Abstract:
An off fire cooling system having an octagonal body shape and split fire system which doubles the coal heating surface area and doubles the coal heat output. The cooking system also has an air introduction system which circulates air throughout the interior of the grill to maintain an optimum cooking temperature. The octagonal maintains the cooking temperature at or above 400 degrees Fahrenheit in the center of the grilling system. The system eliminates grease fires and smoke associated with grease fire flare ups. The charcoal and food products are suspended for optimum cooking while preventing grease from falling onto the burning charcoal coals.

Description:
This application claims the benefit of Provisional No. 60/071,738 filed Jan. 16, 1998. 
    
    
     The present invention relates to an off fire charcoal grill having an octagonal shape and air introduction system which maintains an ambient cooking temperature in excess of 400 degrees Fahrenheit. 
     BACKGROUND 
     Outdoor barbecue grilling has been acknowledged as one of the great American pastimes and is mentioned in the same breath as, baseball, hot dogs and apple pie. Due to its popularity and extent of use, outdoor barbecue grilling has evolved throughout the years in attempts to address common problems encountered while barbecue grilling. 
     For instance, traditional charcoal grilling includes the use of a plurality of charcoal briquets which must be ignited with flammable lighter fluid. However, it is well known that a charcoal coal fire is sometimes hottest at its center while the periphery of the charcoal coal fire has a cooler temperature. Thus, timing of the placement of the meat on the fire is essential. The barbecue chef must use discretion when placing the food to be cooked onto the grill, for if the placement is too early, the meat may be charred and if the placement is too late, there may not be enough of a sufficient coal fire to complete the cooking of the meat, nor may there be a high enough temperature to kill any existing bacteria in the meat. In addition, if the meat is placed onto the grill prior to the complete burning off of the lighter fluid, the meat&#39;s taste could be adversely affected. Moreover, early types of lighter fluid and its volatile characteristics sometimes created a dangerous combination. 
     Various improvements have included gel type lighter fluids that did not flare up when ignited. In addition, the charcoal itself was manufactured to include such a flammable material so that a user needs only to strike a match to prepare the charcoal. 
     However, these improvements failed to correct the uneven cooling temperatures and short life span of an optimum cooking temperature produced by the burning coals. Moreover, as the meats are placed over burning coals the grease droppings associated with the cooking of such meats causes the coals to flare up back toward the meat. This flare up causes charring of the exterior of the meat and may ultimately ruin a meal. In addition, the smoke caused by such a flare of also affects the taste of the meat. 
     Other attempts to correct these problems included the advent of propane gas barbecue grills. However, such grills cannot duplicate the culinary satisfaction of an open fire barbecue grilling of a meal. 
     In addition, recent studies conducted by the MAYO clinic and the American Cancer Society have produced results which indicate that individuals who barbecue their foods, in particular meats, three or more times a month for a five-year period placed those people in a higher percentile for susceptibility to particular types of cancer. 
     Some of the suggestions from these studies to reduce such risks are the following, use of a high temperature to eliminate bacteria, reduce “flare up” caused by grease dripping from the cooking meats and avoid charring of the meat. Some of these studies also indicated that carcinogenic toxins are built up in the meats being cooked due to “flare up” and charring of the meat. 
     SUMMARY OF THE INVENTION 
     The present invention relates to outdoor equipment, and pertains more particularly to an improved charcoal grill. The present invention is directed to a barbeque grill which cooks food products in an off fire cooking system. The present invention provides a split fire system which doubles the coal heating surface area and double the coal heat output. The grilling system also has an air introduction system which circulates air throughout the interior of the grill to maintain an optimum cooking temperature. Moreover, the grill body is octagonal in shape. The octagonal shape also maintains the cooking temperature at or above 400 degrees Fahrenheit in the center of the grilling system. 
     It is one object of the present invention to provide a barbecue grill that will assist in the reduction of health risks associated with barbeque grilling. The present invention provides a barbeque grill that eliminates grease fires and smoke associated with grease fire flare ups. The charcoal is suspended in such a manner as to prevent the cooking grease from falling onto the burning charcoal coals. 
     It is another object of the present invention to provide a grill that will cook meat with a high enough temperature to kill any existing bacteria in the meat. It is also another object of the present invention to prevent “Flare-up,” caused by greases dripping from the meats as they are cooling in the grill. In addition, the prevention of a flare-up will prevent smoke from the burning grease to the affect the flavor of the meat being cooked. Also, the present invention will prevent the charring of the meat, which can be caused by a direct flame positioned below the meat being cooked. 
     The present invention accomplishes this by providing a unique off-fire cooking system that suspends the burning coals in the cooking unit to increase the convection within the grill. This is accomplished by splitting the source of fire into two fire baskets which provide even heat and also doubles the heating surface area provided by the coals. 
