Abstract:
A faucet for discharging water, comprising a spout configured to receive and discharge a supply of water; a light emitter mounted on the spout and configured to emit a light beam; a light sensor mounted on the spout and configured to receive the light beam and detect an interruption of the light beam; a control circuit configured to control the flow of water through the faucet based on the interruption of the light beam; and a touchpad for controlling at least one of a flow rate and a temperature of the water discharged from the spout.

Description:
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS 
       [0001]    This application is a Continuation of U.S. patent application Ser. No. 12/639,112, which was filed on Dec. 16, 2009. U.S. patent application Ser. No. 12/639,112 is incorporated by reference herein in its entirety. 
     
    
     BACKGROUND 
       [0002]    The present application relates to touchless faucets, and more particularly to such faucets that employ a light beam to sense presence of a person and activate the faucet in response to that sensing. 
         [0003]    In hospitals, public rest rooms, and other facilities, it is commonplace to provide a faucet which is turned on and off without requiring the user to touch the faucet. The prior art is replete with devices for sensing the presence of a user and, in response thereto, activating a solenoid valve assembly that controls the flow of water to a faucet. A common sensing technique, as described in U.S. Pat. No. 4,915,347, involves transmitting an infrared light beam into a flow region underneath the outlet of the faucet spout, where a user&#39;s hands or other objects are placed for washing. A hand or object so placed reflects some of the infrared light beam back toward the faucet, where that reflected light is detected by a sensor mounted either on or adjacent the faucet. Detection of reflected light at the sensor indicates the presence of a user in front of the faucet. In response to receiving the reflected light, the sensor emits an electrical signal that causes the solenoid valve to open, sending water from the faucet. When the detection of reflected light ceases, the solenoid valve is de-energized, terminating the flow of water. 
         [0004]    A problem with such proximity activated faucets is that room elements near the faucet, such as a mirror or shiny sink surfaces, can reflect light back to the sensor, thereby falsely triggering the flow of water. Inanimate objects, such as handbags, placed on the front edge of the sink also can falsely cause faucet operation. The false activation of the faucet not only wastes water, but may result in water overflowing the sink, if an unattended object also is blocking the drain opening. 
         [0005]    Prior touchless faucets were not practical for kitchen sinks which are used for operations, such as draining water from a cooking pot or cutting vegetables, during which water from the faucet is not desired. Thus during such activities, the presence of a hand or other object beneath the faucet outlet should not activate the flow of water. 
       SUMMARY 
       [0006]    A faucet assembly includes spout having a base for mounting adjacent a basin of a sink. The basin is the recessed portion of the sink that is designed to receive and retain water. The spout projects upward and away from the base over the basin and terminates at an outlet from which a stream of water is to be produced in a flow region beneath the outlet. A light emitter and a light sensor are mounted to the spout. The light emitter projects a beam of light toward the spout base without the beam of light intersecting the flow region beneath the spout where the water sprays from the outlet. The light sensor produces a signal indicating whether the beam of light is striking the light sensor. In response to the signal, a control circuit opens a valve, thereby conveying water through the spout. 
         [0007]    In one embodiment of this faucet assembly, the light sensor is mounted to the spout base and the light emitter is mounted proximate to the spout outlet with the light beam directed at the light sensor. Here, a person interrupts the light beam, with his or her hands for example, which interruption is indicated by the signal from the light sensor. The control circuit responds to that signal by opening a valve which supplies water to the faucet spout. The light may be in the visible spectrum to provide an indication to the person when the hands have interrupted the light beam. The water valve may remain open until either a predefined time interval elapses or the light beam is interrupted again, which ever occurs first. 
         [0008]    In another faucet assembly embodiment, the light emitter and light sensor are proximate to each other on the spout and the light sensor responds to the reflection of the light beam by an object, such as a person&#39;s hands. In this case, the control circuit opens the valve in response to the signal indicating receipt of the light beam by the light sensor. Here too, the water valve may remain open until either a predefined time interval elapses or the light beam is interrupted again, whichever occurs first. 
         [0009]    Because the light beam does not intersect the flow region beneath the spout where the water sprays from the outlet, a person can use the sink without triggering the flow of water. For example, the person may wash dishes in water retained in the sink or empty a pot of water without impinging the light beam and activating the faucet. Thus the faucet assembly is particularly adapted for use at sinks where activities other than washing hands occur. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1  is a prospective view of a sink on which a faucet assembly, according to an exemplary embodiment, is mounted. 
           [0011]      FIG. 2  is a block diagram of an electrical circuit for controlling the flow of water from the faucet assembly. 
