Humidifier auxiliary drain pan

An auxiliary drain pan for installation vertically below a humidifier. The pan has a base and a peripheral wall around the base and a first opening formed in the base adapted to form an anti-backflow connection with a conduit from the humidifier for directing liquid from the humidifier through the first opening and a first drainage connector, the anti-backflow connection preventing a reverse flow of liquid from the first opening into the humidifier. A second opening is formed in the pan in fluid communication with the first opening to receive the reverse flow of liquid from the first opening. The pan has a structure for supporting the base and having connecting features for connection with a vertical surface in an installed position, with the base secured in a substantially horizontal position in the installed position.

FIELD OF THE INVENTION

The present invention is directed to the field of apparatus and methods for liquid overflow protection, and in particular, for apparatus and methods for humidifier liquid overflow protection.

BACKGROUND OF THE INVENTION

Liquid collection systems are used, for example, in humidifiers in enclosed spaces. Irrespective the system, liquid, whether in the form of condensation created by or otherwise associated with the operation of such systems must be removed to prevent damage to the enclosed spaces or associated contents. A conventional system includes a primary drain pan, which is typically positioned within the humidifier, and receives all liquid generated during operation of the system. The primary drain pan further includes an opening for directing collected liquid to a drain.

Secondary or auxiliary drain pans are positioned vertically beneath a humidifier for emergency purposes, e.g., catching overflow liquid from the humidifier due to a malfunction of the primary drain pan. Unfortunately, there may be insufficient floor space to accommodate a conventional secondary or auxiliary drain pan, and constructing a separate support frame in such tight quarters can prove to be a difficult undertaking.

Moreover, even when the primary drain pan is functioning properly, a drainage back-up, resulting in reverse flow or backflow of liquid from the drain toward the primary drain pan can occur. Due to plumbing requirements, a connection must be inserted between the opening in the primary drain pan and the drain to prevent the reverse flow or backflow of liquid from the drain from reaching the primary drain pan. As a result, although the reverse flow or backflow of liquid from the drain is prevented from reaching the primary drain pan, such reverse flow may not be prevented from otherwise flowing through the inserted connection and causing damage to the structure or contents within the structure adjacent the inserted connection.

There is a need in the art for a humidifier auxiliary drain pan that addresses these shortcomings.

SUMMARY OF THE INVENTION

An embodiment is directed to a humidifier auxiliary drain pan for installation vertically below a humidifier including a base and a continuous wall around a periphery of the auxiliary drain pan extending upwardly from the base to form a container having an open end. The drain pan further includes a first opening formed in the base, the first opening having a first drainage connector extending from the base opposite the wall for connecting with a first drainage conduit, the first opening adapted to receive a backflow preventer for forming an anti-backflow connection with a humidifier conduit extending from the humidifier for directing liquid from the humidifier through the first opening and the first drainage connector, the anti-backflow connection preventing a reverse flow of liquid from the first drain conduit into the humidifier via the humidifier conduit. The drain pan further includes a second opening formed in the auxiliary drain pan in fluid communication with the first opening to receive the reverse flow of liquid from the first drain conduit through the first opening, the second opening having a secondary drainage connector extending from at least one of the base opposite the wall, and the wall away from the base, for connecting with a second drainage conduit. The drain pan further includes a structure extending from the base for supporting the base, the structure having connection features for connection with a vertical surface in an installed position, the structure securing the base in a substantially horizontal position in the installed position.

A further embodiment is directed to a method for providing liquid overflow protection for a humidifier system including positioning an auxiliary drain pan vertically below a humidifier, the auxiliary drain pan having a base, a continuous wall around a periphery of the auxiliary drain pan extending upwardly from the base to form a container having an open end, a first opening formed in the base and a second opening formed in the auxiliary drain pan in fluid communication with the first opening. The method further includes forming a fluid tight connection between the first opening and a first drainage conduit and forming a fluid tight connection between the second opening and a second drainage conduit. The method further includes forming an anti-backflow connection between the first opening and a conduit from the humidifier for directing liquid from the humidifier through the first opening and into the first drainage conduit, the anti-backflow connection preventing a reverse flow of liquid from the first drain conduit from reaching the humidifier through the humidifier conduit, the reverse flow of liquid from the first drainage conduit and through the first opening being received by the second opening and discharged from the auxiliary drain pan via the second drainage conduit.

