary condensate collection pan, most building codes require a safety shut-off switch to be installed in the drain pan. The shut-off switch senses water accumulation in the primary pan and, when the water level reaches a predetermined height that is well below the height of the side walls of the pan, the shut-off switch disables the HVAC system, thereby preventing further condensate accumulation and overflow of the primary pan. A secondary or emergency overflow pan is usually installed below the primary drain pan as an additional precaution and is sized, configured and positioned to catch water that might overflow the primary condensate collection pan. This emergency overflow pan can also be fitted with a shut-off switch and/or a drain line connection. 
         [0008]    In most instances, the overflow safety switch is mounted to the side wall of the drain pan with the use of a metal clip that has a horizontal plate, a vertical plate and an inverted U-shaped portion that is structured and disposed to slip over the top edge of the drain pan and slide down the inner and outer surfaces of the drain pan wall in frictional engagement therewith. A screw is typically used for tightly securing the clip onto the wall of the drain pan. Specifically, a screw passes through the vertical plate of the clip and at least partially into the outer surface of the drain pan wall. The overflow safety switch is attached to the horizontal plate of the mounting clip to support the overflow switch vertically within the drain pan. More particularly, the overflow safety switch has an upper tubular portion or stem that has exterior screw threads. This upper threaded stem is fitted through a circular opening in the horizontal plate and held in place by one or more nuts on the threaded stem. When the clip is installed to the side wall of the drain pan, the overflow safety switch needs to be adjusted to the lowest point in the pan (i.e., the floor of the pan) by threadably manipulating the one or more nuts on the stem. Once the mounting clip is fixed to the side wall of the drain pan, and the overflow switch is in the proper adjusted position, the one or more nuts are tightened against the horizontal plate of the clip to hold the overflow switch in the proper operative position relative to the floor of the drain pan. An example of this type of mounting clip and overflow safety switch arrangement is described and illustrated in Patent Application Publication No. US 2005/0166613 to Oakner et al. 
         [0009]    In many instances, due to the extra work needed for properly adjusting the position of the overflow safety switch relative to the mounting clip and bottom of the drain pan, the installer will simply attach the clip and overflow switch to the side wall of the drain pan with the switch held at a position that is not low enough to sense a rise water level in the drain pan. Thus, the switch is unable to perform its intended function and the rising water level will eventually lead to an overflow of the drain pan. 
         [0010]    Moreover, the manner in which the overflow switch is attached through the circular opening in the horizontal plate requires removal of the entire combined assembly of the mounting clip and overflow switch from the drain pan for purposes of replacement or repair of the overflow switch. Thereafter, installing a new (i.e., replacement) overflow switch on the wall of the drain pan requires another tedious adjusted procedure which, as noted above, is often overlooked. It can therefore be appreciated that the currently and extensively used mounting clip and overflow safety switch arrangement has significant limitations, including the need for time consuming and tedious installation, replacement and adjustment that can result in improper installations that render the overflow switch inoperative and thereby causing drain pan overflows and costly damage. 
         [0011]    Accordingly, there remains a need for an improved mounting device and assembly for easily and efficiently securing an overflow safety switch to the side wall of a condensation collecting drain pan as found in HVACR equipment, and wherein the overflow switch can be easily and quickly adjusted to the proper operative position, and further wherein the overflow switch can be easily removed and replaced without removing the mounting clip from the drain pan. 
       OBJECTS AND ADVANTAGES OF THE INVENTION 
       [0012]    Considering the foregoing, it is a primary object of the present invention to provide a device that allows for fast and easy mounting of an overflow safety switch to the side wall of a condensation collection drain pan without the need to screw into the wall of the pan, and wherein the safety switch can be easily removed and replaced. 
         [0013]    It is a further object of the present invention to provide a device for mounting of an overflow safety switch to the side wall of a drain pan in HVACR equipment, and wherein the device is structured and disposed for allowing fast and easy adjustment of the height of the overflow switch within the drain pan so as to assure proper operative positioning of the overflow switch that will sense water accumulation within the drain pan and disable the HVACR equipment well before an overflow of the drain pan. 
         [0014]    It is still a further object of the present invention to provide a device for mounting an overflow safety switch to the side wall of a drain pan in HVACR equipment and wherein the overflow switch can be easily removed and replaced without removing the mounting device from the side wall of the drain pan. 
