Flow control module

A flow control module is provided. The flow control module includes a housing as well as an on/off solenoid assembly and a proportional solenoid assembly mounted to the housing. A flow body is situated within the housing and is interposed between the on/off solenoid assembly and the proportional solenoid assembly. The flow body provides for flow management of a flow of fluid through the housing.

FIELD OF THE INVENTION

This invention generally relates to valves, and more particularly to solenoid actuated valves, and even more particularly to solenoid actuated flow control valves.

BACKGROUND OF THE INVENTION

Solenoid actuated flow control valves are readily recognized as providing accurate flow control. In their most basic form, a solenoid having movable armature is attached to a housing of the valve. The armature moves linearly to open and close a flow path through the valve and/or control the flow characteristics of the flow through the valve. This armature may act directly on a port along the flow path to open and close the port or control flow through the port. Alternatively, the armature may act on another member such as valve member, e.g. a diaphragm, to effectuate flow control.

Examples of such solenoid actuated flow control valves may be readily seen at U.S. Pat. Nos. 8,418,723, 6,056,264, and 5,374,029, disclosures of which are incorporated by reference herein in their entirety. The invention presents a flow control module which presents improvements in the art relative to such flow control valves and a method of controlling such flow control module. These and other advantages of the invention, as well as additional inventive features, will be apparent from the description of the invention provided herein.

BRIEF SUMMARY OF THE INVENTION

In one aspect, a flow control module is provided which utilizes on/off and proportional solenoid flow control and a flow body to achieve desirable flow characteristics. An embodiment of a flow control module according to this aspect includes a housing having an inlet and an outlet and a passageway extending between the inlet and the outlet, the passageway defining a flow path through the flow control module. The flow control module also includes a first solenoid assembly mounted to the housing. The first solenoid assembly is configured as an on/off solenoid assembly such that the first solenoid assembly is operable to allow a flow of fluid along the flow path through the flow control module in an on position and prevent the flow of fluid along the flow path through the flow control module in an off position. The flow control module also includes a second solenoid assembly mounted to the housing. The second solenoid assembly is configured as a proportional solenoid assembly. The second solenoid assembly is configured to proportionally control the flow of fluid along the flow path through the flow control module downstream from the first solenoid assembly relative to the flow path through the flow control module. The flow control module also includes a flow body having a flow passage therethrough. The flow body is situated in the housing along the flow path and interposed between the first solenoid assembly and the second solenoid assembly.

In certain embodiments according to this aspect, the first solenoid assembly includes a first armature. The first armature includes an axially facing seal member. The seal member is arranged to sealingly engage a seal surface of the flow body. The seal surface is defined by a ridge having a semi-circular cross section and extending axially away from a flange of the flow body.

In certain embodiments according to this aspect, the flow passage through the flow body has an inlet region and a transition region, wherein the transition region has a variable cross sectional area. In one embodiment, the transition region has a maximum diameter of 0.200 inches to 0.350 inches.

In certain embodiments according to this aspect, the first solenoid assembly includes a first armature, and wherein the second solenoid assembly includes a second armature. The second armature has an internal cavity which has an axially facing opening that faces the transition region of the flow body. A maximum diameter of the internal cavity is equal to the maximum diameter of the transition region.

In certain embodiments according to this aspect, the flow body is removable relative to the housing.

In certain embodiments according to this aspect, the first solenoid assembly includes a first armature, and wherein the second solenoid assembly includes a second armature and an outer sleeve surrounding the second armature, wherein the second armature includes an annular flow channel formed into an outer surface of the second armature. The annular flow channel is selectively alignable with a plurality of ports formed through the outer sleeve.

In another aspect, a flow control module is provided which utilizes a flow body tailored for smoothly transitioning a flow from an inlet region of the module to an outlet region. An embodiment of a flow control module according to this aspect includes a housing having an inlet and an outlet and a passageway extending between the inlet and the outlet. The passageway defines a flow path through the flow control module. The flow control module also includes a first solenoid assembly mounted to the housing. The first solenoid assembly has a first armature movable relative to the housing. The flow control module also includes a second solenoid assembly is mounted to the housing. The second solenoid has a second armature movable relative to the housing. The flow control module also includes a flow body situated in the housing along the flow path and interposed between the first armature and the second armature. The flow body defines a flow passage through the flow body. The flow passage through the flow body includes an inlet region and a transition region. The transition region has a variable cross section.

In certain embodiments according to this aspect, the flow body is removable from the housing.

In certain embodiments according to this aspect, the transition region has a maximum diameter of 0.200 inches to 0.350 inches.

In certain embodiments according to this aspect, the first solenoid assembly is configured as an on/off solenoid assembly and the second solenoid assembly is configured as a proportional solenoid assembly. The second solenoid assembly is situated downstream from the first solenoid assembly relative to the flow path through the housing.

In certain embodiments according to this aspect, an annular flow channel is formed in an outer surface of the second armature. The annular flow channel is selectively alignable with a plurality of ports formed in an outer sleeve of the second solenoid assembly.

In yet another aspect, a flow control module is provided which advantageously utilizes an annular flow channel and annular flow region arrangement on an outlet side of the valve for optimal output flow characteristics. An embodiment of a flow control module according to this aspect includes a housing having an inlet and an outlet and a passageway extending between the inlet and the outlet. The passageway defines a flow path through the flow control module. The flow control module also includes first solenoid assembly mounted to the housing. The first solenoid assembly has a first armature movable relative to the housing. The flow control module also includes a flow body situated in the flow path and having a flow passage therethrough. The flow control module also includes a second solenoid assembly mounted to the housing, the second solenoid has a second armature movable relative to the housing. The second armature includes an internal cavity and a plurality of ports formed through an outer surface of the second armature in communication with the internal cavity. The second armature includes an annular flow channel formed in the outer surface of the second armature. The second solenoid assembly includes an outer sleeve surrounding the second armature. An annular flow space is defined between an outer surface of the sleeve and an interior surface of the housing. The annular flow channel movable relative to a plurality of ports formed through the sleeve.

In certain embodiments according to this aspect, the flow body is removable.

In certain embodiments according to this aspect, the flow passage through the flow body includes an inlet region and a transition region.

In certain embodiments according to this aspect, the transition region has a maximum diameter of 0.200 inches to 0.350 inches.

