Abstract:
The present invention relates to an improved barbecue kettle leg support featuring a body that is contoured to fit the curved shape of a barbecue kettle bowl and to receive an end of a leg with a locking formation. Fastener bores are configured for mounting the leg support to the bowl. Preferably, the leg support is mounted midway between the top and bottom of the bowl for increased stability. A keyed bore enables assembly of the leg with the locking formation. The locking formation utilizes a pin which is attached to a bias spring to prevent unwanted detachment of the leg from the leg support. The locking formation is configured to allow assembly and disassembly to be performed without the use of tools.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    The present invention relates to barbecue kettle grills, and more particularly to the leg configuration of a barbecue kettle grill.  
           [0002]    A number of different structures are known for assembling and securing a leg onto a kettle-type barbecue grill. The most common structure is to slidably insert a tubular leg into a mating socket member that has been fixed to the grill as by welding. A friction fit is achieved with a dimple or detent in the socket member which tightly engages the leg.  
           [0003]    A first disadvantage of this system is that welding is both a relatively costly and destructive method of attaching one piece to another. During the welding process, the materials joined are usually weakened. Welding is also inherently inaccurate. Dimensional tolerances for welding require additional room for variations caused by the welding process. Also, the cost of welding is relatively high in this application due to the awkwardness of the process in securing a socket to a curved kettle bowl surface. Cost, accuracy and strength of the welding process could be improved upon by incorporating another way of attaching the leg to the grill which eliminates welding all together.  
           [0004]    A second disadvantage of the conventional barbecue kettle leg attachment is that the grill assembly requires that the leg and the welded socket member have an interference fit relationship. If the manufacturing tolerances are too tight, there may be difficulty in assembly. Removing the interference fit of the leg to the mating grill member will improve the ease of assembly, as well as disassembly, if required.  
           [0005]    In an effort to address the drawbacks of the welded leg support member mentioned above, it is also known to attach the leg to a barbecue kettle grill by using a single bolt, typically passing through the lower kettle portion or bowl and threadably engaging a captured nut in the upper end of the leg. This assembly makes it relatively easy to assemble, but since a single bolt is used, the strength of the joint could be questioned depending on how tight the bolt has been turned by the installer. Also, since there is less support for the leg, the stability of the leg is reduced compared to the welded system described above. Improving the relationship between the grill and the leg will reduce or eliminate the vibration, stripping, stability and strength issues presented by the prior art.  
           [0006]    Grills of this type encounter stability problems when the grill is placed on a curved surface such as a driveway, patio, deck, lawn, or any typical surface where a grill may be found standing. This is caused, in some cases, by the high center of gravity established by the grill due to the configuration of the legs. The legs are placed close to the bottom of the grill to incorporate a straight leg design and maintain a grill base footprint that does not interfere with the operation of the grill. In other cases, instability is caused due the use of four legs. Utilization of four legs is inherently less stable on uneven surfaces. Lowering the center of gravity and utilizing three legs on a kettle-type barbecue grill will improve the stability of the grill on uneven surfaces.  
           [0007]    Accordingly, a first object of the present invention is to provide an improved barbecue kettle leg support configuration that features a body which does not require welding for attachment.  
           [0008]    Another object of the present invention is to provide an improved kettle-type barbecue grill leg support that features a locking mechanism that replaces the prior interference fit and allows for ease of assembly and disassembly of the leg.  
           [0009]    Still another object of the present invention is to provide an improved kettle-type barbecue grill leg support that features a mounting position which allows for a lower center of gravity, causing an increase in overall stability of the grill.  
         BRIEF SUMMARY OF THE INVENTION  
         [0010]    Accordingly, the above listed objects are met or exceeded by the present improved barbecue kettle leg support, featuring a body which, at a first end, is contoured to fit the curved, or spheroidal, shape of the bowl. A second end, opposite the first end, of the leg support is configured with a bore to receive an end of a leg. A center portion, generally positioned between the first and second end, is provided with a throughbore in communication with the second end bore to receive a corresponding locking engagement from the end of the leg. The locking mechanism is positive, yet releasable, and avoids the fit problems identified with the prior art.  
