DE102018116759A1 - Floor module assembly for a heat pump - Google Patents

Abstract

The invention relates to a floor module assembly (2, 3) for a heat pump (12), preferably a heat pump dryer (1), with a floor module (2) which is designed, at least in sections, a process air space (15) for accommodating at least one evaporator (17). the heat pump (12), the floor module (2) having at least one condensate collection basin (21) adapted to receive condensate from the evaporator (17) and an insert element (3) disposed inside the condensate collection basin (21) and is adapted to receive at least the evaporator (17) from above. The floor module assembly (2, 3) is characterized in that the insert element (3) is formed from a foamed material.

Description

The invention relates to a floor module assembly for a heat pump according to the preamble of patent claim 1, a floor module for use in such a floor module assembly according to claim 22 and an insert element for use in such a floor module assembly according to claim 23.

In many electrical appliances today is paid by the user very much on energy efficiency, so that the energy efficiency of an electrical device in operation can be a major factor in the purchase decision of the user as an end customer. This also applies to household appliances in general and in particular household appliances such. Dryers, which may have a comparatively high energy consumption during operation.

In order to achieve the highest possible energy efficiency in operation especially in tumble dryers, these are usually designed as a heat pump dryer, since heat pumps can be operated in principle comparatively energy efficient. Heat pump laundry dryers are therefore widely used on the market.

A heat pump basically consists of a closed heat pump cycle with a compressor (also called a compressor), a condenser (also called a condenser), a throttle such as a compressor. an expansion valve or a capillary and an evaporator. These elements can also be referred to as a refrigeration circuit or heat pump cycle. Through this heat pump cycle, the process air of the clothes dryer can be removed from the moisture that was previously removed from the laundry.

From the point of view of the drying process or the laundry drum, this is considered to be the one previously dehumidified and heated by the heat pump cycle, i. dried and heated process air passed through a rear air duct of a fan of the heat pump cycle through an air supply duct in a laundry drum of the clothes dryer. In the laundry drum, the laundry to be dried is usually moved by means of a drum drive by rotation, so that the process air can reach the laundry as completely and uniformly as possible. The process air absorbs moisture from the laundry and dries it. The moist process air then passes back through an air return duct to a front air duct of the heat pump cycle.

Within the heat pump, the moisture extracted from the process air is condensed in the evaporator and discharged to the outside in liquid form. The energy extracted from the process air is then returned to the process air through the condenser, so that the process air can again dehumidify and, when heated, leave the heat pump cycle in the direction of the laundry drum. The cycle of process air is closed in this way.

The heat pump cycle as a central functional unit of the heat pump usually has fins, which are provided both on the evaporator as evaporator heat exchanger and the condenser as Verflüssigerwärmeübertrager. In the case of both heat exchangers, which can also be referred to as heat exchangers, it is usually possible by design to ensure that a flow of the process air takes place only parallel to the orientation of the lamellae and that there is no exchange perpendicular to the lamellae planes.

Usually, the heat pump cycle, together with other components such as e.g. the drum drive or a condenser pump, arranged on a bottom module of the tumble dryer, wherein the base for this assembly is usually formed by a large plastic component with an associated lid. The floor module usually has a base module lower part and a floor module upper part, which are usually produced separately as injection-molded parts and then welded to the floor module. The upper region of the base module or the bottom module upper part forms, together with the cover, the process air channel which interconnects the air return channel or the front air duct of the heat pump cycle and the air supply duct or rear air duct of the heat pump cycle and the two heat exchangers, i. the evaporator and the condenser, so that they can be flowed through by the process air.

The two heat exchangers are thus located in the process air duct or in the process air space and are enclosed by the bottom module upper part and the lid in such a way that a sealed process air space is created. It should be ensured that almost no process air can escape into the environment, so that a minimum moisture loss of the heat pump tumble dryer can be achieved. Furthermore, a fixed positioning of the heat exchanger should be ensured, so that no vibrations can be transmitted from the oscillating pipeline and compressor system. Furthermore, it should be prevented by the almost positive arrangement of the components that process air above, below and or or laterally on the heat exchangers can flow past without participating in the heat exchange; this would reduce energy efficiency.

When the warm, moisture-saturated process air flows out of the laundry drum through the evaporator heat exchanger and cools down there, water condenses out of the process air. The condensed water usually reaches the surface of the bottom module upper part, on which the evaporator heat exchanger rests, by gravity. From there, the condensed water usually passes through a located below the evaporator heat exchanger flow geometry with a predetermined gradient to an opening and drains into an underlying catch basin, which is formed by the bottom module lower part below the bottom module upper part and can also be referred to as condensate sump. From the catch basin, the condensed water can enter a removable container, which can be removed and emptied by the user if necessary from the heat pump tumble dryer.

In terms of design, it should be noted that the drain geometry usually has sufficiently large cross sections and slopes to ensure reliable drainage of condensate. On the other hand, too large free cross sections below the heat exchanger can in turn lead past the previously described incorrect air flows at the heat exchangers. From the US 2010/0192397 A1 It is known to form support elements for an insert element on the floor module, on which the evaporator heat exchanger is kept at a distance from the bottom of the condensate collecting basin. The insert element has a filter section and condensate discharge openings. Since different heat exchangers with different dimensions can be used depending on the device variant, it can be difficult to find a flow geometry which represents the optimum compromise between good condensate removal and minimum underflow of the heat exchangers for all heat exchanger variants used.

