Patent Abstract:
A mold barrier eliminates the establishment and continued resurgence of microbial colonies on product dispenser components routinely exposed to fluids and food products. The mold barrier may be utilized in a product dispenser to prevent the establishment of mold colonies on the product dispenser. The mold barrier adheres to potentially exposed surfaces to create an impenetrable boundary layer, thereby preventing the errant product from permeating into porous materials not suitable for product contact. Upon contacting the mold barrier, the errant product moves downward. Residues left from the errant product may be removed when the product dispenser and mold barrier are sanitized during routine cleansing operations. Upon sanitization, the product dispenser may be restored to a sanitized condition.

Full Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     The present invention relates to food product dispensing equipment and, more particularly, but not by way of limitation, to methods and an apparatus for creating a mold barrier in a food product dispenser.  
         [0003]     2. Description of the Related Art  
         [0004]     In the food product dispensing industry, product dispensers must conform to stringent design criteria to receive approval for public use from the National Sanitation Foundation. While National Sanitation Foundation approval does not guarantee the elimination of cleanliness problems, it does minimize the possibility of cleanliness issues. National Sanitation Foundation design criteria addresses all food contact components, as well as a food product dispensing area known as a “splash zone.” However, components disposed beneath or beyond the surfaces of the “splash zone” may prove to be problematic at a later time.  
         [0005]     The “splash zone” may include components that are removable for sanitizing purposes. While that solves the problems of sanitizing the “splash zone” components, it does not address items disposed beneath or behind the “splash zone” components. While a splash plate may serve as an effective means for containing sprays and spills, it is not fully effective. For instance, in drop-in ice cooled dispensing equipment, an area behind a splash plate often is routinely exposed to over sprays, spills, splashes, and the like. While the exposed portions of product dispensers are routinely sanitized, those components located behind the exposed portions may be hard to reach or are composed of materials not conducive to cleansing or sanitizing, and therefore may create future problems.  
         [0006]     As product dispensers are typically in the field for years, small cleansing issues normally out of view may fester for extended periods without proper attention. Illustratively, a foamed portion of a tower located directly behind a splash plate may be doused often with either a concentrate or a diluent or both. If untreated, the area may develop mold in the exposed area. Mold on any food product dispenser may be unsightly, cause a health risk, or if left untended, the mold may spread and ultimately force the condemnation of the product dispenser.  
         [0007]     Accordingly, a method and apparatus that eliminates the characteristics conducive to the establishment and continued propagation of a mold colony in a product dispenser would be beneficial to consumers, dispenser operators, food product producers, as well as the manufacturers of the food product dispensers.  
       SUMMARY OF THE INVENTION  
       [0008]     In accordance with the present invention, a method and apparatus for a mold barrier eliminates the establishment and continued resurgence of microbial colonies on product dispenser components routinely exposed to fluids or food products. The mold barrier provides an impenetrable barrier to fluids that may normally come into contact with permeable components, thereby preventing permeation of permeable components. The mold barrier may then be sanitized to restore the mold barrier, the product dispenser component, and the product dispenser on which the mold barrier is installed to a sanitized condition.  
         [0009]     The mold barrier adheres to potentially exposed surfaces to create an impenetrable boundary layer, thereby preventing the errant product from permeating into porous materials not suitable for product contact. Upon contacting the mold barrier, the errant product moves downward. Residues left from the errant product may be removed when the product dispenser and mold barrier are sanitized during routine cleansing operations. Upon sanitization of the mold barrier surfaces, the product dispenser may be restored to a sanitized condition.  
         [0010]     It is therefore an object of the present invention to provide a mold barrier for use on product dispenser components containing porous surfaces.  
         [0011]     It is a further object of the present invention to provide a product dispenser including a mold barrier.  
         [0012]     It is still further an object of the present invention to provide a method for eliminating the establishment and continued propagation of microbial colonies in a product dispenser.  
