Patent Description:
Heat pumps are commercially available for use in connection with many different pools and spas. For example, Zodiac Pool Care Europe (the applicant hereof) sells heat pumps under the marks "Z200," "Z400 iQ," "ZS500," and "Z600. " <CIT>discloses additional information concerning other exemplary types of heat pumps and uses therefor.

Among challenges associated with using existing heat pumps is that the human-machine interface (HMI), or control pad, of the apparatus must be readily accessible to a user desiring to change any operational characteristic of the apparatus. As an example, if the HMI is present on a nominal front surface of an apparatus, that front surface cannot be placed closely adjacent a wall, as the user could not then access the HMI. Accordingly, static placement of an HMI of a conventional heat pump restricts the locations and orientations at which the apparatus may be installed.

Additionally challenging in connection with existing heat pumps is management of condensate associated with their use. For many heat pumps, condensate is allowed simply to drip onto the ground or other surfaces on which the apparatus are mounted. Such a result is not always desirable either aesthetically or functionally. This result also "wastes" water that could be used in alternative manners instead.

<CIT> shows a gas pool heater comprising a body and a cap covering the body, wherein an HMI can be monted at the cap in different orientation. <CIT> shows a dome shaped pool water heater.

<CIT> shows an HMI equipped with a light source.

Embodiments covered by this patent are defined by the claims below, not this summary.

The invention provides a heat pump according to claim <NUM> and a method according to claim <NUM>.

According to some embodiments, a heat pump includes an evaporator, an outlet for returning water to a swimming pool, and means for moving condensate created by operation of the evaporator to the outlet.

According to certain embodiments the HMI may include a light source, the cap may include an opening, and light emitted from the light source may be reflected through the opening.

According to some embodiments, a heat pump includes mounting means. At least one of a plurality of heat pump accessories are attachable to the heat pump via the mounting means.

According to various embodiments, the body of the heat pump includes a first wall, a second wall, and a beveled face of the corner extending between the first wall and the second wall. The beveled face extends at an oblique angle relative to the first wall and the second wall.

According to the invention, heat pumps described herein include an HMI that is movable relative to a housing, or body, of the heat pump. In such embodiments, regardless of the location and orientation of the installation of the body of the heat pump, the HMI may be positioned so that it is accessible to a user. This approach materially enhances the positional flexibility of the apparatus, rendering it suitable for use in more areas than conventionally would be available.

Additionally or alternatively, heat pumps described herein may include management systems for condensate associated with use of such heat pumps. As an example, heat pumps described herein may route condensate from the apparatus to the swimming pool or spa rather than allow it merely to drip beneath the apparatus under force of gravity. Doing so undoubtedly minimizes the volume of water leaking from, or otherwise exiting, the heat pump onto the ground or other mounting surface. It also avoids "wasting" the water by instead using the water further to fill the pool or spa. Heat pumps and associated systems and methods provided herein may also allow for improved attachment of accessories to the heat pump and/or improved communication with a user of the heat pumps. Various other benefits and advantages may be realized with the systems and methods provided herein, and the aforementioned advantages should not be considered limiting.

<FIG> illustrate an exemplary heat pump <NUM> according to embodiments of the invention. The heat pump <NUM> includes a body <NUM>, a base <NUM>, and a cap <NUM>. As discussed in detail below, in some embodiments the cap <NUM> may beneficially incorporate an HMI <NUM>.

As best illustrated in <FIG>, the body <NUM> of the heat pump <NUM> includes walls <NUM> that define a housing area <NUM> (see <FIG>). The walls <NUM> define a top end <NUM> and a bottom end <NUM> of the body <NUM> (see <FIG>). As discussed in detail below, the cap <NUM> may be supported at the top end <NUM> of the body <NUM>, and the bottom end <NUM> may engage the base <NUM> when the heat pump <NUM> is assembled. The walls <NUM> may be separate components that are joined together using various fastening or joining mechanisms as desired (e.g., including but not limited to mechanical fasteners). In other embodiments, the walls <NUM> may be monolithically or integrally formed (e.g., including but not limited to formed by bending a sheet of metal). In the embodiment illustrated, the body <NUM> has a rectangular shape or profile such that adjacent walls are orthogonal or generally orthogonal to each other; however, in other embodiments, the body <NUM> may have other shapes or profiles as desired. As such, the shape of the body <NUM> and/or the number of walls <NUM> illustrated should not be considered limiting.

