Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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SANITARY FAUCET WITH IMPROVED FLOW RESTRICTION FEATURE
AND FOAM CONTROL FEATURE
Cross Reference to Related Applications
[0001] The present application claims the benefit of a United States
Provisional
Patent Application No. 60/425,528 filed on Nov. 12, 2002, which is
incorporated
herein in its entirety for all purposes.
Background of Invention
[0002] The present invention relates to faucets for use with beer tappers and
other
pressurized dispensers and, more particularly, relates to a sanitary flow
control faucet
configured to dispense materials in a regulated manner with a foam control
feature.
[0003] Dispensing faucets are used in a variety of applications in which
materials
are dispensed from pressurized containers or other pressurized sources.
Dispensing
faucets of this type are widely used in beverage dispensing applications in
which beer,
soda, or another beverage is dispensed from a pressurized container such as a
keg.
They are also sometimes used to dispense condiments such as relish or mustard
from
containers under pressure. Indeed, the applications are many and may vary
widely.
[0004] A typical prior art faucet includes a valve operated by a pivotable
lever.
Specifically, a valve element is mounted on a plunger that is slidable
longitudinally
through a bore. When the lever is pivoted forwardly, towards the user, to open
the
valve element, the valve element moves rearwardly through the bore, thereby
permitting dispensed materials to flaw from the inlet of the valve to the
outlet. The
entire valve is exposed to flowing fluid during dispensation, but when the
valve is not
dispensing, major portions of wet valve elements are exposed to air. Standing
fluid in
the valve and exposure of the wet valve elements to air can give rise to
undesirable
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bacterial growth within the valve. Some prior art faucets have overcome
undesirable
bacterial growth by positioning the plunger substantially at the outlet of the
faucet,
such that the great majority of the wet valve components are not exposed to
air at any
time.
[0005] Foaming is produced in the process of dispensing certain pressurized
fluids
through these faucets. Foaming however, occasionally alters the taste and
appearance
of certain fluids, such as beers. Further, foaming may not be desirable when
the fluid
is being dispensed, but may be desirable when the fluid needs to be to topped
off in a
container, such as a mug. Therefore, the need has arisen to improve the design
of a
faucet to introduce controlled foaming in dispensed fluid, while not exposing
the wet
portions of the faucet to bacterial growth.
[0006] Dispensable fluids, for example beers, are at times stored in sealed
kegs,
that is, under conditions that can lead to changes in pressure. In fact, many
kegs that
are put under pressure when filled with draft beer are stored in rooms with
frequent
temperature changes. Variation in temperature results in variation in pressure
inside
these kegs. In order to re-balance the pressure and control the fluid flow
during
dispensing, certain prior art dispensing faucets have compensator units. These
compensator units, however, have limited control over balancing and regulating
pressurized dispensing fluids. Uncontrolled or poorly controlled pressure
exerted by
these fluids ultimately leads to greater wear and tear of the faucet
equipment. Also,
regulating pressure via the use of compensators is not effective because these
regulators may be positioned in limited orientations, resulting in limited
regulation of
pressure. Therefore, the need has arisen to improve the design of a faucet to
provide
improved regulation of pressure.
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[0007] Traditional faucets also require a fairly elaborate method for cleaning
the
valve elements, including taking the valve elements out of the valve body and
washing them at another location. The need has arisen to provide valve
elements that
not only remain clean, but that also can be cleaned effectively without
disassembling
the valve.
Summary of Invention
[0008] The present invention provides a sanitary dispensing faucet with a
number
of advantages. One advantage of the present invention is that the interior of
the valve
does not contain substantial amounts of air under normal usage, thereby
limiting
bacterial growth inside the faucet.
[0009] Another advantage of one embodiment of the present invention is a push-
back foam feature, such that controlled foam may be created, when required or
as
desirable.
[0010] Another advantage of the present invention is a flow restrictor with a
flow
adjustment screw such that the pressure created by the contained fluid may be
graduated and regulated at nmnerous levels.
[0011] Yet another advantage of the present invention is that valve elements
may
be cleaned efficiently without significant disassembly of the valve.
[0012] Generally the sanitary faucet includes (a) a valve body having a valve
bore
that has axially aligned inlet and outlet ports; (b) a plunger assembly
substantially
disposed in the valve body between the inlet and outlet ports; (c) a flow
restrictor
assembly; and (d) an adjusting screw assembly.
