Inventors: Louis Busick

Sacha Polakoff

Paul Bedell

Cross-Reference to Related Applications

[0001] This application is a non-provisional patent application filed under provisions of the Patent Cooperation Treaty and makes a priority claim to US provisional application 62/248,607, filed on October 30, 2015, which is incorporated herein by reference as if fully recited herein.

Technical Field

[0002] Exemplary embodiments relate to devices and methods for heating liquid (preferably water) within a cooler that do not require a separate hot water tank. A preferred exemplary embodiment comprises a heating tube that is wrapped with at least one heating element wherein the heating tube is connected to a water reservoir within a water cooler such that cool or room temperature water may be drawn from the reservoir and into the tube where the water is heated to a desired temperature by the heating elements as the water flows through the tube before ultimately being dispensed by the water cooler.

Background and Summary of the Invention

[0003] It is not uncommon for water coolers to include hot water on tap in order to provide hot water for things such as instant coffee, tea, and soup. In order to provide this hot water, the known water coolers contain a relatively small hot water tank that is similar to a miniature version of a hot water heater that you would find in a home except that the water within the cooler is maintained at a much higher temperature (typically in the 180 to 200 degrees Fahrenheit range). The hot water tanks of the known systems typically hold 50 to 60 ounces of hot water in the target temperature range. When a user of the cooler selects and opens the hot water tap, hot water is dispensed from the tank.

[0004] In the known system, the hot water tank is controlled by a thermostat that is in thermal contact with the tank wall or water contained in the tank. When the temperature falls below a predetermined set point, the thermostat turns on the heating element of the tank and heats the water until the temperature is at the high end of the target range. Heating elements used by the known tank are typically inside the tank exposed to the water or wrapped around the exterior of the tank wall. The heater wattages expended to heat the water in the tank are frequently between 400 and 500 Watts.

[0005] Throughout the day, energy may be expended to the heating elements of the known hot water tank approximately 30% of the time to maintain the hot water target temperature within the tank: even when there is no dispensing of the hot water. Further, a known water cooler at an office will continue to consume energy to heat water even over the weekend when no one is there.

[0006] Another set-back to the known systems of providing heated water to a water cooler is that when water within the hot water tank heats up, it expands. In a water cooler, this heated expansion water flows back into the storage area that is located at the top of the cold water tank. This causes the chilled water in the cooler to warm up which in turn causes the cooling system (which is typically compression-driven) to turn on and cool the water. The hot water tank system wastes energy to maintain hot water when the cooler is not in use and it causes the cooling system to cycle more frequently than is necessary to maintain cold water.

[0007] There is a need in the art for improved systems and methods for providing hot water in a water cooler. A preferred exemplary embodiment uses a tube or a series of tubes wrapped with heating elements, such as a thick-film printed heating element, to heat water as it is being dispensed from a cooler. The flow of the water out of the tank/water reservoir which provides water to the tubing is maintained slow enough and the wattage of the heating elements is high enough that water entering the tube or series of tubes at room temperature will be heated to a temperature of between 180 and 200 degrees Fahrenheit. [0008] A benefit of this system when used in a water cooler is that energy is not wasted maintaining the water at an elevated temperature. Another benefit is the elimination of expansion water that causes the cold water in the cooler's water reservoir to be warmed and the corresponding cycling of the cooling system. Additionally, some exemplary embodiments permit for the user of the water cooler to choose the temperature of the hot water being dispensed. Such embodiments preferably incorporate a microcontroller that measures the temperature of the water at or near the hot water outlet of the cooler and adjusts the flow rate of water through the heating tube/tubes (i.e. a slower flow rate for hotter water and a faster flow rate for cooler water) in order to provide the user with hot water of the selected temperature.

[0009] Preferred exemplary systems additionally comprise an electrical push button or switch that is pushed or switched by the user of the water cooler when it is desired that hot water be dispensed. Pushing the electrical push button or switching the switch activates the water heater and a pump/valve within the cooler that allows water to begin to flow through the heating tube/tubes.

