Segmented Coil Drain Pan Assembly for Condensate Overflow Redundancy
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Solution Overview
Problem
Existing air-conditioning systems face issues with drain pan occlusion, rust, and overflow, leading to additional costs and time for installation and plumbing of auxiliary drain pans, which lack redundancy and efficiency in handling condensate overflow.
Innovation Solution
A segmented drain pan system where a primary drain pan and an auxiliary drain pan are integrated and plumbed together, allowing for simultaneous leveling and plumbing, with the auxiliary pan activated only at an overflow level, reducing the need for separate installation and plumbing of additional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate auxiliary drain pans are installed individually, then redundancy for overflow protection is achieved, but installation time and cost increase significantly
Solution Approach 1:
The patent combines multiple drain pans (primary and auxiliary) into a single integrated segmented pan assembly that is pre-leveled and pre-plumbed during manufacturing. This merging of separate components into one unit eliminates the need for installers to individually level and plague multiple pans, significantly reducing installation time while maintaining the redundancy overflow protection function.
Solution Approach 2:
The drain pans are pre-leveled and pre-plumbed during the manufacturing process before installation. This preliminary action ensures that the pans are correctly positioned and connected to drainage systems before reaching the installation site, eliminating time-consuming field leveling and plumbing operations while ensuring proper overflow protection functionality.
2Reliability
If multiple separate drain pans are installed, then overflow protection is provided, but the complexity of installation and plumbing increases
Solution Approach 1:
Multiple drain pans are merged into a single integrated assembly with common leveling and plumbing requirements. This reduces the complexity by transforming what would be multiple independent installation tasks into one unified installation process, while maintaining multiple levels of overflow protection.
Solution Approach 2:
The segmented pan assembly serves multiple functions simultaneously: it provides primary drainage, auxiliary overflow protection, and is designed to accommodate different installation orientations (horizontal, vertical, slanted). This multi-functionality reduces the need for additional specialized components and simplifies the overall installation process.
3Adaptability or versatility
If individual drain pans are installed without pre-leveling, then flexibility in installation is maintained, but additional leveling time and precision requirements increase
Solution Approach 1:
The drain pans are pre-leveled during manufacturing with built-in leveling features such as integrated support legs or adjustable mounting mechanisms. This preliminary leveling action maintains installation flexibility by allowing the pre-leveled unit to be installed in various orientations while eliminating the need for time-consuming field leveling operations.
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
This solution enhances installation efficiency, reduces costs, and provides redundancy without the need for external auxiliary drain pans, ensuring effective condensate management and preventing damage from overflow.
Implementation Method 1
a first segment of the segmented pan may comprise a primary drain pan positioned to receive the condensate from the evaporator coil. A second segment of the segmented pan may comprise an auxiliary drain pan, which receives the condensate only after an overflow level of condensate is reached in the primary drain pan.
Data Source
AI summary
An air-conditioning system provides a segmented pan with a primary drain segment and a built in auxiliary drain pan segment to receive overflow condensate from the primary drain pan and drains through auxiliary drain lines. The built-in auxiliary drain pan and primary drain pan are plumb with respect to each other and are secured together and/or monolithic. The assembly construction thereby provides reduced time and costs associated with storing, transporting, installing, leveling, and plumbing individual components.