US-12624847-B2 - Humidifier wet-pack assembly

US12624847B2US 12624847 B2US12624847 B2US 12624847B2US-12624847-B2

Abstract

A wet-pack assembly includes a water panel, a scale control configured to surround the water panel on at least three sides, and a distribution tray disposed on a top portion of the water panel and coupled to the scale control via one or more joints. The one or more joints prevent separation of the distribution tray from the scale control. The wet-pack assembly also includes a feed tube extending from a basin formed within the scale control to the distribution tray, where the feed tube is structured to direct water flow from the basin to the distribution tray for recirculation to the water panel.

Inventors

Nathan Adam Hughes
Steven Howard Farra
Ryan Alexander Kitching
Joshua Edwards McKune
Michael Jonathon Schatz

Assignees

RESEARCH PRODUCTS CORPORATION

Dates

Publication Date: 20260512
Application Date: 20240104

Claims (20)

1 . A wet-pack assembly comprising: a water panel; a scale control configured to surround at least a portion of the water panel; a distribution tray disposed on the water panel and coupled to the scale control via one or more joints, wherein the one or more joints prevent separation of the distribution tray from the scale control; and a feed tube extending from a basin formed within the scale control to the distribution tray, wherein the feed tube is structured to direct water flow to the distribution tray for distribution to the water panel.
2 . The wet-pack assembly of claim 1 , wherein the feed tube includes a first portion and a second portion, the first portion being coupled to an eductor outlet.
3 . The wet-pack assembly of claim 2 , wherein the second portion of the feed tube is coupled to a flow divider disposed within the distribution tray.
4 . The wet-pack assembly of claim 2 , wherein the first portion of the feed tube extends from the eductor outlet and through an aperture disposed within the distribution tray.
5 . The wet-pack assembly of claim 1 , wherein the distribution tray comprises a plurality of channels, wherein an end of each of the plurality of channels extends into the water panel.
6 . The wet-pack assembly of claim 5 , wherein the end of each of the plurality of channels extends into a corresponding recess disposed within the water panel.
7 . The wet-pack assembly of claim 1 , wherein the scale control comprises an upper portion, the upper portion being disposed adjacent the distribution tray and comprising a ridge, wherein a wall of the distribution tray is structured to be retained within the ridge.
8 . The wet-pack assembly of claim 7 , wherein the wall of the distribution tray is press-fit within the ridge.
9 . The wet-pack assembly of claim 1 , wherein the one or more joints comprises heat stakes.
10 . The wet-pack assembly of claim 1 , wherein the one or more joints comprises welds.
11 . A humidifier comprising: a wet-pack assembly; and a collection member fluidly coupled to the wet-pack assembly; wherein the wet-pack assembly comprises: a water panel; a scale control configured to enclose the water panel; a distribution tray disposed on a top portion of the water panel and coupled to the scale control, wherein the distribution tray is inseparable from the scale control; and a feed tube extending from a basin formed within the scale control to the distribution tray, wherein the feed tube is structured to direct water flow to the distribution tray for distribution to the water panel.
12 . The humidifier of claim 11 , further comprising a base, wherein the wet-pack assembly is structured to be received within the base such that the distribution tray is configured to couple to a surface of the base.
13 . The humidifier of claim 12 , wherein a surface of the distribution tray comprises a snap feature, the snap feature being structured to be received within a slot disposed within the surface of the base.
14 . The humidifier of claim 13 , wherein the surface of the distribution tray further comprises a first protrusion and a second protrusion, wherein the snap feature is disposed between the first protrusion and the second protrusion.
15 . The humidifier of claim 13 , wherein the surface of the base further comprises a first placement feature and a second placement feature, wherein the slot is disposed between the first placement feature and the second placement feature, and wherein the first protrusion is configured to be received within the first placement feature and the second protrusion is configured to be received within the second placement feature.
16 . The humidifier of claim 11 , wherein the scale control is configured to mount to the collection member such that the scale control is selectively separable from the collection member.
17 . The humidifier of claim 16 , wherein a bottom side of the scale control comprises a dovetail protrusion, the dovetail protrusion being configured to be received within a pocket formed in a housing of the collection member to couple the collection member to the wet-pack assembly.
18 . The humidifier of claim 17 , wherein at least a portion of the dovetail protrusion comprises beveled edges.