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[0013] In one embodiment, the flow restrictor assembly includes a shank that
has
a first and second shank end. The first shank end is removably attached to the
inlet
port of the valve body, while the second shank end is removably attached to a
source
of the dispensing fluid. The flow restrictor assembly further includes a flow
restrictor
member movably disposed within the shanlc. The flow restrictor has a furmel
head
that communicates with the plungex assembly, and a fluted tail having at least
one
groove or channel for permitting flow of inflowing dispensing fluids from the
source.
In a preferred embodiment, the adjusting screw assembly regulates movement of
the
flow restrictor assembly within the shank.
[0014] Another aspect of the present invention includes a method for reducing
foam from a dispensing liquid: The method is practiced by first attaching a
source of
the dispensing fluid to the inlet port of the valve body. The adjusting screw
assembly
is then rotated so as to move the flow restrictor such that the fluid entering
the valve
body has a desired level of pressure. Fluid at a desired pressure is then
permitted to
enter the plunger assembly. Finally, the handle assembly is moved to open and
close
the valve as desired. When the handle assembly is moved forwardly, the plunger
assembly in turn is moved rearwardly. This movement opens the valve by opening
a
passage for the fluid that flows through at least one groove or channel of the
fluted
tail, over the fiumel head, around the plunger assembly, towards the outlet
port and
out of a spout attached to the outlet port. Fluid dispensed by use of tlus
method has a
closely controlled pressure, and therefore results in the fluid being
dispensed
substantially without foam.
[0015] Another embodiment of the method aspect of present invention provides a
method for creating foam from a dispensing liquid that has the capability of
forming
foam, such as beer. According to this method, a source of the dispensing fluid
is
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attached to the inlet port of the valve body. Fluid is permitted to enter the
faucet at a
desired pressure. The handle assembly is then moved rearwardly, which results
in the
plunger assembly being moved forwardly, which results in the larger passage
for the
fluid being closed. The handle assembly is then moved even further rearwardly
against the force of a spring, which has the effect of exposing a transverse
hole in a
retaining screw beyond the valve seat. The beer, being forced through a small
opening, becomes foamy.
[0016] These and other advantages and features of the invention will become
apparent to those skilled in the art from the detailed description and the
accompanying
drawings. It should be understood, however, that the detailed description and
accompanying drawings, while indicating preferred embodiments of the present
invention, are given by way of illustration and not of limitation. Many
changes and
modifications may be made within the scope of the present invention without
departing from the spirit thereof, and the invention includes all such
modifications.
Brief Description of Drawings
[0017] FIG. 1 is an exploded perspective view of a faucet constructed
according
to one embodiment of the invention, depicting a flow restrictor with a flow
adjustment
screw and push-back foam feature.
[0018] FIG. 2 is a sectional view of the valve body of the faucet shown in
FIG.l.
[0019] FIG. 3(a) is a plan sectional view of the faucet shown in FIG. 1
showing a
flow adjustment screw in a certain position, and a push back foam feature in
an
activated position.
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[0020] FIG. 3(b) is a plan sectional view of the faucet shown in FIG. 1
showing
the flow adjustment screw in a different position than FIG. 3(a) and the
faucet in its
closed position.
[0021] FIG. 4(a) is a sectional view of the faucet shown in FIG. 1, showing
the
faucet shown in FIG. 1 in its foam generating mode,
[0022] FIG. 4(b) is a sectional view of the faucet shown in FIG. 1 showingthe
faucet in a closed position.
[0023] FIG. 4(c) is a sectional view of the faucet shown in FIG. 1, shown in
an
open position.
Detailed Description
[0024] A dispensing faucet is provided that is usable in any system in wluch a
faucet is selectively operated to dispense materials from a pressurized
source. For
instance, it is applicable to "tapper" faucets configured to dispense beer or
another
pressurized liquid from a keg or another pressurized container. It is also
applicable to
condiment faucets configured to dispense ketchup, mustard or relish from a
container.
For the purposes of describing this invention, both non-viscous and viscous
materials,
such as beer and hot dog relish, shall be considered fluids or liquids.
[0025] The faucet comprises a valve body and a plunger which is mounted in a
bore in the valve body for reciprocating movement therein. The bore has an
inlet port
that opens into a passage adapted for connection to a pressurized container or
other
source of pressurized fluid, and an outlet port that opens into a dispensing
spout
adapted to deliver the fluid from the faucet. A handle having a pivotable
lever is
disposed partially within the valve body and terminates within a soclcet
provided for
that purpose in the plunger. The lever thus engages the plunger to drive the
plunger to
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reciprocate longitudinally through the bore. A plug on the plunger interacts
with a
valve seat inside the valve body to control the flow of fluid through the
valve.
