Electronic shower valve

Abstract

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 motor assembly is at least partially supported within the outer housing and includes a motor shaft coaxially aligned with the longitudinal axis. A gear assembly operably couples the motor assembly and the flow control element, the gear assembly being configured to rotate the flow control element. The gear assembly includes a sun gear operably coupled to the motor shaft, a planet gear assembly operably coupled to the sun gear, a static ring gear fixed to the outer housing and operably coupled to the planet gear assembly, and a driving ring gear fixed to the movable flow control element and operably coupled to the planet gear assembly.

Description

ELECTRONIC SHOWER VALVECross-Reference to Related Application

[0001] The present application claims priority to U.S. Provisional Patent Application Serial No. 63 / 616,709, 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 a shower valve and, more particularly, to an electronic shower valve cartridge configured to be received within a conventional shower valve body.

[0003] The present invention provides for a compact drive assembly (e.g., motor and gearing) capable of providing speed and torque required to operate a shower valve within the size constraints of an existing valve body.

[0004] According to an 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 motor assembly is at least partially supported within the outer housing and includes a motor shaft coaxially aligned with the longitudinal axis. A gear assembly operably couples the motor assembly and the flow control element, the gear assembly being configured to rotate the flow control element. The gear assembly includes a sun gear operably coupled to the motor shaft, a planet gear assembly operably coupled to the sun gear, a static ring gear fixed to the outer housing and operably coupled to the planet gear assembly, and a driving ring gear fixed to the movable flow control element and operably coupled to the planet gear assembly.

[0005] 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 alongitudinal axis, at least one 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 at least one water inlet. A gear assembly is configured to rotate the flow control element. The gear assembly includes a sun gear operably coupled to the motor shaft, a planet gear assembly operably coupled to the sun gear, a static ring gear fixed to the outer housing, and a driving ring gear fixed to the movable flow control element. The planet gear assembly includes a plurality of planet gears rotatably supported by a carrier. Each planet gear includes a first stage and a second stage. The first stage of each planet gear engages the static ring gear, and the second stage of each planet gear engages the driving ring gear.

[0006] According to another illustrative embodiment of the present disclosure, a 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 motor assembly is at least partially supported within the outer housing and including a motor shaft coaxially aligned with the longitudinal axis. A gear assembly operably couples the motor assembly and the flow control element, and is configured to rotate the flow control element. The gear assembly includes a sun gear operably coupled to the motor shaft, a planet gear assembly operably coupled to the sun gear, a static ring gear fixed to the outer housing, and a driving ring gear fixed to the movable flow control element. The planet gear assembly includes a plurality of planet gears rotatably supported by a carrier, each planet gear including a first stage and a second stage, the first stage engaging the static ring gear, and the second stage engaging the driving ring gear.

[0007] 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 the illustrative embodiment exemplifying the best mode of carrying out the invention as presently perceived.Brief Description of the Drawings

[0008] The detailed description of the drawings particularly refers to the accompanying figures in which:

[0009] FIG. l is a perspective view of an illustrative electronic valve assembly of the present disclosure;

[0010] FIG. 2 is a cross-sectional view taken along line 2-2 of FIG. 1;

[0011] FIG. 3 is a first partially exploded perspective view of the electronic valve assembly of FIG. 1, with a partial cutaway of the valve body;

[0012] FIG. 4 is a second partially exploded perspective view of the electronic valve cartridge of FIG. 1;

[0013] FIG. 5 is a partially exploded perspective view of the gear assembly of the electronic valve cartridge FIG. 4;

[0014] FIG. 6 is a partially exploded perspective view of the gear assembly of FIG. 4;

[0015] FIG. 7 is a cross-sectional view taken along line 7-7 of FIG. 1;

[0016] FIG. 8 is a cross-sectional view taken along line 8-8 of FIG. 1;

[0017] FIG. 9 is a block diagram of electrical components of the illustrative valve assembly of FIG. 1;

[0018] FIG. 10 is a perspective view of a further illustrative electronic valve assembly of the present disclosure;

