Abstract:
An apparatus configured to permit the use of charcoal for cooking in a gas barbecue grill, the gas grill having a bottom casting containing a gas burner element, a cooking rack supported thereabove, and a top casting rotatably affixed thereto. The apparatus includes a tray configured to be received within the bottom casting and the tray includes a pair of handles. Each of the handles includes a proximal end and a distal end, and the handles are rotatably connected to the tray at the proximal ends and the distal ends are configured to support the cooking rack.

Description:
TECHNICAL FIELD 
     The present invention relates generally to barbecue grills, and, more particularly, to a charcoal tray and cooking rack for use in a gas barbecue grill. 
     BACKGROUND OF THE INVENTION 
     In the recent past, outdoor cooking has experienced tremendous growth. This is due in large part to the fact that barbecue grills, both charcoal and gas, have become much easier to use and more efficient at cooking a wide range of food items. Although both charcoal and gas barbecue grills have seen improvements in the recent years, the advantages of gas barbecue grills have been well recognized. Gas barbecue grills can quickly bring a heated surface to a desired temperature and may provide a high rate of heat exchange. Therefore, gas barbecue grills generally require less time to prepare food items than the charcoal grills. Gas barbecue grills allow for finer control of cooking temperatures than do charcoal barbecue grills. Even with these noted advantages, there are still those individuals who would prefer to cook using a charcoal barbecue grill. 
     Charcoal barbecue grills offer a number of advantages as well. For example, charcoal barbecue grills tend to be of simple construction, and therefore, tend to cost less than gas barbecue grills. As well, charcoal barbecue grills do not require an external fuel source, such as, a liquid propane tank. Although means do exist for determining the amount of propane in a tank, it is not uncommon to run out of fuel while preparing food items on a gas grill. Many individuals also prefer the flavor imparted to food items by cooking with charcoal briquettes. Similarly, charcoal barbecue grills allow individuals to use such items as wood chips to further flavor the food items they are preparing. Gas barbecue grills tend to cost more to operate than charcoal barbecue grills because the fuel source must be continually resupplied and items such as replacement burner elements must be purchased periodically to maintain proper operation of the gas barbecue grill. 
     The Krall patent, U.S. Pat. No. 6,173,644, issued Jan. 16, 2001, discloses an apparatus for converting a gas grill into a charcoal burning grill for conveniently using charcoal or other flammable material in a gas grill. The adapter includes an adapter container for holding flammable material and the adapter container is removably positionable in the interior of the housing. Once the adapter container is positioned in the housing, a screen that is removably supported by the housing is replaced such that the screen covers the adapter container. However, because the screen is supported by the housing, the height of the screen above the adapter container can not be easily adjusted. 
     Therefore, a need exists for improved barbecue grills that can function in both the gas and charcoal modes. 
     SUMMARY OF THE INVENTION 
     Embodiments of the present invention include an apparatus configured to permit the use of charcoal for cooking in a gas barbecue grill, the gas grill having a bottom casting containing a gas burner element, a cooking rack supported thereabove, and a top casting hingedly affixed thereto. The apparatus configured for use with a gas grill comprises a tray adapted to be received within the bottom casting, the tray including a pair of handles. Each of the handles includes a proximal end and a distal end. The handles are rotatably connected to the tray at the proximal ends and the distal ends are configured to support the cooking rack. The handles are rotatable between a stowed position and a support position, the stowed position allowing the cooking rack to be disposed on the bottom casting and the support position allowing the cooking rack to be supported by the distal ends of the handles. 
     Other features and advantages of the present invention will become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such features and advantages be included herein within the scope of the present invention, as defined in the appended claims. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The present invention, as defined in the claims, can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale relative to each other, emphasis instead being placed upon clearly illustrating the principles of the present invention. 
     FIG. 1 is a perspective view of a gas barbecue grill including a charcoal tray and associated cooking rack constructed according to an embodiment of the present invention. 
     FIG. 2 is a perspective view of the gas barbecue grill as shown in FIG. 1, with the cooking rack shown in the stowed position. 
     FIG. 3 is a perspective view of the gas barbecue grill as shown in FIG. 1, with the cooking rack positioned for operation of the gas barbecue grill in the gas mode. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     In the following detailed description, reference is made to the accompanying drawings which form a part hereof, and in which are shown by way of illustration specific embodiments of a charcoal tray and associated cooking rack for use in a gas barbecue grill. It is to be understood that other embodiments may be utilized in structural or processed changes may be made. The following detailed description, therefore, is not to be taken in a limiting sense. 
