Patent Publication Number: US-11661729-B2

Title: Electronic faucet including capacitive sensitivity control

Description:
BACKGROUND AND SUMMARY OF THE DISCLOSURE 
     The present disclosure relates generally to an electronic faucet and, more particularly, to a capacitive sensing faucet including user defined sensitivity control. 
     Electronic faucets are known in the art for controlling fluid flow. Some electronic faucets include proximity sensors such as active infrared (IR) proximity detectors or capacitive proximity sensors to control operation of the faucet. Such proximity sensors are typically used to detect a user&#39;s hands positioned near the faucet and automatically start fluid flow through the faucet in response to detection of the user&#39;s hands. Other electronic faucets may use touch sensors to control the faucet. Such touch sensors may include capacitive touch sensors or other types of touch sensors located on a spout or on a handle of the faucet for controlling operation of the faucet. Electronic faucets may also include separate touch and proximity sensors. 
     In capacitive sensing faucets, the connection between the capacitive sensor and the faucet body may be installed inconsistently. For example, capacitive sensing faucets often include a connection clip coupling a mounting shank of the faucet to a controller. Such a connection clip may be excessively stiff, making assembly difficult for the installer. More particularly, the installer may bend the connection clip out of shape to make it easier to connect. This can have the effect of reducing the contact of the connection clip to the mounting shank, thereby resulting in inconsistent performance of the faucet. 
     Traditional capacitive sensing faucets may also have an unusually high capacitive output signal. This is typically found on larger faucets mounted on electrically non-conductive sink decks (e.g., thick composite sink decks vs. thin metal sink decks). Such a high capacitive output signal can significantly reduce the performance of the faucet. 
     As such, there is a need for a connection method that is easier to make, has improved contact with the mounting shank, and provides means for reducing the capacitive output signal for certain mounting applications. 
     According to an illustrative embodiment of the present disclosure, an electronic faucet includes a faucet body having a fluid passageway, an electrically operable valve coupled to the fluid passageway, and a controller operably coupled to the electrically operable valve for controlling fluid flow through the fluid passageway. A capacitive sensor is electrically coupled to the controller, wherein the controller is configured to monitor an output signal from the capacitive sensor in response to input from a user. The input includes at least when a portion of the faucet body is touched by a user or when a user&#39;s hands are located in a detection zone located near the portion of the faucet body. A capacitive sensitivity adjustment device is operably coupled to the controller to change magnitude of the output signal in response to input from the user. 
     According to another illustrative embodiment of the present disclosure, an electronic faucet includes a faucet body having a mounting shank and a fluid passageway, an electrically operable valve coupled to the fluid passageway, and a controller operably coupled to the electrically operable valve for controlling fluid flow through the fluid passageway. A capacitive sensor is electrically coupled to the controller, wherein the controller is configured to monitor an output signal from the capacitive sensor in response to input from a user. The input includes at least when a portion of the faucet body is touched by a user or when a user&#39;s hands are located in a detection area located near the portion of the faucet body. A capacitive sensitivity adjustment device is operably coupled to the controller to change magnitude of the output signal in response to the input from the user. The capacitive sensitivity adjustment device includes an electrode operably coupled to the mounting shank and the capacitive sensor via a control wire. The electrode includes a retainer, a primary contact supported by the retainer in an electrical contact with the mounting shank, and a secondary contact supported by the retainer in spaced relation to the primary contact such that a gap is defined between the first contact and the secondary contact, the secondary contact capacitively coupled to the primary contact. 
     According to a further illustrative embodiment of the present disclosure, a connector assembly includes a retainer, a primary contact including a primary connection tab and supported by the retainer, and a secondary contact including a secondary connection tab and supported by the retainer in radially spaced relation to the primary contact such that a gap is defined between the primary contact and the secondary contact, the secondary contact capacitively coupled to the primary contact. The retainer includes an upper support, a lower support spaced apart from the upper support, and a plurality of slots formed within the lower support to receive the primary connection tab of the primary contact and the secondary connection tab of the secondary contact. 
     Additional features and advantages of the present invention will become apparent of those skilled in the art upon consideration of the following detailed description of the illustrative embodiment exemplifying the best mode of carrying out the invention as presently perceived. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The detailed description of the drawings particularly refers to the accompanying figures in which: 
         FIG.  1    is a perspective view of an electronic faucet mounted to a sink deck with a control box supported below the sink deck; 
         FIG.  2 A  is a block diagram of an illustrative electronic faucet according to  FIG.  1   ; 
         FIG.  2 B  is a block diagram of another illustrative electronic faucet according to  FIG.  1   ; 
         FIG.  2 C  is a block diagram of a further illustrative electronic faucet according to  FIG.  1   ; 
         FIG.  3    is a perspective view of an illustrative connector assembly mounted to a mounting shank; 
         FIG.  4    is a bottom plan view of the illustrative connector assembly of  FIG.  3   , with the faucet mounting shank shown in phantom; 
         FIG.  5    is an exploded perspective view of the connector assembly of  FIG.  3   ; 
         FIG.  6    is a perspective view of a retainer of the connector assembly of  FIG.  3   ; 
         FIG.  7    is a cross-sectional view taken along line  7 - 7  of  FIG.  3   ; and 
         FIG.  8    is a perspective view of a further illustrative capacitive sensitivity adjustment device. 
