Float-Actuated Condensate Drain for Overpressure Discharge
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Solution Overview
Problem
Existing condensate drain devices are complex, prone to errors, and unsuitable for systems with excess pressure at the condensate outlet, requiring a structurally simple and efficient solution for condensate collection and removal.
Innovation Solution
A condensate drain device with a cup-shaped container and a floating body that moves between closed and open positions based on buoyancy and pressure differences, allowing safe operation under overpressure conditions and automatic drainage of condensate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional ball siphons are used for condensate drainage, then condensate can be drained, but the device requires large space, has many individual parts, and is susceptible to assembly errors
Solution Approach 1:
The patent merges the sealing function and drainage function into a single integrated structure. The flexible membrane acts as both the sealing element and the activation mechanism, eliminating the need for separate balls, siphons, and sealing components. This integration directly reduces device complexity while maintaining drainage reliability through the membrane's ability to respond automatically to condensate accumulation.
Solution Approach 2:
The patent employs a flexible membrane as the core component替代traditional rigid ball siphon mechanisms. This thin film structure provides the necessary sealing function while being lightweight and space-efficient. The membrane's flexibility allows it to deform under pressure from accumulated condensate, automatically opening the drainage path without requiring complex mechanical assemblies.
2Reliability
If ball siphons with heavy balls are used, then sealing is improved, but condensate may not drain if the ball is too heavy
Solution Approach 1:
The flexible membrane is designed to automatically respond to the weight of accumulated condensate. When condensate accumulates to a certain level, its weight naturally causes the membrane to deform and open the drainage path. This self-service mechanism eliminates the need for manually selected ball weights, as the system automatically adjusts its response based on the actual condensate load, ensuring both reliable sealing and effective drainage.
Solution Approach 2:
The patent changes the physical state and responsiveness of the sealing mechanism from a fixed-weight ball to a dynamic flexible membrane. The membrane's deformation parameter changes in response to condensate weight, allowing the system to adapt its sealing and drainage behavior based on real-time conditions. This parameter change ensures that the membrane remains sealed under normal conditions but opens automatically when drainage is needed.
3Productivity
If ball siphons with light balls are used, then drainage is improved, but the ball may rattle and disturb users at high pressures
Solution Approach 1:
The flexible membrane, being a continuous thin film structure, naturally dampens vibrations and eliminates rattling sounds that occur with loose ball siphons. The membrane is securely attached at its edges and deforms smoothly under pressure, providing silent operation even at high pressures while maintaining effective drainage through its ability to open and close based on condensate accumulation.
4Reliability
If complex drainage devices are used, then drainage function is achieved, but the system is prone to errors and breakdowns
Solution Approach 1:
The patent combines multiple functions (sealing, drainage activation, and flow control) into a single flexible membrane component. This merging of functions reduces the number of individual parts that can fail, eliminating assembly errors and reducing maintenance requirements while maintaining reliable drainage operation.
Solution Approach 2:
The flexible membrane system is fully automatic and self-regulating, responding to condensate accumulation without external control or complex mechanisms. This self-service operation minimizes potential failure points and eliminates the need for powered components, sensors, or complex control systems that could breakdown.
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
Enables reliable and efficient condensate drainage in systems with excess pressure, ensuring safe operation and reducing the risk of backflows and leakage, while maintaining a compact and simple design.
Implementation Method 1
a floating body (82) which is arranged in the receiving space (73) of the condensate container (72) in such a way that it is capable of moving between a lower closed position (84), in which the floating body (82) closes the condensate drain (78), and an upper open position (85), in which the floating body (82) releases the condensate drain (78)
Implementation Method 2
in the area of the condensate inlet (77), i.e., at or in the container opening (76a) of the condensate container (72), a higher pressure level (86) exists than is the case in the area of the condensate drain (78)
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present invention relates, inter alia, to a method in which condensate (88) accumulating in a, in particular flowing, gaseous medium is collected in a condensate drain device (70) and discharged from it. The condensate drain device (70) comprises an upwardly open condensate container (72) which has a receiving chamber (73) bounded downwards by a container base (74), laterally by a container side wall (75), and upwards by an upper closure (76) with a container opening (76a), a condensate inlet (77) in the upper closure (76) of the condensate container (72) formed by the container opening (76), a condensate outlet (78) in the lower region of the condensate container (72) through which condensate (88) accumulated in the condensate container (72) is discharged, and a float (82) in the receiving chamber (73) of the condensate container (72).The maximum expansion (76b) of the container opening (76a) is greater than the maximum expansion (83) of the float (82). Condensate (88) accumulating in the gaseous medium upstream of the condensate inlet (77), where a higher pressure level (86) is present than the pressure level (87) at the outside of the condensate outlet (78), enters the receiving chamber (73) of the condensate container (72) via the condensate inlet (77). The float (82) is initially in a lower closed position (84) and closes the condensate outlet (78). The float (82) moves from its lower closed position (84) to an upper open position when the buoyant force of the float (82) is greater than the opposing forces acting on the float (82). The condensate drain (78) is released and the condensate (88) in the condensate container (72) flows out of the condensate container (72) via the condensate drain (78).