Abstract:
A carbonator tank assembly is disclosed for use in a beverage machine wherein the beverage dispensed therefrom is a carbonated beverage. The carbonator tank includes walls defining a carbonator tank interior. A probe assembly is provided for coupling in a gaseous and fluid-type manner to the walls of the carbonator tank. The probe assembly has no floats but includes elongated probes having removed ends configured to extend into the interior of the carbonator tank and near ends exposed exteriorly. An electronics module is adapt to fluidly enclose an electronics assembly therein. The electronics module includes walls adapted to receive an electrical cable carrying electrical energy from a remote source.

Description:
[0001]    This application claims the benefit of and incorporates herein by reference, U.S. Provisional Application Ser. No. 61/548,878, filed Oct. 19, 2011. 
     
    
     FIELD OF THE INVENTION 
       [0002]    Carbonators, more specifically, carbonator fluid level sensors and control mechanisms. 
       BACKGROUND OF THE INVENTION 
       [0003]    Carbonators are known in the prior art to take plain water and carbonate it with pressurized CO 2 . The soda water may be used for mixing with syrup in ways known in the art to provide a dispensed drink, such as Coca Cola, Dr Pepper, Pepsi Cola or the like. 
         [0004]    Carbonators include CO 2  pressurized tanks engaged to a pump for pumping plain water thereinto. Electronic float control mechanisms may be used to turn the pump on and off responsive to the level of water in the tank of the carbonator. When the water gets low, a probe senses a low water condition and energizes the pump for providing water into the tank and, when the tank water level reaches a maximum, the electronic probe may sense the level and shut off the pump in ways known in the art. 
       SUMMARY OF THE INVENTION 
       [0005]    Applicants provide an electronic mechanism, including probes and circuitry, for measuring the fluid level of soda water in a carbonator. Applicants separate elements of an electronic control assembly and provide for a modular electronics component having a housing and a base, which together removably engage a separate probe assembly, which probe assembly includes a multiplicity of probes for depending into the interior of the carbonator tank. 
         [0006]    The probe assembly is fluidly and gaseously sealed against a mounting plate on the tank and is separate from a housing containing electronic elements of a fluid level sensor. Easy fastener engagement of the electronics module to the probe assembly is provided, such that the electronics module can be removed (for offsite testing, for example) from the probe assembly, which will remain on the pressurized carbonator. The structure of Applicants&#39; carbonator tank assembly allows for maintaining pressure in the carbonator tank with the sensor elements engaged therewith while removing the electronic elements contained in a separate electronics module for offsite servicing. 
         [0007]    Other than fasteners and the probe conductors themselves, the elements of the probe assembly are typically made of a hard, non-conductive, durable material and contain O-rings to fluidly and gaseously seal them from other elements of the carbonator tank assembly. Likewise, the electronics module is comprised of a hard durable, non-conductive material, excepting the fasteners and the electronic components thereof. O-rings and other fluid/gaseous sealing means are provided to fluidly seal the electronics module from the probe assembly, and from the probe assembly mounting plate. 
         [0008]    By the structure of Applicants&#39; multiple probes, it may accurately record fluid level at almost any carbonator tank tilt angle. Carbonator tanks are usually maintained upright, but may, on occasion, move to an out-of-normal angle and Applicants&#39; probe provides generally accurate readings at such off-normal angles. 
         [0009]    Applicants&#39; probe avoids the need of moving parts as, for example, in prior art switch-type float probes. Moreover, Applicants&#39; electronics module, in a fluid insulated sealed container, receives 110 volts or other high voltage AC source, and steps it down (and, in one embodiment, rectifies) before that source engages the probe assembly and the probes depending therefrom. Thus, there is no direct contact for high voltage AC between the electrodes and the fluid. The  110  volts is completely insulated and isolated from the carbonated water in the tank through the use of non-conductive materials, and the only conductive contacts with the tank water are low voltage DC or AC probe ends and through removable couplings from electronic module, contacts to probes of the probe assembly. 
