Electronically controllable valve and mixing valve

Abstract

To provide a compact and replaceable mixing valve cartridge capable of being engaged with a fixed fitting that is permanently plumbed into pipes of a house.SOLUTION: A mixing valve cartridge is compact and replaceable and can be engaged with a fixed fitting 25 that is permanently plumbed into pipes of a house. The compact size allows the cartridge to be positioned behind the type of removable face plates that are often installed over existing manually-operated mixing valves. Simplified valve actuators and a compact mixing and temperature sensing configuration achieve the compact size. The valve cartridge can easily be accessed, unbolted and removed, without the need for extensive plumbing re-work.SELECTED DRAWING: Figure 6

Description

[Technical field]

[0001] The present invention relates to an electronically controllable mixing valve, in particular but not exclusively to an electronically controllable mixing valve suitable for sanitary purposes. [Background technology]

[0002] Over the years, various valve manufacturers and other innovators have developed various types of electronically controllable valves for use as sanitary mixing valves to provide a uniform temperature of hot water to, for example, showerheads and washbasins.

[0003] The valve is typically housed in a housing which also contains an electronic control system, an actuator, temperature sensing elements, etc. The housing also has separate hot and cold water inlets and a mixed water outlet.

[0004] The mixing valve package is often controlled from a remote control panel and delivers thermostatically controlled water to a showerhead or faucet.

[0005] The devices can be quite large and are therefore often mounted in wall cavities, cupboards, lofts or ceiling spaces of the dwelling. Typical sizes for currently available devices are around 250 x 200 x 70 mm. The devices are usually very expensive and some of them suffer from significant reliability issues. The devices are connected directly to the dwelling's plumbing and the connection usually requires the assembly of a watertight threaded connection.

[0006] In addition to having to disconnect many watertight plumbing connections, e.g. screws and sealed joints, to facilitate removal, the tight location of the devices often makes them difficult and expensive to replace, or if they are located in an easily accessible area, e.g. a cupboard or loft, some distance from the shower, which can increase the time lag between setting the desired temperature and receiving water at that temperature at the showerhead.

[0007] Reliability issues, replacement costs, and difficulty in accessing and removing and replacing the devices have slowed consumer acceptance and purchase of these products.

[0008] What is needed is an electronically controllable mixing valve configuration that is smaller, easier to install, and easier to repair or replace if a problem occurs. The reduced size allows the mixing valve to be located in a more desirable location, such as near the showerhead or under the cover plate of the interface unit. It would also be useful for an electronically controllable mixing valve to be simpler, more reliable, and less expensive to manufacture.

[0009] Unless expressly stated to the contrary, when a document, act or article of knowledge is cited or discussed in this specification, such citation or discussion does not constitute an admission that that document, act or article of knowledge, or any combination thereof, was published, publicly known, part of the common general knowledge, or otherwise known as being relevant to an attempt to solve any of the problems addressed by this specification, at the priority date. Summary of the Invention

[0010] the purpose It is an object of the present invention to provide an electronically controllable valve or valve cartridge, or portion thereof, that goes toward overcoming at least one or more of the problems discussed above, or that provides a useful choice to the public.

[0011] Description of the Invention In a first aspect, the present invention provides a fluid control valve assembly comprising: a movable valve member; at least one stationary valve member; a valve actuator; It may be broadly said to comprise a fluid control valve assembly in which, in use, a movable valve member is actuated in linear motion relative to a fixed valve member by a valve actuator to control the flow of fluid through the fluid control valve assembly.

[0012] Preferably, the movable valve member and the at least one fixed valve member are valve members made from a ceramic based material.

[0013] Preferably, the fluid control valve assembly includes two fixed valve members, with the movable valve member sandwiched between the two fixed valve members.

[0014] Preferably, the movable valve member and the at least one fixed valve member each include a passageway through which fluid flow is controlled by a fluid control valve assembly.

[0015] Preferably, the movable valve member is elongate in shape and the linear movement of the movable valve member is along the length of the elongate shape.

[0016] The valve actuator may include a manually operated lever or rotatable knob or handle, or an electrically powered actuator, but preferably the valve actuator is an electrically powered actuator that includes an electric motor.

[0017] Preferably, the valve actuator includes an electric motor and a linear actuator, the linear actuator being coupled to the moveable valve member.

[0018] Preferably, the linear actuator includes a lead screw assembly, the moveable valve member being coupled to the lead screw assembly.

[0019] Preferably, the electric motor rotates a threaded spindle of a lead screw assembly.

[0020] Preferably, the threaded spindle is an integral part of the main shaft of the electric motor.

[0021] Preferably, the lead screw assembly includes a driven nut or sleeve having threads complementary to the threads on the threaded spindle.

[0022] Preferably, the driven nut or sleeve is connected or coupled to the moveable valve member.

[0023] Preferably, the movable valve member includes a slot or protrusion configured to receive a complementary mating feature of the linear actuator which allows the complementary mating feature of the linear actuator to slide into engagement with the slot or protrusion while preventing rotation of the complementary feature of the linear actuator relative to the movable valve member and preventing linear movement of the complementary feature of the linear actuator relative to the movable valve member in the intended direction of movement of the movable valve member during use of the fluid control valve assembly.

[0024] Preferably, the slot or protrusion is a slot or protrusion having a "T" shaped profile.

[0025] Preferably, the fluid control valve assembly includes a valve member housing configured to hold a movable valve member in sealing contact with a fixed valve member.

[0026] Preferably, the valve member housing includes a guide configured to guide linear movement of the moveable valve member.

[0027] Preferably, the valve member housing comprises a box member and a lid member, both made from a plastic material and welded together around the periphery of the moveable and fixed valve members. Optionally, the two housing members may be held together by a mechanical fastener, which may be made from a metal, for example brass.

[0028] Preferably the electric motor is held fixed relative to the valve member housing.

[0029] Optionally, the at least one fixed valve member is in the form of a valve seat formed in the valve member housing.

[0030] In a second aspect, the invention can be broadly described as a mixing and sensing module for an electronically controllable fluid mixing valve comprising a body and a temperature sensing means, the body having two or more inlet regions, a mixing chamber and an outlet region, each inlet region being connected to the mixing chamber by an associated transport passage, the mixing chamber communicating with the inlet region and the outlet region, each transport passage being configured to induce a vortex motion in the fluid as it enters the mixing chamber, and a temperature sensing element of the temperature sensing means positioned to sense the temperature of the fluid as it moves towards or through the outlet region.

[0031] Preferably, the mixing chamber is a cylindrical mixing chamber and each of the transfer passages directs fluid in a direction substantially tangential to a circle defining a periphery of the cylindrical mixing chamber.

[0032] Preferably, the transfer passage has a larger cross-sectional area adjacent the inlet region than it has adjacent the mixing chamber.

[0033] Preferably, the mixing and sensing module also includes a flow sensing means.

[0034] Preferably the flow sensing means comprises a rotating element which rotates by swirling the fluid within the mixing chamber.

[0035] Preferably the rotating element is in the form of a paddle wheel.

[0036] Preferably, the temperature sensing element is supported on a probe or shaft and a rotating element rotates about an axis coaxial with the shaft or probe.

[0037] Preferably the flow sensing means includes a proximity sensing transducer.

[0038] Preferably, the rotating element of the flow sensing means includes one or more magnetic sensing objects configured to be sensed by a proximity sensing transducer.

[0039] Preferably, the fluid flows entering the inlet region and exiting the outlet region all flow through a single plane.

[0040] Preferably, the mixing and sensing module has two inlet regions.

[0041] Preferably, the body has two substantially parallel faces, namely a first face including the inlet and outlet regions and a second face on which the temperature sensing element is located, and the mixing chamber is located between the first and second faces.

[0042] Preferably, the body is configured to receive fluids from two or more fluid inlet supplies and direct the mixed fluid to the mixed fluid conduit.

[0043] In a third aspect, the present invention can be broadly described as comprising a mixing valve assembly having two or more fluid control valve assemblies substantially as herein specified.

[0044] Preferably, the mixing valve assembly also includes at least one mixing and sensing module substantially as specified herein.

[0045] Preferably, the mixing valve assembly is an electronically controllable mixing valve assembly having a control system configured to receive inputs from each mixing and sensing module and to control operation of the electrically powered actuator of each fluid control valve assembly.

[0046] Preferably, the mixing valve assembly is in the form of a replaceable valve cartridge.

[0047] Preferably, the mixing valve assembly has two inlet ports and one outlet port, all of which are located in a single substantially planar plane.

[0048] Preferably, the replaceable valve cartridge is configured such that a mechanical fastening system can securely hold the replaceable valve cartridge to the fixed valve fitting.

[0049] In a fourth aspect, the present invention provides a valve assembly comprising: a movable valve member; Valve seats, an electric motor; A lead screw assembly; a valve member housing; The valve assembly may be broadly described as comprising: a valve member housing configured to hold a movable valve member against a valve seat and permit only linear movement of the movable valve member relative to the valve seat; and a lead screw assembly configured to be driven by an electric motor, the lead screw assembly configured to move the movable valve member to cause linear movement of the movable valve member to control fluid flow through the valve assembly.

[0050] Preferably, the movable valve member and the valve seat are made from a ceramic material.

