Shielded Condensate Pan Structure to Minimize Sweat Formation
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Solution Overview
Problem
Conventional condensate pans in evaporator assemblies experience sweat formation due to contact with warmer air streams, which reduces their efficiency and leads to condensation blow-off, affecting the overall performance of the cooling system.
Innovation Solution
The design incorporates a condensate pan with sloped secondary channels and a shield system that redirects condensation away from air streams, creating an air pocket to prevent heat transfer and minimize sweat formation, while also using a non-modifying slope attachment for horizontal and vertical orientations to ensure efficient drainage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the condensate pan is exposed to warmer air streams for heat exchange, then heat transfer efficiency is improved, but sweat formation increases
Solution Approach 1:
The patent extracts the harmful thermal interaction by removing the condensate pan from the path of warmer air streams. The shield structure physically separates the pan from air streams, preventing the heat transfer that causes sweat formation while allowing the system to maintain necessary thermal exchange functions elsewhere.
Solution Approach 2:
The shield acts as an intermediary element between the warmer air streams and the condensate pan. It blocks the direct thermal interaction that causes harmful sweat formation while allowing the system to maintain overall heat exchange efficiency through alternative pathways.
2Productivity
If the condensate pan collects condensation efficiently, then drainage performance is improved, but sweat formation increases due to heat transfer
Solution Approach 1:
The patent extracts the condensate pan from the harmful thermal environment by positioning it behind a shield that blocks warmer air streams. This allows the pan to maintain its condensation collection and drainage functions while eliminating the heat transfer that causes sweat formation.
Solution Approach 2:
The shield serves as a protective intermediary that separates the condensate collection function from the harmful thermal exposure. It allows efficient condensation drainage to occur while preventing the heat transfer that would otherwise cause sweat formation on the pan surfaces.
3Productivity
If the condensate pan is positioned to collect condensation from the evaporator coil, then condensation collection efficiency is improved, but exposure to warm air streams increases
Solution Approach 1:
The shield acts as a protective intermediary positioned between the warmer air streams and the condensate pan. It allows the pan to maintain its optimal position for collecting condensation from the evaporator coil while blocking the harmful thermal exposure from air streams that would cause sweat formation.
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 design significantly reduces sweat formation on the condensate pan, enhances condensation collection and drainage efficiency, and maintains system performance across both horizontal and vertical orientations.
Implementation Method 1
redirects condensation away from air streams, creating an air pocket to prevent heat transfer and minimize sweat formation
Implementation Method 2
water vapor condenses on the evaporator coil. The condensate pan of the evaporator assembly collects the condensed water as it drips off of the evaporator coil
Implementation Method 3
The secondary channels of the first and second pan members are connected to a drain channel disposed along a front side of the third pan member
Data Source
AI summary
A condensate pan for an evaporator assembly comprises a first pan member, a second pan member, and a third pan member. The first pan member has an outer wall and an inner wall, wherein a secondary channel is disposed along the outer wall. The second pan member also has an outer wall and an inner wall, wherein another secondary channel is disposed along the outer wall. The third pan member is coupled to the first and second pan members. The secondary channels of the first and second pan members are connected to a drain channel disposed along a front side of the third pan member.