Patent Description:
Condensate pump assemblies are installed at different sites, such as against external walls or ducting, or on different external elements, such as stud bars. Prior art condensate pumps have addressed this problem by making different versions of the same pump or by including a range of fasteners to account for the different installation sites. However, both prior art solutions are wasteful as unused fasteners will be thrown away and manufacturing different versions of the same pump to account for different installation sites is undesirable.

Prior art pump outlet members have one barbed end which connects to a discharge line, and a second threaded end to screw the outlet to the pump body. However, when these pumps need to be removed, for example, for servicing, the installer must twist the discharge line to unscrew the barbed outlet from the pump. This is particularly difficult as discharge lines are often braided tubes which are stiff, and therefore resist twisting of the outlet. The removal of the barbed outlet is made more difficult by the fact condensate pump assemblies are often installed in space-constrained areas which will place further strain on the installer when removing the condensate pump assembly.

Prior art pumps typically include a motor and other electrical components which generate heat in use. However, as the pumps are designed to be in close proximity to liquids, it is undesirable to include large openings to cool the electrical components in case water reaches the electrical components. The lack of openings can often limit the ability of prior art pumps to remain cool.

The present invention seeks to address at least some of these issues.

In <CIT>, there is disclosed a condensate pump assembly as set forth in the preamble of the accompanying claim <NUM>.

In <CIT>, there is disclosed a mounting bracket which may include a base plate, at least one stationary clip disposed on the base plate, a push releasing plate disposed in spaced apart relation to the at least one stationary clip, and at least one movable clip operatively coupled to and movable with the push releasing plate. The stationary clip or clips and movable clip or clips are disposed and configured to mate with cavities in respective ends of a pump when the push releasing plate is in a non-pivoted position.

Viewed from a first aspect, the present invention provides a condensate pump assembly as set forth in the accompanying claim <NUM>, comprising: a housing having an inlet port, a reservoir arranged to receive liquid through the inlet port, and an outlet port having an outlet assembly mounted thereto, a pump arranged to pump liquid from reservoir to the liquid outlet assembly, and a pair of clips releasably connectable to the housing at a first pair of mounting portions and a second pair of mounting portions. Each of the pair of clips has a first portion for connecting to a first external element and a second portion for connecting to a second external element. The pair of clips are configured to mount the housing to the first external element when connected to the first pair of mounting portions. The pair of clips are configured to mount the housing to the second external element when connected to the second pair of mounting portions.

Each clip of the pair of clips may comprise a hook portion for engaging a corresponding tab portion of the housing.

Any of the first pair of mounting portions or second pair of mounting portions may comprise a recess arranged to receive the hook portion of a respective clip in a first direction and allow the clip to translate in a second direction different to the first direction so as to engage the tab portion.

The first pair of mounting portions may comprise a resiliently deformable member arranged to urge the hook portion against the tab portion.

The clip may comprise an aperture having a first portion having a profile corresponding to the first external element and a second portion having a profile corresponding to the second external element.

The housing may comprise a lower section comprising the reservoir and an upper section. The first pair of mounting portions and second pair of mounting portions may be formed in the upper section. Having the mounting portions on the upper section allows the wired and/or plumbed in part of the condensate pump assembly to remain in place, while the lower section (typically containing the reservoir) can be unclipped and/or removed, emptied and cleaned.

The first pair of mounting portions may be arranged on opposed sides of the housing.

The second pair of mounting portions may be arranged on a side of the housing.

The pair of clips may be arranged in a first orientation when connected to the first pair of mounting portions. The clips may be arranged in a second orientation when connected to the second pair of mounting portions. The first orientation may be substantially perpendicular to the second orientation. The first orientation may be horizontal in use. The second orientation may be substantially vertical in use.

The first external element may be an elongate member, such as a stud bar or threaded rod.

The second external element may be a fastener for mounting the condensate pump assembly to a planar surface, such as a vertical plane or an appliance. The vertical plane may be a wall of a room or ducting. The fastener may be a screw, nail, hook or similar fastener that can be anchored to the planar surface onto which the clip may be mounted.

The pump may be arranged to pump liquid to the outlet assembly through a pumping chamber of the housing. The pumping chamber may have an outlet extending through the outlet port to connect to the outlet assembly. The outlet assembly may comprise an outlet member for connecting to a discharge line and a locking element arranged to releasably engage the outlet of the pumping chamber so as to releasably secure the outlet member to the outlet of the pumping chamber.