[0026] Refernng specifically now to FIGs. 1, 2, 3 and 4, a faucet 10
constructed
in accordance with a first embodiment of the invention includes a valve body
12
having a bore 14 witlun it, a spout 16 that is mounted on the valve body 12,
and a
handle 18 that is operable by an operator to move a plunger 20 within the bore
14 to
open the faucet 10 and dispense fluids through the spout 16.
[0027] The valve body 12 may be formed from any material capable of
withstanding the pressures involved, slidably receiving the plunger assembly
20 and
pivotably supporting the handle 18. It preferably is formed from stainless
steel, a
food-grade plastic or another moldable material. The bore 14, which is most
preferably circular in cross-section, is formed axially through the valve
body. In one
embodiment of the present invention, an inlet port 22 comprises the upstream
axial
end of the bore 14 for connecting the faucet 10 to a pressurized fluid
container (not
shown). An outlet port 24 comprises the opposite end of the bore 14 for
delivering
dispensed fluid to the spout 16. A valve seat 26 is located at a reduced-
diameter
portion of the bore 14 located adjacent or at the outlet port 24. A bonnet
bore 28
extends radially from the bore 14, through a boss 30 on the upper surface of
the valve
body 12, and to the outer surface of the valve body 12 for receiving the
handle 18.
[0028] The lower end of the handle 18 forms a pivotable lever 32 that includes
a
partial ball 34 which engages a co~'responding socket 36 of the plunger
assembly 20.
The lever 32 is pivotably mounted in the bonnet bore 28 by a pivot mount,
preferably
formed from a second ball 38 and a bonnet socket 40. Both balls 34 and 38 are
preferably molded integrally with the lever 32. The plunger socket 36
preferably is
formed of a slot in the plunger 20. The bonnet socket 40 is formed from a
bonnet
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washer 42, an upper bearing cup 44, a lower bearing cup 46, and at least one O-
ring
48. The assembly is held in place by a compression bonnet 47 threaded onto the
boss
30 so as to capture the bonnet wasr~er 42, bearing cups 44, 46 and O-ring 48
beneath
itself and within the bonnet bore 28. This construction is described in more
detail in
the specification of Application Serial No. 10/142,751, filed May 9, 2002, the
disclosure of which is hereby incorporated herein by reference.
[0029] The plunger assembly 20 includes a plunger member 60, slidably mounted
in the bore 14. The plunder member 60 is formed generally in the shape of a
geometric solid, of a cross-sectional shape different than the cross-section
of the bore
14, so that the differences in cross-section create openings for permitting
the passage
of the fluid. The plunger member 60 includes an outer peripheral surface 54
and
upstream and downstream axial ends 56, 58. The above-described slot or socket
36
extends radially into the plunger 20 between the ends 56 and 58. The entire
plunger
20 is arranged within the bore 14 such that nearly the entire plunger 20 is
always
immersed in the liquid being dispensed, even when the faucet 10 is not in use.
This is
advantageous because no part located within the bore 14 is exposed to the air
outside
the faucet when constantly surrounded by fluid and enclosed within the valve
body
12.
[0030] The plunger assembly 20 of this embodiment is contemplated for use with
non-viscous fluid, such as beer or another beverage. The plunger assembly 20
is
therefore configured to facilitate fluid flow through and past the plunger
assembly and
the interconnection between the plunger member 60 and the lever 32 so that the
plunger assembly is washed clean of any particulate matter during dispensing.
Most
preferably the plunger member 60 is formed with a substantially square cross-
section,
creating four gaps between itself and the circular-shaped inside cross-section
of the
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bore 14. These gaps act as four channels of passage for the fluid to flow.
Other
shapes may also be used for both of these elements, so long as sufficiently
substantial
channels of passage are still formed thereby.
[0031] One embodiment of the present invention includes an assembly to provide
a foam control feature, for use with a beer dispensing faucet in those
instances where
foam is desirable. The foam control feature provides only foam, in such
instances as
where the user has dispensed nearly a full beer, without raising much foam,
and wants
to provide an attractive head to a glass of beer. In this embodiment, the
plunger 20 is
constructed of a valve stem 60 with a recoiling system that comprises a seal
62, a seal
retainer screw 64 which passes through the seal, a spring cup 66 and a coil
spring 68.
