Modular Condensate Tank Layout for Compact AC Installation
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Solution Overview
Problem
Conventional condensate collection tanks in air conditioning systems face challenges due to limited capacity, maintenance difficulties, and aesthetic issues when positioned within units or conduits, leading to inefficient condensate management and potential blockages from micro-organism growth.
Innovation Solution
A modular condensate collection tank design with a detachable lid and mounting bracket allows for compact placement adjacent to the air conditioning unit, featuring a sensor system with a barrier for protection and a failsafe mechanism, enabling easy maintenance and reduced installation costs by eliminating the need for clearance between the tank and unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the condensate collection tank is positioned within the air conditioning unit or drain conduit to hide it from view, then aesthetics are improved, but the tank capacity is reduced and maintenance becomes difficult
Solution Approach 1:
The tank is divided into a removable lid portion and a body portion. The lid can be detached from the body to provide access to the tank interior for maintenance, while the body remains installed in the confined space. This segmentation allows the tank to be hidden within the unit for aesthetics while maintaining serviceability and adequate capacity in the body portion.
2Shape
If the condensate collection tank is positioned within the air conditioning unit or drain conduit to hide it from view, then aesthetics are improved, but maintenance accessibility worsens
Solution Approach 1:
The lid is designed to be removable from the tank body, allowing maintenance personnel to access the tank interior by simply detaching the lid without removing the entire tank from its installed position. This enables easy cleaning and maintenance while the tank remains concealed within the unit for aesthetic purposes.
3Productivity
If the condensate collection tank is positioned underneath the air conditioning unit for gravity drainage, then drainage efficiency is improved, but a significant clearance is required which increases wall area occupation
Solution Approach 1:
The pump is configured to be movable between an operating position and a stowed position. During operation, the pump extends to provide the necessary clearance for gravity drainage from the tray to the tank. When not in use, the pump retracts or folds away, eliminating the need for permanent clearance and reducing the wall area occupied by the air conditioning system.
4Extent of automation
If a sensor is provided within the condensate collection tank to detect condensate level, then pump operation control is improved, but the sensor is exposed to harsh conditions causing false readings or damage
Solution Approach 1:
A barrier is positioned between the sensor and the condensate environment. This barrier protects the sensor from direct exposure to harsh conditions including condensate, micro-organisms, and debris, while still allowing the sensor to detect condensate level accurately. The intermediary barrier extends beyond the sensor to provide comprehensive protection, preventing false readings and damage.
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 design enhances condensate management efficiency, reduces maintenance complexity, and improves aesthetics by allowing closer placement of the tank to the air conditioning unit, while preventing blockages and false sensor readings through robust and protected sensor placement.
Implementation Method 1
a sensor for determining whether an amount of condensate liquid in the tank exceeds a threshold value
Implementation Method 2
a controller for controlling removal of the condensate liquid from the tank via the outlet port when the sensor determines that the threshold value has been exceeded
Implementation Method 3
as the condensate will typically drain from the collection tray to the collection tank under the force of gravity
Data Source
AI summary
A condensate collection tank (1) for an air conditioning system is provided. The tank (1) comprises a body (20) for storing condensate liquid, a lid (10) releasably connectable to the body (20) to form the tank (1) and a mounting bracket (112) for fixing the lid (10) to a mounting surface. The tank (1) further includes an inlet port (50, 90) for condensate liquid from the air conditioning system, an outlet port (40, 80) for condensate liquid from the tank (1), a sensor (104) for determining whether an amount of condensate liquid in the tank (1) exceeds a threshold value, and a controller for controlling removal of the condensate liquid from the tank (1) via the outlet port (40, 80) when the sensor (104) determines that the threshold value has been exceeded.