The outlet assembly may comprise a sealing element disposed between the outlet member and the outlet of the pumping chamber. The sealing element may be a piston seal. The outlet member may comprise a barbed section.

The outlet assembly may comprise a one-way valve. The one-way valve may be mounted to the outlet member such that the one-way valve remains attached to the outlet member when the outlet member is released from the outlet of the pumping chamber. The outlet member may comprise a barbed end for connecting to the discharge line. The outlet member may comprise a non-threaded end opposed to the barbed end.

The locking element may comprise a threaded section for engaging a corresponding threaded section of the outlet of the pumping chamber.

The housing may comprise an upper section and a lid mounted to the upper section. The condensate pump assembly may comprise a pump motor mounted on the upper section and arranged to drive the pump. A gap may be maintained between the lid and the upper section such that air can flow to the pump motor from outside the housing.

The upper section may comprise a wall extending away from an upper surface of the upper section and at least partially circumscribing the pump motor. The lid may comprise an internal surface having a plurality of fins arranged to abut the wall to maintain the gap. The gap may be less than <NUM>, for example between <NUM> and <NUM>.

The plurality of fins may be spaced equally around the lid. Adjacent pairs of the plurality of fins may be spaced by a distance of between <NUM> and <NUM>. The plurality of fins may be spaced by a distance of approximately <NUM>. This spacing advantageously reduces motor heating, thus increasing the duty cycle of the pump.

At least a part of the lid may provide an overhang over the wall.

<FIG> illustrate perspective views of an exemplary condensate pump assembly <NUM> with clips <NUM> which enable connection to different external elements (e.g. a stud bar <NUM> or a fastener <NUM>) via different mounting positions 155A, 155B (see <FIG>) on the condensate pump assembly <NUM>. When connected to a fastener <NUM>, the clip <NUM> enables connection to a planar surface <NUM>, such as a wall or an appliance (e.g. a casing of an air-conditioner unit) respectively. When the clips <NUM> are mounted vertically as shown in <FIG>, the fastener <NUM> connects the condensate pump assembly <NUM> to the planar surface <NUM>. The condensate pump assembly <NUM> can also be mounted to stud bar <NUM> using the clips <NUM> mounted in the horizontal position shown in <FIG>. This can be achieved by an installer first securing suitable fixings (e.g. nuts) to the stud bar <NUM> such that the clip <NUM> can rest on the fixing to hold the condensate pump assembly <NUM> at the correct height. The condensate pump assembly <NUM> may be provided pre-assembled with the clips <NUM> mounted horizontally (as shown in <FIG>), vertically (as shown in <FIG>), or separately to the condensate pump assembly <NUM>, such that the installer must mount the clips <NUM> to the condensate pump assembly <NUM> when installing the condensate pump assembly <NUM> for the first time. The clips <NUM> have a raised section <NUM> having an aperture <NUM> formed therein (see <FIG>). The aperture <NUM> has two portions 220A, 220B which enable the clip to be connected to different external elements <NUM>, <NUM>. For example, the stud <NUM> may have a diameter corresponding to the first portion 220A. The fastener <NUM> used to connect the clip <NUM> to the planar surface <NUM> may have a second diameter corresponding to the second portion 220B. While round fasteners <NUM> and stud bar <NUM> have been described herein, it would be apparent this was merely exemplary, and the aperture <NUM> may have a profile corresponding to different shaped external elements. A screw <NUM> is a suitable fastener for mounting the condensate pump assembly <NUM> to the wall <NUM>. As the two aperture portions 220A, 220B are connected to one another, the head of the screw is able to pass through the first portion 220A of the aperture <NUM> and the condensate pump assembly can be lowered such that the screw shaft can be slide into the second portion 220B. The screw can then be tightened to fix the condensate pump assembly <NUM> to the wall <NUM>. Should it be necessary to remove the condensate pump assembly <NUM> from the wall, an installer simply needs to loosen the screws <NUM>, as opposed to fully removing the screws, so that the condensate pump assembly <NUM> can be lifted and removed from the screws <NUM> while the screws remain in place. The first 200A and second 220B portions are shown having a round cross section with different diameters. This advantageously allows the same clip <NUM> to be used with different stud <NUM> (e.g. <NUM> and <NUM> stud bar), while also allowing for fastening to a screw <NUM> as explained above. The present clip <NUM> can be made from injection moulding, as the design has the same line-of-draw for both orientations of the clip <NUM>.

