System and method for preventing condensate drain pan flooding, detecting condensate water overflow and shutting off an air conditioner or heat pump to prevent further flooding
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Solution Overview
Problem
Existing condensate drain pan and line cleaning solutions, such as biocide tablets, have short durations and require frequent replacement, often leading to dilution and ineffective disinfection, while float switches and moisture sensors can be impeded by biological growth, causing overflow issues and increased costs.
Innovation Solution
A system that periodically and accurately dispenses a biocide or liquid line cleaning solution through the condensate drain pan, using a pump or solenoid valve to minimize dilution and integrate with overflow protection sensors to prevent flooding, with adjustable dosages and reduced user intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If biocide tablets are placed in the condensate drain pan, then biological growth prevention is improved, but the tablets dissolve too quickly and require frequent replacement
Solution Approach 1:
The biocide tablet is segmented into multiple smaller compartments or layers, each releasing biocide at different rates. This segmentation allows the tablet to provide sustained protection over extended periods by controlling the release timing and rate of biocide from different segments, thereby resolving the contradiction between effectiveness and duration.
Solution Approach 2:
The tablet is designed to release biocide in periodic cycles rather than continuously dissolving. This periodic release mechanism ensures that adequate biocide concentration is maintained in the condensate pan at regular intervals, extending the effective duration while preventing premature dissolution and maintaining reliability.
2Reliability
If biocide tablets are made larger to provide sufficient concentration, then disinfection effectiveness is improved, but the tablets may flow into the flow path and restrict condensate flow
Solution Approach 1:
The tablet incorporates local quality variations with different zones having different densities, solubility characteristics, or biocide concentrations. Heavier or less soluble components are positioned in the lower portion to remain in the pan, while lighter components dissolve first. This spatial differentiation allows sufficient biocide concentration to be achieved without creating a uniformly large tablet that could obstruct flow paths.
Solution Approach 2:
The tablet design transitions from a simple two-dimensional flat structure to a three-dimensional configuration with varying thickness, density, or internal chamber structures. This dimensional complexity allows the tablet to maintain adequate size for effective disinfection while creating flow channels or porous structures that prevent obstruction of condensate flow paths.
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 system provides extended protection against biological growth and clogging, reducing the need for frequent maintenance, minimizing false alarms, and ensuring effective condensate management with a cost-effective solution.
Implementation Method 1
A system that periodically and accurately dispenses a biocide or liquid line cleaning solution through the condensate drain pan, using a pump or solenoid valve to minimize dilution
Implementation Method 2
place a moisture indicating switch in at least one of the condensate overflow port, secondary containing pan or the floor under the air handler of the air conditioner
Data Source
AI summary
An anti-clogging liquid dispersion system and method for an air conditioner or heat pump is disclosed. A tank holds an anti-clogging liquid. A pump or valve connected with the tank periodically supplies the liquid to a condensate drain pan or the outlet of an existing drain line located exteriorly of a structure. One or more sensors are provided to detect moisture, flooding and/or lack of condensate flow and, when so detected, a control circuit causes the liquid to be supplied to the condensate drain pan to prevent flooding of a condensate drain pan or to clear a clogged drain line of an air handler of the air conditioner or heat pump. An additional dose of the liquid can also be supplied at any time when an unacceptable amount of condensate moisture and/or a clogged drain line has been detected.