Nested Pocket Condensate Pan for Compact HVAC Heat Exchangers
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Solution Overview
Problem
Traditional condensate management mechanisms in HVAC systems are inefficient, limiting the number of heat exchange tubes and prone to water and air pressure damage, leading to operational interruptions.
Innovation Solution
A condensate pan with a pocket that increases the condensate collection area and volume, allowing for additional heat exchange tubes without expanding the heat exchanger's footprint, and enhances drainage to prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional condensate collection mechanisms are used, then the heat exchanger structure is simple, but the number of heat exchange tubes is limited and drainage efficiency is poor
Solution Approach 1:
The pocket is nested within the condensate pan structure, with the pocket wall extending downward to define a second opening that is larger than the first opening in the pan surface. This nested configuration allows the condensate collection system to accommodate a greater number of heat exchange tubes while maintaining a compact overall structure, thereby increasing productivity without proportionally increasing device complexity.
Solution Approach 2:
The invention transitions from a single-plane condensate collection surface to a multi-dimensional structure by adding the pocket that extends vertically downward. This dimensional change creates additional collection volume and a larger second opening area, enabling the system to handle more heat exchange tubes and improve drainage efficiency while keeping the footprint compact.
2Reliability
If traditional condensate drainage mechanisms are used, then the structure is compact, but water and air pressure damage may occur
Solution Approach 1:
The pocket structure acts as a cushioning element by providing an additional volume to accommodate condensate before it reaches critical levels. The pocket wall and the enlarged second opening create a buffer zone that prevents water damage and air pressure issues by allowing condensate to accumulate safely in the pocket before draining, thereby improving reliability without significantly increasing complexity.
Solution Approach 2:
The pocket serves as an intermediary chamber between the heat exchange tubes and the main condensate pan. It mediates the condensate flow by providing an intermediate collection point with a larger opening area, which helps regulate drainage and prevents direct pressure transmission that could cause damage, thus enhancing reliability while maintaining structural efficiency.
3Productivity
If the condensate pan opening is enlarged to collect more condensate, then drainage efficiency improves, but the heat exchanger footprint increases
Solution Approach 1:
Instead of enlarging the condensate pan opening in the horizontal plane, the invention exploits the vertical dimension by adding the pocket that extends downward. This creates a larger effective collection area (second opening) without increasing the horizontal footprint of the heat exchanger, thereby improving condensate collection efficiency while maintaining a compact stationary footprint.
Solution Approach 2:
The pocket is nested within the existing condensate pan structure, utilizing the vertical space already available. This nested arrangement allows the system to achieve a larger effective opening area for condensate collection without expanding the external dimensions of the heat exchanger, thus improving productivity without increasing the stationary object's footprint.
Data Source
AI summary
A heat exchanger (e.g., a furnace) for a heating, ventilation, and/or air conditioning (HVAC) system includes a condensate pan having a first opening defined in a surface of the condensate pan. The condensate pan is configured to receive liquid condensate via the first opening, and the first opening comprises a first cross-sectional area. The furnace further includes a pocket comprising a wall circumscribing and defining a second opening. The second opening has a second cross-sectional area greater than the first cross-sectional area of the first opening of the condensate pan. The pocket is configured to be coupled to the surface of the condensate pan such that the wall of the pocket surrounds the first opening in the surface of the condensate pan.