In certain embodiments according to this aspect, the first solenoid assembly is configured as an on/off solenoid assembly and the second solenoid assembly is configured as a proportional solenoid assembly. The second solenoid assembly is situated downstream from the first solenoid assembly relative to the flow path through the housing.

In certain embodiments according to this aspect, the second armature has an internal cavity which has an axially facing opening that faces the transition region of the flow body, wherein a maximum diameter of the internal cavity is equal to the maximum diameter of the transition region.

In certain embodiments according to this aspect a method of controlling the flow control module includes a flow meter in-line with the flow such that the flow meter generates a feedback signal to control the first solenoid assembly and the second solenoid assembly. The flow meter may be located between the inlet port and a fixed orifice.

DETAILED DESCRIPTION OF THE INVENTION

Turning now to the illustrations,FIGS. 1-5illustrate an embodiment of a flow control valve (referred to herein as a flow control module) according to the teachings herein. The flow control module is a dual-solenoid assembly arrangement, with each solenoid assembly functionally acting on a flow through the flow control module. One solenoid assembly is configured as an on/off solenoid assembly, which is defined herein as a solenoid assembly which acts to fully open or fully close a flow path through the flow control module by having two discrete positions, one in which flow is permitted along the flow path and one in which flow is not permitted.

The other solenoid assembly is configured as a proportional solenoid assembly, which is defined herein as a solenoid assembly which acts to proportionally control a flow of fluid along the flow path through the flow control module, where there exists a proportional relationship between flow rate and a position of an armature of the proportional solenoid assembly.

As described below, a flow body is positioned along the flow path between the first and second solenoid assemblies. The flow body advantageously allows for a smooth transition for the flow through the flow control module between the inlet and outlet side thereof. As used herein, the inlet side of the flow control module is the region of the flow path upstream from the flow body relative to a flow direction (i.e. the direction moving from the inlet to the outlet along the flow path), and the outlet side of the flow control module is the region of the flow path downstream from the flow body relative to the flow direction. The flow body achieves this smooth transitioning by employing a passageway having a transition region with a variable cross section.

As also described below, the second solenoid assembly is configured to maintain the laminar characteristics of the flow through the flow control module. In particular, the second solenoid assembly includes an armature having an annular flow channel which is selectively alignable with a plurality of ports formed through an outer sleeve surrounding the armature. These ports open to an annular flow region surrounding the exterior of the outer sleeve and bounded by an interior surface of the housing. This annular flow region is in fluid communication with the outlet port of the flow control module. The annular flow channel and annular flow region, with the aid of the above described flow body, maintain desirable laminar flow characteristics through the flow control module.

Turning now toFIG. 1, an embodiment of the above introduced flow control module20is illustrated. Flow control module20includes a housing22which has an inlet24and an outlet26. A flow path extends between inlet24and outlet26. A first solenoid assembly28is attached to an upper portion of flow control module20as illustrated inFIG. 1. A second solenoid assembly30is attached to a lower portion of flow control module20as illustrated inFIG. 1. As introduced above, first solenoid assembly28is an on/off solenoid assembly. Second solenoid assembly30is a proportional solenoid assembly. Functionally, first solenoid assembly28is responsible for allowing or preventing flow from reaching the outlet side of flow control module20. Second solenoid assembly30is responsible for proportionally controlling the flow to outlet26from the outlet side of flow control module20.

Flow control module20is not limited to any particular application. Indeed, it may be utilized for the flow of any fluid with only minor application specific adjustments needed. As used herein, the term “fluid”, means any liquid or gas. As one non-limiting example, flow control module20is ideally suited for use in controlling the flow of a fluid which must remain generally laminar. Such fluids include but are not limited to carbonated fluids used for beverages or the like, where avoiding turbulence is desired to avoid out gassing.

Turning now toFIG. 2, first solenoid assembly28includes a housing36housing a solenoid winding or coil38(seeFIG. 3). A connector40is used for connecting first solenoid assembly28to a controller described below. First solenoid assembly28also includes a threaded collar44for threadably attaching solenoid assembly28to housing22.

First solenoid assembly28also includes a first armature46which, when acted upon by coil38, linearly moves relative to housing36. First armature46carries an axially facing seal member48which seals against the above introduced flow body50, as described in greater detail below. Additionally, a seal52is situated at a terminal end of collar44. This seal52is responsible for preventing a leak path at the interface of first solenoid assembly28and housing22. Seal52may be formed from any contemporary seal material.

Similarly, second solenoid assembly30includes a housing56housing a solenoid winding or coil58(seeFIG. 3). A connector60is used for connecting second solenoid assembly30to the below described controller. Second solenoid assembly30also includes a threaded collar64for threadably attaching solenoid assembly30to housing22.

Second solenoid assembly30also includes a second armature66(seeFIG. 3) which, when acted upon by coil58, linearly moves relative to housing56. Second armature66is surrounded by an outer sleeve68which includes a plurality of ports70, as described in greater detail below. This outer sleeve68is fixedly attached to the remainder of second solenoid assembly30. Second armature66is movable within a bore of outer sleeve68. Sleeve68includes a flange80which axially abuts a terminal end of collar64.

Additionally, a seal72is situated on flange80. This seal72is responsible for preventing a leak path at the interface of second solenoid assembly30and housing22. Also, an additional seal74is provided at an end of outer sleeve68. Seal74is responsible for preventing a leak path around the exterior of flow body50. Put differently, seal74prevents fluid from short circuiting the flow passage54through flow body50. Seals72,74may be formed from any contemporary seal material.

Still referring toFIG. 2, although described above in the context of a threaded connection, first solenoid assembly28and second solenoid assembly30may be attached to housing22via any known mechanical means. For example, first solenoid assembly28and second solenoid assembly30may be installed onto housing22via welding, adhesives, brazing, etc. The particular means of connection is not limiting on the invention herein.

Although not illustrated herein, each of first and second solenoid assemblies28,30are connected to a controller or the like which governs the actuation thereof. This may be a single controller which communicates with both of first and second solenoid assemblies28,30, or alternatively, separate controllers which are individually connected to each of first and second solenoid assemblies28,30. In either case, electrical current applied to either solenoid assemblies28,30causes their respective armatures to linearly move relative to the remainder of the assembly.

