Note: Descriptions are shown in the official language in which they were submitted.
~ ~ 2132028
63632-1354D
This is a divisional application of Canadian Patent
Application 2,075,000 filed July 30, 1992.
Backqround of the Invention
The present invention is generally directed to a
beverage brewing apparatus and the operational components which
comprise the beverage brewing apparatus.
Many types of beverage brewing apparatus have been
developed in order to accommodate the requirements and uses of
various beverage brewing applications. In particular, a class of
beverage brewing apparatus evolved to accommodate general consumer
applications, such as for home use. A home brewing apparatus
typically has a smaller per use brewing capacity than most
commercial apparatus. Various consumer requirements have raised
problems requiring solutions.
Generally, there are two branches of the home brewing
apparatus class: a flash heating apparatus, and a pour-over or
displacement apparatus. Both types of consumer beverage brewing
apparatus typically are arranged with a hood portion which
supports a brewing basket thereunder with a carafe or decanter
positioned below. The hood portion is
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attached ln some manner to a body portlon whlch houses a
reservolr. In the flash heatlng apparatus, a rapld heatlng
element ls posltloned ln the reservolr to qulckly heat water
whlch ls then transported to the basket to lnfuse the brewlng
substance retalned thereln to create the brewed beverage. In
the dlsplacement system, the reservolr ls slzed to retaln a
prespeclfled quantity of water ln a heated state so that when
water ls poured lnto the brewlng apparatus heated water is
lnstantly dlsplaced from the reservoir to lnfuse the beverage
brewlng substance.
Both types of apparatus requlre water to be poured
lnto the apparatus to brew a beverage. A problem arlses when
the decanter ls used to measure and pour the water lnto the
apparatus. Thls problem ls common ln the flash heatlng type
apparatuæ and even more prevalent ln the dlsplacement type
apparatus. In the dlsplacement type apparatus, once the water
ls poured lnto the apparatus, the water lnstantly dlsplaces
heated water whlch almost lnstantaneously creates a stream of
brewed beverage from the brewlng basket. If the user does not
qulckly place the decanter underneath the basket, the brewed
beverage wlll splll onto the heatlng pad whlch typlcally has
begun to heat. Spllllng of the brewed beverage can result ln
stalnlng the heatlng pad as well as posslbly the heating pad
and any electrlcal connectlons assoclated wlth the heatlng
pad.
Solutlons of the above fllllng problem presented to
date have not appeared to solve the problem. One easy
solutlon provlded the user wlth a decanter and a separate
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measurlng contalner at the tlme the beverage brewlng apparatus
was purchased. Thls solution ls both cumbersome and wasteful
ln that lt requlres a user to use two contalners and requlres
the manufacturer to produce and package an addltlonal
contalner whlch would not be necessary lf the fllllng problem
could be solved. Clearly, lf the measurlng contalner becomes
damaged, the user may resort to uslng the decanter for
measurlng brewlng water or may have to flnd another contalner
for measurlng and pourlng brewlng water.
Other solutlons have attempted to create an
lnterlock draln valve between the funnel draln and the
decanter. In such an apparatus placement of the decanter
below the funnel operates a release mechanlsm operatlng a
draln valve ln the funnel. A problem arlses when the
lnterlocklng mechanlsm becomes damaged or ls not properly used
and brewlng water fllls the basket whlch may result ln an
overflow of the brewlng water, the beverage brewlng substance,
and the brewed beverage; thus creatlng a burdensome mess.
Clearly, lt would be more deslrable to control the flow of
brewlng water before lt has flowed to the brewlng basket.
Prlor beverage brewlng apparatus also have a problem
wlth molsture loss. ~olsture loss ls common ln both the flash
heatlng as well as the dlsplacement brewlng apparatus. In the
flash heatlng apparatus, brewlng water can be lost when the
apparatus ls employed wlth a tlmer such that the brewlng water
ls dlsposed lnto a flll basln prlor to the deslred brewlng
tlme. Dependlng on the condltlons, a conslderable amount of
brewlng water may be lost through evaporatlon prlor to brewlng
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63632-1354D
2132028
thé beverage. In the dlsplacement apparatus, evaporatlve loss
ls accelerated to a degree because a quantlty of heated water
ls retalned ln the reservolr ln a heated state. Naturally
occurrlng alr movement through the brewlng apparatus comblned
wlth the heatlng of the water may result ln conslderable loss
of brewlng water. A reduced quantlty of brewlng water results
ln undeslrable and uncontrollable varlatlons ln the resultant
brewed beverage.