         [0013]     Still other objects, features, and advantages of the present invention will become evident to those of ordinary skill in the art in light of the following. Also, it should be understood that the scope of this invention is intended to be broad, and any combination of any subset of the features, elements, or steps described herein is part of the intended scope of the invention. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]      FIG. 1   a  provides a detail view of a product dispenser component cross section according to the subject invention.  
         [0015]      FIG. 1   b  provides an exploded view of the product dispenser component constituents according to the invention.  
         [0016]      FIG. 1   c  provides a perspective view illustrating the relationship between the mold barrier and an exposed surface of the product dispenser component according to the invention.  
         [0017]      FIG. 1   d  provides a flowchart illustrating the method steps for creating a mold barrier according to the invention.  
         [0018]      FIG. 2   a  provides a perspective view of a product dispenser utilizing a mold barrier according to the invention.  
         [0019]      FIG. 2   b  provides a flowchart illustrating the method steps for creating a mold barrier according to the invention.  
         [0020]      FIG. 3  provides a perspective view of a tower dispenser according to an illustrated example of the invention.  
         [0021]      FIG. 4  provides a detail view of a tower portion including a mold barrier according to the illustrated example.  
         [0022]      FIG. 5  provides an exploded view of a tower portion according to the illustrated example.  
         [0023]      FIG. 6  provides a section view of a tower head containing a mold barrier according to the illustrated example.  
         [0024]      FIG. 7  provides a flowchart illustrating the method steps for restoring a product dispenser to a sanitized condition according to the illustrated example. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0025]     As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. It is further to be understood that the figures are not necessarily to scale, and some features may be exaggerated to show details of particular components or steps.  
         [0026]     In a simplest form, a mold barrier  200  encapsulates porous components that may be utilized in a product dispenser, and may be potentially or temporarily exposed to environments or products that may contain bacteria or may serve as a platform for the establishment of a mold colony. The mold barrier  200  provides a sanitizable surface, thereby restoring the product dispenser components to a sanitized condition. As shown in  FIGS. 1   a - 1   d , a section  207  of a product dispenser component  205  includes an exposed surface  206 , section surfaces  208 , and the mold barrier  200 . The mold barrier  200  may include an inner face  201 , an outer face  202 , and section surfaces  209 . The product dispenser component  205  may be any type of component containing a porous surface as required by a product dispenser, including tubing, insulation, woven components, electrical harnesses, foam inserts, elastomeric seals, and the like. Product dispenser components  205  containing porous exposed surfaces are susceptible to permeation by fluids and malleable solutions including pastes and gels. Examples of fluids and pastes that may penetrate the porous surfaces include beverages and food products. Examples of material types for the various components may include fabrics, insulations, foams, elastomeric sealing components, wood cabinetry, and wood pulp based products.  
         [0027]     The mold barrier  200  is an impervious liner, and may be constructed from virtually any material of a nonporous nature that is resistant to common sanitization chemicals, polystyrene or ABS (acrylonitrile butadiene styrene), for example. Preferably, the mold barrier  200  is of a thin construction to minimize impact on an apparatus outside of its intended purpose. The mold barrier  200  may be flexible to conform to an irregular surface, or the mold barrier  200  may be applied as a spray that adheres to an exposed surface  206  of the product dispenser component  205  and forms a solid nonporous protective coating similar to a spray paint. The mold barrier  200  may further be constructed from other resins, metals, curing gelatins, pastes, ceramics, glass, and the like.  
         [0028]     As shown in  FIG. 1   b , the inner face  201  of the mold barrier  200  is placed adjacent to the exposed surface  206  of the component to encapsulate the exposed surface  206 . It should be clear to one of ordinary skill in the art that the relationship between the exposed surface  206  and the inner surface  201  of the mold barrier  200  is representative of the complementary surfaces of the product dispenser component  205  and the mold barrier  200  disposed about the product dispenser component  205 . The mold barrier  200  may be restrained in place utilizing mechanical restraints or the mold barrier  200  may be applied to the exposed surface  206  to form a curing film, thereby adhering to the exposed surface  206 . One of ordinary skill in the art will further recognize that product dispenser components  205  formed in place may be utilized to adhere to a preformed mold barrier  200 . Illustratively, a two-part foam may be shot into a foaming fixture containing a mold barrier  200 . During curing, the foam permanently adheres to components contacting the foam, including the mold barrier  200 .  