Turning now toFIG. 3, flow control module20is shown in cross-section. In the illustrated view, first solenoid assembly28is illustrated in its on position, i.e. its discrete position wherein fluid is permitted to flow along the flow path through inlet24and enter passageway54of flow body50.

This flow of fluid then continues until it reaches an internal cavity82formed in armature66. A plurality of ports84are also formed through armature66and communicate with internal cavity82. As a result, fluid is allowed to flow through ports84until it encounters outer sleeve68. Depending upon the position of armature66, fluid may be permitted to flow through ports70formed in outer sleeve68. Thereafter, this fluid may then exit through outlet26as described below.

Turning now toFIG. 4, the particulars of flow body50will be described in greater detail. As can be seen in this view, flow body50includes a flange86which seats against an interior surface of housing22to locate flow body50therein. It should be noted that flow body50is illustrated as a separate removable component. This has the advantage of allowing a user to replace flow body50with different flow bodies having other flow passage geometries than that shown to accommodate different applications.

As can also be seen inFIG. 4, an annular region90surrounds armature46and flow body50. Fluid entering through inlet24encounters this annular region and surrounds armature46and flow body50. If first solenoid assembly28is in its on position, flow may then proceed into passageway54. If first solenoid assembly is in its off position, fluid is prevented from entering passageway54from annular region90.

Passageway54includes an inlet region having a constant circular cross-sectional area denoted by D1. This inlet region leads to a transition region having a variable circular cross-sectional area as illustrated. The transition region has a maximum diameter D2which is larger than D1. This allows for a smooth transition from the inlet side to the outlet side of flow control module20, and more particularly, flow body50. It should also be noted that the internal cavity82has a maximum diameter which is equivalent to the maximum diameter D2of the transition region of flow body50. This allows for a gradual increase to the diameter encountered at armature66and more particularly that of internal cavity82, and thus aids in preserving laminar flow characteristics. As non-limiting examples, diameter D1may be about 0.075 inches to about 0.150 inches, while diameter D2may increase from that of D1to a maximum diameter of about 0.200 inches to about 0.350 inches. The term “about” in the preceding is used for allowance of typical manufacturing tolerances for such componentry and materials. The foregoing ranges are exemplary in nature and may be scaled up or down based on sizing and application.

FIG. 5illustrates first solenoid assembly28in its off position, i.e. its discreet position wherein fluid is prevented from flowing along the flow path through flow control module20and through flow body50. This sealed configuration is achieved in part by way of seal48which seals against a sealing ridge88axially extending from flange86as shown inFIG. 4. This sealed configuration is also achieved by way of using a resilient material for the material of flow body50. As a result, flow body50is self-sealing against the interior surface of housing22which it contacts. This resilient material may be any contemporary material used for self-sealing capabilities.

Turning now toFIGS. 6-7, the proportional flow capabilities of second solenoid assembly30will be described in greater detail. Each of these views are taken in the region of ports84of armature66. With particular reference toFIG. 6, assuming first solenoid assembly20is in its on position, fluid may freely enter internal cavity82as described above. Fluid entering this internal cavity82then encounters ports84, also as described above. Ports84are in communication with an annular channel96formed in an exterior of armature66. Annular flow channel96has a radially inner most surface through which ports84extend such that annular flow channel96is in fluid communication with internal cavity82via ports84. This radially inner most surface has an outer diameter which is less than the maximum outer diameter of armature66.

Annular flow channel66evenly distributes a fluid flow band around the exterior of armature66. This annular flow channel96is selectively alignable with ports70. In the particular orientation shown inFIG. 6, annular flow channel96completely radially overlaps flow ports70of outer sleeve68. In other words, the maximum possible flow is presented by this configuration. Once the fluid exits flow ports70on the exterior side of outer sleeve68, it encounters an annular flow region98as shown. This annular flow region98is in fluid communication with outlet26. The use of the above-described annular flow regions and annular flow channel advantageously promotes the preservation of laminar flow to the extent desired through flow control module20.

Turning now toFIG. 7, armature66has been acted upon by coil58such that it has moved downwardly relative to the orientation shown inFIG. 6. In this orientation, fluid is still allowed to flow from flow body50to internal cavity82. This flow is also permitted to flow through ports84to encounter annular flow channel96. However, further fluid flow is prevented given that annular flow channel96is no longer aligned with ports70. In other words, despite first solenoid assembly28being in its on position, fluid is still prevented from flowing to outlet26.

FIG. 8is a block diagram of the flow control module and the associated components for measuring a flow rate. A flow meter92, such as a turbine flow meter (example part number FT-110 by Gems), is disposed within the orifice between the inlet24and the fixed orifice O1followed by on-off solenoid50. The variable orifice70is further disposed prior to the outlet port26. Optionally there is a screen at location A to catch debris before entering the first valve. The screen may be for example an S5mesh.

FIG. 9is a cross-sectional view showing the flow meter92within the inlet orifice within the fluid path.

FIG. 10is a control system block diagram. A recipe database102sends required predetermined flow rates to a controller106. Controller106compares the predetermined flow rate with the signal from the flow meter92, which detects the actual flow rate through the inlet orifice. If the signal received from a pour actuator104indicates an “on” status the controller sends a signal to a solenoid driver108, which in turn sends a signal to the first solenoid assembly28such that first solenoid assembly28causes the flow control module20to flow. Additionally controller106sends a signal to the solenoid driver indicating a voltage level to drive the second solenoid assembly30so that it releases a flow at the predetermined rate.

FIG. 11is a flow diagram of a method of controlling the flow control module. Step112is a command to open the first solenoid assembly28as triggered by actuator104. Proceeding to step114the controller106compares the predetermined flow rate with that of the actual flow rate as measured by the flow meter92. If the flow rate is equal to the predetermined flow rate proceed to step116if not, proceed to step118. In step118the controller determines whether the actual flow rate is higher than the desired flow rate. If yes the controller106sends a signal to solenoid driver108to decrease the voltage for the second solenoid assembly30and proceed to step116. If the flow rate is not too low then the controller106sends a signal to solenoid driver108to increase the second solenoid assembly30flow rate then proceed to step116. In step116the controller determines whether the pour actuator104is still engaged. If yes return to step114. If no then send a signal to solenoid driver108to close the first solenoid assembly24.

FIG. 12is an alternative flow control method wherein a first step126includes setting the second solenoid assembly30to a predetermined setting according to a selected recipe.