         [0015]    It is still a further object of the present invention to provide a device for mounting an overflow safety switch to the side wall of a drain pan in HVACR equipment without the need to screw into the side wall of the drain pan to hold the device in place. 
         [0016]    It is yet a further object of the present invention to provide a device for mounting an overflow safety switch to the side wall of a drain pan in HVACR equipment that allows for fast and easy adjustment of the height of the overflow switch within a variety of drain pans of different depths. 
         [0017]    It is yet a further object of the present invention to provide a device for mounting an overflow safety switch to a side wall of a drain pan in HVACR equipment, and wherein the device easily adapts to varying depth drain pans between 1.5 inches and 3 inches deep to hold a lower end of the overflow switch at the lowest point in the drain pan for optimal function. 
         [0018]    It is still a further object of the present invention to provide a device for mounting an overflow safety switch to the side wall of a drain pan in HVACR equipment and wherein the device includes a clip portion that removably attaches to the side wall with a non-penetrating set screw and further wherein the device includes a bracket that slides within tracks on the clip and adjustably holds the overflow switch. 
         [0019]    It is still a further object of the present invention to provide a device for mounting an overflow safety switch to the side wall of a drain pan in HVACR equipment wherein the bracket of the device includes a C-clip for holding the overflow switch and allowing removal of the overflow switch without removing the bracket from the mounting clip on the wall of the drain pan. 
         [0020]    These and other objects of the present invention are more readily apparent with reference to the detailed description and accompanying drawings. 
       SUMMARY OF THE INVENTION 
       [0021]    The present invention is directed to a device for removably mounting an overflow safety switch to the side wall of a drain pan in HVACR equipment. In one embodiment of the invention, the overflow safety switch is a float switch that has a vertically extending hollow tubular body and a buoyant annual float member that is movable along an outer surface of the tubular body between a lower stop member and an upper stop member. The mounting device of the present invention is structured for supporting the overflow safety switch in a generally vertical and upright position with a bottom end of the hollow tubular body of the float switch positioned in contact with, or just slightly above, the bottom of the drain pan. In the event water from condensation begins to accumulate in the drain pan, as a result of a clog or other obstruction in the drain line system, the buoyant annual float member rises up the hollow tubular body of the switch which causes the switch to close and interrupt operation of the HVACR equipment. 
         [0022]    The overflow safety switch mounting device of the present invention includes a clip member that removably attaches to the side wall of the drain pan and a bracket that removably attaches to the hollow tubular body of the overflow switch at a plurality of adjusted positions. The bracket is slidably received within opposing guide tracks on the clip member for adjustably positioning the overflow safety switch relative to the bottom of the drain pan. The clip member is received over a top edge of the drain pan side wall and engages inner and outer surfaces of the drain pan side wall. A non-penetrating thumb screw (i.e., set screw) is received through an outer downwardly depending leg of the clip member for engagement with the outer surface of the drain pan side wall to effectively lock the mounting device in fixed position on the side wall of the drain pan. 
         [0023]    The structure of the mounting device of the present invention allows the overflow safety switch and bracket to be easily removed from the clip member without removing the clip member from the side wall of the drain pan. Moreover, the overflow safety switch can be easily removed from the bracket without removing the bracket from the clip member. This allows for adjustable positioning of the overflow safety switch relative to the bracket, as well as the bottom of the drain pan. Further, the ability to easily remove the overflow safety switch from the bracket allows for easy replacement of the overflow safety switch without removing the bracket or clip member from the drain pan. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0024]    For a fuller understanding of the nature of the present invention, reference should be made to the following detailed description taken in conjunction with the accompanying drawings in which: 
           [0025]      FIG. 1  is an exploded perspective view showing an overflow safety switch separated from the mounting device which includes a bracket and a clip member; 
           [0026]      FIG. 2  is a perspective view showing the overflow safety switch attached to the bracket with the bracket received within opposing guide tracks of the clip member; 
           [0027]      FIG. 3  is a side elevational view showing the overflow safety switch attached to the bracket with the bracket received within the opposite guide tracks of the clip member and a thumb screw separated from the clip member; 
           [0028]      FIG. 4  is an isolated side elevational view, in partial cross-section, showing the mounting device of the present invention supporting the overflow safety switch in a correct operable position relative to the bottom of the drain pan, with no water accumulation in the drain pan; and 
           [0029]      FIG. 5  is an isolated side elevational view, shown in partial cross-section, showing the mounting device holding the overflow safety switch in the same operable position as seen in  FIG. 4 , and wherein water has accumulated within the drain pan to cause the buoyant annular float member of the overflow safety switch to rise and operate the switch, thereby interrupting operation of HVACR equipment. 
