US20060254428A1 - Coffee making apparatus - Google Patents

Abstract

A brewing apparatus for infusing compacted ground coffee in a grounds cup at a brewing station with heated water under pressure. At a brewing station, a piston head with an active seal that is spaced from the grounds cup wall during motion, extends into the grounds cup. When the piston head begins to compact the ground coffee it activates the seal to form a sealed upper end of a brewing chamber. Hot water is admitted to the brewing chamber to produce the coffee. When the brewing cycle is completed, the piston head displaces further to force additional coffee from the grounds. Then the piston head retracts to allow the infusion chamber assembly to be removed for cleaning.

Description

FIELD OF THE INVENTION
• This invention generally relates to apparatus for brewing beverages by directing a liquid, such as hot water, across a compacted infusible material, such as ground coffee beans, in a sealed infusion chamber.
DESCRIPTION OF RELATED ART
• A large number of commercial devices are available for brewing beverages, particularly coffee, by infusing material with a liquid. Prior art coffee makers have incorporated a variety of percolating, drip, steeping and other brewing approaches. A large number of these coffee makers were also designed to brew coffee in batches, for example, 4-cup to 12-cup batches. Such devices, however, were characterized by difficulties in maintaining coffee flavor over time, in controlling waste as occurred by making excessive coffee that was then discarded, and in cleaning and maintenance of the coffee makers.
• The advent of espresso machines introduced new coffee brewing concepts. Espresso machines produce a small quantity of coffee at any given time, such as a cup of cappuccino or espresso. Espresso was brewed and continues to be brewed by placing an appropriate quantity of ground espresso coffee into an infusion chamber, compacting the ground coffee and closing that chamber. Hot water under pressure infuses the compacted coffee to extract its essence and directs the beverage to a cup.
• This process has become very popular, and there are a variety of implementations primarily for use in espresso machines, but also for machines for brewing coffee. For example, U.S. Pat. No. 4,457,216 to Dremmel discloses an infusion chamber with hydraulically operated upper and lower pistons that close a scalding chamber. The scalding chamber contains coffee grounds and receives hot water. During the brewing process the loose coffee swells. When brewing is complete, the lower piston rises to compress the swollen grounds extract the brewed coffee that passes through the lower piston to a cup or other serving receptacle. After the brewing cycle is complete, the upper piston retracts. Then the lower piston can elevate to position the used compressed coffee grounds above the infusion chamber for removal.
• U.S. Pat. Nos. 4,796,521 and 5,255,594 to Grossi disclose infusion chambers with a piston that delivers hot water by means of a metering unit. The piston is operated to allow the introduction of a filter carrier element and for compressing the coffee powder. U.S. Pat. No. 4,796,521 discloses a direct introduction of ground coffee from a coffee grinder into the infusion chamber. U.S. Pat. No. 5,255,594 discloses a motor drive.
• U.S. Pat. No. 5,230,277 to Bianco discloses two pistons mounted on circulating ball screw actuators for closing the top and bottom of an infusion chamber. The pistons are brought together to compact ground coffee after which hot water is introduced for infusion. After the brewing cycle, both pistons can be raised so the lower piston can eject the used coffee grounds.
• In U.S. Pat. No. 5,237,911 to Aebi a piston moves into an infusion chamber to compress ground coffee. The bottom of the piston comes into direct contact with the compressed ground coffee. There is no specific disclosure of a seal for preventing the escape of water from the infusion chamber past the piston.
• U.S. Pat. No. 5,277,102 to Martinez discloses a vending machine with a lower piston. The lower piston rises to compact ground coffee against a fixed upper plunger or piston.
• In U.S. Pat. No. 5,280,747 to Bonneville an espresso machine has a vertically movable snout for supplying hot water under pressure to ground coffee held in a filter. A cylinder or piston moves against the action of an antagonist spring to cause the snout to penetrate the package and compress the ground coffee.
• U.S. Pat. No. 5,302,407 to Vetterli discloses a brewing or infusion chamber with a movable piston. The brewing chamber has an open top. A closure piston opens and closes the brewing chamber. Pressurized hot water causes the movable piston to move upward to compress the ground coffee.
• In U.S. Pat. No. 5,402,706 to Locati an infusion chamber has a lower filter piston and an upper, two-part infuser piston. The infuser piston has a seal. One part of the upper piston slides into the other part against an opposing spring resistance. The seal remains in a contracted condition at a narrow diameter of a conical seat while the infusion piston enters the infusion chamber. During an operating stage, however, the distance between the two portions of the piston decreases causing the seal to shift upward to a maximum diameter of a conical seat. This process provides a seal and eliminates brushing and scraping of the packing to minimize wear and tear.
• U.S. Pat. No. 5,911,810 to Kawabata discloses a coffee brewing system in which a vertically movable cylinder receives ground coffee and has a top opening. A vertically movable, upwardly urged plunger compacts grounds after second cylinder is elevated.
• U.S. Pat. No. 6,035,762 to Ruckstuhl discloses an espresso machine with a brewing chamber in which two brewing chamber parts can be displaced relative to one another. In a closed position they form a brewing chamber for filter capsules. One of the members has multiple nozzles for directing hot water across the coffee. This approach allows the use of coffee pods of different sizes.
• In U.S. Pat. No. 6,606,938 to Taylor, a beverage brewing apparatus includes a disposable cartridge that is initially pierced and vented by a tubular outlet probe when an arm pivots a water disposing head into a sealing relationship with the top of the removable cartridge.
• U.S. Pat. No. 6,711,988 discloses an espresso machine with a variable volume infusion chamber. A piston with a static seal, shown as an O-ring, seals against and moves relative to an infusion cylinder. During brewing the piston elevates underwater pressure to allow swirling. When a predetermined pressure is obtained, a frothing valve opens. The piston moves toward the frothing valve to press the coffee grounds under a spring-generated force.
• These and other features have been incorporated in a number of single-cup coffee makers, particularly for espresso machines for commercial use, as in restaurants, coffee shops and the like. However, such machines are expensive and not economically attractive to most consumers even though they may make the best coffee.