     A blower unit is also used to introduce a steady stream of air to keep the coals burning at a peak temperature. This system will provide a cooking unit that provides temperature is consistently at a temperature in excess of 400 degrees Fahrenheit. This will allow meat to be cooked without charring and sealing in the natural juices of the meat to provide an enhanced outdoor cooking experience. 
     Thus, the present invention provides a grilling system that reduces health risks associated with barbeque grilling without losing or adversely affecting the barbeque flavors associated with barbeque grilling. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     One way of carrying out the invention is described in detail below with reference to drawings which illustrate a specific embodiment of the invention: 
     FIG. 1 is a front perspective view of the present invention; 
     FIG. 2 is a side elevation view of the present invention; 
     FIG. 3 is a rear elevation view of the present invention; 
     FIG. 4 is a side view illustrating functional components of the present invention; 
     FIG. 5 is a front plane view illustrating the grilling components of the present invention; 
     FIG. 6 is a side view of the charcoal carrying baskets of the present invention; 
     FIG. 7 is a view along lines  7 — 7  of FIG. 6; 
     FIG. 8 is a perspective view of an alternative components of the present invention; 
     FIG. 9 is a top plane view illustrating an alternative component of the present invention; 
     FIG. 10 is a side plane view illustrating an alternative component of the present invention; 
     FIG. 11 is a front plane view illustrating an a component of the present invention; 
     FIG. 12 is a side elevation view illustrating components of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Turning now to FIG. 1, a barbeque grill  10  constructed in accordance with the present invention is illustrated. Grill  10  is constructed out of a heat resistant material, such as cast aluminum, galvanized aluminum, steel, stainless steel or cast iron, which is durable, lightweight and resistant to high temperatures and weathering. This is of particular importance due to grill  10  constant exposure to the elements. 
     Grill  10  comprises a body  12 . Body  12  is supported by a frame  14 . Frame  14  has an extended shelf portion  16  which is secured to one side of frame  14 . Shelf portion  16  has a plurality of wood planks  18  mounted to shelf portion  16  to provide a staging area for food products to be cooked by grill  10 . In addition, condiments and utensils may also be placed on this staging area in preparation for grilling. 
     The positioning of shelf portion  16  is so that the staging area is positioned to coincide with the grill. Alternatively, shelf portion  16  may be positioned on both sides of grill  10  or in front of grill  10 . 
     Frame  14  also has a lower shelf portion  20 . Lower shelf portion  20  is positioned below body portion  12  and is mounted to frame  14  to provide an additional storage space for items. In addition, shelf portion  20  provides stability to frame  14 . A plurality of wood planks  22  are also mounted to shelf portion  20  to provide for this storage area. 
     Planks  18  and  22  are preferably a weather resistant type of wood such as redwood. Alternatively, planks  18  and  22  may be molded out of a durable material such as plastic. 
     To facilitate the movement of grill  10 , a pair of wheels  24  are mounted to the bottom legs of frame  14 . Thus, a user need only lift the portion of frame  14  that has no wheels attached to it to move grill  10 . In the preferred embodiment, shelf portion  16  is positioned to also act as a handle to facilitate the movement of grill  10 . Moreover, the extension of shelf  16  away from grill  10  minimizes the amount of force required to lift frame  14 . 
     Wheels  24  are constructed out of a durable material such as plastic or rubber. In addition, the remaining two legs of frame  14  do not have wheels mounted on them. This feature prevents un-wanted movement of grill  10 . 
     Body portion  12  is configured and dimensioned to define an elongated body having and an octagonal shape. This shape is particularly viewed when body portion  12  is viewed from its side (as illustrated in FIG.  2 ). As an alternative, body portion  12  may be configured to have a hexagonal, polygonal, rectangularly arranged, trapezoidal, cubic or any other similarly shaped arrangement. 
     Referring now to FIG. 2, body portion  12  has an upper body portion  26  and a lower body portion  28 . Portions  26  and  28  are pivotally connected along their elongated sides by a pair of hinges  30  (as illustrated in FIG.  3 ). 
     Referring-back now to FIG. 2, body portion  26  comprises one half of the octagonal shape defined by body  12 . Similarly, body portion  28  defines the other half of the octagonal shape defined by body  12  or more particularly the lower portion. 
     Referring now to FIG. 4, portions  26  and  28  are also configured to define an inner cavity  32 . Inner cavity  32  is positioned within body  12 . Hinge  30  allows for the pivotal movement of portion  26  with regard to portion  28  to allow access for the user into inner cavity  32  (as illustrated in FIG.  4 ). 
     A handle  34  is mounted to the outer surface of portion  26 . Handle  34  allows a user to grip the handle and pivot portion  26  away from portion  28  to allow for access into inner cavity  32 . A support bar  36  limits the pivot of portion  26  away from portion  28 . 
