SYSTEM, APPARATUS AND METHOD FOR CONDITIONING A SPACE

Abstract

An induction heating and cooling unit. Included are a coil suitable to receive room air from a room to be heated or cooled; a mixer having an outside air receiver, and comprising a nozzle suitable to inject the outside air into the presence of the room air at the coil, wherein the injected outside air induces a lower pressure area behind the coil, which thereby draws the room air across the coil to mix the room air with the injected outside air; a plurality of temperature sensors capable of monitoring at least outside air temperature, a temperature of water entering the coil, a secondary water temperature of secondary water being circulated around a building perimeter, discharged air temperature; at least one valve capable of modulating an amount of the water provided to the coil; and at least one controller capable of controlling at least the modulation of the amount of water and a velocity of the injected outside air responsive to data from the plurality of temperature sensors.

Claims

1. An induction heating and cooling unit, comprising: a coil suitable to receive room air from a room to be heated or cooled; a mixer having an outside air receiver, and comprising a nozzle suitable to inject the outside air into the presence of the room air at the coil, wherein the injected outside air induces a lower pressure area behind the coil, which thereby draws the room air across the coil to mix the room air with the injected outside air; a plurality of temperature sensors capable of monitoring at least outside air temperature, a temperature of water entering the coil, a secondary water temperature of secondary water being circulated around a building perimeter, discharged air temperature; at least one valve capable of modulating an amount of the water provided to the coil; at least one controller capable of controlling at least the modulation of the amount of water and a velocity of the injected outside air responsive to data from the plurality of temperature sensors; and a discharge to the room comprising at least a grate, wherefrom the mixed air is delivered to the room to be heated or cooled after passing over the coil.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0027] In order to better appreciate how the above-recited and other advantages and objects of the inventions are obtained, a more particular description of the embodiments briefly described above will be rendered by reference to specific embodiments thereof, which are illustrated in the accompanying drawings. It should be noted that the components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the disclosure. Moreover, in the figures, like reference numerals may or may not designate corresponding parts throughout the different views. Moreover, all illustrations are intended to convey concepts, where relative sizes, shapes and other detailed attributes may be illustrated schematically rather than literally or precisely. More specifically, in the drawings:

[0028] FIG. 1 illustrates aspects of the embodiments;

[0029] FIG. 2 illustrates aspects of the embodiments;

[0030] FIG. 3 illustrates aspects of the embodiments;

[0031] FIG. 4A illustrates aspects of the embodiments;

[0032] FIG. 4B illustrates aspects of the embodiments;

[0033] FIG. 4C illustrates aspects of the embodiments;

[0034] FIG. 4D illustrates aspects of the embodiments;

[0035] FIG. 4E illustrates aspects of the embodiments;

[0036] FIG. 5A illustrates aspects of the embodiments;

[0037] FIG. 5B illustrates aspects of the embodiments;

[0038] FIG. 5C illustrates aspects of the embodiments;

[0039] FIG. 5D illustrates aspects of the embodiments;

[0040] FIG. 5E illustrates aspects of the embodiments;

[0041] FIG. 6A illustrates aspects of the embodiments;

[0042] FIG. 6B illustrates aspects of the embodiments;

[0043] FIG. 6C illustrates aspects of the embodiments;

[0044] FIG. 6D illustrates aspects of the embodiments;

[0045] FIG. 6E illustrates aspects of the embodiments;

[0046] FIG. 7A illustrates aspects of the embodiments;

[0047] FIG. 7B illustrates aspects of the embodiments;

[0048] FIG. 7C illustrates aspects of the embodiments;

[0049] FIG. 7D illustrates aspects of the embodiments;

[0050] FIG. 7E illustrates aspects of the embodiments; and

[0051] FIG. 8A illustrates aspects of the embodiments;

[0052] FIG. 8B illustrates aspects of the embodiments;

[0053] FIG. 8C illustrates aspects of the embodiments;

[0054] FIG. 8D illustrates aspects of the embodiments;

[0055] FIG. 8E illustrates aspects of the embodiments.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE PRESENT INVENTION

[0056] The figures and descriptions provided herein may have been simplified to illustrate aspects that are relevant for a clear understanding of the herein described apparatuses, systems, and methods, while eliminating, for the purpose of clarity, other aspects that may be found in typical similar devices, systems, and methods. Those of ordinary skill may thus recognize that other elements and/or operations may be desirable and/or necessary to implement the devices, systems, and methods described herein. But because such elements and operations are known in the art, and because they do not facilitate a better understanding of the present disclosure, for the sake of brevity a discussion of such elements and operations may not be provided herein. However, the present disclosure is deemed to nevertheless include all such elements, variations, and modifications to the described aspects that would be known to those of ordinary skill in the art.