Brief Description of the Drawings

[0010] Novel features and advantages of the present invention, in addition to those mentioned above, will become apparent to those skilled in the art from a reading of the following detailed description in conjunction with the accompanying drawings wherein identical characters refer to identical parts and in which:

[0011] FIGURE 1 shows exemplary coolers that may comprise an instant hot water heater wherein FIGURE 1 a is a front perspective view of a top-loaded water cooler having a hot water dispenser and a cold water dispenser and which may implement an instant hot water heater of the present invention and FIGURE 1 b is a front perspective cross-sectioned view of a bottom-loaded water cooler having a hot water dispenser and a cold water dispenser and which may implement an instant hot water heater of the present invention;

[0012] FIGURE 2 is a diagram of a known system for providing hot water to a water cooler; [0013] FIGURE 3 is a front plan view of an exemplary fluid heater of the present invention, which comprises a metal tube wrapped with heating elements, that can be utilized by an instant hot water heater system of the present invention for providing hot water to a water cooler;

[0014] FIGURE 4 is a top perspective view of the heating device shown in Fig. 3;

[0015] FIGURE 5 is a schematic of a water cooler comprising an exemplary instant fluid heater of the present invention wherein arrows are utilized to show how water may flow from the cooler's cold water reservoir to the heating tube and then to the hot water outlet of the cooler;

[0016] FIGURE 6 is a top perspective view of an exemplary printed circuit board ("PCB") comprising a power source and an electronic control that may be utilized to process temperature readings and send signals to an exemplary valve or pump that may be utilized in some exemplary embodiments;

[0017] FIGURE 7 is a top plan view of an exemplary temperature sensor that may be utilized in some exemplary embodiments;

[0018] FIGURE 8 is a top perspective view of the exemplary PCB of Fig. 6 shown connected to the exemplary temperature sensor of Fig. 7;

[0019] Figure 9 is a top perspective view of a second exemplary embodiment of a rapidrinstantaneous" fluid heater of the present invention wherein the exemplary heater is shown connected to an exemplary PCB that is electronically connected to an exemplary pump and temperature sensor;

[0020] FIGURE 10 is a bottom plan view of the exemplary heater shown in Fig. 9 wherein the channel for fluid flow that is defined by the base can be seen; and

[0021] FIGURE 1 1 is a schematic illustrating how the exemplary fluid heater shown in Fig. 9 may be connected to a PCB comprising a power source and an electronic control and wherein the PCB is shown connected to an exemplary pump (whose connection to the heater is not shown), a hot fluid dispense switch, fluid volume selection buttons, a temperature sensor, and a dual water tank float switch. Detailed Description of Exemplary Embodiments

[0022] A preferred exemplary embodiment of an instant hot water heater may be utilized by top-loaded and bottom-loaded water coolers such as are shown in FIGURES 1 a and 1 b respectively. In order for these types of coolers to provide heated water, they have traditionally utilized a hot water tank separate from their cold water reservoir wherein said hot water tank maintains a volume of heated water at all times. Such a known system that has typically been used by water coolers for providing heated water is illustrated in FIGURE 2. The arrows in FIGURE 2 show the flow of water through the known system. As can be seen, the known system utilizes a separate water heating tank to provide hot water to a water cooler. This water heating tank is connected to a cold water reservoir were the cooler's child water is maintained. Several problems with the known systems have been discussed. The problem involving the flow of warm water from the water heating tank into the cold water reservoir is depicted using arrows in FIGURE 2. As discussed, there is a need in the art for improved systems and methods of generating hot water within a water cooler.

[0023] The instant hot water heater system disclosed herein solves several problems with the known systems for providing hot water to a water cooler. A preferred exemplary embodiment of an instantaneous/rapid water heater 200 comprises a tube 100 or a series of tubes 100 wrapped with at least one heating element 110, to heat water as it is being dispensed from a cooler. In a preferred exemplary embodiment, the heating element 110 comprises a thick-film printed heating element. An exemplary heating tube 100 is shown in FIGURE 3. As shown, the tube 100 is preferably made from stainless steel or some other material that is thermally conductive and suitable for drinking water. As shown in FIGURE 5, the tube 100 defines an inlet 112 and an outlet 114 such that the tube 100 receives water at its inlet 112 (likely from a cold water reservoir 120 in a water cooler 201 ) and provides heater fluid/water from its outlet 114. While the exemplary embodiments shown in the FIGURES comprise a tube 100 having an interior and an exterior surface wherein the exterior surface of the tube 100 is wrapped with the at least one heating element 110, in some exemplary embodiments, the at least one heating element 110 may line at least part of the interior of the tube 100. When the heating elements 110 line the interior of the tube 100, it may be possible to make the tube 100 from a material that is not thermally conductive and/or which is less thermally conductive.