           [0012]      FIG. 3  is a prospective view of a sink with second faucet assembly mounted thereto. 
           [0013]      FIG. 4  is a diagram illustrating the plumbing and controller associated with the second faucet assembly. 
           [0014]      FIG. 5  illustrates the plumbing and controller associated with a third faucet assembly that has a conventional single outlet manual mixing valve. 
       
    
    
     DETAILED DESCRIPTION 
       [0015]    With initial reference to  FIG. 1 , a faucet assembly  10  includes a faucet  11  that has a mounting plate  12  and a spout  14 . The mounting plate  12  is adapted to stand on the rim  15  of a sink  16  or on a counter surrounding an under-the-counter mounted sink. Some stylized faucets do not have a mounting plate  12  and the bottom of the spout  14  is mounted directly to the surface adjacent the basin  24  of the sink  16 . The spout  14  extends upward from the mounting plate  12  in an inverted J-shaped manner. Specifically, the spout  14  has a first end  17  with a generally vertical, tubular base  18  projecting upward from the mounting plate  12  and connecting into a tubular, arched portion  20  that curves upward and outward over the sink basin  24  and then continues curving downward terminating at a second end  19  that has a water outlet  22 . The water outlet  22  has a nozzle from which a stream  26  of water flows when the faucet assembly  10  is activated. Although the present embodiment is being described in the context of a high arching type spout, the faucet  11  may have other types of spouts which project upward and forwardly outward from a base section to a water outlet. The faucet  11  may have a pull-out style spray head in which the water outlet is attached to a hose that extends through the spout. 
         [0016]    A light emitter  30 , such as a semiconductor laser, light emitting diode (LED) or other device that emits a beam  32  of light, is mounted on the spout  14  adjacent the water outlet  22  and facing the base  18 . The light emitter  30  is oriented to direct the light beam  32  in a downward angle toward the base. A light sensor  34  is located on the base  18  at a position to receive the beam  32  of light. For this embodiment, a semiconductor laser has the advantage of producing a highly collimated, narrow light beam  32  whereby most, if not all, of the light impinges the sensor  34 . Nevertheless light from another type of emitter that is focused into a narrow beam also may be used. Such as narrow light beams provides a relatively small object detection zone along the path of that beam. Preferably, the light is visible to the human eye, so that when a hand of a user or other item blocks the light beam  32 , a visible spot of light appears on that object to indicate that the beam has been interrupted. Nonetheless, a beam of invisible light, such as in the infrared spectrum, can be utilized. Alternatively, the locations of the light emitter  30  and the sensor  34  can be reversed, wherein the light emitter is mounted on or proximate the base  18  and the sensor is on or proximate the spout, however with this variation a spot of light on the hands may not be visible to the user. This alternative also may allow some of the emitted light to travel visibly across the room in which the sink  16  is located. 
         [0017]    Operation of the faucet assembly  10  is controlled by an electrical circuit  40  shown in  FIG. 2  in which the light emitter  30  and the sensor  34  are connected to a controller  44 . The controller  44  is powered by a battery  42  or a low voltage DC power supply connected to a 110 or 220 volt AC electrical system in a building. The light emitter  30  is activated periodically by an output signal from a control circuit  46  and when activated, produces a beam  32  of light. Upon being impinged by the light beam  32 , the sensor  34  produces an electrical signal that is applied to an input of the control circuit  46 . Any of several well-known signal processing techniques or filters can be employed to prevent light in the room from activating the faucet assembly  110 . 
         [0018]    The control circuit  46  preferably is microcomputer based and has a memory that stores a control program which governs operation of the faucet assembly  10  and stores data used by that control program. Inputs of the control circuit  46  are connected to a user input device  50  that in the illustrated embodiment is a touchpad, such as commonly found on laptop computers for the user to move a cursor on the display screen. The touch pad produces output signals indicating a two dimensional location on the surface of the touch pad that is touched by the user. The X signal for one orthogonal axis of touch pad indicates the desired temperature of the water discharged from the faucet  11 , while the Y signal for the other orthogonal axis indicates a desired flow rate of that water. By touching different locations on the touchpad the user is able to change the temperature and flow rate. Alternatively conventional pushbutton switches can be employed as the user input device  50  by which the user increases and decreases the water temperature and flow rate. Pushbutton switches also may be provided for selecting preset water temperatures or flow rates that have been programmed into the control circuit  46 . 
         [0019]    When the faucet  11  is not being used, the light beam  32  travels from the emitter  30  to the light sensor  34 , thereby producing an electrical signal that is applied to an input of the control circuit  46 . As long as the control circuit  46  receives that electrical signal, a determination is made that a user is not present at the faucet  11  and the water is not permitted to flow to the faucet spout  14 . 
