Fluid mixing assembly for valve cartridge

Abstract

An electronic valve assembly including a movable flow control element, a mixer operably coupled to the flow control element, and a temperature sensor configured to detect the temperature of water at a mixed water outlet.

Description

FLUID MIXING ASSEMBLY FOR VALVE CARTRIDGECross-Reference to Related Application

[0001] The present application claims priority to U.S. Provisional Patent Application Serial No. 63 / 616,706, filed December 31, 2023, the disclosure of which is expressly incorporated herein by reference.Background and Summary of the Disclosure

[0002] The present disclosure relates generally to an electronic valve cartridge and, more particularly, to an electronic valve cartridge including a temperature sensor and a mixing chamber.

[0003] The present disclosure relates to an electronic valve cartridge including a temperature sensor or thermistor received within a mixed water outlet passageway, and a mixer for mixing inlet cold water and inlet hot water before reaching the sensing tip of the thermistor. In one illustrative embodiment, the mixer provides impinging or swirling mixing of cold and hot water streams before reaching the thermistor tip. In another illustrative embodiment, an upper valve disk of a cycling valve has control ports which allow cold water and hot water inlet flows to pass through the disk to a chamber in a flow director or mixer where mixing occurs before the combined outlet flow returns through a central opening in the upper disk and reaches the thermistor tip.

[0004] Within the illustrative mixer, a cold water flow from a cold water port follows a path where it meets a hot water flow from a hot water port. Both cold water and hot water flows then continue in the same direction. Mixing is encouraged by two mechanisms in the illustrative mixer. First, an axial (e g., upward) direction of the hot water flow entering the mixer is perpendicular to an arcuate transverse direction of the cold water flow, and the cold water flow has no space or alternative path to divert around the hot water flow. Second, a spiral path provides both length and time for additional mixing of the cold water and hot water flows.

[0005] According to an illustrative embodiment of the disclosure, an electronic shower valve includes a valve body, and a valve cartridge received within the valve body. The valvecartridge includes an outer housing including an internal chamber defining a longitudinal axis, a cold water inlet in fluid communication with the internal chamber, and a hot water inlet in fluid communication with the internal chamber. A flow control element is supported for rotation about the longitudinal axis to control water flow through the cold water inlet and the hot water inlet. A motor assembly is operably coupled to the flow control element. A gear assembly operably couples the motor assembly and the flow control element, and is configured to rotate the flow control element.

[0006] According to a further illustrative embodiment of the present disclosure, an electronic shower valve includes a valve body, and a valve cartridge received within the valve body. The valve cartridge includes an outer housing having an internal chamber defining a longitudinal axis, a cold water inlet in fluid communication with the internal chamber, a hot water inlet in fluid communication with the internal chamber, and a movable flow control element supported for rotation about the longitudinal axis to control water flow through the cold water inlet and the hot water inlet. A mixer is operably coupled to the flow control element, and in fluid communication with the cold water inlet and the hot water inlet. A thermistor extends through the flow control element and the mixer, and is configured to detect a temperature of water provided to an outlet of the mixer.

[0007] According to another illustrative embodiment of the present disclosure, an electronic shower valve includes a valve body, and a valve cartridge received within the valve body. The valve cartridge includes an outer housing having an internal chamber defining a longitudinal axis, a cold water inlet in fluid communication with the internal chamber, a hot water inlet in fluid communication with the internal chamber, and a movable flow control element supported for rotation about the longitudinal axis to control water flow through the cold water inlet and the hot water inlet. A mixer is operably coupled to the flow control element, and in fluid communication with the cold water inlet and the hot water inlet. The mixer includes a body defining a spiral channel configured to fluidly couple the cold water inlet and the hot water inlet with a mixed water outlet. A thermistor extends through the flow control element and the mixer, and is configured to detect a temperature of water provided to the mixed water outlet.

[0008] Additional features and advantages of the present invention will become apparent to those skilled in the art upon consideration of the following detailed description of theillustrative embodiment exemplifying the best mode of carrying out the invention as presently perceived.Brief Description of the Drawings

[0009] The detailed description of the drawings particularly refers to the accompanying figures in which:

[0010] FIG. 1 is a perspective view of an illustrative electronic valve assembly of the present disclosure;

[0011] FIG. 2 is a cross-sectional view taken along line 2-2 of FIG. 1;

[0012] FIG. 3 is a front exploded perspective view of the electronic valve assembly ofFIG. 1, with a partial cutaway of the valve body;

[0013] FIG. 4 is a rear partially exploded perspective view of the valve cartridge of FIG. 3;

[0014] FIG. 5 is a front exploded perspective view of the valve disks of FIG. 3;

[0015] FIG. 6 is a rear exploded perspective view of the valve disks of FIG. 5;

[0016] FIG. 7 is a front plan view of the fixed valve disk of FIG. 3;

[0017] FIG. 8 is a rear plan view of the movable valve disk of FIG. 3;

[0018] FIG. 9A is a top plan view of the cooperating valve discs, with the fixed valve disc shown in phantom, and the movable valve disc shown in an off position;

[0019] FIG. 9B is a top plan view of the cooperating valve disks, with the fixed valve disk shown in phantom, and the movable valve disk shown rotated to a full cold water position;

[0020] FIG. 9C is a top plan view of the cooperating valve disks, with the fixed valve disk shown in phantom, and the movable valve disk shown rotated to a full mixed water position;

[0021] FIG. 9D is a top plan view of the cooperating valve disks, with the fixed valve disk shown in phantom, and the movable valve disk shown rotated to a full hot position;

[0022] FIG. 10 is a detailed cross-sectional view of the electronic valve assembly of FIG.