[0051] Preferably, the valve member housing comprises a top member and a bottom member, both made from a plastic material and welded together around the periphery of the moveable valve member and the valve seat. Optionally, the two housing members may be held together with a mechanical fastener, which may be made from a metal, for example brass.

[0052] Preferably, the valve assembly further includes a top plate comprised of a ceramic material, the movable valve member being sandwiched between the top plate and the valve seat.

[0053] Preferably, the screw shaft or lead screw of the lead screw assembly is driven by an electric motor.

[0054] Preferably, the driven nut of the lead screw assembly is connected to the moveable valve member.

[0055] Preferably, the driven nut is in the form of a driven sleeve having internal threads along at least a portion of the length of the driven sleeve.

[0056] Preferably the driven sleeve is connected to the moveable valve member such that the driven sleeve cannot rotate relative to the moveable valve member.

[0057] Preferably, the movable valve member includes a "C" shaped passage, a first open end of the "C" shaped passage communicating with the first passage in the valve seat member and a second open end of the "C" shaped passage communicating with the second passage in the valve seat member when the valve assembly is in the open configuration.

[0058] Optionally, the movable valve member includes a through passageway from one side of the movable valve member to the other, the through passageway communicating with the passageway in the valve seat and the passageway in the top member when the valve assembly is in the open configuration.

[0059] Preferably, the valve member housing has a fluid inlet port and a fluid outlet port.

[0060] In a fifth aspect, the invention may be broadly described as consisting of a valve module assembly including two or more valve assemblies substantially as herein specified.

[0061] In a sixth aspect, the present invention provides an electronically controllable mixing valve cartridge comprising: at least two fluid inlets and at least one fluid outlet; At least one temperature sensor; at least one moveable valve member and at least one actuator configured to move the moveable valve member; an electronic control system configured to receive inputs from the input device and the temperature sensor and control operation of the actuator; The electronically controllable mixing valve cartridge may be broadly described as comprising a valve cartridge configured to engage a complementary fixed valve fitting, the fixed valve fitting being securable to one or more support members, connectable to a pipe of a plumbing fixture, and having complementary fluid outlets and fluid inlets, such that engagement between the cartridge and the fixed valve fitting establishes a sealed connection between each of the fluid inlets and outlets of the valve cartridge and the complementary fluid outlets and inlets of the fixed valve fitting.

[0062] Preferably, the direction of fluid flow through the fluid inlet and each fluid outlet is a flow direction that is substantially coincident with the direction of movement of the movable valve member.

[0063] Preferably, the electronically controllable mixing valve cartridge includes at least one valve module assembly substantially as specified herein.

[0064] Preferably, the actuator is an electric actuator.

[0065] Preferably, the sealed connections between each fluid inlet and each fluid outlet of the valve cartridge and the complementary fluid outlet and fluid inlet of the fixed valve fitting include elastomeric seals which provide a fluid-tight seal between a surface of the valve cartridge and a surface of the fixed valve fitting.

[0066] Preferably the valve cartridge is in the form of a replaceable valve cartridge.

[0067] Preferably, the valve cartridge is configured such that a mechanical fastening system can securely hold the valve cartridge to the fixed valve fitting.

[0068] Preferably, the mechanical fixation system includes a bayonet fixation system or one or more mechanical fasteners, such as machine screws.

[0069] Preferably, the movable valve member is a ceramic valve member.

[0070] Preferably, the valve cartridge includes a ceramic valve seat configured to engage a ceramic movable valve member.

[0071] Preferably, the electric actuator comprises an electric motor.

[0072] Preferably, the electric actuator comprises a linear actuator.

[0073] Preferably, the linear actuator includes a lead screw assembly.

[0074] Preferably, the direction of fluid flow through the fluid inlet and fluid outlet is a direction of flow that substantially coincides with the direction of movement of the linear actuator.

[0075] Preferably, the electronic control system is configured to receive input from a local or remote input device or user interface via electromagnetic signals, for example via WiFi, Bluetooth or inductive data transfer.

[0076] Optionally, the electronic control system is configured to receive mechanical input from a local input device or user interface having a manually operated knob, lever or similar manually controlled device.

[0077] Optionally, the electronically controllable mixing valve cartridge includes a user interface.

[0078] Preferably, the electronic control system is a closed loop control system.

[0079] Preferably, the temperature sensor is located within the fluid outlet of the valve cartridge.

[0080] Preferably, the one or more channels leading to the fluid outlet of the valve cartridge are configured to induce a vortex in fluid flowing through the fluid outlet.

[0081] Preferably, the electronically controllable mixing valve cartridge includes a fluid mixing chamber.

[0082] Preferably, the fluid mixing chamber comprises: receiving a fluid flow from two or more separate sources; Combining fluid flows, and Actively mixes fluid streams when they meet The fluid mixing module is configured to:

[0083] Preferably, the fluid mixing module actively mixes the fluid streams by swirling the fluid streams in the region where the fluid streams meet.

[0084] Preferably, the fluid mixing module includes a mixing chamber where the fluid streams meet, the mixing chamber having a first diameter in a region where the incoming fluid streams enter the mixing chamber and a second, smaller diameter where the mixed fluids exit the mixing chamber.

[0085] Preferably, the mixing chamber includes a rounded funnel-shaped portion at the transition from the first diameter to the second diameter.

[0086] Preferably, the fluid mixing module is configured to mix two fluid streams, each of the two fluid streams entering the mixing chamber from opposite sides of the mixing chamber.

[0087] Preferably, the fluid mixing module is configured such that the fluid streams each enter the mixing chamber from a direction substantially tangential to a periphery of a portion of the mixing chamber defined by the first diameter.

[0088] Preferably, the flow path in the fluid mixing module for fluids entering the mixing chamber narrows as the flow path approaches the mixing chamber.

[0089] Preferably, the fluid mixing module is configured to accommodate at least one temperature sensor.

[0090] Preferably, the fluid mixing module contains at least one temperature sensor in an outlet portion of the module through which the mixed fluid exits.

[0091] Preferably, at least one temperature sensor housed by the fluid mixing module is positioned to sense the fluid temperature as the fluid exits the mixing module.

[0092] Optionally, the electronically controllable mixing valve cartridge includes one or more flow sensors.

[0093] Preferably, the electronically controllable mixing valve cartridge includes a means for holding stored electrical energy, such as a capacitor or provision for one or more batteries.

[0094] Optionally, the electronically controllable mixing valve cartridge includes a turbo-generator configured to generate electrical energy as fluid flows through the valve cartridge.

[0095] Optionally, the electronically controllable mixing valve cartridge includes an emergency shut-off valve, for example a wax-tube actuated shut-off or diverter valve configured to prevent fluid above a selected temperature from exiting the valve cartridge.

[0096] Preferably, the electronically controllable mixing valve cartridge is configured such that each fluid inlet and each fluid outlet of the valve cartridge is located at a single mating surface and engages a fluid inlet and a fluid outlet on a single mating surface of the fixed valve fitting.

[0097] Optionally, the electronically controllable mixing valve cartridge is configured such that a fluid inlet of the valve cartridge is located on a first mating surface of the valve cartridge and each fluid outlet of the valve cartridge is located on a second mating surface of the valve cartridge, and the valve cartridge is configured to engage with fluid outlets and fluid inlets located on two separate surfaces of a socket or cavity of the fixed valve fitting.

[0098] Optionally, the electronically controllable mixing valve cartridge is configured such that a first fluid inlet of the valve cartridge is located on a first side of the valve cartridge, a second fluid inlet is located on an opposing second side of the valve cartridge, and a fluid outlet of the valve cartridge is located between the first and second sides of the valve cartridge, and the valve cartridge is configured to fit within a fixed valve fitting housing having a first fluid outlet at a first end of the housing, a second fluid outlet at an opposing second end of the housing, and a fluid inlet disposed at a position between the first and second ends of the fixed valve fitting housing.

[0099] Preferably, the fixed valve fitting is permanently connectable to a pipe of the plumbing fixture, for example using a threaded or glued pipe connection.

[0100] Optionally, the fixed valve fitting includes a housing configured to receive an electronically controllable mixing valve cartridge.

[0101] In a seventh aspect, the invention can be broadly stated to comprise a mixing valve assembly including at least one electronically controllable mixing valve cartridge substantially as herein defined and at least one complementary fixed valve fitting.

[0102] Preferably, the fixed valve fitting is configured to engage only one surface of the electronically controllable mixing valve cartridge to form a fluid-tight seal.

[0103] Optionally, the fixed valve fitting includes a socket having a fluid outlet and a fluid inlet located on different faces of the socket and configured to engage complementary tongues of the electronically controllable mixing valve cartridge.

[0104] Optionally, the fixed valve fitting includes a housing configured to completely house the electronically controllable mixing valve cartridge.

[0105] In an eighth aspect, the present invention provides an electronically controllable mixing valve cartridge comprising: at least two fluid inlets and at least one fluid outlet; At least one temperature sensor; at least one moveable valve member and at least one actuator configured to move the moveable valve member; an electronic control system configured to receive input from the input device and configured to receive input from the temperature sensor to control operation of the actuator; It can be broadly described as consisting of an electronically controllable mixing valve cartridge.