[0024] In preferred embodiments, water is supplied to the heating tube 100 via a cold water storage tank 120 within the cooler and the flow of the water out of the cold water storage tank is maintained slow enough and the wattage of the heating elements 110 is high enough that water entering the tube 100 or series of tubes 100 at room temperature will be heated to a temperature of between 165 and 200 degrees Fahrenheit by the time it exits the tube 100. While not shown in the FIGURES, insulation may be provided about the heating tube 100/ heating elements 110 to prevent the activation of the heating elements 110 from too greatly heating the ambient temperature within the water cooler. It will be understood in the art that while the present system is referred to as an "instant" hot water heating system, heating the water to a desired temperature will typically take some time as the water travels through the tube 100.

[0025] FIGURE 5 shows an exemplary hot fluid heating system 200 and how fluid may flow through said system within a cooler 201. As can be seen, fluid (such as water from a water bottle or a plumbed water source (not shown)) may be supplied to a cold reservoir 120 within the cooler. The cold reservoir 120 may have a cooling system that monitors the temperature of the fluid and cycles energy to refrigerant coils 130 when cooling of the water within the reservoir 120 is needed. The system preferably comprises a valve and/or pump 140 that is connected to the cold reservoir 120 such as by a tube 150 as is shown in FIGURE 5. In the preferred exemplary embodiment, the valve 140 is in connectivity with an electric dispense button or a dispense switch (not shown) wherein the button or switch may be selected by a user of the cooler when he or she would like hot fluid to be dispensed from the cooler. When the button or switch for hot fluid has been selected, the valve 140 is activated such that fluid is drawn from the reservoir 120, through tube 150 until it reaches the inlet 112 of tube 100. Selecting the button or switch may also activate the heating of the heating elements 110 such that the water is heated as it flows through tube 100. Thus in such an exemplary embodiment, the button or switch would be in electronic connectivity with the valve 140 as well as the heating element 110.

[0026] In a preferred exemplary embodiment, the valve (or pump) 140 is controlled by an electronic control that measures the temperature of the fluid at or approximately at the outlet 114 of the tube 100 and compares the temperature to a desired set point/temperature. The electronic control may measure the temperature of the fluid by being in connectivity with and obtaining temperature reading information from a temperature sensor where said sensor is positioned near the outlet 114 of the tube 100. The electronic control may be part of a printed circuit board. In exemplary embodiments comprising an electronic control in electronic communication with the valve 140 and at least one temperature sensor, the valve 140 can be opened and closed quickly to regulate the flow of fluid through the tube 100 to the proper speed in order to allow the water to properly heat to the set point temperature. If the temperature of the fluid at the output 114 is too low, then the valve 140 preferably stays closed more than open to allow the fluid to flow through the tube 100 more slowly so that it can obtain additional heating by the heating element 110. The valve may be opened and closed by, for example, supplying power to the valve 140. In the preferred exemplary embodiment, the valve 140 is opened by supplying power to the valve 140 and is closed when no power is being supplied to the valve 140.

[0027] If a pump 140 is used in place of the valve 140, the speed of the pump 140 is preferably controlled by a power source which may be provided on a printed circuit board (PCB) 500 that is in electronic communication with both the pump 140 and at least one temperature sensor 600 that is positioned at or near the outlet 114 of the tube 100. The temperature sensor 600 is preferably able to obtain readings of the temperature of the fluid near the outlet 114 of the tube 100 and send corresponding temperature information to an electronic control which is in electronic communication with a power source that is in electronic communication with the pump 140. In such exemplary embodiments, if the temperature sensor obtains readings of the fluid that indicate the fluid is too cold, the temperature information will preferably be sent to the electronic control which can generate and send a signal to the pump 140 causing the pump 140 to run more slowly. If the temperature sensor 600 obtains readings of the fluid that indicate that the fluid is too hot, the temperature information will be sent to the electronic control which may generate and send a signal to the pump causing the pump 140 to pump the fluid more quickly through the tube 100 resulting in cooler fluid. After the water exits the heating tube 100 via the outlet 114, it may be dispensed from the cooler via a hot water outlet (also not shown).

