Electronically Controllable Valves and Mixing Valves

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, particularly 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, used to provide uniformly hot water to showerheads and sinks, for example.

[0003] The valve is typically housed in a housing which also contains an electronic control system, actuator, temperature sensing elements, etc. The housing also has separate hot and cold water inlets and a combined 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] These devices can be quite large and are therefore often installed in residential wall cavities, cupboards, lofts, or ceiling spaces. Typical dimensions for currently available devices are around 250 x 200 x 70 mm. They are usually very expensive, and some of them have significant reliability issues. They connect directly to the residential plumbing, and this connection usually requires a watertight threaded assembly.

[0006] In addition to the many watertight plumbing connections, e.g., screws and sealed joints, that must be severed 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, they may be some distance from the shower, which can increase the time lag between setting the desired temperature and receiving water at that temperature at the shower head.

[0007] Reliability issues, replacement costs, and difficulty in accessing, removing, and replacing 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 below the cover plate of the interface unit. A simpler, more reliable, and less expensive to manufacture electronically controllable mixing valve would also be beneficial.

[0009] Unless expressly stated to the contrary, where any 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 known to be relevant to any 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 towards 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 can 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 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 a 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 the 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 electric actuator, but preferably the valve actuator is an electric actuator including an electric motor.

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

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

[0019] Preferably, the electric motor rotates a threaded spindle of the 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 movable 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 slot or protrusion allows the complementary mating feature of the linear actuator to slide into engagement with the slot or protrusion, and is configured to prevent rotation of the complementary feature of the linear actuator relative to the movable valve member and to prevent 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 movable 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 movable 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 present invention can be broadly described as a mixing and sensing module for an electronically controllable fluid mixing valve, comprising a body and temperature sensing means, the body having two or more inlet regions, a mixing chamber and an outlet region, each inlet region connected to the mixing chamber by an associated transfer passage, the mixing chamber communicating with the inlet region and the outlet region, each transfer passage configured to impart a vortex motion to 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 passes 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 the periphery of the cylindrical mixing chamber.

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

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

[0034] Preferably, the flow rate 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 comprises 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 detection module has two inlet regions.

[0041] Preferably, the body has two substantially parallel faces, namely a first face including the inlet region and the outlet region 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 invention can be broadly stated to comprise a mixing valve assembly having two or more fluid control valve assemblies substantially as specified herein.

[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 input from each mixing and sensing module and control operation of the electric 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 flat plane.

[0048] Preferably, the replaceable valve cartridge is configured such that a mechanical fastening system securely holds 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 and 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 retain a movable valve member against a valve seat and permit only linear movement of the movable valve member relative to the valve seat, the valve assembly configured to drive a lead screw assembly by an electric motor, the lead screw assembly configured to move the movable valve member to cause linear movement of the movable valve member and control fluid flow through the valve assembly.

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

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

[0052] Preferably, the valve assembly further includes a top plate made 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 movable 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 passageway, a first open end of the "C" shaped passageway communicating with a first passageway in the valve seat member and a second open end of the "C" shaped passageway communicating with a second passageway 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 can be broadly described as comprising a valve module assembly including two or more valve assemblies substantially as specified herein.

[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 movable valve member and at least one actuator configured to move the movable 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 fluid outlets of the valve cartridge and the complementary fluid outlets and fluid inlets of the fixed valve fitting.

[0062] Preferably, the direction of fluid flow through the fluid inlet and each fluid outlet is in 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 connection 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 includes an elastomeric seal that provides 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 comprises a bayonet fixation system or one or more mechanical fixators, 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 manual control 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 the 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: Accepts fluid flows 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 they meet.

[0084] Preferably, the fluid mixing module includes a mixing chamber where the fluid streams meet, the mixing chamber having a first diameter in the 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 so that the fluid streams each enter the mixing chamber from a direction substantially tangential to the 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 the outlet portion of the module from 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 means for holding stored electrical energy, for example a capacitor or provision for one or more batteries.

