Note: Descriptions are shown in the official language in which they were submitted.
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K. S. SCHNEIDER
J. D. VOGEL
87,~831
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
This invention relates generally to fluid
distribution manifolds, and more specifically to
thermoplastic distribution manifolds for use in a
beverage dispensing device.
THE PRIOR ART
A post-mix carbonated beverage dispensing
system generates its own carbonated water from a
pressurized supply of potable water, and then
distributes the carbonated water to a post-mix
valve or valves. Each post-mix valve mixes
carbonated water with syrup and effects dispensing
of a complete beverage. These dispensers are
typically used by fast food retailers, theaters,
convention centers, sports facilities and the like.
Most all post-mix dispensers have some type of
manifold structure to distribute carbonated water
from a single source, which may consist of a single
carbonator connected to a plurality of dispensing
valves. A typical dispenser will include four
dispensing valves, and it is not uncommon to see up
to twelve dispensing valves being supplied from a
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single carbonator. The structure that distributes
the carbonated water plays an important role in
beverage quality, as carbonated water is a very
delicate substance in that it can become
decarbonated very easily by temperature increases
or agitation. Therefore, a manifold made of a
material having a high heat capacity, or structural
flaws in the interior water passages thereof, can
cause unwanted warming of, or turbulence in, the
water flow resulting in reduced carbonation and
poor beverage quality. One known structure for
distributing carbonated water consists of a molded
plastic housing with metal ferrules for an inlet
and plural outlets. However, such a device is
generally located at a remote location from the
cooling structure and, during stand by time,
carbonated water in the housing can warm up and, as
a result thereof, decarbonate. Leakage, ferrule
breakage, stress cracks, and sanitation are also
continually reoccurring problems with such
manifolds.
A metal block with a bored out center section
having bored and tapped transverse apertures using
adapter fittings, has also been used. This
equipment is expensive, heavy/ bulky, leaky, very
difficult to sanitize and generally is not an
effective solution. A typical example is seen in
U.S. Patent No. 3,175,578.
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The most recently commercially used structure
for distributing carbonated water includes a
manifold made of an elongate length of stainless
steel tubing forming an elongate plenum. At least
one end of the tube is closed and the other end may
be an inlet or may be closed, and several
transverse fittings are welded into apertures
drilled transversely into the plenum tube. This
structure has been in use for several years and is
the least costly, and most structurally efficient
device known for distributing carbonated water in a
post-mix dispenser. A typical example of this
structure is shown in U.S. Patent No. 3,892,335.
However, a major problem with this type of manifold
concerns the welding of the transverse fittings to
the plenum tube. Specifically, the problem can
result from such welding wherein the weld causes an
obstruction to be formed within the tube. Such
obstructions can cause undesirable turbulence in
the flow of the carbonated water. The existence of
one or more of such defective outlets can not be
easily determined, visually or otherwise, prior to
actual use. Consequently, maintaining a high level
of quality control in the manufacture of such
manifolds can be very troublesome and costly.
Sanitation problems are also a concern due to
small, hard to clean crevices that can exist as a
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result of the welding process that can provide a
location for bacterial growth. It has been proven
to be a very time consuming and expensive task to
establish, in the field, that a dispensing problem
is due to a defective manifold. Thus, flawed
manifolds present a substantial problem for the
food and beverage industry.
OBJECTS OF THE INVENTION
It is an object of this invention to provide
for a fluid distribution manifold that eliminates
or greatly reduces any unwanted turbulence in the
flow of carbonated water therethrough.
It is an object of this invention to provide
for a fluid distribution manifold that is easy to
sanitize.
It is an object of this invention to provide
for a fluid distribution manifold that reduces the
rate of warming of any carbonated water held
therein.
SUMMARY OF THE INVENTION
The fluid distribution manifold of the present
invention includes an elongate thermoplastic
conduit with an internal plenum or space, plugs
closing the ends of the plenum, and a plurality of
radial apertures extending through the tube and
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into the plenum space. A plurality of novel
thermoplastic inlet and outlet fittings are secured
to the plenum apertures. Each fitting has an
elongate tubular body defining an interior fluid
channel. The fluid channel extends through the
fitting from a releasable connecting end to a
conduit aperture connecting end. The aperture
connecting end of each fitting has a spud extending
therefrom for insertion into one of the apertures,
and a convex saddle extending therefrom around the
spud that conforms to and lies directly adjacent
the exterior surface of the tube when the spud is
inserted into an aperture. The spud includes a
sonic welding energy director extending around the
perimeter thereof for providing secure sonic
welding of the perimeter of the spud to the conduit
to the aperture perimeter. Further rigidity of
such connection is provided for by sonic welding
energy directors located on the interior surface of
each saddle for providing securing of the saddle to
the exterior surface of the plenum.
