Abstract:
A fermentation pressure relief, anti-oxidation and visual observation apparatus and related method, comprising: a collar with an opening therethrough capable of sealably mating to a fermentation vessel lid atop a fermentation vessel; and a flap attached to the collar via a flap-to-collar attachment and situated atop the collar opening to seal the opening when substantially no upward pressure subsists against the flap such that entry of air or other matter downward through the opening is substantially barred; wherein, when the apparatus is attached to the fermentation vessel lid: when pressure subsists within the fermentation vessel the pressure causes the flap to slightly separate from the collar opening and is thereby is permitted to bleed out between the flap and the collar opening through the separation; and after the pressure has bled out the separation is reversed and the flap reverts to a position wherein it again seals the opening, by virtue of the pressure having been bled out.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims benefit of pending U.S. provisional application 61/735,747 filed Dec. 11, 2012, which is hereby fully incorporated by reference into this application. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    One of the most popular fermentation vessels for brewing fermented beverages being used today consists of an opaque bucket or pail with a tightly affixed opaque lid into which is fitted with an airlock. The airlock is a small device that allows gas to escape through a liquid filled, narrow diameter convoluted tube. 
         [0003]    Specifically, the fermenting process causes a thick foamy product to form on the surface of the beer as it is fermenting. This is called krausen. 
         [0004]    This krausen often exceeds the volume of the fermenting bucket and causes problems, which can vary from beer-splattered ceilings to messy floods. 
         [0005]    The current lids on fermenting buckets have a small hole drilled in them where a gasket is inserted and into the gasket is placed an airlock, which is a small liquid filled device that allows carbon dioxide to escape while keeping outside air from getting into the bucket. If the krausen reaches this airlock it clogs and pressure builds until the lid pops causing the above problems. Samples of the beer as it is fermenting are often taken during the various stages and this requires opening the lid on the fermenter allowing introduction of air and the possibility of contamination. 
         [0006]    The current lids are opaque and do not allow any visual inspection of the beer&#39;s progress unless once again the lid is removed. 
         [0007]    Additions of ingredients into the fermenter also require popping the lid and again possibly causing problems. 
         [0008]    Thus, following are some of the problems using such prior art fermenter and airlock systems: 
         [0009]    1. Airlocks can easily and often do become clogged. This can lead to excessive pressure from the production of carbon dioxide in the fermenting vessel. This pressure may push through the clogged airlock spraying the vessel&#39;s contents into the surrounding area. If the clog in the airlock is not blown out the pressure can build to where it blows the entire lid off the bucket causing very messy and possibly dangerous results. 
         [0010]    2. Airlocks are also used to verify that the fermentation process is taking place. Gas bubbling through the airlock shows the production of carbon dioxide indicating active fermentation. This check for activity can only take place if the lid forms a true airtight seal with the bucket and there is an airtight seal where the airlock is inserted. If carbon dioxide escapes through the bucket-lid seal or the airlock seal the airlock will not show activity and fermentation cannot be verified. 
         [0011]    3. If there is a failure in the bucket-lid seal and the airlock shows no activity the only other means of checking fermentation progress is through visual inspection. This removal and reapplication of the lid causes early deterioration of the sealant in the lid as well as deformation to both the lid and the bucket. 
         [0012]    4. During the fermentation process access to the fermenting vessel is often required in order to add ingredients or to withdraw samples for testing. This is done by removing the lid from the bucket or pail. This removal and reapplication of the lid causes early deterioration of the sealant in the lid as well as deformation to both the lid and the bucket. 
         [0013]    5. With the repeated removal and reapplication of lids the layer of carbon dioxide (often referred to as a CO2 blanket) that is formed in the fermenting vessel can be disturbed. If this layer of carbon dioxide is disturbed the fermenting liquid can come in contact with oxygen causing oxidation which will ruin the contents. 
         [0014]    6. With the repeated removal and reapplication of the lid the removed lid as well as the entire surface of the fermenting liquid is exposed to airborne contaminants resulting in the possibility of infection. 