Those of skill in the art will recognize that various modes of operation are capable with the above described configuration. For example, flow may begin by setting first solenoid assembly28to the on position. Thereafter, output flow characteristics may be governed by second solenoid assembly30. As one example, the output flow may begin with a relatively low flow rate by only slightly aligning annular flow channel96with ports70, and then gradually increase by gradually increasing the alignment of flow control channel96with ports70. Thereafter, flow may then be gradually decreased by gradually decreasing the aforementioned alignment. This is only one example of many.

In various embodiments, the flow control module20may be used within a beverage dispensing system to regulate the flow of one or more beverage ingredients. For example, a beverage dispensing system (which may include one or more macro-ingredients and one or more micro-ingredients) combines macro-ingredients (such as sweeteners, water, or carbonated water) and micro-ingredients (such as high intensity sweeteners, flavorings, food acids, or additives) to create a finished beverage. Such micro-dosing functionality may increase the dispensing capabilities of the beverage dispensing system to deliver a large variety of beverages and improve the quality of the beverage dispensed by the beverage dispensing system. Generally described, the macro-ingredients may have reconstitution ratios in the range from full strength (no dilution) to about six (6) to one (1) (but generally less than about ten (10) to one (1)). As used herein, the reconstitution ratio refers to the ratio of diluent (e.g., water or carbonated water) to beverage ingredient. Therefore, a macro-ingredient with a 5:1 reconstitution ratio refers to a macro-ingredient that is to be dispensed and mixed with five parts diluent for every part of the macro-ingredient in the finished beverage. Many macro-ingredients may have reconstitution ratios in the range of about 3:1 to 5.5:1, including 4.5:1, 4.75:1, 5:1, 5.25:1, 5.5:1, and 8:1 reconstitution ratios.

The macro-ingredients may include sweeteners such as sugar syrup, HFCS (“High Fructose Corn Syrup”), FIS (“Fully Inverted Sugar”), MIS (“Medium Inverted Sugar”), mid-calorie sweeteners comprised of nutritive and non-nutritive or high intensity sweetener blends, and other such nutritive sweeteners that are difficult to pump and accurately meter at concentrations greater than about 10:1—particularly after having been cooled to standard beverage dispensing temperatures of around 35-45° F. An erythritol sweetener may also be considered a macro-ingredient sweetener when used as the primary sweetener source for a beverage, though typically erythritol will be blended with other sweetener sources and used in solutions with higher reconstitution ratios such that it may be considered a micro-ingredient as described below.

The macro-ingredients may also include traditional BIB (“bag-in-box”) flavored syrups (e.g., COCA-COLA bag-in-box syrup) which contain all of a finished beverage's sweetener, flavors, and acids that when dispensed is to be mixed with a diluent source such as plain or carbonated water in ratios of around 3:1 to 6:1 of diluent to the syrup. Other typical macro-ingredients may include concentrated extracts, purees, juice concentrates, dairy products or concentrates, soy concentrates, and rice concentrates.

The macro-ingredient may also include macro-ingredient base products. Such macro-ingredient base products may include the sweetener as well as some common flavorings, acids, and other common components of a plurality of different finished beverages. However, one or more additional beverage ingredients (either micro-ingredients or macro-ingredients as described herein) other than the diluent are to be dispensed and mix with the macro-ingredient base product to produce a particular finished beverage. In other words, the macro-ingredient base product may be dispensed and mixed with a first micro-ingredient non-sweetener flavor component to produce a first finished beverage. The same macro-ingredient base product may be dispensed and mixed with a second micro-ingredient non-sweetener flavor component to produce a second finished beverage.

The macro-ingredients described above may be stored in a conventional bag-in-box container in, at and/or remote from the dispenser. The viscosity of the macro-ingredients may range from about 1 to about 10,000 centipoise and generally over 100 centipoises or so when chilled. Other types of macro-ingredients may be used herein.

The micro-ingredients may have reconstitution ratios ranging from about ten (10) to one (1) and higher. Specifically, many micro-ingredients may have reconstitution ratios in the range of about 20:1, to 50:1, to 100:1, to 300:1, or higher. The viscosities of the micro-ingredients typically range from about one (1) to about six (6) centipoise or so, but may vary from this range. In some instances, the viscosities of the micro-ingredients may be forty (40) centipoise or less. Examples of micro-ingredients include natural or artificial flavors; flavor additives; natural or artificial colors; artificial sweeteners (high potency, nonnutritive, or otherwise); antifoam agents, nonnutritive ingredients, additives for controlling tartness, e.g., citric acid or potassium citrate; functional additives such as vitamins, minerals, herbal extracts, nutraceuticals; and over the counter (or otherwise) medicines such as pseudoephedrine, acetaminophen; and similar types of ingredients. Various acids may be used in micro-ingredients including food acid concentrates such as phosphoric acid, citric acid, malic acid, or any other such common food acids. Various types of alcohols may be used as either macro- or micro-ingredients. The micro-ingredients may be in liquid, gaseous, or powder form (and/or combinations thereof including soluble and suspended ingredients in a variety of media, including water, organic solvents, and oils). Other types of micro-ingredients may be used herein.

Typically, micro-ingredients for a finished beverage product include separately stored non-sweetener beverage component concentrates that constitute the flavor components of the finished beverage. Non-sweetener beverage component concentrates do not act as a primary sweetener source for the finished beverage and do not contain added sweeteners, though some non-sweetener beverage component concentrates may have sweet tasting flavor components or flavor components that are perceived as sweet in them. These non-sweetener beverage component concentrates may include the food acid concentrate and food acid-degradable (or non-acid) concentrate components of the flavor, such as described in commonly owned U.S. patent application Ser. No. 11/276,553, entitled “Methods and Apparatus for Making Compositions Comprising and Acid and Acid Degradable Component and/or Compositions Comprising a Plurality of Selectable Components,” which is herein incorporated by reference in its entirety. As noted above, micro-ingredients may have reconstitution ratios ranging from about ten (10) to one (1) and higher, where the micro-ingredients for the separately stored non-sweetener beverage component concentrates that constitute the flavor components of the finished beverage typically have reconstitution ratios ranging from 50:1, 75:1, 100:1, 150:1, 300:1, or higher.

