Sensor assembly for faucet

• US 9,816,257 B2
• Filed: 08/06/2014
• Issued: 11/14/2017
• Est. Priority Date: 08/07/2013
• Status: Active Grant

• Current Assignee: Kohler Company
• Original Assignee: Kohler Company
• Inventors: Blake, Joseph, Erickson, Perry, Esche, John, Radder, Steve, Ristow, Ross, Stauber, Joseph
• Primary Examiner(s): MACKAY-SMITH, SETH WENTWORTH
• Application Number:
  US14/453,522
• Publication Number:
  US 20150040997A1
• Time in Patent Office: 1,196 Days
• CPC Class Codes: E03C 1/057 touchless, i.e. using sensors
• CPC Class Codes: Y10T 137/5987 Solenoid or electromagnetically operated valve
• CPC Class Codes: Y10T 137/8158 With indicator, register, recorder, alarm or inspection means

Abstract

A sensor assembly for controlling a solenoid valve, the solenoid valve controlling the flow of water through a faucet, is described. The sensor assembly includes a head including a bottom portion configured to be supported by a wall and a top portion. The sensor assembly also includes a proximity sensor including a transmitter and receiver. The transmitter projects a beam into a detection zone. The sensor assembly also includes processing electronics configured to cause the solenoid valve to open in response to a receiver detecting a reflection from an object in the detection zone.

Claims

1. A sensor assembly for controlling a solenoid valve, the solenoid valve controlling a flow of water through a faucet, the faucet being spaced apart from the sensor assembly, the sensor assembly comprising:

a shank passing through an aperture in a wall and terminating at a flange at a first end of the shank;

a head coupled to the shank, the head comprising;

a base having a first side configured to be supported by a first side of the wall and a second side configured to interface with a first side of the flange, the base comprising an opening and a hole configured to receive an at least partially-threaded portion of the shank, wherein the flange is entirely contained within the base;

a top portion opposite the base and comprising a transparent or translucent cover that covers the opening of the base; and

circuitry positioned between the transparent or translucent cover and a second side of the flange opposite the first side, the circuitry at least partially received within a recess in the shank and interfacing with the second side of the flange, the circuitry comprising;

a proximity sensor comprising;

a transmitter configured to project a beam into a detection zone on the first side of the wall through the transparent or translucent cover, the beam extending substantially normal to and away from the wall; and

a receiver configured to detect a reflection of the beam off of an object in the detection zone; and

processing electronics configured to cause the solenoid valve to open in response to the receiver detecting a first reflection from the object in the detection zone; and

a nut threadedly coupled to the shank and configured to be supported by a second side of the wall opposite the first side of the wall such that tightening the nut on the shank secures the head on the first side of the wall and secures the nut on the second side of the wall.

2. The sensor assembly of claim 1, wherein the wall comprises a rim extending from a basin, the rim defining the aperture and defining at least one faucet hole for mounting the faucet to the rim, the aperture spaced apart from the at least one faucet hole.

3. The sensor assembly of claim 1, wherein the transmitter comprises an infrared transmitter, and the beam is projected through the transparent or translucent cover into the detection zone.

4. The sensor assembly of claim 3, further comprising an indicia located on the transparent or translucent cover, the indicia indicating to the user where to pass the object in order to actuate the faucet.

5. The sensor assembly of claim 1, wherein the head comprises at least one light emitting diode (LED), and wherein the processing electronics control illumination of the at least one LED to annunciate a state of the solenoid valve.

6. The sensor assembly of claim 5, wherein the at least one LED comprises a plurality of light emitting diodes arranged in a sequence, and wherein the processing electronics cause the at least one LED to illuminate sequentially when the solenoid valve is open.

7. The sensor assembly of claim 1, wherein the head comprises a touch sensor, and wherein the processing electronics cause the solenoid valve to open for a predetermined amount of time in response to the head being touched.

8. The sensor assembly of claim 1, wherein the faucet comprises a spout and at least one mechanical valve, each of the at least one mechanical valve having a handle operably coupled to the at least one mechanical valve, and wherein the solenoid valve is located upstream of the at least one mechanical valve.

9. The sensor assembly of claim 1, wherein the processing electronics are configured to cause the solenoid valve to close in response to the receiver detecting a second reflection from the object in the detection zone.

10. The sensor assembly of claim 1, further comprising:

a magnet disposed in the head and configured to magnetically couple the head to the wall; and

a battery electrically coupled to the processing electronics;

wherein the processing electronics are configured to control the solenoid valve via wireless communication.