         [0020]    Referring again to  FIG. 1 , note that the light beam  32  does not intersect a “flow region” beneath the outlet  22  through which the outlet water stream  26  flows, nor does it intersect any region beneath the water outlet  22  in which the user typically places hands or other objects for washing or other sink use. In one embodiment, the light beam  32  does not intersect a larger “work region”  66  which extends downward from the second end  19  of the spout to the edge of the upper opening  27  of the basin  24 . For the exemplary rectangular basin  24 , the work region  66  has the form of a rectangular pyramid, edges of each side being indicated by dashed lines in  FIG. 1 , however for an circular or oval basin, the work region is conical. In other words, the work region  66  has a lower boundary defined by the upper opening  27  of the basin  24  and tapers upward to the second end  19  of the spout at which the water outlet  22  is located. The work region  66  may in addition include the interior of the basin  24 , thus being bounded further by the side walls and bottom of the basin. 
         [0021]    The path of the light beam  32 , by avoiding the flow region and work region, allows a person to use the sink without activating the water flow. For example, a large pot of water may be emptied into the sink or dishes can be washed in water retained in the basin without that activity interrupting the light beam  132  and thereby triggering the water flow. As used herein the “flow region beneath the outlet” refers to the space under the faucet spout where an object is placed so that water from the outlet will impinge upon the object and excludes other spaces below the vertical location of the outlet where water from the outlet will not strike an object placed there. Although in first faucet assembly  10 , the light sensor  34  is lower than the water outlet  22 , the sensor is set back toward the rear of the sink, so that the light beam  32  that is aimed at the sensor does not intersect the flow region beneath the outlet  22  that is defined by the outlet water stream  26 . 
         [0022]    When a user approaches the sink  16  and desires to activate the faucet  11 , his or her hand or another object is placed between the light emitter  30  and sensor  34 , thereby interrupting the light beam  32 . The path of the narrow light beam  132  defines a detection zone. As noted previously, it is preferred that the light is in the visible spectrum so as to produce a perceptible spot of light on the object to indicate to the user that the light beam is blocked. Furthermore, this spot is visible to the user because the light travels from adjacent the water outlet  22  of the faucet downward toward the back of the sink basin  24  and near the tubular base  18  of the faucet spout. This path illuminates a portion of the hand or the other object that is visible to the user. 
         [0023]    Referring again to  FIG. 2 , interrupting the light beam  32  in this manner terminates the previously occurring electrical signal produced by the light sensor  34  and applied to the input of the control circuit  46 . When the control circuit  46  recognizes that it is not receiving an input signal in response to activating the light emitter  30 , a determination is made that a person is present and desires to use the sink  16 . In response to that determination, the control circuit  46  sends output signals which cause a pair of valve drivers  56  and  58  to open a valve assembly  60  that comprises two proportional solenoid valves  61  and  62 . The two solenoid valves  61  and  62  respectively control the flow of hot and cold water to the spout  14 . Specifically, the outlets of the two solenoid valves  61  and  62  are connected together to produce a mixture of the hot and cold water that is fed through the spout  14  to produce the outlet water stream  26 . The valve assembly  60  may employ other electrically operated valve arrangements to produce a mixture of hot and cold water. The valve assembly  60 , along with the controller  44 , usually are located beneath the sink  16 . 
         [0024]    The amounts to which the hot and cold solenoid valves  61  and  62  are opened are specified independently by respective first and second values stored within the memory of the control circuit  46 . Those values are set by the signals from the user input device  50  and are used by the control circuit to determine the magnitude of the control signals sent to the valve drivers  56  and  58  and thus the level of electric current applied to each proportional solenoid valve  61  and  62 . With reference to the orientation of the touch pad  52  in  FIG. 2 , touching a finger to different locations along the horizontal axis of the touch pad designate different desired temperatures. The resultant signal for that axis of the touch pad  52  causes the control circuit to increases or decrease the first value which designates the amount that the hot water solenoid valve  61  is to open, and changes the second value in the opposite manner to alter the amount that the cold water solenoid valve  62  is to open. For example, moving a finger to the right on the touch pad  52  designates that the water temperature should increase which results in the first value for the hot water solenoid valve  61  increasing and the second value for the cold water solenoid valve  62  decreasing. This action sends more hot water and less cold water to the spout  14 . 