[0019] FIG. 11 is a cross-sectional view taken along line 11-11 of FIG. 10;

[0020] FIG. 12 is a partially exploded view of the electronic valve cartridge of FIG. 10;

[0021] FIG. 13 is an exploded perspective view of the gear assembly of the electronic valve assembly of FIG. 12;

[0022] FIG. 14 is a perspective view of an illustrative end cap of the electronic valve assembly of FIG. 10;

[0023] FIG. 15 is an exploded perspective view of FIG. 14;

[0024] FIG. 16 is a cross-sectional view taken along line 16-16 of FIG. 10;

[0025] FIG. 17 is a perspective view of the planet gear assembly of FIG. 13; and

[0026] FIG. 18 is an exploded perspective view of the planet gear assembly of FIG. 15.Detailed Description of the Drawings

[0027] The embodiments disclosed herein are not intended to be exhaustive or to limit the invention to the precise form disclosed. Rather, the embodiments selected for description have been chosen to enable one skilled in the art to practice the invention.

[0028] 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.

[0029] 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.

[0030] With further reference to FIG. 1, the illustrative valve fitting 12 also 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 second outlet 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 (FIG. 2).

[0031] 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.

[0032] 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. Pat. No. 7,819,134 to Izzy et al., the disclosure of which is expressly incorporated by reference herein.

[0033] With reference 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 a 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.

[0034] 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.

[0035] 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.

[0036] With further reference to FIGS. 2 and 3, 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 hot water and cold 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 from moving 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.

[0037] 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 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).

[0038] 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 in the movable valve disk 64 and provide for selective fluidcommunication 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 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.

[0039] 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. The flow control openings 112 and 114 include control edges 118 and 120 configured to selectively overlap with the hot and cold water inlet openings 92 and 94 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.

[0040] 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 and cold water for delivery 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.

[0041] 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.

[0042] Illustratively, the motor 68 is a brushless direct current (DC) motor. With reference to FIGS. 2 and 6, the motor 68 illustratively includes a stator 122 operably coupled to a rotor 124 for driving a hollow motor shaft 126 in rotation. The stator 122 and the rotor 124 may be received within a case 123 operably coupled to a base 125. Alternative actuators may be substituted for the brushless DC motor 68, such as a brushed DC motor, a stepper motor, a solenoid, etc.

[0043] The illustrative gear assembly 70 may be a planet or planetary gear arrangement. In an illustrative embodiment, the gear assembly 70 may be in the form of a compound planetarygear arrangement (e.g., a Wolfrom gear arrangement). With reference to FIGS. 4-6, the illustrative gear assembly 70 includes a sun gear 128 fixed to the motor shaft 126 for rotation therewith. The sun gear 128 includes a plurality of external teeth 129, and may be fixed to the motor shaft 126 via conventional means, such as snap fingers, retainer clips, brazing, etc. A planet gear assembly 130 is operably coupled to the sun gear 128. More particularly, the planet gear assembly 130 includes a carrier 132 supporting a plurality of rotatable planet gears 134. A plurality of shafts 136 are supported approximately 120 degrees circumferentially from each other by opposing plates 137a and 137b of the carrier 132. The planet gears 134 are supported for rotation on the shafts 136. As may be appreciated, the number and positioning of the planet gears 134 and cooperating shafts 136 may vary.

[0044] With reference to FIGS. 5-8, each planet gear 134 illustratively includes a first stage 138 axially spaced from a second stage 140. The first stage 138 illustratively includes a plurality of external teeth 142, while the second stage 140 includes a plurality of external teeth 144. The teeth 129 of the sun gear 128 cooperate with the teeth 144 of the first stage 138 of the planet gears 134. The dimensions (including diameter and number of teeth 142) of the first stage 138 are illustratively different from the dimensions of the second stage 140 (including diameter and number of teeth 144).