[0106] Preferably, the actuator comprises an electric motor.

[0107] Preferably, the direction of fluid flow through the fluid inlet and fluid outlet is substantially along the axis of rotation of the electric motor.

[0108] Preferably, the actuator comprises a linear actuator.

[0109] Preferably, the direction of fluid flow through the fluid inlet and fluid outlet is a flow direction that substantially coincides with the direction of movement of the linear actuator.

[0110] Preferably, the direction of fluid flow through the fluid inlet and fluid outlet is a flow direction that is substantially coincident with the direction of movement of the movable valve member.

[0111] Preferably, the valve cartridge is configured to engage a complementary fixed valve fitting connectable to a pipe of a plumbing fixture and having a complementary fluid outlet and one or more fluid inlets.

[0112] Preferably, the valve cartridge includes one or more engagement features configured to establish a sealed connection between each fluid inlet and each fluid outlet of the valve cartridge and the fixed valve fitting.

[0113] Preferably, the valve cartridge includes a mixing chamber configured to mix two or more fluid streams and located downstream of each movable valve member and upstream of the at least one temperature sensor.

[0114] Preferably, the valve cartridge includes a transfer passage through which the fluid flows as it approaches the mixing chamber, the transfer passage being configured to create a vortex motion within the mixing chamber.

[0115] Preferably, the mixing chamber is substantially cylindrical in shape and each of the transfer passages is configured to direct fluid in a direction generally tangential to a circle defining the periphery of the cylindrical mixing chamber.

[0116] Preferably, the cross-sectional area of ​​the transfer passage decreases along the direction of flow towards the mixing chamber.

[0117] Preferably the valve cartridge also includes a flow sensing means.

[0118] Preferably the flow sensing means comprises a rotating element which rotates by swirling the fluid within the mixing chamber.

[0119] Preferably the rotating element is in the form of a paddle wheel.

[0120] Preferably, the temperature sensing element of the temperature sensor is supported on a probe or shaft and a rotating element rotates about an axis coaxial with the shaft or probe.

[0121] Preferably the flow sensing means includes a magnetic or proximity sensing transducer.

[0122] Preferably, the rotating element of the flow sensing means includes one or more magnetic sensing objects configured to be sensed by a Hall effect sensing transducer.

[0123] Preferably, the linear actuator includes a lead screw assembly.

[0124] Preferably, the movable valve member is a ceramic valve member.

[0125] Preferably, the movable valve member is elongate in shape and the linear movement of the movable valve member is along the length of the elongate shape.

[0126] Preferably, the valve cartridge includes two fixed valve members associated with a movable valve member, the movable valve member being sandwiched between the two associated fixed valve members.

[0127] Preferably, the at least two fluid inlets and the at least one fluid outlet are all located in a single substantially planar surface.

[0128] Preferably, the engagement features of the valve cartridge include one or more structures configured to retain one or more elastomeric seals.

[0129] Preferably, the valve cartridge is configured such that a mechanical fastening system can securely hold the valve cartridge to the fixed valve fitting.

[0130] In a ninth aspect, the present invention may broadly be described as consisting of an electronically controllable mixing valve assembly comprising an electronically controllable mixing valve cartridge substantially as herein specified and a fixed valve fitting, wherein the electronically controllable mixing valve cartridge is connectable to the fixed valve fitting using a mechanical fastening system, and the fixed valve fitting is connectable to a building's piping system and configured to direct fluid to at least two fluid inlets of the valve cartridge and to receive fluid from at least one fluid outlet of the valve cartridge, and further configured to establish a leak-tight seal between mating features of the electronically controllable mixing valve cartridge and complementary mating features of the fixed valve fitting.

[0131] In a tenth aspect, the present invention provides a method of repairing an electronically controllable valve, comprising the steps of: removing a malfunctioning electronically controllable mixing valve cartridge, substantially as specified herein, from a fixed valve fitting; and b. installing a replacement electronically controlled mixing valve cartridge into the fixed valve fitting.

[0132] The present invention may be broadly described as consisting of the components, elements and features referred to or illustrated in this specification, either individually or collectively, and any and all combinations of two or more of those components, elements and features, and where specific integers having known equivalents are referred to herein, such equivalents are intended to be incorporated herein as if they were individually set forth. [Brief description of the drawings]

[0133] Further aspects of the invention will become apparent from the following description, given by way of example only and referring to the accompanying drawings, in which: [Figure 1] FIG. 1 is a perspective view of a first embodiment of an electronically controllable mixing valve cartridge according to the present invention. [Diagram 2] FIG. 2 is an exploded perspective view of a first embodiment of an electronically controllable mixing valve cartridge. [Diagram 3] FIG. 3 is a perspective view of a valve module assembly of a first embodiment of an electronically controllable mixing valve cartridge. [Figure 4] FIG. 4 is an exploded perspective view of the valve module assembly. [Diagram 5] FIG. 5 is a cross-sectional view of the valve module assembly. [Figure 6] FIG. 6 is a perspective view of a first mixing valve assembly incorporating a first embodiment of an electronically controllable mixing valve cartridge. [Figure 7] FIG. 7 is a perspective view of a second embodiment of an electronically controllable mixing valve cartridge. [Figure 8] FIG. 8 is an exploded perspective view of a second embodiment of an electronically controllable mixing valve cartridge. [Figure 9] FIG. 9 is a perspective view of a second mixing valve assembly incorporating a second embodiment of an electronically controllable mixing valve cartridge. [Figure 10] FIG. 10 is a perspective view of a fluid mixing module of a second embodiment of an electronically controllable mixing valve cartridge. [Figure 11] FIG. 11 is a top view of the fluid mixing module. [Figure 12] FIG. 12 is a perspective view of a third embodiment of an electronically controllable mixing valve cartridge. [Figure 13] FIG. 13 is an exploded perspective view of a third embodiment of an electronically controllable mixing valve cartridge. [Figure 14] FIG. 14 is a perspective view of a third mixing valve assembly incorporating a third embodiment of an electronically controllable mixing valve cartridge. [Figure 15] FIG. 15 is an exploded perspective view of the third mixing valve assembly. [Figure 16]FIG. 16 is a perspective view of the fourth mixing valve assembly. [Figure 17] FIG. 17 is an exploded perspective view of the fourth mixing valve assembly. [Figure 18] FIG. 18 is a perspective view of a fifth embodiment of a mixing valve assembly. [Figure 19] FIG. 19 is an exploded perspective view of a fifth embodiment of a mixing valve assembly. [Figure 20] FIG. 20 is a rear view of the fifth embodiment of the mixing valve assembly, with cross sections AA and BB defined. [Figure 21] FIG. 21 is a cross-sectional view taken along line AA of the fifth embodiment of the mixing valve assembly. [Figure 22] FIG. 22 is a cross-sectional view taken along line BB of the fifth embodiment of the mixing valve assembly. [Diagram 23] FIG. 23 is a front perspective view of the mixing and sensing module of the fifth embodiment of the mixing valve assembly. [Figure 24] FIG. 24 is a rear perspective view of the mixing and sensing module of the fifth embodiment of the mixing valve assembly. [Diagram 25] FIG. 25 is an exploded perspective view of the mixing and sensing module of the fifth embodiment of the mixing valve assembly. [Figure 26] FIG. 26 is a perspective view of an alternative box member for the valve housing of the fifth embodiment of the mixing valve assembly. [Figure 27] FIG. 27 is an exploded perspective view of an alternative valve member configuration. [Figure 28] FIG. 28 is a front view of an alternative valve member configuration. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0134] Four embodiments of a removable electronically controllable mixing valve cartridge according to the present invention are described below with reference to Figures 1-15 and 18-26. Figures 16 and 17 relate to a mixing valve assembly having similar features to the electronically controllable mixing valve cartridge, but without the removable cartridge features. Figures 27 and 28 show an alternative valve member configuration for a mixing valve that is more compact and uses only an actuator.

[0135] In each of the first three embodiments and the fifth embodiment, the electronically controllable mixing valve cartridge is designed as a replaceable or removable unit configured to engage or be used with a mixing valve assembly, for example, a mixing valve assembly used to supply a fluid, such as water at a desired safe temperature, to a showerhead, a hand basin, an industrial process, or the like.

[0136] A mixing valve assembly typically includes one replaceable electronically controllable mixing valve cartridge configured to engage a complementary fixed valve fitting. A fixed valve fitting is typically a fitting or housing that is permanently or semi-permanently attached to the plumbing of a residential, commercial or industrial property or building.

[0137] Both the electronically controllable mixing valve cartridge and the fixed valve fitting are configured to engage with one another to form a fluid-tight seal at the interface between the electronically controllable mixing valve cartridge and the fixed valve fitting. Engagement features on the valve cartridge are configured to engage complementary engagement features on the fixed valve fitting. The operational characteristics of the three embodiments of the cartridge described herein are substantially similar, with the primary difference in each case being the manner in which the cartridge engages with its respective fixed valve fitting.

[0138] For example, some cartridges are configured to engage or form a fluid-tight seal with only one side of the fixed valve fitting. Other cartridges have a tongue configured to engage a complementary socket of the fixed valve fitting, where the tongue forms a fluid-tight seal with two inner surfaces of the socket of the fixed valve fitting. In yet another example, the fixed valve fitting includes a housing configured to completely house the electronically controllable mixing valve cartridge, where a fluid-tight seal is formed on three sides of the cartridge.