For example, the non-sweetener flavor components of a cola finished beverage may be provided from separately stored first non-sweetener beverage component concentrate and a second non-sweetener beverage component concentrate. The first non-sweetener beverage component concentrate may comprise the food acid concentrate components of the cola finished beverage, such as phosphoric acid. The second non-sweetener beverage component concentrate may comprise the food acid-degradable concentrate components of the cola finished beverage, such as flavor oils that would react with and impact the taste and shelf life of a non-sweetener beverage component concentrate were they to be stored with the phosphoric acid or other food acid concentrate components separately stored in the first non-sweetener component concentrate. While the second non-sweetener beverage component concentrate does not include the food acid concentrate components of the first non-sweetener beverage component concentrate (e.g., phosphoric acid), the second non-sweetener beverage component concentrate may still be a high-acid beverage component solution (e.g., pH less than 4.6).

A finished beverage may have a plurality of non-sweetener concentrate components of the flavor other than the acid concentrate component of the finished beverage. For example, the non-sweetener flavor components of a cherry cola finished beverage may be provided from the separately stored non-sweetener beverage component concentrates described in the above example as well as a cherry non-sweetener component concentrate. The cherry non-sweetener component concentrate may be dispensed in an amount consistent with a recipe for the cherry cola finished beverage. Such a recipe may have more, less, or the same amount of the cherry non-sweetener component concentrate than other recipes for other finished beverages that include the cherry non-sweetener component concentrate. For example, the amount of cherry specified in the recipe for a cherry cola finished beverage may be more than the amount of cherry specified in the recipe for a cherry lemon-lime finished beverage to provide an optimal taste profile for each of the finished beverage versions. Such recipe-based flavor versions of finished beverages are to be contrasted with the addition of flavor additives or flavor shots as described below.

Other typical micro-ingredients for a finished beverage product may include micro-ingredient sweeteners. Micro-ingredient sweeteners may include high intensity sweeteners such as aspartame, Ace-K, steviol glycosides (e.g., Reb A, Reb M), sucralose, saccharin, or combinations thereof. Micro-ingredient sweeteners may also include erythritol when dispensed in combination with one or more other sweetener sources or when using blends of erythritol and one or more high intensity sweeteners as a single sweetener source.

Other typical micro-ingredients for supplementing a finished beverage product may include micro-ingredient flavor additives. Micro-ingredient flavor additives may include additional flavor options that can be added to a base beverage flavor. The micro-ingredient flavor additives may be non-sweetener beverage component concentrates. For example, a base beverage may be a cola flavored beverage, whereas cherry, lime, lemon, orange, and the like may be added to the cola beverage as flavor additives, sometimes referred to as flavor shots. In contrast to recipe-based flavor versions of finished beverages, the amount of micro-ingredient flavor additive added to supplement a finished beverage may be consistent among different finished beverages. For example, the amount of cherry non-sweetener component concentrate included as a flavor additive or flavor shot in a cola finished beverage may be the same as the amount of cherry non-sweetener component concentrate included as a flavor additive or flavor shot in a lemon-lime finished beverage. Additionally, whereas a recipe-based flavor version of a finished beverage is selectable via a single finished beverage selection icon or button (e.g., cherry cola icon/button), a flavor additive or flavor shot is a supplemental selection in addition to the finished beverage selection icon or button (e.g., cola icon/button selection followed by a cherry icon/button selection).

As is generally understood, such beverage selections may be made through a touchscreen user interface or other typical beverage user interface selection mechanism (e.g., buttons) on a beverage dispenser. The selected beverage, including any selected flavor additives, may then be dispensed upon the beverage dispenser receiving a further dispense command through a separate dispense button on the touchscreen user interface or through interaction with a separate pour mechanism such as a pour button (electromechanical, capacitive touch, or otherwise) or pour lever.

In the traditional BIB flavored syrup delivery of a finished beverage, a macro-ingredient flavored syrup that contains all of a finished beverage's sweetener, flavors, and acids is mixed with a diluent source such as plain or carbonated water in ratios of around 3:1 to 6:1 of diluent to the syrup. In contrast, for a micro-ingredient delivery of a finished beverage, the sweetener(s) and the non-sweetener beverage component concentrates of the finished beverage are all separately stored and mixed together about a nozzle when the finished beverage is dispensed. Example nozzles suitable for dispensing of such micro-ingredients include those described in commonly owned U.S. provisional patent application Ser. No. 62/433,886, entitled “Dispensing Nozzle Assembly,” PCT patent application Ser. No. PCT/US15/026657, entitled “Common Dispensing Nozzle Assembly,” U.S. Pat. No. 7,866,509, entitled “Dispensing Nozzle Assembly,” or U.S. Pat. No. 7,578,415, entitled “Dispensing Nozzle Assembly,” which are all herein incorporated by reference in their entirety.

In operation, the beverage dispenser may dispense finished beverages from any one or more of the macro-ingredient or micro-ingredient sources described above. For example, similar to the traditional BIB flavored syrup delivery of a finished beverage, a macro-ingredient flavored syrup may be dispensed with a diluent source such as plain or carbonated water to produce a finished beverage. Additionally, the traditional BIB flavored syrup may be dispensed with the diluent and one or more micro-ingredient flavor additives to increase the variety of beverages offered by the beverage dispenser.

Micro-ingredient-based finished beverages may be dispensed by separately dispensing each of the two or more non-sweetener beverage component concentrates of the finished beverage along with a sweetener and diluent. The sweetener may be a macro-ingredient sweetener and/or a micro-ingredient sweetener and the diluent may be water and/or carbonated water. For example, a micro-ingredient-based cola finished beverage may be dispensed by separately dispensing food acid concentrate components of the cola finished beverage, such as phosphoric acid, food acid-degradable concentrate components of the cola finished beverage, such as flavor oils, macro-ingredient sweetener, such as HFCS, and carbonated water. In another example, a micro-ingredient-based diet-cola finished beverage may be dispensed by separately dispensing food acid concentrate components of the diet-cola finished beverage, food acid-degradable concentrate components of the diet-cola finished beverage, micro-ingredient sweetener, such as aspartame or an aspartame blend, and carbonated water. As a further example, a mid-calorie micro-ingredient-based cola finished beverage may be dispensed by separately dispensing food acid concentrate components of the mid-calorie cola finished beverage, food acid-degradable concentrate components of the mid-calorie cola finished beverage, a reduced amount of a macro-ingredient sweetener, a reduced amount of a micro-ingredient sweetener, and carbonated water. By reduced amount of macro-ingredient and micro-ingredient sweeteners, it is meant to be in comparison with the amount of macro-ingredient or micro-ingredient sweetener used in the cola finished beverage and diet-cola finished beverage. As a final example, a supplemental flavored micro-ingredient-based beverage, such as a cherry cola beverage or a cola beverage with an orange flavor shot, may be dispensed by separately dispensing a food acid concentrate components of the flavored cola finished beverage, food acid-degradable concentrate components of the flavored cola finished beverage, one or more non-sweetener micro-ingredient flavor additives (dispensed as either as a recipe-based flavor version of a finished beverage or a flavor shot), a sweetener (macro-ingredient sweetener, micro-ingredient sweetener, or combinations thereof), and carbonated water. While the above examples are provided for carbonated beverages, they apply to still beverages as well by substituting carbonated water with plain water.