With reference to <FIG>, the condensate pump assembly includes multiple inlet ports 110A-110D to facilitate installation in multiple different orientations depending on the specific constraints of the installation site. The selected inlet port 110A can be opened to allow condensate to be introduced into a reservoir <NUM> formed in a lower section <NUM> of the housing. The unused inlet ports 110B-10D may remain plugged to avoid debris falling into the reservoir <NUM>. A pump motor <NUM> drives an impeller housed in a pumping chamber <NUM> and draws condensate from the reservoir <NUM> through an inlet <NUM> and pumps the condensate out of pumping chamber <NUM> through an outlet member <NUM> and an outlet assembly <NUM> which is connected to a discharge line (not shown). A filter <NUM> is also present in the reservoir <NUM> which prevents larger particulate matter from reaching in the impeller. However, it would be apparent this was not essential. As shown in <FIG>, the pump motor <NUM> is housed in a "dry" region of the housing between the upper section <NUM> and the lid <NUM>, and the reservoir <NUM> is within a "wet" lower section <NUM> of the housing.

<FIG> illustrates cross-sectional views of the condensate pump assembly <NUM> with a clip <NUM> connected to a respective mounting portion 155A (see also <FIG>) for mounting the condensate pump assembly <NUM> to a stud bar <NUM> (omitted from <FIG> for clarity). With reference to <FIG> and <FIG>, a pair of mounting portions 155A are provided at opposed sides of the upper section of the housing. The mounting portion 155A has a recess <NUM> for receiving a hook portion <NUM> of the clip <NUM> (see <FIG>). The mounting portion 155A has a resiliently deformable arm <NUM> which extends from one side of the recess <NUM> and urges the hook portion <NUM> against a tab <NUM> formed in the housing. This results in the tab <NUM> being received in a recess <NUM> defined by the hook portion <NUM> which secures the clip <NUM> to the mounting portion 155A. As shown in <FIG>, the clip <NUM> includes a shoulder <NUM> which corresponds to a ridge <NUM> formed on the resiliently deformable arm <NUM>. The ridge <NUM> has a profile which corresponds to the shoulder <NUM> to "lock" the clip <NUM> in the horizontal orientation shown in <FIG>. Ridges <NUM> formed on the clip <NUM> (see <FIG>) increase the stiffness of the clip <NUM> about an axis perpendicular to the ridges <NUM>. This is particularly advantageous when the clips <NUM> are mounted in the horizontal configuration and rest on a nut fixed on the stud <NUM>. As the load water within in the reservoir <NUM> can significantly increase the weight of the condensate pump assembly <NUM>, the ridges <NUM> reduce the deflection of the clip <NUM>. The distance between the aperture <NUM> and hook portion <NUM> provides sufficient space for an installer's thumb and finger to release a nut secured to the stud <NUM>, but is not so large that the bending moment applied to the clip <NUM> would damage or break the clip <NUM> when the condensate pump assembly <NUM> was filled with water. When connected to the mounting portions 155A, the spacing between the apertures <NUM> of the clips <NUM> preferably match the spacing between stud bar <NUM> used to secure prior art pumps fixed in a similar manner, thus facilitating the replacement of condensate pump assemblies as new stud bar does not need to be provided.