[0139] The electronically controllable mixing valve cartridge is designed to provide an easy way to repair a malfunctioning electronically controllable valve. The electronically controllable mixing valve cartridge is designed so that a malfunctioning electronically controllable mixing valve cartridge can be easily removed or disassembled from a fixed valve fitting and a replacement electronically controllable mixing valve cartridge can be installed into the now vacant fixed valve fitting, instead of replacing the entire electronically controllable valve assembly, which would normally require a qualified plumber. The objective is to provide a cartridge that can be easily and quickly replaced, ideally without requiring a qualified plumber to perform the repair.

[0140] First Example A first embodiment of an electronically controllable mixing valve cartridge (11) will be described with reference to Figures 1 to 6. The first embodiment of the electronically controllable mixing valve cartridge (11) includes two fluid inlets (13), one fluid outlet (15), and a temperature sensor (17). Furthermore, the cartridge (11) includes two movable valve members (19) and an actuator (21) configured to move each of the movable valve members (19). In this example, the actuators (21) are electric actuators.

[0141] The cartridge (11) also includes an integrated electronic control system (23) in the form of a printed circuit board. The electronic control system (23) is configured to receive input or feedback from the temperature sensor (17) and input from an input device (not shown) to control operation of the actuator (21). The input device may be a remote control panel, for example having one or more push button, touch screen or control knob (24) style input panel, ideally located at eye level on the shower module.

[0142] As mentioned above, the cartridge (11) is characterized in that it is configured to mate with a complementary fixed valve fitting (25) to form a first mixing valve assembly (26). The valve cartridge (11) is in the form of a replaceable valve cartridge.

[0143] The fixed valve fitting (25) can be fixed to a support, for example to the building framing. The fixed valve fitting (25) can be permanently or at least semi-permanently connected to a pipe in the building plumbing system. The fixed valve fitting (25) can be connected, for example, using a threaded pipe connection or a glued pipe connection.

[0144] The fixed valve fitting (25) includes two complementary fluid outlets (27) and a fluid inlet (29). Engagement between the cartridge (11) and the fixed valve fitting (25) can establish a fluid-tight sealed connection between the fluid inlet (13) and fluid outlet (15) of the cartridge (11) and the complementary fluid outlet (27) and fluid inlet (29) of the fixed valve fitting (25).

[0145] The sealed connection between each fluid inlet (13) and fluid outlet (15) of the valve cartridge (11) and the complementary fluid outlet (27) and fluid inlet (29) of the fixed valve fitting (25) includes an elastomeric seal (31), such as an EPDM (Ethylene Propylene Diene Monomer) rubber O-ring (not shown). Each elastomeric seal (31) provides a fluid-tight seal at the interface between a cartridge mating surface (33) of the valve cartridge (11) and a fixed mating surface (35) of the fixed valve fitting (25). The fluid inlet (13) and fluid outlet (15) of the valve cartridge (11) are disposed on the cartridge mating surface (33) of the cartridge, respectively, such that they engage with the fluid outlet (27) and fluid inlet (29) on the fixed mating surface (35) of the fixed valve fitting (25).

[0146] The movable valve members (19) are ceramic valve members that each engage a fixed ceramic valve seat (37). Each of the movable valve members (19) has a "C" shaped bridge passage (36) that spans and connects the two ports of the mating valve seat (37) when the movable valve member (19) is in a fully open position. The "C" shaped bridge passage (36) does not connect the two ports of the mating valve seat (37) when the movable valve member (19) is in a fully closed position. The movable valve members (19) control flow when in intermediate positions between the fully open and fully closed positions.

[0147] As shown in Figures 4 and 5, each movable valve member (19) is sandwiched between an associated fixed valve seat (37) and a fixed ceramic top plate (38). Each valve "sandwich" consists of one top plate (38), one centrally located movable valve member (19) and one valve seat (37), and the valve sandwich is held securely between a valve housing body (39) and a valve housing base (40). During manufacture, the valve housing body (39) and the valve housing base (40) are clamped together to provide the desired compressive load on the valve sandwich, after which the valve housing base (40) is permanently fixed to the valve housing body (39) using a suitable fastening method such as welding or adhesive.

[0148] Each electric actuator (21) includes an electric motor (42) and a lead screw or jack screw (44). Each lead screw (44) includes a threaded drive shaft (46) that is driven by an associated electric motor (42) and a complementary threaded driven nut or sleeve (47). Each lead screw (44) is ideally part of the electric motor (42), with the lead screw (44) being part of or an extension of the main shaft of the electric motor (42).

[0149] Each driven sleeve (47) is connected to one of the movable valve members (19) and is capable of linear movement, thereby moving the associated movable valve member (19), but is prevented from rotation by its connection with the associated movable valve member (19). The connection between each driven sleeve (47) and its associated movable valve member (19) is sized such that a square or rectangular key (58) on the end of each driven sleeve (47) fits within a complementary square or rectangular socket (59) on each movable valve member (19).

[0150] The components shown in Figure 4, including the top plate (38), the movable valve member (19), the valve seat (37), the electric actuator (21), the valve housing body (39) and the valve housing base (40), when assembled, form the valve module assembly (49) as shown in Figure 3. The valve module assembly (49) is secured to the cartridge body (41) of the cartridge (11) using six machine screws (50) as shown in Figure 2. A fluid-tight connection between the cartridge body (41) and the valve module assembly (49) is achieved using four seal rings (51) configured to span between an upper surface of the cartridge body (41) and an underside of the valve seat (37).

[0151] As mentioned above, the electronic control system 23 is configured to receive input from local or remote input devices or user interfaces. The electronic control system 23 can receive input via electromagnetic signals, for example via WiFi, Bluetooth, or inductive data transfer.

[0152] A temperature sensor (17) is disposed within the fluid outlet (15) of the valve cartridge (11) to provide temperature data that facilitates a closed loop electronic control system, allowing the cartridge to control the temperature of the fluid exiting the cartridge within a desired range.

[0153] The two intermediate channels (61) leading to the fluid outlets (15) are configured to induce vortexes in the fluid flowing through the fluid outlets (15). This vortex action may be important for accelerating the mixing of the fluids, for example the mixing of a hot water stream with a cold water stream, so that a sufficiently accurate mixed fluid temperature measurement can be made before the fluid leaves the cartridge (11).

[0154] To facilitate this mixing action, the cartridge 11 includes a fluid mixing chamber 63 that is disposed within a fluid mixing module 65 of the cartridge 11. The principles of the fluid mixing module 65 will be explained in more detail in the description of the second embodiment below.

[0155] The valve cartridge (11) is configured such that a mechanical fastening system can securely hold the valve cartridge (11) in the fixed valve fitting (25). In this example, an outer housing (53) is used to fasten the valve cartridge (11) to the fixed valve fitting (25). The female threads of the outer housing (53) mate with the male threads (54) of the fixed valve member (25) such that an inner shoulder (not shown) of the outer housing (53) bears against an outer shoulder (55) of the cartridge (11) when the outer housing (53) is turned onto the male threads (54). In this manner, the outer housing (53) is used to press the cartridge mating surface (33) against the fixed mating surface (35) of the fixed valve member (25), thereby compressing the O-ring and preventing leakage from the fluid connection.

[0156] In this first embodiment, the input device is a rotary control knob (24) attached to the free end of the outer housing (53). Manual input from the rotary control knob (24) is converted to an electronic signal and transmitted to the printed circuit board (23) of the built-in electronic control system of the cartridge (11) via, for example, electrical contacts, inductive data transfer, WiFi, etc.

[0157] The printed circuit board (23) is disposed within a slot (67) in the body (69) and a cap (71) surrounds the printed circuit board (23) and the electric motor (42) to protect these items.

[0158] The electronically controllable mixing valve cartridge (11) is ideally powered from a connection to the mains power system. The connection can be a wired connection via a connecting plug, or can also be achieved by electrical connection via inductive power transfer or alternative contactless means. The cartridge (11) can also include a means for holding stored electrical energy, for example a capacitor or provision for one or more batteries. The ability to hold stored electrical energy is advantageous in that the cartridge (11) can be configured to cut off the flow of water to the shower, for example in the event of a mains power failure. This safety feature can minimize the possibility of a person being displaced due to loss of control of the cartridge (11).

[0159] The same style of power source and electrical storage or backup can be used in each of the valve cartridges or valve assemblies described herein.

[0160] The embodiment of the electronically controllable mixing valve cartridge (11) is configured to have a relatively small profile when viewed in a direction that mates with a fixed pipe fitting or fixed valve member (25). One feature that enables this relatively small profile is that the direction of fluid flow through the fluid inlet (13) and fluid outlet (15) is a flow direction that is substantially aligned with the axis of rotation of the electric motor (42). The direction of flow through the inlet port (13) and outlet port (15) also coincides with the direction of motion of the linear actuator or lead screw (44) and the direction of movement of the moveable valve member (19).