It was found that the manifold of the present
invention, when formed by sonic welding of the
particularly designed thermoplastic fittings
results in a manifold having joints that are smooth
and without the flaws that can cause unwanted
turbulence of the carbonated water stream. Also,
the superior smoothness of such joints greatly
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improves the ease of sanitation of such a manifold.
Moreover, the use of thermoplastic provides for a
manifold that better insulate~ the carbonated water
stream against undesirable increases in the
temperature thereof.
Many other advantages, features and additional
objects of the present invention will become
manifest to those versed in the art upon making
reference to the detailed description and
accompanying drawings in which the preferred
embodiment incorporating the principles of the
present invention is set forth and shown by way of
illustrative example.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG 1 is a perspective view of the preferred
embodiment of the thermoplastic carbonated water
distribution manifo~d of the present invention with
a schematically represented beverage dispensing
system.
FIG 2 is a cross-sectional view taken through
lines II-II of FIG 1.
FIG 3 is a cross-sectional view in accordance
with FIG 2 showing a fitting inserted into the
conduit end prior to the sonic welding thereof.
FIG 4 is a detail plan view of an aperture
connecting end of a fluid fitting.
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FIG 5 shows an end plan view of a fitting
aperture end along lines 5-5 of FIG 4.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The carbonated water distribution manifold of
the present invention is seen in FIG 1, and
generally indicated by the numeral 10. For the
purpose of illustration it is understood that
manifold 10 can be used in conjunction with a
beverage dispensing system represented
schematically, including a source of carbonated
water 11, a source of syrup 12, and a beverage
dispensing valve 13. Manifold 10 includes a hollow
conduit 14 having end caps or plugs 15. Carbonated
water source 11 is connected to a pressurized water
supply ~not shown) by an inlet lla, and typically
includes a carbonated water circulating pump 16 and
is fluidly connected therefrom to conduit 14 by a
circulating fitting 17 having a releasable base
connecting end 18. Water source 11 is also
connected to conduit 14 by a further circulating
fitting 17 to provide a return path for the
circulation of carbonated water in the direction as
indicated by the arrows in FIG 1. A plurality of
dispensing valve outlet fittings 19 are secured to
conduit 14 and include a dispensing valve
connection end 20 having an O-ring 20a and an
attachment means receiving annular groove 20b. As
is know in the art, outlet ends 20 are designed for
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cooperation with the inlet 22a of a dispensing
valve 13. Also as is understood in the art,
dispensing valve 13 has a syrup inlet 22b for
connection to a source of syrup 12. In the
preferred form of the present invention, a portion
of the line supplying syrup to valve 13 can consist
of a thermoplastic angled tube 24 having an
appropriate beverage valve connecting end 24a with
a releasable hose connecting end 24b.
It will be understood by those of skill that
fittings 17 and 20 have a channel running centrally
along the axis thereof to provide for fluid flow
therethrough. As the structure of what is referred
to as the conduit connecting ends 26a and 26b
thereof are proportionally the same, for purposes
of efficiency of description herein, the structure
of only an aperture connecting end 26a will be had.
However, it will be understood that such
description will apply equally to the conduit
connecting ends 26b of circulating fittings 17.
As seen in FIG'S 2, 3, and 4, fitting 19
includes an elongate tubular housing 28 defining an
interior channel 30 extending therethrough between
the end 20 and 26b thereof for providing the
communication of fluids therethrough. The manner
of attachment of a fitting 19 to conduit 14 can be
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understood by also referring to FIG'S 2, 3, 4, and
5. Conduit 14 includes a plurality of apertures 32
extending therethrough into the interior plenum of
space 33 thereof. Apertures 32 are spaced from
each other appropriately along the length of
conduit 14 with one aperture 32 being provided for
each fitting 17 and 19. The axis of the apertures
32 that provide for attachment of fittings 20 are
all in a line and are co-planar extending outwardly
from the axis of conduit 14. The attachment ends
30 each have a spud portion 34 having an end 34a
and an outer portion 34b sized slightly smaller
that that of aperture 32 so that the spud portion
34 can project into an aperture 32 leaving a
clearance space 35 there between. Surrounding the
spud 34 is a convex saddle 36 which is integral
with the housing 28 of each fitting 29 and extends
outwardly around the spud 34. The saddle 36 has a
convex interior arcuate shoulder surface 38 which
has the same radius as, and is conformable to, the
exterior surface 39 of conduit 14. Spud 34 has an
angled sonic welding energy director surface area
40 extending around the perimeter thereof. Surface
40 is held a slight distance from surface 38 by a
spud portion 41. The saddle shoulder surface 38
includes a pair of arcuate sonic welding energy
directing ridges 42 extending there along and
outwardly therefrom. The saddle 36, arcuate
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shoulder surface 38 and arcuate energy directors 42
have an arcuate extent or length, as measured about
the axis of conduit 14, that is at least 90 degrees
and preferably 120 degrees thereof. This arcuate
extent is greater than that of apertures 32 to
provide for complete covering thereof.