[0094] Optionally, the electronically controllable mixing valve cartridge includes a turbine-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 on a single mating surface and engages with a fluid outlet and a fluid inlet 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 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 opposite 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, the fixed valve fitting housing having a first fluid outlet at a first end of the housing, a second fluid outlet at an opposite second end of the housing, and a fluid inlet located 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 defined herein 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 movable valve member and at least one actuator configured to move the movable 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 direction of flow 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 the 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 positioned 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 the transfer passages are each 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 rate 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 the probe or shaft and the rotating element rotates about an axis coaxial with the shaft or probe.

[0121] Preferably, the flow sensing means comprises 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 associated two 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 comprising an electronically controllable mixing valve assembly comprising an electronically controllable mixing valve cartridge substantially as defined herein 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: removing a malfunctioning electronically controllable mixing valve cartridge, substantially as specified herein, from a fixed valve fitting; and attaching a replacement electronically controlled mixing valve cartridge to the fixed valve fitting.

[0132] The present invention may be broadly described as consisting of the components, elements and features, individually or collectively, referred to or shown in this specification, 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 explanation of the drawings]

[0133] Further aspects of the present 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. [Figure 2] FIG. 2 is an exploded perspective view of a first embodiment of an electronically controllable mixing valve cartridge. [Figure 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. [Figure 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 the fluid mixing module of the second embodiment of the electronically controllable mixing valve cartridge. [Figure 11] FIG. 11 is a plan 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 of the fifth embodiment of the mixing valve assembly taken along line AA. [Figure 22] FIG. 22 is a cross-sectional view taken along line BB of a fifth embodiment of the mixing valve assembly. [Figure 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. [Figure 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 INVENTION

[0134] Four embodiments of removable electronically controllable mixing valve cartridges according to the present invention are described below with reference to Figures 1-15 and 18-26. Figures 16 and 17 relate to mixing valve assemblies having similar features to the electronically controllable mixing valve cartridges, but without the removable cartridge features. Figures 27 and 28 illustrate alternative valve member configurations for mixing valves that are more compact and use 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 with 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, etc.

[0136] A mixing valve assembly typically includes one replaceable, electronically controllable mixing valve cartridge configured to engage a complementary fixed valve fitting, which 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 features of the three cartridge embodiments described herein are generally the same, 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 surface of the fixed valve fitting. Other cartridges have a tongue configured to engage a complementary socket of the fixed valve fitting, with the tongue forming a fluid-tight seal with two interior surfaces of the socket of the fixed valve fitting. In yet another example, the fixed valve fitting includes a housing configured to completely enclose the electronically controllable mixing valve cartridge, with fluid-tight seals formed on three surfaces 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 removed from a fixed valve fitting and a replacement electronically controllable mixing valve cartridge can be installed into the now emptied 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 replaced easily and quickly, 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). The cartridge (11) further 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 the operation of the actuator (21). The input device may be a remote control panel, for example, having one or more push-button, touchscreen, 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 framing of a building. The fixed valve fitting (25) can be permanently or at least semi-permanently connected to a pipe in the building's 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 outlets (27) and fluid inlet (29) of the fixed valve fitting (25).

[0145] The sealing 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 positioned on the cartridge mating surface (33) of the cartridge, respectively, and 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, each of which engages a fixed ceramic valve seat (37). Each movable valve member (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 the 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 the 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 central movable valve member (19), and one valve seat (37), and the valve sandwich is firmly held between a valve housing body (39) and a valve housing base (40). During manufacture, the valve housing body (39) and valve housing base (40) are clamped together to impart the desired compressive load to the valve sandwich, after which the valve housing base (40) is permanently secured 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 driven by the 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 so 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), movable valve member (19), valve seat (37), electric actuator (21), valve housing body (39), and 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 the upper surface of the cartridge body (41) and the lower surface 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 positioned 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 vortices in the fluid flowing through the fluid outlets (15). This vortex action is believed to be important for accelerating the mixing of the fluids, for example the mixing of hot and cold water streams, 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, cartridge 11 includes a fluid mixing chamber 63, which is located within a fluid mixing module 65 of cartridge 11. The principles of 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 locking system securely holds the valve cartridge 11 in the fixed valve fitting 25. In this example, an outer housing 53 is used to secure 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, and when the outer housing 53 is turned onto the male threads 54, an inner shoulder (not shown) of the outer housing 53 bears against an outer shoulder 55 of the cartridge 11. 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 into an electronic signal and transmitted to the printed circuit board 23 of the cartridge 11's built-in electronic control system via, for example, electrical contacts, inductive data transfer, WiFi, etc.