It should also be noted that, depending on the device variant with different heat exchangers used, the disk packs can be of different lengths in the direction of the flow. It may also happen that depending on the manufacturer of the heat exchanger and different pipe pitches can be used with different distances, whereby the respective disk packs may differ in height. The components of the bottom module upper part, which form the process air space, must therefore be designed for the highest heat exchanger used. However, when using flatter heat exchangers with the same components for the bottom module top, a gap may then be created over the fins of the heat exchangers which must be balanced to avoid the erroneous air flow described above at this point, which could affect the efficiency of the system.

As already mentioned, currently the components of the floor module upper part and the floor module lower part are usually welded in order to obtain the floor module as an overall component, which can form a closed space under the heat exchangers, in which the resulting condensate can be collected.

The disadvantage here is on the one hand, the fixed space height for the heat exchanger, so that for all possible variants of heat exchangers corresponding Bodenmodoberteile and cover must be made. For the injection molding process, this requires the respective tools, which cause not inconsiderable costs.

On the other hand, it is disadvantageous that the welding of the base module lower parts and the base module upper parts to the floor modules can represent a comparatively complicated production method. In other words, the creation of the floor module as welding assembly of upper and lower part requires at least two individually produced plastic components, which leads to an increased production and material costs for the plastic components and to an additional manufacturing step for welding. There are also additional investment costs for the injection molding tools and for the welding device.

Another disadvantage is that, for the cost reasons described above, as far as possible a single type of floor module is to be used, so that the different heat exchanger variants used must have the same height and width in order to match the fixed installation geometry of the one floor module type and the above-described incorrect air flows on the floor Heat exchanger to avoid over. Since there are both heat exchangers in various geometric shapes and different manufacturers of different pipe sections, which favor different dimensions, the maintenance of a fixed height and / or width of the heat exchanger can be a difficult undertaking and otherwise lead to incorrect air flows on the heat exchanger.

Although it is possible to compensate for different heights with a glued in the lid soft foam mat. However, this is only possible with heat exchangers which are smaller than the process air duct to close or at least to the gap between the heat exchanger and the lid reduce. Furthermore, the distance which can be closed or reduced thereby is limited. Furthermore, this measure, which must be performed for each heat pump, an additional effort in terms of component and assembly costs.

Depending on the device variant, different heat exchangers may also be used whose lamellae differ in their length in the direction of flow. If the contour for the drain geometry is introduced in the floor module, it is not possible to realize flow contours optimized for the respective heat exchanger.

Another disadvantage is the comparatively low thermal insulation effect of the bottom module lower parts and the bottom module upper parts, which can adversely affect the efficiency of the heat pump process. Temperatures of approx. 70 ° C to 90 ° C can occur in the area of the condenser, which are used to heat the cooled, saturated with water process air from the evaporator as far as possible, so that they can absorb water from the wet laundry again , For high energy efficiency, the condenser should emit as much heat as possible to the process air. However, since the floor module forms the lower boundary of the heat pump and the heat pump dryer itself and their relatively thin plastic walls have only a small thermal insulation effect, a part of the heat energy of the condenser is released as a loss to the environment.

From the DE 10 2014 211 303 A1 is a bottom group of a housing having a tumble dryer with at least one arranged below a heat pump of the clothes dryer dividing floor on which the heat source and the heat sink stand up. The heat source can also be referred to as a condenser or as a condenser and the heat sink as an evaporator or evaporator. The bottom group has a depression which serves to receive the water condensed on the evaporator. Within the bottom group, the separating tray is arranged so that the condensate sump forms below the separating tray and the two heat exchangers of the evaporator and the condenser are arranged on the separating tray. In order to make the best possible use of the predetermined space of the floor assembly in height and to use the highest possible condenser with a correspondingly high performance, is according to the teaching of DE 10 2014 211 303 A1 the dividing floor formed in two parts. While the region of the separating bottom, which accommodates the evaporator and its condensate, is connected in a fluid-conducting manner to the condensate sump arranged below the separating bottom, the region of the separating bottom which receives the condenser is designed as a closed trough so that the condenser is remote from the condensate and thus can be kept dry. The two areas of the dividing floor are laterally separated. The region of the separating bottom below the condenser protrudes down into the condensate sump in order to allow the use of a comparatively high condenser without additional space.

Advantageous in the bottom group of DE 10 2014 211 303 A1 is that can be dispensed with by the formation of the condenser sump between the recess of the floor assembly and the separating floor on a two-piece floor module. As a result, the production effort associated therewith can be omitted as described above.

However, the lack of simple and cost-effective adaptability of the base group including the cover to the various heat exchanger variants used remains a disadvantage. This concerns both the adaptation of the process air space to the heat exchangers and the adaptation of the drainage structures to the evaporator. Another disadvantage is the comparatively low thermal insulation effect of the floor group.

The invention thus presents the problem of providing a floor module assembly for a heat pump, which can be adapted to different heat exchangers more easily and / or cost-effectively. Alternatively or additionally, the thermal insulation effect of a floor module assembly for a heat pump should be improved. At a minimum, an alternative to known floor module assemblies for a heat pump should be provided.

According to the invention, this problem is solved by a floor module module having the features of patent claim 1, by a floor module having the features of patent claim 19 and by an insert element having the features of patent claim 20. Advantageous embodiments and further developments of the invention will become apparent from the following subclaims.

Thus, the present invention relates to a floor module assembly for a heat pump, preferably for a heat pump of a heat pump dryer, with a bottom module, which is designed to at least partially form a process air space for receiving at least one evaporator of the heat pump. This process air space can be formed together with a lid.

The floor module has at least one condensate collection basin, which is designed to receive condensate of the evaporator. Usually, the condensate, which is condensed by the evaporator from the process air, first received in the condensate collection basin and then discharged into a condensate collection tank. About the usually removable condensate collecting the condensate can then be disposed of by the user.