• Recently several manufactures have introduced so-called “cup-at-a-time” coffee makers. They replace such pistons with hinged top units that latch to a base. A consumer must manually unlatch the hinged top unit, open it to expose a container for receiving either proprietary coffee pods or loose coffee. Then the consumer must manually close and latch the top unit to compact the coffee and form the sealed infusion chamber.
• With cup-at-a-time coffee makers clean up requires the top to be reopened. If the coffee is made with loose grounds, the grounds cup must be removed so the used grounds can be discarded. If a pod is used, it can be lifted from a grounds cup without having to remove the grounds cup.
• In many applications consumers desire automatic systems that incorporate coffee grinders. Such systems are characterized by locating the brewing chamber at an inaccessible location so it becomes impossible or, at best, very difficult, to clean the brewing chamber. Cleaning the brewing chamber in any such coffee maker is very important. If regular cleaning is not undertaken, oils and organic acids present in coffee attack the seal materials used to define the brewing chamber. Such substances also accumulate on the walls of the brewing chamber. If the seal slides over the walls, this material produces a rough surface that can damage the seals with use.
• Some commercially available consumer-oriented coffee makers limit the consumer to proprietary prepackaged coffee filter pods. This can limit consumer choices. Also some consumer-oriented coffee makers are limited to making espresso. These factors and expense limit their market to consumers.
• What is needed is apparatus for brewing a beverage, such as coffee, that is economical and easy to use. Specifically, what is needed is an economical coffee brewing apparatus that eliminates manual operation of latches, facilitates the incorporation of a grinder, simplifies cleaning and maintenance and is adapted for accepting ground coffee in a variety of forms.
SUMMARY
• Therefore it is an object of this invention to provide brewing apparatus for the consumers that has many of the advantages of more expensive commercial systems and that is economical, convenient to use and easy to maintain.
• Another object of this invention is to provide brewing apparatus that eliminates manual latching mechanisms.
• Still another object of this invention is to provide brewing apparatus that is adapted for use with a grinder while maintaining separation between their respective functions in order to facilitate use and maintenance.
• Still another object of this invention is to provide a coffee brewing system that is adaptable for receiving coffee grounds in a variety of forms.
• Yet still another object of this invention is to provide a coffee brewing system in which a grounds cup can be withdrawn for filling or cleaning without the need for releasing manual latches or breaking seals.
• Yet another object of this invention is to provide a coffee brewing apparatus that can be used for brewing regular coffee or espresso.
• In accordance with one aspect of this invention a beverage brewing apparatus includes a housing and a supply for liquid that infuses an infusible material thereby to produce a beverage. An open ending removable infusion chamber has a side wall, an open top and a perforated bottom for receiving the infusible material. A piston supported by the housing moves longitudinally with respect to the side wall. An active seal on the piston head expands into the side wall when said piston head reaches a compacting position whereby said piston and infusion chamber form a brewing chamber. Then the piston directs liquid to the infusible material under pressure.
• In accordance with another aspect of this invention apparatus for brewing coffee by infusing ground coffee with hot water under pressure includes a housing that defines a brewing station. A infusion chamber assembly can be inserted into the housing at the brewing station. The infusion chamber assembly carries the ground coffee and has a dispensing port for dispensing brewed coffee. A piston mounted to the housing proximate the brewing station compresses the ground coffee in the infusion chamber assembly in an extended state. An active seal is formed with the piston. The piston moves the active seal between a radially contracted state wherein the seal is spaced from said infusion chamber assembly and a radially expanded state to form a seal between the piston and the infusion chamber assembly. Hot water is supplied under pressure to the infusion chamber assembly when the seal is in the radially expanded state and the piston means has compressed the ground coffee in said infusion chamber assembly.
• In accordance with yet another aspect of this invention, a beverage brewing apparatus includes an infusion chamber with a cylindrical side wall and a piston head movable within the infusion chamber to a brewing position. An active seal generates a seal between the piston head and the side wall. The piston head comprises a first disk, a second disk and a peripheral seal. The peripheral seal has a central body portion and portions that attach to the first and second disks, respectively, whereby the peripheral seal acts as a flexible coupling between the first and second disks. A third portion on the peripheral seal engages the cylindrical side wall when the first and second disks are compressed thereby to form a seal with the infusion chamber.
• In accordance with yet another aspect of this invention, apparatus for brewing beverages supplies liquid to an infusible material under pressure to produce a beverage. The apparatus includes a housing, a removable reusable infusion chamber and a piston. The housing carries a support at a brewing station for interacting with an engagement structure thereby to allow the infusion chamber to be inserted and withdrawn from the brewing station. The infusion chamber also has a side wall, an open top and a perforated bottom for receiving the infusible material. The piston is supported by the housing and can be displaced into the infusion chamber. The piston directs liquid from the liquid supply to the infusible material. The piston also includes a seal that is positioned intermediate the piston and the side wall for contacting the side wall when the piston enters the infusion chamber thereby to form a brewing chamber in which the material is infused.
BRIEF DESCRIPTION OF THE DRAWINGS
• The appended claims particularly point out and distinctly claim the subject matter of this invention. The various objects, advantages and novel features of this invention will be more fully apparent from a reading of the following detailed description in conjunction with the accompanying drawings in which like reference numerals refer to like parts, and in which:
• FIG. 1 is a perspective view of an espresso machine incorporating this invention;
• FIG. 2 is a perspective view of the interior portions of the espresso machine shown inFIG. 1 taken from the right front;
• FIG. 3 is a perspective view of the espresso machine shown inFIG. 1 taken from the left rear;
• FIG. 4 is an exploded view of a compacting structure used in the espresso machine ofFIGS. 1 through 3;
• FIG. 5 is a detail of a top disk shown inFIG. 4;
• FIG. 6 is a view in section of a portion of the espresso machine taken along lines6-6 inFIG. 3;
• FIG. 7 is a section view of the portion of the infusion chamber taken along lines7-7 inFIG. 6;
