Steam Distributor Tube Outer Shell to Minimize Condensation

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Solution Overview

Problem

Conventional steam distributors for air treatment units suffer from high energy inefficiency due to condensation formation within the system, which is exacerbated by high production costs and labor-intensive insulation methods, leading to increased energy consumption and costly thermal insulation.

Innovation Solution

The steam distributor features thermally insulated diffusion ducts with a unique outer shell design and insert components that provide effective thermal shielding, reducing condensation and production costs through efficient assembly and material usage, including the use of melamine insulating material and cost-effective manufacturing processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If ceramic coating is applied to steam diffusion ducts for thermal insulation, then condensation formation is reduced, but production cost and labor time increase significantly

Engineering Contradiction:

Improvecondensation formationVSAvoidproduction cost

Core Design Contradiction:

Loss of energyVSEase of manufacture

Solution Approach 1:

The patent replaces expensive ceramic coatings with a cheaper alternative material (foam material) that can be applied more economically. While the foam material may have different durability characteristics, it achieves the primary function of reducing condensation at a lower production cost, making thermal insulation more accessible and economically viable.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent changes the material parameter from ceramic coating to foam material, and potentially adjusts the application method parameters. This substitution maintains the thermal insulation function while significantly reducing both material cost and application complexity, directly addressing the contradiction between energy loss reduction and manufacturing ease.

Inventive Principle:

Principle #35Parameter changes

2Loss of energy

If ceramic coating is applied to steam diffusion ducts for thermal insulation, then condensation formation is reduced, but production time and labor intensity increase

Engineering Contradiction:

Improvecondensation formationVSAvoidproduction time

Core Design Contradiction:

Loss of energyVSLoss of time

Solution Approach 1:

The foam material replacement not only reduces cost but also simplifies the application process. Foam materials can typically be applied more quickly and with less specialized labor compared to ceramic coatings, thereby reducing production time and labor intensity while maintaining the thermal insulation effectiveness needed to prevent condensation.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

By changing the material parameter to foam and potentially the application method, the patent reduces the time and labor required for thermal insulation application. This parameter change makes the insulation process more efficient and less labor-intensive while still achieving the goal of minimizing condensation formation.

Inventive Principle:

Principle #35Parameter changes

3Loss of energy

If shielding elements are applied to diffusion ducts, then some thermal insulation is provided, but diffusion orifice portions remain uncovered and insulation effectiveness is reduced

Engineering Contradiction:

Improvethermal insulationVSAvoidinsulation effectiveness

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

The foam material is applied to cover the entire surface of the diffusion ducts, including the previously exposed diffusion orifice portions. This ensures uniform thermal insulation across all surfaces, eliminating the insulation gaps that existed with partial shielding elements and providing consistent thermal protection throughout the duct system.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent uses foam material as a composite insulation solution that can conform to the entire duct surface geometry, including complex areas around diffusion orifices. This composite approach provides comprehensive coverage and effective thermal insulation where simpler shielding elements failed to provide complete protection.

Inventive Principle:

Principle #40Composite materials

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

The solution effectively minimizes condensation and reduces production costs, achieving optimal thermal insulation and energy efficiency while allowing for quick assembly and maintenance, thus improving the overall performance and affordability of the steam distributor.

Implementation Method 1

each of said diffusion ducts (6) comprises an outer shell (9) for thermally shielding the respective diffusion duct (6)

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentEP2442040B1Steam distributor tube for airhumidifier comprising outer shell for thermally shielding

Publication Date: 2014.01.15 CAREL IND SPA

Figure 1~2
Figure 3~4
Figure 5~8

AI summary

Steam distributor for air treatment units, comprising at least one diffusion duct (6) provided with steam outlet orifices (8), and at least one outer shell (9) for thermally shielding said diffusion duct (6) provided with openings (10) corresponding to said orifices (8) of said duct (6).