           [0011]    In the preferred embodiment, the leg support is generally “L”-shaped, and at the first end, has three fastener bores, spaced apart from each other, for mounting to the bowl. Also, at the second end, the leg support is preferably provided with a keyed bore, generally cylindrical in shape, which receives a leg with a locking formation. A release recess and a throughbore that communicates with the keyed bore is preferably housed by the central portion of present the leg support.  
           [0012]    Another feature of the present barbecue leg support is a leg with an upper end housing a locking formation. Preferably the locking formation is a pin that is biased by a spring forcing the pin to extend radially through an opening in the leg. A keyed bore is dimensioned to provide a rotational interface with respect to the leg and locking formation. Upon assembly, the pin from the locking formation radially extends through the leg and the throughbore in the leg support.  
           [0013]    In addition to the barbecue kettle, leg support and leg, the kettle-type barbecue is provided with a tray or shelf-like base configured to allow engagement of a lower end of at least one leg. Also, the present base is preferably configured to define a line between two leg lower ends that is longer than a width of the barbecue kettle itself.  
           [0014]    The present barbecue kettle is configured with a bowl that has a top and bottom. The bowl is configured to allow for assembly of at least one leg support half way between the top and bottom of the bowl. 
       
    
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS  
       [0015]    [0015]FIG. 1 is a perspective view of an embodiment of a kettle-type barbecue with a leg support configuration made in accordance with the teachings of the present invention;  
         [0016]    [0016]FIG. 2 is a cross-sectional view of the leg support of FIG. 1 taken along the line  2 - 2  and in the direction indicated generally;  
         [0017]    [0017]FIG. 3 is a front view of the leg support of FIG. 1;  
         [0018]    [0018]FIG. 4 is a fragmentary cross-sectional view of the leg support of FIG. 3 taken along the line  4 - 4  and in the direction indicated generally;  
         [0019]    [0019]FIG. 5 is a fragmentary vertical section view of an upper end of the present leg including a locking formation; and  
         [0020]    [0020]FIG. 6 is a rear elevational view of the kettle-type barbecue of FIG. 1. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0021]    Referring now to FIG. 1, a kettle-type barbecue is generally designated  10  and includes a barbecue kettle  12 . The barbecue kettle  12  generally consists of a lid  14  and a bowl  16  which are made of porcelamized or powder coated metal. Generally, the lid  14  has a handle  18  and a vent  20 , both of which are preferably located near a lid top  22 , however other locations are contemplated depending on the application. Preferably, the handle  18  is used to manipulate the lid  14 , and the vent  20  is used to control the airflow through the lid  14 . Generally, the lid  14  rests upon a bowl upper surface  24  to provide a closed cooking chamber. As is well known in the art, a food support grill (not shown) rests near the bowl upper surface  24 . Also, a separate charcoal support grid (not shown) is typically placed below the food support grill. A transport handle  26  is attached to the bowl  16  near the bowl upper surface  24 . During transportation of the kettle-type barbecue grill  10 , the transport handle  26  is used for added convenience and control over position of the grill  10 .  
         [0022]    An ash receiver  28  is descendably mounted to a bowl lower surface  30  and circumscribes a lower opening (not shown) in the bowl  16 . Generally, an inexpensive metal, cylindrical container serves well as the ash receiver  28  because of ease of manufacturing. To regulate the flow of combustion air to the fire, the ash receiver  28  preferably includes multiple air vents  32  which can alternatively be located in the bowl  16 . An air vent controller  34 , preferably an apertured ring which selectively blocks the vents  32 , optionally controls the volume of incoming air for combustion. Any material may be used to construct the ash receiver  28 , as long as it will withstand the temperature of hot ash and small burning embers from the fire. Metal, especially when coated with a protective coating such as porcelain, or other ceramic coating, is preferred. An ash receiver handle  36  is preferably mounted on the ash receiver  28  with standoffs  38  as insulation to simplify emptying the ash receiver when hot.  
         [0023]    In the preferred embodiment, the bowl  16  is configured to receive three leg supports  40 . The three leg supports  40  are fastened in spaced relationship about the bowl  24 , and are preferably bolted. As shown, the leg supports  40  are positioned generally mid-way between the bowl upper end  24  and the bowl lower end  30 . This mounting configuration generally lowers the center of gravity of the kettle-type barbecue grill  10 , which generally increases stability.  