The floor module assembly further includes an insert member disposed within the condensate collection basin and configured to receive at least the evaporator from above. According to the invention, the floor module assembly is characterized in that the insert element is formed from a foamed material.

The present invention is based on the finding that by using an insert element, a more flexible adaptation of the floor module assembly can be made to the respective evaporator both with regard to its dimensions and with respect to the drainage structure for the condensate. This is due to the fact that the floor module and the lid can be made uniform. An adaptation of the inner contour of the bottom module from below to the evaporator can then be done by the use of different insert elements. This can reduce the manufacturing cost with improved tightness around the evaporator.

However, the advantage of the reduced production costs can only be partially realized in the design of the insert element as a further plastic injection-molded component, because for each variant of the insert element an injection molding tool is required, which causes not inconsiderable costs.

Therefore, the insert element of the invention is made of foamed material instead of a plastic injection molded component. In this way, the manufacturing costs can be significantly reduced while simultaneously increased flexibility that molding tools for components made of foamed material due to the significantly lower mold internal pressures less massive executed and therefore significantly cheaper can be produced as tools for plastic injection molded parts. This results in comparatively low investment costs, in order to realize for a geometrically different heat exchanger variant a specific inlay variant, which may be e.g. compensates for the height difference and has a precisely adapted to the length of the slats drain geometry for the condensate.

It is also advantageous that an insert element made of foamed material has significantly greater wall thicknesses than a plastic injection-molded part. This alone can already improve the thermal insulation effect in this area of the floor module assembly. Furthermore, a foamed material has a significantly lower thermal conductivity than a compact plastic due to the high gas content in the foam structure, so that a significantly better thermal insulation can be achieved by these two factors.

According to the invention, the insert element is formed from expanded polystyrene or polypropylene. As a result, the advantages described above can be implemented simply, inexpensively and / or effectively.

According to the invention, the insertion element has on its underside a plurality of molded bearing elements which rise on the bottom of the condensate collecting basin and keep the underside of the loading element spaced from the bottom of the condensate collecting basin. In this way, a defined and as large as possible volume can be created below the insert element to collect the condensate of the evaporator, before it can possibly. In a condensate collection tank. Furthermore, condensate can be stored there, if the condensate tank can no longer absorb more condensate.

To make the condensate collection tank as large as possible can represent an additional benefit for the user, since in the condensate collection tank in addition to the condensate collection a certain amount of condensate can be stored, so that the user must empty the condensate collection container less frequently.

The support elements are designed and arranged in such a way that on the one hand, the insert element can be securely positioned and hold the evaporator. On the other hand, at the same time as much volume as possible to accommodate the condensate should be created.

According to the invention, the floor module has at least one projection and the insert element has at least one projection which engages under the projection of the floor module. In this way, the insert element can be easily and safely mounted and held by the projection of the insert member inserted by means of a pivoting movement under the projection of the floor module and, for. the insert element is placed or pressed into the condensate collection basin.

According to another aspect of the present invention, the floor module has at least one Locking means on and the insert element has at least one latching means which cooperates with the latching means of the floor module. As a result, the insert element can be held by the floor module in the condensate collection basin. This is especially true in the event that the insert element has been previously inserted with its projection under the corresponding projection of the floor module.

According to a further aspect of the present invention, the latching means of the floor module has a latching hook and the latching means of the inserting element has a latching hook receptacle, in which the latching hook of the floor module is held in a form-fitting manner, or vice versa. In this way, a latching connection between the insert element and the floor module can be produced in order to achieve a simple, safe and non-destructively separable hold. The connection partners of the latching connection can be exchanged in each case between the insert element and the bottom element.

According to a further aspect of the present invention, the latching means of the floor module on a clamping region and the locking means of the insert member has an elastic clamping portion, wherein the insert member is held by elastic deflection of the clamping portion of the insert member relative to the clamping portion of the floor module frictionally, or vice versa. This variant of a mounting of the insert element in the condensate collection basin of the floor module benefits that the insert element consists of a foamed material and is thus easily deformable. As a result, the insert element may preferably have a slight oversize relative to the contour of the condensate collecting basin, so that the insert element can be pressed into the condensate collecting basin under resilient deformation of its clamping area and retained there in a non-positive manner.

According to a further aspect of the present invention, the floor module has at least one condensate collecting tank extension below a process air outlet of the process air space, which is connected in a fluid-conducting manner to the condensate collecting basin. As a result, the volume of the condensate collecting basin can be increased, so that the user has to empty the condensate collection container less frequently.

According to a further aspect of the present invention, the condensate collecting tank extension together with the process air outlet forms at least one edge which, as a projection of the floor module, is gripped by a projection of the insert element from below. This makes it possible to use the edge of the condensate collecting tank extension, which results from the extension of the condensate collecting tank extension under the process air outlet, at the same time for holding the insert element in the condensate collection basin.

According to a further aspect of the present invention, the condensate collecting basin has a condensate drainage channel, which is designed to remove the condensate from the condensate collecting basin, preferably in a condensate collecting tank. As a result, the condensate can e.g. be discharged to a condensate collection container for emptying.

Preferably, the condensate drainage channel projects in depth into the condensate collection basin and is covered in width by a condensate barrier, so that when the soil module group is tilted in the depth from the condensate barrier, the condensate barrier keeps the condensate away from the condensate drainage channel, preferably at the condensate drainage channel can pass by. As a result, e.g. in case of transport of the heat exchanger or the e.g. Heat pump dryer, which has a heat exchanger with a floor module group according to the invention, e.g. be prevented by means of a sack truck that located in the condensate collection remaining condensate enters the condensate drain and runs out at the back of the heat pump dryer.

