Method of controlling mixing valve

• US 10,106,964 B2
• Filed: 05/13/2016
• Issued: 10/23/2018
• Est. Priority Date: 06/22/2012
• Status: Active Grant

• Current Assignee: Kohler MIRA Limited (Kohler Company)
• Original Assignee: Kohler MIRA Limited (Kohler Company)
• Inventors: Peel, Kevin T.
• Primary Examiner(s): Sanchez-Medina, Reinaldo
• Application Number:
  US15/154,301
• Publication Number:
  US 20160252915A1
• Time in Patent Office: 893 Days
• Field of Search: 137605, 137606, 13762528, 13762533, 13762534
• CPC Class Codes: B05B 1/18 Roses; Shower heads with means for adding soap or the like E03C1/046; jet regulators E03C1/08
• CPC Class Codes: B05B 1/24 incorporating means for heating the liquid or other fluent material, e.g. electrically
• CPC Class Codes: B05D 1/24 Applying particulate materials
• CPC Class Codes: E03B 7/006 Arrangements or methods for cleaning or refurbishing water conduits
• CPC Class Codes: E03B 7/074 Arrangement of water treatment devices
• CPC Class Codes: E03B 7/075 Arrangement of devices for control of pressure or flow rate
• CPC Class Codes: E03B 7/078 Combined units with different devices; Arrangement of different devices with respect to each other
• CPC Class Codes: E03C 1/02 Plumbing installations for fresh water
• CPC Class Codes: E03C 1/04 Water-basin installations specially adapted to wash-basins or baths valves, faucets, mixing valves, taps F16K
• CPC Class Codes: E03C 1/0404 Constructional or functional features of the spout
• CPC Class Codes: E03C 1/0409 Shower handles
• CPC Class Codes: E03C 1/044 having a heating or cooling apparatus in the supply line water heaters, e.g. with continuous flow, F24H
• CPC Class Codes: E03C 1/055 Electrical control devices, e.g. with push buttons, control panels or the like
• CPC Class Codes: F16K 1/44 Details of seats or valve members of double-seat valves
• CPC Class Codes: F16K 11/22 with an actuating member for each valve, e.g. interconnected to form multiple-way valves
• CPC Class Codes: F16K 11/24 with an electromagnetically-operated valve, e.g. for washing machines
• CPC Class Codes: F16K 19/00 Arrangements of valves and flow lines specially adapted for mixing fluids multiple-way valves F16K11/00
• CPC Class Codes: F16K 19/006 Specially adapted for faucets
• CPC Class Codes: F16K 27/0263 multiple way valves
• CPC Class Codes: F16K 31/04 using a motor
• CPC Class Codes: F16K 49/002 : Electric heating means
• CPC Class Codes: F17D 1/00 : Pipe-line systems conveying articles or materials through a pipe- line by means of a fluid carrier B65G51/00, B65G53/00; liquids B67D; special devices for transferring liquids from bulk storage containers into vehicles or boats or vice versa, e.g. loading or unloading vehicles or portable containers B67D7/00; conveying material which has been excavated by a dredger or soil shifter through a pipe-line E02F7/10; sewer pipe-line systems E03F3/00; thermal insulation of pipe-lines F16L59/00; central heating systems F24D
• CPC Class Codes: G05D 11/13 : characterised by the use of electric means
• CPC Class Codes: G05D 11/16 : Controlling mixing ratio of fluids having different temperatures, e.g. by sensing the temperature of a mixture of fluids having different viscosities
• CPC Class Codes: G05D 23/1393 : characterised by the use of electric means
• CPC Class Codes: G05D 23/1858 : by varying the mixing ratio of fluids having different temperatures
• CPC Class Codes: G05D 23/19 : characterised by the use of electric means G05D23/1393 takes precedence
• CPC Class Codes: G05D 23/1917 : using digital means
• CPC Class Codes: G05D 7/0617 : specially adapted for fluid materials
• CPC Class Codes: H05K 999/99 : dummy group
• CPC Class Codes: Y10T 137/0318 : Processes
• CPC Class Codes: Y10T 137/0329 : Mixing of plural fluids of diverse characteristics or conditions
• CPC Class Codes: Y10T 137/0391 : Affecting flow by the addition of material or energy
• CPC Class Codes: Y10T 137/0424 : Liquid cleaning or flushing
• CPC Class Codes: Y10T 137/6606 : With electric heating element
• CPC Class Codes: Y10T 137/7759 : Responsive to change in rate of fluid flow
• CPC Class Codes: Y10T 137/8376 : Combined
• CPC Class Codes: Y10T 137/8593 : Systems
• CPC Class Codes: Y10T 137/86389 : Programmer or timer
• CPC Class Codes: Y10T 137/87668 : Single actuator operates plural flow control means
• CPC Class Codes: Y10T 137/87684 : Valve in each inlet
• CPC Class Codes: Y10T 137/87692 : With common valve operator