[0045] The gear assembly 70 further includes a first or static ring gear 146 configured to cooperate with the first stages 138 of the planet gears 134, and a second or rotatable ring gear 148 configured to cooperate with the second stages 140 of the planet gears 134. The static ring gear 146 illustratively includes a plurality of internal teeth 150 cooperating with the external teeth 142 of the first stage 138 of the planet gears 134. Similarly, the rotatable ring gear 148 includes a plurality of internal teeth 152 cooperating with the external teeth 144 of the second stage 140 of the planet gears 134. Illustratively, the gears 128, 134, 146 and 148 may be formed of a molded polymer (e.g., polyoxymethylene (POM)).

[0046] The static ring gear 146 is illustratively fixed to the outer housing 60. More particularly, a plurality of circumferentially spaced tabs 154 are received within cooperating recesses 156 formed in the sidewall 74 of the outer housing 60 (FIGS. 4 and 7). 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. Othermeans of securing the static ring gear 146 from moving relative to the outer housing 60 may be substituted therefor.

[0047] With reference to FIGS. 7 and 8, an illustrative operation of the drive device 66 is shown. FIG. 7 illustrates cooperation between the sun gear 128, the planet gear assembly 130 and the static ring gear 146. FIG. 8 illustrates cooperation between the planet gear assembly 130 and the rotatable ring gear 148.

[0048] As shown in FIG. 7, when the motor 68 is actuated, the motor shaft 126 and the sun gear 128 rotates (e.g., clockwise as shown by arrow 158). Rotation of the sun gear 128 causes rotation of the first stages 138 of the planet gears 134 (e.g., counter-clockwise as shown by arrows 160), and subsequent rotation of the carrier 132 (e.g., counter-clockwise as shown by arrows 162). With reference to FIG. 8, rotation of the first stage 138 of the planet gears 134 results in corresponding rotation of the second stage 140 of the planet gears 134 (e.g., counterclockwise as shown by arrows 160). This rotation of the second stages 140 of the planet gears 134 causes rotation of the rotatable ring gear 148 (e.g., clockwise as shown by arrows 164). The different numbers of teeth 142 and 144 define a ratio for reducing rotational speed between input at the sun gear 128 and output at the ring gear 148. As further detailed herein, the rotatable ring gear 148 is operably coupled to the movable valve disk 62, such that rotation of the ring gear 148 results in corresponding rotation of the valve disk 62.

[0049] With reference to FIG. 9, a controller 170 (e.g., including a microprocessor) is provided to control operation of the motor 68 in response to various inputs, including input from a user interface 172, an angular or rotational position sensor 174, and / or a temperature sensor 176. The controller 170 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 170 may be in wireless communication with the valve cartridge 14. The controller 170 may include a memory 177 and is in communication with the motor 68. A power supply 178 is illustratively in electrical communication with the controller 170 and is configured to provide selective power to the motor 68.

[0050] The angular or rotational position sensor 174 is in communication with the controller 170 and is configured to provide an indication of the rotational position of the movablevalve disk 62 at any point in time. The angular position sensor 174 may be of conventional design, such as a Hall Effect sensor cooperating with a magnet, or a rotary potentiometer.

[0051] In alternative embodiments, the angular position sensor 174 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 174, it must be assumed that the motor 68 is moved to where it is commanded to move by the controller 170.

[0052] As shown in FIGS. 2 and 9, the illustrative valve cartridge 14 includes the water temperature sensor 176, illustratively a thermistor, in communication with the controller 170. The temperature sensor 176 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 176 may provide an indication of the temperature of water provided to the outlet opening 96 to the controller 170 for display on the user interface 172, 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. The thermistor 176 illustratively includes a sensing portion or probe 180 including a distal sensing tip 181 within the water flow, and a wire 182 extending through a longitudinal extending sleeve 184 to provide electrical communication between the thermistor 176 and the controller 170.