         [0025]    Touching different locations along the vertical axis of the touch pad  52 , oriented as in  FIG. 2 , alters the water flow rate by modifying both the first and second values by the same amount and to alter the changing the opening of both solenoid valves  61  and  62  equally. It should be understood that the two solenoid valves  61  and  62  may not be opened the same amounts as the water temperature setting may designate a greater amount of hot or cold water. For example, moving a finger downward on the touch pad  52  designates that the water flow rate should decrease. This movement will decrease both the first and second values by identical amounts which decreases the flow rates of the hot and cold water to the same extent while maintaining the same proportion of flow rates and thus the same temperature mixture of the water from the faucet  11 . 
         [0026]    Reference herein to directional relationships and movements, such as horizontal and vertical, up and down, or left and right, refer to a relationship and movement associated with the orientation of components as illustrated in the drawings, which may not be the orientation of those components when installed on or near a sink. 
         [0027]    After interruption of the light beam has been indicated either by a spot of light on the user&#39;s hand or by water commencing to flow from the faucet, the hands of the user can be removed from blocking the light beam. Once activated, the faucet  11  may remain open for a fixed period of time, as determined by a software timer implemented by the microcomputer within the control circuit  46 . During that time period, the control circuit continues to periodically activate the light emitter  30  and inspect the signal produced by the light sensor  34 . If the user interrupts the light beam  32  again while water is flowing from the spout  14 , the two solenoid valves  61  and  62  are closed immediately even though the fixed period of time has not elapsed. Alternatively, the faucet assembly  10  could be configured so that the two solenoid valves  61  and  62  remain open only while the light beam  32  continues to be interrupted. 
         [0028]    A person may use the sink without turning on the water. The person may work underneath the spout outlet  22  and not activate the water flow because the light beam does not intersect the flow region beneath the outlet  22  or the larger work region  66 . Thus the person may peel vegetables, place dishes in the sink, or empty a pan of water without water flowing from the spout. The location of the detection zone defined by the path of the light beam  32  allows such use of the sink. Anytime that water flow from the spout  14  is desired, the user simply moves a hand or other object through the detection zone defined by the light beam  32 , thereby momentarily interrupting the light beam. 
         [0029]    Referring to  FIG. 3 , a second faucet assembly  110  includes a faucet  111  that has a mounting plate  112  affixed adjacent the basin  124  of a sink  116  and has a spout  114  projecting upward from the mounting plate inverted J-shaped manner. Specifically, the spout  114  has a generally vertical, tubular base  118  extending upward from a first end  117  abutting the mounting plate  112  and connecting into an arched portion  120  that curves upward and outward over the sink basin  124 . The arched portion  120  continues curving downward to a remote second end  119  of the spout  114 . The second end  119  has a water outlet  122 , also referred to as a spray head, which produces a stream of water  126  when water flows through the spout. 
         [0030]    A proximity detector  130  is mounted on the spout  114  near the second end  119  and faces the base  118 . The proximity detector  130  incorporates a light emitter, such as a light emitting diode (LED), and a light sensor similar to components  30  and  34  in the first faucet assembly  10 . The light emitter and light sensor are arranged near to each other so as to project a narrow beam  132  of visible light downward toward the spout base  118  and sense any light that is reflected back to the detector by an object  133 , such as a user&#39;s hands, that may be placed in the light beam. The path of the light beam  132  forms a detection zone which does not intersect the flow region beneath the water outlet  122 , through which the outlet water stream  26  flows, nor does the light beam intersect the work region of the sink. 
         [0031]    The second faucet assembly  110  includes a manually operated mixing valve  134  that is mounted on the rim of the sink adjacent the mounting plate  112 . Alternatively, the mixing valve could be incorporated into the tubular base  118  of the spout  114  as long as a separate outlet is provided for an automatic mixing valve assembly  147 , as will be described. With reference to  FIG. 4 , this type of mixing valve  134  has a mixing stage that combines water from hot and cold water supply lines  141  and  142  into an intermediate chamber. The proportion of the hot and cold water that mixes in the intermediate chamber is varied by the rotational position of a lever  144 . The mixing valve  134  has a flow shutoff valve that, when open, allows water to flow from the intermediate chamber to a first outlet  145 . The flow shutoff valve is closed by tilting the lever  144  into the downward most position. Raising the lever  144  from that downward most position opens the flow shutoff valve and the amount that the lever is raised proportionally controls the rate of water flow to the first outlet  145 . The first outlet  145  of the mixing valve  134  is connected to the inlet  148  of the spout  114 . The mixing valve  134  has a second outlet  146  that is connected directly to the intermediate chamber. Thus, regardless of the open or closed state of the flow shutoff valve, the hot and cold water mixture in the intermediate chamber always is able to flow from the second outlet  146 . An suitable manual mixing valve is described in U.S. Patent Application Publication No. 2008/0072965, for example, however other types of manual mixing valves can be used. 
