Condensate pan internal corner design

Abstract

An internal corner design of a condensate pan is configured to prevent condensation blow-off in an evaporator assembly. The condensate pan comprises a first rib and a second rib, the first rib and the second rib defining a first groove configured to receive a delta plate.

1 . A condensate pan comprising: 
 a first pan member for receiving a lower end of a first coil slab;    a second pan member for receiving a lower end of a second coil slab;    a third pan member coupled to the first and second pan members; and    a first groove configured to receive a delta plate, wherein the first groove includes a first rib and a second rib, and wherein the first groove is disposed at a first internal corner defined by the first and third pan members.    
   
   
       2 . The condensate pan of  claim 1 , wherein the condensate pan is formed from a plastic.  
   
   
       3 . The condensate pan of  claim 2 , wherein the plastic comprises polystyrene.  
   
   
       4 . The condensate pan of  claim 1 , and further comprising a second groove configured to receive the delta plate, wherein the second groove includes a third rib and a fourth rib, and wherein the second groove is disposed at a second internal corner defined by the second and third pan members.  
   
   
       5 . The condensate pan of  claim 4 , and further comprising a delta plate support disposed between the first groove and the second groove for aligning the delta plate with respect to the condensate pan.  
   
   
       6 . The condensate pan of  claim 5 , and further comprising a plurality of delta plate supports disposed between the first and second grooves.  
   
   
       7 . The condensate pan of  claim 6 , wherein the plurality is equal to five.  
   
   
       8 . The condensate pan of  claim 1 , wherein the condensate pan further comprises an aperture configured to receive a tab member of the delta plate for securing the delta plate to the condensate pan.  
   
   
       9 . The condensate pan of  claim 8 , wherein the condensate pan further comprises a second aperture configured to receive a second tab member of the delta plate for securing the delta plate to the condensate pan.  
   
   
       10 . An evaporator assembly comprising: 
 a condensate pan comprising: 
 a first rib; and  
 a second rib, the first rib and the second rib defining a first groove configured to receive a delta plate;  
   a delta plate at least partially disposed within the first groove.    
   
   
       11 . The evaporator assembly of  claim 10 , wherein the condensate pan further comprises: 
 a third rib; and    a fourth rib, the third rib and the fourth rib defining a second groove configured to receive the delta plate.    
   
   
       12 . The evaporator assembly of  claim 11 , wherein the condensate pan further comprises a delta plate support disposed along an inner wall of the condensate pan between the first and second grooves.  
   
   
       13 . The evaporator assembly of  claim 12 , and further comprising a plurality of delta plate supports disposed along the inner wall of the condensate pan between the first and second grooves.  
   
   
       14 . The evaporator assembly of  claim 12 , wherein the inner wall includes an aperture configured to receive a tab member of the delta plate to secure the delta plate to the inner wall.  
   
   
       15 . A condensate pan comprising: 
 a generally rectangular outer wall;    a generally rectangular inner wall disposed within the outer wall, the inner and outer walls defining a first internal corner comprising: 
 a first rib; and  
 a second rib, the first and second ribs defining a first groove configured to receive a first delta plate.  
   
   
   
       16 . The condensate pan of  claim 15 , wherein the outer and inner walls further define a second internal corner comprising: 
 a third rib; and    a fourth rib, the third and fourth ribs defining a second groove configured to receive the first delta plate.    
   
   
       17 . The condensate pan of  claim 16 , wherein the outer and inner walls further define a third internal corner comprising: 
 a fifth rib; and    a sixth rib, the fifth and sixth ribs defining a third groove configured to receive a second delta plate.    
   
   
       18 . The condensate pan of  claim 17 , wherein the outer and inner walls further define a fourth internal corner comprising: 
 a seventh rib; and    an eighth rib, the seventh and eighth ribs defining a fourth groove configured to receive the second delta plate.    
   
   
       19 . The condensate pan of  claim 18 , wherein the condensate pan further comprises: 
 a first delta plate support disposed between the first and second grooves; and    a second delta plate support disposed between the third and fourth grooves.    
   
   
       20 . The condensate pan of  claim 18 , wherein a first section of the inner wall includes an aperture configured to receive a tab member of the first delta plate, and wherein a second section of the inner wall includes an aperture configured to receive a tab member of the second delta plate.