According to a further aspect of the present invention, the condensate collection basin has a condensate return channel, which is designed to return the condensate from a condensate collection container into the condensate collection basin. This allows excess condensate to pass from the condensate collector back into the condensate collection basin, e.g. if the amount of water contained in the laundry exceeds the capacity of the condensate collector or the user has not emptied the container after the previous drying cycle.

According to another aspect of the present invention, the insert element is further configured to receive the condenser from above. Thus, both heat exchangers can be received by the insert element, so that a separate element can be avoided for this purpose. This can save costs and effort during production and assembly.

According to a further aspect of the present invention, the top of the insert element is designed to be flush with the underside of at least the evaporator, preferably and the condenser. In this way At this point, incorrect air flows can be avoided past the evaporator or past the two heat exchangers.

According to a further aspect of the present invention, the top side of the insert element has at least one evaporator region, which is designed to receive the evaporator from above, wherein the evaporator region of the insert element has at least one drain channel, which is formed, condensate from the evaporator via a drain opening the condensate collection basin supply. Through such a structure of channels, the removal of the condensate away from the evaporator can be enabled or supported.

According to a further aspect of the present invention, the drainage channel has at least one transverse drainage channel, preferably a plurality of transverse drainage channels, which is designed to receive condensate substantially in width, and the drainage channel has at least one central drainage channel, which is formed, the transverse drainage channel to connect fluidly with the drain opening. By means of such a structure of channels, a particularly effective removal of the condensate away from the evaporator can be made possible or supported.

According to another aspect of the present invention, the transverse drainage channel has an inclined surface and a horizontal surface. On the inclined surface of the largest possible area can be created, which can catch the condensate from above and forward to the horizontal surface for removal. It is achieved by the slope of the inclined surface on the one hand, that the collected condensate is discharged and can not collect there. On the other hand, the amount of condensate present in the direction of the slope of the inclined surface to the horizontal surface increases, so that the inclination of the distance to the bottom of the evaporator is increased and increasingly more condensate can be collected.

According to a further aspect of the present invention, the drainage channel has at least two transverse drainage channels, which are spaced from each other by a flush with the underside of the evaporator surface on which the evaporator can be taken from above. In this way, on the one hand by the transverse flow channels as possible a flat and evenly distributed removal of the condensate take place. On the other hand, the evaporator can be accommodated on the surfaces between the transverse drainage channels and thereby also be kept as flat and uniform as possible. In other words, an underflow of the evaporator can be avoided.

According to a further aspect of the present invention, the transverse drainage channel is formed obliquely with respect to a flow direction of the process air of the evaporator. As a result, the removal of the collected condensate can be supported. Furthermore, the evaporator can be kept as even as possible from below, since the fins are aligned in the flow direction and thus are cut obliquely by the oblique transverse flow channel. This allows a more uniform contact between the fins of the evaporator and the top of the insert member than in a parallel or vertical orientation to each other.

According to a further aspect of the present invention, the central drainage channel has at least one elevation, which is designed to receive the evaporator from above. This can be done from below an additional support of the evaporator. Furthermore, the central drainage channel can be made larger area to directly absorb more condensate can. In addition, the continuous in the direction of flow central drainage channel is interrupted by the survey, which minimizes the underflow of the evaporator in this area.

According to a further aspect of the present invention, the top of the insert element further comprises a condenser portion adapted to receive the condenser from above, the condenser portion of the insert member having at least one drain passage formed condensate from the condenser via a drain opening to the condensate collection basin supply. In this way, a discharge of condensate can also be done below the condenser. However, since the liquefier itself does not even produce any condensate due to its function, this discharge possibility of condensate serves the case that during transportation of the heat exchanger or the e.g. Heat pump dryer, which has a heat exchanger with a floor module group according to the invention, condensate passes from the condensate collection tank to the condenser and can be discharged again via this discharge channel.

According to a further aspect of the present invention, the drainage channel has at least one transverse drainage channel, preferably a plurality of transverse drainage channels, which is designed to receive condensate substantially in width, and the drainage channel has at least one longitudinal drainage channel, which is formed, at least one transverse drainage channel to connect fluidly with the drain opening. By such Structure of channels can be a particularly effective removal of the condensate away from the evaporator allows or supported.

The present invention also relates to a floor module for use in a floor module assembly for a heat pump, preferably for a heat pump of a heat pump dryer, as described above, wherein the floor module is adapted to at least partially form a process air space for receiving at least one evaporator of the heat pump, wherein the floor module has at least one condensate collection basin, which is adapted to receive condensate of the evaporator and wherein the bottom module is adapted to receive an insert element as described below. As a result, a floor module can be provided in order to realize the above-described floor module assembly.

The present invention also relates to an insert element for use in a floor module assembly for a heat pump, preferably a heat pump dryer as described above, wherein the insert element is adapted to be received within the condensate collection basin of a floor module as described above, wherein the insert element is further formed, at least to take in the evaporator of the heat pump from above. In this way, an insert element can be provided in order to realize the above-described base module assembly.

