Condensate tray assembly and methods of filtering condensate

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Solution Overview

Problem

Traditional condensate management in heat pump systems leads to system blockages and contamination issues due to the lack of effective contaminant removal mechanisms, requiring cumbersome maintenance and potentially causing damage or inefficiencies.

Innovation Solution

A removable condensate tray assembly with a base plate and contaminant traps that passively filters condensate using gravity, allowing easy installation and removal for cleaning, thereby minimizing clogging and maintenance efforts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional condensate management methods are used, then condensate can be transported to downstream processes, but system blockages and clogging occur due to contamination in the condensate

Engineering Contradiction:

Improvecondensate transport efficiencyVSAvoidsystem blockage resistance

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent extracts and removes contaminants from the condensate stream using removable trap assemblies that can be easily accessed and cleaned. The trap assemblies are positioned to intercept contaminants before they enter downstream processes, separating the contaminant removal function from the main condensate transport path.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The condensate trap assemblies act as intermediary components between the condensate source and downstream processes. These assemblies capture contaminants that would otherwise cause blockages, serving as a mediator that protects the downstream system while allowing condensate to flow through.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If contaminant removal mechanisms are installed, then contaminants can be captured from condensate, but disassembly and maintenance become complex and cumbersome

Engineering Contradiction:

Improvecontaminant removal effectivenessVSAvoidmaintenance accessibility

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The condensate trap system is segmented into removable, modular assemblies that can be independently accessed and maintained. Each trap assembly is designed as a separate unit that can be removed from the condensate tray without disassembling the entire heat pump system, making maintenance straightforward and accessible.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The trap assemblies are designed with dynamic accessibility - they can be easily installed and removed from the condensate tray. The removable design allows maintenance personnel to access and clean the traps without permanent installation, enabling flexible and simple maintenance operations.

Inventive Principle:

Principle #15Dynamics

3Productivity

If condensate flows through the system, then cooling and heating operations can proceed, but overflow and damage risks increase due to contamination accumulation

Engineering Contradiction:

Improveheat pump operation efficiencyVSAvoidcondensate overflow risk

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The trap assemblies are positioned to capture contaminants in advance before they can accumulate to harmful levels. By removing contaminants early in the condensate flow path, the system prevents the accumulation that would lead to overflow and damage, addressing the problem before it occurs.

Inventive Principle:

Principle #10Preliminary action

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 removes contaminants from condensate, reducing the risk of blockages and enhancing system efficiency by facilitating quick and convenient maintenance, thus ensuring safe and reliable operation of heat pump systems.

Implementation Method 1

The proximal end is configured to be elevated relative to the distal end such that the condensate from the heat pump flows from the proximal end of the base plate toward the distal end of the base plate

Methodology Applied

Scientific EffectGravity: Gravitation

Implementation Method 2

The contaminant traps are aligned against the condensate flow to facilitate collection of contaminants present in the condensate as the flow of condensate traverses across the condensate tray

Methodology Applied

Scientific EffectSedimentation: Sedimentation

Data Source

PatentUS20250277601A1Condensate tray assembly and methods of filtering condensate

Publication Date: 2025.09.04 MIDEA GROUP CO LTD

AI summary

Apparatuses and methods of a condensate tray assembly for filtering condensate from a heat pump include a base plate, side walls, and a plurality of contaminant traps. The base plate includes a proximal end, a distal end, a left side edge, and a right side edge. The proximal end is configured to be elevated relative to the distal end such that the condensate from the heat pump flows from the proximal end of the base plate toward the distal end of the base plate. The side walls are removably coupled to the base plate near the side edges. The plurality of contaminant traps are removably coupled to the base plate. Each contaminant trap includes an inflow leg and an outflow leg. The contaminant traps are aligned against the condensate flow to facilitate collection of contaminants present in the condensate as the flow of condensate traverses across the condensate tray