         [0024]    Referring now to FIGS. 1 through 4, the leg support  40  is dimensioned with a first end  42 , a second end  44  and a center portion  46 . In the preferred embodiment, the support leg  40  is generally made from a die castable material such as aluminum or equivalent which is suited to withstand the rigorous outdoor operational environment of the kettle-type barbecue grill  10 . Preferably, the leg support  40  is generally “L”-shaped when viewed from the side, and defines an angle α in the approximate range of 140° to 160° (shown in FIG. 2). Other angular dimensions are contemplated.  
         [0025]    In the preferred embodiment, the first end  42  is contoured to fit the generally curved or spheroidal-shaped bowl  16 . A continuous periphery  48 , which is generally triangularly-shaped when viewed head on (FIG. 3), is the preferred shape of the first end  42 . However, other shapes are contemplated depending on the application. Another feature of the continuous periphery  48  is that it matches the contour of the bowl  16 . A result of the matching contour is a generally equal distribution of load transmitted from the bowl  16  to the leg support  40 . Having a generally uniform distribution of load between the leg support  40  and bowl  16  generally increases the reliability of this joint.  
         [0026]    Preferably, the first end  42  defines a cavity  50  (best seen in FIG. 2). In the preferred embodiment, the cavity  50  is dimensioned to reduce the weight and cost of the leg support  40 . Also, the cavity  50  is dimensioned to facilitate manufacturability of the leg support  40 .  
         [0027]    Additionally, the first end  42  is provided with at least one fastener bore  52 . Preferably, the first end  42  is provided with three fastener bores  52  that are housed within the cavity  50  (shown in FIG. 3). Generally, having the fastener bores  52  housed within the cavity  50  enhances the esthetics of the leg support  40 . In the preferred embodiment the fastener bores  52  are configured with an internal thread  54  (shown best in FIG. 2). Generally, the internal thread  54  is dimensioned to allow communication with a standard bolt (not shown) used to attach the leg support  40  to the bowl  16 . Utilizing three fastener bores  52  generally increases the strength and stability of the attachment of the leg support  40  to the bowl  16 , and reduces the effects of vibration on the bolts. Tapping the fastener bores  52  with the internal thread  54  generally reduces stripping of the bolt.  
         [0028]    In the preferred embodiment, the second end  44  is provided with a bore  56  and a key-way  58  (best seen in FIG. 4). Generally, the bore  56  is cylindrically shaped and extends in a direction perpendicular to a plane defined by the second end  44 . Preferably, the key-way  58  is ramped or angled with respect to the bore  56 . As shown, the bore  56  has a blind end  60 .  
         [0029]    In the preferred embodiment, the center portion  46  is generally located between the first end  42  and the second end  44 . Preferably, the center portion  46  is provided with a throughbore  62  coaxial with a release recess  64 . Generally, the throughbore  62  is radially positioned and in communication with the bore  56  generally near the blind end  60  (shown best in FIG. 2).  
         [0030]    Referring now to FIGS. 1 and 5, the kettle-type barbecue grill  10  includes three legs  66 . Generally, the legs  66  are tubular shaped, straight, and made of a metal that is both durable and lightweight, preferably aluminum. Other materials are contemplated depending on the application. In the preferred embodiment, each leg  66  is provided with an upper end  68  that houses a locking formation  70  (shown in FIG. 5). In the preferred embodiment, the locking formation  70  includes a compression spring  72  and a pin  74 . Generally, the compression spring  72  is a bent piece of spring-steel to which the pin  74  has been stamped, making the spring  72  and the pin  74  one piece. A slot or aperture  76  is provided in the upper end  68 , and is preferably dimensioned to allow the pin  74  to freely pass through the slot. Slidably assembling the compression spring  72  and the pin  74  into the upper end  68  generally forces the pin  74  radially through the slot  76 . Generally, the compression spring  72  contacts two sides of an inner wall  78  of the leg  66  which causes the pin  74  to be biased radially through the slot  76 . Alternatively, other types of biased, lug-like projections are contemplated, including spring balls, spring-biased pins, etc. as are known in the art.  
