Abstract:
A beverage brewer housing ( 10 ) for passing hot water though a dry ingredient to create a freshly brewed beverage with a lower housing section ( 14 ) for protectively containing a hot water tank and an upper housing section ( 12 ) attached to and cantilever supported upon the lower housing section ( 14 ) having a rearward upper section open to the lower housing section ( 14 ) for protectively containing an upper part of the hot water tank and a forward upper section for containing temperature sensitive electronics. A closure plate ( 26 ) defines a floor for the forward upper section to support the electronics and an upwardly extending interior wall ( 27 ) thermally, protectively, separating the forward upper section from heat within the rearward upper section generated by the hot water tank. Both Each of the housing sections ( 12, 14 ) are made from a single work piece of thin-walled stainless steel having a pair of planer side walls, a planer back wall and a curved front wall and an inwardly extending collar to enhance the lateral rigidity, of the lower housing;

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit under 35 U.S.C 119(e) of provisional patent application No. 60/998,574 of the present inventor filed Oct. 11, 2008 and entitled “Sheet Metal Beverage Brewer Housing and Method of Making Same”, and is a continuation in part of and claims the benefit under 35 U.S.C 120 of U.S. application Ser. No. 10/884,149 filed Jul. 2, 2004 of Zbigniew G. Lassota and entitled “Beverage Apparatus with Non-rectilinear, Cornered Housing and Method of Making Same”, both of which applications are hereby incorporated by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention. 
         [0003]    This invention generally relates to commercial beverage brewers and methods of making commercial beverage brewers, and more particularly, to beverage brewer housings made of sheet metal and methods of making same. 
         [0004]    2. Discussion of the Prior Art. 
         [0005]    The drawings of this application relate solely to the construction of the brewer housing and do not shown the inner workings of the beverage brewers disclosed here. The invention does not involve any changes to the basic components that are generally present in any commercial coffee brewer or the like. If information concerning such incidental details is desired, then referenced should be made to one or more of U.S. patents of the present inventor including U.S. Pat. No. 5,000,082, entitled “Beverage Maker And Method Of Making Beverage”, issued Mar. 19, 1991; U.S. Pat. No. 5,331,885, entitled, “Semiautomatic Beverage Maker And Method”, issued Jul. 26, 1994; U.S. Pat. No. 5,943,944, issued Aug. 31, 1999 entitled, “Semiautomatic Beverage Maker and Method”; and U.S. Pat. No. 6,148,717, issued Nov. 21, 2000. entitled. “Beverage Maker with Intermittent Beverage Liquid Dispenser and apparatus and Method for Uniform Contact of Brew Ingredient with Brew Water” of the present inventor and the patents cited therein, all of which are incorporated herein by reference, for structural, mechanical and other details of the conventional components of coffee brewers and the like. 
         [0006]    It is well known to make the housing of beverage makers such as commercial coffee brewers and tea brewers using stainless steel sheet metal. Subassemblies for the housing are often made with planer rectangular panels that are attached to each other at opposite sides to form four sided tubular side-wall subassemblies. The sidewall subassembly has four flat panels extending between four right angled corners with an open top and an open bottom. The four panels comprise a front side, a back side and a pair of parallel sides extending between the front and the back in spaced relationship. 
         [0007]    It is also known to form the sidewall subassembly by bending three comers of a single work piece and then forming the fourth corner by welding together opposite ends of single sheet of metal. While these subassembly structures may be structurally adequate once fully assembled with a top closure and a bottom closure, because the thin walled sheet metal is flexible, there is often insufficient structural integrity to maintain the final shape of the open top and the bottom in a perfectly rectangular shape before attachment with the top closure and the bottom closure. Because of such distortion, the shape of the open top and the open bottom often do not perfectly match the shapes of precut sheet metal pieces that form closures for the open top and open bottom, in such case, smooth easy assembly of the rectangular shapes of the top and bottom closures with the mismatched open top and open bottom. 