Safety concerns are extremely lmportant ln any type
of beverage brewlng apparatus. As such, lt ls lmportant to
provlde safety features to prevent overheatlng of water as
well as to turn off the heatlng element when the water heatlng
reservolr ls emptled. Typlcally, thermostatlc probes have
been employed to sense the temperature of the water ln the
heatlng reservolr. For example, ln the dlsplacement
apparatus, a thermostatlc probe senses the water temperature
and correspondlngly turns the heatlng element on or off ln
order to malntaln a predetermlned temperature range.
Slmllarly, thermostatlc sensors are commonly placed ln or near
the bottom of the heatlng reservolr ln order to sense rapld
changes ln reservolr temperature. A rapld change ln
temperature lndlcates that the reservolr has been emptled
because there ls llttle or no water ln whlch to dlstrlbute the
thermal energy from the heatlng element. When the sensor
senses that the reservolr ls empty, the heatlng element ls
turned off. Clearly, thls low water type sensor ls lmportant
ln any type of beverage brewlng apparatus.
In most beverage brewlng apparatus, the hood portlon
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A 1 63632-1354D
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extends over the decanter and the brewlng basket ls suspended
beneath the hood portlon and above the decanter. A dlscharge
tube extends from the heatlng reservolr through the hood
portlon to dlspense water into the brewlng basket. A
sprayhead ls usually employed to dlstrlbute the heated water
more evenly over the beverage brewlng substance retalned ln
the brewlng basket. As the sprayhead ls posltloned over the
beverage brewlng basket, lt ls prone to accumulate materlals
such as olls, chaff, and flne partlculate matter carrled ln
the steam whlch rlses off of the beverage brewlng substance
durlng the infusion process. Therefore, lt ls deslrable to
provlde a sprayhead whlch ls easily removable from the
beverage brewing apparatus for cleaning and repalr purposes.
In the manufacture of beverage brewlng apparatus, lt
ls deslrable to produce a product whlch ls pleaslng to the eye
ln lts flnal form as well as easy to assemble durlng the
manufacturing process. Typically, a beverage brewing
apparatus must be lnverted and reverted durlng an assembly
process. Therefore, it would be deslrable to provlde a
beverage brewlng apparatus whlch may be cumulatlvely assembled
ln one posltion throughout the entire assembly operation.
Ob~ects and Summary of the Inventlon
A broad general ob~ect of the present lnventlon ls
to provlde a beverage brewing apparatus which improves
operatlng safety.
Yet another ob~ect of the present lnventlon ls to
provlde a beverage brewlng apparatus whlch lmproves a
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63632-1354D
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thermostatlc sensor configuratlon and a low water sensor
conflguratlon.
Brlefly, and ln accordance wlth the foregolng, the
present lnventlon comprlses a beverage brewlng apparatus whlch
employs an lmproved thermostatlc and low water sensor
conflguratlon. The thermostatlc and low water senslng
conflguratlons posltion the temperature sensors outslde of the
water heatlng reservolr to prevent the accumulatlon of mlneral
and other deposlts thereon. A portlon of the wall behlnd
whlch the sensors are posltloned ls thlnned ln order to
provlde more accurate temperature readlngs.
Brlef Descrlptlon of the Drawlnqs
The organlzatlon and manner of the structure and
operatlon of the lnventlon, together wlth further ob~ects and
advantages thereof, may be understood by reference to the
followlng descrlptlon taken ln connectlon with the
accompanylng drawlngs, whereln llke reference numerals
ldentlfy llke elements, and ln whlch:
Flg. 1 ls a perspectlve vlew of a beverage brewlng
apparatus of the present lnventlon;
Flg. 2 ls a front elevatlonal vlew of the beverage
brewlng apparatus;
Flg. 3 ls a slde elevatlonal vlew of the beverage
brewlng apparatus;
Flg. 4 ls a top plan vlew of the beverage brewlng
apparatus;
Flg. 5 ls an enlarged partlal fragmentary cross-
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A~ 63632-1354D
2132028
sectional vlew of the present lnventlon taken through a hood
portlon along llne 5-5 ln Flg. 2;
Flg. 5a ls a partlal fragmentary rear elevatlonal
vlew of the valve assembly as lllustrated ln Flg. 5;
Flg. 6 ls an enlarged detall of a snap-flt assembly
as shown ln Flg. 5;
Fig. 7 ls a top plan view of a valve of a lid
assembly taken along line 7-7 ln Flg. 5;
Flg. 8 ls a partlal fragmentary cross-sectlonal view
of the valve assembly in a closed posltlon;
Flg. 8a is a partlal fragmentary rear elevatlonal
vlew of the valve assembly as lllustrated ln Flg. 8;
Flg. 9 ls an enlarged partlal fragmentary cross-
sectional view of a spray assembly as illustrated in Flg. 5;
Flg. 10 ls the spray assembly as lllustrated ln Flg.