       SUMMARY OF THE INVENTION 
       [0015]    A fermentation pressure relief, anti-oxidation and visual observation apparatus and related method, comprising: a collar with an opening therethrough capable of sealably mating to a fermentation vessel lid atop a fermentation vessel; and a flap attached to the collar via a flap-to-collar attachment and situated atop the collar opening to seal the opening when substantially no upward pressure subsists against the flap such that entry of air or other matter downward through the opening is substantially barred; wherein, when the apparatus is attached to the fermentation vessel lid: when pressure subsists within the fermentation vessel the pressure causes the flap to slightly separate from the collar opening and is thereby is permitted to bleed out between the flap and the collar opening through the separation; and after the pressure has bled out the separation is reversed and the flap reverts to a position wherein it again seals the opening, by virtue of the pressure having been bled out. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]    The features of the invention believed to be novel are set forth in the appended claims. The invention, however, together with further objects and advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying drawing(s) summarized below. 
           [0017]      FIG. 1  illustrates a preferred, non-limiting embodiment of applicant&#39;s fermentation gating system, with a flap thereof shown in a closed position to bar the entry of air into a fermentation bucket. 
           [0018]      FIG. 2  illustrates fermentation gating system of  FIG. 1 , with the flap thereof shown in an open position to enable fermentation pressure and foam and other byproducts to naturally be released, and to enable direct viewing inside the fermentation bucket without having to remove the fermentation bucket lid. 
           [0019]      FIG. 3  illustrates a preferred method by which the fermentation gating system of  FIG. 1  is attached to the fermentation bucket lid. 
           [0020]      FIG. 4  illustrates the fermentation gating system of  FIG. 1  after it has been attached to the fermentation bucket lid. 
           [0021]      FIG. 5  illustrates applicant&#39;s fermentation gating system in an alternative embodiment wherein the gating apparatus is manufactured integrally with the fermentation bucket lid. 
           [0022]      FIG. 6  illustrates an alternative preferred embodiment of applicant&#39;s fermentation gating system, wherein the tether of  FIG. 1  is replaced by a hinge. 
       
    
    
     DETAILED DESCRIPTION 
       [0023]    This device (the FermGate™) is designed to eliminate problems encountered in the fermenting process for home brewers, home wine makers or anyone using closed system fermenting vessels. 
         [0024]    The basic process involved in the above endeavors is fermentation. Fermentation involves the conversion of sugars into alcohol. 
         [0025]    The fermentation process produces several by-products such as carbon dioxide gas and often large amounts of foam. 
         [0026]    A fermentation vessel must allow the escape of carbon dioxide and any excess foam. The vessel must also be designed so that once the fermentation process begins oxygen and other contaminants are prevented from entering into it, because these may cause oxidation or infection. 
         [0027]    The apparatus disclosed entails a simple and inexpensive change in the design of the lid that goes on the fermenting bucket/vessel. While the volume problem could be solved by simply increasing the bucket size, that would still leave many of the other problems associated with the current lids, as described earlier. 
         [0028]    Specifically, one incorporates a 2 to 3 to 4 to 5 inch hole in the lid with a (for example not limitation, silicon) gasket installed and a “flapper” (preferably but not limited to a clear plastic) hinged next to the gasket, similar to the internal flapper in a common bathroom commode. This would allow for several things not possible with the current lids. 
         [0029]    1. It would provide one-way venting to allow gas to escape easily while keeping outside air from entering the system. 
         [0030]    2. It would allow samples to easily drawn off without need to open the entire lid. 
         [0031]    3. It would allow visual inspection via the clear plastic and/or raising of the flapper. 
         [0032]    4. It would allow the easy introduction of brewing ingredients into the system. 
         [0033]      FIG. 1  illustrates a preferred, non-limiting embodiment of applicant&#39;s fermentation gating apparatus  1 . The elements of this are as follows: 
         [0034]    A. The upper  11  and lower  12  collar. A hollow cylinder of appropriate length and diameter as illustrated (such as but not limited to 2 to 3 to 4 to 5 inches in diameter) that is designed to be placed into an appropriately sized port  33  (hole) in the top of a fermenting vessel lid  32 , see  FIG. 3 . 
         [0035]    B. The flap  13 . A circular weighted lid/valve that is designed to overlap the top opening of the cylinder, similar to that of a bathroom commode. C. The seal ring flange  14 . An area where an airtight seal between the collar and the fermenting vessel is established, with our without a gasket  34  as is further illustrated in  FIGS. 3 and 4 . 