The seal retainer screw 64 is threaded into an axial boss 70 at the end of the
valve
stem that faces toward the valve seat 26 inside the valve body 12. The boss 70
includes an axial hole 71 formed therein, which aligns with an axial hole 64a
formed
in retainer screw 64. The axial hole 64a enters the retainer screw 64 at the
threaded
end, but dead ends just before the head of the retainer screw 64. A transverse
hole
64b is formed just under the head of the retainer screw 64, to intersect with
the axial
hole 64a and provide an exit from the axial hole.
[0032] The retainer screw 64 and the seal 62 function as the valve closure.
The
seal 62 is mounted on the downstream end portion of the plunger member 60 for
sealing against the valve seat 26 on the valve body 12 when the plunger member
is in
the non-dispensing, valve-closed position. In the most preferred embodiment,
the seal
62 is a deformable elastomeric O-ring (on the order of 70-90 durometer) sized
so as to
matingly fit with the valve seat 26.
[0033] The retainer screw 64 and the seal 62 may be manufactured from any food
grade material. In one preferable embodiment, the retainer screw 64 is made of
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stainless steel and the seal is made from any food grade polymer. The
recoiling
system of the plunger is effected when the seal 62 and the retainer screw 64
are
inserted into the axial boss 70 as described above, through the spring cup 66
and coil
spring 68. The spring 68 is fitted such that it is capable of compression and
expansion
between the spring cup 66 and the downstream valve stem end 58. As shown in
FIG.
4(c), in a preferred embodiment, when the handle 18 by means of the pivotable
lever
32 is positioned inside the socket 36 of the plunger member 60 and moved to a
dispensing or forward position, the plunger assembly 20 moves away from the
valve
seat 26, allowing a clear, foam-free fluid to be dispensed. On the other hand,
as
shown in FIG. 4(b), when the handle 18 is moved rearwardly to a non-dispensing
position, the plunger assembly 20 moves forward to engage the valve seat 26
and
substantially close the valve 10, thereby preventing the flow of fluids. In
this
embodiment, as shown in FIG. 4(a), the handle 18 may also be positioned in a
further
backward position. When the handle 18 is put in the further backward position,
the
recoiling system is engaged and the spring 68 compresses axially between the
bushing
66 and downstream valve end 58. This action has the effect of exposing the
transverse hole 64b in the retaining screw 64 beyond the valve seat 26, as
shown in
FIGS. 3(a) and 4(a). The beer, being forced through the small openings of
holes 71,
64a and 64b, becomes foamy. The user is thus able to provide foam to top off a
glass
of beer with a nice head without which the glass would not be as attractive.
Each of
the holes 71, 64a and 64b have diameters of a size to create smooth foam for
the
particular beer being dispensed. In the experience of the inventors, diameters
on the
order of about 0.005 inches to about .09 inches provide the best
functionality, but
other diameters are also functional.
to
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[0034] The spout 16 is removably mounted on the downstream end of the valve
body 12, preferably by being threaded onto a threaded boss 76 extending
downstream
from the dow~istream end of the valve body 12. The spout 16 is sealed against
the
valve body 12 by an O-ring 78, which is mounted in a groove 80 on the upstream
axial end of the spout 16. Due to this rotation relationship, removal of the
spout 16
renders all components of the faucet 10 that are exposed to fluid but not
permanently
immersed in it (namely, the valve seat 26, the end of the retainer screw 64,
and the
interior of the boss 76) accessible for easy cleaning by use of a simple swab
or sprayer
(not shown).
[0035] In one embodiment of the present invention, the faucet.10 further
includes
a flow control mechanism, to closely control the flow of the dispensed fluid.
As
shown in FIGS. 1, 3(a) and 3(b), the flow control mechanism includes a flow
control
shank 82, having formed therein a shank bore 84, which is capable of being
connected
to a pressurized fluid container (not shown) via a boss 85. Preferably, the
boss 85 is
connected to the pressurized container via a threaded connection. The interior
of the
bore 82 is essentially funnel-shaped and is designed to substantially fit a
flow
restrictor 86, which has a narrow solid funnel head 88 and a solid fluted tail
90. The
shank 82 and the flow restrictor 86 are both preferably made of stainless
steel. The
head 88 of the flow restrictor 86 further comprises at least one orifice 92
providing an
opening through the solid funnel head 88 and leading into a central chamber 94
of the
funnel head 88. It is preferred that head 88 further comprises at least four
equally
spaced orifices 92, all in fluid communication with the central chamber 94.
