Integral Heating Element Condensate Evaporator for Periodic Energy Use
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing condensate evaporators for large walk-in refrigerators require continuous power usage due to the 'Balco' resistance wire, which draws varying amounts of power based on temperature, leading to inefficiencies and increased energy consumption.
Innovation Solution
A condensate evaporator with a pan and integral heating element, featuring a U-shaped copper tube and coiled electrically conductive wire, where the heating element is cast with the pan, and a plunger-type switch that turns on with accumulated condensate weight and turns off when sufficient condensate is evaporated, minimizing parts and assembly, and optimizing energy usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a Balco resistance wire heater is used in the condensate evaporator, then the heater can continuously draw power to evaporate condensate, but the energy consumption increases due to continuous operation at full or reduced power
Solution Approach 1:
The heating element operates periodically rather than continuously. The controller activates the heater only when condensate is detected in the pan, and deactivates it when the pan is dry or contains insufficient condensate. This periodic operation maintains reliable condensate evaporation capability while dramatically reducing energy consumption compared to continuous operation.
2Ease of repair
If separate heater components are assembled into the condensate pan, then the heater can be installed and replaced independently, but the manufacturing cost and assembly complexity increase
Solution Approach 1:
The heating element is integrally formed with the condensate pan as a single unit, eliminating the need for separate assembly steps. This merging of components reduces manufacturing complexity and cost while maintaining the functional capability of the heater. The integrated design ensures proper thermal contact and eliminates potential failure points from assembly interfaces.
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 allows for economical manufacturing, reduced energy consumption by only powering the heating element when needed, and requires fewer components, enhancing operational efficiency and cost-effectiveness.
Implementation Method 1
a heater pad is provided on the pan for heating condensate in the pan to a point of evaporation
Implementation Method 2
an electrically conductive wire, e.g. a wire that is coiled within the tube and that extends through the tube with each end thereof extending from the tube for connection to an electrical circuit
Implementation Method 3
heating condensate in the pan to a point of evaporation
Data Source
AI summary
The condensate evaporator has a pan for collecting condensate and a heating element that is integral with the pan. The heating element includes a U-shaped copper tube and an electrically conductive wire that extends through the tube with each end thereof extending from the tube for connection to an electrical circuit.