[0053] With further reference to FIGS. 2-4, the illustrative valve cartridge 14 also includes a mixer 190 to facilitate mixing of hot water and cold water for temperature measurement by the thermistor 176. The illustrative mixer 190 includes a body 192 operably coupled to the gear assembly 70 and to the movable valve disk 62. As such, the mixer 190 is coupled for rotation with the movable valve disk 62. More particularly, the rotatable ring gear 148, including the plurality of circumferentially spaced internal teeth 152, may be operably coupled to the body 192. Illustratively, the body 192 may be integrally formed with the ring gear 148, for example via a molded polymer (e.g., polyoxymethylene (POM)).

[0054] Conventional means, such as a retaining clip and / or fastener, may be used to axially retain the thermistor 176 within a center opening 191 of an outer wall (e.g., center end wall) 193 of the mixer body 192. Illustratively, an o-ring 195 is received between a flange 197 on the thermistor 176 and the mixer body 192.

[0055] With reference to FIG. 3, the body 192 of the mixer 190 includes axially extending, circumferentially spaced tabs 194 received within cooperating recesses 196 of the movable valve disk 62. The recesses 196 are circumferentially spaced within an outer edge 198 of the movable valve disk 64. The tabs 194 orient the body 192 of the mixer 190 relative to the movable valve disk 62, and rotationally couple together the mixer 190 and the movable valve disk 62. Illustratively, first tab 194a and first recess 196a are dimensioned differently (e.g., wider) from the other tabs 194b, 194c and recesses 196b and 196c to facilitate proper orientation of the mixer 190 and the movable valve disk 62. While three tabs 194a, 194b, 194c and cooperating recesses 196a, 196b, 196c are illustrated, it should be appreciated that the number and positioning of the tabs 194 and recesses 196 may vary. A seal, such as an o-ring 200, is illustratively positioned intermediate the movable valve disk 62 and the mixer 190.

[0056] In other illustrative embodiments, the mixer 190 may include a screen (not shown) covering at least a portion of the thermistor 176. Holes in the screen would be perpendicular to the water flow, so the water will start out jetting by the holes. Once the chamber 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.

[0057] The user interface 172 may include a sealed display including input regions or buttons, and an output region. Multiple displays may be provided to control the valve cartridge 14. Once paired with the user interface 172, a use 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.

[0058] One or more of the electronic components described above may be part of a user interface device that detachably couples to other components of the electronic valve cartridge 14. For example, the controller 170, the memory 177, the display, and the power supply 178 may be part of a user interface device that detachably couples to other components of the electronic valve cartridge 14. Examples of such user interface devices are described in further detail below.

[0059] A further illustrative embodiment electronic shower valve 210 is shown in FIG. 10-18. The valve 210 includes an illustrative valve cartridge 214 configured to be received within the valve body 12. The valve cartridge 214 illustratively includes many of the samecomponents as the valve cartridge 14 detailed above. As such, in the following description, like reference numbers represent similar components.

[0060] With reference to FIGS. 11 and 12, the electronic valve cartridge 214 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 214 and the housing 30 of the valve body 12. As further detailed herein, the drive device 66' may include a motor 68' and 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 214 within the valve body 12.

[0061] 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.

[0062] Illustratively, the motor 68' is a brushless direct current (DC) motor. With reference to FIGS. 2 and 6, the motor 68' illustratively includes a stator 122' operably coupled to a rotor 124' for driving a hollow motor shaft 126' in rotation. The stator 122' and the rotor 124' may be received within a case 123' operably coupled to a base 125'. Alternative actuators may be substituted for the brushless DC motor 68', such as a brushed DC motor, a stepper motor, a solenoid, etc.

[0063] In the illustrative valve cartridge 214 of FIGS. 10 and 11, an alternative embodiment thermistor 276 is illustratively received within the outlet opening 168 of the mixer 190' and the outlet opening 116 of the movable valve disk 62. An o-ring 224 is illustratively positioned intermediate the thermistor 276 and the body 192' of the mixer 190'. An annular retainer 412 is illustratively received around the thermistor 276 and received within the opening 221 of the end wall 222 to secure the thermistor 436 to the mixer 190'.