[0023] FIG. 11 is a rear perspective view of the mixer and the thermistor of the electronic valve assembly of FIG. 1 ;

[0024] FIG. 12 is a cross-sectional view of the mixer of FIG. 11, showing cooperating openings of the movable valve disk;

[0025] FIG. 13 is a block diagram of electrical components of the illustrative valve assembly of FIG. 1;

[0026] FIGS. 14A-14E are perspective views of illustrative embodiment mixers.

[0027] FIG. 15 is a perspective view of a further illustrative electronic valve assembly of the present disclosure;

[0028] FIG. 16 is a cross-sectional view taken along line 16-16 of FIG. 15;

[0029] FIG. 17 is a rear partially exploded perspective view of the valve cartridge of FIG.15;

[0030] FIG. 18 is a detailed cross-sectional view of the electronic valve assembly of FIG. 16;

[0031] FIG. 19 is a rear perspective view of the mixer and the thermistor of the electronic valve assembly of FIG. 15;

[0032] FIG. 20 is a perspective view of a further illustrative electronic valve assembly of the present disclosure;

[0033] FIG. 21 is a cross-sectional view taken along line 21-21 of FIG. 20;

[0034] FIG. 22 is a perspective view of the outer housing and the mixer of FIG. 20;

[0035] FIG. 23 is a first exploded perspective view of the outer housing and the mixer ofFIG. 22;

[0036] FIG. 24 is a second exploded perspective view of the outer housing and the mixer of FIG. 22;

[0037] FIG. 25 is a first cross-sectional view taken along line 25-25 of FIG. 21, showing the valve assembly in an off position;

[0038] FIG. 26 is a second cross-sectional view taken along line 25-25 of FIG. 21, showing the valve assembly in a full hot position;

[0039] FIG. 27 is a first temperature plot of water flowing through the mixer taken along line 27-27 of FIG. 20; and

[0040] FIG. 28 is a second temperature plot of water flowing through the mixer taken along line 28-28 of FIG. 20.Detailed Description of the Drawings

[0041] For the purposes of promoting and understanding the principles of the present disclosure, reference will now be made to the embodiments illustrated in the drawings, which are described herein.

[0042] With reference initially to FIGS. 1 and 2, an electronic shower valve 10 of the present disclosure includes a conventional valve body or fitting 12 of the type supported within a shower wall for receiving an illustrative electronic valve cartridge 14. The illustrative valve body 12 includes a first or cold water inlet 16, which is configured to be fluidly coupled to a conventional cold water supply 17, and a second or hot water inlet 18, which is configured to be fluidly coupled to a conventional hot water supply 19. The cold water inlet 16 includes a tubular body 20 defining a first or cold water inlet bore 22. Similarly, the hot water inlet 18 includes a tubular body 24 defining a hot water inlet bore 26. In the illustrative embodiment, the cold water inlet 16 is co-axially aligned with the hot water inlet 18.

[0043] The valve body 12 further illustratively includes a mixing valve housing 30 having an end wall 32 and a cylindrical sidewall 34 defining a cavity 36 defining a longitudinal housing axis 38. With reference to FIG. 2, a first or cold water supply port 40 extends through the end wall 32 and is in fluid communication with the cavity 36. Similarly, a second or hot water supply port 42 extends through the end wall 32 and is in fluid communication with the cavity 36.

[0044] With further reference to FIG. 1, the illustrative valve fitting 12 further includes a first outlet 44 and a second outlet 46. The first outlet 44 includes a tubular body 48 defining a first outlet bore 50, while the second outlet 46 includes a tubular body 52 defining a secondoutlet bore 54. In the illustrative embodiment, the first and second outlets 44 and 46 are coaxially aligned and extend substantially perpendicular to the hot and cold water inlets 16 and 18. A connecting bore 56 illustratively fluidly couples the first and second outlet bores 50 and 54 and, in turn, is fluidly coupled to the cavity 36.

[0045] In one illustrative embodiment, the first outlet 44 is configured to be fluidly coupled to a conventional shower head 43 through a shower riser 45. Further illustratively, the second outlet 46 is configured to be fluidly coupled to a conventional tub spout 47, illustratively including a diverter valve (not shown), through a delivery pipe 49. An illustrative arrangement is shown in U.S. Pat. No. 4,899,397 to Crawford et al., the disclosure of which is expressly incorporated herein by reference. In a further illustrative embodiment, an aspirator or ejector (not shown) may be positioned within the connecting bore 56 to produce a vacuum when water is flowing through the tub spout 47, thereby reducing leakage through the shower head 43.

[0046] The valve body 12 may be formed of a metal (e.g., brass) and, for example, may be a Multi Choice® Universal Tub / Shower Rough-Universal Inlets / Outlets Model # R10000- UNBX available from Delta Faucet Company of Indianapolis, Indiana. Additional details of an illustrative valve body 12 are shown in U.S. Patent No. 7,819,134 to Izzy et al., the disclosure of which is expressly incorporated by reference herein.

