U.S. patent application number 15/159374 was filed with the patent office on 2016-11-24 for faucet assembly.
The applicant listed for this patent is Chung-Chia Chen. Invention is credited to Chung-Chia Chen.
Application Number | 20160340879 15/159374 |
Document ID | / |
Family ID | 51521988 |
Filed Date | 2016-11-24 |
United States Patent
Application |
20160340879 |
Kind Code |
A1 |
Chen; Chung-Chia |
November 24, 2016 |
FAUCET ASSEMBLY
Abstract
A touch-free faucet provides control over flow and/or
temperature by detecting object presence in one or more detection
zones. In one embodiment, the faucet provides for continuous-flow
water flow wherein the spout of the faucet pours water for a period
of time regardless of whether an object is detected in a detection
zone, such as the sink, during that time. The faucet may initiate
continuous-flow based on the detection of an object in another
detection zone, and may cause continuous-flow operation for a
determined period of time based on the amount of substantially
uninterrupted time during which an object is detected in a
detection zone associated with initiating continuous-flow mode.
Furthermore, the faucet may provide for user-programmable
sensitivity affecting the amount of continuous-flow time that is
determined based on the amount of time that the faucet detects
object in the continuous-flow mode detection zone.
Inventors: |
Chen; Chung-Chia; (La Habra
Heights, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Chen; Chung-Chia |
La Habra Heights |
CA |
US |
|
|
Family ID: |
51521988 |
Appl. No.: |
15/159374 |
Filed: |
May 19, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
13843148 |
Mar 15, 2013 |
9347207 |
|
|
15159374 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
Y10T 137/86389 20150401;
E03C 1/057 20130101; Y10T 137/9464 20150401; F16K 11/074 20130101;
Y10T 137/1842 20150401; Y10T 137/2496 20150401; E03C 1/0404
20130101; E03C 2001/026 20130101; Y10T 137/8208 20150401; F16K
19/006 20130101 |
International
Class: |
E03C 1/05 20060101
E03C001/05; F16K 11/074 20060101 F16K011/074; E03C 1/04 20060101
E03C001/04 |
Claims
1.-15. (canceled)
16. A control valve apparatus for a touch-free faucet, the control
valve apparatus comprising: an electrical power supply package; a
logic processor electronically coupled to said electrical power
supply package; a user-notification component electronically
coupled to said logic processor; and a water-detection component
configured to detect the presence of water and, in response
thereto, provide a water-detection signal to the logic processor;
wherein said logic processor is configured to receive said
water-detection signal and, in response thereto, transmit a signal
to said user-notification component, thereby causing said
user-notification component to transmit an indication of a detected
water leak.
17. The apparatus of claim 16, wherein said water-detection
component comprises an electronic humidity sensor such as capacitor
humidity sensor, resistive humidity sensor or thermal conductivity
sensor to detect humidity increase inside the control valve box due
to the water leaking from the control box.
18. The apparatus of claim 16, wherein said water-detection
component comprises two sensor diodes such that, in the presence of
sufficient water, the two sensor diodes form a circuit having a
signal conducted by said water and, in the absence of sufficient
water, the two sensor diodes do not form a circuit.
19. The apparatus of claim 16, wherein said user-notification
component comprises an audio notification component configured to
make an audible notification of a detected water leak.
20. The apparatus of claim 17, wherein said audio notification
component comprises a beep-component configured to transmit a
beeping noise as a notification of a detected water leak.
21. The apparatus of claim 17, wherein said audio notification
component comprises a voice-component configured to transmit a
spoken statement as a notification of a detected water leak.
22. The apparatus of claim 16, wherein said user-notification
component comprises a display notification component configured to
provide a visual notification of a detected water leak.
23. The apparatus of claim 22, wherein said display notification
component comprises a light-emitting diode (LED) that provides a
blinking indication of a detected water leak.
24. The apparatus of claim 22, wherein said display notification
component comprises a display screen component configured to
display a plurality of images on a screen, including an image
indicating a detected water leak.
25. The apparatus of claim 16, further comprising a water control
valve configured to receive one or more signals from said logic
processor and, in response thereto, adjust the temperature and/or
flow rate of water passing through the valve, and wherein the logic
processor is further configured, in response to the receipt of a
water-detection signal, to transmit a shutoff signal to the water
control valve thereby causing the water control valve to shut off
the flow of water exiting the water control valve.
26.-28. (canceled)
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application
Ser. No. 13/843,148, filed Mar. 15, 2013, pending, the entire
contents is hereby incorporated by reference herein and made part
of this specification for all that it discloses.
BACKGROUND
[0002] Touch-free faucets can provide a more hygienic means of
washing hands and performing other tasks associated with
traditional faucets. Touch-free faucets typically operate by
sensing the presence of an object in a detection area, and pouring
water in response to that detected object. However, there remains a
need to enhance the available features of faucet assemblies with
touch-free capabilities and to allow users an opportunity to
manipulate various functional attributes.
[0003] Faucet assemblies may include a control valve responsible
for controlling the temperature and/or flow rate of water poured by
the faucet. However, existing control valves may introduce
inefficiencies such as energy loss through lost radiant heat, and
delays in providing water at a desired temperature and flow rate to
the faucet spout.
SUMMARY OF SOME EMBODIMENTS
[0004] In some embodiments, a faucet apparatus for providing
user-controllable continuous water flow may include a spout
configured to direct water flow into a sink; a logic processor; a
first sensor zone comprising a first sensor, said first sensor
facing the area in which the spout is configured to direct water to
flow; and a second sensor zone comprising a second sensor, said
second sensor configured to detect an object in the second sensor
zone and respond to the detection by providing input to the logic
processor; wherein the logic processor is programmed to: determine
whether an electronic representation of a flow state is in either a
primary-water-flow-mode or a continuous-water-flow mode; receive
input from the first sensor indicating the presence of an object
within the first sensor zone and, in response thereto, cause the
spout to direct water flow while the input from the first sensor
indicates than an object is present in the first sensor zone; cause
the spout to stop directing water flow when the input from the
first sensor indicates that no object is present within the first
sensor zone, if it is determined that the electronic representation
of the flow state is in the primary-water-flow-mode; and receive
input from the second sensor indicating the presence of an object
within the second sensor zone and, in response thereto, if the
electronic representation of the flow state is in the
primary-water-flow-mode, determine an amount of time for continuous
water flow based on the amount of substantially uninterrupted time
in which the object is detected in the second sensor zone and in
response thereto, change the electronic representation of the flow
state from the primary-water-flow-mode to the
continuous-water-flow-mode, and cause the spout to direct water
flow for the determined amount of time for continuous water flow,
regardless of whether an object is present in the first sensor
zone.
[0005] In some embodiments, the logic processor may be further
programmed to receive input from the second sensor indicating the
presence of an object within the second sensor zone and, in
response thereto, if the electronic representation of the flow
state is in the continuous-water-flow mode, cause the spout to stop
directing water to flow.
[0006] In some embodiments, the logic processor may be further
programmed to receive input from the second sensor indicating the
presence of an object within the second sensor zone and, in
response thereto, if the electronic representation of the flow
state is in the continuous-water-flow mode, increase the determined
amount of time for continuous water flow.
[0007] In some embodiments, the logic process may be further
programmed to receive input from the second sensor indicating the
presence of an object within the second sensor zone and, in
response thereto, if the electronic representation of the flow
state is in the continuous-water-flow mode, increase the determined
amount of time for continuous water flow as a function of the
amount of time that the object is detected within the second sensor
zone substantially interrupted.
[0008] In some embodiments, the logic process may be further
programmed to receive input from the second sensor indicating the
presence of an object within the second sensor zone and, in
response thereto, if the electronic representation of the flow
state is in the continuous-water-flow mode and the object is
detected for at least a minimum threshold amount of time, increase
the determined amount of time for continuous water flow; and
receive input from the second sensor indicating the presence of an
object within the second sensor zone and, in response thereto, if
the electronic representation of the flow state is in the
continuous-water-flow mode and the object is detected for less than
a minimum threshold amount of time, cause the spout to stop
directing water to flow.
[0009] In some embodiments, the apparatus further may include a
display element, wherein the display element is configured to
provide a visual indication when the electronic representation of a
flow state is in continuous-water-flow mode.
[0010] In some embodiments, the logic processor may be further
programmed to receive a first input from the second sensor
indicating the presence of an object within the second sensor zone
and, in response thereto, if the electronic representation of the
flow state is in the primary-water-flow-mode, determine an amount
of time for continuous water flow based on the amount of
substantially uninterrupted time in which the object is detected in
the second sensor zone and in response thereto, change the
electronic representation of the flow state from the
primary-water-flow-mode to the continuous-water-flow-mode, and
cause the spout to direct water flow for the determined amount of
time for continuous water flow, regardless of whether an object is
present in the first sensor zone; and receive a second input from
the second sensor indicating the presence of an object within the
second sensor zone and, in response thereto, if the electronic
representation of the flow state is in the primary-water-flow-mode
and the second input was received within a predetermined duration
from when the first input was received, change the electronic
representation of the flow state from the primary-water-flow-mode
to the continuous-water-flow-mode, and cause the spout to direct
water flow for the same determined amount of time for continuous
water flow as was determined in response to the receipt of the
first input, regardless of whether an object is present in the
first sensor zone.
[0011] In some embodiments, the assembly further may include a
third sensor zone comprising a third sensor, the third sensor
configured to detect an object in the third sensor zone and respond
to the detection by providing input to the logic processor; and
wherein the logic processor is further programmed to determine an
electronic representation for a continuous-water-flow
timing-sensitivity level; receive input from the third sensor
indicating the presence of an object within the third sensor zone
and, in response thereto, change the electronic representation for
the continuous-water-flow-sensitivity level; and receive input from
the second sensor indicating the presence of an object within the
second sensor zone and, in response thereto, if the electronic
representation of the flow state is in the primary-water-flow-mode,
determine an amount of time for continuous water flow based on both
the amount of substantially uninterrupted time in which the object
is detected in the second sensor zone and the continuous-water-flow
timing-sensitivity level, and in response thereto, change the
electronic representation of the flow state from the
primary-water-flow-mode to the continuous-water-flow-mode, and
cause the spout to direct water flow for the determined amount of
time for continuous water flow, regardless of whether an object is
present in the first sensor zone.
[0012] In some embodiments wherein changing the electronic
representation for the continuous-water-flow-sensitivity level
comprises setting the electronic representation for the
continuous-water-flow-sensitivity level to one of a low-sensitivity
state, a medium-sensitivity state, or a high-sensitivity state, the
logic processor may be further programmed to, in response to
receiving input from the second sensor indicating the presence of
an object within the second sensor zone, determine an amount of
time for continuous water flow as the product of the amount of
substantially uninterrupted time in which the object is detected in
the second sensor zone and either a low-sensitivity multiplier, a
medium-sensitivity multiplier, or a high-sensitivity multiplier,
depending on which of the respective
continuous-water-flow-sensitivity levels the electronic
representation for the continuous-water-flow-sensitivity level is
set to, wherein the low-sensitivity multiplier is a lower numeric
value than the medium-sensitivity multiplier and the
medium-sensitivity multiplier is a lower numeric value than the
high-sensitivity multiplier.
[0013] In some such embodiments, the low-sensitivity multiplier may
be 5, the medium-sensitivity multiplier may be 15, and the
high-sensitivity multiplier may be 60 such that, if an object is
detected in the second sensor zone substantially uninterrupted for
5 seconds, the logic processor is configured to determine the
amount of time for continuous water flow as 25 seconds if the
continuous-water-flow-sensitivity level is in the low-sensitivity
state, the logic processor is configured to determine the amount of
time for continuous water flow as 75 seconds if the
continuous-water-flow-sensitivity level is in the
medium-sensitivity state, and the logic processor is configured to
determine the amount of time for continuous water flow as 5 minutes
if the continuous-water-flow-sensitivity level is in the
high-sensitivity state.
[0014] In some embodiments, wherein changing the electronic
representation for the continuous-water-flow-sensitivity level
comprises setting the electronic representation for the
continuous-water-flow-sensitivity level to a multiple calculated as
a function of the amount of substantially uninterrupted time in
which an object is detected in the second sensor zone.
[0015] In some embodiments, the second sensor zone overlaps with
the third sensor zone.
[0016] In some embodiments the logic processor is further
configured to reset the electronic representation for the
continuous-water-flow-sensitivity level to a default value after a
predetermined period of time.
[0017] In some embodiments further comprising a display element,
the display element may be configured to provide a visual
indication of the continuous-water-flow timing-sensitivity
level.
[0018] In some embodiments, the display element may be a light
emitting diode configured to blink as an indication of the
continuous-water-flow timing-sensitivity level, such that the light
emitting diode is configured to blink a larger number of times as
an indication of a higher continuous-water-flow timing-sensitivity
level and the light emitting diode is further configured to blink a
smaller number of times as an indication of a lower
continuous-water-flow timing-sensitivity level.
[0019] In some embodiments of a control valve apparatus for a
touch-free faucet, the control valve apparatus may include an
electrical power supply package; a logic processor electronically
coupled to said electrical power supply package; a
user-notification component electronically coupled to said logic
processor; and a water-detection component configured to detect the
presence of water and, in response thereto, provide a
water-detection signal to the logic processor; wherein said logic
processor is configured to receive said water-detection signal and,
in response thereto, transmit a signal to said user-notification
component, thereby causing said user-notification component to
transmit an indication of a detected water leak.
[0020] In some embodiments, the water-detection component can
include an electronic humidity sensor such as capacitor humidity
sensor, resistive humidity sensor or thermal conductivity sensor to
detect humidity increase inside the control valve box due to the
water leaking from the control box.
[0021] In some embodiments, the water-detection component can
include two sensor diodes such that, in the presence of sufficient
water, the two sensor diodes form a circuit having a signal
conducted by said water and, in the absence of sufficient water,
the two sensor diodes do not form a circuit.
[0022] In some embodiments the user-notification component
comprises an audio notification component configured to make an
audible notification of a detected water leak.
[0023] In some embodiments, the audio notification component
comprises a beep-component configured to transmit a beeping noise
as a notification of a detected water leak.
[0024] In some embodiments, the audio notification component may
include a voice-component configured to transmit a spoken statement
as a notification of a detected water leak.
[0025] In some embodiments, the user-notification component may
include a display notification component configured to provide a
visual notification of a detected water leak.
[0026] In some embodiments, the display notification component may
include a light-emitting diode (LED) that provides a blinking
indication of a detected water leak.
[0027] In some embodiments, the display notification component may
include a display screen component configured to display a
plurality of images on a screen, including an image indicating a
detected water leak.
[0028] In some embodiments, the water control valve may be
configured to receive one or more signals from said logic processor
and, in response thereto, adjust the temperature and/or flow rate
of water passing through the valve, and wherein the logic processor
is further configured, in response to the receipt of a
water-detection signal, to transmit a shutoff signal to the water
control valve thereby causing the water control valve to shut off
the flow of water exiting the water control valve.