[0157] The printed circuit board (23) is placed in 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 be an electrical connection via inductive power transfer or alternative contactless means. The cartridge (11) can also include a means for retaining stored electrical energy, such as a capacitor or provision for one or more batteries. The ability to retain stored electrical energy is advantageous in that the cartridge (11) can be configured to shut off the flow of water to the shower, for example, in the event of a mains power outage. This safety feature minimizes the possibility of personal injury 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 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 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 movable 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. This 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 outlined below.

[0163] The main difference between the first and second embodiments is that the second embodiment mates with fluid connections on two sides of the second fixed valve fitting (83). The valve cartridge fluid inlet (85) is located on a first mating surface (87) of the valve cartridge (81), and the valve cartridge fluid outlet (89) is located on a second mating surface (91). The valve cartridge (81) is configured to mate with the fluid outlet (93) and 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 surface (87) and the second mating surface (91) are located on a tongue (99) of the cartridge (81), which is fitted within 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 on 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 other.

[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), which will be described later.

[0167] The top plate (107), movable valve member (109), and valve seat (111) each contain a through passageway. Fluid flows through one movable valve member (109) when the through passageway in that movable valve member (109) is partially or fully aligned with the through passageway in its associated top plate (107) and valve seat (111). Each movable valve member (109) can be moved linearly relative to its associated valve seat (111) by an actuator (113) 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 fluid mixing module 65 of the first embodiment. Fluid mixing module 121 has two intermediate channels 123, each channel directing fluid to a combined fluid mixing chamber 125. Mixing chamber 125 is located in the region 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. In this case, the fluids are received into each of the intermediate channels (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 within the fluid mixing chamber (125).

[0170] The mixing chamber (125) has a first diameter (126) in 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 particularly the intermediate channel (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 the 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 mixing.

[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 enabling 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 is held in place by machine screws 101. While a cylindrical cap is used in this example, it is envisioned that the cap 133 can be 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, and this input is 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 outlined 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-sided fluid connections of a third fixed valve fitting (163). One fluid inlet (165) of the valve cartridge (161) is located on a first mating surface (167) on one face or end of the valve cartridge (161), a second fluid inlet (165) is located on a second, opposite mating surface (169) on the other face or end of the valve cartridge (161), and a fluid outlet (171) of the valve cartridge (161) is located on a third mating surface (173) that is located between the first mating surface (167) and the second mating surface (169) and is oriented perpendicular to those surfaces.

[0179] The valve cartridge (161) is configured to mate with fluid outlets (175) and fluid inlets (177) located on three separate or distinct faces of a cavity (179) within a central housing (181) of the fixed valve fitting (163). The first mating face (167) and second mating face (169) are located at opposite ends of a substantially cylindrical body (183) of the cartridge (161). 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 is located on a substantially opposite side of the cylindrical body 183 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 the central housing (181) of the 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 approximately 150-250 millimeters apart. In this manner, the fixed valve fitting (163) can be fixed to a building's piping system.

[0182] 14 and 15, it can be seen that the fixed valve fitting (163) comprises 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) comprises a fitting configured to connect to one of a pair of water pipe connections in a building, and the second end fitting (195) also comprises 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), which are configured to mate 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), which is configured to mate with and form a fluid-tight seal with the fluid outlet (171) of the cartridge (161). In this manner, the fluid inlet (177) is centrally located 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 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 electric actuators 199 are located at opposite ends of cylindrical body 183. In this manner, the two valve sandwich assemblies of valve module 197 are mirror images of the two identical valve assemblies of valve module 49.