[0047] With reference now to FIGS. 2-4, the electronic valve cartridge 14 illustratively includes an outer housing 60, flow control members 62 and 64, and a drive device 66. An o-ring 67 illustratively provides a seal between the outer housing 60 of the valve cartridge 14 and the housing 30 of the valve body 12. As further detailed herein, the drive device 66 may include an electric motor 68 and a cooperating gear assembly 70, and is operably coupled to the movable flow control member 62. A bonnet nut 72 may threadably engage with the sidewall 34 of the valve body 12 to secure the valve cartridge 14 within the valve body 12.

[0048] As shown in FIGS. 2 and 3, the outer housing 60 illustratively includes a cylindrical outer sidewall 74 defining an internal chamber 76 extending along a longitudinal axis 78. An end cap 80 illustratively couples to an outer or distal end of the outer housing 60. The end cap 80 is illustratively captured between the sidewall 74 and the bonnet nut 72.Illustratively, the outer housing 60 and the end cap 80 may be molded from a polymer, such as a thermoplastic.

[0049] A cold water inlet 82 and a hot water inlet 84 extend axially (e.g., downwardly) from an end wall or base 86 at the inner or proximal end of the housing 60. The cold water and hot water inlets 82 and 84 provide fluid communication between the internal chamber 76 and cooperating cold water and hot water supply ports 40 and 42, respectively, formed in the valve body 12 (FIG. 2). O-rings 41 and 43 provide for a seal between the inlets 82 and 84 and the valve body 12. As noted above, the cold water and hot water supply ports 40 and 42 of the valve body 12 are in fluid communication with conventional hot water and cold water supplies 17 and 19, respectively.

[0050] Illustratively, the motor 68 is a brushless direct current (DC) motor. Alternative actuators may be substituted for the brushless DC motor 68, such as a brushed DC motor, a stepper motor, etc. The gear assembly 70 may illustratively include a rotatable ring gear 88 including a plurality of circumferentially spaced internal teeth 90 configured to engage a drive gear 91 driven in rotation by the motor 68 (FIGS. 2 and 3).

[0051] In an illustrative embodiment, the gear assembly 70 of the drive device 66 may comprise a strain wave or harmonic gearing system or assembly. An illustrative strain wave gearing assembly is detailed in U.S. Patent Application Publication No. 2021 / 0388584 to Thomas et al., the disclosure of which is expressly incorporated herein by reference.

[0052] In another illustrative embodiment, the gear assembly 70 of the drive device 66 may be defined by a planetary gear system (not shown). In such a configuration, the motor 68 causes one or more outer, or planet, gears or pinions, to revolve around a central sun gear or wheel. The planet gears may be mounted on a movable arm or carrier, which itself may rotate relative to the sun gear. In such an arrangement, the motor, as defined by the stator and the rotor, and the inner gear assembly are coaxially aligned with the longitudinal axis 78 of the housing 60.

[0053] With reference to FIGS. 2-8, the illustrative flow control members 62 and 64 may comprise cooperating ceramic valve plates or disks. As in a conventional faucet valve cartridge, the valve disks 62 and 64 rotate and seal against one another to mix incoming cold water and hot water through the cold water and hot water inlets 82 and 84. More particularly, the flow control members 62 and 64 are illustratively received within the chamber 76 of the outer housing 60, and include movable or outer valve disk 62 sealingly engaging fixed or inner valve disk 64. The fixed valve disk 64 is supported by the end wall 86 of the outer housing 60 and is fixed frommoving relative thereto. Cold water and hot water inlet openings 92 and 94 extend through the fixed valve disk 64 and are in fluid communication with the cold water and hot water inlets 82 and 84, respectively.

[0054] With reference now to FIGS. 3-8, the fixed valve disk 64 also includes an outlet opening 96 in fluid communication with the outlet bores 50 and 54 of the valve body 12 via the connecting bore 56. A gasket 98 provides a fluid seal between a lower (inner) surface 100 of the lower valve disk 64 and the end wall 86 of the outer housing 60. The gasket 98 is illustratively molded from an elastomer, such as silicone. Notches 102 are illustratively formed in the outer edge 104 of the lower valve disk 64 and receive tabs 106 extending inwardly and axially (e.g., upwardly) from the end wall 86 of the outer housing 60 to rotationally locate and fix the lower valve disk 64 relative to the outer housing 60 (FIG. 3).

[0055] The movable valve disk 62 illustratively includes opposing outer (e.g., upper) and inner (e.g., lower) surfaces 107 and 108. The lower surface 108 sealingly engages with an outer (e.g., upper) surface 110 of the fixed valve disk 64. Cold and hot flow control ports or openings 112 and 114 are formed to extend axially in the movable valve disk 64 and provide for selective fluid communication between the cold and hot water inlet openings 92 and 94 of the fixed valve disk 64. The fixed valve disk 64 also includes an axially extending outlet opening or port 116 in fluid communication with the openings 112 and 114. The ports 112, 114 and 116 extend through the valve disk 62 between the upper and lower surfaces 107 and 108. Illustratively, the opening 96 of the fixed valve disk 64 is co-axially aligned with the opening 116 of the movable valve disk 116.