• 1 einen Querschnitt eines Wärmepumpentrockners mit einer Wärmpumpe mit einer erfindungsgemäßen Bodenmodulbaugruppe;
• 2 eine Detailansicht der Wärmepumpe der 1;
• 3 eine perspektivische Darstellung eines Bodenmoduls der Bodenmodulbaugruppe;
• 4 eine Draufsicht auf das Bodenmodul der 3;
• 5 eine perspektivische Darstellung eines Einlegeelements der Bodenmodulbaugruppe;
• 6 eine Draufsicht auf das Bodenmodul der 3 mit eingebautem Einlegeelement;
• 7 eine Draufsicht auf einen Verdampferbereich des Einlegeelements;
• 8 eine schematische seitliche Ansicht des Verdampferbereichs des Einlegeelements mit aufgenommenem Verdampfer;
• 9 eine schematische seitliche Ansicht der Montage des Einlegeelements in dem Bodenmodul in einem ersten Schritt;
• 10 eine schematische seitliche Ansicht der Montage des Einlegeelements in dem Bodenmodul in einem zweiten Schritt;
• 11 ein Ausschnitt der 10 gemäß einem ersten Ausführungsbeispiel;
• 12 ein Ausschnitt der 10 gemäß einem zweiten Ausführungsbeispiel;
• 13 ein Ausschnitt der 10 gemäß einem dritten Ausführungsbeispiel;
• 14 eine perspektivische Darstellung der 9; und
• 15 eine vergrößerte Darstellung eines Teilbereichs der 14,
• 16 eine perspektivische Darstellung eines Einlegeelements der Bodenmodulbaugruppe gemäß einem weiteren Ausführungsbeispiel des Einlegeelements.

Several embodiments of the invention are shown purely schematically in the drawings and will be described in more detail below. It shows

• 1 a cross section of a heat pump dryer with a heat pump with a floor module assembly according to the invention;
• 2 a detailed view of the heat pump the 1 ;
• 3 a perspective view of a floor module of the floor module assembly;
• 4 a plan view of the floor module of 3 ;
• 5 a perspective view of an insert element of the floor module assembly;
• 6 a plan view of the floor module of 3 with built-in insert element;
• 7 a plan view of an evaporator region of the insert element;
• 8th a schematic side view of the evaporator portion of the insert element with recorded evaporator;
• 9 a schematic side view of the mounting of the insert element in the floor module in a first step;
• 10 a schematic side view of the mounting of the insert member in the floor module in a second step;
• 11 a section of the 10 according to a first embodiment;
• 12 a section of the 10 according to a second embodiment;
• 13 a section of the 10 according to a third embodiment;
• 14 a perspective view of 9 ; and
• 15 an enlarged view of a portion of the 14 .
• 16 a perspective view of an insert element of the floor module assembly according to another embodiment of the insert element.

The above figures are considered in Cartesian coordinates. It extends a longitudinal direction X , which also as depth X can be designated. Perpendicular to the longitudinal direction X extends a transverse direction Y , which also as width Y can be designated. Perpendicular to both the longitudinal direction X as well as to the transverse direction Y extends a vertical direction Z , which also as height Z can be designated.

In the 1 For example, as an exemplary application of the present invention, a heat pump dryer 1 or a heat pump tumble dryer 1 shown in cross section. The heat pump dryer 1 has a housing 10 on, inside of which a laundry drum is located in the upper area 11 which serves to receive and dry laundry. Below the laundry drum 11 is a heat pump 12 arranged, the moist process air from above or from the left in the representations of 1 and 2 via a process air input 14 in a flow direction A through a process air space 15 leads and via a process air outlet 16 in the flow direction A dehumidifies and heats again to the right or above the laundry drum 11 supplies. The dehumidifying of the process air takes place via a first heat exchanger 17 as an evaporator 17 ; the heating of the process air takes place via a second heat exchanger 18 as a liquefier 18 ,

The process air space 15 in which the two heat exchangers 17 . 18 are arranged from below by a one-piece floor module 2 and from above through a lid 13 educated. The floor module 2 consists of a floor module body 20 , as in the 3 and 4 shown. The floor module body 20 is formed as a one-piece plastic injection molded part and shaped such that the lower half of the process air inlet 14 , the process air space 15 and the process air outlet 16 be formed. Furthermore, further elements of the heat pump can be accommodated (not shown). The process air input 14 , the process airspace 15 and the process air outlet 16 be from the top through the lid 13 completed and completed.

Through the floor module body 20 also becomes a condensate collection basin 21 formed, which is below the process air space 15 is arranged. The condensate collection basin 21 has a floor 21a on which the condensate collection basin 21 limited to the bottom and on which the condensate can accumulate, which is above the condensate collecting basin 21 from the evaporator 17 is condensed out of the process air. To remove the condensate from the condensate collection basin 21 remove, this has a condensate drain channel 22 on which is in a condensate collection room 4 opens in the region of the condensate pump. From there, the condensate is pumped into a removable condensate collector, which can be removed and emptied by a user.

To prevent when tilting the heat pump dryer 1 in the deep X to the rear the condensate from the condensate collection basin 21 in the condensate collecting room 4 in the area of the condensate pump and if necessary. About this backwards from the heat pump dryer 1 expires, the condensate drainage channel extends 22 in the deep X forward, so that in width Y laterally next to the condensate drainage channel 22 in each case a volume is created from which condensate when tilting the heat pump dryer 1 in the deep X not to the rear in the condensate drainage channel 22 can get. Furthermore, the input of the condensate drain channel 22 a condensate barrier 23 in the form of a transverse rib 23 on, so when tilting the heat pump dryer 1 in the deep X to the rear condensate, which is further up in the condensate collection basin 21 located at the inlet of the condensate drainage channel 22 can be steered past. The floor module 2 or the floor module body 20 also has a condensate return channel 24 on, over the excess condensate from the condensate collector 4 back to the condensate collection basin 21 can get.