[0186] Note that cylindrical body (183) also forms the valve housing body and valve housing base of valve module (197). The top plate (201) of the valve module is attached to cylindrical body (183) using four machine screws (203), which keep the fixed and moving 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 down between the valve components 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 fabricated 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 Example 16 and 17, a mixing valve assembly (241) according to another embodiment of the present invention will now be described. 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 fluid inlet port nor outlet port 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] Valve module assembly (243) has a flat base that engages with machined surface (261) of valve body (245). A first valve inlet port (249), a second valve inlet port (253), and two valve outlet ports (255) are located on machined surface (261). When valve module assembly (243) is attached to valve body (245) using six machine screws (263), a fluid-tight seal is created between each of ports (249), (253), and (255) and the corresponding port on the bottom of 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 movable 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 achieve 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 the circle defining the circular passageway. This causes the fluid entering the circular passageway to swirl, which aids in the 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 piping, requiring only three pipe connections and power and data connections. Its size allows for easy installation in wall cavities or other locations suitable for plumbing installations.

[0199] Fifth Example 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 primary 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 when exiting the valve cartridge (311). In the valve cartridge (311), the mixed fluid exits through a mixed fluid outlet channel (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 on the fixed valve member (325). In this embodiment, the valve cartridge (311) is fastened to the fixed 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 a 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 of a ceramic-based material. All of the valve members (339, 341) are elongated in shape, with straight sides and rounded ends, and 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), the flow of fluid through which 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). If the passageways (345) do not overlap at all, flow will be zero, and as the passageways (345) move towards perfect alignment, flow will increase, with a range of flow occurring at points in between.

[0205] Valve actuator (343) can include a manually operated lever or rotatable knob or handle, or an electrically powered actuator, and in this example, valve actuator (343) is a powered actuator including an electric motor (347) and a linear actuator (349). Linear actuator (349) is coupled to movable valve member (339). In this example, 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] Sleeve (353) is connected to or directly coupled to movable valve member (339). In this embodiment, the coupling is achieved by engaging a "T"-shaped projection (355) on the free end of sleeve (353) with a complementary "T"-shaped slot (357) on one end of movable valve member (339). "T"-shaped slot (357) is configured to allow the complementary projection (355) to slide into engagement with slot (357), while simultaneously preventing rotation of projection (355) relative to movable valve member (339). Linear movement of sleeve (353) relative to movable valve member (339) in the intended direction of movement of movable valve member (339) during use is also prevented by the "T"-shaped joint between projection (355) and 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 movement of the movable valve member (339) and hold the fixed valve member (341) in place.

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

[0210] The electric motors (347) are mounted on the outside of the valve member housing (329) and are held fixed relative to the valve member housing (329). The two electric motors (347) used in the electronically controllable mixing valve cartridge (311) are housed 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 accept 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, narrowing along the direction of flow and 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 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), forcing the fluid to travel through a narrow gap, thereby accelerating the fluid as it travels 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 while 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 firmly held to the shaft (389) by a retaining ring (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 surfaces: a first surface (393) that includes an inlet region (377) and an outlet region (381), and a second surface (395) to which a temperature sensing element (385) is attached. The mixing chamber (379) is located between the first surface (393) and the second surface (395). The fluid flow into the inlet region (377) and the fluid flow out of the outlet region (381) all occur through a single surface, the first surface (393).

[0218] In this embodiment, two fluid control valve assemblies (315, 317) and a mixing and sensing module (337) are combined to form an electronically controllable mixing valve assembly. The mixing valve assembly is an integral part of a 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 housed within a control box housing (399) and 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, Wi-Fi, 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 retain 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-tight seal. The leak-tight seal is established between the mating surface (323) of the valve cartridge (311) and complementary engagement features of the fixed valve fitting (325), which provide a substantially flat surface that contacts and compresses the elastomeric seal.

