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Possibly a P trap in the exit hose will help.

Possibly gunk buildup near the continuous exit hole increases air inflow velocity to exacerbate the problem.

Possibly the two above things combine.

Gunk buildup in the hose limits outflow, normally not significantly but during periods of peak humidity the limitation is enough to cause water to back up and overflow the pan into the bucket.

The negative pressure theory would be exacerbated by a dirty filter, and by periods of high humidity such as after a storm, and by setting the machine's fan to run continuously rather than in cycle with the dehumidification.

The bucket exit hole is vertical, and it is usually larger than the continuous hole so it does not suffer the same problem.

It drains out between cycles or, if there is enough humidity, it backs up to the point that it drains out to the bucket. Negative Pressure at the continuous flow exit hole produces an inflow of air that prevents water from dripping out.I'm going to summarize the leading theories that I intend to test through experimentation in the coming weeks: Some truly enlightening discussion in the answers and comments here. If it were loose the water would drip on the floor. In my current unit, and at least one other one, the hose outlet is outside the cabinet.

Hose not tight enough? That’s not the problem.The only way for the hose outlet to sometimes randomly be blocked, but never when I’m looking, is ice. The only way for the water to rise to the bucket outlet is for the hose outlet to be blocked. Ice, we don't know why? This one is intriguing me.About 70 degrees and 55% RH all the time (except after the bucket becomes full). Ice because of low temp environment ? No.I clean my filters regularly and at the most recent occurrence it was clean. The flow varies but at its greatest it’s a fast drip. Is the hose big enough? Yes, it’s a regular garden hose.Is there a valve that might be failing? No.It's impossible to photograph this without destroying the machine so here is a diagram: If it is sealed with a cap it fills up, and the water rises to the level of the higher outlet that goes to the bucket. I disassembled several of the units, and they all used the same simple system to select hose or bucket: There is drip tray to collect moisture and the tray has two outlets, one higher than the other. Adding some pics and thoughts on answers and comments (I've had Frigidaire, Delonghi, Kenmore).

There must be something about the design of all these that is causing this. There is something that causes water to enter the bucket and fill it up under certain circumstances. It does not coil or rise back up at any point. I place the dehumidifier up on blocks and the end of the hose inside a sump pit, so there is about 3 feet of vertical fall through the hose.but sooner or later, weeks or months, it does. The bucket does not immediately start to fill up again. After I empty the bucket water continues to flow. Water does flow from the unit into the drain. I had this problem with 5 machines from 3 manufacturers over the last 15 years. With a hose connected, from time to time, the bucket does fill up with water and then the float switch stops the machine. There is a bucket to collect water, and also an outlet for a hose where the water can flow out so water does not collect in the bucket. Several "continuous" dehumidifiers all had the same problem.