         [0008]    Generally, the rigidity may be improved by increasing the thickness of the work piece of the sidewall subassembly but this adds to the cost of materials and also to the weight of the finished housing assembly and the food equipment employing the heavier housing. It is known to mold the housing of a beverage brewer from plastic or the like but such non-metallic, plastic materials are not generally suitable for commercial application in which the housing must be generally impervious to commercial cleaning solvents, beverage stains, hot water, etc. and must be easily cleaned. 
       SUMMARY OF THE INVENTION 
       [0009]    It is therefore an object of the present invention to provide a beverage brewer and method of making same with a sidewall subassembly comprised of a single work piece of stainless steel sheet material that has been bent into desired configuration that will hold its shape to facilitate assembly with a bottom closure and a top closure and thereby overcomes the problems of known brewer housings noted above. 
         [0010]    This is achieved in part by providing the sidewall work piece with four bent, or folded comers intermediate the opposite ends and fastening the opposite ends together at a location spaced from the corners, instead of forming the fourth corner by attaching the opposite ends together at the corner. This technique is also shown in co-pending U.S. application Ser. No. 10/884,149, filed Jul. 2, 2004, and entitled “Beverage Apparatus with Non-rectilinear, Cornered Housing and Method of Making Same”, which is hereby incorporated by reference. 
         [0011]    The object of the invention is also achieved in part by providing at least one of the panels with a top and bottom bearing a series of kerfs along the top and bottom of the panel to facilitate bending of the panel into an arcuate shape to provide improved rigidity to the sidewall subassembly. 
         [0012]    The object is also achieved in part by providing an inwardly extending reinforcing collar at the top and bottom of the panels with opposite V-shaped notches at locations of where the bends are to be made to form the corners to both enhance structural rigidity of the side wall subassembly and to provide a horizontal surface to support and facilitate attachment to top and bottom closures. 
         [0013]    The objective is obtained, partly, by providing a beverage brewer for passing hot water though a dry ingredient to create a freshly brewed beverage, with a brewer housing, having a lower housing section for protectively containing a lower part of a hot water tank, an upper housing section attached to and cantilever supported upon the lower housing section, said upper housing section having a rearward upper section open to tire lower housing section for protectively containing an upper part of the hot water tank and a forward upper section for containing temperature sensitive electronics, said rearward upper section being vertically aligned with the lower housing section and said forward upper section extending forwardly of the lower housing section and the rearward upper section, and a closure plate defining a floor for the forward upper section to support the electronics and an upwardly extending interior wall thermally, protectively, separating the forward upper section from heat within the rearward upper section, generated by the hot water tank 
         [0014]    The objective is also partly acquired by provision of a beverage brewer for passing hot water though a beverage ingredient to make a freshly brewed beverage with a brewer housing, having a lower housing section made from a single work piece of thin-walled stainless steel having a pair of planer side walls, a planer back wall and a curved front wall, an upper housing section made from a single work piece of thin-walled stainless steel having a pair of planer side walls, a planer back wall and a curved front wall, an inwardly extending collar at the top of the lower housing to enhance the lateral rigidity of the lower housing, said upper housing section having an upper forward section, and an upper rearward section attached to the collar of the lower housing section to cantilever mount the upper forward section at a location extending forwardly of the tower housing section. 
         [0015]    The objective is also obtained by providing a beverage brewer for passing hot water though a beverage ingredient to make a freshly brewed beverage, with a brewer housing, a lower housing section with an inwardly extending collar, an upper housing section integrally made from a single thin-walled stainless steel work piece with a top, a bottom, and a pair of planer side walls, a curved front wall, a pair of back end walls joined together by a weld joint to define a back wall, all extending between the top and the bottom. 