• FIG. 8 is an exploded perspective view of a infusion chamber assembly that receives ground coffee;
• FIG. 9 is a cross section of the infusion chamber assembly ofFIG. 8;
• FIG. 10 is a cross section of an active seal shown inFIG. 4;
• FIG. 11A is a cross section that depicts the compacting structure ofFIG. 4 in an intermediate position with the compacting structure located within the infusion chamber assembly;
• FIG. 11B is an enlarged detailed portion of the structure shown inFIG. 12A;
• FIG. 12A is a cross section that depicts the compacting structure ofFIG. 4 in a position that compacts the ground coffee in the infusion chamber assembly;
• FIG. 12B is an enlarged detailed portion of the structure shown inFIG. 12A;
• FIG. 13 is a cross section that depicts the compacting structure ofFIG. 4 in a fully extended position that facilitates cleaning;
• FIG. 14 is a simplified schematic view of a control system for operating the espresso machine shown inFIG. 1; and
• FIG. 15 is a flow chart depicting one embodiment of the operation of the control system inFIG. 14.
DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
• FIG. 1 depicts one embodiment of an apparatus of this invention for brewing beverages, such as coffee, by supplying a heated liquid, such as hot water, under pressure to an infusible material in an infusion chamber. Specifically,FIG. 1 depicts such apparatus in the form of anespresso machine20 with ahousing21 on abase22. Thehousing21 includes a cup warmer23 for cups, such as thecup24, so cups can be preheated before being filled with espresso. The housing includes acontrol panel25, a brewing/steam control knob26 and a grindfineness adjustment knob27 for any included coffee grinder. A water reservoir ortank30 on thebase22 has anintegral handle31 to facilitate removal and filling.
• FIG. 1 depicts a removable, reusable,infusion chamber32 at abrewing station33 that includes agrounds cup holder34 with anintegral handle35. A removabledrip tray assembly36 resting on thebase22 provides a facility for supporting one or twocups37L or37R or both. Thehousing21 also supports asteam nozzle38 and a coffeebean hopper door39. Afill station40 is located at afill station door41
• In use a consumer brews one or two cups of coffee by activating a power-onswitch42 and by checking thewater reservoir30 for a sufficient water level. Then the individual grasps thehandle35 to withdraw theinfusion chamber assembly32 from thebrewing station33 in a straight-forward motion to deposit preground coffee or prepackaged ground coffee into theinfusion chamber assembly32.
• If freshly ground coffee is desired, the individual inserts theinfusion chamber assembly32 into thefill station40 through thefill station door41 again with a straight-forward motion. If thefill station40 has a coffee grinder, the individual moves thefineness adjustment knob27 to a desired position and selects either a one-cup or two-cup quantity by means of a one-cup switch43 or a two-cup switch44. Activating theswitch45 initiates the grinding operation that deposits the appropriate quantity of ground coffee into theinfusion chamber assembly32. Alternatively the fill station would comprise a container for ground coffee and a dispenser for depositing pre-measured quantities of coffee into theinfusion chamber assembly32.
• When the filling operation is completed, the individual merely withdraws theinfusion chamber assembly32 from thefill station40, whereupon thefill chamber door41 closes. Then the individual inserts the infusion chamber assembly back into thebrewing station33. These operations are achieved without any need to manipulate latches or other mechanisms.
• When various visual annunciators, such as LEDs or likelight sources46, indicate brewing can begin and the brew/steam control selector26 is in the brewing position, depressing abrewing switch47 initiates the brewing operation. The consumer sees the result when brewed coffee begins to fill thecoffee cups37L and37R. If only one cup is to be brewed, it is merely necessary to remove thecup37R and center thecup37L below thehandle35, or vice versa.
• Emptying the used coffee grounds requires the individual to withdraw theinfusion chamber assembly32 from thebrewing station33 to dispose of the used coffee grounds and to clean the grounds cup. Periodically an individual can initiate a cleaning cycle whereby a compacting structure becomes readily accessible, as described later. Thecontrol27 can include anaccess ring50 that can be used to remove the front burr of the grinder for cleaning.
• When it is desired to apply steam for foaming milk or for preheating a cup the consumer merely shifts the BREW/STEAM control26 to a steam position. Steam will be dispensed from the bottom of thesteam nozzle38.
• FIGS. 2 and 3 depict theespresso machine20 with thehousing21 removed to view the major components including thebase22, thewater reservoir30, the removabledrip tray assembly36 and the cup warmer23.FIG. 2 additionally discloses the BREW/STEAM control valve26, the grindfineness adjustment knob27 and thesteam nozzle38.
• Thewater reservoir30 has a hingedtop51 andrear wall52 with aconnector53. Theconnector53 includes a check valve (not shown) that closes when thewater reservoir30 is removed from theespresso machine20 for filling. When afull water reservoir30 is inserted and seated in theespresso machine20, a connector on the apparatus, not shown but well known in the art, interacts with theconnector33 to open the check valve. Water is then available to apump54 shown inFIG. 3.
• Thepump54, when active, pumps cold water into aboiler55 through aconventional flow meter56. Tubing, not shown for purpose of clarity, conveys hot water from theboiler55 to aninlet hose57 on a compactingassembly60 that forms a brewing chamber in cooperation with theinfusion chamber assembly32 that is inserted into thebrewing station33. Heat from theboiler55 elevates the temperature of the cup warmer23.
• As shown inFIG. 2, at thebrewing station33 the espresso machine includes asemi-cylindrical support portion61 and two tangentialplanar wall extensions62 that carry ashelf63. Theshelf63 acts as a support for theinfusion chamber assembly32, particularly thegrounds cup holder34. Aninterlock64 provides an enabling input to a brewing controller when theinfusion chamber assembly32 is fully seated and properly aligned in thebrewing station33.
• Thefill station40 has a similar structure with asemi-cylindrical support portion65 and two tangentialplanar wall portions66. Ashelf67, similar to theshelf63, supports theinfusion chamber assembly32 for receiving ground coffee. Aninterlock68 provides an enabling signal to a controller when theinfusion chamber assembly32 is fully seated and aligned in thefill station40.
• Still referring toFIGS. 2 and 3, the compactingassembly60 includes apiston assembly70 driven, in this embodiment, by amotor71 through a speedreduction gear mechanism72. In this specific embodiment theapparatus20 also includes acoffee grinder73 at thefill station40 that grinds beans to ground coffee of a selected coarseness or fineness.
• FIG. 4 depicts thepiston assembly70. It includes a threadedrod74 characterized by anaxially extending slot75 that engages a stationary base plate for preventing rotation. Aradial arm76 serves as a switch actuator for limit switches as described later. A threadedrod retainer77, overlying anupper end80 of the threadedrod74, includes a plurality ofclips81. Theclips81 engage correspondingapertures82 in atop disk83 as more specifically disclosed inFIG. 5.