In some embodiments, and as best illustrated in <FIG>, the heat pump <NUM> may include features such that it can be installed closer to a wall <NUM> than possible with conventional heat pumps. As a non-limiting example, the features may allow for the heat pump <NUM> to be positioned as close as approximately <NUM> to the wall <NUM> as shown in <FIG>, compared with traditional heat pumps that need to be more than <NUM> away from wall <NUM> to accommodate inlet and/or outlet tubing for the heat pump. As illustrated in <FIG>, in certain embodiments, such features may include a recessed or beveled face <NUM>, and the beveled face <NUM> may include one or more of an inlet <NUM> and/or an outlet <NUM> for the heat pump <NUM>. In these embodiments, the beveled face <NUM> may allow for inlet and/or outlet tubing <NUM> connected to heat pump <NUM> (via the inlet <NUM> and/or the outlet <NUM>) to lay flat or nearly flat against wall <NUM> at the connection point with heat pump <NUM>. Such connection in turn enables the heat pump <NUM> to be positioned closer to wall <NUM> than would otherwise be possible. In other embodiments, the inlet <NUM> and/or the outlet <NUM> need not be provided on the beveled face <NUM>, and the inlet <NUM> and/or the outlet <NUM> may be provided on other portions of the heat pump <NUM> and/or the body <NUM>. As an example, the inlet <NUM> and/or the outlet <NUM> may be provided on one or more of the walls <NUM>.

In various embodiments, the beveled face <NUM> extends between adjacent walls <NUM> of the body <NUM>. When included, the beveled face <NUM> may extend at an oblique angle relative to the walls <NUM> of the body. In some non-limiting examples, the beveled face <NUM> may be a rear panel positioned at an angle of approximately <NUM>-<NUM>°, inclusive, relative to adjacent walls <NUM> of body <NUM> of heat pump <NUM>. Optionally, a height of the beveled face <NUM> may be less than the height of the walls <NUM> (i.e., the beveled face <NUM> optionally does not extend from the bottom end <NUM> to the top end <NUM>). However, in other embodiments, the beveled face <NUM> may have other heights relative to the walls <NUM> as desired, including having the same height as the walls <NUM>.

Referring to <FIG>, in addition to or instead of including the beveled face <NUM>, one or more non-linear water connectors <NUM> (e.g., water connectors having opposing ends <NUM>, <NUM> that extend in at least two directions and/or define a non-linear flow path) may be used to connect the tubing <NUM> to the inlet <NUM> and/or the outlet <NUM>. A non-limiting example of a non-linear water connector may be a <NUM>° water connector <NUM> such as illustrated in <FIG>, or a water connector having a first end and a second end that is at a <NUM>° angle relative to the first end. In some embodiments, the water connectors <NUM> may be adjustable to be at various angles as desired. Optionally, the water connectors <NUM> may be configurable between a linear orientation and a non-linear orientation, and/or within the non-linear orientation, the water connectors <NUM> may be adjustable between various angles. As one non-limiting example, the water connectors <NUM> may be configurable between a linear orientation and a non-linear orientation in which the ends <NUM>, <NUM> are at a <NUM>° angle. As another non-limiting example, the ends <NUM>, <NUM> may be at a <NUM>° angle. As another non-limiting example, the water connectors <NUM> may be configurable between a first non-linear orientation (e.g., a <NUM>° angle) and a second non-linear orientation (e.g., a <NUM>° angle, a <NUM>° angle, etc.). Non-linear water connectors in addition to or in place of the beveled face <NUM> may provide further space savings between the heat pump <NUM> and any adj acent wall. Various types of non-linear water connectors may be used as desired. In some embodiments, such water connectors may include threading and/or other complimentary features adapted to heat exchanger connectors (e.g., a male connector to match the female connector on the heat pump <NUM>) (see, e.g., <FIG>).