         [0016]    Moreover, the object is acquired, in part, by providing a beverage brewer for passing hot water though a beverage ingredient to make a freshly brewed beverage, with a brewer housing, including a lower housing section made from a single thin-wailed, stainless steel, work piece having a front wall, a pair of side walls and a pair of inwardly extending, back, end walls separated by a space defining an access panel, and an upper housing section made from another single, thin-walled, stainless steel, work piece having a front wall, a pair of side walls and a pair of inwardly extending, back, end walls joined together by a weld joint. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0017]    The foregoing objects, features and advantages will be described in greater detail and further features and advantages will be made apparent from the detailed description of an embodiment given with reference to the several figures of the drawing, in which; 
           [0018]      FIG. 1  is a perspective view of a beverage brewer housing constructed in accordance with the present invention; 
           [0019]      FIG. 2  is a perspective illustration of the lower housing section after it has been bent into its assembled state; 
           [0020]      FIG. 3  is a plan view of a single piece of metallic sheet material that has been cut in accordance with the invention to form the upper section of the housing of  FIG. 1 ; and 
           [0021]      FIG. 4  is a plan view of a single piece of metallic sheet material that has been cut in accordance with the invention to form the lower section of the housing of  FIG. 1 . 
       
    
    
     DETAILED DESCRIPTION 
       [0022]    Referring to  FIG. 1 , the beverage brewer housing  10  is seen to include an upper housing section  12  and an underlying lower housing section  14  that is attached to and supports the upper housing section  12 . The upper section  12  has a top closure, or brewer top  16 . The lower housing section is supported by a base  18  with a pair of laterally spaced, forwardly extending feet  20  and  22 . The feet  20  and  22  extend forwardly from an aft, bottom closure plate  24 . 
         [0023]    Another closure plate  26  provides a floor for the toward part of upper housing  12  and maintains assists in maintaining the shape of the upper housing section by blocking inward flexing of the planer side wall. It extends backwards from an arcuate front that conforms to upper arcuate wail  28  to an upstanding, reinforcing, knee wall  27 . The knee wait  27  is integrally formed with the closure plate by upwardly bending a back edge. The back portion  29  of the upper housing section  12  has no closure and freely communicates with the lower housing section  14 . A hot water tank (not shown) is substantially housed within the lower housing section  14  along with heating elements and temperature sensors, but a top portion of the hot water tank extends upwardly past the top of the lower housing section  14  and into the back portion  29  of the upper housing section located behind the knee wall  27 . 
         [0024]    Because of the presence of the hot water tank, the back portion  29  is the hottest part of the upper housing section  12 . The knee wall  27 , in addition to providing stiffening of the back edge of the closure plate  26  and general lateral reinforcement, functions to block or deflect hot air away from the portion of the upper housing located in front of the knee wall  27 . The forward portion of housing section  12  houses most of the control and display electronics (not shown) and needs to be protected from excessive heat. Conduit for passing hot water to the brew basket contained within the forward portion is insulated. 
         [0025]    Both the upper housing section  12  and the lower housing section  14  have a generally rectangular cross section except for an upper, arcuate, forwardly extending front wall  28  of the upper housing section  12  and a lower, arcuate, forwardly extending front wall  30  of the lower housing section. All the other walls of both the upper housing section  12  and the lower housing section  14  are substantially planer and the rear corners  32  and  33  of the upper housing section  12  and rear corner  34  of the lower housing section  14  are substantially square, or form ninety degree, right angles. On the other hand, because of the arcuate shape of the upper arcuate wall  28 , the front corners  36  and  38  of the upper housing section  12  form obtuse angles greater than ninety degrees. Likewise, the front corners  40  and  42  of the lower housing section form obtuse angles greater than ninety degrees. A rectangular planer side wall  31  extends between the front corner  42  and the rear corner  34  of the lower housing section  14 . 
         [0026]    The upper, arcuate wall  28  has a rectangular opening  44  for mounting of an electronic alphanumeric display (not shown) and four, substantially identical, circular holes  46  for the mounting of push-button switches (not shown) used to control the beverage brewer when fully assembled. The parallel, planer, sidewall s  48  and  50  of the upper housing section  12  have ventilation holes  52  and  54 , respectively, within which are mounted louvered ventilation covers (not shown). The upper housing section  12  generally houses a hot water delivery system including a dispense valve (not shown) for dispensing hot water into a brew basket that is slideably, removably mounted beneath the forward portion of the closure plate  26  that is cantilever mounted above the space  56  between the feet  20  and  22 . The brew basket is mounted by means of a pair of parallel rails  58  (only one shown) fastened to the underside of the plate  26 . During operation and performance of a brew cycle, a beverage dispenser (not shown) is located in the space  56  to receive the freshly brewed beverage that passes out of a drain hole in the bottom of the brew basket. 
