Hot beverage dispenser with level sensing probe and method of making same

Abstract

A beverage dispenser () having a hollow, insulated dispenser body (), a removable cover () with an inlet opening () for receipt of freshly brewed beverage to an interior of the dispenser body (), a closed bottom () and a faucet () for dispensing beverage from the body () has a level display system including an elongate, relatively flexible, probe body, or down tube () with a flexible probe circuit and having a bottom and a top with a plurality of electrically conductive sensors (and) mounted within an elongate mounting groove (, FIGS.-) formed in, and extending along, the elongate relatively rigid probe body (). The flexible probe assembly () is secured within the groove by non-adhesive means, either by a thermal fusion joint) formed during injection molding (FIG.) of the rigid probe body () or by mechanical tabs (). The flexible probe circuit is made of a flexible plastic strip () with sensor locations () and a leads connector () on one side () of a middle layer () through-connected () to associated elongate leads () on the opposite side of the middle layer () and two covering top and bottom protective covering layers () on opposite sides of the middle layer ().