       
    
    
       [0030]    Like reference numerals refer to like referenced parts throughout the several views of the drawings. 
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0031]    Referring to the several views of the drawings, the overflow safety switch assembly of the present invention is shown and generally indicated as  10 . The overflow safety switch assembly is specifically structured for installation on a side wall  110  of a condensation collecting drain pan  100  for collecting water that drips from condensation producing equipment, particularly HVACR equipment. The overflow safety switch assembly  10  includes an overflow safety switch  20  and a mounting device  30  for removably mounting the overflow safety switch to the side wall  110  of the drain pan  100 . 
         [0032]    In one embodiment of the invention, the overflow safety switch  20  is a float switch that has a vertically extending hollow tubular body  22  and a buoyant annular float member  24  that is movable along an outer surface of the tubular body  22  between a lower stop member  25  and an upper stop member  26 . Wire conductors  27  extend from a top end of the float switch  20  for electrical connection to the condensation producing equipment (e.g., HVACR equipment). The mounting device  30  of the present invention is structured for supporting the overflow safety switch  20  in a generally vertical and upright position with a bottom end  29  of the hollow tubular body  22  positioned in contact with, or just slightly above, the bottom  120  of the drain pan  100 , as seen in  FIGS. 4 and 5 . 
         [0033]    The mounting device  30  includes a clip member  40  that is structured and disposed for removable attachment to the side wall  110  of the drain pan  100 . The clip member  40  includes a primary support structure  42  having a front side  43  and a back surface  44  that engages an inner surface of the drain pan side wall  110 . The clip member  40  further includes an outer leg  46  extending downwardly in spaced relation to the back surface  44  of the primary support structure  42  to form a gap therebetween that is specifically sized for receipt of the side wall  110  of the drain pan  100  therebetween, as seen in  FIGS. 4 and 5 . A finger operated set screw  50  has exterior threads  52  and a blunt distal end  54 . The set screw  50  is received through an opening  48  formed through the outer leg  46  and is threadably advanced therethrough until the blunt distal end  54  of the set screw  50  is forced into engagement with the outer surface of the drain pan side wall  110  to pinch the side wall  110  between the set screw  50  and the back surface  44  of the primary support structure  42 , thereby effectively locking the clip member in fixed position on the side wall  110  of the drain pan  100 , as seen in  FIGS. 4 and 5 . The blunt distal end  54  of the set screw  50  prevents penetration of the set screw through the drain pan side wall  110 . 
         [0034]    The mounting device  30  further includes a bracket  60  that is removably and adjustably fitted to the primary support structure  42  of the clip member  40 . The bracket  60  includes an outwardly extending arm  62  with a C-clip  64  on a distal end of the arm  62  for removable attachment to the tubular body  22  of the overflow safety switch  20 . An upper portion of the tubular body of the overflow safety switch has an arrangement of vertically spaced grooves (preferably three grooves) that allow for selective adjustment of the height of the overflow safety switch  20  within the drain pan  100 . As seen throughout the drawing figures, in a preferred embodiment the tubular body  22  of the overflow safety switch  20  is provided with an arrangement of spaced annular rings to effectively form the grooves that receive the C-clip  64  of the bracket  60 . Specifically, a first groove  70  is defined between the upper stop member and a first annular ring  71 . A second groove  72  is defined between the first annular ring  71  and a second annular ring  73 . A third and uppermost groove  74  is defined between annular ring  73  and a top annular ring  75 . The C-clip  64  on the arm  62  of the bracket  60  is specifically structured to releasably snap into attached engagement with each of the grooves  70 ,  72 ,  74  to removably attach the overflow safety switch  20  to the bracket  60 . The height of the overflow safety switch  20  relative to the bracket  60  and the bottom  120  of the drain pan  100  can be adjusted by moving the attachment of the C-clip  64  to selective ones of the plurality of grooves  70 ,  72  and  74 . Specifically, attachment of the C-clip  64  to the first groove  70  positions the overflow safety switch  20  at the highest position relative to the bracket  60 . The second groove  72  provides an intermediate height adjustment while attachment of the C-clip  64  to the third groove  74  adjustably positions the overflow safety switch  20  at the lowest position relative to the bracket  60 . 