[0057] Embodiments are provided throughout so that this disclosure is sufficiently thorough and fully conveys the scope of the disclosed embodiments to those who are skilled in the art. Numerous specific details are set forth, such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. Nevertheless, it will be apparent to those skilled in the art that certain specific disclosed details need not be employed, and that embodiments may be embodied in different forms. As such, the embodiments should not be construed to limit the scope of the disclosure. As referenced above, in some embodiments, well-known processes, well-known device structures, and well-known technologies may not be described in detail.

[0058] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. For example, as used herein, the singular forms “a”, “an” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The steps, processes, and operations described herein are not to be construed as necessarily requiring their respective performance in the particular order discussed or illustrated, unless specifically identified as a preferred or required order of performance. It is also to be understood that additional or alternative steps may be employed, in place of or in conjunction with the disclosed aspects.

[0059] When an element or layer is referred to as being “on”, “engaged to”, “connected to” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present, unless clearly indicated otherwise. In contrast, when an element is referred to as being “directly on,” “directly engaged to”, “directly connected to” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). Further, as used herein the term “and/or” includes any and all combinations of one or more of the associated listed items.

[0060] Yet further, although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another element, component, region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the embodiments.

[0061] Induction heating and/or cooling (herein referred to as “conditioning”) systems are generally known. Induction Systems are generally employed for perimeter heating and cooling zones of multi-room, multi-story buildings; such as office buildings, patient wings of hospitals, apartments and hotels. By giving each room its own individual induction unit, it is generally possible to satisfy the individual cooling and heating loads in these perimeter zones.

[0062] A perimeter zone may be generalized as the area running along the exterior walls of the building and extending 10 to 20 feet into the building (about 15 feet may be commonly assumed in the design of the system). These perimeter zones are subjected to relatively constant heat gains from lights, people and equipment in the spaces. In addition these areas may be subjected to highly variable temperature gains from sunlight through windows, and/or by heat transmission through the exterior walls/windows.

[0063] There will be times when some of the perimeter zones generally need cooling to remain near a desired temperature (herein referred to as a “setpoint”) while others need heating. For example, perimeter zones facing east may need cooling in the morning while the perimeter zones facing west at the same time may need heating. In these instances it may be desired the building HVAC system have a flexibility to alternatively provide either heating or cooling to every zone. When properly designed an induction system using a two-pipe water distribution network offers this flexibility.

[0064] An induction system generally uses two air streams and cooling/heating water supplied to the induction unit to provide this flexibility. One air stream is delivered from the central air handlers and is referred to as the primary air. The other is referred to as secondary air, and is the space, zone or room air that is induced to flow over the water coil in the induction unit by the primary air. The water is called secondary water and serves the water coil in the induction units.

[0065] Primary air (which may be inlet from outside the building, i.e., outside air) may be filtered, cooled or heated, and dehumidified or humidified for the building (e.g., at the central air handlers in the building). The primary air may be supplied to the induction units through a ductwork system. The primary air passes through the induction unit into the room where it adds or removes sensible heat and moisture. In passing through the induction unit it also draws or induces secondary room air through the water coil in the induction unit. The primary air provides the necessary ventilation, some heating or cooling and supplies the necessary motive power for inducing secondary airflow.

[0066] The secondary room air is induced and flows over the coil of the induction unit. Through the secondary water supplied to the induction unit's coil this secondary room air is heated or cooled, depending on the water temperature, the quantity of heat added to or removed from the secondary air may be controlled by the room thermostat to satisfy the room demands, e.g., maintain room conditions at or near setpoint(s) by controlling the quantity of water flowing through the coil.

[0067] The two air streams and water loop conditions can be controlled/manipulated to provide alternately either cooling or heating to the perimeter zones. The system can be designed to deliver: cold primary air and cold water in the coil; warm primary air and cold water in the coil; cold primary air and warm water in the coil; or warm primary air and warm water in the coil.

[0068] In general a typical induction system design provides occupant comfort as follows.

[0069] Humidity is controlled by controlling the dew point temperature of the primary air.

[0070] Cleanliness is controlled by filtering the primary air at the central air handlers. Lint screens may also be used in the room induction unit to filter the secondary air.

