Air Conditioner Coil Assembly With Multi-Orientation Drain Pans
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Solution Overview
Problem
Air conditioning systems face challenges in achieving desired indoor temperatures and managing condensation moisture, requiring additional components like reheat coils and drain pans, while also needing to be compact and flexible for various installation configurations.
Innovation Solution
A coil assembly with a direct expansion coil, a reheat coil, and multiple drain pans (horizontal and vertical) that are securely interconnected to allow for proper drainage and flexible positioning, enabling efficient dehumidification and temperature adjustment without additional structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple drain pans and reheat coils are added to manage condensation and temperature, then dehumidification and temperature control efficiency are improved, but device complexity increases
Solution Approach 1:
The patent combines multiple drain pans (first horizontal drain pan, second horizontal drain pan, vertical drain pan) and reheat coils into a single integrated coil assembly. The drain pans are interconnected to form a unified drainage system that can handle condensation from multiple locations, while the reheat coils are positioned within the assembly to efficiently reheat dehumidified air. This merging reduces the number of separate components and simplifies installation.
Solution Approach 2:
The coil assembly is designed to perform multiple functions simultaneously: the direct expansion coil provides cooling and dehumidification, the reheat coils provide temperature adjustment, and the interconnected drain pans provide comprehensive condensation drainage. The assembly can be installed in various orientations (horizontal or vertical) while maintaining all functions, making it a universal solution for different installation environments.
2Adaptability or versatility
If the coil assembly is designed to accommodate various installation positions, then adaptability is improved, but structural complexity increases
Solution Approach 1:
The coil assembly is designed with universal adaptability to function in both horizontal and vertical installation positions. The interconnected drain pans are configured to drain condensation effectively regardless of orientation, and the reheat coils are positioned to maintain proper airflow and heating function in any orientation. This universal design eliminates the need for separate assemblies for different installation types.
Solution Approach 2:
The drain pan configuration allows the assembly to adapt dynamically to different installation orientations. The interconnected design enables condensation to flow naturally to drainage points regardless of whether the unit is installed horizontally or vertically, providing automatic adaptation to the installation position without requiring additional mechanical adjustment mechanisms.
3Reliability
If drain pans are positioned to catch condensation from the direct expansion coil, then moisture management is improved, but the space required for the assembly increases
Solution Approach 1:
The drain pans are nested within the overall coil assembly structure rather than being separate external components. The first and second horizontal drain pans are positioned to receive condensation from the direct expansion coil, while the vertical drain pan connects to these horizontal pans to provide continuous drainage. This nesting arrangement minimizes the overall volume of the assembly by utilizing the existing space between coils and housing structures.
Solution Approach 2:
The drain pan system utilizes three-dimensional space efficiently by arranging pans in multiple dimensions - horizontal pans positioned to catch condensation falling vertically from the direct expansion coil, and a vertical pan providing drainage in the vertical dimension. This multi-dimensional arrangement maximizes drainage effectiveness while minimizing the horizontal footprint of the assembly.
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
The coil assembly effectively manages condensation and adjusts temperatures by using interconnected drain pans and reheat coils, ensuring efficient moisture routing and temperature control across multiple orientations, enhancing installation flexibility and reducing design complexity.
Implementation Method 1
a direct expansion coil configured to circulate refrigerant and cool supply air passing over the direct expansion coil by heat exchange between the refrigerant and the supply air to generate dehumidified air
Implementation Method 2
a reheat coil configured to circulate the refrigerant to heat the dehumidified air by heat exchange between the refrigerant and the supply air to generate output air
Implementation Method 3
the moisture drawn from the air must be routed from the direct expansion coil in such a way that it does not harm any portion of the indoor air conditioner unit
Data Source
AI summary
A coil assembly is provided, comprising: a direct expansion (DX) coil circulating refrigerant and cooling supply air passing over the DX coil by heat exchange to generate dehumidified air; a reheat coil circulating the refrigerant and heating the dehumidified air by heat exchange to generate output air; a first horizontal drain pan below the DX and reheat coils in a first horizontal position; a second horizontal drain pan below the DX and reheat coils in a second horizontal position; a first vertical drain pan below the DX and reheat coils in a vertical position, wherein the first and second horizontal drain pans are connected to the first vertical drain pan, the reheat coil is secured between the first and second horizontal drain pans, and the first horizontal drain pan is on an opposite side of the DX coil and the reheat coil from the second horizontal drain pan.