[0161] The relatively small profile allows the electronically controllable mixing valve cartridge (11) to be mounted in a relatively small opening in a wall. Ideally, the valve cartridge (11) can fit into an opening less than 160 millimeters in diameter, and some valve cartridges that have been tried and tested to date can fit into openings less than 120 millimeters in diameter. Such a small size allows the valve cartridge (11) to be easily covered by a faceplate or manual control knob (24), or by an electronic control panel or other user interface.

[0162] Second Example 7-11, a second embodiment of the electronically controllable mixing valve cartridge (81) will be described. The second embodiment of the electronically controllable mixing valve cartridge (81) is similar to the first embodiment of the electronically controllable mixing valve cartridge (11), except as generally described below.

[0163] The main difference between the first embodiment and this second embodiment is that this second embodiment engages with the fluid connections on two sides of the second fixed valve fitting (83). The fluid inlet (85) of the valve cartridge is located on a first mating side (87) of the valve cartridge (81), and the fluid outlet (89) of the valve cartridge (81) is located on a second mating side (91). The valve cartridge (81) is configured to engage with the fluid outlet (93) and the fluid inlet (95) located on two separate or different sides of the socket or cavity (97) of the fixed valve fitting (83). The first mating side (87) and the second mating side (91) are located on a tongue (99) of the cartridge (81), which is mounted in and complementary to the socket (97).

[0164] In this embodiment, the tongue 99 of the valve cartridge 81 is held securely within the socket 97 of the fixed valve fitting 83 by a single machine screw 101. The machine screw 101 threadably engages with a threaded boss 103 of the fixed valve fitting 83.

[0165] The valve module assembly (105) of this second embodiment of the valve cartridge (81) has the same basic components as the valve module assembly (49) used in the first embodiment, with slight differences in those components, primarily related to the fact that in this embodiment, fluid exits from one side of the valve module assembly (105) to the opposite side.

[0166] The valve module (105) includes two top plates (107), two movable valve members (109), two valve seats (111), two electric actuators (113), a valve housing body (115) and a valve housing base (117). Both the valve housing body (115) and the valve housing base (117) have two fluid ports. The valve housing body (115) includes two fluid inlet ports (85) and the valve housing base (117) includes two outlet ports (119). The two outlet ports (119) communicate with passages in a fluid mixing module (121) described below.

[0167] The top plate (107), movable valve member (109) and valve seat (111) each include a passage therethrough. Fluid will flow through one movable valve member (109) when the passage therethrough is partially or fully aligned with the passage therethrough in its associated top plate (107) and valve seat (111). Each movable valve member (109) can be moved linearly by an actuator (113) relative to its associated valve seat (111) to a position where fluid flow stops or through a range of positions to achieve a desired fluid flow rate.

[0168] This second embodiment of cartridge (81) includes a fluid mixing module (121) that operates similarly to the fluid mixing module (65) of the first embodiment. The fluid mixing module (121) has two intermediate channels (123) that each direct fluid to a common fluid mixing chamber (125). The mixing chamber (125) is located in the area where the fluid flows from each intermediate channel (123) meet.

[0169] The fluid mixing module (121) is configured to receive fluid streams from two separate sources, combine the fluid streams, and actively mix the fluid streams when they meet, where the fluids are received into each of the intermediate conduits (123) from two outlet ports (119) of the valve module (105), respectively. The fluid mixing module (121) actively mixes the two fluid streams by rotating the fluids together in the fluid mixing chamber (125).

[0170] The mixing chamber (125) has a first diameter (126) at the region where the incoming fluids enter the mixing chamber (125) and the mixing chamber (125) has a second, smaller diameter (127) where the mixed fluids exit the mixing chamber (125). The mixing chamber (125) includes a rounded funnel-shaped portion at the transition from the first diameter (126) to the second diameter (127).

[0171] The two fluid streams each enter the mixing chamber (125) from opposite sides of the mixing chamber (125). The fluid mixing module (121), and more specifically the intermediate conduit (123), is configured such that the fluid streams each enter the mixing chamber approximately tangentially to the periphery of a portion of the mixing chamber (125) defined by a first diameter.

[0172] As shown in Figures 10 and 11, the flow path or intermediate channel (123) narrows as it approaches the mixing chamber (125), which accelerates the fluid as it enters the mixing chamber (125) and enhances the mixing action.

[0173] Fluid mixing module (121) includes a socket (128) configured to hold a temperature sensor (129) within fluid outlet (89) of valve cartridge (81). Fluid outlet (28) is essentially the outlet portion of fluid mixing module (125). Temperature sensor (129) is positioned to sense the fluid temperature as the fluid exits fluid mixing module (121).

[0174] The fluid mixing module (121) is a critical part of the valve cartridge (81) because it allows for accurate temperature measurement of the mixed water produced by the mixing valve module (105), thereby allowing for closed-loop control within the electronically controllable mixing valve cartridge (81).

[0175] The electrical components of the electronically controllable mixing valve cartridge (81), including the electric actuator (113) and printed circuit board (131), are housed within a cylindrical cap (133). The cylindrical cap (133) is attached to the body (135) of the valve cartridge (81) and held in place by machine screws (101). Although a cylindrical cap is used in this embodiment, it is envisioned that the cap (133) can be of any shape.

[0176] This second embodiment of the electronically controllable mixing valve cartridge (81) does not include an integrated input device. A remote input device, such as a remote device with a touch screen or manual control knob, can be used to provide the desired water temperature, with this input relayed to the valve cartridge (81) via hardwire or a contactless method such as WiFi, Bluetooth or inductive data transfer. Alternatively, the touch screen or manual control knob can be incorporated into the electronically controllable mixing valve cartridge (81).

[0177] Third Example 12-15, a third embodiment of the electronically controllable mixing valve cartridge (161) will be described. The third embodiment of the electronically controllable mixing valve cartridge (161) is similar to the first and second embodiments of the electronically controllable mixing valve cartridges (11) and (81), except as generally described below.

[0178] The main difference with this third embodiment (161) is that this third embodiment is designed to fit within a cylindrical housing and mate with three side fluid connections of a third fixed valve fitting (163). One fluid inlet (165) of the valve cartridge (161) is located at a first mating surface (167) on one side or end of the valve cartridge (161), a second fluid inlet (165) is located at a second opposite mating surface (169) on the other side or end of the valve cartridge (161), and a fluid outlet (171) of the valve cartridge (161) is located at a third mating surface (173) that is located between the first mating surface (167) and the second mating surface (169) and is oriented perpendicular thereto.

[0179] The valve cartridge (161) is configured to engage with fluid outlets (175) and fluid inlets (177) located on three separate or distinct faces of a cavity (179) in a central housing (181) of the fixed valve fitting (163). The first mating face (167) and the second mating face (169) are located at opposite ends of a substantially cylindrical body (183) of the cartridge (161). And the third mating face (173) is located on a flat base portion (185) on a side of the cylindrical body (183). The cylindrical body (183) is configured to fit within and is complementary to the cavity (179).

[0180] The valve cartridge (161) has a display screen (187) located on a second flat portion (189) of the cylindrical body (183), the second flat portion (189) being located on a substantially opposite side of the cylindrical body (183) as compared to the location of the flat base portion (185). A printed circuit board (191) of the control system of the valve cartridge (161) is located below the display screen (187).

[0181] The valve cartridge (161) is configured to fit within a central housing (181) of a fixed valve fitting (163). The fixed valve fitting (163) in this embodiment is configured to connect to hot and cold water pipe connections in a wall, which connections are typically spaced about 150-250 millimeters apart. In this manner, the fixed valve fitting (163) can be fixed to the building's piping system.

[0182] 14 and 15, it can be seen that the fixed valve fitting (163) includes three main components, a first end fitting (193) and a second end fitting (195), each attached to opposite ends of the central housing (181). The first end fitting (193) includes a fitting configured to connect to one of a pair of water pipe connections in a building, and the second end fitting (195) also includes a fitting configured to connect to the other of the pair of water pipe connections.

[0183] The first end fitting (193) also includes one of the fluid outlets (175) of the fixed valve fitting (163) that are configured to engage with and form a fluid-tight seal with the fluid inlet (165) of the cartridge (161). The second end fitting (195) is similarly configured to form a fluid-tight seal with the other fluid inlet (165) of the cartridge (161). The central housing (181) includes the fluid inlet (177) of the fixed valve fitting (163) that is configured to engage with and form a fluid-tight seal with the fluid outlet (171) of the cartridge (161). In this manner, the fluid inlet (177) is located in a central location between the two ends of the housing of the fixed valve fitting. The fluid inlet (177) of the fixed valve fitting (163) receives temperature-controlled water from the cartridge (177) and is typically connected to a showerhead.

[0184] This third embodiment of electronically controllable mixing valve cartridge (161) includes a fluid mixing module (not shown) that functions similarly to the fluid mixing module (125) described with reference to the second embodiment of cartridge valve (81). The fluid mixing module of the third embodiment of electronically controllable mixing valve cartridge (161) is integrally formed within cylindrical body (183) and is located directly below the valve components.

[0185] Valve module (197) of the third embodiment of electronically controllable mixing valve cartridge (161) is similar in most respects to the valve module of the first embodiment of electronically controllable mixing valve cartridge (11) described herein. The most notable difference is that two electrically powered actuators (199) are disposed at opposite ends of cylindrical body (183). In this manner, the two valve sandwich assemblies of valve module (197) are mirror images of the other when compared to the two identical valve assemblies of valve module (49).