         [0036]    D. The flap-to-collar attachment  15 . A mechanical (e.g., hinge, see  FIG. 6 ) or non-mechanical (e.g., molded-in tether is in  FIGS. 1 and 2 ) part of the FermGate™ that holds the flap  13  in proper alignment with the upper collar  11  allowing a proper seal to be maintained and which further allows a pivotal movement of flap  13  as generally indicated by the arc segment  17  in  FIG. 2 . 
         [0037]    In practice, when the flap  13  is rested against the top opening of the collar/cylinder  11 , and no pressure is applied vertically up or down, an airtight seal is formed, as shown in  FIG. 1 . If pressure builds up inside the fermenting vessel, the pressure naturally and without human intervention causes the flap  13  to slightly lift  17  so it can bleed out between the flap  13  and the top opening of the collar/cylinder  11  through the separation, as shown in  FIG. 2 . After the pressure is released the airtight seal is naturally reestablished without human intervention and the configuration reverts to that of  FIG. 1 . 
         [0038]    The FermGate™ is designed as such: 
         [0039]    The collar  11 ,  12  preferably, but without limitation, has an internal diameter of at least  3  to 3.5 inches, which allows access for sampling as one of several benefits of this apparatus. It is fabricated so its lower portion  12  is threaded as illustrated and of the proper length to accept a suitable washer or gasket  34  and a proper nut  31  as shown in  FIG. 3  for completing the airtight seal. Alternatively to threading, a rubberized seal making a frictional seal with the lid  32  of the fermentation vessel may be employed. 
         [0040]    There is a band where the upper collar  11  meets the lower collar  12 . This band, the seal ring flange  14 , is designed to provide a firm bearing surface against the outer lid  32  of the fermenter when a nut  31  on the lower collar is tightened from the inner side of the fermenting vessel&#39;s lid  32 , again see  FIG. 3 . 
         [0041]    Importantly, the upper collar  11  is made so its top edge circumferential about the opening provides a smooth and level and sealable contact surface for the flap  13 . This may optionally include providing a suitable gasket-grade sealing material  18  (illustrated by the thicker drawing line in  FIG. 2 ) about this top circumferential edge. 
         [0042]    The flap  13  is made so it overlaps the diameter of the upper collar  11 , completely and sealably covering it. It has a tab  16  molded into it for gripping. This allows the flap  13  to be lifted without touching the area where the flap  13  contacts the upper collar  11 . This ensures a sanitary seal by avoiding the introduction of bacteria or other foreign matter from the user&#39;s hand. When the tab  16  is employed the flap  13  may be pivoted through a larger arc of rotation than that illustrated in  FIG. 2 . Generally, the tab will only be used to lift the flap  13  when the use wishes to inspect the contents, draw samples, and/or make additions of ingredients to the fermenting brew. Otherwise, the only time when the seal shown in  FIG. 1  between the flap  13  and the upper collar  11  will be broken as in  FIG. 2  is when the fermentation pressure itself causes the separation and bleeds out. 
         [0043]    The flap  13  is designed to be of sufficient weight to produce an adequate seal. 
         [0044]    The flap  13  is attached  15  to the upper collar  11  so that it is held level and in the proper alignment with the rim of the upper collar  12  for a good seal against passive contamination from outside the system. This attachment  15  can be done in several ways including but not limited to a snap on type pivot hinge  51  as in  FIG. 6  or a simple tether arrangement as in  FIG. 1 . 
         [0045]    The FermGate™ and all its parts are made from materials that are food safe and durable enough to withstand repeated use. These materials, including but not limited to liquid silicon rubber and stainless steel, are such that the FermGate™ can be easily cleaned and sanitized. The design is such that there are no places that might harbor dirt or bacteria. 
         [0046]    Referring to  FIG. 3 , for retrofitting to preexisting fermenting vessels the FermGate™ is inserted into a port (hole)  33  introduced into the cover  32  of the fermenting system, with hole  33  sized to mate tightly with the outer circumference of the FermGate™  1 , and is held in place with a nut  31  screwed onto the threaded lower collar  12 . Preferably, a washer or gasket  34  is placed between the seal ring flange  14  and the top of the cover  32  and helps form the required airtight seal. Once these steps are complete, the resulting configuration is that of  FIG. 4 . 
         [0047]    As just illustrated, the FermGate™ is designed so it can easily be retrofitted into existing fermenting systems. But it may also be fabricated according to the principles outlined herein into new systems at the time of their manufacture. All that is required is a lid  32  with a port (hole)  33  of  FIG. 3  of the proper diameter integrally fabricated with the FermGate™. This is illustrated in  FIG. 5 . 