[0056] As the movable valve disk 62 is rotated about its center axis 78, flow from the openings 92 and 94 (and therefore inlets 82 and 84) to the outlet openings 96 and 116 varies, thereby controlling water flow rate and / or water temperature at the outlet opening 96. With reference to FIGS. 7 and 8, the flow control openings 112 and 114 include control edges 118 and 120 configured to selectively overlap with the cold water and hot water inlet openings 92 and 94, respectively, of the fixed valve disk 64 to control water flow from the cold water and hot water inlets 82 and 84 to the outlet opening 96.

[0057] The flow control members 62 and 64 illustratively define a cycling valve. More particularly, cycling valves are known to provide for the mixing of hot water and cold water fordelivery to an outlet. More particularly, outlet water temperature is increased when the valve disk 62 is rotated in a first direction (e.g., clockwise) to provide for an increased ratio of hot water to cold water, and outlet water temperature is decreased when the valve disk 62 is rotated in an opposite direction (e.g., counter-clockwise) to provide for an increased ratio of cold water to hot water.

[0058] FIGS. 9A-9D illustrative different rotational positions of the movable valve disk 62 relative to the fixed valve disk 64 with the fixed valve disk 62 shown in phantom. FIG. 9A is a top plan view of the cooperating valve disks 62 and 64, with the movable valve disk 62 shown in an off position. More particularly, the openings 112 and 114 of the movable valve disk 62 are not aligned with (i.e., sealed from) the openings 92 and 94 of the lower valve disk 64. FIG. 9B is a top plan view of the cooperating valve disks 62 and 64, with the movable valve disk 62 shown rotated clockwise by a predetermined angle al to a full cold water position. More particularly, the cold water opening 112 of the movable valve disk 62 is fully aligned with the cold water opening 92 of the fixed valve disk 64, while the hot water opening 114 of the movable valve disk 62 is not aligned with (i.e., sealed from) the hot water opening 94 of the fixed valve disk 64. In the illustrative embodiment, al is 45 degrees clockwise from the position in FIG. 9A.

[0059] FIG. 9C is a top plan view of the cooperating valve disks 62 and 64, with the movable valve disk 62 shown rotated clockwise by a predetermined angle a2 from the position of FIG. 9B to a full mixed water position. More particularly, the cold water opening 112 of the movable valve disk 62 is partially aligned with the cold water opening 92 of the fixed valve disk 64, while the hot water opening 94 of the movable valve disk 62 is partially aligned with the hot water opening 94 of the fixed valve disk 64. In the illustrative embodiment, a2 is 72 degrees clockwise from the position in FIG. 9A. FIG. 9D is a top plan view of the cooperating valve disks 62 and 64, with the movable valve disk 62 shown rotated clockwise by a predetermined angle a3 from the position of FIG. 9C to a full hot position. More particularly, the cold water opening 112 of the movable valve disk 62 is not aligned with (i.e., sealed from) the cold water opening 92 of the fixed valve disk 64, while the hot water opening 114 of the movable valve disk 62 is fully aligned with the hot water opening 94 of the fixed valve disk 64. In the illustrative embodiment, a3 is 102 degrees clockwise from the position in FIG. 9A.

[0060] Additional details of illustrative valve members defining a cycling valve are disclosed in U.S. Patent No. 8,375,990 to Veros and U.S. Patent No. 10,267,022 to Veros et al., the disclosures of which are expressly incorporated herein by reference.

[0061] With reference to FIG. 3, a controller 130 (e.g., a microprocessor) is provided to control operation of the motor 68 in response to various inputs, including input from a user interface 132, an angular or rotational position sensor 134, and / or a temperature sensor 136. The controller 130 may be supported by a printed circuit board (not shown) received with the valve cartridge 14 or may be positioned external thereto. Illustratively, the controller 130 may be in wireless communication with the valve cartridge 14. The controller 130 may include a memory 138 and is in communication with the motor 68. A power supply 140 is illustratively in electrical communication with the controller 130 and is configured to provide selective power to the motor 68. As further detailed herein, the user interface 132 may include a display 142.

[0062] The angular or rotational position sensor 134 is in communication with the controller 130 and is configured to provide an indication of the rotational position of the movable valve disk 62 at any point in time. The angular position sensor 134 may be of conventional design, such as a Hall effect sensor cooperating with a magnet, or a rotary potentiometer.

[0063] In alternative embodiments, the angular position sensor 134 is not required to control the motor 68. In such embodiments, the motor 68 may be controlled in a manner similar to a stepper motor. Without the position sensor 134, it is assumed that the motor 68 is moved to where it is commanded to move by the controller 130.

[0064] As further shown in FIGS. 2-4 and 13, the illustrative valve cartridge 14 includes the water temperature sensor 136, such as a thermistor, in communication with the controller 130. The temperature sensor 136 monitors the output temperature of the output water (passing through outlet opening 96) thereby providing feedback needed to properly mix the water within the valve cartridge 14. More particularly, the thermistor 136 may provide an indication of the temperature of water provided to the outlet opening 96 to the controller 130 for display on the user interface 132, and / or for adjusting the position of the valve disk 62 to control the temperature of water provided to the outlet opening 96 to match a setpoint or user preset temperature.