[0186] Note that the cylindrical body (183) also forms the valve housing body and valve housing base of the valve module (197). The top plate (201) of the valve module is attached to the cylindrical body (183) using four machine screws (203), which keep the fixed and movable parts of the valve sandwich clamped together.

[0187] The temperature sensor (205) is mounted through a hole in the center of the top plate (201) of the valve module and extends between the valve components and down to the fluid outlet (171) located in the flat base (185) of the cylindrical body (183).

[0188] In an alternative configuration, the third fixed valve fitting (163) can be made as a single piece that connects to the hot and cold water pipe connections in the wall. The third fixed valve fitting (163) can then include a mating surface onto which a modified version of the electronically controllable mixing valve cartridge (161) can be attached. The cartridge can include a unique chrome plated cover and user interface. In this way, the cartridge can be replaced without having to disassemble the fixed valve fitting in any way.

[0189] Fourth embodiment A mixing valve assembly (241) according to another embodiment of the invention will now be described with reference to Figures 16 and 17. In this embodiment, the mixing valve assembly (241) does not include the features of a removable cartridge, but rather the mixing valve assembly includes a valve module assembly (243) similar to that used in the removable cartridge embodiments described herein.

[0190] The mixing valve assembly (241) essentially comprises a valve body (245) to which a valve module assembly (243) is attached. The valve body (245) comprises two fluid inlet ports and one mixed fluid outlet port. Neither of the fluid inlet or outlet ports communicates with the other except through the valve module assembly (243).

[0191] The first fluid inlet port (247) communicates with the first valve inlet port (249), and similarly, the second fluid inlet port (251) communicates with the second valve inlet port (253), and the two valve outlet ports (255) communicate with the fluid outlet port (257) of the valve body (245).

[0192] The valve module assembly (243) has a flat base that engages with a machined surface (261) of the valve body (245). A first valve inlet port (249), a second valve inlet port (253), and two valve outlet ports (255) are located on the machined surface (261). When the valve module assembly (243) is attached to the valve body (245) using six machine screws (263), a fluid-tight seal is created between each of the ports (249), (253), (255) and the corresponding ports on the bottom of the valve module assembly (243) using four elastomeric seals (265).

[0193] The structure and function of the valve module assembly (243) is similar to the valve module assembly (49) described with reference to the first embodiment herein. The valve module assembly (243) includes a moveable valve member (267), a valve seat (269), a valve top plate (271), an electric motor (273) and a lead screw assembly including a threaded drive shaft (275) and a threaded driven sleeve (277).

[0194] The valve module assembly (243) is mounted in a slightly rectangular housing member (279), and the electric motor (273) and printed circuit board (281) are housed within a cap (283) that snaps onto the rectangular housing member (279).

[0195] The temperature sensor (285) is mounted in the valve body (245) and is exposed to the fluid exiting the fluid outlet port (257). The temperature sensor (285) allows the mixing valve assembly to provide closed loop temperature control. Fluid entering the two valve outlet ports (255) is directed into a circular passageway leading to the fluid outlet port (257) at an angle tangent to a circle defining the circular passageway. This causes the fluid entering the circular passageway to swirl, which aids in rapid mixing of the two streams of fluid or water. This mixing occurs immediately upstream of the temperature sensor (285).

[0196] Alternatively, the temperature sensor (285) may be included within the valve module assembly (243) and mounted within the fluid mixing chamber, as in the first, second, and third embodiments described herein.

[0197] Temperature input can be received from a remote input device and relayed to the control system of the mixing valve assembly (241) using wired or wireless methods similar to the cartridges described herein.

[0198] The mixing valve assembly (241) provides closed loop temperature control in a compact configuration that can be easily installed in a building's plumbing pipes, requiring only three pipe connections and power and data connections. Its size allows for easy installation in a wall cavity or other location suitable for plumbing installations.

[0199] Fifth Example With reference to Figures 18-26, a fifth embodiment of the electronically controllable mixing valve cartridge (311) will be described. The fifth embodiment of the electronically controllable mixing valve cartridge (311) is similar in many respects to the second embodiment of the electronically controllable mixing valve cartridge (81) described herein. The main difference between the fifth embodiment of the electronically controllable mixing valve cartridge (311) and the second embodiment of the electronically controllable mixing valve cartridge (81) is the path that the mixed fluid takes as it exits the valve cartridge (311). In the valve cartridge (311), the mixed fluid exits through a mixed fluid outlet conduit (313) located between the first fluid control valve assembly (315) and the second fluid control valve assembly (317).

[0200] The new flow direction of the mixed fluid provides a configuration in which the two inlet ports (319) and the outlet port (321) are all located on one side of the valve cartridge (311), and in fact all located on a single flat mating surface (323). The single mating surface (323) allows the valve cartridge (311) to be attached by engaging with a single mating surface of the stationary valve member (325). In this embodiment, the valve cartridge (311) is fastened to the stationary valve member (325) using two machine screws (not shown) that pass through threaded holes (327) near the outer edge of the valve member housing (329). The valve member housing (329) is shared by both the first fluid control valve assembly (315) and the second fluid control valve assembly (317).

[0201] Another notable difference between the fifth embodiment of the electronically controllable mixing valve cartridge (311) and the second embodiment of the electronically controllable mixing valve cartridge (81) is the location of the temperature sensing means (331) and the addition of the flow sensing means (333). The temperature sensing means (331) and the flow sensing means (333) are each mounted through the rear face of the mixing and sensing module (337).

[0202] Each fluid control valve assembly (315, 317) has a movable valve member (339) and two fixed valve members (341), and a valve actuator (343). Each fluid control valve assembly (315, 317) is configured such that, in use, the associated movable valve member (339) is moved in linear motion relative to the two fixed valve members (341) by the valve actuator (343), thereby controlling the flow of fluid through each fluid control valve assembly.

[0203] The movable valve member (339) is sandwiched between two fixed valve members (341), all of which are made from a ceramic-based material. All of the valve members (339, 341) are elongated in shape with straight sides and rounded ends, and are approximately twice as long as they are wide. The linear motion of the movable valve member (339) is along the length of the elongated shape.

[0204] The movable valve member (339) and the two fixed valve members (341) each contain a passageway (345) through which fluid flow is controlled by the position of the movable valve member (339) relative to the two fixed valve members (341). Maximum fluid flow occurs when the passageways (345) of the movable valve member (339) are perfectly aligned with the passageways (345) of the two fixed valve members (341). There will be zero flow if the passageways (345) do not overlap at all, and flow will increase as the passageways (345) move towards perfect alignment, with a range of flow occurring at points in between.

[0205] The valve actuator (343) may include a manually operated lever or rotatable knob or handle, or a powered actuator, and in this example, the valve actuator (343) is a powered actuator including an electric motor (347) and a linear actuator (349). The linear actuator (349) is coupled to the moveable valve member (339). In this example, the linear actuator (349) is in the form of a simple lead screw assembly.

[0206] The threaded spindle (351) of the lead screw assembly is an integral part of the main shaft of the electric motor (347) such that the threaded spindle (351) is directly driven by the electric motor. The lead screw assembly also includes a driven nut or sleeve (353), which has threads complementary to those of the threaded spindle (351).

[0207] The sleeve (353) is connected or directly coupled to the movable valve member (339). In this embodiment, the coupling is achieved by engaging a "T" shaped projection (355) on a free end of the sleeve (353) with a complementary "T" shaped slot (357) on one end of the movable valve member (339). The "T" shaped slot (357) is configured to allow the complementary projection (355) to slide into engagement with the slot (357) while at the same time preventing rotation of the projection (355) relative to the movable valve member (339). Linear movement of the sleeve (353) relative to the movable valve member (339) in the intended direction of movement of the movable valve member (339) during use is also prevented by the "T" shaped joint between the projection (355) and the slot (357).

[0208] Each fluid control valve assembly (315, 317) includes a valve member housing (329) configured to hold a movable valve member (339) in sealing contact with a fixed valve member (341). In this embodiment, a single valve member housing (329) houses both fluid control valve assemblies (315, 317), and the valve member housing (329) includes a guide (361) configured to guide the linear motion of the movable valve member (339) and hold the fixed valve member (341) in place.

[0209] In this embodiment, the valve member housing (329) comprises a box member (363) and a cover member (364), both of which are made from a relatively rigid plastic material and are welded together to retain and seal the moveable valve member (339) and two fixed valve members (341). The valve member housing (329) also includes a fluid inlet port (319) and a mixed fluid outlet conduit (313) which terminates in a fluid outlet port (321).

[0210] The electric motors (347) are mounted to the outside of and held fixed relative to the valve member housing (329). The two electric motors (347) used in the electronically controllable mixing valve cartridge (311) are contained within a motor housing that includes a motor base plate housing member (365) and a motor cover housing member (366).

[0211] The fifth embodiment of the electronically controllable mixing valve cartridge (311) also includes a mixing and sensing module (337). The mixing and sensing module (337) has a body (371), a temperature sensing means (331) and a flow sensing means (333). The body (371) has two inlet regions (377), a mixing chamber (379) and an outlet region (381). The mixing chamber (379) is located downstream of the movable valve member (339) and upstream of the temperature sensing means (331).