• FIG. 5 is a perspective view taken from above thetop disk83. The top surface of thetop disk83 has a plurality of circumferential lands and grooves that provide a rigid structure while minimizing its weight and material. Thetop disk83 additionally includes apassage84 for enabling a connection to theinlet hose57 inFIG. 3 that connects to theboiler55.
• Referring again toFIG. 4, abottom disk85 includes anaxial shoulder86 and abottom labyrinth87. Thelabyrinth87 facilitates the dispersal of water exiting anipple90 across the extent of and through a supportedperforated disk91 as described later. Aguide ring92 is axially coextensive with theaxial shoulder86 and provides peripheral support for theperforated disk91. Ascrew93 engages a central threadedaperture94 accessible from the bottom of thebottom disk85 thereby to fasten thebottom disk85, theperforated disk91 andguide ring92 into a subassembly. In this assembly the free ends of axially extending walls forming thelabyrinth87 support theperforated disk91 so it does not deform when it engages ground coffee in theinfusion chamber assembly32.
• Awavy spring95 lies intermediate thetop disk83 andbottom disk85. Thetop disk83 andbottom disk85 sandwich aseal96 characterized by a radially contracted state and a radially expanded state. Thetop disk83,bottom disk85,perforated disk91,guide ring92,screw93,wavy spring95 and seal96 thereby form apiston head97 that attaches to the threadedrod74 and provides an active peripheral seal structure. As described in more detail later, theseal96 attaches to thebottom disk85 and to thetop disk83. When the threadedrod74 is in a retracted position, thewavy spring96 exerts a force that tends to separate thetop disk83 from thebottom disk85. Under these conditions theseal96 relaxes, has a minimum diameter and is radially contracted. When the axial distance between thetop disk83 andbottom disk85 decreases, thewavy spring95 compresses and the diameter of theseal96 increases so theseal96 moves to the radially expanded state.
• Theseal96 performs several functions. First, theseal96 engages thecylindrical wall112 of thegrounds cup102 to confine any water or brewed coffee to thebrewing chamber98. Second, theseal96 assures that all the hot water admitted to the labyrinth inFIG. 4 passes through theperforated disk91 and into the ground coffee in thebrewing chamber98. As a third function, theseal96 acts as a flexible coupling that supports thebottom disk85 on thepiston head97. The specific construction of theseal96 and its performance of these functions are described later.
• FIGS. 6 and 7 are useful in understanding the mechanical arrangements of the compactingassembly60 and theinfusion chamber assembly32. When thepiston head97 is positioned in thegrounds cup102 at a position shown by dashedline99 and sealed by theseal96, the area below thepiston head97 bounded by theinfusion chamber assembly32, specifically thegrounds cup102, becomes a brewing chamber.
• In these views, however, themotor71 andgear train72 have retracted the threadedrod74 and thepiston head97 to an upper limit or fully retracted position as defined when theradial arm76 on the threadedrod74 engages anupper limit microswitch100. Alower limit microswitch101 defines a lower-most position or range of travel. When the piston is fully retracted, theinfusion chamber assembly32 is easily removed from thebrewing station33.
• FIGS. 8 and 9 depict theinfusion chamber assembly32 with thegrounds cup holder34 and agrounds cup102. Thegrounds cup holder34 includes aface plate103 with theintegral handle35 and anintegral cylinder104. Spacedcircumferential ribs105 on thecylinder104 form a channel that engages theshelf63 that acts as a supporting track at thebrewing station33 shown inFIG. 2 to position theinfusion chamber assembly34 below the compactingassembly60. Theribs105 also engage theshelf67 inFIG. 2 that acts as a track at thefill station40.
• Still referring toFIGS. 8 and 9, thegrounds cup holder34 has aconcave bottom106, aright dispensing port107 and a left dispensingport110. During brewing, coffee exits from both of these ports. When two coffee cups, such as thecoffee cups37L and37R are arranged as shown inFIG. 1, coffee is dispensed into the two cups simultaneously. However, the spacing between theports107 and110 is such that when a single cup is centered about thehandle35, coffee from both dispensingports107 and110 will be directed into a single cup.
• Referring again toFIGS. 8 and 9, thegrounds cup102 has acylindrical wall112 that extends from an open top with alip113 that engages atop edge114 of thecylinder104, so thegrounds cup102 essentially rests in thegrounds cup holder34. At the bottom, thegrounds cup102 has two taperedportions115 and116 that terminate with a perforated bottom orsieve portion117.
• In accordance with one aspect of this invention, the depth of thecylindrical wall112 is at least equal to the depth of the grounds in thegrounds cup102 plus an amount that enables thepiston head97 to achieve a sealing relationship with thecylindrical wall112 of thegrounds cup102. This depth provides flexibility to a consumer because asingle grounds cup102 will accommodate coffee in different packages or in different quantities. There is no need to inventory different grounds cups. Further, thegrounds cup102 easily separates from thegrounds cup holder34 for cleaning. This structure also allows an accessory element, such as a crema insert, to be located intermediate thegrounds cup102 and thegrounds cup holder34.
• FIG. 10 depicts theannular seal96 that is a component of the active seal. The structures in phantom at the right ofFIG. 10 are useful in conjunction with other drawings for understanding the relationship of theseal96 with components of thepiston head97 and its functions. Specifically, theseal96 has anannular body120 that has a C-shaped cross section to form achannel121 with an opening facing acenter axis122. An annularupper lip123 extends axially and upward to be captured in agroove124 in thetop disk83. An annularlower lip124 extends downward axially to terminate with afree end125. This end is captured between theaxial shoulder86 of thebottom disk85 and theguide ring92. Thefree end125 bears against theperforated disk91. An integral obliquely extendingexterior skirt126 can flex radially with respect to theaxis122.
• In the relaxed or radially contracted state shown inFIG. 10, theupper lip123,annular body120 andlower lip124 form a flexible coupling that suspends thebottom disk85 from thetop disk83. Thelower lip124, particularly the surface at thefree end125, forms a seal to confine the hot water under pressure to the volume between theperforated disk91 and thelower disk85 including thelabyrinth87. This prevents any water from escaping at the periphery of thepiston head97, particularly at theguide ring92. When theseal96 assumes a radially expanded state due to the compression of thewavy spring95 and movement of thebottom disk85 toward thetop disk83, theskirt126 expands into thecylindrical wall122 thereby to form of peripheral seal that defines an upper limit of thebrewing chamber98 and that confines all the hot water under pressure and brewing coffee to thebrewing chamber98.
