Patent Description:
According to an aspect of the invention there is provided a beverage maker platen overflow sensing system as recited in claim <NUM>.

A beverage maker platen overflow sensing system is disclosed. In embodiments, the platen overflow sensing system includes a process control board (PCB) housing one or more processors in communication with solenoid valves of a manifold, the solenoid valves controlling the flow of hot water (or another conductive fluid) into a server positioned in or on a platen of the beverage maker. The PCB includes a memory or other data storage for storing software executable by the processor for controlling the solenoid valves. The PCB further includes an overflow detection circuit connected to the solenoid valves. At least two signal probes are positioned near the forward edge of the platen (e.g., a signal probe on either side of the server) and connected to the PCB via wire harness. Similarly, at least two ground probes are positioned in the platen below the signal probes likewise connected to the PCB via wire harness and providing a ground path thereto. The overflow detection circuit generates an electrical signal between the two signal probes and detects an overflow state when hot water overflowing into the platen grounds the signal between at least one of the signal probes and at least one of the ground probes. While the overflow state persists, the overflow detection circuit ceases the flow of hot water by electrically signaling the solenoid valves to close.

A beverage maker platen overflow sensing system is disclosed. In embodiments, the platen overflow sensing system includes a process control board (PCB) housing one or more processors in communication with solenoid valves of a manifold, the solenoid valves controlling the flow of hot water (or another conductive fluid) into a server positioned in or on a platen of the beverage maker. The PCB includes a memory or other data storage for storing software executable by the processor for controlling the solenoid valves. The PCB further includes an overflow detection circuit connected to the solenoid valves. At least two signal probes are positioned near the forward edge of the platen (e.g., a signal probe on either side of the server) and connected to the PCB via wire harness. A platen probe is disposed within a lower portion of the platen (e.g., a disk centrally located), the platen probe electrically connected to the PCB and providing a ground path to the PCB when the beverage maker is in a default (e.g., non-overflow) state. The overflow detection circuit generates an electrical signal between the two signal probes and detects an overflow state when hot water overflowing into the platen grounds the signal between at least one of the signal probes and the platen probe. While the overflow state persists, the overflow detection circuit ceases the flow of hot water by electrically signaling the solenoid valves to close.

According to another aspect of the invention there is provided a beverage maker device as recited in claim <NUM>.

A beverage maker device is also disclosed. In embodiments, the beverage maker device includes a housing with a platen capable of accommodating a server, the housing installable in an aircraft galley. Within the housing is a manifold plumbed to a hot water tank and capable of dispensing hot water (e.g., for brewing tea or coffee) from the tank into the server, the dispensing controlled by solenoid valves of the manifold. Externally positioned on the housing is a human-machine interface (HMI) capable of accepting control input from a cabin crewmember (e.g., directions for brewing tea or coffee, or dispensing hot water into the server). Also within the housing is a process control board (PCB) housing one or more processors in communication with solenoid valves of a manifold, the solenoid valves controlling the flow of hot water into a server positioned in or on a platen of the beverage maker. The PCB includes a memory or other data storage for storing software executable by the processor for controlling the solenoid valves. A primary overflow sensor (e.g., server level sensor) positioned at or near the top of the server directs the software on the PCB to shut off the solenoid valves if the water level within the sensor reaches a high enough level. As a secondary overflow sensor (e.g., a hardware-based backup sensor system), the PCB further includes an overflow detection circuit connected to the solenoid valves. At least two signal probes are positioned near the forward edge of the platen (e.g., a signal probe on either side of the server) and connected to the PCB via wire harness. Similarly, one or more ground probes (e.g., platen probes) are positioned in the platen below the signal probes likewise connected to the PCB via wire harness and providing a ground path thereto. The overflow detection circuit generates an electrical signal between the two signal probes and detects an overflow state when hot water overflowing into the platen grounds the signal between at least one of the signal probes and at least one of the ground probes. While the overflow state persists, the overflow detection circuit ceases the flow of hot water by electrically signaling the solenoid valves to close.

Various embodiments or examples ("examples") of the present disclosure are disclosed in the following detailed description and the accompanying drawings by way of example only. In the drawings:.

Broadly speaking, embodiments of the inventive concepts disclosed herein are directed to an overflow detection system for a beverage maker device (e.g., a device installable in an aircraft galley for brewing or dispensing coffee, tea, and/or hot water). The overflow detection system may serve as a redundant, hardware-based backup system for software-based server-level sensors. Such software-based systems may be vulnerable to software or sensor malfunctions that may fail to address an overflow state, while the hardware-based backup system operates independently of software and resists false-overflow states associated with incidental spillage.

