Plastic Drain Pan Thread Reinforcement Against Hoop Stress Fracture
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Solution Overview
Problem
Existing drain pans made of plastic are prone to fracturing and leaking when connected to steel pipes due to Hoop Stresses generated by torque forces during threading, leading to condensate leakage in air conditioning systems.
Innovation Solution
A drain pan with a plastic drain and a metal insert that reinforces the plastic threads, providing a spaced relationship between the insert and the plastic drain to mitigate Hoop Stresses and prevent fracturing, while maintaining an economical manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If steel pipe is threaded into plastic drain pan with high torque forces, then connection strength is improved, but plastic threads fracture and leakage occurs
Solution Approach 1:
A metal insert is introduced as an intermediary component between the steel pipe and plastic drain pan. The insert receives the steel pipe threads and transfers loads away from the plastic threads, preventing fracture while maintaining connection strength. The insert acts as a mediator that protects the plastic threads from direct stress exposure.
Solution Approach 2:
The solution combines multiple materials (plastic drain pan, metal insert, steel pipe) to create a composite connection system. Each material is used where it performs best: plastic for the drain pan body, metal insert for thread reinforcement, and steel pipe for drainage. This composite approach resolves the contradiction by leveraging material properties rather than relying on a single material.
2Strength
If metal insert is added to reinforce plastic threads, then thread strength is improved, but device complexity increases
Solution Approach 1:
The metal insert is integrated into the plastic drain pan during the molding process, merging two components into a single manufactured assembly. This reduces the number of separate parts and simplifies installation, offsetting the added complexity of the insert itself. The insert becomes an inherent part of the drain pan structure rather than a separate attachment.
Data Source
AI summary
A drain pan and a method for fabricating a drain pan for use with an air conditioner, the drain pan having a plastic drain having plastic threads, with an insert disposed within the plastic drain to prevent the fracturing of the plastic threads when a steel pipe is threaded into the plastic drain. The insert may be a metal insert.