[0028] FIGURE 6 shows an exemplary PCB 500 comprising an exemplary power source and an exemplary electronic control that may be in electronic connectivity with a pump 140 or valve 140 in order to control fluid flow through the tube 100 in order to obtain fluid of the desired temperature at the outlet 114 as has been discussed. The PCB 500 preferably includes a line 501 , a neutral 502, and a ground 503 as shown in FIGURE 6. FIGURE 7, shows an exemplary temperature sensor 600 that may be in electronic connectivity with an electronic control and at least part of which may be positioned near the outlet 114 of the tube 100 in order to obtain temperature readings of fluid and assist in obtaining fluid of a desired temperature. FIGURE 8 illustrates how the exemplary temperature sensor 600 may be connected to the exemplary PCB, power source, and electronic control 500. In exemplary embodiments, the PCB 500 is positioned within the cabinet of a cooler that includes a fluid heating system 200.

[0029] In a preferred exemplary embodiment, the tube 100 is made from stainless steel and is approximately 6 inches long and has a diameter of 1 .25 inches. In this preferred exemplary embodiment, the heating element 110 is comprised from a thick-film printed hearing element and is wrapped about the exterior of the tube 100. The heating element 110 has a length of approximately 4.5 inches where said length runs parallel with the flow of water through the tube 100. An exemplary heating element 110 is 1400 Watts (in other words, 1400 Watts of energy is provided to the heating element 110 when it is being utilized to heat fluid in the tube 100). In this exemplary embodiment, the flow rate of fluid through the tube 100 is approximately 10 ounces per minute which achieves a fluid heated to approximately 176 degrees Fahrenheit in 60 seconds. In such an exemplary embodiment, it may take approximately 60 seconds for the fluid to flow through the part of the tube 100 wrapped by the heating element 110 in order to obtain fluid heated to the desired set point.

[0030] In a preferred exemplary embodiment, the user of the water cooler may be able to choose the temperature of the hot water being dispensed. Such embodiments preferably incorporate a microcontroller/electronic control in electronic connectivity with a temperature sensor 600 that measures the temperature of the water at or near the hot water outlet 114 of the cooler and adjusts the flow rate of water through the heating tube/tubes 100 (i.e. a slower rate for hotter water and a faster rate for cooler water) in order to provide the user with hot water of the selected temperature. The system would also comprise a means by which the user would select the desired water temperature (i.e. set point). This may consist of at least one electronic push button or switch that permits for a desire temperature to be selected. A dial which permits for the user to select from a range of hot water temperatures may be provided in some embodiments. The means for selecting the desired temperature of the water is preferably in electronic communication with the microcontroller 500 and permits for the system to receive the user's instructions and adjust the temperature of the hot water produced by the instantaneous heater 200 accordingly. In a preferred exemplary embodiment, the user of the water cooler can select from several choices of temperature associated with coffee, tea and soups. The selection would be made by the user pushing an electronic push button provided on the cooler cabinet to select the associated temperature or alternatively by pushing the electronic button to toggle through the preset temperature selections. Another option is to use up/down arrows on the cooler cabinet to allow the user to set the desired water temperature.

[0031] Some exemplary embodiments of a rapid water heater do not comprise a tubular heater. An exemplary embodiment of a rapid/"instantaneous" fluid heater that does not comprise a tubular heater is shown in FIGURE 9. The exemplary heater shown in FIGURE 9 utilizes a thick-film printed heater 700 that is substantially planar and which is placed in contact with a base 701 that defines or contains a path 702 for fluid flow. As shown in FIGURE 9, the substantially planar heater 700 may have a waffle-like appearance on at least one side. The path 702 is preferably connected to and/or defines an inlet 703 for receiving fluid and an outlet 704 for providing heated fluid. As shown in FIGURE 9, the inlet 703 and outlet 704 which provide fluid to and receive heater fluid from the path 702 may be defined by the heater 700 in some exemplary embodiments. The path 702 ideally covers a substantial portion of the surface area of the heater 700. As can be seen more clearly in FIGURE 10, the exemplary embodiment comprises a base 701 that is substantially rectangular and of a similar size and shape as the heater 700. The path 702 defined by (or alternatively contained by) the base 701 preferably is such that fluid may enter into the path at the inlet 703, flow through the length of the path 702 and gain exposure to heating via the heating element 700. The heated fluid may then be removed from the path 702 at the outlet 704. When the path 702 covers a substantial surface area of the heater 700, as is shown in FIGURES 9 and 10, it provides for maximum heating of the fluid, being heated to the desired temperature by the time it reaches the outlet at the end of the path.