<FIG> illustrate cross-sectional views of the condensate pump assembly <NUM> with a clip <NUM> connected to a respective mounting portion 155B (see also <FIG>) for mounting the condensate pump assembly <NUM> to a planar surface <NUM> (omitted from <FIG> for clarity). With reference to <FIG> and <FIG>, a pair of mounting portions 155B are provided on the same side of the upper section of the housing. The mounting portion 155B has a recess <NUM> for receiving the hook portion <NUM> of the clip <NUM>. In contrast to the mounting portions 155A, the clips <NUM> are secured to mounting portions 155B by the lower section <NUM> of the housing pressing against ridges <NUM> of the clip (see <FIG>). The ridges <NUM> are formed on an opposed side of the clip <NUM> to the first shoulder <NUM>. While multiple (e.g. three shown in <FIG>) ridges are shown, it would be apparent this was not essential, and a single ridge <NUM> would be sufficient. The lower portion <NUM> is held against the upper section <NUM> by a releasable snap-fit joint <NUM> (see <FIG>) which provides sufficient force against the ridges <NUM> of the clip <NUM> to lock it in the vertical orientation shown in <FIG>. The mounting portion 155B includes a tab <NUM> with a profile corresponding to the hook portion <NUM>. As explained above, a screw <NUM> can be used to mount the condensate pump assembly in the configuration shown in <FIG>. The spacing between the hook portion <NUM> and the aperture <NUM> is sufficient to allow a screwdriver, or other tool corresponding to the fastener <NUM>, to engage and loosen the screw <NUM> to allow the condensate pump assembly <NUM> to be removed in the manner described above. When the clips <NUM> are mounted in the vertical configuration, the weight of the pump pulls downwards, parallel to the screw <NUM> which presses the underside of the screw head against the front-side of the clip <NUM> (the side facing the condensate pump assembly <NUM>) and flexing the clip <NUM> downwards and open. The ridges <NUM> also function in this configuration to stiffen the clip <NUM> to limit the deflection of the clip <NUM>. When connected to the mounting portions 155B, the spacing between the apertures <NUM> of the clips <NUM> preferably match the spacing used in prior art pumps fixed in a similar manner, thus facilitating the replacement of condensate pump assemblies as new mounting holes do not need to be drilled.

<FIG> illustrates an exemplary assembly process for connecting a clip <NUM> to mounting portion 155A. The hook portion <NUM> of a clip <NUM> can be pressed into the recess <NUM> in a first direction A (shown as vertical in <FIG>) before pressing in a second direction B (shown as horizontal in <FIG>) to urge the hook portion <NUM> around the tab <NUM> and to lock the clip <NUM> in position. To release the clip <NUM> from mounting portion 155A, an installer can simply reverse the process, by first pushing the clip <NUM> towards the upper section <NUM> (the reverse direction of arrow B) and by lifting the clip out of the recess <NUM> (the reverse of arrow A).

<FIG> illustrates an alternative exemplary assembly process for connecting a clip <NUM> to mounting portion 155B. Here, the installer first removes the lower section <NUM> to provide access to the recess <NUM>. With the lower section <NUM> separated from the upper section <NUM>, the clip is first pressed against the upper section <NUM> (arrow A) to position the hook portion <NUM> below the recess <NUM>, and to position the raised section <NUM> of the clip (see <FIG>) in a corresponding notch <NUM> formed in the upper section <NUM> (see <FIG>). The installer can then press the hook portion <NUM> into the recess <NUM>, for example by lifting the clip <NUM> as indicated by arrow B. Once the hook portion <NUM> has abutted the tab <NUM> in the mounting portion 155B, the clip <NUM> is fully inserted into the recess <NUM>, and the installer can re-connect the lower section <NUM> to the upper section <NUM> as indicated by arrow C. The clip <NUM> is clamped in position due to an upper edge of the lower section <NUM> pressing against the ridges <NUM> of the clip <NUM>. As shown in <FIG>, the lower section <NUM> may include a series of recesses corresponding to the ridges <NUM>. This advantageously restricts relative movement between the clip <NUM> and the lower <NUM> and upper <NUM> sections of the housing. To release the clip <NUM> from the mounting portion 155B, an installer simply reverses this process, by first releasing the lower section <NUM> from the upper section <NUM> (e.g. by releasing the snap-fit joint <NUM>), pulling the clip <NUM> out of the recess <NUM> (the reverse of arrow B) and once the raised section <NUM> sits in the notch <NUM>, the hook portion <NUM> can be withdrawn from the recess <NUM> (the reverse of arrow A). While a snap-fit joint <NUM> is shown, it would be apparent this was not essential and other releasable joints may be used to releasably connect the lower section <NUM> to the upper section <NUM>.