9 ln whlch a sprayhead member has been dlsengaged from the
sprayhead assembly;
Flg. 11 ls a perspectlve vlew of the sprayhead
member;
Flg. 12 ls a slde elevatlonal vlew of the sprayhead
member;
Flg. 13 ls a bottom plan vlew of the sprayhead
member;
Flg. 14 ls an enlarged partlal fragmentary cross-
sectlonal vlew of a reservoir assembly of the present
inventlon taken along llne 14-14 ln Flg. 2;
Flg. 15 is a cross-sectional view of the reservolr
assembly taken along line 15-15 ln Flg. 14;
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63632-1354D
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Flg. 16 ls an enlarged partlal fragmentary cross-
sectlonal vlew of a thermostat conflguratlon employed ln the
reservolr assembly of the present lnventlon taken along llne
16-16 ln Flg. 14;
Flg. 17 ls an enlarged slde elevatlonal vlew of a
retalnlng cover used ln the thermostat conflguratlon;
Flg. 18 ls a partlal fragmentary cross-sectlonal
vlew of a bottom portlon of the reservolr assembly taken along
llne 18-18 ln Flg. 15;
Flg. 19 ls a partlal fragmentary cross-sectlonal
vlew of a low water senslng conflguratlon taken along llne 19-
19 ln Flg. 15;
Flg. 20 ls a partlal fragmentary cross-sectlonal
vlew of the low water senslng conflguratlon taken along llne
20-20 ln Flg. 15;
Flg. 21 ls a partial fragmentary slde vlew of the
brewlng assembly of the present lnventlon showlng engagement
mountlng means for retalnlng a brewlng basket on a suspenslon
portlon of the brewlng apparatus;
Flg. 22 ls a bottom plan vlew of the suspenslon
portlon;
Flg. 23 ls a top plan vlew of the suspenslon
portlon;
Flg. 24 ls a top plan vlew of the beverage brewlng
basket as lllustrated ln Flg. 21;
Flg. 25 ls an enlarged partlal fragmentary slde
elevatlonal vlew of a rear portlon of the suspenslon portlon
of the beverage brewlng apparatus; and
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Fig. 26 ls an exploded slde elevatlonal vlew of the
assembly of sub-assemblles of the present lnventlon.
Detalled Descrlptlon of the Preferred Embodlment
Whlle the lnventlon may be susceptlble to embodlment
ln dlfferent forms, there ls shown ln the drawlngs, and hereln
wlll be descrlbed ln detall, a speclflc embodlment wlth the
understandlng that the present dlsclosure ls to be consldered
an exempllflcatlon of the prlnclples of the lnventlon, and ls
not lntended to llmlt the lnventlon to that as lllustrated and
descrlbed hereln.
Referrlng now to the drawlngs, whereln llke parts
are deslgnated by the same reference numerals throughout the
flgures, a beverage brewlng apparatus or brewer 20 ls shown ln
Flg. 1. The beverage brewlng apparatus 20 lncludes a body
structure 22, a hood assembly 24 attached to the top of the
body structure 22, a base assembly 26 extendlng from the body
structure 22 beneath the hood assembly 24, a brewlng basket 28
suspended beneath the hood assembly 24, and a carafe 30
posltloned beneath the basket 28 on the base assembly 26. The
base assembly lncludes a warmer plate 32 whlch malntalns the
temperature of the brewed beverage retalned ln the carafe 30
(see also, Flg. 26). A flrst swltch 34 ls mounted on the hood
assembly 24 and controls the warmer plate 32. A second swltch
36, whlch controls the power to the brewer 20, ls mounted ln
the lower sectlon of the body structure 22. A lld 38 and
multlple vents 40 are posltloned on a top surface 42 of the
hood assembly 24. The constructlon and operatlon of the lld
_g_
' 63632-1354D
A`~
213~028
38 and vents 40 wlll be dlscussed ln greater detall
herelnbelow.
Flgs. 2, 3 and 4 show addltional vlews of the
beverage brewlng apparatus 20 from a front, slde elevatlon,
and top plan vlew, respectively. As shown ln Flgs. 1 and 4, a
set of depresslons 44 pro~ect lnto the surface of the lld 38
and have a rldge 46 therebetween formlng a flnger grlp for
movlng the lld 38.