         [0029]     In use, the mold barrier  200  is placed adjacent to the exposed surface  206  of the product dispenser component  205 , such that the inner surface  201  of the mold barrier  200  is adjacent to and encapsulates the exposed surface  206  of the product dispenser component  205 . In this position, the exposed surface  206  of the product dispenser component  205  is protected from contact with fluids, errant product, weather factors, and airborne microorganisms. The impervious construction of the mold barrier  200  prevents fluids from penetrating the mold barrier  200  to reach the exposed surface  206  of the section  207 , as well as the product dispenser component  205 . The elimination of the porous exposed surface  206  being exposed to fluids prevents the saturation of the porous exposed surface  206  with organic fluids, product, or contaminated fluids, as well as any associated residues that remain after the porous exposed surface  206  dries. Fluids or products coming into contact with the mold barrier  200  remain on the outer surface  202  of the mold barrier  200  or move downward due to gravitational forces. Any residues remaining on the outer surface  202  may be removed and neutralized by wiping the outer surfaces  202  of the mold barrier  200  with a sanitizing solution, thereby restoring the product dispenser component  205  to a sanitized condition.  
         [0030]      FIG. 1   d  provides a flowchart illustrating the method steps associated with utilizing a mold barrier  200 . The process commences with step  25 , wherein a mold barrier  200  is placed adjacent to an exposed surface  206  of a product dispenser component  205 , such that an inner surface  201  of the mold barrier  200  encapsulates the exposed surface  206  of the product dispenser component  205 . Once in position, errant fluids or products may contact the outer surface  202  of the mold barrier  200  in lieu of contacting the exposed surface  206  of the product dispenser component  205 . As the mold barrier  200  is impervious, the fluids or product remain on the outer surface  202  of the mold barrier  200 . The process then continues with step  35 , wherein the outer surface  202  of the mold barrier  200  is sanitized by cleansing with a sanitizing solution, thereby restoring the outer surface  202  of the mold barrier  200  and the product dispenser component  205  to a sanitized condition.  
         [0031]     In an extension of this invention, a product dispenser  300  includes a housing  310 , at least one product dispensing circuit  311 , at least one product valve  312 , and a mold barrier  320 . The housing  310  may be any structure suitable for containing and supporting components of the beverage dispenser  300 . Illustratively, the housing  310  may include a frame  314 , and an insulation  315 . The frame  314  may include an attachment means for the product valve  312  and the product dispensing circuit  311 . The frame  314  may further support the insulation  315  such that the insulation  315  maintains temperatures of the product disposed within the housing  310 . Illustratively, the insulation  315  may be disposed around the outsides of the housing  310  or around components of the product dispensing circuit  311 .  
         [0032]     In this extension of the invention, the product dispensing circuit  311  is in communication with the product valve  312  and a product supply  313 , such that a product is delivered from the product supply  313  to the product valve  312 . The term product dispenser in this extension of the invention is defined to include dispensers of virtually all types of products including beverages and food product dispensers. Illustratively, examples of product types may include carbonated drinks, ambient drinks, juices, milks, teas, soups, condiments, sauces, flavored waters, and the like. The products may further require a diluent, in which case the product dispenser  300  could further include a diluent dispensing circuit  316  connectable to a diluent supply  317 .  
         [0033]     The mold barrier  320  is an impervious layer located adjacent to exposed porous surfaces on or about the housing  310 , thereby encapsulating the porous exposed surfaces of the insulation  315 , insulated product lines, electrical harnesses, and the like. In the installed position, the mold barrier  320  provides an impermeable layer around the surfaces of the insulation  315  that may become exposed to spills, sprays, or drops of a dispensed product. Illustratively, the areas located beneath the product dispensing valve  312  run a substantial risk of becoming exposed to errant product. In this extension of the invention, the mold barrier  320  may be a preformed component that may be secured to the insulation  315  using a variety of methods, or a sprayed on component. One of ordinary skill in the art will recognize that the mold barrier  320  may be flexible to complement the shape of product dispenser  300  components.  