<FIG> illustrates perspective and plan views of an exemplary condensate pump assembly <NUM> with the lid <NUM> omitted for clarity. As shown, the upper section <NUM> has a wall <NUM> extending from an upper surface thereof. The wall <NUM> substantially circumscribes the electrical components of the condensate pump assembly <NUM>, leaving an opening for a power cable <NUM> (see <FIG>) to extend into the "dry" region of the housing defined by the lid <NUM> and the upper section <NUM>. While a pump motor <NUM> has been described, other electrical components, such as pump motor controllers, transformers and liquid level sensors will be contained in the condensate pump assembly <NUM>.

<FIG> illustrates a perspective view of an exemplary lid <NUM> which can be connected to the upper section <NUM>, for example using a snap-fit connection. As shown in <FIG>, a series of fins <NUM> are formed on an inner surface <NUM> of the lid <NUM>. The fins are spaced apart from one another by a distance X1 of <NUM>. However, it would be apparent this was merely an example of a suitable spacing. Other distances X1 between the fins <NUM> may be suitable, depending on the requirements of the end user. When the lid <NUM> is secured to the upper section <NUM>, a shoulder <NUM> of each fin <NUM> abuts an upper edge <NUM> of the wall <NUM> (see <FIG>) which maintains a gap <NUM> between the lower edge <NUM> of the lid <NUM> and the upper section <NUM> and provides an air flow path P into the "dry" region. The air flow path P provides improved cooling of the electrical components. The air flow path P is serpentine as shown in <FIG>. In some cases, the fins <NUM> and wall <NUM> may provide a labyrinth to provide a more complex air flow path, further limiting the ability of water to reach the "dry" region. The fins also include a tail portion <NUM> which extends from the inner surface <NUM> of the lid <NUM> towards an outer side of the wall <NUM> to help prevent ingress of liquid into the "dry" region.

The overhang of the lid <NUM> over the wall <NUM> preferably maintains a gap <NUM> between the upper section <NUM> and the lid <NUM> of between approximately <NUM> and <NUM>. As lid <NUM> overhangs a portion of the upper section <NUM> having a curved profile (see <FIG> and <FIG>), the gap <NUM> between the lid and the upper section <NUM> is not constant along the length of the lid <NUM>. In one example, the maximum distance between the lid <NUM> and the upper section <NUM> is approximately <NUM>, for example <NUM>. In another example, the minimum distance between the lid and the upper section <NUM> is approximately <NUM>, for example <NUM>. It would also be apparent that the upper section <NUM> may have a substantially flat profile which would result in an approximately fixed gap <NUM> between the lid <NUM> and the upper section <NUM>. The gap <NUM> for the air flow path also extends between the overhang of the lid <NUM> and the wall <NUM>. The distance between the overhang of the lid <NUM> and the wall <NUM> is between approximately <NUM> and <NUM>, e.g. <NUM>, but can be independently set based on the fin <NUM> geometry. As shown in <FIG>, the fins <NUM> do not need to have the same geometry. For example, some fins <NUM> may not have either or both of a shoulder <NUM> or tail portion <NUM>. By increasing the distance between the upper edge <NUM> of the wall <NUM> and the lower edge <NUM> of the lid <NUM>, the air flow path can be maintained while providing increased resistance to water ingress due to the longer path between the outside of the housing and the "dry" region. The larger overhang reduces the range of angles which water is able to enter the "dry" region without contacting either the lid <NUM> or the wall <NUM> and dripping back down and out of the housing. The present condensate pump assembly <NUM> advantageously achieves IP-X4 rating which provides splash resistance from any direction. The present condensate pump assembly <NUM> can therefore be reliably deployed in a wider range of sites. While the fins <NUM> are shown with a curved section to accommodate the cross-section of the wall <NUM>, the shape of the fins is not essential to preventing ingress of liquid into the "dry" region. Incorporating vertical fins <NUM> to provide the labyrinth avoids the need for more complex arrangements which would require a more complex manufacturing and assembly process. Thus, the present design advantageously enables the lid <NUM> to be manufactured from a single moulding, as opposed to a two-part moulding, thus simplifying the manufacturing process.

<FIG> illustrate perspective and cross-sectional views of an exemplary outlet assembly <NUM>. The outlet assembly <NUM> includes a locking element in the form of a nut <NUM>, and a barbed outlet <NUM> designed to grip a discharge line and be releasably connected to the condensate pump assembly <NUM>. Thus, if an installer needs to remove the condensate pump assembly or disconnect the discharge line, they are able to unlock the locking element <NUM> independently of the outlet member <NUM> and the connected discharge line. As the discharge line is often braided tube, the present outlet assembly enables the outlet member <NUM> to be removed with greater ease compared to existing outlet members which are one-piece outlet parts with a threaded end for connecting to the pump and a barbed end for connecting to the discharge line which require overcoming the torsional resistance generated in the discharge line as the outlet is disconnected from the pump.