[0071] Air movement is controlled by the amount of primary air delivered and the amount of secondary air induced by the primary air.

[0072] The room's dry bulb temperature is controlled by varying the temperature of the primary air, and varying the secondary water flow and temperature so that the sensible heat gains or losses to the space are balanced.

[0073] There will likely be times, such as during intermediate seasons like spring and fall, when some amount of reheating/re-cooling will occur to simultaneously satisfy zones' heating or cooling loads. This possibility can be largely eliminated if separate air handlers are used to serve each exposure and the interior zones.

[0074] Induction units conventionally operate with a constant volume primary air, meaning the volume of primary air provided to the induction unit does not substantially vary regardless of load. For clarity, load as used herein, refers generally to the sum of heat sources of a space to be conditioned, and is generally expressed either in BTU (British Thermal Units) or Kw (Kilowatts). For an air conditioner to cool a space, such as a room or building, its output must be greater than the heat load.

[0075] An induction unit conditioning may be modulated dependently upon the temperature and volume of water circulated through an induction unit coil, which is used to exchange heat with the air being conditioned, e.g., cooled or heated.

[0076] In conventional applications, the primary air typically consists of between about 50% and 100% outside air, meaning ambient air from outside the building. This ambient air is cooled in the summer and heated in the winter to meet space occupancy requirements, e.g., temperature and/or humidity setpoints. In many environments, this leads to substantial inefficiencies in providing conditioned air to a space, as the outside temperature may vary widely, e.g., depending upon location and season. For example, a desired space temperature may be around 72 degrees Fahrenheit, regardless of whether outside air being provided as primary air is 0 degrees Fahrenheit or 100 degrees Fahrenheit.

[0077] Referring now to FIG. 1, there is shown an exemplary induction unit 10. Unit 10 generally includes a coil 4 that receives room air 3. Air 3 is mixed with primary air being ejected at a high velocity from nozzle 2. This high velocity air induces a low pressure area behind the coil 4 which draws room air 3 across the coil 4, where it mixes with the primary air. This mixed air 1 is provided to the room or space to be heated or cooled, e.g., conditioned, discharge 5, e.g., a grill or grate.

[0078] The nozzles require high pressure primary air in order to induce the air from the space to be circulated across the coils for heating and cooling. It is expensive to raise the pressure of the primary air to these high pressures, as required fan horsepower to provide these pressures may be expected to increase non-linearly, e.g., by the square, compared to a desired pressure to be induced.

[0079] Certain embodiments of the invention advantageously allow for lower velocity primary air to be effectively utilized, resulting in significant energy efficiencies to be realized. An unanticipated advantage of the present invention is that such savings may be realized in retrofitted induction units even when high loads or demands are present, where modulation would not be expected to be useful.

[0080] Referring now to FIG. 2, there is shown a diagrammatic representation of an induction unit system 100 according to an embodiment of the present invention. System 100 includes an induction unit 110, a controller 120 a sensor 130. In certain embodiments of the present invention, induction unit 110 may be retrofitted according to embodiments of the present invention.

[0081] In the illustrated embodiment, induction unit 110 includes a coil 140, nozzles 150, a water valve 160, air valve 170, sensors 180, 190 and 200, control valve 210, pneumatic valve 220 and a termination block 230. Coils 140 may be analogous to conventional induction coils for exchanging heat between supplied heating/cooling water and the air to conditioned. Nozzles 150 may take the form of conventional induction unit nozzles for providing the primary air as discussed. Water valve 160 may take the form of a conventional induction unit water valve used to modulate the volume of heating or cooling water supplied to the coil 140, e.g., responsively to a thermostat.

[0082] Referring still to FIG. 2, according to certain embodiments of the present invention, unit 110 may include an air valve 170. Valve 170 may take the form of an inline, induction air valve (IAV) suitable for modulating the amount of primary air provided to the nozzles 150.

[0083] Sensors 180, 190 and 200 may take the form of a temperature sensors. Sensor 180 may monitor primary air temperature. Sensor 190 may monitor the temperature of water entering the coil, secondary water temperature being circulated around a building perimeter. Sensor 200 may monitor the induction unit 110 discharge air temperature, e.g., the air being provided to the space. Valve 220 may modulate the amount of control air provided to control valve 210. Control valve 210 modulates the amount of water provided to the coil. A termination area, box or other mechanism may be used to provide for electrical connectivity, such as when an otherwise conventional induction unit is being retrofitted.

