Abstract:
A humidifier features a two piece reversible housing which is snap fit together for holding a water panel assembly and a water feed tube to supply water to a water distribution structure disposed on top of the water panel assembly. The water panel assembly is provided with an overflow arrangement for controlling any overflow of water in the water distribution structure.

Description:
FIELD OF THE INVENTION 
     This invention relates generally to humidifiers such as used in conjunction with a furnace or heating system and connected to a plumbing system of a building. Humidifiers of this type generally use an air circulation arrangement to move air across a water soaked evaporation pad. The humidifier is associated with the furnace or heating system so that the humidifier moist air can be combined with the warm, generally dry, heated air and distributed through a building. 
     BACKGROUND OF THE INVENTION 
     Humidifiers are generally characterized by a housing having an evaporative water panel constructed of slit and expanded media removably disposed therein. A water feed tube is connected to a water supply for supplying water via a solenoid valve to a distribution tray from which water flows downwardly by gravity through the water panel. Air is forced through the water panel and the air evaporates water on the water panel so that humidified air is delivered to the building. 
     One such prior art humidifier is disclosed in U.S. Pat. No. 4,125,576 issued Nov. 14, 1978 to Kozinski. In this patent, an evaporative pad is mounted in a three part enclosure consisting of a housing having a furnace duct adapter on one side and plumbing on the other, a water distribution tray removably mounted on top of the housing and a drain pan removably fastened to the bottom of the housing. A water supply means is provided for supplying water to the distribution tray. 
     Sometimes, because of the location of the furnace piping or plumbing, it is necessary or desirable to turn or reverse the housing so that the plumbing and the air duct adapter are on opposite sides. To accomplish this, the distribution tray and drain pan must be removed from the housing by loosening various thumb screws, and then the housing must be removed and rotated 180 degrees. Once this is done, the housing is reinstalled and the distribution tray is then fastened to the bottom of the housing and the drain pan mounted on the top of the housing. This prior art humidifier thus requires manipulation of three separate components with a plurality of fasteners to accomplish the desired housing reversal. 
     In addition, prior art humidifiers such as shown in the &#39;576 patent, sometimes encounter problems in the distribution tray overflowing due to plugged up flow structure or scale build up. In such event, water would leak from the housing and create unwanted puddles. In the worst case, overflow water would be blown through the duct system into the furnace elements causing damage thereto. 
     Accordingly, it is desirable to provide an improved humidifier housing which may be more easily connected and disconnected to effect a reversed orientation to adapt the various existing environmental structure. It is further desirable to provide an improved humidifier water distribution structure which more controllably handles overflow in the event of water obstruction and prevents damage to surrounding structure. 
     SUMMARY OF THE INVENTION 
     It is a general object of the present invention to provide a humidifier which consistently and efficiently delivers the correct amount of moisture as installed in a furnace system. 
     It is one object of the present invention to provide a humidifier having an easily reversible, two part housing which does not require loosening and tightening of fasteners. 
     It is also an object of the present invention to provide a humidifier having water distribution structure which reacts to any blockage in water by channeling overflow along a preferred path inside the housing to drain. 
     It is a further object of the present invention to provide a humidifier which is easier and less costly to manufacture and maintain. 
     In one aspect of the invention, a humidifier includes a base having an adapter in a first position adapted to be connected to a furnace duct. The base houses a water panel assembly and a water feed tube to supply water to a water distribution structure disposed on top of the water panel assembly. A cover is removably connected to the base. The base and the cover are rotatable independent of the water distribution structure to place the adapter in a second position to adapt to a different furnace duct, and the base and cover are snap fit together without fasteners. The base with the adapter in the first position has a top opening in which a cap is removably attached, and a bottom opening in which a drain spud is removably inserted. The base with the adapter in the second position has a top opening and the bottom opening interchanged such that the cap is removably fastened in the bottom opening, and the drain spud is removably inserted in the top opening. The base and the cover are provided with mating latch and catch structure on top and bottom portions thereof. The water panel assembly is comprised of a scale control insert, an evaporative water panel held within the scale control insert and a distribution tray retained within the scale control insert above the water panel. The scale control insert is formed with an upstanding skirt having opposing end panels formed with slots therein. A first upstanding vertical wall is parallel and spaced from a first side panel to form a first overflow channel therebetween. A second upstanding vertical wall is parallel and spaced from a second side panel to form a second overflow channel therebetween. Any excess water in the distribution tray will travel over the first and second walls into the first and second overflow channels and flow downwardly between the water panel and the end panels of the scale control insert to a drain. The distribution tray is provided with tabs which fit in the slots of the skirt. The distribution tray is sized to fit within the end panels and the vertical walls of the skirt. 