[0029] In some embodiments, of a control valve apparatus for
controlling the temperature and flow-rate of water flow, the
control valve apparatus may include a cold water inlet connector; a
warm water inlet connector; a water temperature control housing
comprising a water temperature control cartridge, the water
temperature control housing configured to receive cold water from
the cold water inlet connector and receive warm water from the warm
water inlet connector, wherein the water temperature control
cartridge includes one or more openings arranged to permit the flow
of cold and warm water from the cold water inlet connector and warm
water inlet connector, respectively; a temperature-control motor
unit configured to control the rotational position of the water
temperature control cartridge, wherein the temperature-control
motor unit is configured to receive a temperature control signal
from a logic processor, and in response thereto, control the ratio
of cold water received to warm water received by adjusting the
rotational position of the water temperature control cartridge; a
water flow control valve comprising a water flow control cartridge,
said water flow control cartridge including one or more openings
arranged to provide adjustable amount of flow of mixed-temperature
water through the water flow control valve; a flow-control motor
unit configured to control the rotational position of the flow
control cartridge, wherein the flow-control motor unit is
configured to receive a flow control signal from a logic processor,
and in response thereto, control the rate that mixed-temperature
water flows through the water control valve; and a water outlet
nozzle configured to provide outflow of mixed temperature water at
a temperature and rate controlled by the control valve; wherein
said cold water inlet connector, warm water inlet connector, water
temperature control housing, water flow control valve, and water
outlet nozzle are configured substantially along a single plane;
and wherein the distance between the water temperature control
housing and the water flow control valve is less than the internal
diameter of the water temperature control housing.
[0030] In some embodiments, the motor unit may include a stepper
motor.
[0031] In some embodiments, the water flow control valve may
include a solenoid valve.
BRIEF DESCRIPTION OF DRAWINGS
[0032] The accompanying drawings, which are incorporated in and
form a part of this specification, illustrate example embodiments
of the inventive subject matter, and in no way limit the scope of
protection. The accompanying drawings illustrate embodiments
wherein:
[0033] FIG. 1 depicts an embodiment of a touch-free faucet
assembly, including a spout with embedded sensors, a logic
processor circuit board, a power supply, and a control valve
assembly.
[0034] FIG. 2 illustrates an embodiment of a control valve.
[0035] FIG. 3A illustrates a top view of the control valve of FIG.
2.
[0036] FIG. 3B illustrates a cross-sectional side view of the
control valve of FIG. 2 taken along the line 3B-3B.
[0037] FIG. 4A illustrates a top view of one embodiment of a
control valve cartridge assembly.
[0038] FIG. 4B illustrates a cross-sectional side view of the
control valve cartridge assembly of FIG. 4A taken along the line
4B-4B.
[0039] FIG. 5A illustrates an embodiment of a water-temperature
control module assembly from a control valve cartridge
assembly.
[0040] FIG. 5B illustrates an embodiment of a water-flow control
module assembly from a control valve cartridge assembly.
[0041] FIG. 6 is an exemplary graph illustrating the water flow
pattern of a control valve cartridge assembly, showing water flow
rate as a function of cartridge rotation.
[0042] FIG. 7A illustrates an embodiment of a water-temperature
control module of a control cartridge.
[0043] FIG. 7B illustrates an embodiment of a water-flow control
module of a control cartridge assembly.
[0044] FIG. 7C illustrates another embodiment of a
water-temperature control module.
[0045] FIG. 8 illustrates an embodiment of a water control
cartridge assembly.
[0046] FIG. 9A illustrates an embodiment of a control valve
assembly with open sockets for water control cartridge
assemblies.
[0047] FIG. 9B illustrates a top view of the control valve assembly
of FIG. 9A.
[0048] FIG. 9C illustrates a cross-sectional side view of the
control valve assembly of FIG. 9A taken along the line 9C-9C.
[0049] FIG. 10 is a flow-chart depicting an embodiment of a method
for providing both touch-free primary-flow water operation and
user-set continuous-flow water operation.
[0050] FIG. 11A depicts an embodiment of a control valve assembly
comprising a flow control valve assembly and a temperature control
valve assembly.
[0051] FIG. 11B depicts an embodiment of a control valve assembly
comprising a flow control valve assembly and a temperature control
valve assembly.
[0052] FIG. 12A depicts an embodiment of a control valve assembly
comprising a merged flow control valve assembly and temperature
control valve assembly.
[0053] FIG. 12B depicts an embodiment of a control valve assembly
comprising a merged flow control valve assembly and temperature
control valve assembly.
[0054] FIG. 13 depicts an embodiment of a touch-free faucet
assembly, including a logic processor circuit board, a water flow
control assembly and a water temperature control assembly.
[0055] FIG. 14 depicts an embodiment of a spout for use in a
touch-free faucet assembly, comprising embedded sensors.
[0056] FIG. 15 depicts an embodiment of a logic processor circuit
board, input signals to the circuit board, and output signals from
the circuit board.
[0057] FIG. 16 depicts an embodiment of communications channels
amongst various elements of a touch-free faucet, and various
functionalities associated with those communications channels.
[0058] FIG. 17 depicts an embodiment of functionality associated
with various sensor elements of a touch-free faucet, including
which sensors may trigger which functional program, and certain
user-visible indicators of functional state.
[0059] FIG. 18A illustrates an embodiment of a touch-free control
apparatus for use as a bathtub faucet.
[0060] FIG. 18B illustrates an embodiment of a touch-free control
apparatus.
[0061] FIG. 19 is a flow-chart depicting one embodiment of a method
for adjusting the user-programmable continuous flow timing
sensitivity of a touch-free faucet, and then initiating a
continuous flow based on that user-programmed continuous flow
timing sensitivity.
[0062] FIG. 20 illustrates an embodiment of a faucet apparatus that
includes functionality for water leakage detection in the control
valve box of a touch-free faucet.
[0063] FIG. 21A illustrates an embodiment of a of a faucet control
assembly that includes a sensor control panel assembly to control
water temperature and flow.
[0064] FIG. 21B illustrates an embodiment of a of a faucet control
assembly that includes multiple sensors control water temperature
and flow.
[0065] FIG. 21C illustrates an embodiment of a of a faucet control
assembly that includes a sensor array to control water temperature
and flow.
[0066] FIG. 21D illustrates an embodiment of a of a faucet control
assembly that includes a camera to sense an object to control water
temperature and flow.
[0067] FIG. 22 is a perspective view of a compartment housing
sensors for touch-free control of a faucet.
[0068] FIG. 23 is a front view of a compartment housing sensors for
touch-free control of a faucet.
[0069] FIG. 24 is a rear view of a compartment housing sensors for
touch-free control of a faucet.
[0070] FIG. 25 is a top view of a compartment housing sensors for
touch-free control of a faucet.
[0071] FIG. 26A is a bottom view of a compartment housing sensors
for touch-free control of a faucet.
[0072] FIG. 26B is a bottom view of a compartment housing sensors
for touch-free control of a faucet.
[0073] FIG. 27 is a side view of a compartment housing sensors for
touch-free control of a faucet.
[0074] FIG. 28 is a side view of a compartment housing sensors for
touch-free control of a faucet.
[0075] FIG. 29 is a perspective view of a touch-free,
wall-mountable faucet.
[0076] FIG. 30 is a top view of a touch-free, wall-mountable
faucet.
[0077] FIG. 31 is a bottom view of a touch-free, wall-mountable
faucet.
[0078] FIG. 32 is a front view of a touch-free, wall-mountable
faucet.
[0079] FIG. 33 is a rear view of a touch-free, wall-mountable
faucet.
[0080] FIG. 34 is a side view of a touch-free, wall-mountable
faucet.
[0081] FIG. 35 is a side view of a touch-free, wall-mountable
faucet.
DETAILED DESCRIPTION
[0082] The following description is made for the purpose of
illustrating various embodiments and is not meant to limit the
inventive concepts described or claimed herein. Further, particular
features described herein can be used in combination with other
described features in each of the various possible combinations and
permutations. Unless otherwise specifically defined herein, all
terms are to be given their broadest possible interpretation
including meanings implied from the specification, as well as
meanings understood by those skilled in the art and/or as defined
in dictionaries, treatises, etc. The description discloses several
embodiments of a control valve assembly for use with faucet
assemblies, as well as operation and/or component parts thereof.
While the following description will be described in terms of
control valve assembly for automatic touch-free faucets for clarity
and placing various embodiments in context, it should be kept in
mind that the teachings herein may have broad application to other
types of systems, devices, and methods.
[0083] FIG. 1 depicts an illustrative touch-free automatic faucet
including a control valve assembly according to an embodiment and a
schematic representation of additional components that may be
associated therewith. The illustrative touch-free automatic faucet
system (100) includes a faucet spout (101) with sensor assembly
(103), a logic processor circuit board (105), an electrical power
supply package (104) and a control valve assembly (106). In some
embodiments, the power supply package (104) may include one or more
a batteries, a solar cell system, direct current voltage supplied
from an AC/DC converter, or any combination thereof.
[0084] The sensor assembly (103) is configured to received sensing
signals from sensors which may be positioned on the faucet spout.
In some embodiments, the sensors may be positioned on a separate
control console and can communicate with the logic processor
circuit board (105). Communication between the sensors may be
through a wired link or wireless for example using Bluetooth or
wireless communication technologies. The logic processor circuit
board (105) can be powered (122) by an electrical power supply
package (104) and can communicate with control valve assembly (106)
to control the input cold water supply (111) and hot water supply
(112) and output the adjusted mixed water (115) at the desired
water temperature to the faucet spout. In some embodiments, sensors
may communicate individually with the logic processor circuit board
(105) without a sensor assembly.
[0085] Embodiments of the control valve assembly (106) may include
a water temperature control valve assembly (107) including a two
way temperature control valve (131), which, in some embodiments,
can be a motorized gear driven valve, though other types of valves
are also possible. The control valve assembly (106) may also
include a water flow control valve assembly (108) which may include
a water-flow control valve (132), a water temperature detection
device (133), and an on/off valve 134. In some embodiments, the
water-flow control valve (132) may be a motorized gear driven
valve, though other types of valves are also possible. In some
embodiments, valve (134) may be a solenoid valve, though other
types of valves are also possible. In some embodiments, valve (134)
is capable of rapid shifts from a first closed position to a second
position. In some embodiments, the second position may be partially
or fully open and the valve is configured to return to the second
position that was used prior to switching to the first position.
Thus, such valves are capable of rapidly returning to a position
that allows a set flow there through.
[0086] In some embodiments, the control valve assembly (106) may
receive signals to manipulate the flow of fluid through the
assembly. For example, the water temperature control valve assembly
(107) may receive one or more control signals (123) from a logic
processor (105) instructing the valve to adjust the water mixing
ratio of cold water (111) and hot water (112). For example, the
temperature control valve may adjust the mixing ratio of hot water
and cold water by controlling the relative intake levels of hot
water from a hot water input (112) and cold water from a cold water
input (111).
[0087] In some embodiments, the water flow control valve assembly
(108) receives one or more signals (124) from logic processor (105)
to adjust the rate at which the temperature-controlled, mixed water
(113) may flow though the control valve assembly (106). For
example, by restricting the flow rate through the flow control
valve (108), the control valve assembly (106) may restrict the rate
of flow of water through various portions of the water flow path,
including the flow through the temperature detection device (133),
which in some embodiments may be a thermometer, thermister,
thermocouple, etc. The mixed hot/cold water (114) can then flow
through a valve (134) that may serve to toggle water flow on and
off. As discussed above, in some embodiments, valve (134) may be a
solenoid or other appropriate valve capable of rapid switching. In
some embodiments, a solenoid valve may facilitate on/off water
toggling by rapidly returning to the state of water flow from prior
use when water flow is resumed. A mechanical valve may be capable
of shutting water flow off by rotating to a fully closed position,
however a mechanical valve may subsequently turn water flow back on
by first rotating through a range of low flow rate before reaching
a desired flow rate.
[0088] By placing a valve (134) that is capable of rapid on/off
flow rate control in line with a valve (132), the valve (134) may
control on/off toggle so that the valve (132) retains its
rotational position for a selected flow rate, causing water flow to
promptly resume at that rate once flow is turned back on. A valve
134 dedicated to on/off functionality may further provide a more
rapid response to signals instructing water flow to turn on or off.
In the illustrated embodiment, the flow controlled water (115) is
output to the faucet spout (101).
[0089] In some embodiments, a temperature detector (133) measures
the temperature of the water after the hot water has been mixed
with the cold water in the temperature control valve assembly
(107). The detector 133 may transmit one or more water temperature
signals (125) to the logic processor (105). The system may respond
to the water temperature signals (125) by sending signals back to
the control valve assembly (106) to adjust the temperature. For
example, the logic processor (105) may transmit a signal to the
temperature control valve (107) instructing it to adapt the
temperature mixing ratio in order to generate mixed water flow 114
consistent with a selected temperature.
[0090] In some embodiments, the logic processor (105) may send a
signal to reduce water temperature if the water temperature signal
(125) reveals that the water has exceeded a maximum temperature
safety level. In some embodiments, the faucet apparatus may display
the measured water temperature, based on the water temperature
signal (125) to a user, for example by displaying the temperature
on a liquid crystal display incorporated into the faucet or a
secondary, separate assembly.
[0091] FIG. 2 illustrates an embodiment of a control valve assembly
(106). The lower portion (201) of the water inlet portion of
control valve assembly (106) may include a cold water inlet
connector (111) with a cold water strainer housing (224), which may
include a cold water strainer and a check valve in some
embodiments. The lower portion (201) may also include a hot water
inlet connector (112) with a water strainer housing (225) which may
include a hot water strainer and a check valve in some embodiments.
The upper portion (202) of the control valve assembly (200) may
include a cold water connection nozzle (215) and a hot water
connection nozzle (216). The water temperature control valve
housing (211) houses a water temperature control cartridge that is
used to control the mixing ratio for hot water to cold water. The
upper portion (203) of the motorized gear assembly includes a motor
(231) such as a stepper motor, and a gear actuator (232) connecting
the water temperature control cartridge to the water temperature
control valve housing (211). The water temperature cartridge may be
capable of adjusting the ratio for mixed water flow; this may
control the flow from the housing (211) through a water channel
(113) to a water flow control valve housing (213).
[0092] The portion of the water flow control valve (132) shown as
immediately following the water channel (113) receives the mixed
water through the water channel (113) from the water temperature
control valve housing (211). Attached to the water flow control
valve (132) is a motorized gear assembly (205) that includes a
motor (233), such as a stepper motor, and a gear actuator (234)
connecting the water flow control cartridge housed in the flow
control valve housing (213). The water flow cartridge adjusts water
flow rate and output through the connecting water channel (214)
where a temperature detector (133), for example a thermometer, may
be present to detect water temperature and feed a signal regarding
the temperature back to the logic processor (105). In certain
embodiments, the logic processor uses this signal for water
temperature control in a subsequent portion of the valve (134).
[0093] In the illustrated embodiment, the subsequent portion of
solenoid valve (134) includes a solenoid actuator (236) and a
solenoid valve body (237) to toggle water flow. The use of a
solenoid valve may provide fast response to electronic instructions
affecting turning water flow on or off (e.g., the primary water
flow control Primary-Water-Flow-Mode by Primary Sensor, and
continuous water flow control Continuous-Water-Flow-Mode by
secondary sensor). The use of a solenoid valve may reduce the work
load of water flow control valve (132) and extend the life of motor
gear (205).
[0094] In the illustrated embodiment, a water outlet nozzle (115)
connects an outlet nozzle housing (226). In certain embodiments, a
water flow regulator is included to restrict water flow rate is
housed in the outlet nozzle housing (226). For example, this may
provide water conservation and may comply with regulations or code
such as "water sense" or "NSF". In various embodiments, the valve
housing 106 is formed out of one or more materials including metal,
for example copper, bronze, or stainless steel, or plastic. In some
embodiments, the valve housing is formed of a combination of
plastic, metal, and/or other material. The housing may be formed
through material injection, molding, cutting, 3-dimensional
printing, or other techniques.