[0065] With reference to FIGS. 2-4, 10 and 11, the illustrative valve cartridge 14 also includes a mixer 150 to facilitate mixing of hot water and cold water for temperature measurement by the thermistor 126. The illustrative mixer 150 includes a body 152 operably coupled to the gear assembly 70 and to the movable valve disk 62. As such, the mixer 150 is coupled with the movable valve disk 62 for rotation about the longitudinal axis 78. More particularly, the ring gear 88, including the plurality of circumferentially spaced internal gear teeth 90, may be operably coupled to the body 152. Illustratively, the body 152 may be integrally formed with the ring gear 88, for example via a molded polymer (e.g., polyoxymethylene (POM)).

[0066] With reference to FIGS. 3 and 11, the body 152 of the mixer 150 includes axially extending, circumferentially spaced tabs 154 received within cooperating recesses 156 of the movable valve disk 62. The recesses 156 are circumferentially spaced within an outer edge 158 of the movable valve disk 64. The tabs 154 orient the body 152 of the mixer 150 relative to the movable valve disk 62, and rotationally couple together the mixer 150 and the movable valve disk 62. Illustratively, first tab 154a and first recess 156a are dimensioned differently (e.g., wider) from the other tabs 154b, 154c and recesses 156b and 156c to facilitate proper orientation of the mixer 150 and the movable valve disk 62 (FIG. 8). While three tabs 154a, 154b, 154c and cooperating recesses 156a, 156b, 156c are illustrated, it should be appreciated that the number and positioning of the tabs 154 and recesses 156 may vary. An o-ring seal 159 is illustratively positioned intermediate the movable valve disk 62 and the mixer 150.

[0067] With reference to FIGS. 10-12, an arcuate, illustratively spiral, mixing channel 160 extends within an inner surface 162 of the body 152 of the mixer 150 and is fluidly coupled to the cold water opening 112, the hot water opening 114 and the outlet opening 116 of the movable valve disk 62. As shown in FIG. 12, the spiral channel 160 extends between a proximal or upstream end 164 and a distal or downstream end 166. An outlet opening 168 is in fluid communication with the downstream end 166 of the spiral channel and is co-axially aligned with the openings 96 and 116 of the valve disks 62 and 64, respectively. More particularly, the cold water opening 112 is fluidly coupled to the upstream end 164, the outlet opening 116 is fluidly coupled to the downstream end 166 via the outlet opening 168, and the hot water opening 116 is fluidly coupled intermediate the upstream end 164 and the downstream end 166. The cross-sectional area of the spiral channel 160 increases downstream of the hot water opening 116 (i.e., toward the distal end 166), causing reduced water pressure (e g., via a Venturi effect). This promotes enhanced mixing of cold water and hot water as it passes to the outlet opening 116.

[0068] Within the illustrative mixer 150, a cold water flow (arrows 167 in FIGS. 10 and 12) from the cold water opening 112 follows a path where it meets a hot water flow (arrows 169 in FIGS. 10 and 12) from the hot water opening 116. Both cold and hot water flows 167 and 169 continue in the same direction. Mixing is encouraged by two mechanisms in the illustrative mixer 150. First, the upward direction of the hot water flow 169 entering the mixer 150 (FIG.10) is perpendicular to the cold water flow 167 (FIG. 12), and the cold water flow 167 within the spiral mixing channel 160 has no space or alternative path to divert around the hot water flow 169. Second, the spiral mixing channel 160 provides both length and time for additional mixing of the cold and hot water flows 167 and 169 as the mixed water flow (arrows 171 in FIGS. 10 and 12) passes though the outlet 168.

[0069] FIGS. 14A-14E show different illustrative mixers that may be substituted for the mixer 150 detailed above. In the following description, like reference numbers represent similar components. FIG. 14A illustrates a mixer 170 including upwardly extending arcuate walls 172 and 174 in spaced relation on opposite sides of the outlet opening 168. Vanes or deflectors 176 and 178 extend outwardly from the walls 172 and 174, respectively. FIG. 14B illustrates a mixer 180 including a single arcuate wall 182 extending partially around the outlet opening 168. A vane or deflector 184 extends outwardly proximate one end of the wall 182. FIG. 14C illustrates a mixer 190 including a plurality of vanes 192 extending circumferentially around the outlet opening 168. FIG. 14D illustrates a mixer 200 including upwardly extending arcuate walls 202 and 204 in spaced relation on opposite sides of the outlet opening 168. A vane or deflector 206 is illustratively positioned circumferentially intermediate the walls 202 and 204. FIG. 14E illustrates a mixer 210 including upwardly extending arcuate walls 212 and 214 positioned in a spiral arrangement relative to the opening 168.

[0070] In other illustrative embodiments, the mixer 150 may include a screen (not shown) covering at least a portion of the thermistor 136. Holes in the screen would be perpendicular to the water flow, so the water will start out jetting by the holes. Once thechamber 76 fills up, back pressure and turbulence will force the water through the holes in the screen. As the waterjets through the screen, water mixing will be facilitated.

[0071] With reference to FIGS. 2, 10 and 11, the thermistor 136 is illustratively received within the outlet opening 168 of the mixer 150 and the outlet opening 116 of the movable valve disk 62. Conventional means, such as a retaining clip and / or fastener, may be used to axially retain the thermistor 136 within a center opening 221 of an outer wall (e.g., center end wall) 222 of the mixer body 152. An o-ring 224 is illustratively received between a flange 226 on the thermistor 136 and the mixer body 152.