         [0034]     In use, the product dispenser  300  receives a dispense command and delivers a product or a diluent or both to the product dispensing valves  312  for mixing and delivery into an operator&#39;s cup. During the execution of the dispense command, exposed faces of the product dispenser  300  may be exposed to over sprays, drips, and spills. The errant product lands on the mold barrier  320 , is unable to penetrate the mold barrier  320 , and is forced to move downward. As the errant product is unable to soak through the mold barrier  320 , the errant product will remain on the outer surfaces of the mold barrier  32 , and may be removed at a later time by an operator using a normal cleansing process. Illustratively, the operator may wipe the outer surface of the mold barrier  320  with a sponge soaked in a readily available sanitizing solution, thereby restoring the product dispenser  300  to a sanitized condition.  
         [0035]      FIG. 2   b  provides a method flowchart illustrating the method steps for eliminating surfaces conducive to the establishment of a microbial colony. The process commences with step  45 , wherein an impenetrable barrier is created on outside surfaces of potentially exposed components that include penetrable surfaces. The process continues with step  55 , wherein outer surfaces of the impenetrable barrier are sanitized to exterminate any microbial growth, thereby eliminating the continued propagation of microbial colonies on the impenetrable and the penetrable surfaces.  
         [0036]     While this mold barrier  320  has been disclosed as a thin layer about the product dispenser  300  components, one of ordinary skill in the art will recognize that the mold barrier  320  may be formed from other types of construction, including plastic wraps, shrink wrap, and anti-microbial materials. One of ordinary skill in the art will further recognize that the method of application and the thickness of the mold barrier  320  may vary with the form of construction. Illustratively, the mold barrier  320  could be brushed on or sprayed on either before or after assembly to create an impenetrable surface. Still further, the mold barrier  320  could be a preformed component suitably restrained to provide coverage to exposed porous surfaces, or even a preformed component adhered to the exposed porous surfaces.  
         [0037]     An illustrative example of a mold barrier application in a product dispenser is shown in  FIGS. 3-8 , wherein a product dispenser  100  includes a housing  110  having a lower portion  124 , and a tower assembly  125 . The product dispenser  100  may be designed to suspend from a counter, such that the tower assembly  125  protrudes from a counter top. The lower portion  124  may include a storage chamber  115  for storing ice until use, and may further include a cold plate  112  that serves as a floor of the storage chamber  115 , such that the cold plate  112  is cooled by the ice stored within the storage chamber  115 . Access to the storage chamber  115  is gained through an access port  116  of the storage chamber  115 .  
         [0038]     The lower portion  124  may still further include fluid flow paths  133  containing inlets  138  and outlets  139  connectable to a product source and a diluent source for the delivery of a diluent and a concentrate to the outlets  139  and the tower assembly  125 . In this illustrative example, the outlets  139  are disposed at an upper end of the lower portion  124 , such that they are accessible from the top. The concentrate and diluent flow paths may be conditioned by the cold plate  112 , and may include flow metering and control devices commonly utilized in a product dispenser for the regulation of fluids disposed within the flow paths. The housing  110  may further include a drip tray  118  that collects spills, sprays, and drips from dispensing operations. The drip tray  118  may further close out the storage chamber  115  to protect and insulate the ice.  
         [0039]     The tower assembly  125  includes a tower head assembly  150 , a shroud  130 , a shroud cap  131 , and a splash plate  120 . The tower head assembly  150  includes a tower head  151  and product dispensing valves  135 . The tower head  151  may include product and diluent flow paths  153 , an insulation  152 , a mold barrier  160 , a face plate  154 , and a pry bracket  155 . In this illustrative example, the product and diluent flow paths  153  include inlets  164  for communicating with the outlets  139  of the product and diluent flow paths  133  of the lower portion  124  and outlets  165  for communicating with the inlets of the product dispensing valves  135 .  
