Automated Fog-Based Cleaning System for Air Handler Evaporator Coils
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Air conditioners suffer from reduced efficiency and potential health hazards due to mildew buildup on evaporator coils, which is often not addressed until problems arise, leading to costly repairs and unhealthy indoor air quality.
Innovation Solution
A system that cleans the evaporator coil and internal air handling components automatically, using wands with nozzles and a metering pump to deliver a cleaning solution, which can be operated on a schedule without human intervention, ensuring the air conditioner is powered down during cleaning to allow the solution to work before resuming normal operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If evaporator coils are cleaned manually by removing panels or coils, then cleaning effectiveness is improved, but time consumption and operational disruption increase
Solution Approach 1:
The system enables automatic cleaning of evaporator coils without human intervention. A pump delivers cleaning solution through nozzles positioned within the plenum, and a controller automates the entire cleaning cycle including powering down the air conditioner, spraying the solution, waiting for effectiveness, and restoring operation. This self-service mechanism resolves the contradiction by maintaining high cleaning effectiveness while eliminating manual labor time consumption.
Solution Approach 2:
The system performs preliminary cleaning actions before mildew buildup becomes severe. By scheduling regular automatic cleanings, the system prevents the need for more intensive manual interventions later. The controller programs cleaning cycles in advance, ensuring coils are maintained proactively rather than reactively, thus reducing both time investment and operational disruption.
2Reliability
If evaporator coils are cleaned frequently manually, then mildew buildup is prevented, but operational disruption and labor requirements increase
Solution Approach 1:
The automatic cleaning system eliminates the need for human operators to manually access and clean coils. The controller manages the entire process autonomously: it powers down the air conditioner, activates the pump to deliver cleaning solution through nozzles, waits for the solution to work, then restores normal operation. This self-service approach maintains reliable mildew prevention while completely removing operational disruption from the user perspective.
Solution Approach 2:
The system introduces intermediary components (pump, nozzles, controller) that mediate between the cleaning solution and the evaporator coils. These intermediaries enable frequent cleaning without requiring direct human intervention or significant operational disruption. The controller acts as an intermediary that coordinates the timing and execution of cleaning cycles, ensuring they occur reliably but unobtrusively.
3Manufacturing precision
If cleaning solution is applied generously, then cleaning effectiveness is improved, but solution consumption and cost increase
Solution Approach 1:
The system applies cleaning solution locally and precisely where needed on the evaporator coils. Nozzles are positioned within the plenum to target specific coil surfaces directly. The pump delivers solution in controlled amounts only to the areas requiring cleaning, rather than applying generous quantities system-wide. This localized application maintains high cleaning effectiveness while minimizing solution consumption and associated costs.
Solution Approach 2:
The system controls the parameters of solution delivery, including flow rate, pressure, and duration. The pump is programmed to deliver solution at optimal parameters that maximize cleaning effectiveness per unit of solution. By precisely controlling these parameters, the system achieves thorough cleaning without wasteful over-application, thus reducing solution consumption and cost.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution maintains air conditioner efficiency, reduces repair costs, prevents leaks and flooding, and ensures healthier indoor air by regularly removing mildew, thus avoiding the need for costly repairs and improving air quality.
Implementation Method 1
The solution kills and breaks down mildew that has grown on surfaces of the evaporator coil
Implementation Method 2
A pump may be used to deliver the cleaning solution through the air handler system
Data Source
AI summary
The present invention is directed to systems for cleaning a component inside a machine, such as an evaporator coil inside an air conditioner. A pump is connected to a controlling device. The pump is also connected to a metering device. The metering device is connected to one or more reservoirs. The metering device is also connected to one or more devices, adapted to generate a fog whose particles have a mean diameter of less than about 15 microns. To perform the cleaning of the component, the controlling device disables the machine. The controlling device then activates the pump. The pump causes cleaning solution to be drawn from the one or more reservoirs into the metering device, which then transfers the cleaning solution into the fog generating device(s). The controlling device then allows the machine to resume operation.