• FIGS. 6 and 7 depict theespresso machine20 with thepiston97 and threadedrod74 retracted to an open position, thearm76 having activated the upper limitmicro switch100. In this fully retracted position, the compactingapparatus60 has retracted thepiston head97 to a position that allows theinfusion chamber assembly32 to be inserted into thebrewing station33 withcoffee130. Thecircumferential ribs105 engage the support provided by theshelf63 inFIG. 2. When fully seated, thegrounds cup holder34 engages theinterlock64. When the structures are oriented as shown inFIGS. 6 and 7, thewavy spring95 separates the top andbottom disks83 and85 by a maximum distance so that theseal96 is in its radially contracted state.
• As described later, when water temperature and other conditions are satisfied, the consumer pushes thebrewing switch47 inFIG. 1. Themotor71 displaces the threadedrod74 andpiston head97 toward theinfusion chamber assembly32.FIGS. 11A and 11B depict thepiston head97 as it first enters thegrounds cup102. Theseal96, particularly theseal skirt126, is spaced from thegrounds cup cylinder112.
• As will be apparent, the position of thegrounds cup102 relative to thepiston head97 will not be held to close tolerances. Thus, it is possible for a misalignment to exist during normal operations. In contemplation of this possibility, theguide ring92 shown inFIGS. 4, 11A and11B serves to prevent any damage to theseal96. Specifically, theguide ring92 has anannular body131 and angularly spaced, radially extendingtabs132 with outer, downwardly located chamfers133. Should there be any misalignment, achamfer133 will contact thelip113 and center thepiston head97 within thegrounds cup102. Thus thewall112 does not contact theskirt126 as thepiston head97 enters thebrewing chamber98.
• Consequently theguide ring92 protects theseal96 from damage. Moreover there is no wear on theseal96 during this downward motion.
• Themotor71 continues to drive the threadedrod74 andpiston head97 downward with the configuration shown inFIGS. 11A and 11B, until theperforated disk91 contacts theground coffee130. Further downward motion of thepiston head97 begins to compact theground coffee130. In addition at some point the force exerted on theperipheral disk91 will be greater than the force exerted by thewavy spring95. As a result, the distance between the top andbottom disks83 and85 decreases. Consequently theseal96 moves to the radially expanded state and drives theskirt126 against the cylinder wall to form the seal.
• As the ground coffee compacts, the load on themotor71 increases. When the current reaches a first specified threshold, themotor71 is de-energized. The gear ratios lock thepiston head97 in its vertical position. The seal formed by theskirt126 now defines the top of thebrewing chamber98. This event enables hot water to pass from theboiler55 through thehose57 and thepiston97 and to permeate thecoffee130 under pressure.
• As can be seen fromFIG. 4, the water under pressure travels through thenipple90 to emerge in thelabyrinth87. The pressure required to displace the water into thelabyrinth87 is less than that needed to force the water through theperforated disk91 and the compactedcoffee grounds134 inFIGS. 12A and 12B. Thus, the water initially fills thelabyrinth87 and then passes through the entire surface of theperforated disk91 bounded by thelower lip124 of theseal97 thereby to permeate theground coffee130 uniformly.
• Referring toFIG. 12B, the brewedcoffee134 in thebrewing chamber98 above theground coffee130 may be under pressure. To the extent such pressure exists, it does not detract from the sealing force that drives theskirt126 against thecylindrical wall122. Although such brewedcoffee134 enters agap135 between theseal body120 andskirt126, it produces an additive pressure component that further perfects the seal. Consequently the compactingapparatus60 provides both compacting force and a mechanism for controlling the active seal.
• In one embodiment of this invention, the brewing cycle has another step. After the brewing cycle is completed themotor71 is energized again to drive the threadedrod74 downwardly thereby over compacting thecoffee grounds130 to extract additional beverage. This downward force increases motor current to a next higher threshold. When the threshold is reached, themotor71 reverses to retract the threadedrod74 andpiston head97 back to the position shown in11A.
• During the processes of compression and over compression and initial retraction, theseal96, primarily theskirt126, undergoes only minimal sliding against thecylindrical wall112. As soon as themotor71 produces any significant upward displacement during retraction, thewavy spring95 begins to expand to separate the top andbottom disks83 and85 so theseal96 with itsskirt126 retracts radially from thecylindrical wall112. Consequently, theseal96 will not wear and have a long life.
• When themotor71 fully retracts the threadedrod74 and thepiston head97, theradial arm76 again engages theupper limit microswitch100 to de-energize themotor71 and conclude the brewing cycle, so a consumer can remove a cup and drink the beverage. Also in this position, the consumer can easily remove theinfusion chamber assembly32 from thebrewing station33 for cleaning after each use and for filling with fresh ground coffee.
• Generally this per use cleaning of theinfusion chamber assembly32 will be sufficient. Cleaning thepiston head97 can be done less frequently because during brewing the only elements in contact with brewed coffee and coffee grounds are theinfusion chamber assembly32 and the bottom surface of thepiston head97, that is, theperforated disk90 andguide ring92 and the surface of theseal96 at agap135. The water under pressure prevents thebottom disk85 including thelabyrinth87,upper disk83 and internal surfaces of theseal96 from accumulating any residue.
• When it is desired to clean thepiston head97, the consumer initiates a cleaning cycle by activating a “clean”switch136 inFIG. 1 while theinfusion chamber assembly32 is removed. This operation energizes themotor71 and drives the threadedrod74 downwardly until thearm76 strikes thelower limit microswitch101. As shown inFIG. 13, theentire piston assembly97 is then accessible for cleaning in thebrewing station33. Generally it is merely necessary to wipe the surface of theperforated disk91 andguide ring92 with a damp cloth or sponge. A more thorough cleaning might be achieved by means of a special cleaning cycle, like a brew cycle, with aninfusion chamber assembly32 inserted at thebrewing station33.
• FIG. 14 is a block schematic that summarizes the various control inputs and outputs that can be utilized in theespresso machine20 ofFIG. 1. In this specific embodiment, acontroller140 has connections to thewater pump54, theboiler55, theflow meter56, thepiston motor71 and thegrinder56. Theflow meter56 produces a FLOW input signal for thecontroller140. Atemperature sensing circuit141 generates a TEMP input signal. Acurrent sensor142 provides a CURRENT signal to athreshold level circuit143. The threshold level circuit produces one of two outputs to acontrol unit144. The first is from aLEVEL1detector145 that represents the current that exists as compactingassembly60 compacts the coffee grounds to an appropriate level. ALEVEL2detector146 is set at a higher level and serves to provide a reversing signal for the post brewing over compression sequence. Awater level sensor147 indicates the presence of a sufficient quantity of water for a brewing operation.