The various ingredients may be dispensed by the beverage dispenser in a continuous pour mode where the appropriate ingredients in the appropriate proportions (e.g., in a predetermined ratio) for a given flow rate of the beverage being dispensed. In other words, as opposed to a conventional batch operation where a predetermined amount of ingredients are combined, the beverage dispenser provides for continuous mixing and flows in the correct ratio of ingredients for a pour of any volume. This continuous mix and flow method can also be applied to the dispensing of a particular size beverage selected by the selection of a beverage size button by setting a predetermined dispensing time for each size of beverage.

FIG. 13illustrates an exemplary beverage dispenser system500suitable for implementing the several embodiments of the disclosure. As shown, the beverage dispenser system500is configured as an ice cooled beverage dispenser. Other configurations of beverage dispensers are contemplated by this disclosure such as a drop-in ice-cooled beverage dispenser, a counter electric beverage dispenser, a remote recirculation beverage dispenser, or any other beverage dispenser configuration.

The beverage dispenser system500includes a front room system502with a beverage dispenser504and a back room system506. The beverage dispenser504includes a user interface508, such as a touchscreen display, to facilitate selection of the beverage to be dispensed. The user interface508may employ various screens to facilitate user interactions on the beverage dispenser504and/or receive a user profile through interaction with a user's mobile device552, such as described in commonly owned U.S. patent application Ser. No. 14/485,826, entitled “Product Categorization User Interface for a Dispensing Device,” which is herein incorporated by reference in its entirety.

Upon receiving a beverage selection via the user interface508, a pour button510may be activated to dispense the selected beverage from the beverage dispenser504via a nozzle514. For example, the pour button510may be an electromechanical button, capacitive touch button, or other button selectable by a user to activate the beverage dispenser504to dispense a beverage. While shown as a button, the pour button510may alternatively be implemented as a lever or other mechanism for activating the beverage dispenser504to dispense a beverage. As shown inFIG. 13, the pour button510is separate from the user interface508. In some implementations, the pour button510may be implemented as a selectable icon in the user interface508.

In some implementations, the beverage dispenser may also include an ice lever514. Upon being activated, the ice lever514may cause the beverage dispenser504to dispense ice through an ice chute (not shown). For beverage dispensers that do not have an ice bin, such as counter-electric or remote recirculation beverage dispensers, the ice lever514may be omitted.

The beverage dispenser504may be secured via a primary door516and an ingredient door518. The primary door516and the ingredient door518may be secured via one or more locks. In some implementations, the locks are a lock and key. In some implementations, the lock on the ingredient door518may be opened via an RFID reader (not shown) reading an authorize ingredient package528. The primary door516may secure electronic components of the beverage dispenser504including one or more controllers520. The ingredient door518may secure an ingredient compartment that houses an ingredient matrix524.

The ingredient matrix524includes a plurality of slots526for receiving ingredient packages528. In various implementations, the ingredient packages528may be micro-ingredient cartridges. The micro-ingredient cartridges may be single cartridges or double cartridges, such as described in commonly owned U.S. patent application Ser. No. 14/209,684, entitled “Beverage Dispenser Container and Carton,” and U.S. patent application Ser. No. 12/494,427, entitled “Container Filling Systems and Methods,” which are both herein incorporated by reference in their entirety. As shown inFIG. 13, there are three drawers of ingredients in the ingredient matrix524. One or more of the drawers may slide back and forth along a rail so as to periodically agitate the ingredients housed on the drawer. Other configurations of the ingredient matrix524are possible, such as via one or more static and/or agitated ingredient towers.

Each ingredient package528may comprise an RFID tag, a fitment530, and a fitment seal532. The fitment seal532may be removed prior to installation into the beverage dispenser504. Upon installation, the fitment530may engage with and provide a fluidic communication between a probe (not shown) in the slot526and the ingredients contained in the ingredient package528. The ingredient matrix524may also contain one or more large volume micro-ingredient packages534, such as for one or more micro-ingredient sweetener sources.

The beverage dispenser504may also include a carbonator (not shown) for receiving water and carbon dioxide to produce carbonated water. The beverage dispenser504may also include one or more heat exchangers (not shown), such as a cold plate, for cooling one or more of the beverage ingredients contained in or received by the beverage dispenser504. In some implementations, one or more of the micro-ingredients dispensed via the nozzle512are not cooled via the heat exchanger or are otherwise maintained at an ambient temperature. Macro-ingredients dispensed via the nozzle512are typically cooled via the heat exchanger prior to being dispensed.

The back room system506is typically located in a back room remote from the front room system502, such as a storage area in a merchant location. The back room system506includes a water source536such as a municipal water supply that provides a pressurized source of plain water. The water received via the water source536may be filtered or otherwise treated by a water treatment system538. The treated water may optionally be pressurized to a desired pressure with a water booster540and supplied to the beverage dispenser. A carbon dioxide source542may supply carbon dioxide to the beverage dispenser504.

One or more macro-ingredient sources544may be located in the back room. The macro-ingredient from each macro-ingredient source544may be supplied to the beverage dispenser504via a pump546. The pump546may be a controlled gear pump, diaphragm pump, BIB pump, or any other suitable pump for supplying macro-ingredients to the beverage dispenser504. The back room system506may also include a rack with one or more storage locations548for spare micro-ingredients and one or more storage locations550for spare macro-ingredients.