         [0027]    A planer, rectangular rear wall has two sections  55  and  57  that are joined in abutting relationship and welded to each other along a juncture  59 . Attached to the tops of the of the front wail  28 , the side wall  48 , the side wall  50  and the rear wall formed by section  55  and  57  are inwardly extending, horizontal, top collars  29 ,  49 ,  51 ,  61  and  63 , respectively. The top collar  29  has a series of kerfs extending along its length. Also attached to the bottoms of these walls, but not seen in  FIG. 1 , are inwardly extending, horizontal, bottom collars that are substantially identical to and located directly opposite the top collars  29 ,  49 ,  51 ,  61  and  63 . The bottom collar opposite the top collar  29  has a series of kerfs running extending along its length. The portion of the work piece from which the bottom collars are formed is described below with respect to  FIG. 3 . 
         [0028]    Referring to  FIG. 2 , the lower housing section  14  is seen to include another planer sidewall  60  that is parallel to the opposite side wall  31  and extends between the forward corner  40  and a rearward, right angle bent corner  62 . A pair of relatively narrow, planer back walls  64  and  66  extend inwardly toward each other from the right angle corners  62  and  34 , respectively. Back wall  64  terminates at a straight edge  68 , and back wall  66  terminates at a straight edge  70 . The space between the edges  68  and  70  is filled by a removable access panel closure  72  made of a rectangular piece of sheet metal. The access panel closure  72  is held in position by suitable releasable fasteners such as resilient snap fasteners (not shown). Except for the closure  72  the lower housing section is farmed from a single work piece. 
         [0029]    A pair of horizontal top back collars  74  and  76  is integrally formed with the tops of back walls  64  and  66 , respectively, and a pair of corresponding horizontal bottom back collars  78  and  80  is integrally formed with the bottom of the back walls  64  and  66 , respectively. The back collars  74 ,  76 ,  78  and  80  form right angles relative to the plane of the back walls  64  and  66  and are parallel to each other. 
         [0030]    Similarly, a pair of horizontal top side collars  82  and  84  is integrally formed with the tops of the side walls  60  and  32 , respectively, and a pair of corresponding horizontal bottom side collars  86  and  88  is integrally formed with the bottoms of side walls  60  and  32 , respectively. The side collars  82 ,  84 ,  86  and  88  form right angles relative to the parallel planes of the side walls  60  and  62 . 
         [0031]    The top side collars  82  and  84  abut the back collars  74  and  76  along 45-degree miter lines  90  and  92 , respectively, and welded together to hold their associated side walls and back walls in a right angled relationship. 
         [0032]    The arcuate front wall  30  also has a horizontal, top front collar  94  and a horizontal bottom front collar  96  integrally formed with the top and bottom of the arcuate front wall  30 , respectively. The collars  94  and  96  have a slightly less width dimension than the other collars. The top front collar  96  forms a right angle relative to the vertical surface of the arcuate front wall  30 . The top front collar  94  has a pair of opposite ends that abut with the top side collars  82  and  84 , respectively, along abutment junction lines  98  and  100 , and are welded together along the abutment junction lines  98  and  100 . 
         [0033]    Similarly, the bottom front collar  96  forms aright angle relative to the vertical surface of the arcuate front wall  30 , and has a pair of opposite ends that abuts with tire bottom side collars  86  and  88 , respectively, along abutment junction lines  102  and  104 . The opposite ends of the bottom front collar  96  are welded to the bottom side collars  86  and  88  along the abutment junction lines  102  and  104 . 
         [0034]    Unlike the other collars, the front collars  94  and  96  have a series of kerfs  106  and  108 , respectively, cut inwardly from the distal edges to the juncture of the collars with the arcuate front wall  30 . The series of kerfs  106  and  108  extend for the entire length of the collars and end at the abutment junction lines  98  and  100 . The kerfs, cuts, or slots are approximately 1/16-inch to ⅓-inch wide and the distance between the cuts, or the width of the kerf fingers, is approximately ¼-inch. There are approximately thirty-two kerfs in the series. 