• Theupper limit microswitch100 and thelower limit microswitch101 provide two other control inputs to thecontroller140. Still other control inputs are provided by theinterlock64 that indicates the proper alignment of theinfusion chamber assembly32 in thebrewing station33. Theinterlock68 indicates the proper positioning of theinfusion chamber assembly32 in thefill station40. Other inputs include the power-onswitch42, the one-cup and two-cup switches43 and44, thebrewing switch47 and thegrind switch136.
• FIG. 15 is a basic flow diagram for outlining the logical operations that can occur within acontroller140, including thecontrol unit144. When theapparatus20 is plugged into an outlet,control unit144 is enabled and step150 senses the existence of a full power status. When that condition is realized, step151 transfers control to step152 and may at that point also energize a power-on annunciator.
• Step152 reads the input signal from thewater level sensor147 inFIG. 14. If insufficient water exists, step152 waits for water to be added by the consumer instep153. When that test is completed,step154 determines whether the water temperature is above a first operating threshold, typically set at the bottom of an acceptable brewing temperature range. On initialization this typically will not be the situation, so control passes fromstep154 to step155 to energize theboiler55.Steps156 and157 also monitor the water temperatures for values in excess of an upper limit of an acceptable range for de-energizing the boiler instep157. As shown this control sensor enters into aloop including steps154 through157 thereby to constantly control the temperature of the water during the brewing cycle
• Once the water temperature is in an appropriate range, the consumer receives a notification as the illumination of a ready to brew light. This may initiate a time-out to limit the maximum interval before thebrew button47 inFIGS. 1 and 14 is actuated. The time-out interval terminates the operation of theboiler55.
• Once thebrew button47 is actuated, control passes to step162 to determine whether theinfusion chamber assembly32 is properly aligned by monitoring theinterlock switch64 shown inFIGS. 2 and 14. When both the conditions ofsteps160 and162 are met within the time-out interval,step163 energizes themotor71 to extend thepiston head97. When thepiston head97 begins to compact the ground coffee as shown inFIG. 12A, the signal from the motorcurrent sensor142 increases until the current reaches the first threshold established by theLevel 1detector145. When this occurs, step156 de-energizes themotor71. Now the system is ready to infuse the compacted ground coffee.
• Next thecontrol unit144 determines whether the one-cup switch43 or the two-cup switch44 has been actuated. As will be apparent, such switches should be ganged so only one of the two switches can be depressed at any time. Step166 establishes the amount of water that must transfer through thebrewing chamber98 in response to the selection of one or two cups. Step167 energizes thepump154 so heated water flows to thebrewing chamber98 until theflow meter56 records the specified quantity. When this occurs step171 turns off the water.
• Step172 then energizes the motor to produce over-compacting. Step173 monitors the current from thecurrent sensor142 until theLevel 2detector146 indicates that second threshold has been reached. At thatpoint step174 reverses the motor and begins the retraction process. When theradial arm76 engages theupper limit microswitch100, step175 transfers control to de-energize the motor atstep176. As will be apparent, whenstep176 de-energizes the motor, the brewing cycle has been completed.
• In summary, theespresso machine20 ofFIG. 1, specifically the structure that forms thebrewing chamber98 including theinfusion chamber assembly32 with itsgrounds cup102 and thepiston head97 with itsseal96, facilitates and simplifies an operation by which coffee grounds are compacted and then infused under pressure. Sealing is enhanced because the water pressure acts to increase, rather than decrease, the sealing force. Further, as the seal is radially contracted for most discrete piston head motion, it will have a long life. As a result it is possible to construct a brewing chamber that is sealed across the top with a single piston and that enables theinfusion chamber assembly32 to be removed for cleaning and to be transferred to a remote site for receiving ground coffee, such as at thefill station40 or even some separate filling position remote from theapparatus20.
• The simplicity of this design allows theespresso machine20 to be available for consumers with many of the advantages of the more expensive commercial systems. Yet thisespresso machine20 is easy to use because there is no need for a consumer to manipulate manual latching mechanisms. Moreover, owing to the fact that theseal96 seals against theside wall112 of thegrounds cup102 the machine can accommodate ground coffee or a variety of coffee pods of different diameters and in differing amounts and quantities up to some arbitrary maximum depending on the depth of thegrounds cup102. As a result, theespresso machine20 inFIG. 1 is readily adapted for accommodating a wide range of infusible materials.
• This invention has been disclosed in the form of aparticular espresso machine20. It will be apparent, however, that variations could be incorporated or applied to the specifically enclosed embodiment without departing from the invention. For example, the compactingassembly60 ofFIGS. 4, 6 and7 utilizes a particular motor and drive means for producing the vertical displacement of thepiston head97. Mechanical, hydraulic, pneumatic or other mechanisms and driving structures might be utilized for displacing thepiston head97 to its various positions. Thepiston head97 is disclosed with a particular arrangement of top and bottom disks, an intermediate spring and a sealing structure. Alternate implementations of each of those elements could provide equivalent functions. For example, the specifically disclosed structure of theseal96 with theskirt126 is particularly suited for the high-pressure environment associated with espresso brewing applications. The pressure required to brew regular coffee is considerably less. In such an application a variation of theactive seal96 with the skirt removed by be substituted. As another alternative, the active seal could be replaced by a passive seal, such as an O-ring. Thegrounds cup102 is disclosed as a deep drawn element; shallower grounds cup could be substituted. Accessory devices might be interposed between bottoms of thegrounds cup102 and thegrounds cup holder32, all while still realizing some, if not all, the advantages of this invention. The specifically disclosed control sequence could be altered while still achieving the advantages of this invention. Therefore, it is the intent of the appended claims to cover all such variations and modifications as come within the true spirit and scope of this invention.