The barbed outlet <NUM> has a shoulder <NUM> which allows the barbed outlet <NUM> to rest on the outlet <NUM> of the pumping chamber <NUM>. As shown in <FIG>, the barbed outlet <NUM> extends into the pumping chamber outlet <NUM>. A corresponding shoulder <NUM> formed in the nut <NUM> is designed to clamp the shoulder <NUM> to hold the barbed outlet member <NUM> in position. The inner diameter of the shoulder <NUM> maintains a space with the barbed outlet member <NUM> for receiving the discharge line. The pumping chamber outlet <NUM> has a threaded outer surface which corresponds to the internal threaded surface of the nut <NUM>.

The outlet assembly <NUM> includes a piston seal <NUM> to provide a fluid-tight seal between the pumping chamber outlet <NUM> and the barbed outlet member <NUM>. A piston seal <NUM> advantageously does not require a large clamping force to maintain the fluid-tight seal (e.g. a finger-tight fit is sufficient). While a piston seal <NUM> is described, it would be apparent this was exemplary and other seals would be suitable.

The outlet assembly <NUM> also includes a one-way valve <NUM> (shown as a duck-billed valve in <FIG>). The one-way valve <NUM> is fixed to the barbed outlet member <NUM> via a clamping part <NUM>. As shown in <FIG>, the locking member <NUM> and clamping part <NUM> have corresponding mechanical elements to provide a snap-fit joint <NUM> to ensure the clamping part <NUM> and the one-way valve <NUM> remain connected to the barbed outlet member <NUM> when the barbed outlet member <NUM> is removed from the pumping chamber outlet <NUM> (see <FIG>).

The present outlet assembly <NUM> therefore, prevents ingress of liquid into the pumping chamber <NUM> via the outlet <NUM> during normal operation of the condensate pump assembly <NUM> when the outlet assembly is connected to the pump chamber outlet <NUM> as shown in <FIG>. However, the installer may need to remove the pump from its installed location, for example, to maintain the condensate pump assembly <NUM>. By providing a separate locking element <NUM> to the barbed outlet member <NUM>, the installer can simply unlock the locking element <NUM>, which can rotate independently of the barbed outlet member <NUM>, and pull the barbed outlet member <NUM> free from the outlet <NUM> of the pumping chamber <NUM> with the discharge line, clamping part <NUM> and one-way valve <NUM> still connected to one another. As the one-way valve <NUM> is located in the discharge line, this stops liquid that may be present in the discharge line from spilling from the barbed outlet member <NUM> onto the surrounding area when the outlet assembly is disconnected from the pump chamber outlet <NUM>, greatly reducing the risk of water damage to ducting or other nearby appliances, or onto the condensate pump assembly <NUM> itself.

Throughout the description and claims of this specification, the words "comprise" and "contain" and variations of them mean "including but not limited to", and they are not intended to (and do not) exclude other components, integers or steps.

Claim 1:
A condensate pump assembly (<NUM>) comprising:
a housing having an inlet port (110A-110D), a reservoir (<NUM>) arranged to receive liquid through the inlet port, and an outlet port having an outlet assembly (<NUM>) mounted thereto, and
a pump (<NUM>) arranged to pump liquid from reservoir (<NUM>) to the liquid outlet assembly (<NUM>), and
a pair of clips (<NUM>);
characterised in that the pair of clips (<NUM>) are releasably connectable to the housing at a first pair of mounting portions (155A) and a second pair of mounting portions (155B), wherein each of the pair of clips (<NUM>) has a first portion (220A) for connecting to a first external element (<NUM>) and a second portion (220B) for connecting to a second external element (<NUM>),
wherein the pair of clips (<NUM>) are configured to mount the housing to the first external element (<NUM>) when connected to the first pair of mounting portions (155A), and
wherein the pair of clips (<NUM>) are configured to mount the housing to the second external element (<NUM>) when connected to the second pair of mounting portions (155B).