[0220] The replaceable valve cartridge 311 is configured to securely hold the replaceable valve cartridge to the fixed valve fitting 325 via a mechanical fastening system, or to allow for such a system to be configured. In this embodiment, two machine screws (not shown) are threaded through two machine-threaded holes 327, threaded into two internally threaded holes in the fixed valve fitting 325, and tightened to secure the valve cartridge 311 to the fixed valve fitting 325, compressing an elastomeric O-ring seal to form a leak-tight seal. This method of attachment and sealing allows for easy and quick replacement of the replaceable valve cartridge 311 as needed, and the replacement 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 secured to the building structure. The fixed valve fitting (325) is permanently connected to two fluid supplies, such as hot and cold water supplies, and to an outlet pipe, such as a pipe that supplies temperature-regulated water to a shower rose. This configuration allows the valve cartridge (311) to be replaced or repaired without disconnecting the permanent plumbing connections.

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

[0223] While the valve cartridge 311 may be powered by a wired connection to a power source, it is alternatively contemplated 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 the two inductive power transfer modules are adjacent to each other when the valve cartridge 311 is connected to the fixed valve fitting 325.

[0224] A working model of the valve cartridge (311) has been constructed and tested by the inventors. The constructed valve cartridge (311) measures 90 x 80 x 64 mm and can handle a flow rate of approximately 14 liters per minute, sufficient for most home showers. This cartridge size is comparable to competing electronically controllable mixing valve modules currently on the market, which measure 240 x 180 x 68 mm. 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] Figure 26 shows an alternative box member (363A) for valve member housing (329) in which the passages connecting alternating inlet ports (319A) and alternating outlet ports (321A) are passages having right-angle bends such that the inlet ports (319A) and outlet ports (321A) lie in a plane perpendicular to the direction of movement of linear actuator (349).

[0226] In this alternative configuration, the direction of fluid flow through the fluid inlet (319A) and fluid outlet (321A) 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 movement of the linear actuator (349) and the direction of movement of the movable valve member (339).

[0227] This alternative configuration allows the electronically controllable mixing valve cartridge (311) to be constructed with a reduced 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 its 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 manner similar to the first embodiment of the electronically controllable mixing valve cartridge (11) shown in FIG.

[0228] Sixth Example 26 and 27, an alternative valve member configuration (411) is described which can 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 key difference from the alternative valve member configuration (411) is the use of a single movable valve member (417) 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 of 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 combined first and second inlet ports (421, 423). 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, and 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 in which the control port (429) is located above both the first inlet port (421) and the second inlet port (423) of the first stationary member, allowing fluid from both the first inlet port (421) and the second inlet port (423) to pass through the valve member assembly; and A 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 feeding multiple showerheads from separate input panels.

[0235] The valve module assemblies described herein include a linearly moving movable valve member. In an alternative embodiment, it is contemplated 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 operated actuators and two mating pairs of valve members, it is also 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 valve member and the fixed valve member are made of a ceramic material, and each can be made of a different ceramic material to reduce friction; for example, one of a pair of mating valve members can be made of alumina and the other can be made 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 made of a metal, such as brass, with mechanical fasteners holding them together.

[0240] All of the embodiments described herein include electrically powered actuators, although other means of powering the actuators are also 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 can be configured to receive mechanical input from a local input device or user interface having a manually operated knob, lever, or similar manual control 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 turbine-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, for example, a wax-tube actuated shut-off valve or diverter valve configured to prevent fluid 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 actuator effort. In this option, the actuator controls only the flow rate and not the shutoff function, thereby reducing the power used by the electronically controllable mixing valve cartridge.

[0246] The coupling between the electric motors and the movable valve members can take a variety of forms. For example, in an alternative embodiment, the movable valve members can 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 can optionally engage internal threads formed in the main shaft of the electric motor.

[0247] The mechanical connection between the linear actuator and the movable valve member, which includes an engaging "T" shaped slot and protrusion, can alternatively have the protrusion on the movable valve member and the slot on the linear actuator.