Flg. 5 provldes a partlal fragmentary cross-
sectlonal vlew taken along llne 5-5 ln Flg. 2. Generally,
Flg. 5 shows a cross-sectlon through the hood assembly 24 but
also shows an upper portlon of a brewlng assembly 46 suspended
from a suspenslon portlon 48 of the hood assembly 24, and an
upper portlon of a reservolr assembly 50 retalned lnslde of
the body structure 22. Whlle the lower portlon of the
reservolr assembly 50 ls not shown, a reservolr or tank 52 of
the reservolr assembly 50 extends downwardly to a closed
bottom (as better shown ln Flg. 14).
The hood assembly 24 lncludes a flll basln 54 lnto
whlch brewlng water ls poured to dlsplace heated water
retalned ln the tank 52. Water ls poured lnto the flll basln
54 through an openlng 56 formed through the top surface 42 of
the hood assembly 24. Water dlsposed lnto the flll basln 54
flows through a flll port 58 formed ln a lowermost portlon
thereof. Water passes from the flll port 58 through the entry
port 60 lnto a flll tube 62 whlch dlrects the flow downwardly
towards the bottom of the tank 52. When flll water dlsplaces
the heated water retalned ln the tank 52, the heated water ls
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~ 1 63632-1354D
2132028
forced upwardly through a draln port 64 formed near the top of
the tank 52 and out through a dlscharge tube 66 to the brewlng
assembly 46.
A flll water control assembly 68 controls the flow
of water through the brewer 20. The flll water control
assembly 68 lncludes a lld assembly 70 and a valve 72. The
lld assembly 70 lncludes the lld member 38 and a shaft 74
attached thereto and pro~ectlng downwardly lnto the hood
assembly 24 through an assembly hole 76 centered on and formed
through the top surface 4Z of the hood aæsembly 24 behlnd the
openlng 56. As shown, the lld member 38 ls slzed and
dlmensloned for coverlng the openlng 56 and ls lntegrally
formed wlth the shaft 74 as a slngle plece unltary body. The
lld member 38 rotates about a shaft axls 78 extendlng through
the shaft 74. When the lld member 38 ls rotated about the
æhaft axls 78 the lld 38 ls moved to the slde of the openlng
56 thereby uncoverlng the openlng 56 to provlde access to the
flll basln 54.
The valve 72 of the flll water control assembly 68
lncludes an arm member 80 havlng a flrst end 82 wlth a stopper
84 attached thereto. The prlmary purpose of the valve 72 ls
to control the flow of water to the brewlng assembly 46 before
lt ls dlscharged to the basket 28. The stopper 84 ls movably
posltloned over the flll port 58. The shaft 74 extends
through a hole 85 ln the second end 86 of the arm member 80
coupllng the shaft 74 wlth the arm member 80 ln a manner that
translates rotatlonal movement of the shaft 74 lnto rotatlonal
movement of the arm member 80. An axle 88 attached to the arm
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A? 63632-l354D
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2132028
member 80 ls posltloned ln a rocker slot 90 on a base
structure 92. Support of the arm 80 by a base structure 92
permlts rotatlon of the flrst and second ends 82,86 of the arm
80 about a plvot axls 96 posltloned lntermedlate the flrst end
82 and the second end 86 extendlng through the axle 88 when
the shaft 74 ls rotated. Whlle Flg. 5 shows a base structure
92 mounted to a bottom 94 of the basln 54, the base structure
92 could also be mounted overhead whlle achlevlng the same
functlon.
Aæ shown ln Flg. 5, the lld 38 ls posltloned to
cover the openlng 56. Wlth addltlonal reference to Flg. 5a,
when the lld 38 covers the openlng 56 a fln 98 extendlng
generally perpendlcularly away from the shaft 74 presses
agalnst the second end 86 of the arm 80 to llft the stopper 84
away from the flll port 58. Wlth reference to Flgs. 8 and 8a,
when the shaft 74 ls rotated (as lndlcated by arrow 100) by
movlng the lld member 38 to elther slde of the openlng, the
angled second end 86 of the arm 80 rotates upwardly (as
lndlcated by arrow 102) about the plvot axls 96 and
correspondlngly the flrst end 82 rotates (as lndlcated by
arrow 104) downwardly about the plvot axls 96 causlng the
stopper 84 to plug the flll port 58.
