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Condensate pump

Condensate pump description/claims

This application claims priority from U.S. Provisional Patent Application Ser. No. 60/956,741 filed on Aug. 20, 2007, which is incorporated herein in its entirety.

This invention relates to a condensate pump that collects condensate water from the evaporator of an HVAC system and pumps the condensate water to another location for disposal. More specifically, the condensate pump of the present invention includes an improved impeller pump, an improved component mounting assembly, and an improved reservoir attachment mechanism.

A condensate pump is used in an HVAC system to collect condensate water from the evaporator of the HVAC system and to pump the condensate water to a remote location for disposal. Particularly, the condensate pump typically comprises a reservoir, an impeller pump for pumping the water out of the reservoir to the remote location, and an electric motor to drive the impeller pump. A float detects the level of condensate water in the reservoir and activates control circuitry to control the operation of the electric motor.

Condensate pumps are often located in extreme environments and are subjected to moisture, heat, and cold. Moreover, condensate pumps are often installed in inaccessible locations where maintenance is difficult, and therefore reliability over many years is necessary. Further, the condensate pump should operate quietly and without excessive buildup of heat from the operation of the electric motor.

The present invention addresses the issues raised by the installation of a condensate pump in an extreme environment. Particularly, the condensate pump of the present invention is capable of operating reliably in such an extreme environment over an extended period of time. Further, the condensate pump of the present invention is designed to operate quietly and efficiently.

In order to achieve the objects outlined above, the condensate pump of the present invention embodies a number of features that together produce an improved condensate pump. The condensate pump of the present invention includes a reservoir and a unitary top support plate, which forms the backbone of the condensate pump. The major components of the condensate pump are mounted to the unitary top support plate. In order to mount the condensate pump components, the unitary top support plate has an impeller pump support structure, a pump motor support structure, a cover support structure, a control circuitry support structure, and a float assembly support structure. A pump motor, a motor cover, an impeller pump, a float assembly, and control circuitry are mounted on the unitary top support plate by means of the respective support structures.

With respect to quiet operation, the pump motor is mounted by means of rubber bushings to the unitary top support plate to isolate the vibrations of the motor and heat generated by the motor from the unitary top support plate. Further, the unitary top support plate is tightly mounted to the top of the reservoir by means of a snap connection so that the unitary top support plate, with its mounted components cannot vibrate on top of the reservoir.

Quiet operation is also enhanced by the design of the cylindrical volute chamber of the impeller pump. Particularly, the transition from the cylindrical volute chamber to the tangential output port of the impeller pump has a swept diagonal surface that creates a gradual transition from the cylindrical volute chamber to the tangential output port. The gradual transition minimizes the pulsing that occurs each time the water between successive blades of the impeller rushes through the output port of the volute chamber. The reduction of pulsing by the smooth transition to the tangential output port increases efficiency and reduces noise of the impeller pump.

In addition, in order to promote a constant flow of water into the central intake port of the volute chamber of the impeller pump, a reservoir intake profile with a concave surface and vortex inhibiting vanes are molded into the bottom of the reservoir adjacent the central intake port of the impeller pump. The vortex inhibiting vanes break up any vortex within the reservoir induced by the action of the impeller pump, and the reservoir intake profile directs the water upward in a smooth transition as it flows toward the central intake port of the impeller pump. In addition, the impeller has a matching impeller intake profile with a concave surface centered on the impeller and extending toward the reservoir intake profile to complete the flow transition of the water into the central intake port. The intake profiles and the vortex inhibiting vanes help assure a constant flow of water into the central intake port of the impeller pump thereby minimizing the intake of air by the impeller pump. Minimizing the intake of air by the impeller pump increases the efficiency of the impeller pump and reduces noise resulting from the intake of air.

Further objects, features and advantages will become apparent upon consideration of the following detailed description of the invention when taken in conjunction with the drawings and the appended claims.

FIG. 1 is a front perspective view of the condensate pump in accordance with the present invention.

FIG. 2 is a front elevation view of the condensate pump in accordance with present invention.

FIG. 3 is a front elevation view of the condensate pump (with the reservoir and cover cut away) in accordance with the present invention.

• Provisional Patent
• Utility Patent

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