Air Conditioner Fan Assembly with Weep Hole and Segmented Filtration

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Solution Overview

Problem

Conventional air conditioner units, particularly packaged terminal air conditioners (PTACs), face challenges in effectively filtering make-up air due to size, cost, and maintenance constraints, leading to issues such as moisture accumulation and mold growth, which can interfere with proper functioning.

Innovation Solution

A fan assembly with a fan housing and auxiliary fan, incorporating a vertical weep hole and air filter, designed to exhaust moisture and filter make-up air efficiently, minimizing parts and maintenance costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional air filters are used in the make-up air subsystem, then the system structure is simple, but the filtration effectiveness is insufficient at higher flow rates

Engineering Contradiction:
Improvesystem structure simplicityVSAvoidfiltration effectiveness
Core Design Contradiction:
Ease of manufactureVSReliability

Solution Approach 1:

The air filter assembly is divided into multiple filter media sections (first filter media, second filter media, third filter media) arranged in series within the bulkhead. This segmentation allows each filter section to handle a portion of the filtration task, enabling effective filtration at higher flow rates while maintaining a relatively simple overall structure that integrates into the existing make-up air subsystem.

Inventive Principle:
Principle #1Segmentation

2Productivity

If the vent aperture is equipped with an auxiliary fan for make-up air flow, then the air flow rate increases, but moisture accumulation and condensation problems worsen

Engineering Contradiction:
Improvemake-up air flow rateVSAvoidmoisture accumulation
Core Design Contradiction:
ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent converts the harmful effect of moisture accumulation into a beneficial drainage system. The weep hole is positioned at the lowest point of the bulkhead, and the drain line is configured to collect and remove condensation from the make-up air pathway. This transforms the problematic moisture into a manageable drainage flow, allowing the auxiliary fan to operate at higher flow rates without suffering from condensation issues.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If multiple filter media are integrated into the bulkhead, then filtration effectiveness improves, but device complexity increases

Engineering Contradiction:
Improvefiltration effectivenessVSAvoidfilter assembly structure
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the filter assembly directly into the bulkhead structure, integrating the first, second, and third filter media within the existing bulkhead geometry. The filter assembly is positioned to utilize the bulkhead's internal space, and the drain line is integrated into the same structure. This merging approach achieves multi-stage filtration without adding separate external filter housings or complex assembly structures.

Inventive Principle:
Principle #5Merging (Combining)

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 design prevents moisture accumulation, effectively filters large air flow rates, and reduces maintenance needs while ensuring proper functioning of the air conditioner unit.

Implementation Method 1

The fan housing may include a bottom wall defining a vertical weep hole to permit water to exhaust from the makeup air duct apart from the vent aperture

Methodology Applied
Scientific EffectGravity: Gravitation

Implementation Method 2

The fan assembly may include a fan housing and an auxiliary fan. The makeup air duct may be in fluid communication with the vent aperture. The auxiliary fan may be positioned within the fan housing

Methodology Applied
Scientific EffectPhysical filtration: Filter (physical)

Data Source

PatentUS20250297747A1Fan assembly for an air conditioner appliance
Publication Date: 2025.09.25 HAIER US APPLIANCE SOLUTIONS INC
  • US20250297747A1 patent drawing
  • US20250297747A1 patent drawing
  • US20250297747A1 patent drawing

AI summary

An air conditioner unit may include a bulkhead, a vent aperture, and a fan assembly. The bulkhead may define an indoor portion and an outdoor portion. The vent aperture may be defined in the bulkhead. The fan assembly may urge a flow of make-up air from the outdoor portion through the vent aperture to the indoor portion. The fan assembly may include a fan housing and an auxiliary fan. The makeup air duct may be in fluid communication with the vent aperture. The fan housing may include a bottom wall defining a vertical weep hole to permit water to exhaust from the makeup air duct apart from the vent aperture. The auxiliary fan may be positioned within the fan housing.