[0212] In this embodiment, the two inlet regions (377) and the outlet region (381) are all on the same side of the body (371). In this manner, the mixing and sensing module (337) can receive two separate fluid streams from the valve member housing (329), combine or mix the two fluid streams, and then direct the mixed fluid back through the mixed fluid outlet conduit (313) of the valve member housing (329).

[0213] The mixing chamber (379) communicates with two inlet regions (377) and with an outlet region (381). Each of the two inlet regions (377) is connected to the mixing chamber (379) by an associated transfer passage (383). Each transfer passage (383) is tapered and narrows along the direction of flow and is configured to induce a vortex motion in the fluid as it enters the mixing chamber (379).

[0214] The mixing chamber (379) is a cylindrical mixing chamber, and the transfer passages (383) each direct the fluid in a direction approximately tangential to a circle defining the circumference of the cylindrical mixing chamber (379). The cross-sectional area of ​​the transfer passages (383) decreases along the direction of flow toward the mixing chamber (379). The transfer passages (383) have a larger cross-sectional area adjacent the inlet region (377) than adjacent the mixing chamber (379), and the fluid is forced to move through a narrow gap, causing the fluid to accelerate as it moves toward the mixing chamber (379).

[0215] The temperature sensing means (331) includes a temperature sensing element (385) positioned to sense the temperature of the fluid as it passes toward or through the outlet region (381) or when it is in the mixed fluid outlet channel (313).

[0216] The flow sensing means (333) includes a rotating element (387) that is rotated by the swirling fluid in the mixing chamber (379). The rotating element (387) is in the form of a paddle wheel. The temperature sensing element (385) is supported on a probe or shaft (389) and the rotating element (387) is supported on the shaft (389) and rotates about an axis coaxial with the shaft (389). The rotating element (387) is held firmly to the shaft (389) by a fixed wheel (390). The rotating element (387) includes one or more magnetic sensing objects configured to be sensed by a magnetic or proximity sensing transducer (391), e.g., a Hall effect transducer, of the flow sensing means (333).

[0217] The module body (371) has two substantially flat, parallel faces, a first face (393) that includes an inlet region (377) and an outlet region (381), and a second face (395) to which a temperature sensing element (385) is attached. The mixing chamber (379) is located between the first face (393) and the second face (395). All of the fluid flows entering the inlet region (377) and leaving the outlet region (381) are through a single plane of the first face (393).

[0218] In this embodiment, the two fluid control valve assemblies (315, 317) and the mixing and sensing module (337) are combined to form an electronically controllable mixing valve assembly. The mixing valve assembly is an integral part of the replaceable valve cartridge (311). The replaceable valve cartridge (311) further includes a control system including an integrated circuit (397) configured to receive input from the mixing and sensing module (337) and control the operation of the electric motor (347) of each fluid control valve assembly (315, 317). The integrated circuit (397) is contained within a control box housing (399) and a control box lid (401) secured to the module body (371). As with other embodiments described herein, the control system is configured to receive command inputs from a variety of means, such as a manual rotary knob, WiFi, Bluetooth, or other data transmission.

[0219] As described above, the replaceable valve cartridge (311) has two inlet ports and one outlet port, all located on a single engagement feature in the form of a substantially flat mating surface (323). The substantially flat mating surface (323) includes structure in the form of an O-ring groove configured to hold an elastomeric O-ring seal. The elastomeric seal is disposed around the connection of each inlet and outlet port (319, 321) to a fixed valve fitting (325) and is used to create a leak-proof seal. The leak-proof seal is established between the mating surface (323) of the valve cartridge (311) and a complementary engagement feature of the fixed valve fitting (325), which provides a substantially flat surface that contacts and compresses the elastomeric seal.

[0220] The replaceable valve cartridge (311) is configured to or allows for a mechanical fastening system to securely hold the replaceable valve cartridge to the fixed valve fitting (325). In this embodiment, two machine screws (not shown) are threaded through two machine threaded holes (327) and threaded into two internally threaded holes in the fixed valve fitting (325) and then tightened to secure the valve cartridge (311) to the fixed valve fitting (325) to compress an elastomeric O-ring seal and form a leak-proof seal. This method of mounting and sealing allows for easy and quick replacement of the replaceable valve cartridge (311) when necessary, and can be performed without specialized plumbing training.

[0221] The fixed valve fitting (325) is a plumbing hardware device that can be permanently installed in a piping system and fixed to the building structure. The fixed valve fitting (325) is permanently connected to two fluid supplies, e.g., hot and cold water supplies, and to an outlet pipe, e.g., a pipe that supplies temperature conditioned water to a shower rose. This configuration allows the valve cartridge (311) to be replaced or repaired without having to disconnect any permanent plumbing connections.

[0222] The valve cartridge (311) or fixed valve fitting (325) may be fitted with a filter and a check valve, if required.

[0223] The valve cartridge (311) may be powered by a wired connection to a power source, but alternatively, it is envisioned that the valve cartridge (311) may be powered by inductive power transfer. For example, an inductive power transfer module may be provided in the fixed valve fitting (325) and a corresponding inductive power transfer module may be provided in the valve cartridge (311), such that when the valve cartridge (311) is connected to the fixed valve fitting (325), the two inductive power transfer modules are adjacent to one another.

[0224] A working model of the valve cartridge (311) has been constructed and tested by the inventors. The constructed valve cartridge (311) is 90x80x64mm in size and is capable of handling a flow rate of approximately 14 liters per minute, which is sufficient for most home showers. This cartridge size can be compared to competing electronically controllable mixing valve modules currently on the market that are 240x180x68mm in size. This dramatic reduction in overall size allows the valve cartridge (311) to be mounted in a much more convenient and accessible location, for example, the valve cartridge (311) can be mounted within shower control modules, fittings or housings currently designed to accommodate manual shower mixing valves.

[0225] 26 illustrates an alternative box member (363A) for the valve member housing (329) in which the passages connecting the alternating inlet ports (319A) and the alternating outlet ports (321A) are passages having right angle turns such that the inlet ports (319A) and outlet ports (321A) lie in a plane perpendicular to the direction of motion of the linear actuator (349).

[0226] In this alternative configuration, the direction of fluid flow through the fluid inlet (319A) and fluid outlet (321A) is a flow direction that is substantially aligned with the direction of the axis of rotation of the electric motor (347). The direction of flow through the inlet port (319A) and outlet port (321A) is also aligned with the direction of motion of the linear actuator (349) and the direction of movement of the moveable valve member (339).

[0227] This alternative configuration allows the electronically controllable mixing valve cartridge (311) to be constructed with a smaller profile when viewed in the direction in which the valve cartridge (311) engages the fixed valve fitting (325). That is, in this alternative configuration, the valve cartridge (311) can be mounted in a smaller opening in a wall or shower lining as a result of the smaller profile when mounted to the fixed valve fitting (325). In this manner, the electronically controllable mixing valve cartridge (311) can be used in a similar manner to the first embodiment of the electronically controllable mixing valve cartridge (11) shown in FIG.

[0228] Sixth embodiment 26 and 27, an alternative valve member configuration (411) is described which may be used in an electronically controlled mixing valve cartridge of the type described herein with appropriate modifications to the valve member housing to provide two inlet feeds to a single set of valve members which are used to control mixing using only a single actuator.

[0229] The single actuator includes an electric motor (413) and lead screw assembly (415) similar to the actuators shown in other embodiments herein. The significant difference with the alternative valve member configuration (411) is that a single moveable valve member (417) is used to control two inlet ports on a first stationary member (419). A first inlet port (421) on the inlet stationary member (419) can be connected to, for example, a cold water supply, and a second inlet port (423) on the inlet stationary member (419) can be connected to a hot water supply.

[0230] As with other embodiments described herein, the movable valve member (417) is sandwiched between two stationary valve members, all of which are made from a ceramic material. In this case, the movable valve member (417) is sandwiched between a first stationary member (419) and a second stationary member (425). The second stationary member (425) has an outlet port (427). The outlet port (427) has an overall size similar to the circumference of the first and second inlet ports (421, 423) combined. The movable valve member (417) has a control port (429) that is approximately half the size of the outlet port (427).

[0231] The movable valve member (417) can be said to move through four regions by the actuator. The four regions are: a first region in which the control port (429) is completely covered by a solid region of the first stationary member, whereby no fluid passes through the valve member assembly; a second region where the control port (429) is above the first inlet port (421) of the first stationary member, whereby only fluid from the first inlet port (421) can pass through the valve member assembly; a third region where the control port (429) is over both the first inlet port (421) and the second inlet port (423) of the first stationary member, whereby fluid from both the first inlet port (421) and the second inlet port (423) can pass through the valve member assembly; and The control port (429) is a fourth region above the second inlet port (423) of the first fixed member, the fourth region allowing only fluid from the second inlet port (423) to pass through the valve member assembly.

[0232] In this manner, the alternative valve member configuration (411) can control the mixing of two fluid streams using only a single actuator. The alternative valve member configuration (411) can be used in combination with a temperature sensor and an electronic control system to provide an electronically controllable mixing valve cartridge of the type described herein.