     
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS 
     For the purposes of promoting an understanding of the principles of the present disclosure, reference will now be made to the embodiments illustrated in the drawings, which are described herein. The embodiments disclosed herein are not intended to be exhaustive or to limit the invention to the precise form disclosed. Rather, the embodiments are chosen and described so that others skilled in the art may utilize their teachings. Therefore, no limitation of the scope of the claimed invention is thereby intended. The present invention includes any alterations and further modifications of the illustrated devices and described methods and further applications of principles in the invention which would normally occur to one skilled in the art to which the invention relates. 
     Referring initially to  FIGS.  1  and  2 A , an illustrative faucet  10  is shown supported by a conventional support, such as a mounting or a sink deck  12  above a basin or sink  14 . The illustrative electronic faucet  10  includes an upper faucet body having a delivery spout  16  supported by a hub  18  coupled to the sink deck  12 . The delivery spout  16  supports a water outlet  20  for dispensing water into the sink basin  14 . The water outlet  20  may be defined by a conventional aerator supported within a pullout wand or sprayhead  22  removably coupled to an outlet end of the delivery spout  16 . The delivery spout  16  is illustratively formed of an electrically conductive material, such as a die-cast zinc or a chrome plated polymer. 
     A manual valve is 26 is illustratively supported by the delivery spout  16  and is fluidly coupled to a hot water source  30  and a cold water source  32 . The hot water source  30  and the cold water source  32  may be defined by conventional water valve stops ( FIG.  1   ). More particularly, a flexible hot water inlet tube  34  fluidly couples the hot water source  30  to the manual valve  26 , and a flexible cold water inlet tube  36  fluidly couples the cold water source  32  to the manual valve  26 . In an illustrative embodiment, an electrically operable valve  40  is fluidly coupled in series with, and downstream from, the manual valve  26 . The electrically operable valve  40  is illustratively part of a control unit  42 . A flexible connecting tube  44  illustratively fluidly couples the manual valve  26  to the electrically operable valve  40 . A flexible outlet tube  46  may define a fluid passageway fluidly coupling the electrically operable valve  40  to the water outlet  20 . The flexible outlet tube  46  may be slidably received within the hub  18  and the delivery spout  16  to permit removal of the sprayhead  22  from the outlet end of the delivery spout  16 . The tubes  34 ,  36 ,  44  and  46  may be formed of a polymer, illustratively a cross-linked polyethylene (PEX). 
     A lower faucet body includes an externally threaded mounting shank  48  illustratively extending down from the faucet hub  18  and in electrical communication therewith. The mounting shank  48  is formed of an electrically conductive material, illustratively a metal, such as aluminum or brass. A mounting nut  50  threadably couples with the mounting shank  48  and is configured to secure the faucet  10  to the sink deck  12 . Illustratively, a capacitive sensor  52  is electrically coupled to the hub  18  and the delivery spout  16  via the mounting shank  48 . An electrode, illustratively a connector assembly  54 , is in electrical contact with the mounting shank  48 . Illustratively, a control wire  56  electrically couples the connector assembly  54  to a controller  58  forming part of the control unit  42 . 
     The electrically operable valve  40  is in electrical communication with the controller  58 . The controller  58  illustratively includes a processor  60  in communication with a memory  62  for processing output signals from the capacitive sensor  52 . A power supply  64 , such as a battery, is in electrical communication with the processor  60 . The control unit  42  (including the electrically operable valve  40 , the capacitive sensor  52 , the controller  60 , the memory  62 , and the power supply  64 ) may be received within a control housing  66  ( FIG.  1   ). A user interface, such as a control switch  68 , is illustratively supported by the control housing  66  and is in electrical communication with the processor  60  ( FIGS.  1  and  2 B ). 
     The controller  58  is configured to monitor an output signal from the capacitive sensor  52  in response to input from a user. Such an input may be defined by a user touching or being in proximity to the upper faucet body. For example, the capacitive sensor  52  generates an output signal when the delivery spout  16  or the hub  18  is touched by a user, and/or when a user&#39;s hands are located in a detection area located near the delivery spout  16  or the hub  18 . 