[0095] FIG. 3A illustrates a top view of the embodiment shown in
FIG. 2. A cold water inlet connector (361), hot water inlet
connector (371) and a water temperature control motor (231) are
shown. The water channel from water temperature control valve (202)
flows through the connection channel (113) to the water flow
control valve housing (321). The water flow control motor (233) and
gear actuator (234) are also shown.
[0096] FIG. 3B illustrates a side section view of the embodiment
shown in FIG. 2, and as a cross-section of the embodiment shown in
FIG. 3A. As shown, the water supply inlet assembly can include a
cold water inlet connector (111) with a cold water inlet housing
(361). The illustrated cold water inlet housing (361) includes a
cold water strainer (362) to remove foreign particles and/or debris
in the cold water supply and a check valve (363) to prevent
backflow from the hot water supply. The embodiment also includes a
hot water inlet connector (112) with a water inlet housing (371)
for hot water strainer (372) to remove foreign particles and/or
debris in the hot water supply and a check valve (225) to prevent
backflow from the cold water supply. The water temperature control
valve also includes a cold water connect nozzle (364) and a hot
water connect nozzle (374). The water temperature control valve
housing (311) houses the water temperature control cartridge body
(312), a control module including a control disk (313) and a
bushing (367) coupled with a holding spring (366) to control cold
water from the water inlet channel (365). In some embodiments, a
bushing is not present and a different rotation element, such as a
bearing, may be used. The control disk (313) also includes a
bushing (377) coupled with a holding spring (376) to control hot
water from the hot water inlet channel (375) at a mixing cold/hot
water ratio according to the temperature control signal (123) from
the logic processor (105) as shown in FIG. 1. The mixed hot/cold
water flows from the opening of cartridge chamber (314) through the
water channel (113) to the flow control valve (132). A cartridge
shaft housing (315) and a locking nut (316) are also shown. The
bracketed portion of the motorized gear assembly (203) includes a
motor (231), such as a stepper motor, and a gear actuator (232)
connecting the water temperature control cartridge (312). The motor
(231) in the temperature control valve gear assembly (203) turns a
gear actuator (232) that connects with the top portion of the
temperature valve cartridge stem (331). As one or more signals are
received from the logical processor (105), the motor turns the
temperature control valve stem (331) and rotates it to adjust the
size of the cold/hot water control cartridge module opening (313).
In another embodiment, an alternative mechanical control device is
used instead of the illustrated motor.
[0097] The flow control valve housing (321) includes a flow control
cartridge (322) and a control module. The flow control module
includes a control disk (323) and a bushing (319) coupled with a
holding spring (318) to control the mixed hot/cold water from the
water channel (113). In this example, the flow rate of the mixed
hot/cold water is set according to the signal from the logic
processor (105). This is accomplished by rotating the step motor
gear assembly to control the flow rate. A cartridge shaft housing
(325) and a locking nut (326) are also shown. The adjusted water
flow flows through the cartridge opening (324) to the temperature
detection chamber (327) of the bracketed portion of solenoid
control assembly (306). The illustrated solenoid control assembly
(306) includes a thermocouple (133), a solenoid actuator (236) with
a solenoid body (351), a water outlet nozzle (115), a water outlet
connector (381) and a water regulator housing (382). The
thermocouple (133) is positioned to detect the temperature of
outbound water flow and provide information concerning that
temperature to logic processor (105) for water temperature control
and display. The solenoid actuator includes a solenoid coil (352),
a plunger (353), a spring (354) and power supply (355).
[0098] The solenoid valve (236) in embodiment of FIG. 3B is a
direct-acting type solenoid valve. Other embodiments use one or
more other types of solenoid valve, such as a bi-state type
solenoid valve or a diaphragm piloted valve. Still other
embodiments use a different type rapid on-off valve, rather than a
solenoid valve. Similarly, though threaded connectors are shown
with the water inlets and outlets, other sealable connections may
be used.
[0099] FIG. 4A illustrates a top view of one embodiment of a
cartridge assembly (400), such as a water temperature cartridge
assembly or flow cartridge assembly. The cartridge assembly may be
of the type used in FIG. 3, including elements 311-316. In the
illustrated embodiment, two locking bracket (402 and 403) are
attached to the cartridge disk (401). The cartridge shaft (404) and
the motor gear shaft hole (405) that connect the motor gear
assembly are also shown. In another embodiment, securing elements
other than mounting brackets are used. For example, bolts or
adhesive may be used.
[0100] FIG. 4B illustrates a side section view of the water control
cartridge assembly (400) embodiment shown in FIG. 4A. The water
control cartridge (400) includes a cartridge body (451) with
cartridge shaft (452), a cartridge housing (453) and a control
module disk (313). The control module disk (313) controls water
flow through the cartridge chamber (314) and also the water flow
that exits the control valve. O-rings (461 and 462) seal water
leakage between the cartridge shaft (454) and cartridge housing
(453). O-ring (463) seals leakage from the cartridge housing (453)
and water control valve housing (e.g., 311 or 321). In some
embodiments, O-rings are not present and another sealing element
may be used. In the illustrated embodiment, a gasket (315) reduces
the friction between the lower portion (312) of cartridge shaft
(452) and cartridge housing (453) for smooth operation. A thread
hole (316) on the cartridge shaft (452) secures the motor gear
shaft in the motor gear shaft hole (454).
[0101] FIG. 5A illustrates one example of a water temperature
control module assembly, such as the control module in the
cartridge assembly of the embodiment shown in FIG. 3. The water
temperature control module assembly (500) includes a control disk
(313) attached with two locking clips (502 and 503) to lock onto
the water temperature control cartridge (312) in FIG. 3B. The water
temperature control module assembly (500) also includes two sets of
bushings (510 and 512) and holding springs (511 and 513) mounted on
the control valve body (311) of the water temperature control valve
(302) as shown in FIG. 3B. The illustrated example includes a
spring (366) set into the bushing (367). The spring (366) may push
the bushing (367) against the control disk (313) of the cold water
control disk opening (504) on the control disk (313), which may
control the flow of cold water into the cartridge chamber (314) of
FIG. 3B. Cold water flows (521) from the inner opening of one of
the bushings (367) through the cold water control disk opening
(504) of the control disk (313) into the cartridge chamber (314) of
FIG. 3B. Hot water flows (522) from the opening of another bushing
(377) which may be pushed by the spring (376) against the hot water
control disk opening (505) on the control disk (313) into the
cartridge chamber (314) of FIG. 3B. The hot water is mixed with the
controlled cold flow in the chamber (314). The ratio of cold and
hot water flow is controlled by the rotation angle of the control
cartridge and the shape formed by the intersection of the control
disk openings (504) on the control disk (313) with the opening of
bushings (510 and 512). In one example, the shape of disk openings
(504 and 505) on the control disk (313) provide a substantially
linear pattern of cold and hot water flow change, individually, as
the control cartridge rotation angle changes. FIG. 6 illustrates
one example of varying hot water flow and cold water flow rates as
functions of cartridge rotation. In certain embodiments, the
control module disk (313) is constructed of one or more of metal,
plastic, ceramic material, and/or some other material(s). In other
embodiments, a faucet uses a water mixing mechanic other than a
rotating control disc in order to control the ratio of hot water
and cold water that are mixed.
[0102] FIG. 5B illustrates an embodiment of the water flow control
module assembly in the cartridge assembly of the embodiment shown
in FIG. 3. The water flow control module (550) includes a control
disk (323) attached with two locking clips (552 and 553) which may
lock onto the water flow control cartridge (322) in FIG. 3B, a
bushing (319), and a holding springs (318) mounted onto the water
control valve body (321) of the water flow control valve (132) as
shown in FIG. 3B. The spring (318) is set into the bushing (319)
which may cause it to push the bushing (319) against the control
disk (323) of the water flow control disk opening (554) on the
control disk (323). In the present embodiment, this alters the rate
of water flow into the cartridge chamber (324) of FIG. 3B. Water
from the water temperature control valve flows (561) from the
opening of one bushing (319) through the water flow control disk
opening (554) of the flow control disk (323). By affecting the flow
rate of that water, the faucet apparatus adjusts the water flow
rate and output to the temperature detection chamber. In one
example, the shape of the control disk opening (554) on the control
disk (323) may provide for a near linear flow pattern, such as the
pattern illustrated in FIG. 6. The flow rate of the mixed water
flowing from the mixing chamber is affected by the rotation angle
of the control cartridge, the shape and placement of the control
disk opening (554) on the control disk (323) and the opening of the
bushing (319). In certain embodiments, the control module disks may
be constructed of one or more of metal, plastic, ceramic material,
and/or some other material(s).
[0103] FIG. 6 illustrates one example of a graph representing water
flow rates for an embodiment of the water temperature control valve
assembly of the embodiment shown in FIG. 5A. The X-axis (601)
represents the rotational angle of the control cartridge in
degrees. The Y-axis (602) represents the water flow rate in
milliliters per minute. Water flow rate is shown for: hot water
flow, cold water flow, and water flow control rate for the
resulting, mixed water. The flow curve (612) represents the cold
water flow rate when the hot water supply is shut off. The flow
curve (611) represents the hot water flow pattern when the cold
water supply is shut off. The flow curve (613) represents the flow
rate for the mixed water flow of both hot and cold water. All three
of the cold water flow curve (612), the hot water flow curve (611)
and the mixed water flow curve (613) shown in the FIG. 6 are
substantially linear. This may allow a logic processor, such as
logic processor (105) of FIG. 1 to cause substantially linear
changes in water flow rate by sending signals instructing for the
performance of substantially linear changes in cartridge rotation
angle. Referring to FIG. 3B, in the illustrated embodiment, a check
valve (363) is installed before the cold water inlet (365) and
another check valve (375) is installed before the hot water inlet
(112) of the control valve (311) to prevent backflow to the cold or
hot water supply inlet. A water flow control valve (132) is
downstream of the water temperature control valve; as a result, it
is not necessary to shut off both the cold and hot water at same
time. Although the X-axis in FIG. 6 shows a maximum rotation angle
of about 90 degrees, in certain embodiments, other maximum rotation
angles may be used. For example, the shape and size of the cold and
hot control disk openings (504 and 505) of the control disk (313)
can be designed for an angle of about 150 degrees or more according
to the diameter of control disk and the opening size of bushings.
Embodiments with larger rotation angles may still provide
substantially linear flow response. For example, a rotation angle
between about 110 and about 135 degrees may provide for water-flow
response that is both. The control of the angle may be accomplished
by step motor as shown in the illustrated embodiment. The water
flow control disk opening (554) of water flow control disk (323) as
shown in FIG. 5B also can be shaped to obtain a substantially
linear flow pattern similar to the FIG. 6 with a maximum rotation
angle of about 270 degrees or greater. For example, a maximum
rotation angle of about 180 degrees may provide accurate and fast
response for program control by the logic processor (105) in the
illustrated embodiment.
[0104] FIG. 7A illustrates another embodiment of a water
temperature control module of the control cartridge assembly shown
in FIG. 3B. The water temperature control module (700) includes a
top control disk (701) and a bottom control disk (711). The top
control disk has fastening elements (702 and 703) for use in
mounting on the rotation cartridge (312) as shown in FIG. 3B. In
the illustrated embodiment, the fastening elements are
indentations; in other embodiments, clips and/or other fastening
elements may be used. The illustrated embodiment also includes a
cold water control disk opening (704) and a hot water control disk
opening (705). The bottom control disk (711) also has fastening
elements (712 and 713) for use in mounting on the water temperature
control valve body (311) of the water flow control valve (132) as
shown in FIG. 3B, a cold water disk opening (714), and hot water
disk opening (715). The incoming cold water flows (721) from the
bottom of the control disk (711) through the cold water control
disk opening (704) of top control disk (701) into the cartridge
mixing chamber (312) of the water temperature control valve (202)
as shown in FIG. 3B. The incoming hot water flows (722) from bottom
of the control disk (711) through the hot water control disk
opening (705) of top control disk (701) and is mixed with the cold
water in the cartridge mixing chamber (312) of the water
temperature control valve (202) as shown in FIG. 3B. The
illustrated embodiment includes a gasket which may seal the gap
between the bottom control disk (711) and control valve body (311)
to prevent or reduce water leakage into the chamber through some
path other than through the control disk openings (714 and 715). In
another embodiment, a sealing element other than a gasket, such as
packing, is used. In certain embodiments, the control module disks
(701 and 711) are constructed of one or more of metal, plastic,
ceramic material, and/or some other material(s).
[0105] FIG. 7B illustrates another embodiment of a water flow
control module of the control cartridge assembly shown in FIG. 3B.
The water flow control module (750) includes a top control disk
(751) and a bottom control disk (761). The top control disk has
fastening elements (752 and 753) for use in mounting on the
rotation cartridge (322) as shown in FIG. 3B. In the illustrated
embodiment, the fastening elements are indentations; in other
embodiments, clips and/or other fastening elements may be used. The
illustrated embodiment also includes and a water flow control disk
opening (754). The bottom control disk (761) also has fastening
elements (762 and 763) for use in mounting on the water flow
control valve body (321) of water flow control valve (132) as shown
in FIG. 3B and a water flow disk opening (754). The incoming mixed
water flows (764, 723) from the bottom of the control disk (761)
through the water flow control disk open (754) of the top control
disk (751) into the cartridge chamber (322) of the water flow
control valve (132) as shown in FIG. 3B and then flows to the
temperature detection chamber (327) as shown in FIG. 3B. The
illustrated embodiment includes a gasket which may seal the gap
between the bottom control disk (761) and water flow control valve
body (321) to prevent or reduce water leakage into the chamber
through some path other than through the control disk openings (764
and 754). In certain embodiments, the control module disks (751 and
761) are constructed of one or more of metal, plastic, ceramic
material, and/or some other material(s).
[0106] FIG. 7C illustrates another embodiment of a module disk
assembly 770 of the water temperature control module shown in FIG.
3B. The top control module disk (771) includes fastening elements
for use in mounting on the water temperature control valve body
(311) of water temperature control valve (202) as shown in FIG. 3B.
In the illustrated embodiment, the fastening elements are
indentations (772 and 773); in other embodiments, clips and/or
other fastening elements may be used. The illustrated embodiment
also includes a cold water control disk opening (776) and a hot
water control disk opening (777). The generally trapezoidal shape
of the openings of the present embodiment couple with the openings
(774 and 775) of the bottom control module disk to enable the water
flow in a substantially linear pattern. This may enable the logic
processor (105) programming to produce substantially linear changes
in flow characteristic in response to substantially linear changes
in disk rotation. The combination of the top and bottom control
module disk with the trapezoidal shape design can extend the disk
rotation angle 778 to approximately 150 degrees for better water
temperature control. In certain embodiments, both of the control
module disks are constructed of one or more of metal, plastic,
ceramic material, and/or some other material(s). The generally
trapezoidal shape of the openings of the disk design can be applied
on the other flow control disks also disclosed herein.
[0107] FIG. 8 illustrates an embodiment of a water control
cartridge assembly 800 of the water control cartridge assembly
shown in FIG. 3B. The water control cartridge includes a cartridge
body (801) with a shaft (802), a cartridge housing (803) with a
locking clip (804), an O-ring (824) to seal the cartridge, a
control module includes a top control module disk (824), a bottom
module disk (821) and a bottom seal gasket (823). Water flows into
the bottom of the gasket openings (811 and 812) through the opening
of bottom module disk (821) and through the opening of the top
module disk (822), thereby providing control the water flow and
flow out of the cartridge chamber (813 and 814). In some
embodiments, a C-clip (805) holds the cartridge shaft (802) on the
cartridge housing (803). A cut on the cartridge shaft (802) is also
shown. The water control cartridge can be designed for either water
temperature control to mix cold/hot water or to control the water
flow rate according to the design of control module opening of the
top control module disk (822) and bottom control module disk
(821).