         [0032]    The second outlet  146  is connected to an electrically operated valve assembly  147  having a single solenoid valve that couples the second outlet to the inlet  148  of the spout  114 . Operation of the valve assembly  147  is governed by a controller  150  that includes a control circuit  152  for operating a valve driver  154  connected to the valve assembly  147 . The control circuit  152  has an output connected to a light emitter  156  and an input connected to a light sensor  158 , wherein the light emitter and the light detector are parts of the proximity detector  130 . The controller  150  includes a power supply  159 , such as a battery. 
         [0033]    The second faucet assembly  110  can be operated automatically in a similar manner as the first faucet assembly  10  by placing a hand or other object in the light beam  132 . Such action reflects light back to the sensor within the proximity detector  130 . Since light from that light beams only strikes the sensor  158  when an object is present, the control circuit  152  only receives an active signal from the light sensor at that time. At such time, the control circuit responds by sending an output signal to the valve driver  154  that responds by opening the valve assembly  147  to feed the mixture of hot and cold water from the second outlet  146  of the mixing valve  134  to the inlet  148  of the spout  114 . The amount that the valve assembly  147  is opened, and thus the flow rate of the water, is preset in the control circuit. Note that the water temperature is determined by the mixing stage of the manual mixing valve  134 . Thereafter, the control circuit  152  closes the valve assembly  147  upon either the user again placing a hand or other object in the light beam  132  or after a predefined activation time period has elapsed, whichever occurs first. 
         [0034]    The second faucet assembly  110  can be operated manually by the user lifting the lever  144  which opens the flow control valve stage of the mixing valve  134 . The amount that the lever is raised determines the degree to which the flow control valve stage opens and thus the flow rate of the water. The flow control valve stage of the mixing valve  134  is connected in parallel with the electrically operated valve assembly  147 , thus when either one is open water flows from the intermediate chamber of the mixing valve to the faucet spout  114  and water outlet  122 . Regardless of which one of the manual mixing valve  134  or the electrically operated valve assembly  147  is open, rotating the lever  144  of the mixing valve  134  controls the temperature of the water fed to the water outlet  122 . 
         [0035]      FIG. 5  illustrates a third faucet assembly  180  that is similar to the second faucet assembly  110 , except for using a manually operated mixing valve  182  that has a single outlet  184 . Components of the third faucet assembly  180  that are the same as those in the second faucet assembly  110  have been assigned identical reference numerals. Rotation of a lever  186  of the mixing valve  182  varies the proportion of the hot and cold water in the mixture that exits the valve and thus varies the output water temperature. The amount that the lever  186  is tilted controls the flow rate of the water exiting the mixing valve. The mixing valve  182  has an internal electric switch that conducts electric current only when that valve is open thereby providing an valve signal to the control circuit  152  via a cable  188 . 
         [0036]    The outlet  184  of the mixing valve  182  is connected to the inlet of the electrically operated valve assembly  147 , thus those two valves are fluidically connected in series. To turn on the faucet, a user must raise the lever  186  to open the mixing valve  182 . This action also closes the internal electric switch of the mixing valve which sends the valve signal to the control circuit  152  indicating that the mixing valve has been opened. The control circuit  152  responds to that valve signal by opening the electrically operated valve assembly  147  to the fully open state. This sends the mixture of water from the mixing valve  182  to the faucet spout  114  and through the water outlet  122 . The user does not have to place a hand or other object in the path of the light beam  132  for this water flow to commence. 
         [0037]    Now, however, if the user places a hand or other object in the path of the light beam  132 , the resultant signal from the light sensor  158  causes the control circuit  152  to close the electrically operated valve assembly  147  and turn off the water flow. If the mixing valve  182  remains open, as indicated to the control circuit  152  by the valve signal on cable  188 , removing the hand or other object from the light beam and then reinserting that hand or object into the light beam again causes the control circuit to open the valve assembly  147 . Interrupting the light beam repeatedly, toggles the valve assembly  147  between open and closed states as long as the control circuit  152  continues to receive a valve signal indicating that the mixing valve  182  is open. 
         [0038]    The foregoing description was primarily directed to a preferred embodiment of the invention. Although some attention was given to various alternatives within the scope of the invention, it is anticipated that one skilled in the art will likely realize additional alternatives that are now apparent from disclosure of embodiments of the invention. Accordingly, the scope of the invention should be determined from the following claims and not limited by the above disclosure.