Referring to <FIG>, the water connectors <NUM> (or other suitable connectors) optionally may include a feature (such as a tab <NUM> or other projection) to facilitate connection and disconnection of the water connectors <NUM>. As an example, a user may pull/push the tab(s) <NUM> to help screw and unscrew the water connectors with the tubing <NUM> and the heat pump <NUM>. The water connectors <NUM> (or other suitable connectors) optionally may include a seal (e.g., rubber) trapped in a groove of the connectors in a loose, but not stuck, fashion.

Referring to <FIG>, water connectors <NUM> provided herein optionally include one or more position indicators <NUM> (e.g., markings) for positioning of the connector <NUM>. Specifically, since the starting position of the connector and the thread length impact the final screwed position, the one or more position indicators <NUM> may help align the <NUM>° water connector (or other non-linear water connector) in the proper position once threaded with the tubing <NUM> and the heat pump <NUM>. When included, the one or more position indicators help inform an installer or other user regarding how to position the water connector in the female fitting to ensure proper orientation of the male connector in the suitable area. Other types of features facilitating installation of the heat pump <NUM> may be included on or with the body <NUM> as desired, and the beveled face <NUM> and/or water connectors should not be considered limiting.

As mentioned, the walls <NUM> define the housing area <NUM>. Referring to <FIG>, for example, part or all of a heat exchanger <NUM> (e.g., such as but not limited to an evaporator) may be contained partially or completely within the body <NUM>, as may a controller (e.g., processor and/or memory and/or other electronic logic) for the heat pump <NUM> (see, e.g., a printed circuit board or regulation board <NUM> as a portion of the controller in <FIG>). If appropriate, the heat pump <NUM> additionally or alternatively may comprise other standard or optional components supported on, by, or within the body <NUM>, such as, but not limited to, a condenser, the heat exchanger <NUM>, a compressor, a fan <NUM>, combinations thereof, and/or other components or features as desired.

Referring to <FIG>, in various embodiments, the body <NUM> includes an upper support <NUM>. When included, the upper support <NUM> may define a support location for one or more components of the heat pump <NUM>. In the embodiment illustrated, the upper support <NUM> includes a central aperture <NUM> that may at least partially receive the fan <NUM>.

The upper support <NUM> may also support the cap <NUM> of the heat pump <NUM> and/or allow for rotation and/or orientation of the cap <NUM> relative to the body <NUM>. In such embodiments, the upper support <NUM> of the body <NUM> may include attachment features <NUM> facilitating attachment of the cap <NUM> to the body <NUM>. In the embodiment illustrated, the attachment features <NUM> are screw apertures configured to received mechanical fasteners such as screws; however, other types of attachment features <NUM> may be used as desired. The upper support <NUM> optionally defines one or more support locations <NUM>, and when the cap <NUM> is assembled, the cap <NUM> may be positioned and/or oriented relative to the upper support <NUM> such that the HMI <NUM> is aligned with one of the support locations <NUM>. As shown in <FIG>, the upper support <NUM> of the body <NUM> optionally may include a plurality of clips <NUM>, which may facilitate installation of cables or wiring to the board <NUM> (wiring represented by dashed line <NUM> in <FIG>) and accommodation of any surplus-length of cables or wiring. In such embodiments, the clips <NUM> (or other storage features as desired) may store the cables and/or wiring tightly enough to contain them and avoid any interaction with fan blades of the fan <NUM>, yet loose enough to allow slack so the cables/wiring can rotate with cap <NUM> as cap <NUM> rotates into the desired orientation (discussed in detail below).

Referring to <FIG> and <FIG>, the heat pump <NUM> includes the cap <NUM>, and the cap <NUM> includes the HMI <NUM>. The cap <NUM> is supported at or proximate to the top end <NUM> of the body <NUM>. As discussed in detail below, the cap <NUM> is movable relative to the body <NUM> such that regardless of the location and orientation of the installation of the body of the heat pump, the HMI <NUM> may be positioned so that it is accessible to a user.