In thls posltlon, slnce the lld member 38 has been
moved away from coverlng the opening 56, water may be poured
into the flll basln 54 through the openlng 56 and wlll not
draln lnto the tank 52 slnce the valve 72 has plugged the flll
port 58. A bottom edge 106 of the fln 98 ls rounded to
facllltate rotatlon 102,104 of the arm 80. Closlng the lld
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? 63632-1354D
A
`- 2132d~8
member 38 over the openlng 56 once again rotates the shaft 74
thereby lmposlng forces on the second end 86 whlch llft the
stopper 84 away from the flll port 58 allowlng water ln the
flll basln 54 to flow lnto the tank 52.
The flll basln 54 18 formed wlth a bottom 94 whlch
slopes downwardly from all edges towards the flll port 58. A
ralsed portlon 108 of the bottom 94 provldes elevatlon for the
base structure 92 of the valve 72. Water ln the flll basln 54
flows around the ralsed portlon 108 to the flll port 58.
Flg. 6 lllustrates an enlarged partlal fragmentary
vlew of an upper portlon of the hood assembly 24 as
lllustrated ln Flg. 5. Wlth reference to Flgs 5 and 6, a
cover 110 ls attached to a top edge 112 of the flll basln 54.
Engagement of the cover 110 wlth the top edge 112 ls
accompllshed by a snap-flt means 114 formed on an lnslde
surface 116 of the cover 110 and on a corre~pondlng outslde
surface 118 of the flll basln 54. As shown, the snap-flt
means 114 lncludes a male portlon 120 formed on one of the
surfaces and a female portlon 122 formed on the other surface
to provlde a frlctlonal engagement therebetween to prevent the
cover 110 from belng removed from the top edge 112 of the flll
basln 54. Clearly, other snap-flt or press-flt means may be
employed to attach the cover 110 to the flll basln 54,
however, the cover 110 18 attached wlthout fasteners.
Attachment by snap-flt means 114 greatly facllltates assembly
of the brewer 20 as wlll be dlscussed ln greater detall
herelnbelow.
Flg. 5 lllustrates a molsture recovery assembly 124
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A 63632-1354D
2132028
whlch collects and returns molsture whlch evaporates from the
basln water to the flll basln 54. Included ln the molsture
recovery asæembly 124 ls a hollow sleeve 126 whlch ls attached
to the cover 110 and extends downwardly into the flll basln 54
towards the bottom 94. The openlng 56 extends through the
hollow sleeve 126. A lower end 128 of the sleeve 126 ls
spaced ln close proxlmlty to the bottom of the basln 94,
separated only by a small gap 130.
Molsture whlch collects on the lnslde of the flll
basln 54 can collect on an outslde surface 132 of the sleeve
126 and draln back lnto the flll basln 54. Because the sleeve
pro~ects downwardly lnto the flll basln 54 very close to the
bottom 94 leavlng only the small gap 130 therebetween, only
the surface area of the water lnslde of the sleeve 126 ls
potentlally exposed to evaporatlve alr currents through the
openlng 56. Addltlonally, molsture whlch does rlse off of the
water lnslde of the hollow sleeve 126 may collect on a grlll
structure 134 extendlng over the openlng 56. The grlll
structure 134 has numerous cross members 136,138 runnlng
generally perpendlcularly to one another. The grlll structure
134 has a generally partlally spherlcal shape whlch alds ln
dlrectlng water whlch condenses thereupon back lnto the flll
basln 54.
Another component of the molsture recovery assembly
124 are the vents 40 whlch pro~ect through the top surface 24
of the cover 110. As shown ln the plan vlew of Flg. 4, the
vents 40 have a generally elongated shape and are posltloned
ln serles generally parallel to one another on the top surface
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A 63632-1354D
2132028
42 of the cover 110. The vents 40 have an lnwardly pro~ectlng
collectlng portlon 140 and a baffle openlng 142 formed through
a slde 144 thereof. Formlng the baffle openlngs 142 through a
slde 144 helps reduce the flow of alr therethrough yet permlts
dlsplacement of alr therethrough when water ls poured lnto the
flll basln 54 through the openlng 56 ln hollow sleeve 126.
The downwardly extendlng collectlng portlon 140 provldes a
polnt at whlch condensatlon whlch collects thereon can drlp
downwardly lnto the flll basln 54. Between brew cycles, when
the flll basln 54 ls empty, some molsture may rlse through the
flll tube 62 from the tank 52 slnce the stopper 84 does not
seal the flll port 58 between brew cycles. Molsture whlch
rlses from the flll tube 62 may elther collect on the stopper
84 and drlp back lnto the flll basln 54 or may collect on the
collectlng portlon 140 and drlp back lnto the flll basln 54.