[0108] FIG. 9A illustrates an embodiment of the water control valve
body assembly (900). The water control valve body (900) includes
cold water inlet connector (224), a hot water inlet connector
(225), a water temperature control valve (211) with a water
temperature control cartridge housing (914), a water flow control
valve (213) with a flow control cartridge housing (915), a water
temperature detection housing (916) and a water outlet connector
(217). The water control valve body (900) also includes a water
temperature motor control gear assembly bracket (903) and water
flow motor control gear assembly bracket (904).
[0109] FIG. 9B illustrates a top view of one embodiment of a water
control valve body assembly. The water control valve body assembly
includes a water temperature control valve housing (931), a water
flow control valve housing (213), a water temperature motor and
gear control assembly bracket (933), a water flow motor and gear
control assembly bracket (915), a cold water inlet connector (941)
and a hot water inlet connector (113). A cold water inlet channel
(942) with a bushing housing (943), and a hot water inlet channel
(952) with a bushing housing (953) are also shown.
[0110] FIG. 9C illustrates a side view of one embodiment of a water
control valve body assembly. The water control valve body assembly
includes a cold water inlet connector (961) with a cold water inlet
housing (224), a hot water inlet connector (962) with a hot water
inlet housing (225), a water temperature control valve housing
(963) with a water temperature control cartridge housing (914), a
cold/hot mixed water channel (113), a water flow control valve
housing (213) with a water flow control cartridge housing (915), a
thermocouple housing (916) and a water outlet connector (217) with
a water outlet housing (976). Cold water enters (111) from the cold
water connector (961) into the mixing chamber (993) where it mixes
with hot water that enters (112) from the hot water connector (962)
into the mixing chamber (993). The mixed water flows through the
connecting channel (113) to the water flow control valve housing
(213). The mixed water is adjusted by the water flow control
cartridge and flows through the thermocouple housing (916) then
flows out (115) to the water outlet connector (217). In certain
embodiments, the water flow control valve (213) is designed to have
an angle of at least about 90 degrees to the water temperature
control valve (963). For example, this arrangement may provide for
a short path that will reduce the delay of water temperature
response to logic processor control. In some embodiments, the
connecting channel (113) is shorter than the internal diameter of
the cold water inlet housing (225). In some embodiments, the
distance between the water temperature control housing and the
water flow control valve is less than the internal diameter of the
water temperature control housing. In some embodiments, the inlets
and outlets of the assembly 900 are arranged generally parallel to
reduce the turbulence and facilitate movement through the assembly
while keeping the overall size of the assembly small and
efficiently manufactured. Thus, in some embodiments the general
fluid path 994 through the assembly 900 will make a first
approximately 90 degree turn from the inlet portion and mixing
chamber toward the flow control housing through the connecting
channel. The general fluid path 994 then makes a second
approximately 90 degree turn to head toward the fluid outlet.
[0111] In some embodiments, an efficient layout of the control
valve assembly may be used with more or less combinations of the
various components disclosed herein. For example, FIG. 11A
schematically illustrates a control valve assembly having hot water
inlet (112) and cold water inlet (114) directing fluid flow into
temperature control valve assembly (107) which includes a mixing
valve assembly (131) which can adjust the temperature of the water
by adjusting the ratio of the hot and cold water permitted to pass
through. In some embodiments, mixing valve assembly (131) can
utilize a mechanical valve or other valve. For example, the water
temperature control valve assembly A (107) comprises a three-way
motorized gear valve (131) to adjust the cold/hot water flow ratio
from the cold water inlet (111) and the hot water inlet (112)
according to the input signal (123) from the output of logic
processor (105). The adjusted water can then flow into flow control
assembly (108) which can include a valve assembly (132) that can be
used to toggle the fluid flow on and off through the control valve
assembly (106). In some embodiments, valve assembly (132) can
adjust for both flow volume as well as to turn the flow
substantially on or off. In some embodiments, mixing valve assembly
(131) can utilize a mechanical valve or other valve. For example,
the flow control valve assembly B (108) comprises a motorized gear
valve (132). The motorized gear valve (132) adjusts the water flow
(106) to spout (101) according to the signal input (124).
[0112] FIG. 11B illustrates an embodiment of the invention of the
water temperature control valve assembly B (1152) and flow control
valve assembly A (1151). The temperature control valve assembly B
(1152) comprises a three-way motorized gear valve (131) to adjust
the cold/hot water flow ratio from the cold water inlet (111) and
the hot water inlet (112) according to the input signal (123) from
the output of logic processor (105). The flow control valve
assembly B (1151) comprises a motorized gear valve (132) and a
solenoid valve (134). The motorized gear valve (132) adjusts the
water flow according to the signal input (124). The solenoid valve
(134) receives a signal (124) from the logic processor (105) to
toggle on/off the valve (134) to start/stop water flow (106) to the
faucet spout (101). Though described as a solenoid valve, valve
(134) may be any valve capable of rapid response to input
signals.
[0113] FIG. 12A illustrates another water temperature and flow
control valve assembly A/B (1201) according to some embodiments.
The temperature/flow control valve assembly A/B (1201) comprises
two two-way motorized gear valves (1202) (1203) to toggle on/off,
and to adjust the cold/hot water flow ratio from the cold water
inlet (111) and the hot water inlet (112) according to the input
signal (123 and 124) from the output of logic the processor
(105).
[0114] FIG. 12B illustrates a combined water temperature/flow
control valve assembly A (1252) and water on/off flow control valve
assembly B (1251) according to some embodiments. The
temperature/flow control valve assembly A (1252) comprises two
motorized gear valves (1255) and (1256) to adjust the cold/hot
water flow ratio from the cold water inlet (111) and the hot water
inlet (112) respectively, according to the input signal (123) from
the output of logic processor (105). The solenoid valve (1254) of
flow control valve assembly (1251) receives a signal (124) from the
logic processor (105) to toggle on/off the valve (1254) to
start/stop water flow to faucet spout.
[0115] Referring to FIG. 13, there is illustrated an example of a
faucet apparatus with sensors (31-35) for touch-free control. Due
to differences in materials, programming, valves, and other
elements, the structure of FIG. 13 may encompass multiple
embodiments. For convenience, when discussing these embodiments,
the primary sensor (31) will be referred to as "Sensor C" while the
other illustrated sensors will be referred to as "Sensor A" (32),
"Sensor B" (33), "Sensor D" (34) and "Sensor E" (35). Various of
the embodiments described with reference to these sensors by letter
may include fewer, or more than five sensors. In the illustrated
configuration, Sensor C (31) is forward facing, while Sensors A, B,
D, and E are side-facing (32-35). In other embodiments, some or all
of these sensors may face alternative directions. For example, one
or more sensors may face upward. In addition, in some embodiments,
one or more of the sensors may be fixed relative to each other
while one or more may be able to move relative to others of the
sensors.
[0116] Some embodiments provide a touch-free automatic faucet. The
faucet may include a faucet housing including a plurality of
sensors for controlling water flow and water temperature. A
processor is connected to the sensors. A first control valve
assembly is connected to the processor. A second control valve
assembly is connected to the processor. A power source is connected
to the processor, the first control valve assembly and the second
control valve assembly. Water flow and water temperature are
controlled by the sensors without touching of the faucet
housing.
[0117] Another embodiment provides a touch-free automatic faucet.
The touch-free automatic faucet may include sensors for controlling
water temperature. A processor is coupled to the sensors. A voltage
source is coupled to the processor. A temperature control valve
assembly is coupled to the processor. The processor controls water
flow and temperature of water exiting the touch-free automatic
faucet.
[0118] Yet another embodiment provides a faucet. The faucet
includes a plurality of sensors including: a main faucet control
sensor, a primary and secondary temperature control sensor, and a
primary and secondary water flow control sensors. A processor is
coupled to the plurality of sensors. A water flow control valve
assembly is coupled to the processor. A temperature control valve
assembly is also coupled to the processor. A power supply is
coupled to the processor and is configured to control water flow
through the water flow control valve assembly and to control water
temperature through the temperature control valve assembly.
[0119] Still another embodiment provides a faucet housing including
a plurality of sensor windows. A plurality of sensor assemblies are
removably coupled to the faucet housing. A shaft is at least
partially disposed within the faucet housing and coupled with a
securing nut. The securing nut is configured to hold the sensor
assemblies within the faucet housing, and for aligning the
plurality sensor assemblies with the plurality of sensor
windows.
[0120] Some embodiments include a touch-free automatic faucet
system comprising a touch-free automatic faucet mode; wherein water
flow and water temperature are controlled by a flow control valve
assembly and a temperature control valve assembly in response to
the electronic sensors through a logic processor circuit board. The
faucet can be operated, for example, in either automatic mode or
manual mode.
[0121] In some embodiments, the faucet apparatus may include a
plurality of sensors. These sensors can include a primary
electronic sensor (Sensor C) that may cause the faucet spout to
flow water (Primary-water-flow-mode) so long as an object is
detected by that sensor. For example, the primary sensor (Sensor C)
may be located facing a sink basin so that it sends a signal when a
user's hands are detected in the sink basin. A logic processor may
receive the signal and cause the faucet to pour water into the
sink. The embodiment may also include a pair of secondary sensors
(Sensor A and Sensor B) and a pair of tertiary sensors (Sensor D
and Sensor E), any or all of which may be pointed in different
directions than the sink. For example, the secondary and tertiary
sensors may be pointed at about 90 degree angles from each other to
reduce interference. The secondary and tertiary sensors may provide
for touch-free control of the following exemplary functions: water
temperature control (Temperature-control-mode), continuous water
flow control (Continue-water-flow-mode), faucet pause control
(Faucet-pause-mode), water flow adjustment control
(Water-flow-control-mode), default setting control
(Common-default-mode) and user defined preset(s)
(Save-preset-mode). One or more of these functions may provide for
convenient operation, water conservation and personal hygiene
protection. For example, the system may maintain an electronic
representation of a flow state, such as by maintaining a data
object or data structure in some memory, such as Random Access
Memory, flash memory, a hard disk, or some other memory storage
medium. The system may determine the state of the flow state by
querying this electronic representation in memory.
[0122] In certain embodiment, one of the secondary sensor provides
a timer function (Timer-mode) which can set the timer for use with
the user-control of the faucet spout water flow. In one such
embodiment, the tertiary sensor may provide a program function
(User-defined-program-mode) for receiving user-provided logic
processor parameter(s) and/or function(s).
[0123] Some embodiments include a programmed logic processor with a
circuit board that receives input from the sensors and, in response
thereto, controls the behavior of, a water flow control valve
assembly and a temperature control valve assembly. For example,
upon the detection of an object in presence within the detection
zone of the primary sensor (Sensor C), the logic processor may
activate the flow control valve assembly (Valve B) for water flow
to the faucet spout (activation of Primary-water-flow-mode). This
embodiment may be used, for example, as a sink faucet.
[0124] In some embodiments, upon activation of
Primary-water-flow-mode, the water flow control valve assembly
(Valve B) is in an activated position for water flow, and when the
primary sensor (Sensor C) senses that no object is present within
the corresponding detection zone (for example, in a sink), the
logic processor deactivates the water flow control valve assembly
(Valve B) to stop water flow to the faucet spout (deactivation of
flow during Primary-water-flow-mode).
[0125] In one or more embodiments, should both secondary sensors
(Sensor A and Sensor B) sense the presence of an object (for
example, a hand) within the corresponding detection zone(s) for a
predetermined time period (Time Continue-flow-on), the logic
processor activates the water flow control valve assembly (Valve B)
for a continuous water flow (Continuous-water-flow-mode), during
which the faucet pours water from the spout regardless of whether
an object is detected by the primary sensor or not. Continuous
water flow may occur until the faucet receives input from a user
instructing for a stop of the continuous water flow, or for a
predetermined period of time, or for a calculated period of time,
or some combination thereof, or whichever occurs first. This
Continuous-water-flow-mode operation may be convenient for a user
who wishes to fill a sink or container without keeping his hands
within the detection zone of the primary sensor (Sensor C) in order
to obtain continuous water flow. In another embodiment, the system
detects the presence of an object using one or more sensors while
the faucet is providing continuous water flow, and increases the
time for the continuous water flow in response to the detection.
This may allow a user to increment the continuous flow time without
interrupting the flowing water. The amount of time that the system
increments may be a fixed amount, a function of the time that the
object was detected, or some other amount of time.
[0126] In some embodiments, the water flow control valve assembly
(Valve B) is activated for water flow to the faucet spout. Sensor A
of the secondary sensors detects the presence of an object (for
example, a finger) within the detection zone. The logic processor
increases the faucet water flow temperature by increasing hot water
flow and/or decreasing cold water flow of the temperature control
valve assembly (Valve A) accordingly depending on the sensing time
period of sensor (Sensor A). Sensor B of secondary sensors senses
the presence of an object (for example, a finger) within the
detection zone. The logic processor decreases the faucet water flow
temperature by decreasing hot water flow and/or increasing cold
water flow of the temperature control valves assembly (Valve A)
accordingly depending on the sensing time period of sensor (Sensor
B). In some embodiments, faucet water flow temperature is
controlled by the function of the pair of secondary sensors (Sensor
A and Sensor B) without requiring a user to touch any part of the
faucet body (touch-free Temperature-control-mode).
[0127] In one or more embodiments, the water flow control valve
assembly (Valve B) enters an activated position for water flow when
Sensor D of the tertiary sensors senses the presence of an object
(for example, a finger) within the detection zone. The logic
processor increases the water flow to the faucet spout by
increasing both hot and cold water flow of the water flow control
valve assembly (Valve B). The amount of increase may correspond to
the sensing time period of Sensor D--that is, the amount of time
during which Sensor D detected an object substantially
uninterrupted in the corresponding sensing zone. When sensor E of
the tertiary sensors senses the presence of an object (for example,
a finger) within the detection zone, the logic processor decreases
the water flow to the faucet spout by decreasing both hot and cold
water flow of the water flow control valves assembly (Valve B). The
amount of decrease may correspond to the sensing time period of
Sensor E. In these embodiments, faucet water flow may be adjusted
by the function of the pair of tertiary sensors (Sensor D and
Sensor E) without any touching of any part(s) of the faucet. In
other embodiments, a combination of touch-free and touch controls
are provided. For example, the faucet may include sensors for
touch-free control, and a faucet lever for touch control.
[0128] In some embodiments, in the Continue-Water-flow-mode, the
water flow control valve assembly (Valve B) is activated for water
flow. In this mode, both of the secondary sensors (Sensor A and
Sensor B) sense the presence of an object (for example, a hand)
within the detection zone for a predetermined time period (Time
Continuous-flow-off). The logic processor deactivates the water
flow control valve assembly (Valve B) to stop continuous water flow
(Continuous-water-flow-mode) to the faucet spout (deactivation of
Continuous-water-flow-mode) upon the sensors not sensing the
presence of an object.
[0129] In one or more embodiments, the faucet includes a stand-by
condition in which the primary sensor (Sensor C) does not sense an
object's presence within the detection zone and the flow control
valve assembly (Valve B) is in a deactivation condition. In the
stand-by mode, no water flows from the faucet spout. Detection of
an object (for example, a hand or finger) within the detection zone
of Sensor A of the secondary sensors for a predetermined time
period (Time Sc-pause) triggers the logic processor to pause the
function of the primary sensor (Sensor C) referred as
"Faucet-pause-mode." In this Faucet-pause-mode, a user can work
within the primary sensor detection zone without activating faucet
water flow for water conservation (beginning of
Faucet-pause-mode).