Referring to <FIG>, for example, the HMI <NUM> may include an interface <NUM> and an optional cover <NUM>. The interface <NUM> may include one or more selectable features that a user may utilize to receive information from the heat pump <NUM> and/or to perform various controls of the heat pump <NUM>. Non-limiting examples of selectable features may include real and/or virtual buttons <NUM>, a display <NUM>, knobs, dials, a touchscreen, sub-combinations thereof, and/or other means by which a user may engage the heat pump <NUM> for receiving or providing information to the heat pump <NUM>, such as to change operating characteristics of heat pump <NUM>. When the display <NUM> is included, the display <NUM> may provide information to the user, such as confirming the user's changes, providing status indications of the heat pump <NUM>, and/or providing other information to the user as desired.

If present, the cover <NUM> may help protect interface <NUM> from damage caused by, for example, the external environment. As shown, cover <NUM> may be configured to pivot about an axis <NUM> so as to cover, or reveal, the interface <NUM>. In other embodiments, the cover <NUM> may have other configurations as desired and/or may be movable relative to the cap <NUM> using other techniques or mechanisms as desired. As a non-limiting example, the cover <NUM> may include two sub-covers, each of which is hingedly attached to the cap <NUM>. Other types of covers <NUM> may be used as desired.

Referring to <FIG> and <FIG>, the HMI <NUM> may include at least one printed circuit board (PCB), denoted as HMI board <NUM> in FIG. The HMI board <NUM> may include electronic and other components and devices suitable for operation of HMI <NUM>. As non-limiting examples, the HMI board <NUM> may include processing logic, control logic, memory, actuators, and wired or wireless transmit and receive equipment. Alternatively, some of these components may be included on the regulation circuit board <NUM>. A lower cover <NUM> optionally may be included for protecting the HMI board <NUM>; however, in other embodiments, the lower cover <NUM> may be omitted.

In some optional embodiments, the heat pump <NUM> may include a light guide reflective assembly. In such embodiments, and as illustrated in <FIG> and <FIG>, one or more light sources may be provided on the HMI board <NUM>, and light emitted from the one or more light sources may be reflected through the cap <NUM> and/or the body <NUM>. In the embodiment illustrated, the light sources are one or more light emitting diodes (LEDS) <NUM> mounted or otherwise affixed to HMI board <NUM>, such as to a bottom face <NUM> of HMI board <NUM>. In certain embodiments, the one or more light sources are provided on a face of the HMI board <NUM> opposite from the one or more selectable features. Although three LEDS <NUM> are illustrated, any suitable number may be included.

In addition to the one or more light sources, the body <NUM> and/or the cap <NUM> may include an opening <NUM> through which light emitted from LEDS <NUM> (or other light sources) may pass. In the embodiment illustrated, the opening <NUM> is defined in the cap <NUM>. In some cases, as shown in <FIG>, the light (represented by arrow <NUM>) emitted from the one or more LEDs <NUM> may be reflected off the optional cover <NUM> and directed to the opening <NUM>. In such embodiments, the cover <NUM> may be configured to protect the HMI board <NUM> in addition to reflecting light emitted from the LEDS <NUM>. In such embodiments, the cover <NUM> may include various characteristics or features for facilitating reflection of light from the light sources. As a non-limiting example, the cover <NUM> may have a white coating to optimize the light reflectance. Optionally, the light guide reflective assembly may include a diffuser <NUM> that diffuses the reflective light before it passes through opening <NUM>. Various other components or features may be used with the light guide reflective assembly for controlling the optical characteristics of the light emitted through the opening <NUM>.