Turnlng now to the reservolr assembly 50 as
lllustrated ln Flgs. 14-20, a thermostat conflguratlon 146 and
a low water senslng conflguratlon 148 are shown. As best
shown ln Flgs. 14-17, the thermostat conflguratlon 146 ls
arranged wlth a thermostatlc sensor 150 of known constructlon
posltloned outslde of the tank 52 and senslng temperature
through the slde wall of the tank 52. The thermostatlc sensor
150 18 posltloned behlnd a flrst portlon 152 whlch has a
thlckness dlmenslon whlch ls substantlally smaller than a
thlckness dlmenslon 156 of the surroundlng slde wall 158.
Posltloned ln close proxlmlty to the flrst portlon 152 (see
Flg. 16) the thermostatlc sensor 150 accurately reads the
temperature of the water lnslde of the tank 52 through the
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A 63632-l354D
flrst portlon 152. 2132028
The thermostat conflguratlon 146 also lncludes a
thermostat nlche 160 whlch pro~ects lnto the side wall 158 of
the tank 52. The thermostat nlche 160 protects the
thermostatlc sensor 150 from unlntended lmpacts and from alr
movements whlch may affect temperature readlngs. As shown ln
Flg. 16, the nlche 160 lncludes a sklrted portlon 162 whlch
results ln encloslng the thermostatlc sensor 150 on all sldes
but the bottom 164. To cover the bottom portlon, a retalnlng
cover 166 18 provlded to flt lnto the thermostat nlche 160
wlth a press flt between an outslde surface 168 of the slde
wall 150 and an lnslde surface 170 of the sklrt 162.
The sensor 150 18 posltloned to sense the water
temperature through the flrst portlon 152 whlch 18 vertlcally
orlented and formed ln the slde wall 158. The vertlcal
orlentatlon of the thermostatlc sensor prevents accumulatlon
of sedlment and mlneral deposlts thereupon whlch would
otherwlse occur lf the sensor 150 was horlzontally posltloned.
A sedlmentatlon layer bulld-up on a horlzontally orlented
flrst portlon 152 would lnterfere wlth accurate sensor
readlngs. Accuracy of the sen~or's readlngs ls lmproved by
the vertlcal orlentatlon of the flrst portlon 152 ln the
present lnventlon. A top portlon 172 of the nlche 160 ls
curved to help further reduce any accumulatlon of
sedlmentatlon or deposlts whlch mlght otherwlse accumulate and
extend over the flrst portlon 52.
Slmllar to the thermostat conflguratlon 146, the low
water senslng conflguratlon 148 ls arranged wlth a
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thermostatlc sensor 150a posltloned behlnd a flrst portion
152a whlch has a reduced thlckness dlmenslon 154a compared to
the wall dlmenslon 156a of the surroundlng slde walls 158a.
Common elements of the thermostat conflguratlon 146 and the
low water senslng conflguratlon 148 are denoted wlth a common
reference numeral, however, a sufflx (for example "a") has
been added to the common reference numeral to denote the low
water senslng conflguratlon 148 components.
A low water sensor nlche 174 houses the thermostatlc
sensor 150a of the low water senslng conflguratlon 148. In
the low water senslng conflguratlon 148 the flrst portlon 152a
ls formed ln a top surface of the sensor nlche 174. Whlle the
flrst portlon 152a ln the low water senslng conflguratlon 148
ls prone to accumulate sedlmentatlon and mlneral deposlts as
dlscussed above, such accumulatlons have a mlnor effect ln the
low water senslng conflguratlon 148 as compared to the
thermostat conflguratlon 146. For example, the thermostat
conflguratlon 146 ls used to sense subtle dlfferences ln water
temperature to malntaln the water temperature wlthln a
predetermlned deslred range, for example 1950 F+/- lOoF. On
the other hand, the low water senslng conflguratlon 148 ls
used to sense gross temperature changes lnslde the tank 52.
To further facllltate accurate and qulck response
tlme ln a low water condltlon, the flrst portlon 152a ls
posltloned beneath the lowermost portlon 176 of a heatlng
element 178. The close proxlmlty of the lowermost portlon 176
of the heatlng element 178 to the flrst portlon 152a results
ln the thermostatlc sensor 150a behlnd the flrst portlon 152
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qulckly senslng a low water condltlon.