         [0031]    Referring again to FIGS. 1 through 5, the locking formation  70  is slidably and rotatably inserted to the leg support  40 . Generally, the bore  56  is dimensioned to allow for a slip fit with the upper end  68 . Depressing the pin  74  and aligning it with the key-way  58  allows the locking formation  70  to interface with the leg support  40  via the bore  56 . Once inside the bore  56 , the pin  74  is released to ride freely on the key-way  58  and the leg  66  is pushed toward the blind end  60  until the upper end  68  contacts the blind end  60 . Preferably, the leg  66  is then rotated to align the pin  74  with the throughbore  62 . Once the pin  74  is aligned with the throughbore  62 , the pin  74 , which is biased by the spring  72 , radially extends through the slot  76  and throughbore  62 . This extrusion of the pin  74  through the throughbore  62  creates a lock which prevents the leg  66  from becoming detached from the leg support  40 . An advantage of the present invention is that the length of the pin  74  is such that it is flushly received in the throughbore  62  and does not protrude past the outer edge of the throughbore. Thus, inadvertent jostling or depression of the pin is prevented which could cause unwanted disengagement of the leg  66  from the leg support  40 .  
         [0032]    If for some reason detachment of the leg  66  is required, such as for disassembly of the kettle-type barbecue grill  10 , the pin  74  is depressable to overcome the biasing force of the spring  72  and disengage the pin  74  from the throughbore  62 . Once the engagement is released, the leg  66  can be detached from the leg support  40  by linearly moving the upper end  68  away from the blind end  60 .  
         [0033]    It will be appreciated that the present leg support  40  and the legs  66  are assembled and disassembled without tools. The time required to perform the assembly of the kettle-type barbecue grill  10  is greatly reduced due to the lack of the need for tools.  
         [0034]    Referring again to FIG. 1, the legs  66  each have a lower end  80 . Generally, the lower end  80  is either provided with an interface for a foot  82  or an axle  84 . The foot  82  generally has the tubular shape of the leg  66  at the lower end  80 . Preferably, the foot  82  is cylindrical shaped and made out of either plastic, rubber or equivalent resilient material. The foot  82  is press fit onto the lower end  80 . Assembly of the foot  82  generally reduces the amount of movement of the kettle-type barbecue grill  10  during operation. An axle interface  85  (FIG. 6) is generally flat and is provided with a throughhole  86 . Generally, the throughhole  86  is dimensioned to allow the axle  84  to pass freely through the throughhole.  
         [0035]    A base  88  is also provided with the kettle-type barbecue grill  10 . Generally, the base  88  is generally triangular-shaped when viewed from above and is provided with a skirt  90 , a storage surface  92  and a leg hole  94 . The leg hole  94  is located at one point of the triangular shaped base  88  and is in a co-planar relation to the storage surface  92 . Preferably, the leg hole  94  is dimensioned to accommodate one of the legs. In the preferred embodiment, the leg  66  that passes through the leg hole  94  receives the foot  82 . Generally, the skirt  90  is perpendicular to, and describes the perimeter of the storage surface  92 . On each corner opposite the leg hole  94  corner, the skirt  90  is provided with a flange hole  96 . Preferably, the flange hole  96  is in a planar relation to the flange  90  and is dimensioned to freely and rotatably accommodate the axle  84 . Thus, the base  88  ties all three legs  66  together, which generally increases the stability of the kettle-type barbecue grill  10 .  
         [0036]    Furthermore, referring now to FIGS. 1 and 6, the kettle-type barbecue grill  10  is configured with generally two wheels  98 . Generally, the wheels  98  are configured to be fastened upon corresponding ends of the axle  84 . This locking interface between the axle  84  and the wheels  98  allows the kettle-type barbecue grill  10  to be easily transported. Generally, the wheels  98 , two legs  66  and the base  88  define a line L that is longer than a width W of the bowl  16  (shown in FIG. 6). This longer line L generally increases the stability of the kettle-type barbecue grill  10 .  
         [0037]    While specific embodiments of the leg support for a barbecue kettle of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the invention in its broader aspects and as set forth in the following claims.