[0084] As will be appreciated by those of ordinary skill in the pertinent arts, in a conventional induction unit system 100, valve 210 may take the form of a pneumatic valve that responds to a pneumatic signal or pressure, e.g., from a thermostat for the space. In the embodiment of FIG. 2, valve 210 may take the form of a pneumatic valve that controls the amount of water supplied to the coil responsively to electronic solenoid valve 220.

[0085] In certain embodiments of the present invention, controller 120 may take the form of an application specific integrated circuit or microprocessor based controller. It may provide control signals whether in heating or cooling.

[0086] In certain embodiments of the present invention, sensor 130 may take the form of a room temperature, humidity and/or carbon dioxide sensor, for example.

[0087] Referring now to FIG. 3, there is shown an exemplary valve 370 according to certain embodiments of the present invention. Valve 370 generally includes body sections 380, 390 that mate together to form an elongated, cylinder valve body through which primary air may be directed. Valve disc 400 may be within the valve body and rotated via an actuator (e.g., up to 90 deg.) to modulate the amount of primary air that passes through the valve body. The actuator may be of any form suitable to rotate disc 400 dependently upon controller 120 signaling, e.g., it may be pneumatic or electro-mechanical in nature.

[0088] Valve disc 400 generally includes first and second mating bodies or portions 400a, 400b. Disc 400 generally includes first and second sections or portions 430, 440. Section 430 may generally take the form of stem suitable for mechanically coupling to the actuator, to enable the actuator to rotate the disc 400. Disc 400 further includes bearings 450a, 450b. Bearing 450a is generally positioned at an end of stem portion 430 proximate the second portion 440. Bearing 450b is generally disposed on the opposite side of second portion 440 from bearing 450a. The bearings 450a facilitate rotation of disc 400 within the housing or valve body formed of portions 380, 390.

[0089] Referring still to FIG. 3, the second portion may be substantially ovoidal. This may facilitate passing air through the valve body with less pressure drop and less noise than a substantially circular in cross-section second portion of the disc. Portion 440 also includes first and second oppositely disposed faces or surfaces 480a, 480b. In certain embodiments of the present invention, these surface may each be convex in nature. This convex shaping my further reduce pressure drop and noise as well or in lieu of the above discussed ovoidal shaping. In certain embodiments of the present invention, surfaces 480a, 480b may be smooth to further or alternatively, mitigate operational pressure drops and noise. Such smoothness may be accomplished in the case of a molded embodiment of disc 400 by polishing the corresponding mold face(s), for example. In certain embodiments of the present invention, the faces 480a, 480b may be substantially smoother than other surfaces of the valve.

[0090] In certain embodiments of the present invention, a plurality of fins 460 that longitudinally project from a periphery, or thereabout, of surfaces 480a, 480b, at least where those peripheries will become proximate to portions 380, 390 when disc 400 is rotated to a closed position, may be provided. Fins 460 may advantageously guide air flow through the body when disc 440 approaches a closed positioning, as it opens and/or closes, which may prevent so-called jet streaming. Jet streaming may create noise and undesirable pressure losses, that may even be downstream unrecoverable pressure losses.

[0091] In certain embodiments of the present invention, disc portion 440 further includes a flange 470 about at least a portion of the periphery, and in some embodiments at least most of the periphery, to seat against a lip 490 of portions 380, 390 to help seal the valve in the closed position.

[0092] Certain unanticipated advantages of such embodiments may include user acceptance of retrofitted induction units, as air volume is not typically throttled, and throttling primary air volume as discussed herein may otherwise lead to undesirable air circulation noise through the valve that otherwise may not exist.

[0093] In certain embodiments of the present invention, valve 400 may be molded of plastic. In certain embodiments of the present invention, it may be formed of a molded ABS plastic. In certain embodiments it may be molded of Acrylonitrile Butradiene Styrene, such as is sold under the brand name POLYLAC PA-765A, for example.

[0094] Bearings 450a, 450b may be composed of nylon or another self lubricating material, for example, such as bunting type NN08, by way of example.

[0095] In certain embodiments of the present invention, valve 400 may include one or more mounting portions 500 for mounting an actuator mechanically coupled to the stem, e.g., mounted directly or via a platform, for example.