     In another aspect of the invention, a humidifier includes a base adapted to be connected to a furnace duct. The base houses a water panel in a water panel framework, and a water feed tube for supplying water to a distribution tray disposed in the water panel framework above the water panel. A cover is removably connected to the base. The water panel framework is provided with overflow structure for directing and confining any overflow of water in the distribution tray within the water panel framework. The overflow structure is comprised of a pair of overflow channels disposed longitudinally on opposite sides of the distribution tray. 
     In yet another aspect of the invention, a humidifier includes a two piece reversible housing snap fit together for holding a water panel assembly and a water feed tube to supply water to a water distribution structure disposed on top of the water panel assembly. The water panel assembly is provided with an overflow arrangement for controlling any overflow of water in the water distribution structure. 
     Various other features, objects and advantages of the invention will be made apparent from the following description taken together with the drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The drawings illustrate the best mode presently contemplated for carrying out the invention. 
     In the drawings: 
     FIG. 1 is a perspective view of an assembled humidifier embodying the present invention; 
     FIG. 2 is an exploded view of the humidifier of FIG. 1; 
     FIG. 3 is a view similar to FIG. 2 showing a housing of the humidifier rotated 180 degrees; 
     FIG. 4 is a partial, bottom view of a humidifier base showing adaptability of a cap or drain spud therein; 
     FIG. 5 is a perspective view of a water panel assembly inside the humidifier base; 
     FIG. 6 is a partial, exploded, perspective view of a distribution tray removed from a scale control insert of the water panel assembly; and 
     FIG. 7 is a perspective view of the distribution tray placed inside the scale control insert. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     As seen in FIGS. 1 and 2, a humidifier  10  embodying the present invention includes a base  12  and a cover  14  which defines a two piece housing that is attached to a portion of a furnace. Base  12  holds an evaporative water panel  16  preferably formed of slit and expanded media mounted in a framework or scale control insert  18 . The scale control insert  18  reduces the bypass around water panel  16  and contains the mineral deposits that build up upon water panel  16  as a result of the evaporative process. Base  12  also includes a water feed tube  20  retained by a holder  22  and having one end which supplies water to a removable distribution tray  24  (FIG. 7) for the water panel  16 . Another end of the feed tube  20  is joined to a solenoid valve  26  mounted on a side wall  27  of the base  12  for controlling the flow of water through the feed tube  20 . Solenoid valve  26  is, in turn, permanently connected to the plumbing or water supply of a building. Although not shown, it should be understood that the humidifier  10  is associated with air circulation means, such as a fan or blower, for directing air through the wetted water panel  16 . A humidistat (also not shown) is commonly used to establish a desired humidity set point. Water drainage from water panel  16  is discharged to a drain spud  28  and a drain  30  connected thereto. 
     FIG. 2 shows that the base  12  is a generally rectangular enclosure having a rear wall  32 , a top wall  34 , a bottom wall  36  and side walls  27  and  38 . As illustrated in FIG. 5, the base  12  is sized and shaped to hold the water panel assembly or wet pack comprised of the water panel  16 , the scale control insert  18  and the distribution tray  24 . Top wall  34  is formed with an opening  40  plugged by a cap  41  for a purpose to be appreciated hereafter and carries a first latch  42  thereon. Bottom wall  36  is provided with a drain hole  44  within which drain spud  28  is received, and also carries a second latch  46  in spaced apart alignment with the first latch  42 . Opening  40  and drain hole  44  are similarly sized as will be understood later. Side wall  38  is designed to include a damper adapter  48  which accommodates a furnace duct or pipe as shown in phantom lines  50  in FIG.  1 . As is known, the adapter  48  usually carries a pivotally mounted, damper plate  52  which is controlled by a rotatable handle  54 . Cover  14  has a curved outer wall  56  and side walls  58  and  60  (FIG.  3 ). The top of cover  14  is provided with a first catch  62  which receives first latch  42  in a snap fit without fasteners. The bottom of cover  14  is similarly provided with a second catch  64  (FIG. 3) which receives second latch  46  in a snap fit without fasteners. In FIG. 2, humidifier  10  has its two part housing  12 ,  14  in a left hand inlet mode, that is, the furnace pipe adapter  48  is physically located on the left side to cooperate with the existing furnace pipe or duct  50 , while the solenoid valve  26  is located on the right. However, in accordance with the invention, the housing  12 ,  14  is easily and conveniently reversed or converted, as shown in FIG. 3, to a right hand inlet mode in the event the furnace pipe or duct  50  or plumbing dictate such orientation. 