         [0040]     The shroud  130  is of a sheet metal construction, preferably stainless steel to meet cleanability requirements. The shroud  130  is adaptable to the lower portion  124  and the face plate  154  to surround and protect the tower head  151 . The shroud cap  131  is also constructed from stainless steel, and is utilized to close out a top of the tower head assembly  150 . The splash plate  120  is similarly constructed from stainless steel to meet cleanability requirements. The splash plate  120  is removable, and is used to close out the portion of the tower assembly  125  disposed beneath the product dispensing valves  135 .  
         [0041]     The insulation  152  is of a closed cell construction, preferably a two part urethane. The insulation  152  surrounds the product and diluent flow paths  153 , thereby insulating the product and diluent flow paths  153 . In this detailed example, the insulation  152  is formed in a foaming fixture to simplify the insertion of the insulation  152  around the product and diluent flow paths  153 .  
         [0042]     The mold barrier  160  is disposed around the insulation  152  to provide an impermeable layer around the surfaces of the insulation  152  that may become exposed to spills, sprays, or drops of a dispensed product. Illustratively, the areas located beneath the product dispensing valve  135  and behind the splash plate  120  run a substantial risk of becoming exposed to errant product. In this detailed example, the mold barrier  160  is a preformed thirty thousandths of an inch polystyrene sheet that may be secured to the insulation  152  using a variety of methods. The mold barrier  160  includes a planar face  171  having a first flange  173 , a second flange  174 , a third flange  172 , and a fourth flange  178 . The planar face  171  is complementary in shape to a front face  157  of the tower head  151 . The flanges  172 ,  173 ,  174 , and  178  extend in a direction towards the tower head  151 , such that they are adjacent to a first side  181 , a second side  182 , and a third side  183  of the tower head  151 . One of ordinary skill in the art will recognize that the mold barrier  160  may include additional flanges or adjoining sides to further complement the shape of the tower head  151  or additional components. The mold barrier  160  further includes a first relief  175  in the first flange  173 , a second relief  176  in the second flange  174 , and a third relief  177  in the fourth flange  178 . The first relief  173  and the second relief  174  allow the mold barrier  160  to pass over an installed pry bracket  155 . The third relief  177  allows for the passage of the product and diluent flow paths  153  through to the lower portion  124 . Illustratively, the mold barrier  160  may be placed into a foaming fixture that is filled with a curing foam, thereby permanently attaching the mold barrier  160  to the insulation  152 , or the preformed sheet may be secured using adhesives, or mechanical fasteners.  
         [0043]     The face plate  154  and the pry bracket  155  may be constructed from formed stainless steel, and may include apertures to accommodate the inlets  164  or outlets  165  of the product and diluent flow paths  153 . The outlets  165  of the product and diluent flow paths  153  may pass through the apertures in the face plate  154  for alignment during foaming operations. The inlets  164  of the product and diluent flow paths  153  may pass through the apertures of the pry bracket  155  to gain access to the lower portion  124 . The pry bracket  155  further includes attachment points for connection to the shroud  130 .  