In the manufacture of the manifold 10 and in the
practice of the method of the invention, the conduit 14
is cut to the desired length and apertures 32 are drilled
therein. The plurality of fittings 19 and 17 are then
secured to conduit 14. Specifically, conduit 14 is
placed upon a sonic welding anvil, not shown. A fitting
17 or 19 is loaded into a sonic welding horn, not
shown, and the spud 34 thereof is piloted into an
appropriate aperture 32. It is preferable that
apertures 32 are counterbored to give a flat exterior
surface that allows for uniform contact with the spud 34.
Specifically, as seen in FIG 3, energy director space
40 includes a portion having a slightly greater diameter
than that of aperture 32. Thus, further insertion
of spud 34 into aperture 32 of conduit 14 is stopped
at that point. It can be seen that this situation
creates a space 44 between energy directing ridges
42 and exterior conduit surface 39. Ultrasonic energy is
then applied through the horn and the fitting 17 or
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19 wherein the spud energy director 40 is driven
into and fused to the tube 14 in the aperture 32.
A portion of the plastic material in the vicinity
of ener~y director 40 is melted and flows into
and substantially fills clearance space 35.
Thus, a near field weld is then produced
around the perimeter spud 34 and aperture 32. The
near field weld extends from the spud energy
director 40 to the interior 33 of tube 14 and, as
stated, substantially filling space 35. A "near
field weld" is welding occurrinq within 1/4 inch
(6mm) from the point of horn contact with the
fitting 17 or 19. As a result of the space 44
between ridges 42 and surface 39, such ridges are
not initially welded to surface 39. However, it
can be appreciated that as spud 34 is welded to
aperture 32 it is further inserted therein, thus
causing contact between the ridges 42 and surface
39. As a result thereof, ridges 42 are
simultaneously welded to surface 39 subsequent to
the weldin~ of spud 34 to aperture 32. It will be
appreciated by those of skill in the art, that this
sequence of steps insures a better sealing weld
between spud 34 and aperture 32 by concentrating
the energy of the equipment at that point initially
then followed by the welding of the saddle ridges
42 to surface 39 of conduit 14. It can also be
appreciated that during the welding of the saddle
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36 to conduit 14 there will exist further time for
welding of spud 34 to aperture 32. In this manner,
a complete seal around the entire perimeter of spud
34 to aperture 32 is insured. Fitting 19,
therefore, becomes essentially integral with
conduit 14, as is depicted in FIG 3. The welds
between the energy directors 40 and 42 and the
conduit 14 consist of three structurally discrete
welds. The weld around spud 34 provides a fluid
tight seal for the flow of fluids, such as
pressurized carbonated water, within manifold 10,
as well as for retention of the fittings 17 or 19
to the conduit 14. The arcuate sonic welds between
the ridges 42 and surface 39 of conduit 14 provide
for stable reinforcement of the attachment of
fittings 17 or 19 to condui~ 14, and in particular
provide for stress distribution to prevent twisting
or blow out thereof from the conduit 14.
The manifold 10 is extremely effective for
carbonated water distribution. The particular
structure of fitting attachment ends 26a and 26b
and method of securing thereof to conduit 14
results in a manifold routinely free of defects
that would result in disruption of carbonated water
flow or sanitation problems. In addition, the
manifold 10 is made entirely of injection molded
thermoplastic, there being no metal parts or metal
welding. Thus, manifold 10 does not need pickling
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and passivating, and does not affect beverage taste
or react with carbonic acid. Moreover, manifold 10
has low thermal conductivity to resist rapid
warming of the carbonated water held therein, and
is extremely suitable for being surrounded with
urethane foam to provide for further thermal
insulating thereof. It can be seen in FIG 1 that
syrup tube 24 includes a pair of fins 45 integral
with and extending outwardly from the exterior
thereof. Fins 45 lie in a common plane on opposite
sides of tube 24 and provide for better holding of
urethane foam poured there around. Fins 46 are
shown in ghost outline on fittings 17 and 19 and
are useful thereon for the same reason, and help
in the manipulation thereof during the welding
process. It can also be appreciated that manifold
10 is ideally suited for robotic assembly.
Although other advantages may be found and
realized and various modifications may be suggested
by those versed in the art, it should be understood
that we wish to embody within the scope of the
patent warranted hereon, all such embodiments as
reasonable and properly come within the scope of
our contributions to the art.
The embodiments of the invention in which an
exclusive property or privilege is claimed are
defined as follows:
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