11. A system for controlling a flow of water through a faucet that provides water to a sink, the sink having a basin and a rim, the rim defining at least one faucet hole for mounting the faucet to the rim and defining an accessory hole spaced apart from the at least one faucet hole, the faucet having an outlet for discharging water into the basin and having at least one mechanical valve for controlling a temperature and a volume of the flow of water when the water is flowing, the system comprising:

a solenoid valve fluidly interconnected between the at least one mechanical valve and the outlet;

a shank passing through the accessory hole, the shank terminating on one end in a flange located on a first side of the rim, the flange having a first side and a second side, the first side configured to interface with a base of a head, the base comprising a hole and the base configured to be supported by the first side of the rim, wherein the flange is entirely contained within the base;

a proximity sensor positioned on circuitry that interfaces with the second side of the flange and configured to detect an object in a detection zone above the base; and

a nut threadedly coupled to the shank and configured to be supported by a second side of the rim opposite the first side of the rim such that tightening the nut on the shank secures the base on the first side of the rim and secures the nut on the second side of the rim;

wherein the solenoid valve is configured to close in response to a first detection by the proximity sensor of an object in the detection zone.

12. The system of claim 11, wherein the base comprises at least one of a vacuum breaker and a soap dispenser.

13. The system of claim 11, wherein the proximity sensor comprises an infrared transmitter, and the proximity sensor is configured to detect an object within approximately 30 centimeters of the infrared transmitter.

14. The system of claim 11, further comprising an indicia proximate the proximity sensor cueing the user where to pass an object in order to actuate the faucet;

wherein the indicia is illuminated when the solenoid valve is closed.

15. A kit for retrofitting an existing faucet system from manual to touchless operation, the existing faucet system including a faucet having an outlet for discharging water from the faucet into a basin and having a mechanical valve fluidly coupled to the outlet for controlling a flow of water through the faucet, the mechanical valve configured to receive water from a water supply, the kit comprising:

a solenoid valve assembly having at least one solenoid valve, an inlet, and an outlet;

a proximity sensor assembly configured to detect an object in a detection zone comprising;

circuitry comprising a transmitter configured to project a beam into the detection zone on a first side of a wall, the beam extending substantially normal to and away from the wall;

a head having a base having a first side configured to be supported by the first side of the wall and the base having a second side configured to interface with a first side of a flange of a shank, the base comprising a hole configured to receive a portion of the shank, wherein the shank terminates on one end at the flange, wherein the flange is entirely contained within the base, and wherein a second side of the flange interfaces with the circuitry within the base; and

a nut threadedly coupled to the shank and configured to be supported by a second side of the wall opposite the first side of the wall such that tightening the nut on the shank secures the head on the first side of the wall and secures the nut on the second side of the wall;

processing electronics configured to toggle the at least one solenoid valve between an open state and a closed state in response to the proximity sensor assembly detecting the object in the detection zone; and

instructions for retrofitting the existing faucet system, the instructions comprising;

fluidly decoupling the outlet of the faucet from the water supply;

fluidly coupling the solenoid valve assembly to the mechanical valve;

placing the object in the detection zone to cause the at least one solenoid valve to toggle between the open state and the closed state.

16. The kit of claim 15, wherein:

the basin has a rim coupled to a countertop;

at least one of the basin and the countertop define at least one faucet hole for mounting the faucet;

at least one of the basin and the countertop define an accessory hole spaced apart from the at least one faucet hole; and

the instructions further comprise inserting the shank into the accessory hole.

17. The kit of claim 15, wherein the transmitter comprises a wireless communication transmitter, and the solenoid valve assembly comprises a wireless communication receiver, and wherein the instructions further comprise establishing wireless communication between the proximity sensor assembly and the solenoid valve assembly.

18. The kit of claim 15, wherein the instructions for retrofitting the existing faucet system specify that fluidly decoupling the outlet of the faucet from the water supply comprises fluidly decoupling the mechanical valve from the water supply;

wherein the instructions for retrofitting the existing faucet system specify that fluidly coupling the solenoid valve assembly to the mechanical valve comprises fluidly coupling the outlet of the solenoid valve assembly to an inlet of the mechanical valve; and

wherein the instructions further comprise;

fluidly coupling the water supply to the inlet of the solenoid valve assembly; and

operably coupling at least one of the proximity sensor assembly and the processing electronics to the solenoid valve assembly.

19. The kit of claim 18, wherein:

the inlet of the mechanical valve comprises a first hot inlet and a first cold inlet;

the outlet of the solenoid valve assembly comprises a hot outlet and a cold outlet;

the inlet of the solenoid valve assembly comprises a second hot inlet and a second cold inlet;

the water supply comprises a hot supply and a cold supply;

fluidly coupling the inlet of the mechanical valve to the outlet of the solenoid valve assembly comprises fluidly coupling the first hot inlet to the hot outlet and fluidly coupling the first cold inlet to the cold outlet; and

fluidly coupling the water supply to the inlet of the solenoid valve assembly comprises fluidly coupling the hot supply to the second hot inlet and fluidly coupling the cold supply to the second cold inlet.