[0064] The thermistor 276 illustratively includes a sensing portion or probe 280 positioned within the internal chamber 76 of the valve cartridge 214, and a wire 282 extending outside of the valve cartridge 214 to provide electrical communication between the sensingportion 280 and the controller 170. A distal sensing tip 281 is illustratively positioned within the water flow axially adjacent the lower surface 100 of the fixed valve disk 64. The wire 282 may form part of a cable 284 to also provide electrical communication with the motor 68 and the controller 170.

[0065] The probe 280 of the thermistor 276 includes a distal sensing tip 281 illustratively positioned downstream from the outlet 168 of the mixer 190'. More particularly, the sensing tip 281 is illustratively positioned axially proximate the outlet opening 96 of the fixed valve disk 64. In the illustrative embodiment as shown in FIG. 11, the sensing tip 281 is positioned axially proximate the lower surface 100 of the fixed valve disk 64. The extended mixing length provided by the positioning of the thermistor 276 facilitates more complete mixing of the cold water and the hot water supplied to the mixer 190’ for improved temperature measurement accuracy. Retainer 283

[0066] With reference to FIGS. 12 and 13, the end cap 80' includes a plurality of circumferentially spaced locking tabs 286 for receipt within cooperating openings 288 formed within the sidewall 74' of the outer housing 60'. More particularly, a plurality of axially extending grooves 290 extend radially outwardly within an inner surface 292 of the sidewall 74' and receive arms 294 supporting the locking tabs 286. The openings 288 are each formed within one of the grooves 290. The arms 294 are biased radially outwardly to force the locking tabs 286 within the openings 288 to secure the end cap 80' to the housing 60'.

[0067] The end cap 80' further includes circumferentially spaced slots 296 configured to receive a plurality of tabs or castles 298 of the ring gear 146'. More particularly, the castles 298 are circumferentially spaced for receipt within the slots 296. Engagement between the slots 296 and the castles 298 clock (i.e., rotationally orient) the teeth 150 of the ring gear 146', while also preventing lateral deformation of the ring gear 146'.

[0068] With reference to FIGS. 14 and 16, the sun gear 128' is coupled to the motor shaft 126' proximate a rear surface 300 of the case 123' of the motor 68'. Illustratively, the sun gear 128' includes resilient snap fingers 302 having tabs 304 received within an annular groove 306 of the motor shaft 126'.

[0069] With further reference to FIGS. 11 and 12, the sidewall 74' of the outer housing 60' illustratively includes snap fingers 308 having radially inwardly extending tabs 310. The body 192' of the mixer 190' includes an annular groove 312 to receive the tabs 310. More particularly, the snap fingers 308 bias the tabs 310 into the groove 312 to axially retain the mixer 190' to the outer housing 60' while permitting rotation therebetween.

[0070] With further reference to FIGS. 11 and 12, the end wall 193 of the mixer 190' includes first and second bearing surfaces 314a and 314b to engage the plate 137a of the carrier 130'. The first and second bearing surfaces 314a and 314b are illustratively axially outwardly extending (i.e., bumped out) surfaces arranged in concentric rings (i.e., annular) to reduce surface contact between the mixer 190' and the carrier 130'.

[0071] With further reference to FIGS. 11-13, 17 and 18, an outer surface of the carrier 130' illustratively includes a bearing surface 316 to engage the rear surface 300 of the motor case 123'. The bearing surface 316 illustratively includes an axially outwardly extending (i.e., bumped out) surface arranged in a ring (i.e., annular) to reduce surface contact between the carrier 130' and the motor 68'.

[0072] With reference to FIGS. 11 and 18, each planet gear 134 includes bearing surfaces 318a and 318b supported by outer surfaces of the first and second stages 138 and 140, respectively. These bearing surfaces 318a and 318b illustratively include axially outwardly extending (i.e., bumped out) surfaces engaging opposing inner surfaces of the carrier plates 137a and 137b, respectively. These bearing surfaces 318a and 318b are illustratively ring shaped (i.e., annular).