A further embodiment is directed to a humidifier system for providing climate control to a space including a humidifier and an auxiliary drain pan positioned vertically below the humidifier. The auxiliary drain pan includes a base and a continuous wall around a periphery of the auxiliary drain pan extending upwardly from the base to form a container having an open end. The auxiliary drain pan further includes a first opening formed in the base, the first opening having a first drainage connector extending from the base opposite the wall for connecting with a first drainage conduit; the first opening adapted to receive a backflow preventer for forming an anti-backflow connection with a humidifier conduit extending from the humidifier for directing liquid from the humidifier through the first opening and the first drainage connector, the anti-backflow connection preventing a reverse flow of liquid from the first drain conduit into the humidifier via the humidifier conduit. The auxiliary drain pan further includes a second opening formed in the auxiliary drain pan in fluid communication with the first opening to receive the reverse flow of liquid from the first drain conduit through the first opening, the second opening having a secondary drainage connector extending from at least one of the base opposite the wall, and the wall away from the base, for connecting with a second drainage conduit. The auxiliary drain pan further includes a structure extending from the base for supporting the base, the structure having connection features for connection with a vertical surface in an installed position, the structure securing the base in a substantially horizontal position in the installed position.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides a novel auxiliary drain pan having a first opening for accommodating liquid flow therethrough from a humidifier to a first drain. In case the drain is clogged, the first opening also forms an anti-backflow connection preventing a reverse flow or backflow of “waste water” or liquid from the first drain into the humidifier. The drain pan includes a second opening in fluid communication with the first opening to receive the reverse flow or backflow from the first drain, permitting such reverse flow or backflow to be directed to a second drain. Further, the drain pan includes structure for supporting the drain pan, and providing a convenient means for simplifying the installation of the drain pan. The structure has connection features for connecting or securing the drain pan to a vertical surface or suspending the drain pan from the humidifier, as floor space may not be available in the region surrounding the humidifier. Moreover, even the floor space is available in the region surrounding the humidifier, positioning a conventional drain pan on the floor, which is generally at least 4 feet to 5 feet vertically below the humidifier, results in the drain pan becoming a “splash pad” that is not effective, and subjects the enclosed space and its surroundings to water damage. These features will be discussed in further detail below.

For purposes herein, the terms “humidifier auxiliary drain pan,” “auxiliary drain pan,” “humidifier secondary drain pan,” “secondary drain pan,” “drain pan” and the like may be used interchangeably.

FIG. 6shows a humidifier system100including an auxiliary drain pan10positioned vertically below a humidifier12, each being supported by a vertical surface or wall14. In one embodiment, the auxiliary drain pan is positioned vertically beneath the humidifier. Preferably, the vertical spacing separating humidifier12and auxiliary drain pan10is sufficiently small such that liquid dropping from the humidifier into the drain pan does not result in splashing, which could result in water damage of the enclosed space and/or contents thereof. In one embodiment, vertical wall14includes a wall structure of the enclosed space. In one embodiment, vertical wall14includes ducting for distributing or moving air interacting with a climate control system, such as an HVAC unit. Features of the novel auxiliary drain pan10will be discussed in further detail below.

As further shown inFIGS. 1-4, auxiliary drain pan10includes a base16, with a continuous wall18extending upwardly around a periphery of base16to form a container having an open end, with base16forming the closed end of the container. A first opening20and a second opening22are formed in base16. First opening20includes a first drainage connector24extending away from base16in a direction opposite of wall18. First drainage connector24is adapted to connect with one end of a first drainage conduit26(FIG. 6), with the other end of first drainage conduit26connecting to a first drain28(FIG. 6). In one embodiment, base16can have a planar surface. In one embodiment, base16can have a non-planar surface. When placed in an installed position, base16is substantially horizontal such that liquid accumulating on the surface of the base will be urged by force of gravity to flow toward and be received by at least second opening22. In one embodiment, liquid accumulating on the surface of the base will be urged by force of gravity to flow toward and be received by first and second openings20,22.

Second opening22includes a second drainage connector30extending away from base16in a direction opposite of wall18. Second drainage connector30is adapted to connect with one end of a second drainage conduit32(FIG. 6), with the other end of second drainage conduit32connecting to a second drain34(FIG. 6). Preferably, first drain28and second drain34are spaced away from each other such that if first drain28is clogged, second drain34may be unclogged, permitting the auxiliary drain pan10to operate as intended.

It is to be understood that first drainage connector24and second drainage connector30can utilize threads, such as pipe threads, quarter-turn fasteners, barbs, treated surfaces, including protrusions and/or recesses and surfaces adapted to increase the static coefficient of friction, clamps, adhesives, or other features or mechanical components or combination thereof in order to secure a fluid tight connection with the respective first drainage conduit26and second drainage conduit32. In one embodiment, drain pan10, first drainage connector24and second drainage connector30are of one-piece or unitary construction, such as produced by injection molding. The drain pan can be constructed of any suitable material, such as a plastic, having acceptable material properties, including corrosion resistance, rigidity and material strength.

As further shown inFIG. 1, first opening20and second opening22are in fluid communication with each other. For reasons discussed below, first opening20must be formed in base16, while second opening22can also be formed in base16, although alternately or additionally, a second opening22A can be formed in wall18. The position of second opening(s)22,22A can be formed anywhere in drain pan10so long as any accumulation of liquid in the drain pan as a result of reverse liquid flow or backflow from first drain28(FIG. 6) through first opening20can be received by or directly received by or flows or directly flows into second opening22, then into second drainage connector30, then into second drainage conduit32, and finally into second drain34. In other words, a reverse liquid flow or backflow from first drain28that further flows through first opening20and into the drain pan is received by second opening22, which removes the reverse liquid flow or backflow from the drain pan, the reverse liquid flow or backflow being received by second drain34. In a conventional climate control system, the backflow may not have a corrective rerouting arrangement, resulting in possible damage to the enclosed space. In one embodiment, drain pan10includes optional features, such as a third drainage connector44and a backflow preventer38as are discussed in further detail below.