Below the input of the process air outlet 16 is in width Y on both sides of the condensate drainage channel 22 each a condensate collection tank extension 25 formed, which the condensate collection basin 21 in the deep X to the rear under the entrance of the process air outlet 16 extend and thereby enlarge. In this way, more condensate from the condensate collection basin 21 be recorded. At the same time, the edges form 26 the condensate collecting tank extension 25 one projection each 26 on which of the holder of an insert element 3 serves as will be described below. This also applies to two locking means 27 which in depth X towards the front on the inner contour of the condensate collecting basin 21 are formed.

The aforementioned insert element 3 , which already in the 1 and 2 roughly shown in the installed state, is in the 5 individually and in the 6 shown in detail in the installed state. The insert element 3 is a one-piece insert body 30 of a foamed material, which in these embodiments is expanded polystyrene. The insert element 3 points in the horizontal plane, which through the width Y and the depth X is formed, a substantially rectangular extent, which the inner contour of the condensate collecting basin 21 is adjusted. The insert element 3 can the two heat exchangers 17 . 18 take on and within the process air space 15 position. Furthermore, between the insert element 3 and the floor 21a of the condensate collecting tank 21 a volume for receiving the condensate formed by the evaporator 17 is condensed from the process air.

It is achieved by the foamed material that on the one hand, the insert element 3 can be made comparatively inexpensive, so that for each type of heat exchanger 17 . 18 a matching insert element 3 can be manufactured and used. This allows the most accurate fit of the heat exchanger 17 . 18 in the process air space 15 despite varying degrees, can be achieved easily, reliably and cost-effectively. This can be incorrect air flows at the heat exchangers 17 . 18 avoid over. Furthermore, by the foamed material, the heat dissipation C reduced towards the bottom and thereby a comparatively good thermal insulation can be achieved, which improves the efficiency of the heat pump 12 can improve.

The top 30a of the insert body 30 or the insert element 3 has an evaporator area 34 on, on which the evaporator 17 the heat pump 12 can be included. Furthermore, the top side 30a of the insert body 30 or the insert element 3 a condenser area 35 on which the condenser 18 the heat pump 12 can be included, cf. each 1 and 2 ,

The evaporator area 34 the top 30a has a drainage channel 36 on, which through Depressions within the top 30a of the insert body 30 or the insert element 3 is created, cf. eg 5 to 8th , The drainage channel 36 of the evaporator section 34 has a plurality of transverse drainage channels 36a on, which each about from the edge of the insert element 3 in width Y run to the middle. The crossflow channels run 36a obliquely to the flow direction A the process air of the heat exchanger 17 . 18 so that the condensate more effectively a central drainage channel 36b can be fed, which is the condensate of a drain opening 36c feeds, over which the condensate into the condensate collecting space 4 arrives, cf. 1 , The crossflow channels 36a each have an inclined surface 36d , which essentially serves to collect the condensate from above, and a horizontal surface 36e on, which essentially the forwarding of the condensate to the central drainage channel 36b serves. Within the central drainage channel 36b is at least one survey 36f provided, which extends upwards and with the remaining upper side 30a flush. By means of this survey 36f can the evaporator 17 be picked up and supported from below. Thus, the continuous flow in the direction of the central flow passage is interrupted by the survey, which minimizes the underflow of the evaporator in this area.

The condenser area 35 the top 30a is comparably formed and accordingly has a drainage channel 37 with several crossflow channels 37a and two parallel longitudinal drainage channels 37b on, which converge and together in a drain opening 37c lead. About the drainage channel 37 the condenser area 35 can condensate, which unintentionally under the condenser 18 from there into the condensate collection basin 21 be dissipated.

16 shows a further embodiment of the insert element, which is designed for receiving narrower evaporator. The evaporator area 34 the top 30a also has a drainage channel 36 on, which by depressions within the top 30a of the insert body 30 or the insert element 3 is created. The drainage channel 36 of the evaporator section 34 has a crossflow channel 36a on, which each about from the edge of the insert element 3 in width Y extends to the center and compared to the embodiment according to 5 widened is formed. The crossflow channel runs at right angles to the direction of flow A the process air of the heat exchanger 17 . 18 so that the condensate more effectively a central drainage channel 36b can be fed, which is the condensate of a drain opening 36c feeds, over which the condensate into the condensate collecting space 4 arrives. For this purpose, the drainage surface (AF) in the direction of the drain opening ( 36c) inclined formed and also serves to collect the condensate from above.

The condenser area 35 the top 30a is similar to in 5 shown formed and accordingly has a drainage channel 37 with several crossflow channels 37a and two parallel longitudinal drainage channels 37b on, which converge and together in a drain opening 37c lead. About the drainage channel 37 the condenser area 35 can condensate, which unintentionally under the condenser 18 from there into the condensate collection basin 21 be dissipated.

The 9 to 15 show several embodiments for mounting the insert element 3 in the condensate collection basin 21 , The 11 to 13 each show a section D of the 10 ,

In each embodiment, the first assembly step is such that the insert element 3 with a lead 32 his in the depth X rear edge, which also as a supernatant 32 can be designated obliquely from the front under the two edges 26 is plugged, which by the condensate collecting tank extension 25 and the process air outlet 16 be formed, see 9 . 14 and 15 , Then the insert element 3 by a pivoting movement B from the top into the condensate collection basin 21 pressed and held there, see 10 ,

This holding, for example, according to a first embodiment of 11 be achieved in that the front edge of the insert element 30 an overcut 33 as a clamping area 33 of the insert element 3 opposite the inner contour 27 of the condensate collecting tank 21 as a clamping area 27 of the floor module 2 having. Since the foamed material of the insert element 3 is elastically deformable, the overcut becomes 33 of the insert element 3 through the contact with the inner contour 27 of the condensate collecting tank 21 pressed in and the insert element 3 held strong.