[0096] In certain embodiments of the present invention, the valve may be sized, e.g., have an outside diameter and/or other dimensions, to make it well suited to directly mount within a spigot of a conventional induction unit, thereby simplifying retrofitting of existing induction units. Exemplary dimensions may be seen FIG. 3. The relative short length of the valve may be further advantageous, as induction units are conventionally positioned along the outside walls of a building, where space is at a premium and conventional air valving may not fit.

[0097] In certain embodiments of the present invention, valve 400 may advantageously provide for a pressure recovery factor of greater than about 60% or even 70%, 80% or 81%, meaning pressure available downstream of the valve for application to the nozzles is high, even at reduced flows when less primary air volume is called for by space demand.

[0098] In a cooling mode, in a conventional induction unit, a controller would modulate valve 210 to control the amount of cooling water provided to coil 140, and a constant volume of air would pass through nozzles 150 to induce a constant volume of airflow across coil 140 and thus to the space to be cooled.

[0099] According to embodiments of the present invention, upon a detected increase in room temperature above a desired setpoint, as sensed by sensor 130 for example, controller 120 may signal valve 170 to open, e.g., by increasing or decreasing a voltage or current provided to valve 170. Upon a detected decrease in room temperature below a desired setpoint, as sensed by sensor 130 for example, controller 120 may signal valve 170 to close, e.g., by increasing or decreasing a voltage or current provided to valve 170 in a substantially opposite manner to that provided when an increase in temperature is detected. An opening of valve 170 increases primary air flow, while closing valve 170 decreases primary air flow across a secondary side of the coil 140. In such an embodiment, valve 210 may remain in a substantially constant position, e.g., fully open. The required horsepower to produce the necessary primary air volume for nozzles 150 may advantageously be reduced depending on cooling load, as opposed to constantly running it at a sufficiently high speed to induce the necessary induction across coil 140 at full load. In such an embodiment the power required to provide air volume and pressure may be reduced. It has been found that while a constant demand of cooling water at or near full load requirements may be expected to increase the ongoing demand for pumping horsepower, a typical amount of horsepower needed for increased cooling water flow may be substantially less than the savings effected by fan power reductions, such that the overall system efficiency still improves. An unanticipated advantage of the present invention is that such a savings may be experienced even at full load conditions, where fan throttling may not be expected, but may nonetheless be effected.

[0100] Upon valve 170 being sufficiently closed to or beyond an operational threshold, the amount of primary air provided by nozzles 150 may become sufficiently low that induction of room return air across coils 140 may substantially cease. Upon such an occurrence, which may be determined by the operational position of the disc 400 by controller 120, cooling by the coil 140 will no longer be efficiently effected, and depending upon desired operational parameters the cooling valve 210 can be opened or closed, or fixed in a predetermined or current position, for example.

[0101] In a heating mode, in a conventional induction unit, a controller would modulate valve 210 to control the amount of heating water provided to coil 140, and a constant volume of air would pass through nozzles 150 to induce a constant volume of airflow across coil 140 and to the space to be heated.

[0102] According to embodiments of the present invention, upon a detected decrease in room temperature below a desired setpoint, as sensed by sensor 130 for example, controller 120 may signal valve 170 to open, e.g., by increasing or decreasing a voltage or current provided to valve 170. Upon a detected increase in room temperature to or above a desired setpoint, as sensed by sensor 130 for example, controller 120 may signal valve 170 to close, e.g., by increasing or decreasing a voltage or current provided to valve 170 in a substantially opposite manner to that provided when a decrease is detected. An opening of valve 170 increases primary air flow, while closing valve 170 decreases primary air flow across a secondary side of the coil 140. In such an embodiment, valve 210 may remain in a substantially constant position as discussed. The required horsepower to produce the necessary primary air volume for nozzles 150 may advantageously be reduced depending on heating load, as opposed to constantly running it at a sufficiently high speed to induce the necessary induction across coil 140 at full load or demand. In such an embodiment the power required to provide air volume and pressure may be reduced. It has been found that while a constant demand of heating water at or near full load requirements may be expected to increase the ongoing demand for pumping horsepower, a typically amount of horsepower needed for increased heating water flow may be substantially less than the savings effected by fan power reductions, such that the overall system efficiency still improves. An unanticipated advantage of the present invention is that such a savings may be experienced even at full load conditions, where fan throttling may not be expected, but may nonetheless be effected.