Referring to <FIG>, a beverage maker device <NUM> is disclosed. The beverage maker device <NUM> may include a server <NUM> insertable in a platen <NUM> and an overflow detection system comprising signal probes <NUM> and ground probes <NUM> positioned within the platen.

In embodiments, the beverage maker device may include two signal probes <NUM> positioned toward the front of the platen <NUM>, and two ground probes <NUM> positioned rearward of the signal probes in a lower (e.g., deeper) portion of the platen. For example, under normal operating conditions an electrical signal may be generated between the two signal probes <NUM>. Should the water level within the server <NUM> (e.g., as the server is being filled by the beverage maker device <NUM> with hot water) overflow into the platen <NUM>, the overflowing hot water within the platen (e.g., a conductive fluid) may create a ground path from either or both of the signal probes <NUM> to either or both of the ground probes <NUM>, electronically indicating an overflow state and inducing a shutoff of the hot water flow into the server <NUM>.

Referring to <FIG> and <FIG>, the beverage maker device <NUM> is shown. In embodiments, the beverage maker device <NUM> may include a hot water tank <NUM>, a manifold <NUM>, solenoid valves 206a-c, a process control board <NUM> (PCB), wire harnesses <NUM>, tank heaters <NUM>, a platen heater <NUM>, a server level sensor <NUM>, a platen drain <NUM>, and a human/machine interface <NUM> (HMI).

In embodiments, the PCB <NUM> may house an overflow detection circuit connecting the signal probes <NUM> and ground probes <NUM> to the solenoid valves 206a-c on the manifold <NUM>. The PCB <NUM> may be supplied with input power (<NUM>) from an aircraft-based power system (e.g., via a galley insert (GAIN) interface by which the beverage maker device <NUM> is connected to aircraft power supplies and networks).

The hot water tank <NUM> may be plumbed to the manifold <NUM> for dispensing hot water from the hot water tank, e.g., for the brewing of coffee (<NUM>) to an external brew cup (via the solenoid valve 206a), for the brewing of tea (<NUM>) via hot water dispensed to the server <NUM> (via the solenoid valve 206b), or for the dispensing of hot water through an external faucet <NUM> (via the solenoid valve 206c). In some embodiments, as the outflow of the external faucet <NUM> is external to the platen (<NUM>, <FIG>), the solenoid valve 206c may not be regulated by the overflow detection circuit. The water may be heated by tank heaters <NUM> within the hot water tank <NUM> and kept warm by the platen heater <NUM> within the platen <NUM> (e.g., directly underneath and in contact with the server <NUM>). The hot water tank <NUM> may include an external drain <NUM>; further, the platen <NUM> may be plumbed to the platen drain <NUM>, allowing any spillage within the platen to flow to an aircraft wastewater system.

In embodiments, the PCB <NUM> may include software (e.g., stored to memory or otherwise loaded to the PCB) for controlling the solenoid valves 206a-c to dispense hot water based on control input submitted via the HMI <NUM> (e.g., via a cabin crewmember or flight attendant). Under normal conditions, the signal probes <NUM> and ground probes <NUM> (positioned on the platen <NUM> below the signal probes) may be connected to the PCB <NUM> via the wire harnesses <NUM>. The PCB <NUM> may create an electrical signal between the signal probes <NUM> while the ground probes <NUM> provide a ground path back to the PCB.

Referring now to <FIG>, the beverage maker device <NUM> is shown. In embodiments, an overflow state of the beverage maker device <NUM> may exist when the platen <NUM> is substantially filled with fluid <NUM> (hot water or any other appropriate conductive or water-based fluid). For example, fluid <NUM> within the platen <NUM> may create a connection, or grounded signal <NUM>, between the signal probes <NUM> and the ground probes <NUM>. The server level sensor <NUM> may be positioned toward the top of the server <NUM> such that, if the server level sensor detects a water level consistent with an overflow state (e.g., at or above the level of the server level sensor), the server level sensor may direct the software loaded onto the PCB (<NUM>, <FIG>/<FIG>) to close the solenoid valves (206a-b, <FIG>/<FIG>) stopping the flow of water from the manifold (<NUM>, <FIG>/<FIG>).