     Turning now to FIG. 5, the details of inner cavity  32  are illustrated. Lower body portion  28  supports portions of the grilling system. A pair of Charcoal baskets  38  are positioned to hang at either end of inner cavity  32  as defined by lower body portion  28 . 
     In the preferred embodiment, charcoal baskets  38  are constructed out of a steel diamond mesh to define charcoal baskets  38 . In the preferred embodiment charcoal baskets  38  have the following dimensions 4″×9″×12″ and are manufactured out of an expanded metal mesh with a plurality of holes. The plurality of holes allows for a uniform burning of the charcoal briquets. The holes of the bottom portion of baskets  38  are of a size large enough to allow for heat convection and burning while being small enough to keep ashes from the burnt coals dropping through the bottom of basket  38 . 
     Referring now to FIGS. 5,  6  and  7 , baskets  38  have a pair of hanging arms  40  which are positioned and connected to either side of baskets  38 . Moreover, baskets  38  are configured to have an opening at the top for placement of charcoal into basket  38 . 
     Arms  40  support baskets  38  from a support frame  42  which has a pair of support bars  44 . Bars  44  are affixed to the inner surface of lower portion  28  and run along the elongated portion of inner cavity  32  which is defined by lower body portion  28 . 
     An inner frame  46  is affixed to frame  42 . Inner frame  46  is configured to receive and support a plurality of inside cooking racks  48  at a midpoint along their sides. Inner frame  46  is configured to have its supporting structure approximately 8′ from the top lip of lower portion  28 . In addition, inner frame  42 , bars  44  and inner frame  46  are positioned to support cooling rack  48  and baskets  38 . 
     Cooking racks  48  are positioned in between charcoal baskets  38  so that they may receive the radiant heat given off from charcoal coals burning within baskets  38 . 
     Cooking racks  48  are also configured to have an opening at their top. The opening allows for the user to place food products within rack  48 . In the preferred embodiment, six cooking racks  48  are positioned in between charcoal baskets  28 . 
     As an alternative and referring to FIG. 8, racks  48  can be configured to define a pair of mesh boxes pivotally connected by a hinge  47  for pivotally connecting either side rack  48  with respect to each other. Hinge  47  would allow a user to open rack  48  and place and/or remove food products. 
     In yet another variation, rack  48  can be configured to define a basket having one of its side walls pivotally connected to rack  48  to allow a user to open rack  48  to place and/or remove food products. These features would also allow an individual to place rack  48  on a flat surface for ease of placing food products in basket  48 . Then rack can be hung as illustrated in FIG.  5 . 
     Cooking racks  48  each have a pair of hanging arm supports  49 . Arm supports  49  make contact with frame  46  to support racks  48 . 
     In addition, each of the cooking racks has a handle  50  affixed to them. Handle  50  is positioned to allow for easy removal of racks  48  from frame  46 . 
     Cooking racks  48  are constructed out of a heat resistance material which is resistant to corrosion and will not affect the taste of the food being cooked, such as stainless steel or steel diamond mesh. In addition, racks  48  are also TEFLON coated to prevent the cooking food products from sticking to racks  48 . 
     Racks  48  are also manufactured to have a plurality of holes. The plurality of holes allows for a uniform cooking of food products placed within basket  48 . 
     As can be seen from FIG. 5, the positioning of racks  48  is in a configuration to provide an air gap  52  between each of the racks. An air gap  54  is also present between charcoal baskets  38  and the cooking racks  48  which are 
     positioned in a position closest to charcoal basket  38 . These air gaps allow for the radiant heat from the burning charcoal to be circulated throughout inner cavity  32 . 
     Referring now to FIGS. 9 and 10 and as an alternative, a flat cooking surface  56  is supported by a plurality of hangers  57  which support surface  56  at a depth of three inches from frame  46 . Thus, surface  56  provides a cooking surface with having a height of 11″ from the lip of lower body portion  28 . 
     As an alternative, surface  56  may be equipped with adjustable hanger  57  to vary the height of surface  56  with regard to the lip of lower body portion  28 . In fact lower body portion may be configured to support surface  56  at its periphery. 
     In the preferred embodiment, cooking surface  56  comprises a stainless steel or steel grill having a 12″×18  cooking area (as illustrated in FIG. 9) and a TEFLON coated. 
     Referring back now to FIGS. 1 and 5, an air introduction system  58  is mounted to the outer surface of portion  26 . In the preferred embodiment, system  58  is positioned on the opposite side of shelf portion  16  to allows for a user to access the staging area defined by shelf portion  16  without interference from system  58 . System  58  has an internal fan  60  which when activated introduces a steady and consistent flow of air into inner cavity  32 . 