[0248] It is contemplated that the one or more stationary 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 location 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 rate 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 dry.

[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 operation and accurate feedback provides a highly convenient electronically controllable mixing valve cartridge that can be easily configured for easy installation and removal.

Claims

1. An electronically controllable mixing valve, the mixing valve comprising: at least two fluid inlets and at least one fluid outlet; at least one temperature sensor; at least one movable valve member and at least one actuator configured to move the movable valve member; a mixing chamber configured to mix two or more fluid streams, the mixing chamber being located downstream of the movable valve member and upstream of the at least one temperature sensor; 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; 1. A mixing valve, wherein the mixing chamber includes a flow sensing means, the flow sensing means including a rotary element, the flow sensing means configured to provide fluid flow feedback to an electronic control system.

2. In the mixing valve according to claim 1, A mixing valve characterized in that the rotating element of the flow rate detection means rotates due to the swirling flow in the mixing chamber.

3. The mixing valve according to claim 1, The mixing valve includes a transfer passage through which the fluid flows as it approaches the mixing chamber, the transfer passage being configured to generate a vortex motion within the mixing chamber.

4. The mixing valve according to any one of claims 1 to 3, A mixing valve characterized in that the mixing chamber is substantially cylindrical.

5. The mixing valve according to claim 3 or 4, A mixing valve, wherein the transfer passages are configured to direct fluids in directions substantially tangential to a circle defining the outer periphery of the cylindrical mixing chamber.

6. A mixing valve according to any one of claims 1 to 5, A mixing valve characterized in that the rotating element is in the form of a paddle wheel.

7. A mixing valve according to any one of claims 1 to 6, The temperature sensor comprises a probe or shaft disposed within the mixing chamber, the probe or shaft supporting a temperature sensing element configured to sense the temperature of the mixed fluid as it moves toward the at least one fluid outlet.

8. The mixing valve according to claim 7, A mixing valve characterized in that the rotating element is supported by a probe or shaft that supports a temperature sensing element.

9. The mixing valve according to claim 8, A mixing valve characterized in that the rotating element rotates about an axis coaxial with the probe or shaft.

10. A mixing valve according to any one of claims 1 to 9, A mixing valve, wherein the rotating element includes one or more magnetically sensitive objects configured to be sensed by a magnetic or proximity sensitive transducer of the flow sensing means.

11. The mixing valve according to claim 3, A mixing valve characterized in that the cross-sectional area of ​​the transfer passage decreases along the direction of flow towards the mixing chamber.

12. A mixing valve according to any one of claims 1 to 11, A mixing valve characterized in that the mixing valve is in the form of a replaceable cartridge.

13. A mixing valve according to any one of claims 1 to 12, A mixing valve characterized in that at least two fluid inlets and at least one fluid outlet are on the same side of a single mounting surface.

14. The mixing valve according to claim 13, A mixing valve characterized in that the single mounting surface is a substantially flat surface.

15. The mixing valve according to any one of claims 1 to 14, A mixing valve configured to engage a complementary fixed valve fitting connectable to a pipe of a plumbing fixture and having a complementary fluid outlet and fluid inlet.

16. The mixing valve according to claim 15, A mixing valve characterized in that the mixing valve includes one or more engagement features configured to establish a sealed connection between each fluid inlet and each fluid outlet of the mixing valve and a fixed valve fitting.

17. A mixing valve according to any one of claims 1 to 16, A mixing valve, wherein the actuator includes an electric motor and a lead screw assembly.

18. 18. The mixing valve according to any one of claims 1 to 17, A mixing valve characterized in that the movable valve member has an elongated shape, and the linear movement of the movable valve member is along the length direction of the elongated shape of the movable valve member.

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

19. A system comprising an electronically controllable mixing valve according to any one of claims 1 to 18 and a fixed valve joint, an electronically controllable mixing valve 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 mixing valve and to receive fluid from at least one fluid outlet of the mixing valve, and configured to establish a leak-tight seal between the electronically controllable mixing valve and the fixed valve fitting.

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