Condensate Leak Switch Using a Dissolvable Biocide Tablet
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Solution Overview
Problem
Existing devices for detecting abnormal water levels in air conditioning condensate collection pans and water leak containment pans lack effective solutions for minimizing algae growth, providing audible and visual signals, automatic system shutdown, and ease of installation and testing.
Innovation Solution
A corrosion-resistant control switch with a water-soluble biocide tablet support structure that activates an alarm system when water levels exceed a threshold, using a self-contained, battery-powered alarm unit with audible and visual alerts, and a compact design for easy installation and testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a control switch is designed to detect abnormal water levels in condensate pans, then water level monitoring capability is improved, but the device complexity increases
Solution Approach 1:
The patent extracts the biocide tablet from the traditional control switch housing and places it in a separate, easily replaceable compartment. This allows the monitoring function to be maintained while simplifying maintenance operations, as the tablet can be replaced without disturbing the electrical components or calibration of the switch.
Solution Approach 2:
The control device is segmented into distinct functional modules: the control switch housing, the biocide tablet compartment, and the alarm unit. This segmentation allows each component to be independently maintained and replaced, reducing overall device complexity while maintaining monitoring precision.
2Object-affected harmful factors
If a biocide tablet is integrated into the control switch, then algae growth minimization is improved, but the ease of manufacture decreases
Solution Approach 1:
The biocide tablet is pre-loaded into a dedicated compartment during assembly, but designed to be easily removable and replaceable. This preliminary placement ensures algae prevention from the start, while the modular design simplifies future maintenance without requiring complex disassembly procedures.
Solution Approach 2:
The patent introduces a separate biocide tablet compartment as an intermediary between the control switch electronics and the condensate pan environment. This mediator allows the biocide function to be added without complicating the electrical components, as the tablet compartment can be manufactured and assembled independently.
3Reliability
If an alarm unit with audible and visual signals is added, then alarm signal reliability is improved, but the device complexity increases
Solution Approach 1:
The alarm unit combines both audible (horn) and visual (strobe light) signaling functions into a single integrated housing. This merging provides redundant alerting methods for improved reliability, while the compact integration avoids the need for separate alarm devices that would increase overall system complexity.
Solution Approach 2:
The alarm unit is designed as a self-contained module that provides multiple functions: audible alarm, visual alarm, and test capability, all within a single device. This multi-functionality improves reliability by providing multiple alerting modes while avoiding the complexity of multiple separate components.
4Reliability
If the control switch is made corrosion resistant, then durability in wet environments is improved, but the ease of repair decreases
Solution Approach 1:
The control device is segmented into corrosion-resistant housing and easily replaceable internal components. The housing provides durable protection against corrosion, while the modular internal components (tablet compartment, alarm unit) can be independently accessed and replaced, maintaining ease of repair despite the protective housing.
Solution Approach 2:
The biocide tablet and alarm unit are extracted as separate, easily removable components from the corrosion-resistant housing. This allows maintenance personnel to access and replace these components without having to disassemble or compromise the corrosion-resistant structure, preserving both durability and ease of repair.
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 solution effectively minimizes algae growth, provides timely alerts through audible and visual signals, and allows for easy operability testing, ensuring efficient water level monitoring and system shutdown in air conditioning and hot water heater systems.
Implementation Method 1
a water soluble tablet, such as a biocide composition tablet used in air conditioning condensate pans to minimize algae growth
Data Source
AI summary
An air conditioning system condensate collection pan or water leak containment pan electrical control switch includes a housing or frame for supporting a switch unit which includes an elongated actuator arm. The housing includes a slot disposed adjacent a distal end of the actuator arm for receiving a water soluble tablet engageable with the actuator arm to bias the arm into a predetermined position of the switch. Abnormal accumulation of condensate or leaking water dissolves the tablet and allows the actuator arm to move to a position to effect actuation of the switch. The switch may be connected to a control unit, a thermostat and/or to an alarm generator including a self-contained unit having battery powered audio and/or visual alarm devices, an on-off switch and a circuit test switch.