     An insulator base  74  is illustratively positioned intermediate to the faucet hub  18  and the sink deck  12 . The insulator base  74  is illustratively formed of an electrically insulating material, such as polymer, and may support an indicator light  76 . The indicator light  76  is illustratively in electrical communication with the controller  58  and may provide, for example, an indication of faucet status (e.g., on/off, low battery, etc.) or a parameter water (e.g., color indicating temperature, intensity indicating flow rate, etc.) supplied to the outlet  20 . 
     With reference to  FIGS.  3 - 6   , the connector assembly  54  defines an illustrative capacitive sensitivity adjustment device operably coupled to the controller  58  to adjust the magnitude of the output signal from the capacitive sensor  52 . The connector assembly  54  illustratively includes a retainer  82 , and a capacitive coupling  84  defined by a main or primary contact  86  and an auxiliary or secondary contact  88  separated from the primary contact  86  by an annular gap  90 . The retainer  82  is illustratively formed of an electrically insulating material, such as a molded polymer. The contacts  86  and  88  are illustratively formed of an electrically conductive material, such as a stamped metal, illustratively copper. 
     With reference to  FIGS.  3 - 5  and  7   , the primary contact  86  illustratively includes a main body  92  and a downwardly extending primary connection tab  94  laterally offset from the main body  92 . The secondary contact  88  illustratively includes a main body  96  and a downwardly extending secondary connection tab  98  laterally offset from the main body  96 . The main bodies  92  and  96  of the primary and secondary contacts  86  and  88  are radially spaced apart from each other by the gap  90  to define the capacitive coupling  84 . More particularly, the annular gap  90  is positioned intermediate an outwardly facing surface  99  of the primary contact  86  and an inwardly facing surface  101  of the secondary contact  88 . An insulator coating  100  is illustratively supported by the main body  96  of the secondary contact  88 . The insulator coating  100  is illustratively formed of an electrically insulating material, such as an epoxy. 
     As shown in  FIGS.  5  and  6   , the illustrative retainer  82  includes an upper support  102  and a lower support  104  defining an opening  105  for receiving the mounting shank  48 . In the illustrative embodiment, the retainer  82  is sized to couple to mounting shank  48  having an outer diameter of approximately 0.725 inches. A plurality of vertical arms  106  extend between the upper support  102  and the lower support  104 . Radially outwardly extending protrusions or supports  108  and  112  include slots  110  and  114  for receiving the connection tabs  94  and  98  of the primary and secondary contacts  86  and  88 , respectively. 
     More particularly, the connection tab  94  of the primary contact  86  is assembled through the slot  110  in the retainer  82  so that the connection tab  94  projects from below the protrusion  108  of the lower support  104 . The connection tab  98  of the secondary contact  88  is assembled through the slot  114  in the retainer  82  so that the connection tab  98  projects beneath the protrusion  112  of the lower support  104  at a different level than connection tab  94  of the primary contact  86 . 
       FIG.  4    is a bottom view of the connector assembly  54  with the mounting shank  48  inserted within the opening  105 . The retainer  82  is sized to make sure the contact of the spout shank  48  rather than the retainer  82 . The capacitive sensor  52  and the controller  58  is alternately electrically coupled to the primary contact tab  94  or the secondary contact tab  98  by control wire  56  (typically via a conventional receiver or socket connector (not shown)). More particularly, when connected to the control wire  56  the primary contact tab  94  defines a high capacitive output signal setting, while the secondary contact tab  98  defines a low capacitive output signal setting. This will allow for a good performing faucet  10  for a mass majority of the installations. A high capacitive sensitivity mode is defined by the controller  58  when the control wire  56  is electrically coupled to the primary connection tab  94 . A low capacitive sensitivity mode is defined by the controller  58  when the control wire  56  is electrically coupled to the secondary connection tab  98 . In an illustrative embodiment, the output signal from the capacitive sensor  52  in the low capacitive sensitivity mode is approximately 60% of the output signal from the capacitive sensor  52  in the high capacitive sensing mode in response to the same input (e.g., when a portion of the delivery spout  16  or hub  18  is touched by a user, or when a user&#39;s hands are located in a detection area located near the delivery spout  16  or hub  18 ). 
     As noted above, the secondary contact  88  is capacitively coupled to the primary contact  86  to define the capacitive coupling  84 . The characteristics of the capacitive coupling  84  are dependent upon the geometry and arrangement of the connectors  86  and  88 . More particularly, the strength of the capacitive coupling  84  depends upon the overlapping surface area of the opposing surfaces  99  and  101  of the primary and secondary contacts  86  and  88  and the width of the gap  90  (i.e., distance between the surfaces  99  and  101 ). In the illustrative embodiment, the overlapping surface area is approximately 0.43 square inches. Based on the geometry of the two connectors  86  and  88 , the gap  90  between the opposing surfaces  99  and  101  of the two connectors  86  and  88  is illustratively 0.003 inches. The connection tab  98  of the secondary contact  88  is shielded by the protrusion  112 , and the epoxy coating  100  of the main body  96  of the contact  88 . The connection tab  98  is shielded by the coating  100  as it may need to be electrically connected to the electronics of the controller  58 . 