[0072] The thermistor 136 illustratively includes a sensing portion or probe 228 extending along the longitudinal axis 78 within the water flow, and a wire 230 extending through a longitudinal extending sleeve 232 to provide electrical communication between the thermistor 136 and the controller 130. A distal sensing tip 234 of the probe 228 is illustratively positioned downstream from the outlet 168 of the mixer 150. More particularly, the sensing tip 234 is illustratively positioned within the outlet opening 116 of the movable valve disk 62.

[0073] The user interface 132 may include a sealed display 142 including input regions or buttons, and an output region. Multiple displays may be provided to control the valve cartridge 10. Once paired with the user interface 132, a user will be able to control the shower valve with a push of a button or dial in the shower, with a remote (via phone, tablet, etc.), and / or by using an application (app) on a smart device.

[0074] One or more of the electronic components described above may be part of a user interface 132 that detachably couples to other components of the electronic valve cartridge 14. For example, the controller 130, the memory 138, the display 142, and / or the power supply 140 may be part of a user interface device that detachably couples to other components of the electronic valve cartridge. Examples of such user interface devices are described in further detail below.

[0075] With reference to FIGS. 15-19, a further illustrative embodiment electronic shower valve 310 is shown. The electronic shower valve 310 includes a valve cartridge 314 configured to be received within the valve body 12. The valve cartridge 314 illustrativelyincludes many of the same components as the valve cartridge 14 detailed above. As such, in the following description, like reference numbers represent similar components.

[0076] In the valve cartridge 314, an alternative embodiment thermistor 336 is illustratively received within the outlet opening 168 of the mixer 150' and the outlet opening 116 of the movable valve disk 62. Conventional means may be used to retain the thermistor 136, such as a retaining clip and / or fastener. A pair of o-rings 212 are illustratively positioned intermediate the thermistor 136 and the body 152' of the mixer 150'. The thermistor 336 illustratively includes a sensing portion or probe 338 positioned within the internal chamber 76 of the valve cartridge 314, and a wire 340 extending outside of the valve cartridge 314 to provide electrical communication between the sensing portion 216 and the controller 130.

[0077] The probe 338 of the thermistor 336 includes a sensing tip 342 illustratively positioned downstream from the outlet 168 of the mixer 150. More particularly, the sensing tip 342 is illustratively positioned axially proximate the outlet opening 96 of the fixed valve disk 64. By positioning the sensing tip 342 further downstream within the valve cartridge 14, the outlet water detected by the thermistor 336 is provided with additional opportunity for mixing. As such, this facilitates more accurate water temperature measurements. More particularly, the mixer 150 ' and the extending passageway provides for more complete impinging or swirling mixing of cold and hot water streams before reaching the thermistor sensing tip 342.

[0078] With reference to FIGS. 15 and 16, a bracket 344 is illustratively couples the probe 338 of the thermistor 336 to the end cap 80. The illustrative probe 338 extends along the longitudinal axis 78 through a hollow motor shaft 348 of the motor 68. As such, the thermistor 336 (including the wire 340) remains stationary relative to rotation of the motor shaft 348.

[0079] In an illustrative embodiment, the controller 130 may be positioned external to the valve cartridge 14. In such an embodiment, a control cable 350 may provide communication between various electrical components (e.g., motor, angular sensor and / or temperature sensor) and external controller 130.

[0080] A further illustrative embodiment electronic shower valve 410 is shown in FIGS. 20-26. The electronic shower valve 410 includes an illustrative valve cartridge 414 configured to be received within the valve body 12. The valve cartridge 414 illustratively includes many ofthe same components as the valve cartridge 14, 314 detailed above. As such, in the following descriptions like reference numbers represent similar components.

[0081] In the illustrative valve cartridge 414 of FIGS. 20 and 21, an alternative embodiment thermistor 436 is illustratively received within the outlet opening 168 of the mixer 150' and the outlet opening 116 of the movable valve disk 62. An o-ring 224 is illustratively positioned intermediate the thermistor 436 and the body 152' of the mixer 150". An annular retainer 412 is illustratively received around the thermistor 436 and within the opening 221 of the end wall 222 to retain the o-ring 224 relative to the thermistor 436 and the mixer 150".

[0082] The thermistor 436 illustratively includes a sensing portion or probe 438 extending along the longitudinal axis 78 and positioned within the internal chamber 76 of the valve cartridge 414. A wire 440 extends outside of the valve cartridge 414 to provide electrical communication between the sensing portion 438 and the controller 130. The wire 440 may form part of a cable 442 to also provide electrical communication with the motor 68 and the controller 130.

[0083] The probe 438 of the thermistor 436 includes a distal sensing tip 444 illustratively positioned downstream from the outlet 168 of the mixer 150". More particularly, the sensing tip 444 is illustratively positioned axially proximate the outlet opening 96 of the fixed valve disk 64. In the illustrative embodiment as shown in FIG. 21, the sensing tip 444 is positioned axially proximate the lower surface 100 of the fixed valve disk 64. As further detailed herein, the extended mixing length provided by the positioning of the thermistor 444 facilitates more complete mixing of the cold water and the hot water supplied to the mixer 150" for improved temperature measurement accuracy.