         [0035]    Referring now to  FIG. 2 , the upper housing is made from a single work piece  12 P that has been cut with an Industrial laser cutter from a 12-14 gage, rectangular planer sheet of series 300-400 stainless steel. The bottom collars located opposite the upper collars  61 ,  49 ,  29 ,  51  and  63  are  110 ,  112 ,  114 ,  116  and  118 , respectively. The work piece  12 P has a width of approximately 4-inches and a length of approximately 45-inches. In addition to cutting out the perimeter shape, the kerfs are formed as well as the openings for ventilation, electronic display and push button control switches. Also, all the collars, except the arcuate collars  29  and  114 , have a plurality of small, round rivet holes  119  cut for receipt of rivets for fastening the upper housing section  12  to the lower housing section  14 , as shown in  FIG. 1 . 
         [0036]    The collars are provided with a pairs of V-shaped cuts at each of the corners. The pairs of V-shaped slots  120  and  122  of corners  32  and  33  are 45-degrees such that when the walls on opposite sides of the slots form a right angle the edges of the slots come into abutment with each other which prevents further bending beyond 90-degrees. On the other hand, the pair of opposed V-shaped slots  124  and  126  on opposite sides of the corners  36  and  38  are less than 45-degrees, and accordingly, further bending of the front wall relative to the side walls  48  and  50  is prevented by the abutment of opposite edges of the V-shaped slots prior to 90-degrees being reached. In the case of the V-shaped cuts having an angle of only 30-degrees, abutment occurs when the angle between the front wall and the side walls  48  and  50  reach only 120-degrees. This may be used to limit further bending of the front wall but preferably both the abutment of the ends of the kerf fingers, or tabs, and the abutment of the V-shaped slots  124  and  126 . 
         [0037]    In accordance with the method of making the brewer housing of the present invention, the following steps are performed in order to shape the work piece  12 P into the upper housing section  12  shown in  FIG. 1 . First, a brake machine is used to bend all the collars until they form a right angle with the body of their associated housing walls. Second, the break machine is used to bend the body at the corners  36  and  38  and then the corners  32  and  33 , The corners  36  and  38  are bent to an angle greater than 90-degrees and the corners  32  and  33  are bent to an angle of approximately 90-degrees. Third, the opposite ends  59 A and  59 B are brought together into abutting relationship and welded together to form juncture  59  of  FIG. 1 . As the ends  59 A and  59 B are brought together, the front wall  28  bends into an arcuate shape as shown in  FIG. 1 , and the distal ends of adjacent kerf fingers of the collars  29  and  114  abut one another when the final arcuate shape is reached and thereby block further bending. 
         [0000]    It is the pre-weakening of the collars  29  and  114  by the series of kerfs, and specifically the gaps formed by the kerfs, that enable the bending of the front wall into an arcuate shape. The collars of the planer sidewalk, on the other hand, have no kerfs and therefore are maintained in a planer configuration during bending. Widening the width of the kerfs increases the degree to which the front wall  28  will be bent away from a planer shape. Once the ends of the adjacent kerf fingers abut each other, no further bending of the front wall  28  takes place. This preferably occurs before or concurrently with the abutment of the opposite sides of the V-shaped slots as previously noted. Preferably, this degree of bending occurs only when the opposite ends  59 A and  59 B are brought together, and not before, to enhance the rigidity of the collars  29  and  114 . The alignment of the kerf and tabs on the upper and lower collars affect a uniform and straight curve. 