[0032] An exemplary embodiment of a planar rapid fluid heating device comprises a planar heater 700 that is supplied with 1350 Watts of energy at 1 15 volts of alternating current when it is being used to heat fluid. The 1 15 volts of alternating current may be provided to the PCB 500 via an electronic connection such as via a water cooler being plugged into a standard power outlet. In such exemplary embodiments, the total power supplied to the system could be 1362 Watts which would include the power being supplied to the Heater 700, the pump 140 and the PCB 500 when the heater 700 is being used to heat fluid. In some exemplary embodiments, the PCB may be supplied with a stand-by input wattage of 0.75 Watts Maximum when the heater 700 is not being used to heat fluid. The stand-by power may be used to operate certain items connected to and/or part of the PCB such as the at least one temperature sensor 600, electronic control, etc. In the exemplary embodiment shown in FIGURES 9 through 1 1 , the size of the heater 700 and the pump 140 is approximately 225 mm height by 50 mm width by 200mm D. Such an exemplary embodiment would preferably have a rate of fluid flowing through the path 702 of 300 ml a minute. In such an exemplary embodiment, fluid would arrive to the path via the inlet 703 having a cooler temperature (for example a temperature of approximately 22.2 degrees Celsius) while water received from the outlet 704 after flowing the length of the path 702 and being exposed to heating via the heater 700 would have a temperature greater or equal to 80 Degrees Celsius. In some exemplary embodiments a barb water supply or tube may be utilized to supply fluid to a base 701 defining (or containing) a path 702. In some exemplary embodiments, all materials that come into contact with fluid are comprised of 304 or 430 stainless steel and/or silicone. Such exemplary embodiments meet FDA guidelines for providing safe contacts for liquids for human consumption.

[0033] In a preferred exemplary embodiment, a PCB 500 is connected to refrigerant coils that are connected to a cold water reservoir in a water cooler as well as to a heater 110 and/or 700. In such an exemplary embodiment, the electronic control on the PCB 500 may be connected to a first temperature sensor 600 that is positioned near the hot fluid outlet 114 or outlet 704 and is connected to a second temperature sensor 600 that is positioned in or near the cold reservoir 120. The first sensor 600 preferably sends temperature reading information to the electronic control when heated fluids are needed/being produced via the rapid heating element 110 and/or 700 while the second sensor 600 preferably sends temperature reading information to the control in order to maintain the water within the cold reservoir at a desired set point. The electronic control on the PCB 500 may cause power to be sent to the refrigerant coils that are connected to the cold water reservoir (see FIGURE 5 for example) when water in the reservoir needs to be cooled and may cause power to be sent to the heater 110 and/or 700 when heated fluid is desired.

[0034] FIGURE 1 1 shows how the exemplary heater shown in FIGURES 9 and 10 may be connected to a PCB 500 which comprises a power source and an electronic control. As shown in FIGURE 1 1 , the PCB 500 may additionally be connected to a pump 140. The pump 140 may be a positive displacement pump. Though not shown in FIGURE 1 1 , it is to be understood that the pump 140 is connected to a source of fluid (such as a room temperature water in a water reservoir in a water cooler) as well as to the base 701 such that it may cause fluid to flow from the fluid source to the path 702 when power is supplied to the pump 140. The PCB is ideally connected to a temperature sensor 600 part of which is preferably disposed near the outlet 704 such that it may obtain temperature readings of the fluid after it has flown through the length of the path 702. In such exemplary embodiments, the sensor 600 may send temperature reading information to an electronic control that is part of the PCB 500. The electronic control is preferably in electronic connectivity with the pump 140 such that the control can send a signal to the pump 140 increasing or decreasing the flow of fluid through the path depending on whether the temperature of the water (as determined by the sensor 600 temperature information) is higher or lower than it is supposed to be. If the temperature of the water as observed by the sensor 600 is too high, then the pump 140 will preferably increase the rate that fluid flows through the path 702 causing the fluid to be in the path for a shorter period of time thereby gaining lesser exposure to heating by the heater 700. If, the temperature of the water is too low, the pump ideally decreases the rate of fluid flow so that the fluid is in the path 702 for a longer period of time gaining greater exposure to heating via the heating element 700. The electronic control preferably regulates the heated fluid such that the fluid is between 80 degrees Celsius and 85 Degrees Celsius by the time is reaches the outlet 704.