         [0010]    A carbonator tank assembly is disclosed for use in a beverage machine wherein the beverage dispensed therefrom is a carbonated beverage. The carbonator tank includes walls defining a carbonator tank interior. A probe assembly is provided for coupling in a gaseous and fluid-type manner to the walls of the carbonator tank. The probe assembly has no floats but includes elongated probes having removed ends configured to extend into the interior of the carbonator tank and near ends exposed exteriorly. An electronics module is adapt to fluidly enclose an electronics assembly therein. The electronics module includes walls adapted to receive an electrical cable carrying electrical energy from a remote source. Elements within the electronics module, such as integrated circuits, receive the electrical energy from the cable and provide it to electrodes extending from the walls of the electronics module. The electrodes and the electronics module are adapted to removably couple to the probe assembly such that the electrodes provide energy from the electronics assembly located in the interior of the electronics module and receive signals back from the probes and provide these signals to the electronics assembly. The signals are a function of an immersed/exposed condition of the removed ends of the probes, the immersed/exposed conditions reflecting an immersion or exposure to the fluid level in the carbonator tank of carbonated fluid. The signals received by the electronics assembly are sent to the pump and other elements of the dispensing assembly to control the pump so as to provide water to the carbonator tank responsive to a low-fluid signal. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]      FIG. 1A  is a top elevational view of the housing of the electronics module of the carbonator tank assembly. 
           [0012]      FIGS. 1 ,  2 , and  2 A are cross-sectional views of Applicant&#39;s carbonator level control mechanism  10  engaged to carbonator tank  12  through section E ( FIG. 1 ) section C ( FIG. 2 ), and section G ( FIG. 2A ). 
           [0013]      FIGS. 1 and 2  are cross-sectional views through the sections set forth in  FIG. 1A  above. 
           [0014]      FIG. 3  illustrates a bottom perspective view of the electronics module  16  with a base  24  engaged to housing  22 , the view illustrating most predominantly the bottom or lowest surface of the base. 
           [0015]      FIG. 3A  is a detail cross-sectional view of the housing to cable connection. 
           [0016]      FIG. 4  is a top perspective view of the probe assembly of Applicant&#39;s carbonator level control mechanism illustrating most prominently an upper surface of the base thereof. 
           [0017]      FIG. 5  illustrates a top perspective view of the probe assembly mounting plate. 
           [0018]      FIG. 6  illustrates a perspective top view of the assembly without the electronics module housing (showing the top surface of the base of the electronics module) and without the tank. 
           [0019]      FIG. 7  illustrates the bottom perspective view of the probe assembly mounting plate. 
           [0020]      FIGS. 8 and 9  illustrate side perspective views of the assembly together and exploded, respectively. 
           [0021]      FIG. 10  illustrates in cross-sectional view, the various water levels as they interact with the probes. 
           [0022]      FIG. 11  illustrates the carbonator tank with a carbonator control module engaged therewith as part of a carbonated beverage dispensing system. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0023]      FIGS. 1-10  illustrate a carbonator tank assembly  10 , including a carbonator tank  12  having a probe assembly mounting plate  70  welded (typically a filet weld) thereto. Probe assembly mounting plate  70  is adapted to receive a probe assembly  42  having a multiplicity of probes  50 / 52 / 54  (short, medium, long) thereon for depending into the interior of tank  12 . Probe assembly  42  is adapted to be removably engaged to probe assembly mounting plate  70  in a fluid and gas sealing manner. Probe assembly mounting plate  70  engages tank top  12   a  by welds so as to be completely sealed to top  12   a  in a gaseous and fluid sealing manner. Adapted to be receivably and removably engaged to probe assembly  42  is an electronics module  16 , which electronic module  16  includes a housing  22  removably engaged to a base  24 . 