[0073] Each planet gear 134 illustratively includes angular alignment features. More particularly, FIGS. 17 and 18 show planet gears 134 including a plurality of circumferentially spaced slots 320a, 320b, 320c, 322 formed in a face 323 of the first stage 138. The slot 322 cooperates with a slot 324 formed in the plate 137a of the carrier 130' to define an alignment device for the planet gear 134.

[0074] More particularly, each slot 320a, 320b, 320c has a first arc length while the slot 322 has a second arc length, wherein the second arc length is greater than the first arc length. The slot 324 has an arc length similar to the second arc length of the slot 322. Alignment of theslot 322 of the carrier 130' with the slot 324 of the planet gear 134 angularly aligns (i.e., rotationally orients) the planet gear 134 to the carrier 130', and thus the teeth 142 of the planet gear 134 to the teeth 150 of the static ring gear 146'. A tool including a curved blade (not shown) may be inserted into the slots 322 and 324 to align the planet gear 134. As may be appreciated, the tool blade may have a width greater than the first arc length of the slots 320a, 320b, 320c but less than the second arc length of the slot 322 for receipt therein. As such, the tool blade will only fit within the slot 322 and not within the slots 320a, 320b, 320c.

[0075] 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 motor assembly at least partially supported within the outer housing and including a motor shaft coaxially aligned with the longitudinal axis; a gear assembly operably coupling the motor assembly and the flow control element, the gear assembly configured to rotate the flow control element; and wherein the gear assembly includes a sun gear operably coupled to the motor shaft, a planet gear assembly operably coupled to the sun gear, a static ring gear fixed to the outer housing and operably coupled to the planet gear assembly, and a driving ring gear fixed to the movable flow control element and operably coupled to the planet gear assembly.

2. The electronic shower valve of claim 1, wherein the planet gear assembly includes a plurality of planet gears rotatably supported by a carrier, each planet gear including a first stage and a second stage, the first stage engaging the static ring gear, and the second stage engaging the driving ring gear.

3. The electronic shower valve of claim 2, wherein the carrier of the valve cartridge includes opposing plates supporting the planet gears, and each planet gear includes outwardly extending bearing surfaces engaging inner surfaces of the opposing plates of the carrier.

4. The electronic shower valve of claim 2, wherein the carrier includes an annular bearing surface engaging the motor assembly.

5. The electronic shower valve of claim 2, wherein the valve cartridge further includes a planet gear alignment device, the planet gear alignment device having a plurality of circumferentially spaced slots supported by each planet gear, and a cooperating slot supported by the carrier for alignment with one of the slots of the planet gear.

6. The electronic shower valve of claim 1, wherein the gear assembly is at least partially supported within the outer housing and is coaxially aligned with the longitudinal axis.

7. The electronic shower valve of claim 1, wherein the motor assembly includes a fixed stator coaxially aligned with the longitudinal axis, and a rotor configured for rotation relative to the stator.

8. 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.

9. 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.

10. The electronic shower valve of claim 9, wherein the temperature sensor comprises a thermistor, the flow control element includes a center opening, and the thermistor extends through the center opening.

11. The electronic shower valve of claim 1, wherein the valve cartridge further includes a mixer operably coupled to the flow control element, and in fluid communication with the cold water inlet and the hot water inlet.

12. The electronic shower valve of claim 11, wherein the outer housing of the valve cartridge includes a plurality of snap fingers, and the mixer of the valve cartridge includes an annular groove, the snap fingers received within the annular groove to axially retain the mixer to the outer housing while permitting relative rotation therebetween.

13. The electronic shower valve of claim 11, wherein the planet gear assembly of the valve cartridge includes a plurality of planet gears rotatably supported by a carrier, and the mixer of the valve cartridge includes an annular bearing surface engaging with the carrier.

14. The electronic shower valve of claim 1, wherein the outer housing of the valve cartridge includes a plurality of circumferentially spaced openings, and the motor assembly of the valve cartridge includes a plurality of circumferentially spaced locking tabs received within the openings of the outer housing.