The beverage dispenser504may include one or more network interfaces for communicating directly with devices in the front room or the back room, communicating with devices in the front room or the back room in a local area network (LAN), or communicating with devices remote from a location with the beverage dispenser system500via a wide area network (WAN) connection. For example, the beverage dispenser504may include networking devices such as a near field communication (NFC) module, a BLUETOOTH module, a WiFi module, a cellular modem, an Ethernet module, and the like. The beverage dispenser504may communicate via a direct communication or via a LAN with a user's mobile device552or a point-of-sale (POS) device554to receive a beverage selection or user profile of a user for configuring the beverage dispenser504to dispense one or more beverages based on the beverage selection or user profile. The user profile may include stored favorite beverages for the user, mixed or blended beverages created or stored by the user in their profile, and/or one or more beverage preferences, such as preferred nutritive level. The beverage dispenser504may also communicate via a WAN556for communicating with one or more remote servers558to receive software updates, content updates, user profiles, or beverage selections made via the remote server558.

FIG. 14illustrates an exemplary fluidic circuit800with pumping or metering devices from ingredient source802to the nozzle512of the beverage dispenser504. The beverage dispenser504may include none, one, or a plurality of the fluidic circuits shown inFIG. 14. For each ingredient source, the beverage dispenser504may include the fluidic circuit shown inFIG. 14. For example, the fluidic circuit for one or more of the macro-ingredient sources may include the fluidic circuit shown inFIG. 14. In some implementations, the fluidic circuit for the carbonated water and/or the still water source may include the fluidic circuit shown inFIG. 14.

FIG. 14illustrates an exemplary fluidic circuit800with a dynamic mechanical flow control808, a flow meter810, and a shut-off valve812suitable for implementing the several embodiments of the disclosure. The dynamic mechanical flow control808receives a pressurized beverage ingredient from an ingredient source802and provides an adjustable flow rate of the beverage ingredient to the nozzle512. The dynamic mechanical flow control808may include a variable sized orifice that adjusts to dynamically change the flow rate of the beverage ingredient supplied to the nozzle512based on control signals provided by the one or more controllers520. A flow meter810downstream of the dynamic mechanical flow control808measures a flow rate of the beverage ingredient being supplied by the dynamic mechanical flow control808and provides a feedback loop to the dynamic mechanical flow control808for controlling the variable sized orifice. A shut-off valve812downstream of the dynamic mechanical flow control808may be actuated to open and close in order to dispense or prevent dispensing the beverage ingredient from the nozzle512. In various implementations, the dynamic flow control module808, the flow meter810, and the shut-off valve812may be substituted for the flow control module20as described herein. As discussed above, the flow control module20has a different order of components that shown for the dynamic flow control module808, the flow meter810, and the shut-off valve812inFIG. 14.

The ingredient source802may be a micro-ingredient source or a macro-ingredient source housed in the ingredient matrix524of the beverage dispenser504, remote from the beverage dispenser504in the front room (e.g., adjacent to the beverage dispenser504or under a counter on which the beverage dispenser504is located), or located in the back room. The ingredient source802may also be the municipal water supply536or other pressurized ingredient source. When the ingredient source802is not pressurized, the fluidic circuit800may include a pump806for pressurizing the beverage ingredient from the ingredient source802. The pump806may be any pump suitable for pressurizing the beverage ingredient from the ingredient source802, such as a BIB pump, CO2 driven pump, controlled gear pump, or positive displacement pump. The fluidic circuit800may also optionally include a sold-out sensor804for detecting when the ingredient source802is empty.

While the components of the fluidic circuit800are shown in a particular order in, any order of the components described above may be used. Other variations are readily recognizable by those of ordinary skill in the art. Additionally, one or more heat exchangers (not shown) may be used at any location in the fluidic circuit800. The heat exchanger may include an ice bin, water bath, cold plate, or remote recirculation system.

FIG. 15illustrates an exemplary block diagram of a control architecture1000that may be used to control the beverage dispenser504suitable for implementing the several embodiments of the disclosure. As shown inFIG. 15, control architecture1000may comprise a core dispense module (CDM)1006, a human machine interface (HMI) module1004, a user interface (UI)1002, and a machine bus (MBUS)1005. HMI1004may connect to or otherwise interface and communicate with at least one external device (e.g., mobile device552or POS554) being external to beverage dispenser504. HMI1004may also control and update display screens on UI1002. CDM1006may control flows from a plurality of pumps and/or valves1010in beverage dispenser504according to a recipe to mix and dispense a product (e.g., a beverage) from beverage dispenser504. For example, the CDM1006may control the flow of a beverage ingredient through the flow module20.

Beverage ingredients (e.g., micro-ingredients, macro-ingredients, and/or diluents) may be combined to dispense various products that may include beverages or blended beverages (i.e., finished beverage products) from beverage dispenser504. However, beverage dispenser504may also be configured to dispense beverage components individually.

An example of control architecture1000for beverage dispenser504may be described in U.S. Ser. No. 61/987,020, entitled “Dispenser Control Architecture”, filed on May 1, 2014, the entirety of which is hereby incorporated by reference. MBUS1005may facilitate communication between HMI1004and CDM1006via one or more API calls. HMI1004, MBUS1005, and CDM1006may collectively comprise common core components, implemented as hardware or as combination of hardware and software, which may be adapted to provide customized functionality in beverage dispenser504. Beverage dispenser504may further include memory storage and a processor. Examples of UI1002may be described in U.S. Ser. No. 61/877,549, entitled “Product Categorization User Interface for a Dispensing Device”, filed on Sep. 13, 2013, the entirety of which is hereby incorporated by reference.

UI1002may detect what area of a touch screen has been touched by a user (e.g., user108). In response, UI1002may send HMI1004data regarding where the touch screen was touched. In response, HMI1004may interpret this received data to determine whether to have UI1002display a different UI screen or to issue a command to CDM1006. For example, HMI1004may determine that the user touched a portion of the touch screen corresponding to a beverage brand. In response, HMI1004may issue a command to CDM1006to pour the corresponding beverage brand. In response to receiving the command to pour the corresponding beverage brand, the CDM1006in turn issues commands via one or more control buses1008to the pumping or metering devices1010for the beverage ingredients needed to dispense the beverage brand. Or HMI1004may determine that the user touched a portion of the touch screen corresponding to a request for another screen. In response, HMI1004may cause UI1002to display the requested screen.