[0084] With reference now to FIGS. 21-24, a plurality of circumferentially spaced snap fingers 452 are supported by the sidewall 74' of the outer housing 60'. The snap fingers 452 each include an arm 454 supporting a distal tab or lip 456. The arms 454 are biased radially inwardly from the sidewall 74' of the outer housing 60'. More particularly, the tabs 456 are biased inwardly such that tabs 456 are received within an annular grove 458 of the mixer body 152.The snap fingers 452 axially retain the mixer 150' to the housing 60 while permitting rotation therebetween.

[0085] As shown in FIGS. 24-26, the mixer 150' is operably coupled to the moveable valve disk 62 for simultaneous rotation about the longitudinal axis 78. With further reference to FIGS. 26-28, cooperating first and second rotational stops 460a, 460b and 462a, 462b are supported by the outer housing 60 and the mixer 150' to limit relative rotation therebetween. The rotational stops 460a and 460b illustratively include diametrically opposed tabs 461a and 461b supported by the outer housing 60'. More particularly, the tabs 461a and 461b extend radially inwardly from the sidewall 74 of the outer housing 60 and each include opposing end stop surfaces 464 and 466. The rotational stops 462a and 462b illustratively include diametrically opposed tabs 463a and 463b supported by the mixer 150". More particularly, the tabs 463a and 463b extend axially downwardly from the body 152' of the mixer 150" and each include opposing end stop surfaces 468 and 470.

[0086] FIG. 25 shows the electronic valve assembly 410 in an off position with no water flow through the valve cartridge 414. In this position, the rotational stop 462a of the mixer 150' engages the stop 460a of the outer housing 60', and the stop 462b engages the stop 460b. More particularly, the end surface 464 of the rotational stop 460a engages the end surface 470 of the rotational stop 462a. Simultaneously, the end surface 466 of the rotational stop 460b engages the end surface 470 of the rotational stop 462b.

[0087] FIG. 26 shows the electronic valve assembly 410 in a full hot position with only hot water flowing through the valve cartridge 414 at a full flow rate. In this position, the valve disk 64 and the mixer 150' is rotated by angle a (illustratively, 100 degrees) clockwise from the position shown in FIG. 27. In this position, the rotational stop 462a of the mixer 150' engages the stop 460b of the outer housing 60, and the stop 462b engages the stop 460a. More particularly, the end surface 464 of the rotational stop 460b engages the end surface 468 of the rotational stop 462a. Simultaneously, the end surface 466 of the rotational stop 460a engages the end surface 468 of the rotational stop 462b.

[0088] FIGS. 27 and 28 are temperature plots illustrating the mixing of water through the mixer 150" to the sensing tip 444 of the thermistor 436. More particularly, FIG. 27 illustrates lateral mixing of cold water 472 and hot water 474 as it flows through the spiral channel 160 from the cold water inlet 112 to the hot water inlet 114 and forms mixed water 476 at the outlet168. FIG. 28 illustrates axial mixing of cold water 472 and hot water 474 to form mixed water 476 as it flows from the outlet 476 to the sensing tip 442 of the thermistor 436.

[0089] FIGS. 27 and 28 illustrate the structure of mixer 150" providing for effective mixing of cold water 472 and hot water 474 to form mixed water 476. Axial (e.g., upward) flow direction of the hot water 474 entering the mixer 150" is perpendicular to an arcuate transverse flow direction of the cold water 472, and the cold water 472 has no space or alternative path to divert around the hot water 474. Spiral path of the channel 160 along with axial positioning and length of the thermistor 436 provides both length and time for additional mixing of the cold water and hot water flows.

[0090] Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the spirit and scope of the invention as described and defined in the following claims.

Claims

CLAIMS:

1. An electronic shower valve comprising: a valve body; and a valve cartridge received within the valve body, the valve cartridge including: an outer housing including an internal chamber defining a longitudinal axis, a cold water inlet in fluid communication with the internal chamber, a hot water inlet in fluid communication with the internal chamber, a movable flow control element supported for rotation about the longitudinal axis to control water flow through the cold water inlet and the hot water inlet; a mixer operably coupled to the flow control element, and in fluid communication with the cold water inlet and the hot water inlet; a motor assembly at least partially supported within the outer housing and coaxially aligned with the longitudinal axis; and a gear assembly operably coupling the motor assembly and the flow control element, the gear assembly configured to rotate the flow control element.

2. The electronic shower valve of claim 1, further comprising a controller, and an angular sensor configured to detect an angular position of the flow control element and provide a signal indicative thereof to the controller.

3. The electronic shower valve of claim 1, further comprising a controller, and a temperature sensor configured to detect a temperature of water provided to an outlet and provide a signal indicative thereof to the controller.

4. The electronic shower valve of claim 3, wherein the temperature sensor comprises a thermistor, the movable flow control element includes a center opening, and the thermistor extends through the center opening.

5. The electronic shower valve of claim 4, wherein the thermistor includes a sensing tip positioned downstream of the mixer.

6. The electronic shower valve of claim 5, wherein the sensing tip is positioned downstream of the movable flow control element.

7. The electronic shower valve of claim 1, wherein the mixer includes a body defining a spiral channel configured to fluidly couple the cold water inlet and the hot water inlet with a mixed water outlet.

8. The electronic shower valve of claim 7, wherein the mixer rotates with the movable flow control element.

9. The electronic shower valve of claim 8, further comprising a temperature sensor configured to detect a temperature of water provided to the mixed water outlet.

10. The electronic shower valve of claim 1, wherein the valve cartridge further includes a plurality of snap fingers coupling the outer housing to the mixer.