     The insulator coating  100  of the secondary contact  88  illustratively provides two functions. The insulating coating  100  defines the proper gap  90  for the capacitive coupling  84 , and protects the rest of the secondary contact  88  from water droplets. If the inwardly facing surface  101  of the secondary contact  88  was not coated, a droplet of water could potentially breech the primary contact  86  and the secondary contact  88  negating the capacitive coupling effect. 
     With reference to  FIGS.  3 - 5   , the primary and secondary contacts  86  and  88  are illustratively assembled to the retainer  82  from above. The primary contact  86  includes ears  116  and  118  received within recesses  120  and  122  in the retainer  82 . The connection tab  94  of the primary contact  86  also passes through the mating slot  110  of the retainer  82 . Opposing ends of the primary contact  86  illustratively includes projections or lips  128  and  130  secured by retainers  132  and  134 , respectively. More particularly, the lips  128  and  130  are received within recesses  136  and  138 , respectively, of the retainer  82 . 
     The secondary contact  88  is received within a recess  124 , while the connection tab  98  is received within the mating slot  114  of the retainer  82 . A small barb (not shown) can be formed on the tabs  94  and  98  to act as retainers for the connector assembly  54 . The retainer  82  holds the secondary contact  88  in proximity to the primary contact  86  making a capacitor (i.e., the capacitive coupling  84 ) that can be used to reduce a signal to the hub  18  and the delivery spout  16  in certain applications (e.g., mounting on thick composite sink decks). 
     One illustrative function of the connector assembly  54  is to easily connect to the spout shank  48  while maintaining good electrical contact with the spout shank  48 . The connector assembly  54  will connect to the spout shank  48  by pressing the assembly  54  onto the shank  48  through the opening  105 . The main contact  86  is illustratively heat treated to a spring temper which will act to clip onto the spout shank  48  and will contact the shank surfaces at contact areas  126  ( FIG.  4   ). The retainer  82  acts to hold the assembly together, not as a clip itself. 
     Another function of the connector assembly  54  is to provide a reduced signal to installations where the signal strength is particularly high. The excessively high signal strength can negatively affect the performance of the faucet  10 . As noted above, this is typically in larger faucets mounted on thick composite (electrically non-conductive) sink decks. Because the secondary contact  88  is capacitively coupled to the primary contact  86  and not in direct contact therewith, reduced capacitive output signals are transmitted by the capacitive sensor  52  as a result of user input (when the delivery spout  16  or the hub  18  is touched by a user, or when a user&#39;s hands are located in a detection area located near the delivery spout  16  or hub  18 )., thereby improving the performance of faucet  10 . 
     The surface area of the overlapping contact surfaces  99  and  101  of the primary and secondary contacts  86  and  88 , and the gap  90  between them must be sized appropriately. For instance, the two surfaces  99  and  101  of the contacts  86  and  88  were the same size, and were held at 0.040 inches apart, a typical wall thickness for injection molding, a capacitive signal provided via the secondary contact  88  would typically not be sufficient to provide a functioning faucet  10 . The size of the connector assembly  54 , the surface area of the overlapping surfaces  99  and  101  in the gap  90  between the two contacts  86  and  88  have to be sized appropriately, changing one feature would require a change to the other. 
     With reference to  FIGS.  1  and  2 B , a further illustrative embodiment faucet  10 ′ includes a capacitive sensitivity adjustment device defined by the user operable control switch  68  including at least two positions. A high capacitive sensitivity mode is defined by the controller  58  when the control switch  68  is in a first position, and a low capacitive sensitivity mode is defined by the controller  58  when the control switch  68  is in a second position. 
     According to a further illustrative embodiment faucet  10 ″ shown in  FIGS.  2 C and  8   , a capacitive sensitivity adjustment device is defined by an electrode  154  electrically coupled in series with a resistor  156 . The electrode  154  illustratively comprises a clip including a quick connect  158  to the resistor  156  at a first end, and opposing arms  160  and  162  at a second end. A high capacitive sensitivity mode is defined by the controller  58  when the resistor  156  is uncoupled from the electrode  154 , and a low capacitive sensitivity mode is defined by the controller  58  when the resistor  156  is coupled in electrical series with the electrode  154 . 
     Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the spirit and scope of the invention as described and defined in the following claims.