For example, the CDM1006issues commands via a control bus1008to the flow control module20in response to receiving a command to pour a selected beverage brand, as described above in conjunction withFIGS. 10-12. For example, the controller106may be implemented by the CDM1006. Alternatively, the CDM1006may issue commands via the control bus to the controller106for controlling operation of the flow control module20. Upon the HMI1004receiving a selection of a beverage brand, the CDM1006may obtain a recipe for the selected beverage from the recipe database102. Upon the HMI1004receiving a command to pour the beverage (e.g., pour actuator104indicates an “on” status), the CDM1006sends a signal to a solenoid driver108, which in turn sends a signal to the first solenoid assembly28such that first solenoid assembly28causes the flow control module20to flow (e.g., the on/off solenoid assembly28turns on and opens armature46so that the flow may proceed into passageway54). Additionally, the CDM1006sends a signal to the solenoid driver indicating a voltage level to drive the second solenoid assembly30so that it releases a flow at the predetermined rate (e.g., armature66is acted upon by coil58such that it moves to allow the flow at the predetermined rate). CDM1006compares the predetermined flow rate with a signal from the flow meter92, which detects the actual flow rate through the inlet orifice24and adjusts the voltage level to drive the second solenoid assembly30accordingly throughout the dispense of the beverage in accordance with the recipe.

In some embodiments, UI1002in beverage dispenser504may be utilized to select and individually dispense one or more beverages. The beverages may be dispensed as beverage components in a continuous pour operation whereby one or more selected beverage components continue to be dispensed while a pour input is actuated by a user or in a batch pour operation where a predetermined volume of one or more selected beverage components are dispensed (e.g., one ounce at a time). UI1002may be addressed via a number of methods to select and dispense beverages. For example, a user may interact with UI1002via touch input to navigate one or more menus from which to select and dispense a beverage. As another example, a user may type in a code using an onscreen or physical keyboard (not shown) on beverage dispenser504to navigate one or more menus from which to select and dispense a beverage. As a further example, a user may interact with the HMI1004via a user interface of an application on the mobile device552.

UI1002, which may include a touch screen and a touch screen controller, may be configured to receive various commands from a user (i.e., consumer input) in the form of touch input, generate a graphics output and/or execute one or more operations with beverage dispenser504(e.g., via HMI1004and/or CDM1006), in response to receiving the aforementioned commands. A touch screen driver in HMI1004may be configured to receive the consumer or customer inputs and generate events (e.g., touch screen events) that may then be communicated through a controller to an operating system of HMI1004.

Beverage dispenser504may be in communication with one or more external device (e.g., mobile device552or POS554). In some embodiments, the communication between beverage dispenser504and the external device may be accomplished utilizing any number of communication techniques including, but not limited to, near-field wireless technology such as BLUETOOTH, Wi-Fi and other wireless or wireline communication standards or technologies, via a communication interface.

FIG. 16illustrates an exemplary computer system1100suitable for implementing the several embodiments of the disclosure. For example, one or more components or controller components of the beverage dispenser504may be implemented as the computer system1100. In some implementations, one or both of the HMI1004and the CDM1006may be implemented as the computer system1100.

Referring toFIG. 16, an example computing device1100upon which embodiments of the invention may be implemented is illustrated. For example, each of the content source, key server, segmentations servers, caching servers, and client devices described herein may each be implemented as a computing device, such as computing device1100. It should be understood that the example computing device1100is only one example of a suitable computing environment upon which embodiments of the invention may be implemented. Optionally, the computing device1100can be a well-known computing system including, but not limited to, personal computers, servers, handheld or laptop devices, multiprocessor systems, microprocessor-based systems, network personal computers (PCs), minicomputers, mainframe computers, embedded systems, and/or distributed computing environments including a plurality of any of the above systems or devices. Distributed computing environments enable remote computing devices, which are connected to a communication network or other data transmission medium, to perform various tasks. In the distributed computing environment, the program modules, applications, and other data may be stored on local and/or remote computer storage media.

In its most basic configuration, computing device1100typically includes at least one processing unit1106and system memory1104. Depending on the exact configuration and type of computing device, system memory1104may be volatile (such as random access memory (RAM)), non-volatile (such as read-only memory (ROM), flash memory, etc.), or some combination of the two. This most basic configuration is illustrated inFIG. 16by dashed line1102. The processing unit1106may be a standard programmable processor that performs arithmetic and logic operations necessary for operation of the computing device1100. While only one processing unit1106is shown, multiple processors may be present. Thus, while instructions may be discussed as executed by a processor, the instructions may be executed simultaneously, serially, or otherwise executed by one or multiple processors. The computing device1100may also include a bus or other communication mechanism for communicating information among various components of the computing device1100.

Computing device1100may have additional features/functionality. For example, computing device1100may include additional storage such as removable storage1108and non-removable storage1110including, but not limited to, magnetic or optical disks or tapes. Computing device1100may also contain network connection(s)1116that allow the device to communicate with other devices such as over the communication pathways described herein. The network connection(s)1116may take the form of modems, modem banks, Ethernet cards, universal serial bus (USB) interface cards, serial interfaces, token ring cards, fiber distributed data interface (FDDI) cards, wireless local area network (WLAN) cards, radio transceiver cards such as code division multiple access (CDMA), global system for mobile communications (GSM), long-term evolution (LTE), worldwide interoperability for microwave access (WiMAX), and/or other air interface protocol radio transceiver cards, and other well-known network devices. Computing device1100may also have input device(s)1114such as a keyboard, keypads, switches, dials, mice, track balls, touch screens, voice recognizers, card readers, paper tape readers, or other well-known input devices. Output device(s)1112such as a printer, video monitors, liquid crystal displays (LCDs), touch screen displays, displays, speakers, etc. may also be included. The additional devices may be connected to the bus in order to facilitate communication of data among the components of the computing device1100. All these devices are well known in the art and need not be discussed at length here.

In an example implementation, the processing unit1106may execute program code stored in the system memory1104. For example, the bus may carry data to the system memory1104, from which the processing unit1106receives and executes instructions. The data received by the system memory1104may optionally be stored on the removable storage1108or the non-removable storage1110before or after execution by the processing unit1106.