Air Conditioner Condensate Collection System

Abstract

In one embodiment, an auxiliary condensate collection system for an air conditioner includes a guide sheet and a drain pan. The guide sheet is positioned under an air handler of the air conditioner to collect condensate overflow and direct the condensate to a drain pan. The guide sheet is large, but flexible, so that it can be rolled up to fit through an attic access hole. The drain pan is small enough that it fits through the attic access hole also. In other embodiments, the auxiliary condensate collection system includes two or more drain pans that can fit through an attic access hole and a bridge that spans a seam formed between the edges of the drain pans arranged side-by-side or end-to-end to seal the seam and direct condensate into the side-by-side or end-to-end drain pans. In other embodiments, each drain pan has an integral overlapping flange so that a matrix of drain pans can be connected together both side-by-side and/or end-to-end.

I claim: 
     
         1 . An auxiliary condensate collection system for collecting condensate from the combination of an air handler and attach plenums, the combination having a footprint area and wherein the combination is installed in an attic having an attic access hole with an opening having an opening area less than the footprint area, the condensate collection system comprising a guide sheet configured to fit through the attic access hole and a first drain pan sized to fit through the attic access hole wherein the guide sheet is positioned below the air handler and attach plenums for receiving condensate emitted from the air handler or attach plenums and for directing the condensate to the first drain pan. 
     
     
         2 . The auxiliary condensate collection system of  claim 1 , wherein the guide sheet is flexible, has an open area equal to or greater than the area of the footprint area, and is foldable to fit through the attic access hole. 
     
     
         3 . The auxiliary condensate collection system of  claim 2 , wherein the sheet has a first end connected to the air handler or the plenums and a second end attached to the first drain pan. 
     
     
         4 . The auxiliary condensate collection system of  claim 3 , wherein the sheet has a center section, and the first end of the sheet and the second end of the sheet are connected to the air handler or the plenums and the center section is attached to and empties into the first drain pan. 
     
     
         5 . The auxiliary condensate collection system of  claim 1 , wherein the sheet is flexible, has an open area equal to or greater than the area of the footprint area, and is rolled into a configuration that fits through the attic access hole. 
     
     
         6 . The auxiliary condensate collection system of  claim 5 , wherein the sheet has a first end connected to the air handler or the plenums and a second end attached to the first drain pan. 
     
     
         7 . The auxiliary condensate collection system of  claim 1 , further comprising a second drain pan sized to fit through the attic access hole, wherein the first drain pan has a side and an end and the second drain pan has a side and an end, and the first drain pan and second drain pan are aligned side-by-side or end-to-end with a joint between the sides or ends, and wherein the guide sheet forms a bridge spanning the joint and directing condensate into each drain pan. 
     
     
         8 . The auxiliary condensate collection system of  claim 7 , wherein the joint is open. 
     
     
         9 . The auxiliary condensate collection system of  claim 7 , wherein the joint is closed. 
     
     
         10 . The auxiliary condensate collection system of  claim 7 , wherein the bridge is connected to the side of the first drain pan and overlaps the side of the second drain pan when the first drain pan and the second drain pan are aligned in a side-by-side relationship. 
     
     
         11 . The auxiliary condensate collection system of  claim 7 , wherein the bridge is connected the end of the first drain pan and overlaps the end of the second drain pan when the first drain pan and the second drain pan are aligned in an end-to-end relationship. 
     
     
         12 . The auxiliary condensate collection system of  claim 7 , wherein the bridge is connected to one end of the first drain pan and is connected to one side of the first drain pan, and the bridge overlaps an adjacent side or an adjacent end of the second drain pan when the first drain pan and the second drain pan are aligned in a side-by-side relationship or an end-to-end relationship. 
     
     
         13 . The auxiliary condensate collection system of  claim 7 , wherein the first pan and the second pan have risers for supporting the air handler and attached plenums. 
     
     
         14 . The auxiliary condensate collection system of  claim 13 , wherein the bridge includes a riser for supporting the air handler and attach plenums. 
     
     
         15 . An auxiliary condensate collection system for collecting condensate from the combination of an air handler and attach plenums, the combination having a footprint area and wherein the combination is installed in an attic having an attic access hole with an opening having an opening area less than the footprint area, the condensate collection system comprising:
 a. a first drain pan sized to fit through the attic access hole and having a side, an end, and a first drain pan area;   b. a second drain pan sized to fit through the attic access hole and having a side, an end, and a second drain pan area, wherein the first drain pan and second drain pan are aligned side-by-side or end-to-end with a joint between the sides or ends; and   c. a bridge having a bridge area and spanning the joint and directing condensate from the air handler and attach plenums into at least one of the drain pans,   
       wherein the sum of the bridge area, the first drain pan area, and the second drain pan area is equal to or greater than the footprint area of the air handler and attach plenums. 
     
     
         16 . The auxiliary condensate collection system of  claim 15 , wherein the joint is open. 
     
     
         17 . The auxiliary condensate collection system of  claim 15 , wherein the joint is closed. 
     
     
         18 . The auxiliary condensate collection system of  claim 15 , wherein the bridge is connected to the side of the first drain pan and overlaps the side of the second drain pan when the first drain pan and the second drain pan are aligned in a side-by-side relationship. 
     
     
         19 . The auxiliary condensate collection system of  claim 15 , wherein the bridge is connected the end of the first drain pan and overlaps the end of the second drain pan when the first drain pan and the second drain pan are aligned in an end-to-end relationship. 
     
     
         20 . The auxiliary condensate collection system of  claim 15 , wherein the bridge is connected to one end of the first drain pan and is connected to one side of the first drain pan, and the bridge overlaps an adjacent side or an adjacent end of the second drain pan when the first drain pan and the second drain pan are aligned in a side-by-side relationship or an end-to-end relationship.