Claims (36)

1. Apparatus for brewing beverages including a housing and means for supplying a liquid to an infusible material under pressure thereby to produce a beverage, said apparatus comprising:

A) infusion chamber means supported by said housing including a side wall, an open top and a perforated bottom for receiving the infusible material,

B) piston means supported by said housing for being displaced into said infusion chamber means, said piston means including means for directing the liquid from the liquid supply means to the infusible material,

C) active sealing means mounted on said piston means intermediate said piston means and side wall means, said active sealing means including a seal, means for displacing said seal into an expanded state wherein said seal contacts said side wall when said piston means compacts the infusible material whereby said piston means and infusion chamber means form a brewing chamber in which the material is infused.

2. Apparatus as recited inclaim 1 wherein said infusion chamber means includes:

i) grounds cup means for receiving the infusible material and including said perforated bottom and a cylindrical side wall as said side wall, and

ii) grounds cup holder means for supporting said grounds cup means in the housing in alignment with said piston means.

3. Apparatus as recited inclaim 2 including complementary means for removably supporting said grounds cup means in said grounds cup holder means.

4. Apparatus as recited inclaim 2 wherein said piston means includes piston head means for compressing the infusible material in said grounds cup means.

5. Apparatus as recited inclaim 4 wherein said cylindrical side wall has a height that is at least equal to the depth of the infusible material in said grounds cup means plus an amount that enables said piston head means to achieve a sealing relationship about said cylindrical side wall.

6. Apparatus as recited inclaim 4 wherein said perforated bottom constitutes a central sieve and includes at least one annular tapered section supporting said central sieve from said cylindrical wall.

7. Apparatus as recited inclaim 1 wherein said piston means includes:

i) a piston rod

ii) drive means for moving said piston rod between retracted and extended positions, and

iii) piston head means attached to said piston rod including said active sealing means for compressing the infusible material in said infusion chamber.

8. Apparatus as recited inclaim 7 wherein said displacement means includes spaced top and bottom disks and intermediate biasing means for applying a force thereto whereby said top and bottom disks are displaced away from each other and said active sealing means is in its radially contracted state.

9. Apparatus as recited inclaim 8 wherein said bottom disk includes a labyrinth facing said brewing chamber and said piston includes a perforated disk overlying said labyrinth thereby to distribute the liquid evenly over the infusible material during brewing.

10. Apparatus as recited inclaim 9 wherein said seal in said active sealing means includes a peripheral sealing portion for sealing the periphery of said perforated disk and said bottom disk to confined liquid to emerge from said piston head means into the infusible material through said perforated disk.

11. Apparatus as recited inclaim 1 wherein said seal in said active sealing means includes an annular flexible body portion with a first and second lip means and a peripheral skirt for forming a seal with said infusion chamber means in a radially expanded state of said sealing means.

12. Apparatus as recited inclaim 11 wherein said piston means includes spaced top and bottom disks and intermediate biasing means for applying a force thereto whereby said top and bottom disks are displaced away from each other, said top and bottom disks having first and second attachment means for attaching to said first and second lip means, respectively, whereby said sealing means supports said bottom disk from said top disk and whereby compressing said bottom disk against said top disk displaces said seal to the radially expanded state.

13. Apparatus as recited inclaim 12 wherein said seal includes a skirt portion extending from the periphery of said annular flexible body portion.

14. Apparatus as recited inclaim 13 wherein said piston means additionally includes guiding means for aligning said piston means with said infusion chamber means thereby to protect said skirt from damage when said piston means moves in said infusion chamber means.

15. Apparatus for brewing coffee by infusing ground coffee with hot water under pressure comprising:

A) a housing,

B) means for defining a brewing station in said housing,

C) a infusion chamber assembly for being inserted into said housing at said brewing station, said infusion chamber assembly carrying the ground coffee and having dispensing port means for dispensing brewed coffee,

D) piston means mounted to said housing proximate said brewing station for compressing the ground coffee in said infusion chamber assembly in an extended state.