In certain embodiments, the HMI board <NUM> may be programmed so the color emitted from LEDS <NUM> provides a visual indication to a user of HMI <NUM> about a status or operating state of heat pump <NUM>. In such embodiments, at least one characteristic of the one or more light sources may be controlled to provide different information to the user about the heat pump <NUM>. For example, LEDS <NUM> emitting a first color light may be activated when heat pump <NUM> is in a first operating state, while LEDS <NUM> emitting a second color light may be activated when heat pump <NUM> is in a second operating state, and so forth (e.g., a first light color may correspond to a heating state, while a second light color may correspond to a cooling state, while a third light color may correspond to an error state, etc.). In other embodiments, the light sources may be controlled to have a steady / constant on pattern for a first status, a first blinking pattern for a second status, etc. Various other controls of the light sources may be used as desired to provide various information about the heat pump <NUM>.

In addition to supporting the HMI <NUM>, various optional add-on assemblies for heat pump <NUM> may be attached via the cap <NUM>. As an example, and referring to <FIG>, the cap <NUM> may include a lid <NUM>, which may be plastic or any suitable material, that is easily removable from cap <NUM>. In such embodiments, removal of the lid <NUM> may expose screw inserts <NUM> that permit mounting of the desired add-on assembly to heat pump <NUM> via cap <NUM>. Referring to <FIG>, non-limiting examples of add-on assemblies include an air deflector <NUM> (<FIG>), a cosy (aesthetically pleasing/comforting) light fixture or assembly <NUM> (<FIG>), a combination air deflector/cosy light assembly structure <NUM> (<FIG>), a technical room kit <NUM> (<FIG>), combinations thereof, and/or other structures as desired.

As mentioned, the cap <NUM> is movable and repositionable relative to the body <NUM>. In certain embodiments, the cap <NUM> may be easily removed from, and easily attached (or reattached) to, the body <NUM>. <FIG> illustrate a simple screw-hole fastening system in which four screws attach the cap <NUM> to the body <NUM>. Regardless of the orientation of cap <NUM>, one of its openings <NUM> (see <FIG>) can align with each corresponding attachment feature <NUM> (see <FIG>) of body <NUM> and receive a screw or other attachment device. In other embodiments, other attachment mechanisms or features may be used to attach the cap <NUM> to the body <NUM>.

In at least some versions of heat pump <NUM>, cap <NUM> may be moved relative to body <NUM> without disconnecting any cables or wiring to board <NUM>. In certain embodiments, the cap <NUM> may be moved relative to the body <NUM> without removing the cap <NUM> from the body <NUM>. In some embodiments, the cap <NUM> optionally may include movement mechanisms to facilitate movement of the cap <NUM> relative to the body <NUM>. Such movement mechanisms may include sliders, rollers, gears, combinations thereof, and/or other mechanisms facilitating movement of the cap <NUM> relative to the body <NUM> as desired. In other embodiments, the cap <NUM> need not include movement mechanisms.

Referring to <FIG>, the HMI <NUM> (as part of cap <NUM>) is movable relative to the body <NUM> to have a desired orientation or position relative to the body <NUM>. In each of <FIG>, the body <NUM> is oriented so that, e.g., the board <NUM> appears on the right-hand side of the body <NUM> (the board <NUM> is visible in the drawings because part of body <NUM> is cut-away. ) For comparison purposes, <FIG> illustrates a "standard," or "nominal," placement of the cap <NUM> so that the HMI <NUM> is present in the lower left-hand side of the figure. The placement illustrated in <FIG> may be useful, for example, if the body <NUM> is positioned such that the walls <NUM> that arrows <NUM> are pointing towards are positioned most proximate to a wall. By contrast, in <FIG>, the HMI <NUM> is located in the upper left-hand side of the figure, such placement being useful, for example, if the body <NUM> is positioned relative to a wall such that the walls <NUM> with arrows <NUM> are most proximate to the wall. In <FIG>, the HMI <NUM> is located in the lower right-hand side of the figure, such placement being useful, for example, if the body <NUM> is positioned such that walls <NUM> with arrows <NUM> are most proximate to a wall. Although not shown in any of <FIG>, in some versions of the heat pump <NUM>, the cap <NUM> may be rotated so that HMI <NUM> is located in the upper right-hand side of a figure.