According to the second embodiment of the 12 for mounting the insert element 3 in the condensate collection basin 21 has the inner contour 27 of the condensate collecting tank 21 a latching hook 27 on, which in a corresponding locking hook receptacle 33 of the insert element 3 intervenes. In the third embodiment of the 13 this is reversed. In any case, the locking hooks 27 . 33 an inclined surface, which by the impressions of the insert element 3 in the condensate collection basin 21 an increasing impression of the latching hook 27 . 33 in the deep X favored. On the opposite side, the catch hook 27 . 33 a surface which prevents loosening of the holder.

In each of the three embodiments, the upper edge of the inner contour 27 of the condensate collecting tank 21 a chamfer 28 on to the impressions of the insert element 3 in the condensate collection basin 21 to simplify.

The insert element 3 or its insert body 30 has a bottom 30b on which of the top 30a in height Z is opposite. On the bottom 30b is a plurality of support elements 31 arranged, see eg 2 and 5 which is a distance between the bottom 30b of the insert element 3 and the floor 21a of the condensate collecting tank 21 create in which the condensate can be collected.

According to the invention, as described above, the production costs for a plastic injection-molded component and the welding process are eliminated. Components of foamed material (in particular expanded polystyrene) are generally much cheaper to produce at approximately the same dimensions as compact injection molded components, so that in total is to be expected with a significant manufacturing cost savings.

Similarly, the cost of creating the tools. It eliminates the tooling costs for an injection molded component, the additional costs for the insert element 3 made of a foamed material fall significantly lower. Likewise, the creation costs for a welding device are eliminated.

Due to the relatively low tooling costs for the insert element 3 It is economically justifiable to create a separate inlay variant for heat exchanger variants with different dimensions. Thus, the optimum flow through the heat exchanger 17 . 18 realized with coordinated geometries and the best possible energy efficiency can be achieved.

Due to the better thermal insulation effect of the insert element 3 a foamed material reduces heat losses to the environment and improves the energy efficiency of the heat pump dryer 1 be achieved.

The insert element 3 can also be used as packaging material by the supplier. Then then the heat exchanger would 17 . 18 with the insert element 3 into the floor module 2 be used.

LIST OF REFERENCE NUMBERS

A

Process air stream; Flow direction of the heat exchanger 17 , 18

B

Pivoting movement for mounting the insert element 3 in the floor module 2

C

Heat dissipation through insert element 3 through

D

Detail of the 10

X

Longitudinal direction; depth

Y

Transverse direction; width

Z

vertical direction; height

1

heat pump dryer

10

casing

11

washing drum

12

heat pump

13

Cover of the heat pump 12

14

Process air input

15

Process airspace

16

Process air output

17

first heat exchanger; Evaporator

18

second heat exchanger; condenser

2

(one-piece) floor module

20

Floor module body

21

Condensate collection basin; Condensate collecting basin; Drain pan; condensate sump

21a

Bottom of the condensate collecting tank 21

22

Condensate drain channel

23

Condensate cover; rib

24

Condensate return channel

25

Condensate collection tank expansion; condensate pocket

26

Head Start; Edge of the condensate collecting tank extension 25

27

Latching means; Locking hooks; Latching hook receptacle, clamping area; inner contour

28

chamfer

3

(one-piece) insert element

30

Insertion member body

30a

Top of the insert body 30th

30b

Bottom of the insert body 30th

31

support element

32

Head Start; Got over

33

Latching means; Latching hook receiving; Locking hooks; Terminal area; overcut

34

Evaporator area of the top 30a of the insert body 30

35

Condenser area of the top 30a of the insert body 30

36

Drainage channel of the evaporator 34th

36a

Crossflow channels of the evaporator 34th

36b

central outlet channel of the evaporator area 34

36c

Drain opening of the evaporator 34th

36d

inclined surface of the transverse drainage channels 36a the evaporator section 34

36e

horizontal surface of the crossflow channels 36a of the evaporator section 34 ; Reason for the crossflow channels 36a the evaporator section 34

36f

Collection of the central drainage channel 36b the evaporator section 34

37

Outflow channel of the condenser region 35

37a

Crossflow channels of the condenser region 35

37b

Longitudinal drainage channels of the condenser region 35

37c

Drain opening of the condenser region 35

4

Condensate collection space

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• US 2010/0192397 A1 [0011]
• DE 102014211303 A1 [0020, 0021]

Claims (20)