Abstract

A method including configuring a valve so that an operating force to actuate the valve when in an open position is substantially independent of water flow. The valve includes a first valve member assembly comprising a spool having a connector portion; a first valve member mounted on the spool at a first location and configured to seat against a first valve outlet in a closed position of the valve; and a second valve member mounted on the spool at a second location spaced apart from the first location and configured to seat against a second valve outlet in the closed position of the valve. The method also includes controlling the valve to output a flow of the water having a desired flow rate by moving the spool in a linear direction with a portion of a stepper motor coupled directly to the connector portion of the spool.

Claims

1. A method of controlling flow rate of outlet water from a valve, the method comprising:

configuring the valve so that an operating force to actuate the valve when in an open position is substantially independent of water flow, the valve including a first valve member assembly comprising;

a spool having a connector portion;

a first valve member mounted on the spool at a first location and configured to seat against a first valve outlet in a closed position of the valve; and

a second valve member mounted on the spool at a second location spaced apart from the first location and configured to seat against a second valve outlet in the closed position of the valve;

controlling the valve to output a flow of the water having a desired flow rate by moving the spool in a linear direction with a portion of a stepper motor coupled directly to the connector portion of the spool;

heating the valve to an elevated temperature with a heating element that extends in the valve in a direction that is generally parallel the spool of the first valve member assembly; and

monitoring the elevated temperature with a thermistor and controlling a power input to the heating element to control the elevated temperature and prevent overheating the housing of the valve.

2. The method of claim 1, wherein the valve further comprises a valve housing having a valve inlet configured to receive water from a water supply, the first valve outlet, and the second valve outlet, and wherein another portion of the stepper motor is coupled directly to the valve housing.

3. The method of claim 2, wherein the spool includes a first end and a second end, the second end including the connector portion and the first end being received within a blind guide bore in the valve housing.

4. The method of claim 3, wherein each of the first and second valve outlets includes a cylindrical center section between two end sections that taper toward the center section, and wherein each valve member is configured to seat against the center section of the associated valve outlet when the valve is in the closed position.

5. The method of claim 4, wherein the valve further comprises:

a first seal located in an annular recess in the first valve member, wherein the first seal is configured to seal against the center section of the first valve outlet when the valve is in the closed position; and

a second seal located in an annular recess in the second valve member, wherein the second seal is configured to seal against the center section of the second valve outlet when the valve is in the closed position.

6. The method of claim 1, wherein the valve is a mixing valve that includes a first inlet chamber configured to receive cold water, a second inlet chamber configured to receive hot water, and a mixing chamber for mixing the cold water and hot water;

and wherein the first and second valve outlets associated with the first valve member assembly fluidly connect the first inlet chamber to the mixing chamber.

