Abstract:
A system that allows for hot water on demand and once the water is heated, it is delivered to flavor containing solid material in a pressurized pulse. By heating the water on demand, a more uniform temperature can be achieved and by delivering the heated water in a pressurized pulse, the extraction of flavor from the flavor containing solid material is greatly improved. In addition, to determine the volume of water used in the system, the number of pressurized pulses are counted and that gives a more uniform consistent measurement of the volume of water used instead of the timed delivery of water.

Description:
CLAIM OF PRIORITY 
     This application claims the benefit of U.S. Provisional Application No. 60/871,649 filed Dec. 22, 2006 which is incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Technical Field 
     This invention relates to brewers, and more particularly, to commercial brewers for flavor containing solid materials. 
     2. Description of Related Art 
     It has been known for centuries to prepare coffee, tea, herb extracts and other flavor-containing liquids by steeping the corresponding flavor containing solid materials in hot water under ambient or elevated pressure. The steeping of roasted and ground coffee under ambient pressure emerged in the late 14th century and throughout the 19th and even the early 20th centuries, it was considered adequate to add ground coffee to hot water in a saucepan, boil the mixture until it smelled right, and pour the brew into a cup. It was not until later in the 20th century, that coffee making became somewhat automated. 
     The modern coffeemaker is a kitchen appliance used to brew coffee without having to boil water in a separate container. While there are many different types of coffeemakers using a number of different brewing principles, in the most common devices, coffee grounds are placed in a paper or metal filter inside a funnel. The funnel is then set over a glass or ceramic coffee pot. Cold water is poured into a separate chamber, and the water is heated up to the boiling point and directed into the funnel. This is commonly called an automatic drip-brew or drip brew coffee maker and is the most popular method used to brew coffee or tea. 
     Extraction time, water volume and water temperature are among the most critical considerations when brewing coffee with a drip brew coffee maker and in order to achieve a consistent tasting coffee, all three must be kept relatively constant. Typical hot water tank type brewers maintain the temperature of the water in the tank at a preset level through the use of a thermostat. 
     When a brewing cycle is selected in a typical tank type brewer, water solenoids are opened or closed by an electronic or electromechanical timer. The solenoids control the flow of water from a tank to a basket that contains the solid flavor material to be brewed. To replace the hot water sent to the brewing basket from the tank, cold water from a water source flows into the tank as the hot water is sent to the basket. This water inflow causes the tank temperature to drop during the brew cycle, effecting the extraction of the product from the flavor containing solid material. Various control systems, including solid-state controls, have been used to improve the operation of tank brewers and improve extraction of product. However, the effectiveness of these control systems is arguable, as they have a problem with consistent control, are typically not efficient, and do not keep the temperature and volume of water used relatively constant from brew cycle to brew cycle. 
     What is needed is a brewer that can heat the water quickly and uniformly and then deliver the water to the material to be brewed in a manner that will enhance the brewing. In addition, the brewer should not use a time based method to measure the amount of water used. It would be beneficial if a more accurate system was used determine the water volume for each brewing cycle. 
     SUMMARY OF INVENTION 
     The present invention solves the above-described problem by providing a system that allows for hot water on demand and delivers the heated water to flavor containing solid material in a pressurized pulse. By heating the water on demand, a more uniform temperature can be achieved and by delivering the heated water in a pressurized pulse, the extraction of flavor from the flavor containing solid material is greatly improved. In addition, to determine the volume of water used in the system, the number of pressurized pulses are counted. This results in a more uniform consistent measurement of the volume of water used instead of the timed delivery of water used in the prior art. 
     During use, the present invention is activated via a control panel. Before activation, water in the system is not being heated and is not flowing through the system. Upon activation, water enters the system through a water inlet and a heater heats the water to a desired temperature. Next, the heated water is delivered in pressurized pulses into a basket that contains flavor contains solid material. The pressurized pulsating water flow into the basket provides better water to ingredient surface contact and agitation for improved extraction of the brewed product. 
