Overflow sensor assembly in temperature control systems

Patent metadata

Field	Value
Publication number	US-12313271-B2
Application number	US-202418407989-A
Country	US
Kind code	B2
Filing date	Jan 9, 2024
Priority date	Nov 14, 2018
Publication date	May 27, 2025
Grant date	May 27, 2025

Abstract

Embodiments include overflow sensor assemblies for water heaters, HVAC systems, and other devices for which temperature control systems may be used. An example overflow sensor assembly for detecting fluid leaks at a device may include a sensor probe configured to be in electrical communication with a power supply, and a sensor mounting bracket that forms a ground, where the sensor mounting bracket is configured to be adjustably coupled to a mounting surface on the device, such that the sensor mounting bracket can deflect about the mounting surface. The sensor probe is suspended from the sensor mounting bracket.

First claim

That which is claimed is:

1. An overflow sensor assembly for detecting fluid leaks at a device, the overflow sensor assembly comprising:
a sensor probe configured to be in electrical communication with a power supply; and
a sensor mounting bracket that forms a ground, wherein the sensor mounting bracket is configured to be adjustably coupled to a mounting surface on the device, such that the sensor mounting bracket can deflect about the mounting surface;
wherein the sensor probe is suspended from the sensor mounting bracket.

2. The overflow sensor assembly of claim 1 , wherein an overflow detection circuit is activated when the sensor probe and the sensor mounting bracket come in contact with a fluid.

3. The overflow sensor assembly of claim 2 , wherein the fluid forms a portion of the overflow detection circuit.

4. The overflow sensor assembly of claim 1 , wherein the sensor mounting bracket is configured to be pivotally coupled to the mounting surface.

5. The overflow sensor assembly of claim 1 , wherein the sensor probe is suspended in a condensate drain pan of the device.

6. The overflow sensor assembly of claim 1 , wherein the sensor probe comprises at least one metal spring.

7. The overflow sensor assembly of claim 6 , wherein the at least one metal spring is configured to swing in a lateral direction.

8. The overflow sensor assembly of claim 6 , wherein the at least one metal spring is coupled to a screw.

9. The overflow sensor assembly of claim 8 , wherein an insertion depth of the at least one metal spring is adjustable via rotation of the at least one metal spring with respect to the screw.

10. The overflow sensor assembly of claim 1 , wherein the sensor mounting bracket comprises:
a leg portion; and
an L-shaped portion, wherein the sensor probe is coupled to the leg portion;
wherein the sensor probe and an end of the leg portion are disposed at a same vertical elevation, and wherein the sensor mounting bracket is separated from the leg portion by a distance.

11. An overflow sensor assembly for use with a device, the overflow sensor assembly comprising:
a sensor probe in electrical communication with an overflow detection circuit of the device; and
a sensor mounting bracket in electrical communication with the overflow detection circuit, wherein the sensor mounting bracket is configured to be adjustably coupled to a mounting surface on the device, such that the sensor mounting bracket can deflect about the mounting surface;
wherein the sensor probe is suspended from the sensor mounting bracket.

12. The overflow sensor assembly of claim 11 , wherein the overflow detection circuit of the device is closed when the sensor probe and the sensor mounting bracket both come in contact with a condensate fluid.

13. The overflow sensor assembly of claim 12 , wherein the condensate fluid forms a portion of the overflow detection circuit.

14. The overflow sensor assembly of claim 11 , wherein the sensor mounting bracket is configured to be pivotally coupled to the mounting surface.

15. The overflow sensor assembly of claim 11 , wherein the sensor probe is suspended in a condensate drain pan of the device.

16. The overflow sensor assembly of claim 11 , wherein the sensor probe comprises at least one metal spring.

17. The overflow sensor assembly of claim 16 , wherein the at least one metal spring is configured to swing in a lateral direction.

18. The overflow sensor assembly of claim 16 , wherein the at least one metal spring is coupled to a screw.

19. The overflow sensor assembly of claim 18 , wherein an insertion depth of the at least one metal spring is adjustable via rotation of the at least one metal spring with respect to the screw.

20. The overflow sensor assembly of claim 11 , wherein the sensor mounting bracket comprises:
a leg portion; and
an L-shaped portion, wherein the sensor probe is coupled to the leg portion;
wherein the sensor probe and an end of the leg portion are disposed at a same vertical elevation, and wherein the sensor mounting bracket is separated from the leg portion by a distance.

Assignees

• Rheem Mfg Co

Inventors

• Long Robert L
• Frederick Kenneth D
• Ray Kevin M
• Tallakson Karl S
• Gopalnarayanan Sivakumar

Classifications

• F24F13/222

  for evacuating condensate · CPC title

• F24F2013/227

  Condensate pipe for drainage of condensate from the evaporator · CPC title

• F24F2140/30

  Condensation of water from cooled air · CPC title

• F24F11/32 Primary

  Responding to malfunctions or emergencies · CPC title

• F24F1/36 Primary

  Drip trays for outdoor units · CPC title