In embodiments, the signal probes <NUM> and ground probes may directly sense the spillage or overflowing of fluid <NUM> into the platen <NUM> (as opposed to indirectly measuring flow rates or pressure losses) and respond thereto by generating the grounded signal <NUM>. When the overflow detection circuit on the PCB <NUM> detects the grounded signal <NUM> (as opposed to the standard electrical signal between the signal probes <NUM>), the overflow detection circuit may close the solenoid valves 206a-b to stop the flow of hot water through the manifold <NUM> into the platen <NUM>. As long as the overflow state persists, the overflow detection circuit may prevent the solenoid valves 206a-b from opening (e.g., until the fluid <NUM> causing the grounded signal <NUM> is terminated and the electrical signal between the signal probes <NUM> is restored).

In embodiments, the signal probes <NUM> may be positioned toward the forward edge of the platen <NUM>. Similarly, the ground probes <NUM> may be positioned more centrally and lower in the platen <NUM>, such that the signal probes are above the ground probes. Accordingly, incidental spillage within the platen <NUM> may not rise to the level of the signal probes <NUM> and thus may not trigger the detection of an overflow state by the overflow detection circuit; in these cases the operation of the solenoid valves 206a-b may not be interrupted.

Referring to <FIG>, the beverage maker device <NUM> is shown. The overflow detection circuit on the PCB (<NUM>, <FIG>/<FIG>) may detect the overflowing or spillage of fluid (<NUM>) at a variety of angles, regardless of the positioning of the beverage maker device <NUM> within the aircraft galley or the current angle of flight. For example, if the spillage of fluid <NUM> occurs only within a portion of the platen <NUM>, a ground path may be established only between the signal probe 106a and the ground probe 108a. The resulting grounded signal (<NUM>) may still be detected by the overflow detection circuit, resulting in the PCB (<NUM>, <FIG>/<FIG>) shutting down the solenoid valves (206a-b, <FIG>/<FIG>).

In embodiments, the signal probes <NUM> and ground probes <NUM> may be raised or elevated from their surrounding platen surfaces, such that the probes are resistant to debris and scale and easily cleaned by cabin crew. In some embodiments, the lower surface of the platen <NUM> may be designed or shaped to direct the flow of fluid <NUM> away from the central portion <NUM> (which may include the platen heater (<NUM>, <FIG>)) toward the signal probes <NUM>. Further, the forward placement of the signal probes <NUM> may ensure that the overflow detection signal closes the solenoid valves 206a-b only when the fluid <NUM> overflows toward the front of the platen <NUM>.

Referring in particular to <FIG>, the beverage maker device 100a is shown. The beverage maker device 100a may be implemented and may function similarly to the beverage maker device <NUM> of <FIG>, except that in place of the ground probes (<NUM>, <FIG>) the beverage maker device 100a may incorporate a single ground probe incorporated into a disk <NUM> (or any other appropriately shaped electrically conductive material) centrally located within the platen <NUM>. For example, any connection between a signal probe <NUM> and the disk <NUM> via the overflowing fluid <NUM> may result in a grounded signal detectable by the overflow detection circuit.

Referring to <FIG>, the overflow detection circuit <NUM> may be positioned on the PCB (<NUM>, <FIG>/<FIG>) for detection of an overflow state within the platen (<NUM>, <FIG>) of the beverage maker devices <NUM>, 100a of <FIG>. Broadly speaking, the overflow detection circuit <NUM> is entirely hardware-based, operating independently of software, and allows the solenoid valves (206a-b, <FIG>/<FIG>) controlling coffee and tea brewing (<NUM>/<NUM>, <FIG>) to open only if an overflow condition is not detected.

In embodiments, the overflow detection circuit <NUM> comprises five sections <NUM>, <NUM>, <NUM>, <NUM>, <NUM>. For example, the first section <NUM> may include an inverter <NUM> (e.g., Schmitt trigger CD40106) for generating an oscillating signal between the signal probes <NUM> (e.g., <NUM>, <NUM>% duty cycle, 0V to 5V peak to peak logic level square wave) to be buffered and conditioned and appear on signal probes <NUM>, easily grounded by a conductive fluid (e.g., fluid <NUM>, <FIG>). The oscillating nature of the signal may further mitigate the accumulation of hard water scale on the signal probes <NUM> and ground probes <NUM>.