     Because the water is heated using a tankless system, the water can be heated to a more uniform temperature. This not only creates a more uniform brewing temperature but also helps prevent deposits in the tank. In the tank based systems, as water evaporates from the tank, a fill control adds cold supply water to keep it filled at a specific volume. This allows a virtually small steady stream of water that typically contains dissolved minerals. At each down cycle of the thermostat, the minerals in the water precipitate and slowly form a buildup on the walls and floor of the water tank as well as the heating coils. This affects the water volume in the tank and the energy needed to keep the water in the tank at the preset temperature. In the present invention, the precipitation of minerals is reduced to virtually zero because only a relatively small amount of relatively cool room temperature water is held in the heating block held at until needed,. 
     Other features and advantages of the present invention will become apparent upon reading the following detailed description of embodiments of the invention, when taken in conjunction with the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front view of the brewer in accordance with an embodiment of the present invention. 
         FIG. 2  is a side view of the brewer in accordance with an embodiment of the present invention. 
         FIG. 3  is a block diagram of the heater in accordance with an embodiment of the present invention. 
         FIG. 4  is a block diagram of the main heating block in accordance with an embodiment of the present invention. 
         FIG. 5  is a flow diagram depicting the steps used in accordance with an embodiment of the present invention. 
         FIG. 6  is a flow diagram depicting the steps used in accordance with an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     In the following detailed description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration, specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized. It is also to be understood that structural, procedural and system changes may be made without departing from the spirit and scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims and their equivalents. For clarity of exposition, like features shown in the accompanying drawings are indicated with like reference numerals and similar features as shown in alternate embodiments in the drawings are indicated with similar reference numerals. 
     Referring to  FIG. 1 , shown is tankless pulse brewer  102  containing control panel  104 , brew basket  106 , filter  110  and carafe  108 . Control panel  104  allows the user to control the operation of tankless pulse brewer  102  and is used to start an automated pre-determined brew cycle for brewing flavor containing solid material such as coffee or tea or a delayed start “autobrew” where the brewing starts at a pre-determined clock time. In addition, control panel  104  can create a brew cycle or adjust a predetermined cycle. For example, the adjustment to a predetermined cycle may be an adjustment to the volume of water used where the adjustment is made to the pulse count and/or percentage of by pass water used during a brewing cycle. (The use of a pulse count and by pass water will be described in more detail below.) Brew basket  106  contains the flavor containing solid material that is to be brewed and such material may be any flavor containing solid material that may be brewed such as coffee or tea. Carafe  108  captures and stores the brewed flavor containing liquid. 
       FIG. 2  is a side view showing water inlet  202 , water system  204 , basket water line  206 , by-pass water line  208 , and cold by-pass water line  210 . During use, tankless pulse brewer  102  is activated via control panel  104 . Upon activation, water enters through water inlet  202  and water system  204  either heats the water and delivers the heated water to brew basket  106  or does not heat the water and delivers the relatively cool water to carafe  108 . If the water is heated and delivered to brew basket  106 , the heated water may be delivered via basket water line  206  in pressurized pulses directly onto the flavor containing material contained in filter  110 . Alternatively, the heated water may be delivered to brew basket  106  away from the flavor containing material on the outside of filter  110  via by-pass water line  208 . The pressurized pulsating water flow emanating from basket water line  206  onto the flavor containing material contained in filter  110  provides better water to ingredient surface contact and agitation resulting in an improved extraction of the brewed product. The use of by-pass water line  208  allows for more hot liquid to be delivered to carafe  108  without excessive brewing of the flavor containing material. 
       FIG. 3  shows a detailed view of water system  204 . Water system  204  contains water supply inlet  302 , water supply cut off solenoid  304 , pressure regulator  306 , cold water by-pass solenoid  308 , water supply pressure switch  312 , main heating block  314 , by-pass heater block  324 , manifold  316 , cold water supply  318 , heater inlet  320 , main heating block outlet  322 , by-pass heating block outlet  330 , main heating block pulse counter  326 , and by-pass heating block pulse counter  328 . Main heating block  314  is connected to basket water line  206 . By-pass heating block  324  is connected to by-pass water line  208 . 
     Water supply inlet  302  is connected to water inlet  202 . Water supply cut off solenoid  304  regulates the flow of water into water system  204  and can be used to shut off the flow completely, allow water to freely flow into water system  204 , or in one embodiment, regulate the flow depending on the user&#39;s preferences. The flow may be regulated by the user via control panel  104  or may be regulated as part of an automated process. 