15. 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, at least one 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 at least one water inlet; a gear assembly configured to rotate the flow control element; wherein the gear assembly includes a sun gear operably coupled to the motor shaft, a planet gear assembly operably coupled to the sun gear, a static ring gear fixed to the outer housing, and a driving ring gear fixed to the movable flow control element; and wherein the planet gear assembly includes a plurality of planet gears rotatably supported by a carrier, each planet gear including a first stage and a second stage, the first stage engaging the static ring gear, and the second stage engaging the driving ring gear.

16. The electronic shower valve of claim 15, further comprising a motor assembly at least partially supported within the outer housing and including a motor shaft coaxially aligned with the longitudinal axis, the motor assembly operably coupled to the gear assembly.

17. The electronic shower valve of claim 16, wherein the motor assembly includes a fixed stator coaxially aligned with the longitudinal axis, and a rotor configured for rotation relative to the stator.

18. The electronic shower valve of claim 15, wherein the at least one inlet includes a cold water inlet and a hot water inlet.

19. The electronic shower valve of claim 15, wherein the gear assembly is at least partially supported within the outer housing and is coaxially aligned with the longitudinal axis.

20. The electronic shower valve of claim 15, 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.

21. The electronic shower valve of claim 20, 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.

22. The electronic shower valve of claim 21, wherein the temperature sensor comprises a thermistor, the flow control element includes a center opening, and the thermistor extends through the center opening.

23. The electronic shower valve of claim 15, wherein the valve cartridge further includes a planet gear alignment device, the planet gear alignment device having a plurality of circumferentially spaced slots supported by each planet gear, and a cooperating slot supported by the carrier for alignment with one of the slots of the planet gear.

24. The electronic shower valve of claim 15, wherein the valve cartridge further includes a mixer operably coupled to the flow control element, and in fluid communication with the at least one water inlet.

25. The electronic shower valve of claim 24, wherein the outer housing of the valve cartridge includes a plurality of snap fingers, and the mixer of the valve cartridge includes an annular groove, the snap fingers received within the annular groove to axially retain the mixer to the outer housing while permitting relative rotation therebetween.

26. 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 motor assembly at least partially supported within the outer housing and including a motor shaft coaxially aligned with the longitudinal axis; a gear assembly operably coupling the motor assembly and the flow control element, the gear assembly configured to rotate the flow control element; wherein the gear assembly includes a sun gear operably coupled to the motor shaft, a planet gear assembly operably coupled to the sun gear, a static ring gear fixed to the outer housing, and a driving ring gear fixed to the movable flow control element; and wherein the planet gear assembly includes a plurality of planet gears rotatably supported by a carrier, each planet gear including a first stage and a second stage, the first stage engaging the static ring gear, and the second stage engaging the driving ring gear.

27. The valve cartridge of claim 26, wherein the motor assembly includes a fixed stator coaxially aligned with the longitudinal axis, and a rotor configured for rotation relative to the stator.

28. The valve cartridge of claim 26, wherein the gear assembly is at least partially supported within the outer housing and is coaxially aligned with the longitudinal axis.

29. The valve cartridge of claim 26, further comprising a temperature sensor configured to detect a temperature of water within the internal chamber.

30. The valve cartridge of claim 29, wherein the temperature sensor comprises a thermistor, the flow control element includes a center opening, and the thermistor extends through the center opening.

31. The valve cartridge of claim 26, further including a planet gear alignment device, the planet gear alignment device having a plurality of circumferentially spaced slots supported by each planet gear, and a cooperating slot supported by the carrier for alignment with one of the slots of the planet gear.

32. The valve cartridge of claim 26, further including a mixer operably coupled to the flow control element, and in fluid communication with the cold water inlet and the hot water inlet.

33. The valve cartridge of claim 32, wherein the outer housing includes a plurality of snap fingers, and the mixer includes an annular groove, the snap fingers received within the annular groove to axially retain the mixer to the outer housing while permitting relative rotation therebetween.

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