[0130] In some embodiments, in the Faucet-Pause-Mode, the primary
sensor (Sensor C) is paused--that is, the faucet behavior is not
affected by the presence of an object in the Sensor C detection
area. Sensor A of the secondary sensors detects an object (for
example, a hand or finger) within the detection zone for a
predetermined time period (Time Sc-reset), which triggers the logic
processor to reset the function of primary sensor (Sensor C). The
faucet system may then reset back to the stand-by condition (reset
of Faucet-pause-mode).
[0131] In some embodiments, a primary sensor (Sensor C), the pair
of secondary sensors (Sensor A and Sensor B) and the pair of
tertiary sensors (Sensor D and Sensor E) are functional to control
the water flow and water temperature of touch-free automatic faucet
embodiments for commercial and residential applications. In one
embodiment, the water temperature control valve assembly has two
fluid inlets (a cold water inlet and a hot water inlet) and one
fluid outlet (mixed cold/hot water flow) conduits. The water may
then flow to a flow control valve assembly, which may affect the
rate of flow of the mixed water. The water temperature control
valve assembly and flow control valve assembly may combine with one
or more electric solenoid valves and/or electric motorized gear
valves therefrom to control water flow to the faucet spout.
[0132] In one or more embodiments, when the faucet is in the
Primary-water-flow-mode or Continuous-water-flow-mode, the water
flow control valve assembly (Valve B) is in an activated position
for water flow. Both of the Sensor D and Sensor E of the tertiary
sensors sense the presence of object (for example, a hand) within
the detection zone for a predetermined time period
(Time-default-setting). The logic processor sets the current
temperature and flow condition as the default settings for water
flow (Common-default-mode). The default flow and temperature reset
function prevents a user from accidently becoming injured by sudden
hot water flow from a previous usage and maintains faucet water
flow at a minimum requirement for water conservation.
[0133] In one embodiment, at least three default settings exist for
the faucet. In one example, the default settings are as follows:
(1) Common default setting.--for all users, when the faucet does
not have either Customized Preset 1 or 2; (2). User defined Preset
1--used with Sensor D; and (3) User defined Preset 2--used with
Sensor E.
[0134] Using Preset 1: When the water is not flowing as Flow
control valve A is Off, Sensor D senses an object (e.g., a finger,
a hand, etc.) for a predetermined time period and the water flow is
turned on with Sensor C or Continuous Water Flow Mode within
another predetermined time period, then water will flow using the
temperature and/or flow-rate stored as the Preset 1 condition.
Similar behavior may occur for Preset 2. In other embodiments, the
faucet has more or fewer presets.
[0135] In one embodiment, the faucet includes a Stand-By mode in
which the water flow commences with detection by Sensor C or Sensor
A and B. Water initially flows at the Common-default flow rate, and
the flow rate may be adjusted by the user after the default is
initially used. After a Time-default amount of seconds without
water flow, the faucet is set back to the Common-default-mode. Also
in that embodiment, the logic processor is configured so that, in
response to sensing by Sensor D, temporarily utilize a preset such
that, if water flow is triggered by Sensor C or Sensor A and B, the
preset is used. After the predetermined Time-default period without
water flow, the faucet is set back to the Common-default-mode.
Similar triggering of a second preset by using Sensor E may also
occur.
[0136] In one or more embodiments, the logic processor sets the
faucet at Common-default-mode, the second sensor (Sensor B) of the
secondary sensors detects an object (for example, a hand or finger)
within the detection zone for a time period (water-flow-timer), the
LED indicator flashes accordingly and the faucet is activated in
the Primary-water-flow-mode or Continuous-water-flow-mode within a
predetermined time period (Time preset activation), the water flow
control valve assembly (Valve B) activates and water flow from the
spout for a period of time according to the user defined timer
(water-flow-timer) and water temperature control valve assembly
(Valve A) responds for water flow at the second user defined preset
water flow and temperature (Timer-mode).
[0137] In some embodiments, user presets can be saved using
touch-free controls. For example, when the water is turned on with
Preset 1, both sensors D and E (tertiary sensors) may sense an
object for a predetermined time period and, in response thereto,
cause the logic processor to save the current settings as the
Preset 1 settings. The same is true for Preset 2, albeit the
predetermined time period may be different, for example. The faucet
may receive certain user input and in response thereto, change the
default water flow rate or default temperature. For example, the
logic processor may be configured to receive input from the
secondary and/or tertiary sensors, and save a new Common-default in
response thereto. As an example of providing functionality for
user-settable presets, after Sensor D senses an object, the faucet
enters a preset-configuration state; after sensing Sensor C
(primary flow mode) or Sensors A and B (continuous flow mode), the
faucet pours water at a flow and temperature associated with preset
1. A user may then change water flow rate or temperature to a new
condition and save to a new preset 1 by having Sensors D and E
sense an object. Similar functionality may be provided for a preset
2, for example by using different sensors, different combinations
of sensors, different detection times, some other trigger
mechanism, and/or some combination thereof.
[0138] In one or more embodiments, when one sensor (e.g., Sensor D)
of the plural of tertiary sensors detects an object (for example, a
hand or finger) within the detection zone for a predetermined time
period (time Sd-preset), the logic processor sets a state to
"User-defined-preset-mode" and then, if the faucet is activated in
the Primary-water-flow-mode or Continuous-water-flow-mode within a
predetermined time period (time preset activation), the water flow
control valve assembly (Valve B) and water temperature control
valve assembly (Valve A) respond for water flow at the first user
defined preset water flow and temperature.
[0139] In one or more embodiments, when a second sensor (e.g.,
Sensor E) of the plural of tertiary sensors detects an object (for
example, a hand or finger) within the detection zone for a
predetermined time period (time Se-preset), the logic processor
sets a state to "User-defined-preset-mode" and then, if the faucet
is activated in the Primary-water-flow-mode or
Continuous-water-flow-mode within a predetermined time period (time
preset activation), the water flow control valve assembly (Valve B)
and water temperature control valve assembly (Valve A) respond for
water flow at the second user defined preset water flow and
temperature.
[0140] In one or more embodiments, when the first sensor (Sensor D)
of the plural of tertiary sensors detects an object (for example, a
hand or finger) within the detection zone for a predetermined time
period (time Sd-preset), the logic processor sets a state to
"User-defined-preset-mode" and then, if the second sensor (Sensor
B) of the secondary sensors detects an object (for example, a hand
or finger) within the detection zone for a time period
(water-flow-timer), the LED indicator flashes accordingly and then,
if the faucet is activated in the Primary-water-flow-mode or
Continuous-water-flow-mode within a predetermined time period (time
preset activation), the water flow control valve assembly (Valve B)
activates and water flow from the spout for a period of time
according to the user defined timer (water-flow-timer) and water
temperature. For example, the control valve assembly (Valve B) may
respond for water flow at the second user defined preset water flow
and temperature (Timer-mode).
[0141] In one or more embodiments, when the second sensor (Sensor
E) of the plural of tertiary sensors detects an object (for
example, a hand or finger) within the detection zone for a
predetermined time period (time Se-preset), the logic processor
sets a state to "User-defined-preset-mode" and then, if the second
sensor (Sensor B) of the secondary sensors detects an object (for
example, a hand or finger) within the detection zone for a time
period (water-flow-timer), the LED indicator flashes accordingly
and then, if the faucet is activated in the Primary-water-flow-mode
or Continuous-water-flow-mode within a predetermined time period
(time preset activation), the water flow control valve assembly
(Valve B) activates and water flow from the spout for a period of
time according to the user defined timer (water-flow-timer) and
water temperature. For example, the control valve assembly (Valve
B) may respond for water flow at the second user defined preset
water flow and temperature (Timer-mode).
[0142] In one or more embodiments, when the faucet is in stand by
condition and no water flow from the spout, both of the first
sensor (Sensor D) and second sensor (Sensor E) of the plural of
tertiary sensors detects an object (for example, a hand or finger)
within the detection zone for a predetermined time period
(time-to-program), the logic processor sets a state to
"User-program-mode" and an LED indicator of the faucet apparatus
flashes in a color at a certain speed continuously (for example;
LED flashes in red color at one flash per second to indicate the
faucet is in User-program-mode). Upon the first sensor (Sensor A)
of the plural of secondary sensors (the-program-select-sensor can
be one of the plural of secondary sensors or the plural of tertiary
sensors for different program) detecting an object (for example, a
hand or finger) within the detection zone for a time period
(time-to-activate), the LED indicator stops flashing and will emit
a colored light (such as a red color for first program, yellow
color for second program and green for third program) to that
indicate the second sensor of the plural of secondary sensors is
ready for setting a parameter for the timer of Timer-mode. When the
second sensor of the plural of secondary sensors detects an object
(for example, a hand or finger) within the detection zone for a
time period (time-program-parameter) (for example: one LED flash
means one minute water flow per LED flashing for the Timer-mode,
two LED flashes mean two minutes water flow per LED flashing for
the Timer-mode and so on to set the timer parameter for different
faucet applications, (i.e. bathtub faucet water flow can be set
longer than the kitchen faucet). The User-program-mode may be saved
by the logic processor by activating both (Sensor D and Sensor E of
the plural of tertiary sensors. For example, the logic processor
may be in communication with non-volatile memory storage such as
flash storage to store preset information within.
[0143] In one or more embodiments, the faucet is configured such
that, when it is activated by one of the user defined presets
(User-preset-mode), and the water flow control valve assembly
(Valve B) is in an activated position for water flow, then, if both
Sensor D and Sensor E of the tertiary sensors sense the presence of
object (for example, a hand) within the detection zone for a
predetermined time period (time-default-setting), the logic
processor will set the current temperature and flow condition as
the user defined preset default settings for water flow
(User-defined-preset-default-mode). This user-defined preset
default flow feature and temperature function feature may provide
comfort and convenience to users.
[0144] In one or more embodiments a logic processor circuit board
comprises a logic processor, for example a Micro Chip, and a
circuit board. The logic processor is programmed to function in
response to input from sensors (e.g., Sensor A, Sensor B, Sensor C,
Sensor D and Sensor E), and to provide output to water flow control
valve assembly (Valve B) and water temperature control valve
assembly (Valve A). The faucet apparatus may also include an
electricity power supply package includes a battery pack
(rechargeable or not) and an alternating current to direct current
(AC-DC) transformer to supply direct current to the logic processor
circuit board to activate the sensors, the flow control valves
assembly and the motorized temperature control valves assembly.
[0145] Some embodiments may include touch-free automated control
that provide water conservation. The water flow and temperature may
be maintained at a comfortable temperature and economic flow rate
for water conservation and user comfort.
[0146] In some embodiments the function of the plural of secondary
sensors (Sensor A and Sensor B) controls the faucet water
temperature with a "touch-free" operation. The default temperature
reset function prevents injury by sudden hot water flow. Activation
of first and second sensors of secondary sensors (Sensor A and
Sensor B) controls a continuous water flow of the faucet. Sensor A
of the secondary sensors pauses the function of the primary sensor
(Sensor C) and stops water flow for a user to work within the
primary detection zone without activating faucet water flow for
water conservation. The plurality of tertiary sensors (Sensor D and
Sensor E) adjust faucet water flow.
[0147] An illustrative embodiment provides a faucet for use in one
or more of a lavatory or a kitchen. The faucet may be that can be
fully functional for all operational needs without requiring touch.
In another embodiment, some functions can be controlled by either a
touch-based and-or touch-free manner. In order to provide
water-efficient operation that is easy and convenient to use, the
water flow is activated and deactivated in response to a primary
electronic sensor that detects an object presence under the spout,
so as to provide water-efficient operation in
Primary-water-flow-mode. For other applications, such as filling
the sink or bathtub, a container or for washing dishes, washing
food, running a shower, etc., continuous water flow is provided. In
one embodiment, the faucet can be switched in/out a
Continuous-water-flow-mode without touching any part(s) of the
faucet body.
[0148] Another illustrative embodiment with a Timer-mode can
provide a touch-free automatic faucet to fill a container in the
kitchen or fill a tub at a user defined timed interval without the
user needing to watch the water level in the container or tub. Yet
another invented function to allow the user to program the logic
processor.
[0149] FIG. 13 is a diagram of an illustrative touch-free automatic
faucet according to some embodiments. The illustrative touch-free
automatic faucet system is shown coupled to a cold water source
(111), a hot water source (112) and an outlet for mixed water flow
to the faucet spout (106). The system includes a primary electronic
sensor C 131), a secondary electronic sensor assembly including
sensors A and B (32 and 33), a tertiary electronic sensor assembly
including sensors D and E (34 and 35), an electrical power supply
package (104), a logic processor circuit board (105), a water
temperature control assembly valve A (107), a status indicator
(36), a water flow control assembly valve B (108) and a water
temperature sensor (114). In one embodiment, the power supply
package (104) may be one or more a batteries, one or more
rechargeable batteries, a solar cell system, a DC voltage supplied
from an AC/DC converter, etc.
[0150] The sensing signals (141, 142, 143, 144 and 145) from the
primary electronic sensor C (31), the secondary sensors A and B
(32, 33) and the tertiary sensors D and E (34, 35) input signals to
the logic processor circuit board (105). The outputs of the logic
processor (123 and 124) control the water temperature control
assembly A (107) and flow control assembly B (108). The electricity
power supply package (104) supplies electrical power (148) to the
logic process circuit board (105) for powering the whole system. In
one embodiment, water flow (113) exits the temperature control
assembly A (107) and enters the water flow control assembly B
(108). In one embodiment, the water flows from the water flow
control assembly B (108) through the water temperature sensor (114)
and flows to the faucet as a stream of mixed-temperature,
flow-controlled water (106).
[0151] In one embodiment, the water temperature sensor (114)
detects the mixed water temperature flow (106) to the faucet spout.
The sensed temperature signal (125) is transmitted to the logic
processor (105), and may be used for displaying the water flow
temperature on a display device, such as an LED lighting device,
LCD lighting device, etc. In one embodiment, the display may be
located on the faucet spout (101), or within a close proximity to
the faucet. In another embodiment, the water temperature sensor
controls the water temperature control assembly (131) to control
excessive temperature that is sensed, which can prevent injuries
due to excessive water temperature being sensed by the water
temperature sensor (114), which transmits a signal to the logic
processor (105) to control the temperature control assembly (107).
In another embodiment, the sensed temperature is used to adjust the
water-temperature control assembly A in order to adjust the water
stream (106) to more closely match a selected temperature, even if
the water is within safe temperature levels.
[0152] FIG. 14 is a diagram illustrating one embodiment of a faucet
with different touch-free functions. The function of the primary
sensor C (31) is to activate the Primary-water-flow-mode when water
is needed in the sink area (102) for washing hands or foods,
filling the sink, etc. The plural of secondary sensors Sensor A
(32) and Sensor B (33) serves three different functions: adjusting
water temperature, pausing the primary sensor (Sensor C) and the
effect of triggering both Sensors A and B (32 and 33) substantially
simultaneously is to toggle between a Continuous-water-flow-mode
and a Primary-Flow-Mode. For example, continuous-water-flow-mode
may be used for filling a sink, a container, or to wash dishes,
wash food, etc.
