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
Engineering 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
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.
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
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.
3Reliability
If multiple filter media are integrated into the bulkhead, then filtration effectiveness improves, but device complexity increases
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.
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
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
Data Source
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.