         [0035]    The bracket  60  has a mounting member  66  that is structured and disposed for adjustably fitting to the primary support structure  42  of the clip member  40 . Specifically, the mounting member  66  includes opposite side edges  80 ,  82  extending from a top end  84  to a bottom end  85 . An upper transverse portion  86  extends between the opposite side edges  80 , 82 . The arm  62  of the bracket  60  extends outwardly from the transverse portion  86 . An open lower portion  88  below the transverse portion  86  allows the opposite side edges  80 , 82  to flex slightly inward at the lower portion of the mounting member when yielding to external pressure on the opposite side edges. The mounting member  66  of the bracket  60  further includes a handle  90  above the transverse portion. The primary support structure  42  of the clip member  40  includes a slot on the front side for sliding, adjustably positionable receipt of the mounting member  66  of the bracket therein, as seen in  FIGS. 2-5 . The slot is formed by a pair of spaced apart and opposing guide tracks  92 ,  94  extending vertically on the front side  43  of the primary support structure  42 . The guide tracks  92 ,  94  are specifically sized, structured and configured for sliding, frictional engagement with the side edges  80 ,  82  of the bracket mounting member  66  for adjustable positioning of the bracket  60  relative to the clip member  40  and the bottom  120  of the drain pan  100 . By pushing downwardly on the top handle  90  of the bracket  60 , the bracket  60  is moved further down within the slot on the clip member  40  as the lower portion of the side edges  80 ,  82  of the bracket mounting member  66  are able to flex inwardly in response to frictional forced engagement of the guide tracks  92 ,  94  with the opposite side edges of the bracket mounting member. This allows the bracket  60  to be moved by sliding up or down within the slot, while remaining held in place once the desired adjusted position is achieved. 
         [0036]    As seen in  FIGS. 4 and 5 , the desired adjusted position of the overflow safety switch  20  is to position the bottom end  29  of the tubular body  22  of the overflow safety switch in contact with or very close to the bottom surface  120  of the drain pan. This position allows the overflow safety switch to quickly react to accumulation of water within the drain pan. As seen in  FIG. 5 , as water begins to accumulate in the drain pan, the buoyant float member  24  of the float switch (i.e., overflow safety switch) begins to rise up the tubular body  22  to effectively operate the switch and interrupt operation of the condensation producing equipment and/or to operate an alarm that indicates a potential clog or obstruction in the drain line system. 
         [0037]    Downward adjusted movement of the bracket  60  within the guide tracks  92 ,  94  on the clip member is limited by a stop member  98  that protrudes from the front wall surface of the primary support structure on the clip member. Specifically, continued downward adjusted movement of the bracket  60  within the clip member  40  will eventually result in abutting engagement of the stop member  98  with a bottom edge of the transverse portion  86  on the bracket  60 , thereby preventing further downward movement of the bracket  60 , as seen in  FIG. 2 . 
         [0038]    The ability to adjust the height of the overflow safety switch  20  by sliding the bracket  60  downwardly or upwardly relative to the clip member  40 , and further by changing position of the attachment of C-clip  64  to any one of the plurality of grooves  70 ,  72  or  74 , allows the overflow safety switch assembly  10  of the present invention to be installed on a wide variety of size drain pans having varying side wall heights. In the HVACR industry, typical drain pan side walls range in height from between 1.5 inches to 3 inches. The overflow safety switch assembly  10  of the present invention allows for easy adjusted installment of the overflow safety switch  20  to these varying depth drain pans with minimal time and effort, thereby ensuring that the overflow safety switch  20  is properly positioned to immediately sense undesirable water accumulation in the drain pan before an overflow occurs. 
         [0039]    While the present invention has been shown and described in accordance with a preferred and practical embodiment thereof, it is recognized that departures from the instant disclosure are fully contemplated within the spirit and scope of the present invention which are not to be limited except as defined in the following claims, as interpreted under the Doctrine of Equivalence.