         [0038]    After, the junction  59  has been formed and welded, the bottom closure  26  is inserted through the top and positioned for underlying support by die bottom collars  112 ,  114  and  116  with the arcuate shaped portion of the closure abutting the interior surface of the front wall  28  and the sides of the wall abutting against the interior sides of the walls  48  and  50 , as shown in  FIG. 1 . The closure, or floor,  26  is fastened to the bottom collars  112  and  116  by means of rivets that pass through the rivet holes  119  and mating rivet holes in the top collars of the lower housing section  14 . There are no rivets attaching the floor  26  to the arcuate bottom collar  114  of the front wall 
         [0039]    Advantageously, the bending of the stainless steel front wall  28  into an arcuate shape places it into a stressed state. Because of the resilient memory of the high grade stainless steel, release of the opposite ends of the arcuate wall  28  after being bent would result in the arcuate front wall returning to a planer configuration. This stressed state, as well as the arcuate shape, enhances the rigidity and structural integrity of the upper housing section  14 , particularly the front arcuate wall  28 . Structural integrity and rigidity of the portion of the closure  26  suspended between the opposed bottom collars  112  and  116  also enhanced by provision of the upstanding knee wall  27 , discussed above with respect to  FIG. 1 , and the rivet attachment of the floor  26  to bottom collars  112  and  116  prevents the side walls  48  and  50  from being distorted into a non-planer shape. 
         [0040]    Referring to  FIG. 4 , the lower housing  14  is made from a single work piece  14 P that is cut from 300-400 series stainless steel 12-14 gage sheet. It is generally like the work piece  12 P. It has 45-degree V-shaped slots  130  and  132  at opposite sides of the corners  34  and  62 , respectively, and smaller degree V-shaped slots, such as 60-degree slots,  134  and  136  at opposite ends of the corners  40  and  43 , respectively. A plurality of round rivet holes  138  are provided in the top collars  76 ,  84 ,  82 , and  74 , and a different plural number of rivet holes  140  are provided in the bottom collars  80 ,  88 ,  86  and  78 . No rivet holes are provided in the arcuate collars  94  and  96 . Rivet holes  140  are also provided in the narrow back wails  64  and  66  for attachment to an upstanding frame member (not shown) contained within the lower housing section  14 . 
         [0041]    Relatively long narrow reinforcing strips  142  and  144  are attached along the sides of edges  70  and  72 ,  FIG. 1 . The reinforcing strips  142  and  144  have no collars and their top ends are beneath the adjacent collars when the collars are bent 90-degrees relative to the narrow back walls  66  and  68 , respectively. Stress release slots  146  in the reinforcing strips  142  are located adjacent the rivet holes to reduce dimpling when the rivets are fastened to the support member (not shown). The arcuate collars  96  and  94  and the kerfs formed therein are generally the same as described above with respect to the collars  29  and  114  of the work piece  12 P. 
         [0042]    The lower housing section  14  is formed from the work piece  14 P in the same general way as described above with respect to the formation of the upper housing section  12  from the work piece  12 P. First, the collars are bent 90-degrees relative to the bodies of their associated walls. Next, the corners are formed by folding the work piece along a lines extending between the V-shaped notches with right angles being formed at the corners  34  and  62  and less than right angles being formed at the corners  42  and  40 , the reinforcing strips  142  and  144  are bent to form 90-degree corners relative to the narrow back walls  66  and  64  along lines  148  and  150 . The work piece is then otherwise bent to the position shown in  FIGS. 1 and 2  and the bottom collars are attached to the base plate  24  and the narrow back walls riveted to the vertical support members. 
         [0043]    Next, the upper housing section  12  is placed on top of the lower housing section and the bottom collars of the upper housing section  12  are riveted to the top collars of the lower housing section in the configuration shown in  FIG. 1 . In all cases where rivets are employed, spot welding may also be used to supplant or supplement these mechanical fasteners. The operating parts of the brewer are then installed into the upper housing section and the lower housing section. When all the parts have been installed, the access panel, door  72  is mounted the close the opening between the narrow back walls  66  and  64 . 
         [0044]    While a detailed description of a preferred embodiment of the invention has been, provided, it should be appreciated that many variations may be made without departing from the spirit of the invention. For instance, kerfs could be provided at different ones of the collars to enable them to also assume an arcuate shape. The bending could be inward instead of outward and the degree of bending can be altered by changing the size, number and spacing of the kerfs. Other variations will occur to persons of ordinary skill in the art.