Condensate pan insert

Abstract

A condensate pan insert for an evaporator assembly is configured to snap onto a condensate pan to prevent condensation blow-off in a down flow application. The condensate pan insert comprises a cover member, a snap member, a first wing member, and a second wing member. The snap member is coupled to the cover member and configured to engage with the condensate pan. The first wing member is insertable between a first surface of the condensate pan and a bottom of a first evaporator coil slab. The second wing member is insertable between a second surface of the condensate pan and a bottom of a second evaporator coil slab.

1 . A condensate pan insert for an evaporator assembly comprising: 
 a cover member;    a snap member coupled to the cover member and configured to engage with a condensate pan;    a first wing member insertable between a first surface of the condensate pan and a side of a first evaporator coil slab; and    a second wing member insertable between a second surface of the condensate pan and a side of a second evaporator coil slab.    
   
   
       2 . The condensate pan insert of  claim 1 , wherein the snap member engages with a bottom edge of the condensate pan.  
   
   
       3 . The condensate pan insert of  claim 1 , wherein the condensate pan insert is formed from a polymeric material.  
   
   
       4 . The condensate pan insert of  claim 3 , wherein the polymeric material comprises polycarbonate.  
   
   
       5 . The condensate pan insert of  claim 1 , wherein the condensate pan insert is formed from sheet metal.  
   
   
       6 . The condensate pan insert of  claim 1 , wherein the condensate pan insert is formed from aluminum.  
   
   
       7 . The condensate pan insert of  claim 1 , wherein the cover member further comprises a raised arch portion extending in a direction opposite of the snap member.  
   
   
       8 . The condensate pan insert of  claim 1 , wherein the cover member is configured to enclose a drain channel of the condensate pan.  
   
   
       9 . The condensate pan insert of  claim 8 , wherein the cover member is sloped in a downward direction from a front side to a rear side of the drain channel.  
   
   
       10 . An evaporator assembly comprising: 
 a casing:    an evaporator coil positionable within the casing, wherein the evaporator coil comprises a first coil slab and a second coil slab;    a condensate pan comprising a first channel within a first pan member, a second channel within a second pan member, and a third channel within a third pan member, wherein the first coil slab is configured to mate with the first pan member, and wherein the second coil slab is configured to mate with the second pan member; and    a condensate pan insert attachable to the condensate pan, wherein the pan insert is configured to enclose an open side of the third channel.    
   
   
       11 . The evaporator assembly of  claim 10 , wherein the condensate pan insert further comprises: 
 a cover member configured to enclose the open side of the third channel; and    a snap member attached to the cover member for securing the cover member to the condensate pan.    
   
   
       12 . The condensate pan insert of  claim 10 , wherein the cover member is sloped in a downward direction from a front side to a rear side of the drain channel.  
   
   
       13 . The evaporator assembly of  claim 1 , wherein the condensate pan insert further comprises: 
 a first wing member insertable between the first coil slab and the first pan member; and    a second wing member insertable between the second coil slab and the second pan member.    
   
   
       14 . The evaporator assembly of  claim 10 , wherein the first pan member and the second pan member are substantially parallel.  
   
   
       15 . The evaporator assembly of  claim 14 , wherein the third pan member is substantially perpendicular to the first pan member and the second pan member.  
   
   
       16 . The evaporator assembly of  claim 10 , wherein the pan insert further comprises a pan wall member that forms a portion of an outer wall of the first pan member.  
   
   
       17 . A method of preventing condensate blow-off from a condensate pan in an evaporator assembly, the method comprising the steps of: 
 collecting condensation from a first coil slab in a first channel of the condensate pan;    collecting condensation from a second coil slab in a second channel of the condensate pan;    directing the condensation in the first and second channels towards a condensate drain in a third channel of the condensate pan; and    covering a top side of the third channel with a condensate pan insert to prevent a stream of air from contacting the condensation.    
   
   
       18 . The method of  claim 17 , wherein the first coil slab and the second coil slab are arranged in a vertical coil configuration.  
   
   
       19 . The method of  claim 17 , wherein the condensate pan insert includes a snap member for securing the pan insert to the condensate pan.  
   
   
       20 . The method of  claim 17 , wherein the condensate pan insert includes a first wing member insertable between a first air gap formed between the first coil slab and the first channel, and a second air gap formed between the second coil slab and the second channel, wherein the first and second wing members are configured to prevent the stream of air from entering the first and second channels.