         [0024]    Turning to  FIGS. 1 ,  1 A,  2 , and  2 A, it is seen that fluid level assembly  14  comprises electronics module  16  removably engaging probe assembly  42 . Probe assembly  42  includes a base  43 , which typically remains fixed by fasteners to probe assembly mounting plate  70 . Electronics module  16  is removably attached to the base of probe assembly  42  with only fasteners and it may thus be seen that electronics module  16  can be removed from the probe assembly of carbonator tank assembly  10 , so as to service the electronic portion of the carbonator tank assembly  10  without depressurizing the tank or removing the probe assembly  42 . Probe assembly  42  removably seals to probe assembly mounting plate  70  and may stay engaged thereto. 
         [0025]    Indeed, the modular nature of Applicant&#39;s carbonator tank assembly  10  may be appreciated with reference to  FIGS. 1 ,  1 A,  2 ,  2 A, and  9 . It is seen that a housing  22 , typically for enclosing electronic elements, has an interior thereof. In one embodiment, mounted in the interior thereof is at least a first integrated circuit  18  and a second integrated circuit  20 . The first integrated circuit is adapted to receive 110 volts AC from electrical cables  19  through a control connector clip  25 . In one embodiment, first integrated circuit  18  functions, among other things, to rectify the AC and second integrated circuit  20  may step down DC voltage to the range of about 24 to about 12 volts. Thus, it is seen that, in one embodiment, probes  50 / 52 / 54  receive only low voltage DC through the electronics assembly contained within housing  22 . 
         [0026]    An electrical conductor cable  23  typically engages an upper portion of housing  22  through retainer nut  21 , control cable  23  carrying one or more electrical wires  19  therethrough to engage the electronics within the housing, including the integrated circuits  18 / 20  thereof. Electronics, including integrated circuits  18 / 20  thereof, will provide low voltage AC or DC through contacts  32 / 34 / 36 , which contacts may be spring loaded. These contacts, when electronics module  16  is nested and plugged into probe assembly  42  will contact in electrically coupled fashion the exposed near ends  50   c / 52   c / 54   c  (see  FIG. 4 ) of probes  50 / 52 / 54 . 
         [0027]    It is to be understood that housing  22  engages base  24  (the two comprising the electronics module) in fluid sealing relation. Moreover, it is seen that base  24  provides electrical engagement for the removed ends of probes  50 / 52 / 54  through a water-tight engagement of elements  32 / 34 / 36  extending through the base. Moreover, an O-ring  21   a  is provided (see  FIG. 3A ) where control cable  23  usually carrying AC voltage extends through retainer nut  21 . O-ring  21   a  is provided (see  FIGS. 1 and 3A ), where cable  23  passes through retainer nut  21  and into the interior of housing  22 . It is seen that O-ring  21   a  provides fluid-tight sealing for both retainer nut/housing and cable/housing interfaces. Thus, it is seen that housing  22  and base  24  provide an electronics module  16  that is water-tight and is removable from probe assembly  42  with fasteners or other suitable means in a manner that does not require depressurization of the carbonator tank. 
         [0028]    As seen in  FIGS. 9 ,  10 , and  11 , probe assembly  42  acts as a water level control sensor and is arranged in the carbonator tank  12 , such that, when carbonated water in carbonator tank  12  falls under a predetermined level b, it actuates a pump to supply water from water supply Water coming from water supply may be cooled by a cooling coil that is immersed in a cooling tank before it is fed into the carbonator tank  123 . When carbonated water rises above level C, the pump will shut off. 
         [0029]    Probe assembly  42  may include O-rings  43   a  which may engage extended member or arm  48  of base  43  as seen in  FIG. 2  to fluidly seal against the side walls of probe assembly mounting plate  70 . The near ends of the probes extend through base  43  in ways known in the art in a fluid and gaseous-tight seal so there is no leakage of fluid or gas either where base  43  engages probe assembly mounting plate  70  or where base  43  engages the probes extending through it. Thus, electronics module  16  itself removably couples with electronic connection to the removed ends of the probe, which probe assembly itself is fluidly sealed and gaseously sealed from the contents of the carbonator tank. 