     Pressure regulator  306  regulates the pressure of the water entering water system  204  and in one embodiment the pressure is between about  30  psi and about  40  psi. Pressure switch  312  is used to monitor the water pressure to ensure the pressure is sufficient for brewing and there is not a leak within the tankless pulse brewer  102 . If pressure regulator  306  does detect a problem with the water pressure, pressure regulator  306  can activate water supply cut off solenoid  304  to shut off the flow of water into the system until the problem is resolved. 
     After the water has passed pressure regulator  306 , it is delivered to manifold  316 . Manifold  316  is operationally connected to main heating block  314 , by-pass heating block  324 , and cold water by-pass solenoid  308 . Main heating block  314  heats the water to a predetermined temperature and the heated water is delivered to the flavor containing material in brew basket  106  via basket water line  206 . By-pass heating block  324  heats the water to a predetermined temperature and the heated water is delivered to brew basket  106  via by-pass water line  208 . As stated above, by-pass water line  208  delivers the heated water outside filter  110  and away from the flavor containing material. The predetermined temperature is dependent on the temperature of the water needed to brew the flavor containing material or the desired temperature of the brewed liquid delivered to the carafe. 
     Cold water by-pass solenoid  208  does not heat the water and the unheated water is delivered to carafe  108  via cold by-pass water line  210 . In one embodiment, cold water by-pass solenoid  308  delivers unheated water directly to basket  106 . 
     Main heating block  314  and by-pass heating block  324  are identical in construction and may be used interchangeable in the description that follows. Main heating block  314  is show in more detail in  FIG. 4 . Main heating block  314  contains inlet  402 , check valve spring  404 , check valve ball  406 , water chamber  408 , thermal actuator spring  410 , thermal actuator  412 , at least one cartridge heater  414 , and outlet  416 . Check valve spring  404  and check valve ball  406  create a check valve and temporally prevent water flow from the inlet  402  into water camber  408 . In one embodiment, shown in  FIG. 4 , main heating block  314  contains two parallel chambers with each chamber housing cartridge heater  414 . 
     Inlet  402  accepts water sent from regulator  306 . Check valve spring  404  holds check valve ball  406  against water chamber  408  and does not allow water to enter water chamber  408  until the water inside water chamber  408  reaches a predetermine temperature. The predetermined temperature is the desired temperature of the brewed liquid delivered to the carafe and/or is the temperature needed to brew the flavor containing material. The predetermined temperature is typically between about 197 degrees to about 205 degrees Fahrenheit. 
     The water inside water chamber  408  is heated by cartridge heater  414  and when the temperature of the water inside water chamber  408  reaches the desired brewing temperature, thermal actuator  412  expands forcing check valve ball  406  away from water chamber  408  thus allowing the pressurized unheated water from inlet  402  to enter water chamber  408 . The pressurized water entering water chamber  408  from inlet  402  forces the heated water in water chamber  408  to exit through outlet  416 . When thermal actuator  412  is cooled by the cool incoming water, it retracts allowing the check valve ball  406  to reseat closing off the water flow. This open/close cycle produces a “pressurized pulse” wherein the pressure comes from the regulated water supply. The pressurized pulse is counted by main heating block pulse counter  326  and a signal is sent to control panel  104  where, as described below, the system determines if the brew cycle has completed. 
     Once the relatively cool pressurized water has entered water chamber  408 , thermal actuator  412  is cooled and contracts and check valve ball  406  is forced against water chamber  408  by check valve spring  404 . The cold water inside water chamber  408  is heated by cartridge heater  414  until thermal actuator  412  expands forcing check valve ball  406  away from water chamber  408  and the process is repeated until the brewing cycle is completed. Once the brewing cycle is completed, cartridge heater  414  is shut off, the water inside water chamber  408  is no longer heated, and thermal actuator  412  will not expand and force check valve ball  406  away from water chamber  408 . Because check valve ball  406  is held against water chamber  408 , water does not flow through the system and is held at room temperature until needed. Because the water is not heated until needed, the system creates a more efficient method for heating the water and reduces the precipitation of minerals to virtually zero. 