         [0048]    To draw samples, make additions or to make visual observations the flap  13  is lifted using the tab  16  then dropped back in place by releasing the tab  16  when done. 
         [0049]    To clean or sanitize the FermGate™ once the fermentation is finished, one only needs to soak the apparatus in any commonly used cleanser and/or in any of the commonly-available sanitizers. 
         [0050]    Depending on manufacturing methods there can be several variations in the collar&#39;s design. Some variations may omit the seal ring flange  14 . In such variations the entire upper collar  11  is constructed of a thicker wall to ensure a strong bearing surface for the nut  31  and sealing washer  34  when the washer  34  is tightened on the inside of the fermenter. The gasket  34  may be added to facilitate an airtight seal at the point where the collar  11 ,  12  inserts into the fermenter lid  32 , although it is envisioned that in some embodiments the seal ring flange  14  may integrally include suitable materials for sealing so that a separate washer  34  may be omitted. 
         [0051]    Other variations may include a seal ring flange  14  such as is illustrated in  FIG. 1 , but with the lower collar  12  having no threading. Depending on the material it is made of it could be inserted using any number of ways to maintain a seal, such as via a frictional contact. 
         [0052]    When applicant&#39;s fermentation gating system (FermGate™) is installed, the problems with the prior art are solved as follows: 
         [0053]    1. There is no possibility of a dangerous pressure build up in the fermenting vessel, since there is nothing that can become clogged. If there should be an overly large formation of foam, causing it to overflow the FermGate™&#39;s upper collar  11 , the designed height of the FermGate™&#39;s upper collar  11  as well as the design of the flap  13  will prevent the overflow from re-entering and possibly contaminating the vessel&#39;s contents. It is essentially a one-way valve permitting outflow but not inflow. The design of the FermGate™ also makes cleanup from accidental overflows an easy chore while still maintaining a sanitary closed system. 
         [0054]    2. In the event of any minor leaks in the seal between the bucket and lid or a minor leak where the airlock is inserted active fermentation can be verified with a simple visual inspection. 
         [0055]    3. There is no need to constantly remove the lid from the fermenting vessel. Once the lid is in place it can stay in place until the finished product is removed and the fermenting vessel can then be cleaned and reused. This will greatly add to the life span of the fermenting equipment. 
         [0056]    4. The addition of ingredients or the withdrawal of samples is simple, fast and sanitary without the need to remove the lid. 
         [0057]    5. Since the FermGate™&#39;s port is elevated away from the fermenting liquid&#39;s surface and is small in comparison to the entire vessel&#39;s surface the carbon dioxide layer (CO2 blanket) will remain relatively undisturbed. Any chance of oxidation will be greatly reduced if not totally eliminated. Any ambient air that may enter the collar when it is opened will be forced out by the heavier carbon dioxide being produced it the vessel. 
         [0058]    6. The FermGate™&#39;s port, when opened, presents a much smaller window of opportunity for airborne contamination than a bucket with the lid removed. This greatly reduces the possibility for infection. 
         [0059]    The knowledge possessed by someone of ordinary skill in the art at the time of this disclosure, including but not limited to the prior art disclosed with this application, is understood to be part and parcel of this disclosure and is implicitly incorporated by reference herein, even if in the interest of economy express statements about the specific knowledge understood to be possessed by someone of ordinary skill are omitted from this disclosure. While reference may be made in this disclosure to the invention comprising a combination of a plurality of elements, it is also understood that this invention is regarded to comprise combinations which omit or exclude one or more of such elements, even if this omission or exclusion of an element or elements is not expressly stated herein, unless it is expressly stated herein that an element is essential to applicant&#39;s combination and cannot be omitted. It is further understood that the related prior art may include elements from which this invention may be distinguished by negative claim limitations, even without any express statement of such negative limitations herein. It is to be understood, between the positive statements of applicant&#39;s invention expressly stated herein, and the prior art and knowledge of the prior art by those of ordinary skill which is incorporated herein even if not expressly reproduced here for reasons of economy, that any and all such negative claim limitations supported by the prior art are also considered to be within the scope of this disclosure and its associated claims, even absent any express statement herein about any particular negative claim limitations. 
         [0060]    Finally, while only certain preferred features of the invention have been illustrated and described, many modifications, changes and substitutions will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.