CA2132028C - Water heating assembly for a beverage brewing apparatus - Google Patents

Abstract

A beverage brewing apparatus which employs a water control assembly, a moisture recovery assembly, an improved thermostatic and low water sensor configuration and an easily removable sprayhead. The control assembly controllably regulates the flow of water from the fill basin into the reservoir using a valve which is interconnected with a lid covering a fill opening in the hood portion. Water from the basin will not flow into the reservoir, and thus will not produce a brewed beverage, until the lid is closed by the user. The moisture recovery assembly employs a baffle opening and a collection portion on a vent to return condensation which may accumulate on the vent to the fill basin. A sleeve is positioned in the fill water opening in the hood portion to collect condensation and to reduce the surface area of the water which may be affected by air movements through the brewing apparatus. The thermostatic and low water sensing configurations position the temperature sensors outside of the water heating reservoir to prevent the accumulation of mineral and other deposits thereon. A
portion of the wall behind which the sensors are positioned is thinned in order to more accurately read the corresponding temperatures.

Description

~ ~ 2132028 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 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 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 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 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 ` 2132028 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-A~ 63632-1354D

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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~`- 2132028 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 j 63632-1354D
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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
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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 ~ 1 63632-1354D

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 A? 63632-l354D
~, 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 ? 63632-1354D
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`- 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 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 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 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 A 63632-l354D

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 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 A t 63632-1354D

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 ~ ~ 63632-1354D

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 A ~ 63632-13S4D
~. ~

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 _ 63632-1354D
A~

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 -21a-A~ 63632-1354D

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.

-21b-A`q

Claims (10)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. An improved thermostat configuration for use with a water heating assembly of a beverage brewing apparatus, said water heating assembly including a reservoir for retaining water during heating and a heating element, said reservoir having side walls;
said thermostat configuration comprising a first portion of said side wall having a thickness which is less than the surrounding area of said side wall and a thermostatic sensor retained outside of said reservoir in close proximity to said first portion such that said thermostatic sensor senses the temperature of water in said reservoir from the outside of the reservoir through said reservoir side wall.

2. An improved heated water reservoir assembly according to claim 1 wherein said reservoir is formed of a suitable plastic material having heat resisting characteristics capable of continuously withstanding substantially on the order of 205°F.

3. An improved thermostat configuration according to claim 1 further including a thermostat niche protruding into a side wall of said reservoir, said first portion being formed on a surface of said thermostat niche, said thermostat niche shielding said thermostatic sensor from unintended impact and air movements on the outside of the reservoir which would affect temperature readings.

4. An improved thermostat configuration according to claim 3 wherein said first portion is positioned on a side of said thermostat niche for preventing the accumulation of sedimentation and mineral deposits on said first portion which would otherwise compromise temperature readings by said thermostatic sensor positioned therebehind.

5. An improved thermostat configuration according to claim 4 further including a retaining cover engageable with said thermostat niche for retaining said thermostatic sensor in said thermostat niche and shielding said thermostatic sensor from errant air movements.

6. An improved low water sensing configuration for use with a water heating assembly of a beverage brewing apparatus, said water heating assembly including a reservoir for retaining water and a heating element, said reservoir having side walls and a bottom; said low water sensing configuration comprising a first portion having a thickness which is less than the surrounding area of said bottom and a thermostatic sensor retained outside of said reservoir in close proximity to said first portion such that said thermostatic sensor senses the temperature in said reservoir from the outside of said reservoir through said first portion when the water level in said reservoir drops below a predetermined level.

7. An improved heated water reservoir assembly according to claim 6 wherein said reservoir is formed of a suitable plastic material having heat resisting characteristics capable of continuously withstanding substantially on the order of 205°F.

8. An improved low water sensing configuration according to claim 6 further including a low water sensor niche protruding upwardly into the bottom of said reservoir, said first portion being formed on the surface of said low water sensing niche, said low water sensing niche shielding said thermostatic sensor from unintended impact and air movements on the outside of said reservoir which would effect temperature readings.

9. An improved low water sensing configuration according to claim 8 wherein said low water sensing niche protrudes upwardly into said reservoir near said heating element and said first portion is positioned in close proximity to said heating element such that a low water level condition is quickly sensed by said thermostatic sensor when the water level in said reservoir drops below a predetermined level.

10. An improved low water sensing configuration according to claim 8 further including a retaining cover engageable with said low water sensing niche for retaining said thermostatic sensor in said low water sensing niche and shielding said thermostatic sensor from errant air movements.