The change in orientation of the HMI <NUM> relative to the body <NUM> may occur due to the movability of cap <NUM> relative to body <NUM>. The movability of the HMI <NUM> relative to the body <NUM> may allow for the HMI <NUM> to remain accessible to a user regardless of how the body <NUM> of the heat pump <NUM> is installed at a particular location. This is true notwithstanding that various portions of body <NUM> may be positioned immediately adjacent the walls (with exemplary distances as small as <NUM>, <NUM>, <NUM>, and <NUM>, among others).

Referring to <FIG>, in certain embodiments, heat pumps <NUM> described herein may include a condensate management system <NUM>, which may route condensate from the heat pump <NUM> to the swimming pool or spa rather than allow it merely to drip beneath the apparatus under force of gravity. Such condensate management systems may minimize the volume of water leaking from, or otherwise exiting, the heat pump <NUM> onto the ground or other mounting surface and may also avoid wasting the water by instead using the water further to fill the pool or spa.

In certain embodiments, the condensate management system <NUM> includes means for moving condensate created by operation of the heat pump <NUM> to the outlet <NUM> of the heat pump <NUM>. In various embodiments, the condensate management system <NUM> includes the base <NUM> of the heat pump <NUM>. As illustrated in <FIG>, in some optional embodiments, the base <NUM> of the heat pump <NUM> may include a steep/sloped surface <NUM> that directs the condensate toward an area <NUM> (e.g., adjacent an inner wall <NUM> in the embodiment of <FIG>) that may facilitate movement of the condensate to the means for moving the condensate. Optionally, the base <NUM> may further include a drainage port <NUM> allowing for the base <NUM> to be selectively drained; however, in other embodiments, the drainage port <NUM> may be omitted.

As shown conceptually in <FIG>, condensate formed through operation of the evaporator of heat pump <NUM> may drip to the bottom region <NUM> of the body <NUM> and/or in the base <NUM>. From there, the condensate may be pumped or otherwise transferred (represented by arrows <NUM>) directly or indirectly to a return line <NUM> from the heat pump <NUM> for introduction of the condensate into a swimming pool <NUM> or other body of water. Preferably (although not necessarily), the condensate may be mixed with water output from a heat exchanger <NUM> so that only one return line <NUM> is needed.

<FIG> illustrate a peristaltic pump <NUM> as available to pump condensate to return line <NUM>. Persons skilled in the art will, of course, recognize that other means for moving the condensate may be utilized as desired, including other types of pumps and/or or other processes (e.g. Venturi effect, gravity) may be used instead to move the condensate. Optionally, and as illustrated in <FIG> and <FIG>, a saddle/paddle clamp <NUM> (or other introducing means) may be provided on, around, or proximate to the outlet <NUM> of the body <NUM>, which may allow for the condensate to enter return line <NUM>. <FIG> further illustrates a filtration pump <NUM> and an outboard line <NUM> allowing pool water to flow from the pool <NUM> to the inlet <NUM> of the body <NUM> for heating by the heat pump <NUM>. <FIG> also illustrate a suction strainer and/or filtrating foam <NUM>, which optionally may be used to strain and/or filter any debris from the collected condensate before it is pumped (or otherwise returned) to the return line <NUM>. Other filtering means optionally may be used in other embodiments. As mentioned, and referring back to <FIG>, the steep/sloped surface <NUM> of the embodiment illustrated directs the condensate toward the area <NUM> in the vicinity of suction strainer and/or filtrating foam <NUM>. Various other components or features may be included with the condensate management system <NUM> in addition to the means for moving condensate created by operation of the heat pump <NUM> to the outlet <NUM> of the heat pump <NUM>, and the features illustrated in <FIG> should not be considered limiting.

Claim 1:
A heat pump (<NUM>) for a swimming pool or spa comprising a body (<NUM>) and a cap (<NUM>) repositionable relative to the body, with the cap comprising a human-machine interface (HMI) (<NUM>), characterized in that the cap (<NUM>) is repositionable in its orientation to align the human-machine interface (HMI) (<NUM>) with a corner of the body (<NUM>) of the heat pump (<NUM>).