         [0044]     In this illustrative example, the tower head  151  is assembled utilizing a foaming fixture. Assembly commences with the insertion of a mold barrier  160  into the foaming fixture. In a foaming position, the mold barrier  160  nests in the foaming fixture, and substantially lines the walls of the foaming fixture. Next, the product and diluent flow paths  153 , the pry bracket  155  and the face plate  154  are oriented in the foaming fixture. The inlets  164  of the product and diluent flow paths  153  are positioned in the apertures of the pry bracket  155 , such that they are in positions complementary to the outlets  139  of the fluid flow paths  133  disposed in the lower portion  124 . The outlets  165  of the product and diluent lines  153  are then located in the apertures of the face plate  154 , such that the locations of the outlets  165  are complementary to the spacing of the inlets of the product dispensing valves  135 . The pry bracket  155  is then oriented in the first relief  175  and the second relief  176 , such that the pry bracket  155  is fully inserted into the first relief  175  and the second relief  176 . Once fully inserted, the foaming fixture may be closed, and a two part foam may be injected into the foaming cavity. Upon curing, the two part foam adheres to the face plate  154 , the pry bracket  155 , the product and diluent flow paths  153 , and the mold barrier  160 , and then hardens to form an integral tower head  151 . Once cured, the product and diluent flow paths  153  and the mold barrier  160  in the tower head  151  are permanently located in position, and the tower head  151  may be installed or removed as a unit. As shown in  FIG. 6 , the mold barrier  160  lines the front face  157  of the tower head  151  and extends to adjacent faces, thereby sealing the potentially exposed surfaces of the tower head  151 .  
         [0045]     Upon further assembly, the tower head  151  is mounted to the lower portion  124  of the product dispenser  100  such that the outlets  139  of the lower portion  124  are coupled to the inlets  164  of the tower head  151 . The product dispensing valves  135  may then be installed onto the face plate  154  of the tower head  151  such that the inlets of the product dispensing valves  135  are coupled to the outlets  165  of the product and diluent flow paths  153  of the tower head  151 , thereby completing the product and diluent delivery circuits. The shroud  130  may then be installed to protect the tower head  151 . The build continues with the installation of the shroud cap  131  onto the open portion of the shroud  130 . The installation of the splash plate  120  follows, thereby fully encapsulating the tower head  151  behind the shroud  130 , the cap  131 , and the splash plate  120 . As the splash plate  120  is removable for cleaning, the area directly behind the splash plate  120  may occasionally be exposed to splashes, drips, or sprays when the splash plate  120  is incorrectly installed or removed from the product dispenser  100 .  
         [0046]     In use, when the product dispenser  100  receives a dispense command, it delivers a product or a diluent or both to one of the product dispensing valves  135  for mixing and delivery into an operator&#39;s cup. In cases where the splash plate  120  is removed during the execution of a dispense command, exposed faces of the tower head  151  may be exposed to oversprays, drips, and the like. The errant product lands on the planar face  171  of the mold barrier  160  on the tower head  151 , is unable to penetrate the mold barrier  160 , and is forced to move downward. As the errant product is unable to soak into the mold barrier  160 , the errant product may be removed at a later time by an operator using a normal cleansing process, illustratively, wiping the tower head  151  with a sponge soaked in a readily available sanitizing solution, thereby restoring the product dispenser  100  to a sanitized condition.  
         [0047]      FIG. 7  provides a method flowchart illustrating the method steps for eliminating surfaces conducive to the establishment of a microbial colony. The process commences with step  10 , wherein an impenetrable barrier is created on outside surfaces of potentially exposed components that include penetrable surfaces. The process continues with step  20 , wherein outer surfaces of the impenetrable barrier are sanitized to exterminate any microbial colonies, thereby eliminating the continued propagation of microbial colonies on the impenetrable and the penetrable surfaces.  
         [0048]     While this mold barrier  160  has been disclosed as a formed sheet of polystyrene that is foamed in place, one of ordinary skill in the art will recognize that the mold barrier  160  may be formed from other types of construction, including plastics, plastic wraps, shrink wrap, and anti-microbial materials. One of ordinary skill in the art will further recognize that the method of application and the thickness of the mold barrier  160  may vary with the form of construction. Illustratively, the mold barrier  160  could be brushed on or sprayed on either before or after the tower head  151  is foamed to create an impenetrable surface.  
         [0049]     Although the present invention has been described in terms of the foregoing preferred embodiment, such description has been for exemplary purposes only and, as will be apparent to those of ordinary skill in the art, many alternatives, equivalents, and variations of varying degrees will fall within the scope of the present invention. That scope, accordingly, is not to be limited in any respect by the foregoing detailed description; rather, it is defined only by the claims that follow.

Technology Classification (CPC): 0