[0153] In the Primary-water-flow-mode or the
Continue-water-flow-mode, when water is flowing from the faucet,
the plural of secondary sensors (Sensor A and Sensor B) (32 and 33)
function to adjust water temperature (Temperature-control-mode)
up/down. When the primary sensor (Sensor C) (31) does not detect an
object, activation of Sensor A (32) triggers a "Faucet-pause-mode"
to pause the function of Sensor C (31) to enable the user to work
in the vicinity of faucet without water flowing. The tertiary
sensors (Sensor D, Sensor E) (34) (35) control the water flow of
the faucet (Adjust-water-flow-mode).
[0154] The secondary sensors (Sensor A and Sensor B) (32 and 33)
and tertiary sensors (Sensor D and Sensor E) (34 and 35) control
the default setting of water flow and temperature of the faucet
(Common-default-mode). In one embodiment, a common default mode may
be used for pre-setting water flow and/or temperature control. In
one example, when the water flow control valve assembly B (108) in
FIG. 13 is placed in an activated position for water flow by the
logic processor (105) upon both the first sensor D (34) and the
second sensor of the tertiary sensor E (35) sensing presence of an
object (e.g., a finger) within the respective detection zones for a
predetermined period of time (e.g., about 2 seconds, about 5
seconds, etc.), an LED indicator light blinks (and/or a sound chip
produces an audio indication), the logic processor (105) sets a
current temperature and water flow condition as a common default
setting (Common-default-mode).
[0155] The secondary sensors (Sensor A and Sensor B) (32 and 33)
and the tertiary sensors (Sensor D and Sensor E) (34 and 35)
control the customized preset default operation of water flow and
temperature of the faucet (User-save-preset-mode). In one
embodiment, one of the tertiary sensors may be used for pre-setting
water flow and/or temperature control. In one example, when the
first sensor (Sensor D) (34) of the tertiary sensors senses the
presence of an object (e.g., a finger) within the respective
detection zone for a predetermined period of time (e.g., about 2
seconds, about 5 seconds, etc.), an LED indicator light blinks,
and/or a sound chip produces an audio indication. The water flow
control valve assembly B (108) is then placed in an activated
position for water flow by the logic processor (105) upon the
activation of the Primary Sensor C (31) for a
Primary-water-flow-mode or by secondary sensors (Sensor A and
Sensor B) (32 and 33) for a Continuous-water-flow-mode within a
predetermined period of time (e.g., about 2 seconds, about 5
seconds, etc.), then the faucet will cause water to flow at
temperature and flow condition of the customized preset 1
(User-save-preset-mode).
[0156] In another example, when the second sensor (Sensor E) (35)
of the tertiary sensors senses the presence of an object (e.g., a
finger) within the respective detection zone for a predetermined
period of time (e.g., about 2 seconds, about 5 seconds, etc.), an
LED indicator light blinks, and/or a sound chip produces an audio
indication. The water flow control valve assembly B (108) is placed
in an activated position for water flow by the logic processor
(105) upon the activation of the Primary Sensor C (31) for a
Primary-water-flow-mode or by the plural of secondary sensors
(Sensor A and Sensor B) (32 and 33) for a
Continuous-water-flow-mode within a predetermined period of time
(e.g., about 2 seconds, about 5 seconds, etc.), then the faucet
will cause water to flow at temperature and flow condition of the
customized preset 2 (User-save-preset-mode).
[0157] The secondary sensors (Sensor A, Sensor B) (32 and 33) and
the tertiary sensors (Sensor D, Sensor E) (34 and 35) control the
customized preset default setting of water flow and temperature of
the faucet (User-save-preset-mode). In one embodiment, one of the
tertiary sensors may be used for pre-setting water flow and/or
temperature control. In one example, when the water flow is
initiated by the customized preset 1 condition as described above
paragraph, the water flow control valve assembly B (108) is placed
in an activated position for water flow by the logic processor
(105) upon both the first sensor D (34) and the second sensor of
the tertiary sensors sensor E (35) sensing presence of an object
(e.g., a finger) within the respective detection zones for a
predetermined period of time (e.g., about 2 seconds, about 5
seconds, etc.). In that embodiment, an LED indicator light blinks,
and/or a sound chip produces an audio indication, and the logic
processor (105) sets a current temperature and water flow condition
as a new customized preset 1 (User-save-preset-mode).
[0158] In another example, when the water flow is initiated by the
customized preset default preset 2 condition as described above,
the water flow control assembly B (108) is placed in an activated
position for water flow by the logic processor (105) upon both the
first sensor D (34) and the second sensor of the tertiary sensor E
(35) sensing presence of an object (e.g., a finger) within the
respective detection zones for a predetermined period of time
(e.g., about 2 seconds, about 5 seconds, etc.). In that embodiment,
an LED indicator light blinks, and/or a sound chip produces an
audio indication, and the logic processor (105) sets a current
temperature and water flow condition as a new customized preset 2
(User-save-preset-mode).
[0159] In another example, upon the water flow control assembly B
(108) being placed in an inactivated position (where no water
flows) by the logical processor (105) when either the first
tertiary sensor, Sensor D (34), or the second tertiary sensor,
Sensor E (35), senses an object within their respective detection
zones for a predetermined time period (e.g., about 2 seconds, about
5 seconds, etc.), the logical processor (108) activates the first
preset or second preset for temperature control and water flow. In
another example, whenever a change of temperature or water flow is
made, it will clear the preset operation conditions for temperature
and water flow. In one embodiment the water outlet (202) may house
the primary sensor (31).
[0160] FIG. 15 is a diagram of an illustrative touch-free automatic
faucet according to one embodiment. The illustrative touch-free
automatic faucet system is shown coupled to a cold water source
(111), a hot water source (112) and an outlet for mixed water flow
(106) to the faucet spout. The system includes one primary
electronic sensor C (31), a plural of secondary electronic sensor
assembly sensor A and B (32 and 33), a plural of tertiary
electronic sensor assembly sensor D and E (34 and 35), an
electrical power supply package (104), a logic processor circuit
board (105), a water temperature control assembly A (131), a water
flow control assembly B (108) and a water temperature sensor (133).
In one embodiment, the power supply package (104) may include one
or more batteries, one or more rechargeable batteries, a solar cell
system, and/or a DC voltage supplied from an AC/DC converter,
etc.
[0161] The sensors (31, 32, 33, 34, and 35) sense the presence of
one or more objects in sensor zones (1361, 1362, 1363, 1364, and
1365). For example, an optical sensor may sense the presence of an
object in a sensor zone immediately in front of the optical sensor.
As another example, an infrared sensor may detect the presence of a
warmth-emitting object within a certain distance in front of the
sensor. One or more of the sensors (31-35) may detect the presence
of an object and transmit a sensing signal (141-145) in response.
The sensing signals (141, 142, 143, 144 and 145) from the primary
electronic sensor C (31), the secondary electronic sensors A and B
(32, 33) and tertiary electronic sensors D and E (34, 35) input
signals to the logic processor circuit board (105). The outputs of
the logic processor (123 and 124) control the water temperature
control assembly A (131) and water flow control assembly B (108).
The electricity power supply package (104) supplies electrical
power (148) to logic process circuit board (105) for powering the
whole system. In one embodiment, water flow (113) exits the
temperature control assembly A (131) and enters the water flow
control assembly B (108). In one embodiment, the water flows from
the water flow control assembly B (108) through the water
temperature sensor (133) and flows to the faucet as a stream
(106).
[0162] In one embodiment, the water temperature sensor (133)
detects the mixed water temperature flow (106) to the faucet spout.
The sensed temperature signal (125) is transmitted to the logic
processor (105), and may also be used for displaying the water flow
temperature on a display device, such as an LED lighting device,
LCD lighting device, etc. In another embodiment, the water
temperature sensor controls the water temperature control assembly
(131) to control excessive temperature that is sensed, which can
prevent injuries due to excessive water temperature being sensed by
the water temperature sensor (133), which transmits a signal to the
logic processor (105) to control the temperature control assembly
(131).
[0163] FIG. 16 is a logic diagram that shows various logic
procedures and methods of one embodiment of a system using an
electronic sensor (e.g., infrared sensor or others), detection
devices, logic processor, and water flow control valves to enable
touch-free and automatic faucet operation.
[0164] When the faucet detects an object present within the primary
Sensor C (31) detection zone (for example, in a sink), it activates
(141) the primary sensor (Sensor C) (31) and the logic processor
program (1458) activates (124) the flow control assembly (108) for
water flow to the faucet spout (101) (activation of
Primary-water-flow-mode).
[0165] When the faucet is in Primary-water-flow-mode (1401)
operation and an object is detected in the primary detection area,
the water flow control assembly (108) is in activated position for
water flow, and when the primary sensor (Sensor C) (1411) does not
detect (1441) that an object is present within the detection zone
(for example, in a sink), the logic processor program (1457)
deactivates (124) the water flow control assembly (108) to stop the
water flow to the faucet spout (101) (deactivation of
Primary-water-flow-mode).
[0166] If the faucet detects that both of the secondary sensors
(Sensor A and Sensor B) (32 and 33) sense the presence of an object
(for example, a hand) within the detection zone for a predetermined
time period (Time Continue-flow-on) (1442 and 1450), and no water
is flowing from the spout (1455), the logic processor program
(1454) activates (124) the water flow control assembly B (108) in
order to trigger a continuous water flow
(Continuous-water-flow-mode) (1402) to the faucet spout (101).
[0167] As illustrated in FIG. 16 the water flow control assembly B
(108) is in an activated position for water flow (106) to flow to
the faucet spout (101). If Sensor A (32) detects (1443) the
presence of an object (for example, a finger) within its detection
zone, the logic processor program (1448) increases the faucet water
flow temperature by increasing the intake of hot water flow (112)
and decreasing the intake of cold water flow (111) at the
temperature control assembly B (131) accordingly, depending on the
sensing time period of Sensor A (142). When the Sensor B (33)
detects (1447) the presence of an object (for example, a finger)
within its detection zone, the logic processor program (1449)
decreases the faucet water flow temperature by decreasing the
intake of hot water flow (112) and decreasing the intake of cold
water flow (111) to the temperature control assembly A (131),
depending on the sensing time period of the Sensor B (1447). Faucet
water flow temperature may be controlled by the functioning of the
plural of secondary sensors (Sensor A and Sensor B) (33 and 34)
without a person or object touching any part(s) of the faucet body
(101) (Temperature-control-mode) (403). In one embodiment, the
water temperature sensor (133) operates to sense the temperature
and feedback a signal (125) to the logical processor (105). In this
embodiment, the logical processor program (432) sends a signal
(123) to either the temperature control assembly A (131) to reduce
temperature if the sensed temperature exceeds a predetermined
temperature, or sends a signal (125) to the flow control assembly B
(108) to turn off water flow if the predetermined maximum
temperature setting is exceeded. The faucet, including its water
temperature sensor may thereby provide safe functionality to
prevent a person from coming in contact with water heated to an
excessive temperature. Additionally, the water temperature sensor
(133) may communicate with or comprise an indicator to alert users
of the current water temperature. In one example, the indicator is
an LED indicator that displays temperature in either degrees
Fahrenheit or Celsius. In another example, the indicator is a sound
indicator that produces a sound (e.g., a beep) or states the
temperature in a preferred language. In another example, both sound
and light indicators are used to indicate the current water
temperature to users.
[0168] In one embodiment, when the faucet is in the
Continuous-water-flow-mode (402), the water flow control assembly B
(108) is activated for water flow (106) to the faucet spout (101).
Both of the secondary sensors (Sensor A and Sensor B) (32 and 33)
sense the presence of an object (for example, a hand) within the
detection zone (1492 and 1493) for a predetermined time period
(Time Continuous-flow-off), the logic processor program (1454)
deactivates (124) the water flow control assembly B (108) to stop
continuous water flow (124) (Continuous-water-flow-mode) (402)
(deactivation of Continuous-water-flow-mode) (402).
[0169] In one embodiment, when the faucet (100) is in a stand-by
condition, the primary sensor, Sensor C (31), does not sense an
object present within the detection zone, and the flow control
assembly B (108) is set to a deactivation condition (1456) where no
water flows (106) from the faucet spout (101). Detection (1446) of
an object (for example, a hand or finger) within the detection zone
of the first sensor A (32) of the plural of secondary sensors for a
predetermined time period (Time Sc-pause) triggers the logic
processor program (1457) to pause (1457) the function of Sensor C
(31), which is referred to as the "Faucet-pause-mode" (1405). In
the Faucet-pause-mode, a user can work within the primary sensor
detection zone without activating faucet water flow for water
conservation (beginning of Faucet-pause-mode).
[0170] When the faucet is in the Primary-water-flow-mode (1401) or
the Continuous-water-flow-mode (1402), the water flow control
assembly B is in an activated position for water flow (1464). Then,
if both the first sensor, Sensor D (34), and, Sensor E (35), sense
the presence of an object (for example, a hand) within the
detection zone for a predetermined time period
(Time-default-setting), the logic processor program (1466) sets the
current temperature and flow condition as the default settings for
water flow (Common-default-mode) (1406). The user-defined flow and
temperature reset function (User-save-preset-mode) (1406) prevents
a user from accidently becoming injured by sudden hot water flow
from a previous usage (e.g., maximum hot temperature) and maintains
the faucet water flow at a minimum requirement for water
conservation.
[0171] When the user activate Sensor D (34) and start water flow
from the faucet with the Primary-water-flow-mode (1401) or the
Continuous-water-flow-mode (1402), the water flow control assembly
B is in an activated position for water flow (464), and both,
Sensor D (34), and, Sensor E (35), sense the presence of an object
(for example, a hand) within the detection zone for a predetermined
time period (Time-default-setting). In this state the logic
processor program (1466) sets the current temperature and flow
condition as the default settings for water flow of
User-save-preset-1 (User-save-preset-mode) (1406). The faucet
provides similar functionality for Sensor E (35) to enable a user
to save settings as the User-save-preset-2.
[0172] In one embodiment, when the faucet (100) is in a stand-by
condition, it does not pour water (106) from the spout (101).
However, once the faucet detects (1451) of an object (for example,
a hand or finger) within the detection zone of Sensor B (33) for a
predetermined time period (Time Sb-timer), the detection triggers
the logic processor program (1453) to start a timer (Timer
Water-flow) referred as Timer-mode (407) to set the water flow from
the faucet spout (101) at a time period corresponding to the time
period (Timer Water-flow) of the detection time period of the
second sensor B (33) of the plural of secondary sensors when the
faucet starts flow by the Primary-water-flow-mode or
Continuous-water-flow-mode. For example, the function of the
Timer-mode is very convenient for use in filling a kitchen faucet
to fill a container, or a bathroom faucet to fill a tub.
[0173] In one embodiment, when the faucet (100) is in a stand-by
condition, the faucet does not pour water (469) from the spout
(101). Then, detection (1467 and 1462) of an object (for example, a
hand or finger) within the detection zone of, Sensor D (34), and
the, Sensor E (35), for a predetermined time period (Time Sb-timer)
triggers the logic processor program (1470) to start setting a
program procedures by the user referred as User-program-mode (1408)
to set a program parameters for the control of the faucet.
[0174] In one embodiment, the water flow control assembly (108) and
the water temperature control assembly (131) have a shared cold
fluid inlet (112), a hot fluid inlet (111) and one fluid outlet
(106) conduits, combined with one or more of electric solenoid
valves and electric motorized gear valves therefrom to control
water flow (106) to the faucet spout.