E) active sealing means formed with said piston means, said piston means including means for moving said active sealing means between a radially contracted state wherein said sealing means is spaced from said infusion chamber assembly and a radially expanded state wherein said sealing means forms a seal between said piston means and said infusion chamber assembly, and

D) means for supplying hot water under pressure to said infusion chamber assembly when the sealing means is in the radially expanded state and said piston means has compressed the ground coffee.

16. Apparatus as recited inclaim 15 wherein said water Supply means includes:

i) a water reservoir for containing water to be brewed,

ii) a pump for pressurizing the water for delivery to said infusion chamber assembly,

iii) a boiler for heating the water, and iv) means for interconnecting said water reservoir, pump and boiler in an operative relationship thereby to supply heated water to said infusion chamber assembly under pressure.

17. Apparatus as recited inclaim 16 including a control panel and control means responsive to the inputs from said control panel and said water supply means for controlling the movement of said piston means relative to said infusion chamber assembly.

18. Apparatus as recited inclaim 17 wherein said piston means includes electric drive means and said control means includes means for controlling the energization of said electric drive means.

19. Apparatus as recited inclaim 17 wherein said control means includes means for controlling the temperature and quantity of the water from said water supply means.

20. Apparatus as recited inclaim 15 wherein said piston means includes a piston head with a bottom disk having a lower labyrinth and with a perforated disk overlying said labyrinth whereby heated water under pressure passes through said labyrinth and perforated disk to infuse the ground coffee, said bottom disk including means for conveying the heated water under pressure to said labyrinth.

21. Apparatus as recited inclaim 15 wherein said active sealing means includes a seal with an annular body portion and an outer skirt that forms a continuous seal around the periphery of said infusion chamber assembly.

22. Apparatus as recited inclaim 15 wherein said housing includes means for defining a brewing station and said infusion chamber assembly includes:

i) a grounds cup holder with means for being supported in said housing at said brewing station including said dispensing port means, and

ii) a grounds cup having a cylindrical side wall and perforated bottom for passing brewed coffee to said grounds cup holder dispensing port, said active sealing means in its radially expanded state forming an upper limit of the brewing chamber.

23. Apparatus as recited inclaim 22 wherein said active sealing means includes a seal with an annular body portion and an outer, downwardly extending skirt whereby said skirt contacts said grounds cup cylindrical wall to form a continuous seal around the circumference of said grounds cup when said seal is in its expanded state.

24. Apparatus as recited inclaim 23 wherein said piston means includes top and bottom disks with an intermediate spring for biasing said top and bottom disks apart, said top and bottom disks being attached to upper and lower portions, respectively, of said seal whereby continued extension of said piston means into ground coffee in said grounds cup overcomes the bias of said spring thereby to decrease the separation between said top and bottom disks and cause said sealing means to expand radially into said grounds cup cylindrical wall.

25. Apparatus as recited inclaim 14 wherein said housing includes:

i) means for defining a fill station,

ii) means for supporting said infusion chamber assembly in said fill station,

ii) means for dispensing ground coffee into said infusion chamber assembly at said fill station whereby the infusion chamber assembly with the ground coffee can be transferred from said fill station to said brewing station.

26. Apparatus as recited inclaim 25 wherein said ground coffee dispensing means includes:

a) a grinder for grinding coffee beans, and

b) a hopper for directing coffee beans into said grinder.

27. In a beverage brewing apparatus including an infusion chamber with a cylindrical side wall and a piston head movable within said infusion chamber to a brewing position, an active seal for generating a seal between said piston head and said side wall, said piston head comprising:

A) a first disk,

B) a second disk,

C) a peripheral seal having a central body portion and first and second means for attachment to said first and second disks, respectively, whereby said peripheral seal acts as a flexible coupling between said first and second disks, said peripheral seal having a third portion for engaging said cylindrical side wall when said first and second disks are compressed thereby to form a seal with the infusion chamber.

28. An active seal as recited inclaim 27 including means for biasing said first and second disks apart whereby said peripheral seal is spaced from said side wall.

29. An active seal as recited inclaim 28 wherein said central body portion has a C-shape that radially expands when the first and second disks overcome said biasing means and the distance between said disks decreases.

30. An active seal as recited inclaim 29 wherein said peripheral seal includes a skirt about the periphery of said central body portion for contacting the surface of said infusion chamber in the expanded state of said active seal.

31. Apparatus for brewing beverages including means for supplying a liquid to an infusible material under pressure thereby to produce a beverage, said apparatus comprising:

A) a housing with support means at a brewing station,

B) removable reusable infusion chamber means slidably supported by said housing including a side wall, an open top, and a perforated bottom for receiving the infusible material and engagement means for interacting with said support means whereby said infusion chamber means can be inserted and withdrawn from said brewing station, and

C) piston means supported by said housing for being displaced into said infusion chamber means, said piston means including:

i) means for directing the liquid from the liquid supply means to the infusible material, and

ii) sealing means intermediate said piston means and side wall means for contacting, said sealing means including a seal, wherein said seal contacts said side wall when said piston means enters said infusion chamber compacts the infusible material whereby said piston means and infusion chamber means thereby to form a brewing chamber in which the material is infused.

32. Apparatus as recited inclaim 31 including means in said housing for detecting an alignment between said infusion chamber means and said piston means.

33. Apparatus as recited inclaim 32 wherein said support means includes a track for interacting with said engagement means.

34. Apparatus as recited inclaim 31 wherein said support means includes a track for interacting with said engagement means.

35. Apparatus as recited inclaim 31 wherein said apparatus includes fill station means for dispensing ground coffee into said infusion chamber means, said fill station means including fill station support means for interacting with said engagement means.

36. Apparatus as recited inclaim 32 wherein said fill station support means includes a track corresponding to the track at said brewing station thereby to facilitate the transfer of said infusion chamber means between said fill and brewing stations.

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