As further shown inFIGS. 6-7, humidifier12of humidifier system100includes a humidifier conduit36for directing liquid away from the humidifier. As shown, humidifier conduit36is fluidly connected to a backflow preventer38. Backflow preventer38prevents an unintentional reversal of flow or backflow through the humidifier conduit into the humidifier. In one embodiment, a backflow preventer can incorporate an air gap, which is generally defined as an unobstructed vertical distance through the free atmosphere between the lowest opening of a liquid-providing source (e.g., a pipe or tube) and the flood-level rim of the liquid-receiving source (e.g., a top surface of a wall of the drain pan). The distance is generally two (2) times the effective diameter of the liquid-providing pipe or tube. In one embodiment, backflow preventer38is connected to one end of humidifier conduit36. In one embodiment, backflow preventer38is inserted between opposed ends of humidifier conduit36. In either arrangement, backflow preventer38is received (i.e., either directly or indirectly) by first opening20.

It is to be understood other embodiments of backflow preventers may be utilized, such as valves or other mechanical devices, including valves controlled by control systems, although a backflow preventer in the form of an air gap fitting has no moving parts and is less expensive than other types of backflow preventers.

As further shown inFIGS. 6-7, backflow preventer38is directly received by first opening20with an air gap portion40of the backflow preventer positioned vertically above a top surface42of wall18, thereby preventing a backflow of liquid from first drain28into drain pan10.

In one embodiment, as shown inFIG. 8, which is taken along line7-7ofFIG. 6, the end of humidifier conduit36is inserted into first opening20, and can extend into or even through first drainage connector24and into first drainage conduit26. The end of humidifier conduit36and the proximate or laterally corresponding portion of first drainage connector24or first drainage conduit26forms an air gap portion40. As long as the diameter of the end of humidifier conduit36is generally one half of the effective diameter of the proximate or laterally corresponding portion of first drainage connector24and first drainage conduit26, an unintentional reversal of flow or backflow from first drainage conduit26to humidifier12(FIG. 6) via humidifier conduit36is prevented.

It is to be understood that the flow of liquid from humidifier conduit36flowing through first opening20does not accumulate in drain pan10, but is “pass through flow” that is directed into first drain28. It is only the liquid backflow from first drain28which is delivered to the drain pan via first opening20that this removed via second opening22. The backflow into the drain pan represents an emergency situation.

In one embodiment, the footprint of the pan, i.e., the lateral surface area of base16(FIG. 1), is less than the footprint of the humidifier. In one embodiment, the footprint of the pan is equal to or greater than the footprint of the humidifier.

As further shown inFIGS. 1-4, drain pan10includes a support structure46. As shown, structure46includes a back plate48having a portion50extending away from base16in one direction beyond or past top surface42of wall18, and a portion52extending away from base16in a direction opposite portion50. Structure46further includes a support member54such as a pair of gussets extending from opposed edges of portion52to base16for providing additional structural support for the drain pan. Back plate48includes a plurality of connection features56including openings formed through back plate48, as well as fasteners58, such as blind fasteners such as screws and toggle bolts, as well as other kinds of fasteners including nuts and bolts, hooks, tape, including adhesive tape, clamps or other suitable mechanical fasteners or devices for securing the drain pan to vertical surface or wall14(FIG. 6). As shown inFIG. 10, an exemplary drain pan10is secured by fastener58, in the form of a hook, to vertical surface14, which in this instance is a ventilation duct. As further shown inFIG. 6, the portion of vertical surface or wall14to which the drain pan is secured is not a surface of humidifier12, as the humidifier is positioned vertically above the drain pan. As further shown inFIG. 6, when the drain pan is installed or placed in an installed position, structure46and connection features56secure base16(FIG. 1) in a substantially horizontal position such that backflow preventer38, openings20,22and associated connectors, conduits and drains operate in a manner as previously discussed.

It is to be understood that with the drain pan supported in an installed position, the support structure can extend beneath the base.

For example, as shown inFIG. 5, one or more of support members60,62can be used to provide structural support for drain pan10. Support member60is connected at one end to a portion of vertical wall14that is vertically below the drain pan in the installed position, and to a pivotable support64at the other end. Support member60has rigidity to withstand compressive forces. Support member62is connected at one end to a portion of vertical wall14that is vertically above the drain pan in the installed position, and to a pivotable support64at the other end. Support member60does not require rigidity, but must be able to withstand tensile forces.

In one embodiment, as shown inFIG. 9, structure46extends over humidifier12such that drain pain10is suspendedly supported thereby. Structure46can be a strap or include one or more elongate members secured to or extending over humidifier12to support drain pan10. In other words, drain pan10does not need to be supported or secured to vertical wall14(FIG. 6).