[0175] FIG. 17 illustrates logic, interconnection, and components
for one embodiment of a faucet. When the faucet (100) is in a
stand-by condition, no water flows (1536) from the spout (101), and
activation (1540) of Sensor D (1504) indicates detection (1540) of
an object (for example, a hand or finger) within the detection zone
of Sensor D (1504). This may require detection for at least a
minimum time (Time Sd-timer. In this condition, activation (1541)
of Sensor E (1505) triggers the logic processor (105) to provide an
(1542) LED indication (1513) flashing (for example, in red, yellow,
and/or green colors) to indicate the initiation of
User-program-mode (1512). Then, another signal (1544) from the
logic processor couples with the activation (1543) of Sensor A
(1501)triggers the logic processor program (1514) to provide an LED
indication (1520) (for example, in yellow color) to indicate the
initiation of program A (1514) of User-program-mode (1512). The
signal (1556) also initiates a User-program-condition to be set by
the activation (1557) of Sensor B (1502). The logic processor
program (1518) triggers (1558) a LED indication (1521) (for
example, in red color) to indicate the setting condition of the
program A (for example, the parameter of Timer-mode) (1518). The
setting (1563) of the program A (1514) and program A condition
(1518) of User-program-mode (1512) can be saved (1519) by
activation (1561 and 1562) of both the first sensor, Sensor D
(1504), and second sensor, Sensor E (1505), of the tertiary
sensors. An LED indicator (1522) may indicate the completion of the
User-program-mode programed (1565) in logic processor (1523). The
User-program-mode can be programed by changing the program A (1514)
from activation (1543 and 1544) of Sensor A (1501) to program B
(1515) of activation (1545 and 1546) of Sensor B (1502) of, the
program D (1516) of activation (1547 and 1548) Sensor D (1504) or
the program E (1517) of activation (1549 and 1550) the second
sensor, Sensor E (1505), of the plural of secondary sensors. The
User-program-mode (1512) enables the user defined favorite water
temperature, flow and water flowing timer condition for comfortable
and water saving. In another embodiment, for example, Program B can
be set to check and display the system status information such as
the battery life level, motor resistance status, and/or PCB circuit
status.
[0176] In another embodiment, a water leaking detection system
contains a water leaking detection sensor (1571) and LED warning
light (1572) provides early warning function in case of water
leakage from the water control valve assembly (106 of FIG. 1) which
is enclosed in a control valve box. The water leaking detection
sensor (1571) can be an electronic hygrometer or humidity such as
capacitive humidity sensor, resistive humidity sensor or thermal
conductivity humidity sensor to measure the relative humidity
inside the control valve box. The relative humidity signal (1575)
inside the control valve box is monitored by the water leaking
detection sensor (1571) and input to logic processor (1523). Water
leakage from the control valve (106 of FIG. 1) will increase a
certain percentage of the relative humidity in a period of time
inside the control valve box. The logic processor (1523) detects
this change and may take one or more actions, such as activating
(1576) a flashing LED (1572) on the faucet spout (101) in order to
warn the user of the water leaking inside the control valve
box.
[0177] FIG. 18A illustrates one embodiment of a touch-free
automatic faucet system (1600) installed with a bathtub (1601). In
this embodiment, the faucet spout (1602) and separate faucet sensor
compartment (1603) are conveniently attached to the bath tub
(1601). A digital controller (1604) remotely includes a water
temperature control assembly (123) and a water flow control
assembly (124). These assemblies are connected with the sensors
housed in separate faucet sensor compartment (1603) via a wired or
wireless connection (1605) for communicating signals to one
another. In this embodiment, the faucet (1602) may be turned on
with continuous water flow of first and second secondary sensors to
fill up the bathtub (1601) to a desired water level at the desired
temperature. In one example, the digital controller (1604) may be
installed inside a wall or next to or under the bathtub (1601) for
easy access for maintenance. The sensor compartment (1603) includes
the sensors 621, 622, 623 and 624, a LED indicator (1625) and a LCD
display panel (1610). The LCD display panel can show the water
temperature, flow and other information such as the timer to fill
the tub. In one embodiment the primary sensor C (111) is not
included in the sensor compartment (1603) as it is typically not
necessary for a bathtub (1601) to have the water flow momentarily
on. It should be noted that other embodiments may include the
primary sensor C (111) for bathtub applications. In some
embodiments, the preset default temperatures allow users to
customize the temperature settings to the desired temperature so
that temperature does not have to be adjusted every time the
bathtub (1602) is used.
[0178] In some embodiments, a customized timer is included for
maintaining continuous water flow at the desired temperature. With
this embodiment, based on the use of the bathtub (1601) in the
past, a user can set the timer to automatically shut the water flow
off after the predetermined time limit (Timer-mode). This
embodiment allows the bathtub (1601) to fill without having to
watch for a desired water level to be reached. This feature allows
users to do other things while the bathtub (1601) is self-filling
at the desired temperature. In some embodiments, the timer and
sensors are controllable via a remote control from either a
handheld remote control or via a network, such as the Internet or
mobile phone network. In this embodiment, the bathtub (1601) can be
filled at the desired level at the desired temperature without a
user having to be in the same room, or location. In still another
embodiment, the timer also includes a day and time setting feature
for setting the bathtub (1601) to be filled in advance.
[0179] Some embodiments, including the illustrated examples,
comprise automatic, touch-free control for use in controlling. In
other embodiments, manual flow and/or temperature control may be
used in addition or in the alternative.
[0180] As shown in FIG. 18B, some embodiments include a control
console (1660) with multiple sensor sets (1651, 1652, 1653, and
1654) in a LCD panel (1661). The LCD is configured to display a
signal (1668) indicating a current function of the logic processor
(105). Alternatively, or additionally, an LED indicator (1625) may
display apparatus status information. For example, the LCD and/or
LED may display information indicative of the current water flow
temperature (1665), water flow rate (1667) and flow timer
(1666).
[0181] In one embodiment the sensors described herein, including
sensors A, B, C, D and E have a sensing range from about 0.1 inch
to about 36 inches. In one example, Sensor A, B, D and E will be in
the range of about 0.1 to about 10 inches, whereas the Sensor C
will have a range of about 0.1 to about 36 inches. In one
embodiment, the sensing range is set during manufacturing depending
upon use (e.g., commercial, home, based on a handicap, based on age
of typical users, etc.). In another embodiment, the range may be
adjusted by an installer.
[0182] In one embodiment, the distance between the plural of
secondary sensors (Sensor A and Sensor B) ranges from about 0.1
inch to about 6 inches, depending upon the application and size of
faucet. In one example, a distance ranges about 0.1 to about 2.5
inches is used. In another embodiment, the distance between the
plural of third sensors (Sensor D and Sensor E) may range from
about 0.1 to about 6 inches. In one example, a distance ranges from
0.1 to about 2.5 inches is used. In another example, there are no
distance limitation between the plural of secondary (Sensor A and
Sensor B) and the plural of third sensors (Sensor D and Sensor E).
In another embodiment, the sensing range is adjusted depending on
the faucet design.
[0183] According to an embodiment, according to the logic program,
coverage of the plural of the Sensor A and Sensor B by an object
(e.g., a person's hand(s)) will turn on or off the
Continuous-flow-mode (402) depending on the current faucet
condition/mode. In one example, the action of a hand covering both
of the Sensor D and Sensor E will activate the
User-save-preset-mode (406) and set the current faucet condition as
the default condition.
[0184] In one embodiment, the predetermined time periods for the
sensors may vary. In one example, the predetermined time periods
range from about 0.1 to about 3600 seconds for various the logic
functions. In another example, the predetermined time period of
each function is set based on the specific applications (e.g.,
commercial, industrial, home, targeted user, etc.). In one
embodiment, there are default predetermined time periods for each
function (e.g., raise/lower temperature, increase/decrease flow,
on/off, continuous flow, etc.). In one embodiment, the
predetermined time periods are set during manufacturing depending
upon use (e.g., commercial, industrial, home, based on a handicap,
based on age of typical users, etc.). In another embodiment, the
predetermined time periods may be adjusted by an user.
[0185] In one embodiment, the automatic touch-free faucet is
operated at a low voltage to prevent shock. In one embodiment, the
whole faucet system uses low voltage direct current (e.g., about 3
volts, about 6 volts, or about 24 volts), so there is no concern
about harm from electric shock. In one embodiment, batteries can be
used for operating the sensors and other electrical and electronic
components. In this embodiment, a low battery signal alerts the
user(s) so that the one or more batteries can be changed before
failure, such as a sound alert, a light alert (e.g., LED signal),
both sound and light, etc.
[0186] In one embodiment, the faucet is set to a factory default
temperature range of about 55.degree. to 140.degree. F., depending
on the geologic market area for comfort usages, type of use (e.g.,
commercial, industrial, home, targeted users, etc.). In one
example, users may change the default to a personal (i.e.,
favorite) default temperature and flow at their preference by
covering both the Sensor D and Sensor E of the plural of tertiary
sensors for a time period referred as the User-save-preset-mode
when the faucet water is in their favorite flowing condition. In
one embodiment, the default temperature range is set during
manufacturing depending upon use (e.g., commercial, home, based on
a handicap, based on age of typical users, etc.). In another
embodiment, the default temperature range may be adjusted by an
installer, or the user.
[0187] In one embodiment, the time period related to
increasing/decreasing temperature is dependent on the pressure and
temperature of both the hot and cold water supply. In one example,
a convenient adjusting speed for temperature and flow is set so
that the increase/decrease in temperature does not change at an
inconvenient rate (e.g., too fast, too slow, etc.). In one
embodiment, the temperature and flow adjustment rates are set
during manufacturing depending upon use (e.g., commercial, home,
based on a handicap, based on age of typical users, etc.). In
another embodiment, the adjustment rates may be adjusted by an
installer or user (User-program-mode).
[0188] In one embodiment the sensors A, B, C, D and E are single IR
sensors. In one embodiment, the IR sensors have varying wave length
and emitting angles for various applications. In one embodiment,
the sensing angle range is adjustable depending on the type of use
(e.g., a sensing angle range of about 35 degrees to about 270
degrees or more). In another embodiment, the Sensors A, B, D and E
use an electronic capacity sensor, such as the function used in a
"touch lamp." However, this type of sensor is not a "touch-free"
type of sensor. In one example, the electronic capacity sensor is
only used where a non-touch-free operation is desired. Other motion
type sensors may also be employed in other embodiments. In one
embodiment the sensors A, B, C, D and E are single ultrasonic
sensors. In one embodiment, the ultrasonic sensors have varying
wave lengths and emitting angles for various applications.
[0189] In some embodiments, the maximum hot water temperature is
conveniently set based on age of the targeted users. For example,
when the faucet is in use in a senior home, a pre-school, etc., the
maximum temperature may be set accordingly to prevent injury to
those that may be more susceptible to higher water temperatures. In
other uses, such as industrial use or commercial use, where the
maximum temperature is necessarily higher, a higher maximum
temperature may be set accordingly. The maximum temperature setting
is therefore set to avoid injuries or to be used for a particular
purpose (i.e., commercial, industrial, etc.). It should be noted
that in some embodiments, the water temperature is reset to a
default temperature to avoid injury to the next person after a
person using the faucet at a maximum temperature. In another
embodiment, a maximum water temperature set knob is located on the
logic processor board or on the outside surface of digital
controller.
[0190] In one embodiment, the continuous flow mode may run
indefinitely once entered into. In one example, the
Continue-water-flow-mode will perform same function as somebody
opens a manual faucet and lets it flow continuously. In one
example, the main purpose of this mode is targeted for residential
applications where a basic knowledge about faucet operation
principles are known, and not for just commercial usages like a
restroom in airport or restaurants. However, the maximum water
flowing time period (Timer-mode) can be set in the logic processor,
or by the User (User-program-mode), and/or by the manufacturer. In
one embodiment, if power to the automatic faucet is interrupted,
the flow control valve B (solenoid valve) will shut off (normal
close) to shut off water flow in case the power goes out or battery
dies. In one embodiment, a backup battery system detects a drop in
battery voltage below a predetermined minimum level and, in
response thereto, provides a warning signal and shuts off the water
flow control valve B. This may prevent the battery from being
entirely depleted.
[0191] In some embodiments, since there is only one water tube and
an electronic wire connection from faucet body to the housing of
the digital controller, the installation of the embodiments are
even easier than traditional manual faucets.
[0192] In one embodiment, the left/right sensors are fully
reversible or at the same side based on need (e.g., a handicap,
left handed vs. right handed, etc.). Additionally, the sensors may
be installed in different parts of faucet body depending upon the
application and/or need.
[0193] Referring to FIG. 10, there is depicted one example method
for a touch-free faucet to provide both primary-flow and
continuous-flow operations. The faucet senses for the presence of
an object in motion sensing areas, including both a primary
motion-sensing area and a continuous-flow motion-sensing area.
While an object is detected in the primary motion-sensing area, the
faucet pours water. When an object is detected in the
continuous-flow motion-sensing area, the faucet calculates the
amount of time that the object is detected for a substantially
uninterrupted period of time. The faucet then calculates an amount
of time for the continuous flow operation, based upon the amount of
time that the object was detected. The faucet pours water for that
calculated amount of time. In one example, the faucet begins
pouring water while the object is still detected in the
continuous-flow motion-sensing area such that the final amount of
time for continuous flow operation has not yet been calculated. In
other embodiments, different methods may be used to provide
user-programmable continuous-flow operation. For example, the
system may detect one or more objects in one or more detection
zones and may determine a continuous-flow time based on factors
such as the amount of time that the object or objects were
detected, the distance of the objects from the sensors, motion
gestures of the objects, and any combination thereof.
[0194] Embodiments of a touch-free faucet may include a plurality
of sensor zones, which may be in distinct or overlapping areas. A
sensor zone may comprise one or more sensors capable of detecting
objects within the sensor zone. For example, a temperature increase
sensor zone may comprise a touch-free sensor that detects the
presence of an object within a detection proximity of the
touch-free sensor, and may provide an electronic signal in response
to the detection, where a logic processor responds to the receipt
of the electronic signal by increasing the temperature of water
flow. The same embodiment may also include a continuous-flow sensor
zone that comprises both the touch-free sensor used for temperature
increases, and a second touch-free sensor used similarly for
temperature decreases. The continuous-flow sensor zone may
encompass the smaller sensor zones for the two sensors that it
comprises, such that when a user holds a hand out in front of both
sensors simultaneously, the user activates the continuous-flow
sensor zone. In such an embodiment, the logic processor is
programmed to detect that, when the two sensors transmit a signal
indicating that they each detect an object, and those signals are
transmitted and/or received substantially simultaneously, the user
action is interpreted based on an action associated with the
activation of both sensors, rather than the actions associated with
the activation of the sensors individually. In this example, the
system detects the user's hand in proximity to both sensors and
performs continuous-flow operation based on that detection.
[0195] Referring to FIG. 19, there is depicted a method for a
touch-free faucet to provide both primary-flow and continuous-flow
operations, with the continuous-flow operations including a
user-programmable sensitivity. The faucet maintains a sensitivity
multiplier, sMult, which can be initially set to 10 seconds of flow
per second of detection. The faucet senses for objects in its
motion-sensing areas. If an object is detected in the
sensitivity-programming motion-sensing area, the sMult is set as a
function of the amount of uninterrupted seconds that the object is
detected in that sensing area. This allows a user to change the
sMult variable, thereby changing the faucet's sensitivity for
continuous-flow operation. The faucet detects whether there is an
object in the continuous-flow motion-sensing area. If there is an
object detected, the faucet sets the variable senseDuration to the
number of uninterrupted seconds that the object is detected in that
motion-sensing area. The faucet then initiates continuous-flow
water flow for an amount of time calculated from both the
senseDuration variable and the sMult variable. In this example, the
continuous-flow time is set as the product of senseDuration and
sMult. In other embodiments, other algorithms may be used.