In embodiments, the second section <NUM> may include a comparator 514a (e.g., half of a LM193D dual comparator, the other half 514b incorporated into the fourth section <NUM>) for comparing the square wave output of the first section <NUM> to a reference signal (e.g., a ½ Vcc reference created by the resistors <NUM>) and generating a buffered output.

In embodiments, the third section <NUM> may receive the buffered <NUM> output of the second section <NUM> and remove its DC component, sending the resulting signal to the voltage divider <NUM>. The signal probes <NUM> may be connected to the voltage divider <NUM> while the ground probes <NUM> are connected to the ground circuit <NUM>. Under normal conditions, when the signal between the signal probes <NUM> is ungrounded, the buffered signal may remain nominal (e.g., ~<NUM> V peak) at point <NUM> at the top of the voltage divider <NUM>. The third section <NUM> may further include capacitors <NUM>, <NUM> (respectively for AC coupling and smoothing of the <NUM> V - ~<NUM> V signal) and diodes <NUM>, <NUM> (respectively for half-wave rectification of the signal and protection against overvoltage). However, when the signal probe <NUM> is shorted by fluid <NUM> within the platen <NUM>, creating the grounded signal <NUM> to ground probe <NUM> and the ground circuit <NUM>, the signal at point <NUM> may drop to near zero voltage.

In embodiments, the fourth section <NUM> includes the second comparator 514b (e.g., the second half of the dual comparator device, along with the first comparator 514a) which may compare the <NUM> V - ~ <NUM>. 2V output signal of the third section <NUM> with another reference signal (e.g., a 1V reference). When the signal probes <NUM> and ground probes <NUM> are shorted (e.g., <NUM> V) the output of the second comparator 514b may be HIGH, and when not shorted (e.g., ~<NUM> V) the comparator output may be LOW.

In embodiments, the fifth section <NUM> includes a second inverter <NUM> and logic gates <NUM>, <NUM> (e.g., CD4081 AND gates) associated with signals to driver transistors within the respective solenoid valves 206a, 206b. For example, the logic gate <NUM> may control the signal to the solenoid valve (206b, <FIG>/<FIG>) regulating tea brewing (<NUM>, <FIG>) while the logic gate <NUM> may control the signal to the solenoid valve (206a, <FIG>/<FIG>) regulating coffee brewing (<NUM>, <FIG>). For example, when the signal probes <NUM> are unshorted (e.g., output of the second comparator 514b is LOW), the LOW signal may be sent to the second inverter <NUM> and the HIGH inverter output sent to logic gates <NUM>, <NUM> in order that the signals to the driver transistors of the tea and coffee solenoid valves 206a, 206b are passed. However, when the signal probes <NUM> are shorted to the ground probes <NUM> (e.g., grounded signal <NUM>, <FIG>) and the output of the second comparator 514b is HIGH, the HIGH signal may be sent to the second inverter <NUM> and the LOW inverter output sent to logic gates <NUM>, <NUM> instead, turning off the driver transistor signals for the respective tea and coffee solenoid valves 206a, 206b.

Claim 1:
A beverage maker platen overflow sensing system, comprising:
a platen (<NUM>);
at least one process control board (PCB) (<NUM>) comprising:
at least one processor communicatively coupled to one or more solenoid valves (206a-c), the solenoid valves (206a-c) configured to control a flow of a fluid into a server (<NUM>) positioned in the platen (<NUM>);
at least one memory coupled to the processor, the memory configured to store encoded instructions for controlling the solenoid valves (206a-c), the encoded instructions executable by the processor;
and
an overflow detection circuit electrically coupled to the solenoid valves (206a-c);
at least two signal probes (<NUM>) disposed within a forward portion of the platen (<NUM>), the signal probes (<NUM>) electrically coupled to the PCB (<NUM>) via wire hardness (<NUM>);
and
at least one platen probe (<NUM>) disposed below the at least two signal probes (<NUM>) and within a lower portion of the platen (<NUM>), the platen probe (<NUM>) electrically coupled to the PCB (<NUM>) and configured to provide a ground path to the PCB (<NUM>) when the system is in a default state;
the overflow detection circuit configured to:
generate at least one electrical signal between the signal probes (<NUM>);
detect an overflow state of the system based on a ground signal between at least one of the signal probes (<NUM>) and the platen probe (<NUM>), the ground signal conducted by the fluid;
and
when the overflow state is detected, cease the flow by electrically closing the solenoid valves (206a-c).