Multi-Tier Drain Pan for Air Conditioner Condensate Freezing
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Solution Overview
Problem
Conventional air-conditioning systems face issues with draining condensate at temperatures below freezing, leading to freezing and blockage of drain holes, which prevents efficient operation of heat pumps and increases energy consumption.
Innovation Solution
An air-conditioning system with a multiple-tiered drain pan that includes a slinging trough, draining trough, and pumping trough, equipped with a drain pump and fan to manage condensate removal, and a temperature-controlled drain valve to ensure condensate is removed regardless of outdoor temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a conventional drain hole is used to drain condensate, then water can drain out of the drain pan in normal conditions, but the drain hole becomes blocked when outdoor temperature drops to freezing or below
Solution Approach 1:
The drain pan is divided into multiple functional zones: a drain hole for gravity drainage, a pump for active removal, and a slinger mechanism for centrifugal ejection. Each zone handles drainage under different conditions, ensuring reliable operation across all temperature ranges.
Solution Approach 2:
The system changes the drainage mechanism based on temperature parameters. Above freezing, gravity drainage through the drain hole is sufficient. Below freezing, the system activates the pump and/or slinger to actively remove water before it can freeze and block the drain hole.
2Loss of energy
If heat pumps operate below freezing temperatures, then energy usage is reduced, but condensate accumulates in the drain pan and overflows
Solution Approach 1:
The system uses the existing fan motor to drive the slinger mechanism, and the pump motor to actively remove condensate. These components serve dual purposes: their primary function and condensate removal, eliminating the need for separate dedicated drainage components.
Solution Approach 2:
The drainage system transitions from passive gravity drainage to active pumped removal and centrifugal ejection based on operational conditions. The controller dynamically activates different drainage mechanisms to match the condensate generation rate and temperature conditions.
3Ease of operation
If electric strip heat is used for heating below freezing temperatures, then heating can be provided, but operating costs increase significantly
Solution Approach 1:
The heat pump serves as an intermediary system that can operate across a wide temperature range. By enabling heat pump operation below freezing through reliable condensate management, the system provides a more efficient heating alternative to electric strip heat.
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 effective drainage of condensate at all temperatures, allowing heat pumps to operate below freezing and reducing energy usage by preventing freezing issues and overflow.
Implementation Method 1
a fan configured to blow air on the outdoor coil, the fan including a fan blade having a slinger ring, the slinger ring being configured to take liquid from the slinging trough and move the liquid from the slinging trough onto the outdoor coil when the fan is operating
Implementation Method 2
a drain pump configured to selectively pump liquid out of the pumping trough through a drain hose
Implementation Method 3
a drain valve configured to selectively allow liquid in the drain trough to pass through the drain hole
Implementation Method 4
an indoor coil configured to exchange heat with indoor air at an indoor location; an outdoor coil configured to exchange heat with outdoor air outside of the indoor location
Implementation Method 5
When the temperature of one of the coils drops below the dew point, water may condense out of the corresponding air (indoor or outdoor) and form on the corresponding cooling coil
Data Source
AI summary
An air-conditioner, comprising: an indoor coil; an outdoor coil; a drain pan under the indoor and outdoor coils, the drain pan including a slinging trough having a slinging depth, a draining trough having a draining depth, a pumping trough having a pumping depth, and a drain hole formed in a bottom surface of the draining trough; a drain valve for selectively allowing liquid to pass through the drain hole; a drain pump for selectively pumping liquid out of the pumping trough; a fan for blowing air on the outdoor coil and moving the liquid from the slinging trough onto the outdoor coil when the fan is operating; and a controller for controlling operation of at least the drain pump and the fan, wherein the pumping depth is greater than the draining depth, the draining depth is greater than the slinging depth.