         [0030]    The three probe arrangement may be provided for sensing low fluid, high fluid, and return (see  FIG. 10 ). However, other arrangements may be used. Here, electronics module  16  includes a base  24  removably attached to the housing  22  therethrough to a multiplicity, here, four, fasteners  26  on housing  22 . Fasteners  26  engage the lower surface  24   a  of base  24  and engage threaded fastener shoulders  27  on housing  22  (see  FIGS. 1 and 2 ). O-rings  29  are compressed as fasteners  26  thread into fastener shoulders  27  and pull base  234  against housing  22 . 
         [0031]    Attention now is drawn to base  24  of electronics module  16 . More specifically, with reference to FIGS.  1 , 2 , and  3 , it is seen how base  24  includes plug  28  extending downward from lower surface  24   a  (reference  FIG. 3 ) which will plug, in a fluid sealing manner with O-rings, into a cavity  46  in upper surface  44  of base  43  of probe assembly  42 . Here, four elongated fasteners  37  are spaced around the exterior of housing  22  on shoulders  38 . These electronics module-to-probe assembly fasteners  37  are seen to pass through holes  37   b  in base  24  so that removed ends  37   a  of fasteners  37  extend below lower surface  24   a  of base  24 . These removed ends  37   a  thread into threaded recesses (four)  61  for receiving the removed ends  37   a , so as to removably fasten the electronics module  16  to probe assembly  42 . That is to say, removal of four easily accessible fasteners  37 , when threaded out of engagement with threaded recesses  61 , will allow one to unplug the frictionally held plug  28  to cavity  46  engagement to separate the electronics module  16  from the tank  12  without affecting the position or engagement of the probes to the tank. Following such removal, if desired, base  24  can be threadably removed and retainer nut removed so electronics module  16  is easily sent away for service or testing. 
         [0032]    Turning now to  FIGS. 3 ,  4 ,  4 A,  5 ,  5 A, and  6 , the details of the engagement of the base to the housing to comprise a fluid-tight electronics module and then the electronics module to the fluid and gaseously sealed probe assembly and the probe assembly to the probe mounting plate may be appreciated. It is seen with reference to  FIG. 3  that lower surface  24   a  of base  24  is seen to have a small alignment pin  39  and two large alignment pins  40 , which will allow only a one-way (rotationally speaking) engagement to the one small alignment hole  62  and the two large alignment holes  64  in the engagement of upper surface of base  43  of the probe assembly  42 . This one-way alignment ensures that electonics module contacts  32 / 34 / 36  engage the correct exposed near end  50   c / 52   c / 54   c  of probes  50 / 52 / 54  (short, medium, long).  FIG. 3  also shows the manner in which fastener recesses  26   a allow for recessing the heads of fasteners  26 , which fasteners, here four, will hold the module base  24  to the housing  22  as set forth above. Additionally,  FIG. 3  illustrates how an alignment tab  24   b  pointing upward from the top of base  24  removably engages a cutout  22   a  in the lower perimeter of the housing to allow one-way (rotationally speaking) alignment of base  24  to housing  22 . 
         [0033]    Turning back again to  FIG. 3 , four holes  37   b  are seen to allow removed ends  37   a  of fasteners  37  to pass through base  22  so they may removably engage the four threaded recesses  61  in the base  43  of probe assembly  42 . 
         [0034]    Turning to  FIG. 4 , elements, structure and function of probe assembly  42  may be appreciated. Probe assembly  42  includes a multiplicity, here three probes  50 / 52 / 54  (short, medium, long) molded integral (or by epoxy or other suitable sealing means) to and into near the upper ends thereof of an arm  48 . Arm  48  is configured with O-rings  43   a  thereon to slide and fluidly seal into cylindrical channel  82  of probe assembly mounting plate  70 . Fasteners (typically, four)  60  are provided here for removably engaging probe assembly  42  to probe assembly mounting plate  70 . Fasteners  60  are received in recesses  60   a , which recesses are in the upper surface  44  of base  43 . Using recesses in the various elements, including the lower surface  24   a  of base  24  and upper surface  44 , allow the surfaces of the bases to sit flush against each other as plug  28  removably and fluid sealingly engages cavity  46  of probe assembly  42  as best seen in  FIGS. 1 and 2 . 