[0103] Further, when the valve 170 has been signaled to its minimum position, and air volume and pressure is at or near a minimum operating state, undesired further heating may nonetheless still occur. In a certain embodiments of the present invention, when the room temperature is sensed in such a condition and exceeds the primary air temperature as sensed by sensor 180 (e.g., by 1 or degrees for 1 or more minutes) controller 120 may automatically, temporarily switch to cooling mode, as discussed above, from heating mode. In such a case it may operate as discussed above for cooling, but with valve 210 in a closed position, thereby using primary air for direct cooling on an induction unit by induction unit basis. In such an embodiment improved space by space heating/cooling control and efficiency may be effected.

[0104] Induction units are designed to operate for both cooling and heating. The nozzles in the units create a lift to pull the air over the coil and propel the air into the room to about 15 feet into the room back from the perimeter. The amount of energy that needs to be imparted to the room air to pull it through the coil and propel it into the room varies greatly from winter to summer. This is because the cool air for air conditioning is heavier that the warm air for heating. Heating does not have to be propelled into the core of the building since there is already a heating load in the core from lights and people. Cooling has to be propelled from the induction units to pick up this load.

[0105] Therefore the induction units can be provided with much less energy from the primary air in the winter than in the summer. Embodiments of the present invention reduce energy demand and consumption by throttling the primary air to the nozzles thereby reducing the pressure and flow of primary air so as to provide only the amount of energy required to induce air across the coils in sufficient quantity to provide heat to the space at the perimeter.

[0106] FIGS. 4A-4E illustrate an exemplary center valve disc. As illustrated in FIG. 4A, the center valve disc may comprise a 2 piece design, such as having 2 identical components molded as a single cavity. The center disc may have continuous Interlocking rib/channel design for precise alignment and assembly—that is, no welding or glue may be required—as shown in FIG. 4B. A stopper Lug to prevent the disc from over turning, i.e., the lugs may stop on the interior ribs of the housing in the valve-open position, as shown in FIG. 4C. As illustrated in FIG. 4D, bunting bearings may be used to assure tight assembly.

[0107] FIGS. 5A-5E illustrate a housing halved with mounting holes. The housing halves are designed with a snap-fit assembly eliminating the need for welding or glue, as shown in FIG. 5. One housing half has snap ins, and one housing half has the snap windows (such as in 4 places). FIG. 5 also show that bosses were designed for a screw, such as a #10 self-tapping screw. FIG. 5 show an interlocking rib/channel design for air tight assembly. A similar design is currently used on a medical blower housing. This housing half has the channel side of the assembly.

[0108] Location of the bunting bearings may be uniquely redesigned. The bottom is closed off and the top has an enclosed area for the bearing. This will help locate the disc-assembly properly every time and reduce noise. Further, the stop rib may be slightly modified to allow for more economical molding (no side action mechanisms), i.e., it may be extended up to the hole opening.

[0109] FIGS. 6A-6E illustrate a molding/assembly process for the elements discussed above. The disc may be molded in a single cavity tool (standard open/close design with no additional mechanical actions). Once the discs are molded, they are press fit together (this may occur during the molding process). The bunting bearing may then be assembled onto the top and bottom shaft of the disc assembly.

[0110] The 2 housing halves can be molded in a 2 cavity family tool that produces one of each side every cycle. The disc assembly with bearings is then aligned and assembled into the housing. The housing snaps together holding the disc and bushings in place.

[0111] FIG. 7 illustrate, in FIG. 7A, a top bearing assembly. FIG. 7B shows a bottom bearing assembly. FIG. 7C shows a disc assembly cross-section. FIG. 7D shows a housing interlock/snap-fit cross-section. FIG. 7E illustrates a housing rib/lug—open position embodiment.

[0112] Finally, FIGS. 8A-8E show various positions of the valve referenced above in at least FIG. 3. Positions include valve open and closed, and in the process of both opening and closing.

[0113] Yet further, in support of the foregoing description, attached hereto are a plurality of graphs and diagrams which may include additional description related to the foregoing. As such, these additional attachments are incorporated in this description by reference.

[0114] In the foregoing detailed description, it may be that various features are grouped together in individual embodiments for the purpose of brevity in the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that any subsequently disclosed or claimed embodiments require more features than are expressly recited.

[0115] Further, the descriptions of the disclosure are provided to enable any person skilled in the art to make or use the disclosed embodiments. Various modifications to the disclosure will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other variations without departing from the spirit or scope of the disclosure. Thus, the disclosure is not intended to be limited to the examples and designs described herein, but rather is to be accorded the widest scope consistent with the principles and novel features disclosed herein.