     Referring now to the figures, wherein like reference numerals indicate corresponding components throughout the several views, one example of a charcoal tray and associated cooking rack constructed in accordance with the present invention is illustrated in FIG. 1. A preferred embodiment includes a charcoal tray  100  and a convertible cooking rack  120  disposed within the bottom casting  152  of a gas barbecue grill  150 , above the gas burner elements  154  (FIG. 3 ). The charcoal tray  100  includes a firepan  102 , a front wall  104 , a back wall  106 , a pair of side walls  108  and a pair of handles  130 . The charcoal tray  100  is sized to substantially span the interior of the bottom casting  152 . As such a plurality of vents  110  are formed in both the front wall  104  and back wall  106 . As shown, each of the front and back walls  104 ,  106  includes a substantially horizontal ledge  107  in which the vents  110  are located. The vents  110  insure that adequate airflow exists within the barbecue grill to support combustion of both charcoal and/or the fuel provided to the gas burner elements  154  and provide additional heat transfer between the burner element or elements and the charcoal being ignited. For convenience, the convertible cooking rack  120  is provided with a pair of lifting members  122 . The charcoal tray  100  can also be sized such that the tray  100  does not span the entire interior of the bottom casting  152 . Such embodiments allow the gas barbecue grill  150  to be used in the gas mode and charcoal mode simultaneously. 
     The handles  130  are rotatably connected to the charcoal tray  100  such that they can be moved between a support position and a stowed position. Each handle includes a proximal end  132  and a distal end  136 . The proximal ends  132  are rotatably connected to the charcoal tray  100  in any suitable fashion. Preferably, the proximal ends  132  of the handles are outwardly depending and fit into corresponding apertures in the charcoal tray  100 . The distal ends  136  of the handles  130  are configured to support the convertible cooking rack  120  at opposing ends thereof. Preferably, the distal ends  136  are configured such that the convertible cooking rack  120  can be supported at a number of different levels above the charcoal tray  100 . For added stability, it is desirable to secure the handles  130  in the support position during use of the convertible cooking rack  120 . As shown, this is accomplished by engaging one or more securing apertures  114  formed in the charcoal tray  100  with downwardly depending pins  134 . To place the handles in the stored position, the user simply lifts up slightly on each handle  130  to disengage the downwardly depending pins  134  from the securing apertures  114  and rotates them inwardly until they contact the fire pan. 
     As shown in FIG. 2, the preferred embodiment includes a hanging member  140  that is used to stow both the charcoal tray  100  (FIG. 1) and the convertible cooking rack  120  when they are not in use. The hanging member  140  includes a pair of hooks  142  and is disposed along the back edge of the bottom casting  152 . This configuration allows the charcoal tray  100  and convertible cooking rack  120  to be safely stored out of the way and allows the use of the barbecue grill  150  in the gas mode. 
     As shown in FIG. 3, the convertible cooking rack  120  may also be used when the barbecue grill  150  is functioning in the gas mode. When the convertible cooking rack  120  is used in this manner, it is supported by a bar  156  disposed in the upper casting  153  and a support element  157  rotatably attached to the bottom casting  152 . Preferably, the support element  157  includes a pair of legs  158  and a horizontal member disposed therebetween, upon which the convertible cooking rack  120  rests. Each leg  158  includes an outwardly depending end  159  configured to rotatably engage the bottom casting  152 , thereby connecting the support element  157  to the bottom casting  152 . The convertible cooking rack  120  is maintained in a substantially horizontal disposition above a primary cooking rack (not shown) as the upper casting  153  is moved between an open and a closed position. 
     OPERATION 
     As previously noted, the charcoal tray  100  allows a gas barbecue grill  150  to be operated in either a gas mode or a charcoal mode. To operate in the charcoal mode, the charcoal tray  100  is removed from the stowed position and is placed in the bottom casting  152  above the gas burner elements  154  (FIG.  3 ). Preferably, the handles  130  are secured in the support position by placing the downwardly depending pins  134  in the securing apertures  114  formed in the charcoal tray  100 . Charcoal  160  is placed in the fire pan  102  and ignited. Ignition of the charcoal can be accomplished with an external flame, such as a match, lighter, etc., or preferably, can be accomplished by using the gas burner elements  154 . Once the charcoal  160  has been adequately lit, the fuel source to the gas burner elements  154  is secured. Note, however, use of the gas burner elements  154  is not required, meaning the charcoal tray  100  can be used even when no external fuel source is available. 
     Once the charcoal  160  is lit, the convertible cooking rack  120  is supported at the desired level above the charcoal tray  100  by the distal ends  136  of the handles  130 . Note that the charcoal tray  100  may also be used with the primary cooking rack (not shown) of the barbecue grill  150 . Typically, the primary rack is supported by the bottom casting  152 . To use the primary rack with the charcoal tray  100 , the handles  130  are simply rotated into the stowed position and the primary rack positioned on the bottom casting  152  such as it would be placed during regular gas mode operation. Using the primary rack in this fashion permits the user to position the convertible cooking rack  120  on the bar  156  and support element  157 , as shown in FIG. 3, and effectively increase the amount of cooking surface that is available. Embodiments are also envisioned where it is possible to support the primary cooking rack on the distal ends  136  of the handles  130 . 
     During gas mode operations, the charcoal tray (FIG. 1) is placed on the hanging member  140  along with the convertible cooking rack  120 , or the rack  120  may be used as a cooking surface, as is shown in FIG.  3 . 
     It should be emphasized that the above-described embodiments of the present invention, particularly, any “preferred” embodiments, are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the invention. Many variations and modifications may be made to the above-described embodiment(s) of the invention without departing substantially from the spirit and principles of the invention. All such modifications and variations are intended to be included herein within the scope of this disclosure and the present invention and protected by the following claims.