     To accomplish such conversion, the cover  14  in FIG. 2 is separated from the base  12  by disengaging or unsnapping the latches  42 ,  46  from the catches  62 ,  64 . The water panel assembly or wet pack consisting of water panel  16 , scale control insert  18  and distribution tray  24  is removed as are the drain spud  28  and cap  41  from base  12 . Then, the base  12  and the cover  14  are rotated 180 degrees as shown in FIG. 3, with drain spud  28  reinstalled in opening  40  and cap  41  reinstalled in drain hole  44  (FIG.  4 ). The similar sizing of opening  40  and drain hole  44  permit the interchangeability of drain spud  28  and cap  41 . Lastly, the wet pack  16 ,  18 ,  24  is reinserted in the base  12  again with the distribution tray  24  at the top, and cover  14  is again closed onto the base  12  using the snap fit latches  42 ,  44  and the catches  62 ,  64 . It is important to note that the distributor  24  and wet pack do not have to be reversed. Installation is completed by attaching the furnace duct  50  to the reversed adapter  48  and making the necessary plumbing connections to connect feed tube  20  with the water supply. 
     Further in accordance with the invention, FIGS. 6 and 7 show details of the scale control insert  18  and distribution tray  24  which is equipped with integral overflow protective structure. The top portion of the scale control insert  18  includes a generally rectangular, upstanding skirt  66  formed with vertical slots  68 ,  70  on its end panels  72 ,  74 . Skirt  66  is molded with a first upstanding vertical wall  76  which is parallel to and spaced from one side panel  78  to form a first, longitudinally extending, overflow channel  80  therebetween. A second upstanding vertical wall  82  is parallel to and spaced from another side panel  84  to create a second, longitudinally extending, overflow channel  86  therebetween. Distribution tray  24  is formed with a series of spaced apart, circular, discharge openings  88  provided with V-shaped notches or weirs  90  on cylindrical risers  92 . The weirs  90  are used to evenly spread water from tube  20  along the top of the water panel  16 . The length of distribution tray  24  is sized to cover the entire top portion of the water panel  16 . The opposed respective ends  94 ,  96  of the distribution tray  24  are formed with respective T-shaped tabs  98 ,  100  which snap fit into the slots  68 ,  70  on skirt  66 . The width of distribution tray  24  is sized to fit between the walls  76  and  82  on skirt  66 . Distribution tray  24  is also formed with the comer shoulders  102  which fit into corresponding recesses at the end of walls  76  and  82 . 
     Should the distribution tray  24  overflow because of blocked weirs or because of a scale build up due to mineral deposits, the water will go up over the shoulders  102 , and walls  76  and  82  into channels  80  and  86 . The water will flow along the channels  80  and  86  to the ends of the scale control insert  18  and travel downwardly between the water panel  16  and the end of the scale control insert  18  to the drain hole  44 . Overflow water is thus controllably channeled inside the scale control insert rather than outside so that puddles will not form and excess moisture will not be blown into the furnace system. 
     It should now be understood that the present invention provides an improved humidifier having a two part housing which may be easily reversed to match existing environmental structure without the need for any tools, without any fasteners and without reversing the wet pack. The simplicity of employing a two part housing with snap fit latch structure and interchangeable drain holes improves over prior art three piece housing with multiple fasteners which require time to remove and reinstall. The present invention also provides a useful, economical structure for handling overflow of water in the distribution tray in the event of blockage or mineral build up. Such structure reduces maintenance and prevents damage to components in the furnace system. 
     While the invention has been described with reference to a preferred embodiment, those skilled in the art will appreciate that certain substitutions, alternations and omissions may be made without departing from the spirit thereof. Accordingly, the foregoing description is meant to be exemplary only, and should not be deemed limitative on the scope of the invention set forth with the following claims.