         [0035]    The underside of probe assembly  42  as seen in  FIG. 7  is seen to include an alignment pin  59  (ghosted in). Alignment pin  59  will allow the position of probe assembly  42  to be fixed with respect to the tank as alignment pin  59  will be received in alignment pin hole  78  of probe assembly mounting plate  70  (see  FIGS. 2 and 9 ). Thus, the configuration or position of the near ends of the three probes will always be fixed both with respect to the tank and with respect to contacts  32 / 34 / 36 . This is important as signals, such as conductivity of water, are analyzed in terms of the probes received therefrom to electrify or shut off the pump (not shown) so as to control the level of water in the carbonator tank. Upper surface  44  of base  43  is seen to have a cavity  46 , which has cavity bottom wall  46   a . Arm  48  extends below cavity bottom wall  46   a and sealingly and moldingly and sealingly receives probes  50 / 52 / 54 , such that no gas or fluid can leak between the probes and their engagement and molding in arm  48 . 
         [0036]    Probes include insulation sheaths  50   a / 52   a / 54   a . Within the sheaths are conductors,  52   b / 52   b / 54   b , such as stainless steel rods. The removed ends  50   d / 52   d / 54   d  are exposed so they may engage the fluid level and measure the fluid level of the water. 
         [0037]    Turning now to  FIGS. 2 and 5A , probe assembly mounting plate  70  is provided. It includes a base  74  having a top surface  72 . Top surface  72  includes four threaded fasteners holes  76  for threadable receipt of removed ends of fastener  60  thereinto, so as to removably engage the probe assembly  42  to the probe assembly mounting plate  70 . Dependent portion  80 , which may be cylindrical, extends through cutout in the top  12   a  of tank  12  and a weld is provided as best seen in  FIG. 1 , the weld provided where the dependent portion  80  passes through the cutout  12   b.    
         [0038]    Turning to  FIG. 10 , it is seen that probe assembly  42  with probes  50 / 52 / 54  may sense several different fluid levels A, B, and C in the interior of tank  12 . As set forth hereinabove, electronic elements within the electronic module will, in one embodiment, rectify AC to DC and step down the DC voltage, which stepped-down voltage may be applied, one polarity to probes  50 / 52  and the opposite to probe  54 . In this condition, fluid at level C will prompt signals from  50 / 52  to return  54  and, through logic elements of the circuits, will detect “too high fluid” level and send a signal to shut off the water pump. Current flow from probes  52  to  54  will allow the pump to continue pumping, as seen at level B, for example. Dropping below the removed end of probe  52  will generate a no-current signal and prompt a signal to pump control elements (not shown) to generate water flow to the tank, thus maintaining fluid between B and C. 
         [0039]      FIG. 11  shows the carbonator tank with Applicant&#39;s novel carbonator tank assembly  10  engaged therewith as part of a carbonated beverage dispensing system  100 . The beverage dispensing system  100  may take any configuration that includes the need for carbonated water. In the configuration shown in  FIG. 11 , carbonator tank  12  receives high-pressure CO 2  from a high-pressure CO 2  source in ways known in the art. Carbonated water out may be provided to a beverage dispensing tower or in a bar gun or any other beverage dispensing device or head. Ambient water from a water source may be provided directly to the carbonator tank or, as shown, through a cooling cabinet that provides chilled water to a water pump/pump motor which in turn provides the chilled water in to the carbonator tank responsive to immersed/exposed condition of the removed ends of the probe of the probe assembly  42 . A cooling cabinet may be provided for one or all elements of the assembly and the chilled water out from the water source may be chilled by means known in the art, including a cold plate. 
         [0040]    Although the invention has been described in connection with the preferred embodiment, it is not intended to limit the invention&#39;s particular form set forth, but on the contrary, it is intended to cover such alterations, modifications, and equivalences that may be included in the spirit and scope of the invention as defined by the appended claims.