Floor module assembly (2, 3) for a heat pump (12), preferably a heat pump dryer (1), with a bottom module (2) which is formed, at least in sections, a process air space (15) for receiving at least one evaporator (17) of the heat pump (12 ), wherein the floor module (2) comprises at least one condensate collection basin (21), which is designed to receive condensate of the evaporator (17), and with an insert element (3), which is arranged and formed inside the condensate collection basin (21), at least the evaporator (17) from above to receive, characterized in that the insert element (3) is formed of a foamed material, preferably of expanded polystyrene or polypropylene, wherein the insert element (3) on its underside (30b) a plurality of molded support elements (31), which on the bottom (21 a) of the condensate collecting basin (21) stand up and that the bottom module (2) at least one projection ung (26), and in that the insert element (3) has at least one projection (32) which engages under the projection (26) of the floor module (2). Floor module assembly (2, 3) according to Claim 1 , characterized in that the floor module (2) has at least one latching means (27), and in that the insert element (3) has at least one latching means (33) which cooperates with the latching means (27) of the floor module (2). Floor module assembly (2, 3) according to Claim 1 or 2 , characterized in that the latching means (27) of the floor module (2) has a latching hook (27), and that the latching means (33) of the insert element (3) has a latching hook receptacle (33), in which the latching hook (27) of the floor module (2) is held positively, or vice versa. Floor module assembly (2, 3) according to one of the preceding claims, characterized in that the latching means (27) of the floor module (2) has a clamping region (27), and in that the latching means (33) of the insert element (3) has an elastic clamping region (33 ), wherein the insert element (3) by elastic deflection of the clamping portion (33) of the insert member (3) relative to the clamping portion (27) of the floor module (2) is held non-positively, or vice versa. Floor module assembly (2, 3) according to one of the preceding claims, characterized in that the bottom module (2) below a process air outlet (16) of the process air space (15) has at least one condensate collecting tank extension (25), which is connected to the condensate collecting tank (21) fluidly , Floor module assembly (2, 3) according to Claim 5 , characterized in that the condensate collecting tank extension (25) forms together with the process air outlet (16) at least one edge (26) which as a projection (26) of the floor module (2) from a projection (33) of the insert element (3) from below becomes. Floor module assembly (2, 3) according to one of the preceding claims, characterized in that the condensate collection basin (21) has a condensate drainage channel (22) which is designed to remove the condensate from the condensate collection basin (21), preferably into a condensate collection tank, preferably the condensate drainage channel (22) projects so far into the condensate collecting basin (21) in the depth (X) and is covered by a condensate barrier (23) in the width (Y), so that when the soil module group (2, 3) is tilted in the Depth (X) of the condensate barrier (23) away the condensate barrier (23), the condensate from the condensate drain channel (22) keep away, preferably vorbekenswiesen on the condensate drain channel (22) can. Floor module assembly (2, 3) according to one of the preceding claims, characterized in that the condensate collecting tank (21) has a condensate return duct (24), which is designed to return the condensate from a condensate collection tank in the condensate collection basin (21). Floor module assembly (2, 3) according to one of the preceding claims, characterized in that the insert element (3) is further adapted to receive the condenser (18) from above. Floor module assembly (2, 3) according to one of the preceding claims, characterized in that the upper side (30a) of the insert element (3) is formed flush with the underside of at least the evaporator (17), preferably and the condenser (18) complete. Floor module assembly (2, 3) according to one of the preceding claims, characterized in that the upper side (30a) of the insert element (3) has at least one evaporator region (34) which is formed to receive the evaporator (17) from above, wherein the evaporator portion (34) of the insert member (3) has at least one drain channel (36) which is formed, condensate from the evaporator (17) via a drain opening (36c) the condensate collection basin (21). Floor module assembly (2, 3) according to Claim 11 characterized in that the drainage channel (36) comprises at least one transverse drainage channel (36a), preferably a plurality of transverse drainage channels (36a) adapted to receive condensate substantially in width (Y), and in that the drainage channel (36) at least one central drainage channel (36b), which is designed to connect the transverse drainage channel (36a) to the drainage opening (36c) in a fluid-conducting manner. Floor module assembly (2, 3) according to Claim 12 , characterized in that the transverse drainage channel (36a) has an inclined surface (36d) and a horizontal surface (36e). Floor module assembly (2, 3) according to Claim 12 or 13 , characterized in that the drainage channel (36) has at least two transverse drainage channels (36a), which are spaced from each other by a flush with the underside of the evaporator (17) surface on which the evaporator (17) can be received from above. Floor module assembly (2, 3) according to one of Claims 12 to 14 , characterized in that the transverse drainage channel (36a) opposite to a flow direction (A) of the process air of the evaporator (17) is formed obliquely. Floor module assembly (2, 3) according to one of Claims 12 to 15 , characterized in that the central drainage channel (36b) at least one elevation (36f), which is adapted to receive the evaporator (17) from above. Floor module assembly (2, 3) according to one of the preceding claims, characterized in that the upper side (30a) of the insert element (3) further comprises a condenser region (35) adapted to receive the condenser (18) from above, the condenser region (35) of the loading element (3) has at least one discharge channel (37) which is designed to supply condensate from the liquefier (18) to the condensate collecting basin (21) via a discharge opening (37c). Floor module assembly (2, 3) according to Claim 17 characterized in that the drainage channel (37) comprises at least one transverse drainage channel (37a), preferably a plurality of transverse drainage channels (37a) adapted to receive condensate substantially in width (Y), and in that the drainage channel (37) at least one longitudinal drainage channel (37b) which is designed to connect at least one transverse drainage channel (37a) to the drainage opening (37c) in a fluid-conducting manner. Floor module (2) for use in a floor module assembly (2, 3) for a heat pump (12), preferably a heat pump dryer (1), according to any one of Claims 1 to 18 in that the floor module (2) is designed to form, at least in sections, a process air space (15) for accommodating at least one evaporator (17) of the heat pump (12), wherein the floor module (2) has at least one condensate collection basin (21) which is formed To receive condensate of the evaporator (17), and wherein the bottom module (2) is formed, an insert element (3) after Claim 20 take. Insertion element (3) for use in a floor module assembly (2, 3) for a heat pump (12), preferably a heat pump dryer (1), according to any one of Claims 1 to 18 , wherein the insert element (3) is formed, within the condensate collecting basin (21) of a floor module (2) after Claim 19 to be received, wherein the insert element (3) is further adapted to receive at least the evaporator (17) of the heat pump (12) from above.

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