Overflow Switch Mounting Clip for Fast HVAC Drain Pan Adjustment
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Solution Overview
Problem
Current overflow safety switch mounting systems for HVACR equipment are cumbersome, requiring time-consuming adjustments and installations, often resulting in improper positioning and costly overflows due to the need for screwing into the drain pan wall and complex replacement procedures.
Innovation Solution
A device featuring a clip member that removably attaches to the side wall with a non-penetrating set screw and a bracket that slides within tracks, allowing easy adjustment and removal of the overflow safety switch without removing the mounting device from the drain pan, enabling quick and proper positioning of the switch to sense water accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal clip with screw mounting is used to secure the overflow safety switch to the drain pan wall, then the switch can be firmly attached, but the installation and replacement process becomes time-consuming and complex
Solution Approach 1:
The mounting device is divided into separate functional components: a C-shaped clip member for attachment to the drain pan wall, and a separate bracket for mounting the overflow safety switch. This segmentation allows the clip to be quickly installed and adjusted independently, without requiring time-consuming screw operations, while still providing firm attachment through the resilient engagement of the clip legs with the pan wall.
Solution Approach 2:
The mounting device incorporates adjustable elements that allow dynamic repositioning. The bracket can be moved along the C-shaped clip member to adjust the vertical position of the switch, and the entire clip assembly can be repositioned on the drain pan wall. This dynamic adjustability eliminates the need for precise pre-positioning and complex replacement procedures associated with fixed screw mounting.
2Stability of the object's composition
If the overflow safety switch is mounted with a fixed mounting clip, then the switch is securely positioned, but adjustment and replacement require complete removal of the mounting device
Solution Approach 1:
The mounting device separates the attachment function (C-shaped clip member) from the switch mounting function (bracket). The bracket is designed to detachably engage with the clip member, allowing the switch to be easily removed and replaced by simply detaching the bracket from the clip, while the clip remains securely mounted on the drain pan wall. This eliminates the need to remove the entire mounting device for switch replacement.
Solution Approach 2:
The C-shaped clip member is pre-installed and securely attached to the drain pan wall before the overflow safety switch is mounted. This preliminary attachment creates a stable base that remains in place during switch replacement operations, allowing the switch bracket to be quickly attached and detached without affecting the underlying mounting structure.
3Reliability
If a screw-based mounting system is used, then the overflow switch can be firmly secured to the drain pan, but the installation process becomes complex and prone to improper positioning
Solution Approach 1:
The invention extracts the fastening function from the mounting device itself and relies instead on the resilient engagement of the C-shaped clip member's legs with the drain pan wall. This eliminates the need for separate screws or fasteners, simplifying the overall system while maintaining reliable securing through the elastic deformation and frictional engagement of the clip legs.
Solution Approach 2:
The C-shaped clip member is designed to be self-securing through its resilient structure. When the legs are inserted between the drain pan wall and the pan bottom, they automatically engage and hold the mounting device in place through elastic recovery and friction, without requiring additional fasteners or complex assembly steps. The clip member self-adjusts to accommodate variations in pan wall thickness and material.
4Strength
If the mounting device requires complete removal for switch replacement, then secure attachment is maintained, but installation efficiency decreases
Solution Approach 1:
The mounting device is segmented into a permanently mounted C-shaped clip member and a detachable bracket for the overflow safety switch. This allows the clip to remain firmly attached to the drain pan wall while the bracket and switch can be quickly replaced by simply detaching from the clip, dramatically improving installation efficiency without compromising attachment strength.
Solution Approach 2:
The C-shaped clip member is pre-installed and firmly secured to the drain pan wall before the overflow safety switch is mounted. This preliminary action creates a permanent, strong attachment point that remains in place during all switch replacements, allowing rapid installation of new switches without requiring removal or reinstallation of the underlying mounting structure.
Data Source
AI summary
A mounting device for removably supporting an overflow safety switch in operable position within a condensation collecting drain pan in HVACR equipment. The mounting device includes a clip member that is secured to the drain pan side wall and locked in place by a non-penetrating thumb screw. A bracket removably attaches to the overflow safety switch at several adjusted positions and is slidably adjustable on the clip member for adjustably positioning the overflow safety switch relative to a bottom of the drain pan. The overflow safety switch is easily removed from the bracket for adjustment and replacement while the bracket remains fitted to the clip member. Moreover, the bracket is easily removed from the clip member without removing the clip member from the drain pan side wall.