A retalnlng cover 166a ls used to retain the
thermostatic sensor 150a in a close position behind the flrst
portlon 152a. Addltlonally, a fuse 180 ls posltloned ln the
low water sensor nlche 174 next to the thermostatlc sensor
150a for rapldly responding should a low water condltlon arlse
thereby provldlng addltional safety and preventing a potential
problem.
The flll tube 62 ls shown ln Figs. 14, 15 and 18
engaged wlth a group of flll tube retalners 182. The flll
tube retalners 182 engage a lower portlon 184 of the fill tube
62 ln a notch 186 whlle an upper end 188 ls mated wlth the
entry port 60. The flll tube retalners 182 malntaln the lower
end 84 a dlstance above a bottom surface 190 of the tank 52.
When a cap member 192 ls attached to the top rlm 194 of the
tank 52 of the flll tube 62 mated wlth the entry port 60 and
engaged wlth the flll tube retalners 182 ls securely retalned
and thus prevented from dlsengaglng or flexlng lnto contact
wlth the heatlng element 178. As shown ln Flgs. 14, 15 and
18, the flll tube 62 extends through the loop of the heatlng
element 178.
The tank 52 ls lntegrally formed as a slngle piece
body of a sultable plastlc materlal havlng heat reslstant
characterlstlcs capable of contlnuously wlthstandlng
substantlally on the order of up to 205O. An example of such
materlal ls ULTEM~ whlch ls an amorphous thermoplastlc
polyetherimlde produced by GE Plastics of Pittsfleld,
Massachusetts. In particular, ULTEM~ 1010 is a preferred form
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of the materlal for thls appllcatlon although other materlals
may be selected.
A sprayhead agsembly 196 ls shown ln Flg. 5 and
further detalled ln Flgs. 9-13, 22 and 23. The spray assembly
196 lncludes a spray panel 198 whlch 18 mounted to the
suspenslon portlon 48 havlng a dlscharge nozzle 200 attached
thereto, and a sprayhead member 202 attachable to sald spray
panel 198 over a dlscharge port 204 of sald dlscharge nozzle
200. The sprayhead assembly 196 ls posltloned ln an upper
portlon of the brewlng assembly 46 and dellvers water thereto
through the dlscharge nozzle and dlstrlbuted by the sprayhead
member 202. As shown ln Flgs. 22 and 23, the sprayhead panel
198 has mountlng holes 206 formed therethrough whlch are
allgnable wlth mountlng posts 208 formed on the suspenslon
portlon 48. Addltlonal mountlng support for the spray panel
198 ls provlded by the mountlng tabs 210 whlch engage an upper
edge 212 lf the body structure 22. As wlll be dlscussed
further herelnbelow, the spray panel 198 must be mounted ln
such a way so as to support the brewlng assembly 46 when the
basket 28 ls fllled wlth a beverage brewlng substance as well
as brewlng water durlng a brew cycle.
A sprayhead recess 214 ls formed ln the sprayhead
panel 198 to prevent the sprayhead member 202 from lnterferlng
wlth the basket 28 when the basket ls mounted thereto. As
better shown ln the enlarged partlal fragmentary cross-
sectlonal vlews of Flgs. 9 and 10, the sprayhead member 202
mounts lnslde of the sprayhead recess 214 by way of engagement
means 216. The engagement means 216 lnclude partlal thread
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2132028
portlonæ 218 whlch are formed on an outslde surface of the
sprayhead member 202 and on an lnslde surface of the sprayhead
recess 214. Engagement of the sprayhead member 202 wlth the
sprayhead recess 214 ls facllltated by a grlp portlon 220
whlch ls formed as a ralsed extended portlon extendlng across
the face of the sprayhead member 202.
A foramlnous face 222 havlng a generally partlally
spherlcal shape ls provlded on the sprayhead member and
posltloned lmmedlately below the dlscharge port 204 when the
sprayhead 202 ls mounted to the sprayhead recess 214. Brew
water dlscharged through the dlscharge nozzle 200 flows
through the foramlnous face 222 to provlde a generally even
dlstrlbutlon of water over the beverage brewlng substance
retalned ln the basket 28. The constructlon of the sprayhead
202, whlch ls an lntegrally formed slngle plece unltary body,
lncludlng the grlp portlon 220, facllltates easy removal from
the sprayhead recess 214 to facllltate cleanlng. It ls
lmportant to be able to remove the sprayhead 202 slnce
materlal may bulld up ln the holes of the foramlnous face 222
due to sedlmentatlon partlcles and coffee olls whlch are
carrled in steam whlch rlses from the beverage brewlng
substance durlng the brewlng process.