7. The method of claim 6, wherein the mixing valve also includes a second valve member assembly for controlling the flow of hot water from the second inlet chamber to the mixing chamber, the second valve member assembly comprising:

a spool having a connector portion;

a first valve member mounted on the spool of the second valve member assembly at a first location and configured to seat against a first valve outlet of the second inlet chamber in a closed position of the valve; and

a second valve member mounted on the spool of the second valve member assembly at a second location spaced apart from the first location and configured to seat against a second valve outlet of the second inlet chamber in the closed position of the mixing valve.

8. The method of claim 7, further comprising controlling the mixing valve to output a flow of the water having a desired temperature and the desired flow rate by moving each spool of the first and second valve member assemblies independently of one another.

9. The method of claim 8, wherein the stepper motor is a first stepper motor and the mixing valve also includes a second stepper motor configured to move the spool of the second valve member assembly in the linear direction, and wherein a portion of the second stepper motor is coupled directly to a connector portion of the spool of the second valve member assembly.

10. The method of claim 7, further comprising heating the mixing valve to a disinfecting temperature with a heating element that extends in a direction that is generally parallel to each spool of the first and second valve member assemblies.

11. A method of controlling a valve in a water delivery device, the method comprising:

controlling a flow rate of water through the valve by moving a spool of a valve member assembly in a first linear direction with a motor;

controlling a disinfection cycle of the valve by activating a heater extending in the valve in a direction that is generally parallel to the first linear direction; and

monitoring a disinfection temperature with a thermistor and controlling a power input to the heater to control the disinfection temperature and prevent overheating the valve.

12. The method of claim 11, wherein the motor and the heater are controlled by a controller located in the water deliver device and coupled to the valve, and wherein the controller receives a signal from a user interface for selecting the flow rate and the disinfection cycle.

13. The method of claim 12, wherein the user interface is located remotely from the water delivery device.

14. A method of controlling a valve in a water delivery device, the method comprising:

inputting at least one of a desired temperature and a desired flow rate of the valve into a user interface located remotely from the water delivery device;

sending a signal indicating the at least one of the desired temperature and the desired flow rate from the user interface to a controller located in the water delivery device; and

moving at least one of a first motor and a second motor with the controller, wherein movement of the first motor in turn inputs an operating force that moves a spool of a first valve member assembly of the valve and movement of the second motor in turn inputs an operating force that moves a spool of the second valve member assembly of the valve to output the at least one of the desired temperature and the desired flow rate from the valve;

wherein each of the first valve member assembly and the second valve member assembly comprises first and second valve members mounted on the respective spool so that the operating force is substantially independent of water flow.

15. The method of claim 14, further comprising heating the valve to an elevated temperature with a heating element that extends in the valve in a direction that is generally parallel the spool of the first valve member assembly.

16. The method of claim 15, further comprising insulating an external surface of a housing of the valve from the heat produced by the heating element.

17. The method of claim 16, further comprising monitoring the elevated temperature with a thermistor and controlling a power input to the heating element to control the elevated temperature and prevent overheating the housing of the valve.

18. The method of claim 17, further comprising disabling the valve such that the valve is unable to move to the open position until the valve reaches a cool down temperature following a heating cycle in which the heating element heats the valve.

19. The method of claim 14, further comprising inputting a user input comprising at least one of a temperature and a first period of time into the user interface for controlling a disinfection cycle of the valve by a heating element.

20. A method of controlling a valve in a water delivery device, the method comprising:

inputting a desired flow rate of the valve into a user interface located remotely from the water delivery device;

sending a signal indicating the desired flow rate from the user interface to a controller located in the water delivery device;

moving a linear actuator with the controller, which in turn moves a spool of a valve member assembly of the valve to output the desired flow rate from the valve; and

inputting a user input comprising at least one of a temperature and a first period of time into the user interface for controlling a disinfection cycle of the valve by a heating element;

wherein the user input comprises the first period of time, the controller disables the valve during the first period of time, and the controller also disables the valve for a second period of time following the disinfection cycle to allow the valve to reach a cool down temperature that is less than an elevated temperature reached during the disinfection cycle.