[0233] Variations It will be understood that aspects of the present invention have been described by way of example only and that modifications and additions can be made thereto without departing from the scope thereof.

[0234] Although some mixing valve assemblies described herein include only one electronically controllable mixing valve cartridge, it is envisioned to use multiple cartridges, for example assemblies supplying multiple showerheads from separate input panels.

[0235] The valve module assemblies described herein include a movable valve member that moves linearly. In an alternative embodiment, it is envisioned that the valve module assembly includes a rotatable movable valve member, such as a quarter-turn ceramic valve disc commonly used in manual mixing valves.

[0236] Similarly, although all of the examples described herein include two electrically powered actuators and two mating pairs of valve members, it is envisioned that the valve may include only one mating pair and be operated by a single actuator.

[0237] Although the valves described herein include two fluid inlets and one fluid outlet, it is envisioned that the same operating principles and components can be used to manage more than two fluid inlets and any number of fluid outlets. Similarly, multiple temperature sensors can be used to accommodate alternative embodiments.

[0238] The movable and fixed valve members are made of a ceramic material and each may be made of a different ceramic material to reduce friction, for example, one of a pair of mating valve members may be made of alumina and the other of zirconia, silicon carbide or silicon nitride.

[0239] In the embodiment described herein, the two housing members are made of a plastic material and welded together, however, it is also envisioned that the two housing members could be held together by mechanical fasteners and made of a metal, such as brass.

[0240] All of the embodiments described herein include electrically powered actuators, although other means of powering the actuators are envisioned, such as hydraulically driven actuators (e.g., using water pressure) or pneumatically driven actuators.

[0241] The electronic control system of either the valve cartridge or the mixing valve assembly may be configured to receive mechanical input from a local input device or user interface having a manually operated knob, lever, or similar manually controlled device.

[0242] The electronically controllable mixing valve cartridge may optionally include one or more flow sensors, for example for use in managing water usage or as an alternative method of controlling temperature.

[0243] Optionally, the electronically controllable mixing valve cartridge may include a turbo-generator configured to generate electrical energy as fluid flows through the valve cartridge.

[0244] The electronically controllable mixing valve cartridge may also include an emergency shut-off valve, e.g., a wax-tube actuated shut-off valve or diverter valve configured to prevent fluids above a selected temperature from exiting the valve cartridge for added safety, particularly in the event of a power outage.

[0245] The electronically controllable mixing valve cartridge can also include manual flow control and shutoff valves to improve safety and reduce the work done by the actuator. In this option, the actuator only controls the flow and not the shutoff role, thereby reducing the power used by the electronically controllable mixing valve cartridge.

[0246] The coupling between the electric motors and the movable valve members may take a variety of forms. For example, in an alternative embodiment, the movable valve members may be directly coupled to their respective electric drive motors via threaded couplings. A threaded shaft that is part of or connected to the movable valve members may, as one option, engage with internal threads formed in the main shaft of the electric motor.

[0247] The mechanical connection between the linear actuator and the moveable valve member, which includes a mating "T" shaped slot and protrusion, may alternatively include a protrusion on the moveable valve member and a slot on the linear actuator.

[0248] It is contemplated that the one or more fixed valve members may take the form of a valve seat formed in the valve member housing. It is also contemplated that the valve technology described herein may be used to manufacture flow control valves, for example, flow control valves having one inlet, one outlet and a flow sensor.

[0249] definition Throughout this specification the word "comprise" and variations thereof such as "comprises" and "comprising" are not intended to exclude other additives, components, integers or steps.

[0250] advantage It can be seen that at least preferred forms of the present invention provide an electronically controllable mixing valve cartridge that is simpler and easier to install and replace, thereby reducing labor costs. The relatively small size of the valve cartridge means that it can be installed in the same locations as currently used manually operated mixing valves and can be connected to the same style fittings.

[0251] The cartridge design is also intended to reduce valve size and valve cost without compromising the expected reliability of the electronically controllable valve of which it is a part.

[0252] The mixing valve assembly is similarly simple and compact, reducing manufacturing costs and increasing installation flexibility.

[0253] By using two valve assemblies in a mixing valve, both the total flow and the mixing can be adjusted or controlled independently.

[0254] The use of ceramic valve members provides reliable sealing and long life.

[0255] The linear motion of the movable valve member allows actuation using a relatively small electric motor and lead screw combination which is low cost and powerful enough to reliably move the movable valve member even when it is partially stuck, for example when the valve is dried out.

[0256] The mixing and sensing module described herein allows for useful feedback on temperature and flow rate to be obtained within a very compact valve cartridge. The swirling action within the mixing chamber rapidly mixes the two fluid streams, and the mixing chamber provides a suitable location for a flow sensing paddle wheel.

[0257] The combination of reliable valve actuation and accurate feedback provides a highly convenient electronically controllable mixing valve cartridge that can be easily configured for easy installation and removal.

Claims

1. 1. An electronically controllable mixing valve cartridge, comprising: At least two fluid inlets and at least one fluid outlet; At least one temperature sensor; at least one moveable valve member and at least one actuator configured to move the moveable valve member; a valve cartridge comprising: an electronic control system configured to receive input from an input device and configured to receive input from a temperature sensor to control operation of the actuator.

2. 2. The valve cartridge of claim 1, The valve cartridge, wherein the actuator includes an electric motor.

3. 3. The valve cartridge according to claim 2, A valve cartridge, wherein a direction of fluid flow through the fluid inlet and the fluid outlet is substantially along an axis of rotation of the electric motor.

4. The valve cartridge according to any one of claims 1 to 3, The valve cartridge, wherein the actuator includes a linear actuator.

5. 5. The valve cartridge according to claim 4, A valve cartridge, characterized in that the direction of fluid flow through the fluid inlet and the fluid outlet is a flow direction that is substantially aligned with a direction of movement of a movable valve member.

6. 6. The valve cartridge according to claim 1, The valve cartridge is configured to mate with a complementary fixed valve fitting connectable to a pipe of a plumbing fixture, the complementary fixed valve fitting having a complementary fluid outlet and one or more fluid inlets.

7. 7. The valve cartridge according to claim 6, The valve cartridge includes one or more engagement features configured to establish a sealed connection between each fluid inlet and fluid outlet of the valve cartridge and a fixed valve fitting.

8. 8. The valve cartridge according to claim 1, A valve cartridge comprising a mixing chamber configured to mix two or more fluid streams, the mixing chamber being located downstream of a movable valve member and upstream of at least one temperature sensor.

9. 9. The valve cartridge of claim 8, The valve cartridge includes a transfer passage through which the fluid flows as the fluid approaches the mixing chamber, the transfer passage being configured to generate a vortex motion within the mixing chamber.

10. 10. The valve cartridge of claim 9, A valve cartridge, characterized in that the mixing chamber is substantially cylindrical, and the transfer passages are each configured to direct fluids in a direction substantially tangential to a circle defining an outer periphery of the cylindrical mixing chamber.

11. 11. The valve cartridge according to claim 9 or 10, A valve cartridge characterized in that the cross-sectional area of ​​the transfer passage decreases along the direction of flow towards the mixing chamber.

12. A valve cartridge according to any one of claims 1 to 11, The valve cartridge further comprises a flow sensing means.

13. 13. The valve cartridge of claim 12, A valve cartridge, wherein the flow sensing means includes a rotating element that is rotated by swirling fluid within the mixing chamber.

14. 14. The valve cartridge according to claim 12 or 13, A valve cartridge characterized in that a temperature sensing element of the temperature sensor is supported on a probe or shaft, and a rotating element rotates about an axis coaxial with the shaft or probe.

15. A valve cartridge according to any one of claims 4 to 14, The valve cartridge, wherein the linear actuator includes a lead screw assembly.

16. 16. A valve cartridge according to any one of claims 1 to 15, A valve cartridge, wherein the movable valve member is a ceramic valve member.

17. 17. A valve cartridge according to any one of claims 1 to 16, A valve cartridge, wherein the movable valve member is elongated in shape, and the linear movement of the movable valve member is along the length of the elongated shape.

18. 18. A valve cartridge according to any one of claims 1 to 17, A valve cartridge, wherein the at least two fluid inlets and the at least one fluid outlet are all located on a single substantially planar surface.

19. 19. A valve cartridge according to any one of claims 1 to 18, A valve cartridge, characterized in that the valve cartridge is configured such that a mechanical fastening system is capable of securely holding the valve cartridge relative to a fixed valve fitting.

20. 1. An electronically controllable mixing valve assembly comprising:

20. A mixing valve cartridge comprising: an electronically controllable mixing valve cartridge according to any one of claims 1 to 19; and a fixed valve joint, An electronically controllable mixing valve cartridge is connectable to a fixed valve fitting by a mechanical fastening system; 1. An electronically controllable mixing valve assembly, comprising: a fixed valve fitting connectable to a building's piping system and configured to direct fluid to at least two fluid inlets of the valve cartridge and to receive fluid from at least one fluid outlet of the valve cartridge, and configured to establish a leak-proof seal between mating features of the electronically controllable mixing valve cartridge and complementary mating features of the fixed valve fitting.

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