19 . The humidifier of claim 17 , wherein the pocket comprises a first wall and a second wall, and wherein a thickness of at least one of the first wall or the second wall varies from a base of the pocket to an upper edge of the pocket.
20 . The humidifier of claim 11 , wherein the distribution tray comprises an air seal extending downward from an outer wall of the distribution tray, the air seal configured to surround an upper portion of the water panel.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Patent Application No. 63/437,015, filed Jan. 4, 2023, the entirety of which is herein incorporated by reference. BACKGROUND The present disclosure relates generally to humidifying systems for increasing humidity of ambient air. More specifically, the present disclosure relates to a unitary wet-pack design for a humidifier to reduce risk of leakage, misalignment and component shift during maintenance (e.g., installation, replacement, cleaning, etc.) and/or use. SUMMARY One aspect of the present disclosure relates to a wet-pack assembly. The wet-pack assembly includes a water panel, a scale control configured to surround the water panel on at least three sides, and a distribution tray disposed on a top portion of the water panel and coupled to the scale control via one or more joints. The one or more joints prevent separation of the distribution tray from the scale control. The wet-pack assembly further includes a feed tube extending from a basin formed within the scale control to the distribution tray, where the feed tube is structured to direct water flow from the basin to the distribution tray for recirculation to the water panel. In various embodiments, the feed tube includes a first portion and a second portion, where the first portion is coupled to an eductor outlet disposed within the basin. In some embodiments, the second portion is coupled to a flow divider disposed within the distribution tray. In other embodiments, the first portion extends from the eductor outlet and through an aperture disposed within the distribution tray. In yet other embodiments, the distribution tray includes a plurality of channels, where an end of each of the plurality of channels extends into the water panel. In various embodiments, the end of each of the plurality of channels extends into a corresponding recess disposed within the water panel. In some embodiments, the scale control includes an upper portion, where the upper portion is disposed adjacent the distribution tray and includes a ridge, and where a wall of the distribution tray is structured to be retained within the ridge. In other embodiments, the wall of the distribution tray is press-fit within the ridge. In yet other embodiments, the one or more joints includes heat stakes. In some embodiments, the one or more joints includes welds. Another aspect of the present disclosure relates to a humidifier. The humidifier includes a wet-pack assembly and a valve and drain assembly fluidly coupled to the wet-pack assembly. The wet-pack assembly includes a water panel, a scale control configured to enclose the water panel, and a distribution tray disposed on a top portion of the water panel and coupled to the scale control, where the distribution tray is inseparable from the scale control. The wet-pack assembly also includes a feed tube extending from a basin formed within the scale control to the distribution tray, where the feed tube is structured to direct water flow from the basin to the distribution tray for recirculation to the water panel. In various embodiments, the humidifier also includes a base, where the wet-pack assembly is structured to be received within the base such that the distribution tray is configured to couple to a surface of the base. In some embodiments, a surface of the distribution tray includes a snap feature, where the snap feature is structured to be received within a slot disposed within the surface of the base. In other embodiments, the surface of the distribution tray further includes a first protrusion and a second protrusion, where the snap feature is disposed between the first protrusion and the second protrusion. In yet other embodiments, the surface of the base further includes a first placement feature and a second placement feature, where the slot is disposed between the first placement feature and the second placement feature, and where the first protrusion is configured to be received within the first placement feature and the second protrusion is configured to be received within the second placement feature. In various embodiments, the scale control is configured to mount to the valve and drain assembly such that the scale control is selectively separable from the valve and drain assembly. In some embodiments, a bottom side of the scale control includes a dovetail protrusion, where the dovetail protrusion is configured to be received within a pocket formed in a housing of the valve and drain assembly to couple the valve and drain assembly to the wet-pack assembly. In other embodiments, at least a portion of the dovetail protrusion includes beveled edges. In yet other embodiments, the pocket includes a first wall and a second wall, where a thickness of at least one of the first wall or the second wall varies from a base of the pocket to an upper edge of the pocket. In various embodiments, the distribution tray includes an air seal exten