[0196] In some embodiments, the assembly may include multiple
default settings for the sMult variable. For example, the assembly
may include low, medium, and high sMult variables. In that example,
when the assembly detects an object for less than a first
predetermined period of time, the assembly selects the low-sMult
variable. When the assembly detects an object for more than the
first predetermined period of time, but less than the second
predetermined period of time, the assembly selects the medium-sMult
variable. When the assembly detects an object for more than the
second predetermined period of time, the assembly selects the
high-sMult variable. The system may provide a visual indication of
the sMult variable, for example by flashing once to indicate the
low-sMult variable, flashing twice to indicate the medium-sMult
variable, and flashing three times to indicate the high-sMult
variable. For example, the low-sMult variable may correspond to a
low sensitivity state, where the continuous flow functionality is
calculated using a multiplier of 5, such that triggering
continuous-flow by placing an object before the appropriate sensor
for 10 seconds will result in 50 seconds of continuous flow.
Similarly, the medium-sMult variable may correspond to a medium
sensitivity state, where the continuous flow functionality is
calculated using a multiplier of 15, such that triggering
continuous-flow by placing an object before the appropriate sensor
for 10 seconds will result in 150 seconds of continuous flow.
Similarly, the high-sMult variable may correspond to a high
sensitivity state, where the continuous flow functionality is
calculated using a multiplier of 60, such that triggering
continuous-flow by placing an object before the appropriate sensor
for 60 seconds will result in 600 seconds of continuous flow. In
some embodiments, the system includes functionality for two default
sensitivity levels rather than three. In other embodiments, the
system includes functionality for more than three default
sensitivity levels. A range of multiplies may be used such that the
levels can be adapted to a variety of preferences.
[0197] For example, the apparatus of claim 9, wherein the
low-sensitivity multiplier is 5, the medium-sensitivity multiplier
is 15, and the high-sensitivity multiplier is 60 such that, if an
object is detected in the second sensor zone substantially
uninterrupted for 5 seconds, the logic processor is configured to
determine the amount of time for continuous water flow as 25
seconds if the continuous-water-flow-sensitivity level is in the
low-sensitivity state, the logic processor is configured to
determine the amount of time for continuous water flow as 75
seconds if the continuous-water-flow-sensitivity level is in the
medium-sensitivity state, and the logic processor is configured to
determine the amount of time for continuous water flow as 5 minutes
if the continuous-water-flow-sensitivity level is in the
high-sensitivity state.
[0198] Referring to FIG. 20, a control valve apparatus (2004) is
shown with functionality for moisture detection. The control valve
apparatus (2004) is at least partially within a housing (2003) that
also includes moisture-detection components. For example, in the
illustrated embodiment, moisture detection elements (2015, 2016,
and 2021) are shown. Various embodiments may use a variety of
moisture detection components, such as moisture detection circuits,
humidity detection circuits, optical water recognition, or
hydrostatic testing of the control valve apparatus frame. In the
illustrated embodiments, moisture detection element (2021) forms a
completed circuit between two electrodes (2015 and 2016) when water
is present. The system transmits one or more signals (2112 and
2113) to the logic processor circuit board (105) corresponding to
this moisture detection. The circuitry includes a ground circuit
(2014), and the electrical power supply package (104) provides a
current (148) to the logic processor circuit (105). When the water
detection elements (2015, 2016) transmit one or more signals to the
logic processor circuit board (105) indicating the presence of
water, the logic processor circuit board (105) sends a signal to
the control valve apparatus (2004) instructing it to restrict the
flow of water in order to reduce further leakage. Further
communications can be sent to outside agencies. For example, notice
of a possible leak may be sent to a handheld remote or via a
network, such as the Internet or mobile phone network.
[0199] FIG. 21A illustrates another embodiment of the water control
apparatus (1060). The water control apparatus includes a control
panel assembly (2001) with a base (2002). A sensor (2003) is
mounted on the base (2002) to sense an object in the sink area,
which may start an intermittent water flow. The control panel
(2001) includes a printed panel with printed indication of the
various control options: water temperature cold (2011), temperature
hot (2012), flow low (2013) and flow high (2014) for user to
control the water flow with a finger (2004) or other object.
[0200] FIG. 21B illustrates another embodiment of the water control
assembly (2030). The water control assembly includes a panel cover
(2031) and a sensor board (2032). Four sensors (2035a, 2035b,
2035c, and 2035d) are mounted on the four corners of the board
(2032) in an array arrangement to sense an object (2034) on the top
of control panel. The apparatus controls water temperature and flow
using a scale which is decided by the relative position of the
object (2034a) in relation to the sensors. For example, the
apparatus senses the distances between the object and each of the
four sensors (2036a, 2036b, 2036c and 2036d). The distances between
the object and each of the four sensors (2036a, 2036b, 2036c and
2036d) can be calculated from the signal strength received by the
four sensors (2035a, 2035b, 2035c and 2035d) and hence control the
water temperature and water flow. This may provide for control of
water flow functionality using three dimensions in space, for
example.
[0201] FIG. 21C illustrates another embodiment of the water control
sensor board (2040). Multiple sensors (2045a, 2045b, 2045c, 2045d,
2045e, 2045f, 2045g, 2045h, 2045i, 2045j, 2045k, 2045l, 2045m,
2045n, 2045o, 2045p) are mounted on the board (2042) in an array
arrangement to sense an object (2044) on the top of control panel.
The water temperature and flow are controlled using a scale that is
determined at least in part by the relative position of the sensors
such as the object (2044a) to the four sensors (2045a, 2045b, 2045e
and 2045f). The distances between the object and each of the four
sensors (2046a, 2046b, 2046e and 2046f) can be calculated from the
signal strength received by the four sensors (2045a, 2045b, 2045f
and 2045e) and can be used by the apparatus to control the water
temperature and water flow.
[0202] FIG. 21D illustrates another embodiment of the water control
assembly (2050). The water control assembly includes a panel cover
(2051) and a camera set (2052). The camera set (2052) is mounted
under the control panel cover (2051). The apparatus captures images
of an object using the camera set (2052). The apparatus may then
process one or more images to determine the position of object
(2054) and use that determined position to control the water
temperature and flow. In various embodiments, an infrared camera,
optical camera, or infrared/optical hybrid camera may be used, for
example. Other technology such as eye ball tracking technology can
be applied in this invention.
[0203] FIGS. 22-28 depict various perspectives of compartment
housing sensors for touch-free control of a faucet. The compartment
may be configured to be mounted next to a faucet, and may include
sensors that control the flow of water from the faucet in manners
such as those described above within this application. The
illustrated embodiment includes two cylindrical shaft sections,
either or both of which may be either rotated or fixed. For
example, the bottom section includes a primary sensor (C-sensor)
that may sense the presence of an object within a sink area in
order to control temporary flow in response to the detection. The
cylindrical shaft section housing that sensor may be rotated
approximately 360 degrees so that the sensor points toward the
sink, depending on the placement of the compartment in relation to
the faucet and sink. Similarly, the upper cylindrical shaft section
houses additional sensors used for functions such as increasing and
decreasing temperature and flow. This upper cylindrical section may
also be rotated so that the functions may be conveniently accessed
by a user.
[0204] Referring to FIG. 22, the compartment of the illustrated
embodiment has a cap (2212), an upper cylindrical section (2220), a
lower cylindrical section (2222), a base (2224), and a
below-surface section (2226). In the present embodiment, a primary
sensor (e.g., "C-Sensor") (31) is embedded within the lower
cylindrical section (2222) while the secondary and tertiary sensors
(e.g., "A-Sensor," "B-Sensor," "D-Sensor," and "E-Sensor") (32-35)
are embedded within the upper cylindrical section (2220). The
cylindrical section (2220) and/or the lower cylindrical section
(2222) are housed on a rotational element, such as bearings or
bushings. A separation spacing (2234) between the section, a
separation spacing (2232) above the upper cylindrical section
(2220) and a separation spacing (2236) below the lower cylindrical
section (2222) permit one or both of the sections to rotate
angularly. For example, the compartment may be mounted to the right
of a faucet, near the back of a kitchen sink. The user may rotate
the lower cylindrical section clockwise approximately 60 degrees so
that the primary sensor (31) is pointed directly toward the sink
basin. In one embodiment, one or more of the cylindrical sections
can be rotated and then fixed into place, for example using a bolt,
pin, or spring. In another embodiment, one or more of the
cylindrical sections remains freely rotatable.
[0205] The sensor compartment may include a cap (2212) which, in
certain embodiments, may include an embedded, upward-facing sensor.
The compartment may also include a base (2224) that is designed to
be mounted against a flat surface, such as a kitchen counter or the
rim of a sink. A portion of the compartment (2226) may be designed
to mount beneath the surface, and may include components for
securing the compartment to the surface. For example, the
illustrated embodiment includes bolts (e.g., 2232 and 2234)
mounting. A below-surface shaft (2238) may include a cutout (2240),
for example to permit wiring from the sensors to pass through.
[0206] FIGS. 29-35 depict various perspectives of a touch-free,
wall-mountable faucet. The illustrated embodiment includes a faucet
head that is rotatable in relation to the rest of the faucet body.
For example, the faucet outlet is housed in a cylindrical shaft
portion that may be rotated approximately 360 degrees in order to
adapt the spout angle in relation to the mounting angle and sink
location. The other illustrated portion of the cylindrical shaft
houses sensors, and may also be either capable of rotation, or
fixed, depending on the embodiment.
[0207] The wall-mountable faucet (2900) may include a spout (202)
embedded within a spout portion (2910) and sensors (31-35) within a
sensor portion (2912). In another embodiment, the spout portion
(2910) includes at least one sensor. In certain embodiments, the
spout portion (2910) and/or the sensor portion (2912) may rotate. A
separation spacing (2922) between the spout portion (2910) and the
sensor portion (2912) and a separation spacing (2924) between the
sensor portion (2912) and the base (2914) permit one or both
portions to rotate angularly. The base (2924) may be designed to
fit against a flat, vertical surface, such as a wall next to a
bathtub or sink.
TERMINOLOGY
[0208] The headings provided herein, if any, are for convenience
only and do not necessarily affect the scope or meaning of the
claimed invention. Although the exemplary embodiments are described
in relation to a touch-free faucet, embodiments of the present
disclosure can be applied in any application where control of water
flow is desired. Many other variations than those described herein
will be apparent from this disclosure. For example, depending on
the embodiment, certain acts, events, or functions of any of the
algorithms described herein can be performed in a different
sequence, can be added, merged, or left out altogether (e.g., not
all described acts or events are necessary for the practice of the
algorithms). Moreover, in certain embodiments, acts or events can
be performed concurrently, e.g., through multi-threaded processing,
interrupt processing, or multiple processors or processor cores or
on other parallel architectures, rather than sequentially. In
addition, different tasks or processes can be performed by
different machines and/or computing systems that can function
together.
[0209] The various illustrative logical blocks, modules, and
algorithm steps described in connection with the embodiments
disclosed herein can be implemented as electronic hardware,
computer software, or combinations of both. To clearly illustrate
this interchangeability of hardware and software, various
illustrative components, blocks, modules, and steps have been
described above generally in terms of their functionality. Whether
such functionality is implemented as hardware or software depends
upon the particular application and design constraints imposed on
the overall system. The described functionality can be implemented
in varying ways for each particular application, but such
implementation decisions should not be interpreted as causing a
departure from the scope of the disclosure.
[0210] The various illustrative logical blocks and modules
described in connection with the embodiments disclosed herein can
be implemented or performed by a machine, such as a general purpose
processor, a digital signal processor (DSP), an application
specific integrated circuit (ASIC), a field programmable gate array
(FPGA) or other programmable logic device, discrete gate or
transistor logic, discrete hardware components, or any combination
thereof designed to perform the functions described herein. A
general purpose processor can be a microprocessor, but in the
alternative, the processor can be a controller, microcontroller, or
state machine, combinations of the same, or the like. A processor
can also be implemented as a combination of computing devices,
e.g., a combination of a DSP and a microprocessor, a plurality of
microprocessors, one or more microprocessors in conjunction with a
DSP core, or any other such configuration. Although described
herein primarily with respect to digital technology, a processor
may also include primarily analog components. For example, any of
the signal processing algorithms described herein may be
implemented in analog circuitry. A computing environment can
include any type of computer system, including, but not limited to,
a computer system based on a microprocessor, a mainframe computer,
a digital signal processor, a portable computing device, a personal
organizer, a device controller, and a computational engine within
an appliance, to name a few.
[0211] The steps of a method, process, or algorithm described in
connection with the embodiments disclosed herein can be embodied
directly in hardware, in a software module executed by a processor,
or in a combination of the two. A software module can reside in RAM
memory, flash memory, ROM memory, EPROM memory, EEPROM memory,
registers, hard disk, a removable disk, a CD-ROM, or any other form
of non-transitory computer-readable storage medium, media, or
physical computer storage known in the art. An exemplary storage
medium can be coupled to the processor such that the processor can
read information from, and write information to, the storage
medium. In the alternative, the storage medium can be integral to
the processor. The processor and the storage medium can reside in
an ASIC. The ASIC can reside in a user terminal. In the
alternative, the processor and the storage medium can reside as
discrete components in a user terminal.
[0212] Conditional language used herein, such as, among others,
"can," "might," "may," "e.g.," and the like, unless specifically
stated otherwise, or otherwise understood within the context as
used, is generally intended to convey that certain embodiments
include, while other embodiments do not include, certain features,
elements and/or states. Thus, such conditional language is not
generally intended to imply that features, elements and/or states
are in any way required for one or more embodiments or that one or
more embodiments necessarily include logic for deciding, with or
without author input or prompting, whether these features, elements
and/or states are included or are to be performed in any particular
embodiment. The terms "comprising," "including," "having," and the
like are synonymous and are used inclusively, in an open-ended
fashion, and do not exclude additional elements, features, acts,
operations, and so forth. Also, the term "or" is used in its
inclusive sense (and not in its exclusive sense) so that when used,
for example, to connect a list of elements, the term "or" means
one, some, or all of the elements in the list.
[0213] While the above detailed description has shown, described,
and pointed out novel features as applied to various embodiments,
it will be understood that various omissions, substitutions, and
changes in the form and details of the devices or algorithms
illustrated can be made without departing from the spirit of the
disclosure. As will be recognized, certain embodiments of the
inventions described herein can be embodied within a form that does
not provide all of the features and benefits set forth herein, as
some features can be used or practiced separately from others.
[0214] Reference in the specification to "an embodiment," "one
embodiment," "some embodiments," or "other embodiments" means that
a particular feature, structure, or characteristic described in
connection with the embodiments is included in at least some
embodiments, but not necessarily all embodiments. The various
appearances of "an embodiment," "one embodiment," or "some
embodiments" are not necessarily all referring to the same
embodiments. If the specification states a component, feature,
structure, or characteristic "may," "might," or "could" be
included, that particular component, feature, structure, or
characteristic is not required to be included. If the specification
or claim refers to "a" or "an" element, that does not mean there is
only one of the element. If the specification or claims refer to
"an additional" element, that does not preclude there being more
than one of the additional element.
[0215] While certain exemplary embodiments have been described and
shown in the accompanying drawings, it is to be understood that
such embodiments are merely illustrative of and not restrictive on
the broad inventions, and that the inventions not be limited to the
specific constructions and arrangements shown and described, since
various other modifications may occur to those ordinarily skilled
in the art. Although the inventions have been described in terms of
certain preferred embodiments, other embodiments will be apparent
to those of ordinary skilled in the art, including embodiments that
do not include all of the features and benefits set forth
herein.
* * * * *