     By way of example and not of limitation,  FIG. 5 , shows the steps used during operation of the system. First the system is activated, Step  502 . Next, the brewing cycle is selected from control panel  104 , Step  504 . Then, the system opens water inlet  202 , Step  506  and the system determines if main heating block  314  should be activated, Step  508 . If the system determines main heating block  314  should not be activated, then the system determines if by-pass heating block  324  should be activated, Step  512 . If the system determines main heating block  314  should be activated, then the system activates cartridge main heating block  314 , Step  510  and continues to Step  512  where the system determines if by-pass heating block  324  should be activated, Step  512 . 
     If the system determines by-pass heating block  324  should not be activated, then the system determines if cold water by-pass solenoid  208  should be activated, Step  516 . If the system determines by-pass heating block  324  should be activated, then the system activates by-pass heating block  324 , Step  514  and continues to Step  516  where the system determines if cold water by-pass solenoid  208  should be activated, Step  516 . 
     If the system determines cold water by-pass solenoid  208  should be activated, then the system activates cold water by-pass solenoid  208 , Step  518  and continues to Step  520  where the system determines if the brewing cycle has completed, Step  520 . If the system determines by-pass heating block  324  should not be activated, then the system determines if the brewing cycle has completed, Step  520 . If the system determines the brewing cycle has completed, then the system enters into standby mode, Step  522 . If the system determines that the brewing cycle has not completed, then the system goes back to Step  508  and the process continues piecewise until the brewing cycle is completed. 
     As shown in  FIG. 6 , to active main heating block  314 , the system activates cartridge heater  414  in main heating block  314 , Step  602 . Then the water in main heating block  314  is heated to the predetermined temperature, Step  604 . Then, thermal actuator  412  expands forcing check valve ball  406  away from water chamber  408 , Step  606  and the valve created by check valve ball  406  seated on water chamber  408 , or check valve, is opened, Step  608 . As check valve ball  406  is forced away from water chamber  408 , the check valve is opened, and pressurized unheated water from inlet  402  is forced into water chamber  408 , Step  610 . The pressurized water entering water chamber  408  from inlet  402  forces the heated water to exit through outlet  416  and the expulsion or pulse is counted by pulse counter  326 , Step  612 . 
     When the unheated water from inlet  402  enters water chamber  408 , thermal actuator  412  is cooled, Step  614  and retracts allowing check valve ball  406  to reseat against water chamber  408  closing off the water flow, Step  616 . If main heating block  314  was used to heat the water, the hot water expelled or pulsed from water chamber  408  in Step  612  flows through basket water line  206  to the spray head above brewing chamber  106  and onto the flavor containing material. If by-pass heating block  324  was used to heat the water, the hot water expelled or pulsed from water chamber  408  in Step  612  and flows through cold by-pass water line  210  into brewing chamber  106  but away from the flavor containing material in brewing chamber  106 . It should be noted that the above process described for the activation of main heating block  314  can also be used to describe the activation of by-pass hearing block  324 . 
     When a brew cycle is selected from control panel  104 , control panel  104  determines the number of pulses from main heating block  314  and from by-pass heating block  324  required for the selected brew cycle. Control panel  104  also determines when main heating block  314  and by-pass heating block  324  should be activated during the brew cycle. In addition, control panel  104  calculates the volume of water necessary to flow through cold water by-pass solenoid  208  for the selected brew cycle and when by-pass solenoid  208  should be activated during the brew cycle. Control panel  104  then cycles through the above process and activates main heating block  314 , by-pass heating block  324 , and/or cold water by-pass solenoid  208  at the appropriate time. 
     By way of example and not of limitation, to brew less than one gallon of coffee, the brew cycle may only require the activation of main heating block  314  whereas to brew more than one gallon of coffee, the brew cycle may require the activation of main heating block  314  and by-pass heating block  324  so an proper amount of hot liquid can be produced without over brewing the flavor containing material. 
     To brew tea for use in iced tea, after the first pulse from main heating block  314 , by-pass solenoid  208  is activated allowing relatively cold or room temperature water to be added directly into carafe  108  via cold by-pass water line  210 . By adding the relatively cool or room temperature water directly into the carafe  108 , the relatively hot flavor containing liquid from brew basket  106  is cooled down to prepare the flavor containing liquid to be served with ice. 
     It should be understood that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.