[0036] The shank 82 containing the flow restrictor 86 is positioned relative
to the
bore 14 in the upstream end of the inlet port 22 with the aid of a keeper
spring 96, a
lceeper ring 102 and a ferrule 100. The ferrule 100 is preferably connected to
the inlet
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port 22 by any suitable removable connection such as threading, thereby
trapping the
head of the flow restrictor 86 inside the valve body 12.
[0037] The inlet valve 22 further comprises an angled bore 105 for receiving a
flow adjusting screw 106. The bore 105 is positioned, and the screw 106 sized,
so
that the end of the screw may contact the head of the flow restrictor 86. In
this
manner, rotation of the flow adjust~lent screw 106 controls the amount of
axial
displacement of the flow restrictor 86 to a very fme degree of adjustment,
providing
very closely regulated flow control.
[0038] The adjusting screw 106 may be of a conventional type with a knurled
head, or, alternatively, may be provided with a tamper resistant flow
adjustment screw
head 108 and an adjusting key 112, which are axially fitted with each other.
An O-
ring 110 may also be provided to reduce leakage around the adjusting screw
106.
Preferably, the screw end 108 and the adjusting key are made from stainless
steel and
the O-ring is made from elastomeric material. The angled bore 105 on the inlet
valve
22 is positioned at a slanting angle, preferably 45° to the inlet
valve. When the
adjusting key 112 or knurled head is rotated clockwise, the screw end 108
enters
further inside the bore 14 of the inlet valve 22.
[0039] In operation, as illustrated in the preferred embodiment shown in FIGS.
1,
3(a) and 3(b), when the shank 82 containing the flow restrictor 86 is coupled
with the
inlet valve 22, then the flow restrictor 86 is positioned such that it may
partially slide
inside the bore 14 in the valve. As the adjusting key 112 is rotated, the
adjusting
screw 106 enters further inside the bore 14 of the inlet valve 22 via the
angled bore
105. The screw 106 constricts the movement of the flow restrictor 86 inside
the bore
14. When the adjusting screw 106 is gradually rotated clockwise, as shown in
FIG.
3(a), the movement of the flow restrictor 86 is gradually constricted. The
adjusting
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screw 106 is capable of at least 360-degree rotation, thereby allowing for
very finely
controlled movement of the flow restrictor 86.
[0040] When the pressurized fluid coming from upstream into the inlet port 22
has higher than desirable pressure, the adjustment screw 106 is rotated
clockwise to
constrict the movement of the flow restrictor 86, which in turn restricts the
fluid flow.
On the other hand, if the pressure of the fluid is lower than desirable, then
more fluid
can be allowed to flow through the faucet 10 by simply gradually turning the
adjustment screw 106 counter-clockwise to effect a desirable pressure-flow of
the
fluid, as shown in FIG. 3(b).
[0041] Preferably, as shown in FIG. 1 and 4, the fluid will enter the shank
82, will
pass along the fluted tail 90, will enter the central chamber 94 of the head
88 via the
orifices 92 and then will pass through bore 14 into the channels of passage
surrounding the plunger assembly 20. If the plunger assembly 20 is in a
dispensing
position, the valve 10 would open said fluid of desirable pressure and clarity
will be
dispensed, as shown in FIG. 4(c). If the plunger assembly 20 is a non-
dispensing
position, the fluid would fill the bore 14, and the plunger assembly,
including its parts
as described above, will be immersed in the fluid without any exposure to air
or
bacterial growth, as shown in FIG 4(b). Further, as shown in FIG, 4(a), the
fluid
entering the shank 82 may be forced through the plunger assembly 20 in a
partially
open foam-making position. Positioning the handle 18 in a push back foam
generating mode, creates foam to top off fluids, such as beer with a head.
[0042] Thus, although the invention has been herein shown and described in
what
is perceived to be the most practical and preferred embodiments, it is to be
understood
that the invention is not intended to be limited to the specific embodiments
set forth
above. Rather, it is recognized that modifications may be made by one of skill
in the
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art of the invention without departing from the spirit or intent of the
invention and,
therefore, the invention is to be taken as including all reasonable
equivalents to the
subject matter of the present invention.
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