11. The electronic shower valve of claim 10, wherein the plurality of snap fingers axially retain the outer housing to the mixer, while permitting rotation between the outer housing and the mixer.

12. The electronic shower valve of claim 1, wherein the valve cartridge further includes a first rotational stop supported by the outer housing, and a second rotational stop supported by the mixer, the first rotational stop cooperating with the second rotational stop to limit rotation between the outer housing and the mixer.

13. The electronic shower valve of claim 12, wherein the first rotational stop includes a pair of diametrically opposed first tabs having opposing end surfaces, and the second rotationalstop includes a pair of diametrically opposed second tabs having opposing end surfaces, the end surfaces of the first tabs selectively engaging with the end surfaces of the second tabs.

14. An electronic shower valve comprising: a valve body; and a valve cartridge received within the valve body, the valve cartridge including: an outer housing including an internal chamber defining a longitudinal axis, a cold water inlet in fluid communication with the internal chamber, a hot water inlet in fluid communication with the internal chamber, a movable flow control element supported for rotation about the longitudinal axis to control water flow through the cold water inlet and the hot water inlet; a mixer operably coupled to the flow control element, and in fluid communication with the cold water inlet and the hot water inlet; a thermistor extending through the flow control element and the mixer, the thermistor configured to detect a temperature of water provided to an outlet of the mixer.

15. The electronic shower valve of claim 14, wherein the thermistor includes a sensing tip positioned downstream of the movable flow control element and the mixer.

16. The electronic shower valve of claim 14, further comprising: a motor assembly at least partially supported within the outer housing and coaxially aligned with the longitudinal axis; and a gear assembly operably coupling the motor assembly and the flow control element, the gear assembly configured to rotate the flow control element.

17. The electronic shower valve of claim 14, wherein the mixer includes a body defining a spiral channel configured to fluidly couple the cold water inlet and the hot water inlet with the outlet.

18. The electronic shower valve of claim 17, wherein the mixer rotates with the movable flow control element.

19. The electronic shower valve of claim 14, further comprising a controller, and an angular sensor configured to detect an angular position of the flow control element and provide a signal indicative thereof to the controller.

20. The electronic shower valve of claim 14, further comprising a controller, wherein the thermistor is configured to provide a signal indicative of water temperature at the outlet to the controller.

21. The electronic shower valve of claim 14, wherein the valve cartridge further includes a plurality of snap fingers coupling the outer housing to the mixer.

22. The electronic shower valve of claim 21, wherein the plurality of snap fingers axially retain the outer housing to the mixer, while permitting rotation between the outer housing and the mixer.

23. The electronic shower valve of claim 14, wherein the valve cartridge further includes a first rotational stop supported by the outer housing, and a second rotational stop supported by the mixer, the first rotational stop cooperating with the second rotational stop to limit rotation between the outer housing and the mixer.

24. The electronic shower valve of claim 23, wherein the first rotational stop includes a pair of diametrically opposed first tabs having opposing end surfaces, and the second rotational stop includes a pair of diametrically opposed second tabs having opposing end surfaces, the end surfaces of the first tabs selectively engaging with the end surfaces of the second tabs.

25. A valve cartridge comprising: an outer housing including an internal chamber defining a longitudinal axis; a cold water inlet in fluid communication with the internal chamber; a hot water inlet in fluid communication with the internal chamber; a movable flow control element supported for rotation about the longitudinal axis to control water flow through the cold water inlet and the hot water inlet; a mixer operably coupled to the flow control element, and in fluid communication with the cold water inlet and the hot water inlet; wherein the mixer includes a body defining a spiral channel configured to fluidly couple the cold water inlet and the hot water inlet with a mixed water outlet; and a thermistor extending through the flow control element and the mixer, the thermistor configured to detect a temperature of water provided to the mixed water outlet.

26. The valve cartridge of claim 25, wherein the mixer rotates with the movable flow control element.

27. The valve cartridge of claim 25, further comprising: a motor assembly at least partially supported within the outer housing and coaxially aligned with the longitudinal axis; and a gear assembly operably coupling the motor assembly and the flow control element, the gear assembly configured to rotate the flow control element.

28. The valve cartridge of claim 26, wherein the thermistor includes a sensing tip positioned downstream of the mixer.

29. The valve cartridge of claim 28, wherein the sensing tip is positioned downstream of the movable flow control element.

30. The valve cartridge of claim 25, further comprising a controller, wherein the thermistor is configured to provide a signal indicative of water temperature at the outlet to the controller.31 . The electronic shower valve of claim 25, further comprising a plurality of snap fingers coupling the outer housing to the mixer.

32. The electronic shower valve of claim 31, wherein the plurality of snap fingers axially retain the outer housing to the mixer, while permitting rotation between the outer housing and the mixer.

33. The electronic shower valve of claim 25, further comprising a first rotational stop supported by the outer housing, and a second rotational stop supported by the mixer, the first rotational stop cooperating with the second rotational stop to limit rotation between the outer housing and the mixer.

34. The electronic shower valve of claim 33, wherein the first rotational stop includes a pair of diametrically opposed first tabs having opposing end surfaces, and the second rotational stop includes a pair of diametrically opposed second tabs having opposing end surfaces, the end surfaces of the first tabs selectively engaging with the end surfaces of the second tabs.

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