Condensate trap
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Solution Overview
Problem
Existing condensate traps in gas furnaces fail to effectively manage high positive pressures and prevent leakage of flue gases into the room, leading to safety hazards and reduced system efficiency due to clogged vents and high inducer motor speeds, while also allowing contaminants to enter the flue path.
Innovation Solution
A condensate trap design featuring a back portion with a first passage and a front portion, each with specific float configurations and constrictions to control the flow of condensate and flue gases under both positive and negative pressures, preventing flue gas leakage and ensuring proper condensate management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing condensate trap design is used, then the structure is simple, but it cannot handle high positive pressures and allows flue gas leakage into the room
Solution Approach 1:
The condensate trap is divided into multiple chambers (first chamber, second chamber, third chamber) with separate float mechanisms (first float, second float, third float) for different pressure zones. Each chamber handles specific pressure conditions independently, allowing the system to manage high positive pressures effectively while maintaining overall structural organization.
Solution Approach 2:
The trap employs dynamic float mechanisms that automatically adjust to pressure changes. The first float responds to positive pressure in the first chamber, the second float to negative pressure in the second chamber, and the third float to pressure conditions in the third chamber. This dynamic response enables reliable operation under varying pressure conditions without requiring complex external control systems.
2Object-affected harmful factors
If existing condensate trap is used, then the device is simple, but it allows flue gases to leak into the room under high pressure conditions
Solution Approach 1:
Multiple floats act as intermediaries between the pressure system and the discharge path. The first float controls the first passage, the second float controls the second passage, and the third float controls the third passage. These intermediary elements prevent direct communication between high-pressure flue gases and the room, blocking harmful factors while maintaining relatively simple individual component designs.
Solution Approach 2:
The trap establishes preliminary barriers through the float mechanisms before high-pressure flue gases can escape. The floats are positioned to close passages proactively when pressure conditions warrant, preventing flue gas leakage before it can occur rather than responding after the fact.
3Object-affected harmful factors
If existing condensate trap is used, then the structure is straightforward, but it allows contaminants to enter the flue path when furnace is not operating
Solution Approach 1:
The second float mechanism dynamically responds to negative pressure conditions that occur when the furnace is not operating. When negative pressure is detected in the second chamber, the second float automatically adjusts to close the second passage, preventing contaminants from entering the flue path during idle periods without requiring complex control systems.
4Reliability
If existing condensate trap is used, then the device is simple, but it cannot prevent condensate spillage under high pressure conditions
Solution Approach 1:
The condensate containment system is segmented into multiple chambers with independent float-controlled passages. The first float manages condensate in the first chamber under positive pressure, the second float manages condensate in the second chamber under negative pressure, and the third float manages condensate in the third chamber. This segmentation allows reliable condensate containment under high pressure conditions while maintaining manageable structural complexity through modular design.
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 prevents flue gas leakage into the room and maintains system efficiency by managing pressures and contaminants, ensuring safe and efficient operation of gas furnaces even under high pressure conditions.
Implementation Method 1
A first float is placed over the first opening such that the float does not travel below the first opening
Implementation Method 2
A second float is placed below the second opening such that the second float does not travel through the second opening
Implementation Method 3
the third passage comprises a levered flap to enclose the third passage
Data Source
AI summary
Aspects of the invention are directed to condensate traps having a back portion and a front portion. The back portion includes a first passage enclosed between the first wall, a second wall, and a back wall. A first opening in the back portion connects the first wall and the second wall with a first float placed over the first opening and does not travel below the first opening and is prevented from leaving the first passage by a first constriction. The front portion of the condensate trap includes a second passage enclosed between the third wall and the fourth wall. A second opening connects the third wall and the fourth wall in the front portion and a second float is placed below the second opening such that it does not travel through the second opening and is prevented from falling below a predetermined level by a second constriction.