Flgs. 21-25 provlde detalls as to the structure and
functlon of the brewlng assembly 46 and mountlng means 224 for
attachlng the basket 28 to the suspenslon portlon 48 of the
hood assembly 24. The mountlng means 224 lnclude a partlally
clrcumferentlal channel 226 attached to the upper edge 228 of
the basket 28 and a partlally clrcumferentlal rlm 230 attached
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2~320~
to an outwardly facing surface 232 of the spray panel 198.
The resultlng engagement of the mountlng means 224 conceals
the mountlng means 224 behlnd a generally contlnuous surface
234. The partlally clrcumferentlal channel 226 has an upper
llp 236. Leadlng edges 238 of the upper llp 236 are generally
spaced apart on the open end of the partlally clrcumferentlal
channel 226 and have parallel edge portlons 240 whlch help to
gulde the channel 226 lnto engagement wlth the rlm 230. The
generally parallel portlon 240 also help prevent the basket 28
from swlvelllng when engaged wlth the rlm 230.
A retalnlng protruslon 242 extends downwardly from a
surface of the spray panel 198 generally opposlte the mountlng
means 224. The protruslon 242 engages the lnslde of a front
edge 244 to provlde addltlonal retalnlng force when the basket
28 ls engaged wlth th suspenslon portlon 48. When removlng
the basket 28, a sllght force ls applled to a handle 246 of
the basket 28 to overcome the retalnlng force created by the
protruslon on the lnslde front edge 244.
The present lnventlon addltlonally lncludes a novel
method for assembllng the brewer 20 of the present lnventlon
as lllustrated ln Flg. 26. Generally, the brewer 20 ls
assembled lnto subassemblles whlch are then assembled ln a
contlnuous process whereln the subassemblles are stacked and
secured to one another. Wlth reference to Flgs. 1, 14 and 26,
the ma~or subassemblles lnclude the hood portlon 24, the
reservolr assembly 50, the body structure 22 and a base
assembly 248.
Referrlng to Flgs. 1 and 14, the hood assembly 24 ls
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2132028
assembled and placed ln an inverted orientatlon on an assembly
llne. Wlres 250 extendlng from the flrst swltch 34 ln the
hood assembly 24 are threaded through the hood assembly 24
prlor to engagement of the reservolr assembly 50 thereto. In
the next assembly step, the reservolr assembly 50 ls lnverted
and engaged wlth the hood assembly 24. A hollow tower
portlon 252 of the body structure 22 ls assembled over the
lnverted reservolr assembly 50 and engaged wlth the hood
assembly 24. The wlres 250 from the flrst swltch 34 are
threaded through the hollow tower portlon 252 prlor to the
engagement wlth the hood portlon 24. Wlres 251, 251a, 253
leadlng from the thermostatlc sensors 150, 150a and the
heatlng element 178, respectlvely, are also threaded through
the hollow tower portlon 252. Slmllarly, wlres 255 from the
second swltch 36 are threaded through the tower portlon 252.
As best shown ln Flg 5, an engaglng edge 254 of the
body structure 22 engages a llp 256 of the reservolr assembly
50. The edge 254 and lip 256 structurally support the
reservolr assembly 50 lnslde of the body structure 22 when the
brewlng apparatus, as flnally assembled, ls re-lnverted.
Screw holes 258 are formed through a ledge 260 of the body
structure 22 for recelvlng fasteners 262 therethrough. The
fasteners 262 engage mountlng posts 264 whlch are formed on a
cooperatlve surface of the hood portlon 24. In the lnverted
orlentatlon, the fasteners 262 are drlven lnto the mountlng
posts 264 to securely engage the hood portlon 24, reservolr
assembly 50, and body structure 22.
The flnal step of the assembly process lncludes
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2132028
attachlng the wlres 250, 251, 251a, 253, 255 to approprlate
connectlons ln the base assembly 248. The base assembly 248
ls lnverted and the warmlng plate 32 ls posltloned lnslde the
openlng formed ln the base structure 26. Once the base
assembly 248 ls properly posltloned fasteners 266 are driven
through holes ln the base assembly and lnto mountlng posts
whlch are cooperatlvely formed and posltloned on the lnslde of
the body structure 22 (mountlng posts not shown).
Whlle a preferred embodlment of the present
lnventlon ls shown and descrlbed, lt ls envisioned that those
skllled ln the art may devlse varlous modlfications of the
present lnventlon without departing from the spirit and scope
of the appended claims. The lnventlon ls not intended to be
limlted by the foregolng dlsclosure.
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