[0035] Some exemplary embodiments of a rapid fluid heating device may comprise a dual water tank float switch 850. In preferred exemplary embodiments, this switch is connected to a float within a cooler's water reservoir and works to ensure the cooler does not run out of water. When the cooler runs out of water the heater can run dry which is not desirable. So, in some exemplary embodiments the dual water tank float switch detects when the tank is out of water and prevents the heater from being energized.

[0036] FIGURE 1 1 also shows an exemplary embodiment of how a heating device of the present invention (tubular or non-tubular) may comprise a hot fluid switch 800 as well as volume indicators 900 which permit for a user to indicate the amount of hot water they need to be dispensed. The indicators 900 may comprise a plurality of buttons as shown in FIGURE 1 1 . In the preferred exemplary embodiment, the switch 800 and/or indicators 900 are positioned on a user interface which may be, for example, on the external part of a water cooler or similar device. In exemplary embodiments comprising a hot fluid switch 800, the switch can be selected by a system user which may then cause a signal to be sent to the PCB 500 which sends a signal to the pump 140 or valve 140 as well as causes power to be sent to the heater 700. When power is supplied to the pump 140 or valve 140, fluid is drawn from a source (such as a cold water reservoir in a water cooler) and flown into the tube 100 or path 702. In exemplary embodiments comprising size selection buttons 900, a user may be able to select between different fluid volumes in order to indicate what amount of heated fluid is needed. In the exemplary embodiment shown in FIGURE 1 1 , 10 and 8 ounce volume options are available, but it should be understood that other fluid amounts could be utilized. Similarly, a system could permit for more than two fluid volume options. In some exemplary embodiments, there may be a constant flow option which permits for a system user to obtain any desired amount of heated fluid. For example, a system user might be able to hold down a button and keep holding it until the system has dispensed the desired amount of heated fluid. [0037] Exemplary embodiments may also comprise a method of using an instant water heater as shown in FIGURES 2 through 8 and/or as has otherwise been described herein. Such an exemplary embodiment may comprise one or more or all of the steps of: receiving water, or another type of fluid, at the inlet 112 of a tube 100 wherein said tube 100 has been wrapped - internally or externally - with at least one heating element 110, causing approximately 1400 Watts of power to be supplied to the heating element 110 and causing the heating element 110 to be heated, flowing the fluid through the tube 100 (for example at a rate of 10 ounces per minute), and providing fluid that has been heated (for example to approximately 176 degrees Fahrenheit) to the outlet 114 of the tube 100. The tube 100 in this embodiment may be approximately 6 inches long having a diameter of 1 .25 inches and the heating element 110 wrapped about said tube may have a length of approximately 4.5 inches. Said method may further comprise one or more of all of the steps of: receiving at a control panel 500 an instruction from a user interface wherein said instruction indicates the desired temperature that the fluid should be when it reaches the outlet 114 of the tube 100 and adjusting the flow of liquid through the tube and/or adjusting the temperature to which the heating element 110 is heated so that the fluid obtains the desired temperature by the time it reaches the outlet. Said method may further comprise the step of altering the rate of fluid flow through the tube 100 by receiving a signal at a valve 140 which causes the fluid to flow more quickly through the tube 100 for cooler fluid and which causes a slower flow of liquid through the tube 100 for hotter liquid.

[0038] Any embodiment of the disclosed system and method may include any of the optional or preferred features of the other embodiments of the present invention. The exemplary embodiments herein disclosed are not intended to be exhaustive or to unnecessarily limit the scope of the invention. The exemplary embodiments were chosen and described in order to explain the principles of the present invention so that others skilled in the art may practice the invention. Having shown and described exemplary embodiments of the present invention, those skilled in the art will realize that many variations and modifications may be made to affect the described invention. Many of those variations and modifications will provide the same result and fall within the spirit of the claimed invention. It is the intention, therefore, to limit the invention only as indicated by the scope of the claims.