     Air is introduced into inner cavity  32  through a hole  61  (not shown) in upper body portion  26 . A diffuser  62  (as illustrated in FIG. 11) having a plurality of holes  63  is mounted over hole  61  and to the inner surface of portion  26 . When activated fan  60  will introduce air through holes  63  into inner cavity  32  as indicated by arrows  64 . 
     The air current created by fan  60  causes air to travel in the directions of arrows  64 . As can be seen, the air first travels across the portion of inner cavity  32  as defined by upper portion  26  and then through charcoal basket  38 . This causes the air to be heated and accordingly increases the internal temperature of grill  10 . 
     In addition, as air is introduced in the direction of arrows  64 , air flow is created in the direction of arrows  67  causing heated air to make contact with non-heated air being introduced by fan  60 . This air flow helps to maintain a uniform temperature within inner cavity  32  and cause the charcoal briquets to burn more efficiently. 
     Furthermore, the octagonal configuration of grill  10  causes the air flow to be centralized within inner cavity  32 , thus, providing an optimum cooking temperature for grilling. 
     Moreover, gaps  52  and  54  along with the constant air circulation from fan  60  provides for an air introduction and heating system which supplies grill  10  with a uniform ambient cooking temperature. A temperature gage  65  is mounted to the outer surface of upper body portion  26  and having its temperature sensing elements positioned within inner cavity  32 . 
     As an alternative, air introduction system  58  may be equipped with a baffle or cover  59  to cover the inlet port of fan  60  to prevent the introduction of outside air into inner cavity  32 . Thus, fan  60  can be used to only circulate the air already heated within cavity  32 . 
     As yet another alternative and in order to supplement the air circulation of inner cavity  32  a variable release vent  61  having the capability of being manipulated by a user to be either in an open position and/or a closed position to allow heated air and/or excess smoke to escape from or remain within inner cavity  32  is positioned on the surface of grill body  12 . 
     Release vent  61  can be positioned to coincide with the air flow created by fan  60  or it can be completely removed from the air flow created by fan  60 . Moreover, a plurality of release vents may be positioned on grill body  12  to allow for such positioning. 
     The octagonal configuration of grill  10 , as illustrated in FIG. 12, also provides for a unique heating convection in the direction of and as illustrated by arrows  78 . Accordingly, grill  10  and its octagonal configuration provides for a unique convection heating of the food placed within cooking rack  48 . 
     In addition, since grill  10  is manufactured out of a heat conductive material such as aluminum, the convection of heat in the direction of arrows  78  is also magnified. 
     As an alternative, body  12  of grill  10  may be made out of a more durable material such as cast iron while the inner surface of lower portion  24  and upper portion  26  may be coated with a heat reflective substance such as aluminum. 
     Accordingly, the present invention provides a unique off-fire cooking system that maintains a uniform ambient cooking temperature while the same is provided by a charcoal fire which traditionally produces an uneven cooking temperature. 
     Thus, the constant circulation of air and the octagonal configuration of body  12 , causes the inner temperature to be maintained in excess of 400 degrees Fahrenheit. 
     In addition and referring back now to FIG. 5, as a portion of meat  66  is cooking within cooking basket  48 , grease droppings  68  travels in a downward direction toward the lower surface  70  of portion  28 . 
     As illustrated, grease  68  does not make any contact with the coals contained in charcoal baskets  38  and accordingly there is no potential for a grease fire flare-up 
     Referring back now to FIG. 12, lower body portion  28  defines a point  72 . Point  72  which is the lowest point of the octagonal shape of body  12 . As previously discussed in FIG. 5, as grease  68  drips in a downward direction, caused by gravity, grease  68  will tend to accumulate at the channel defined by lower point  72 . 
     To facilitate the easy removal of grease from grill  10  a grease collecting pan  74  is mounted to portion  28  to coincide with point  72  which is the lowest point of inner cavity  32 . 
     A plurality of holes  76  are positioned in portion  28  to allow grease  68  to travel from inner cavity  32  into grease collection pan  74  for disposal. 
     The octagonal shape of grill  10  creates a natural point of removal of grease  68  from grill  10 . 
     These droppings will not make contact with the charcoal as in conventional grilling systems. This is of particular importance in that the burning grease from the food products will not be entrained into the air and ultimately into the food being cooked. 
     Referring in particular to FIG. 12, support bars  44  are positioned so that baskets  38  and racks  48  (not shown) are positioned to hang slightly above upper lip  80  of lower body portion  26 . This placement allows for the heated air to travel throughout inner cavity  32 . Moreover, this configuration allows for a slightly larger air gap at the top of grill  10  to coincide with the placement of air introduction system  58 . 
     As an alternative, frames  42 ,  46  and bars  44  may be positioned within lower body portion  28 , while the supporting arms  40  and  49  of baskets  38  and racks  48  respectfully, are positioned to maintain baskets and racks accordingly. 
     In yet another embodiment, baskets  38  and racks  48  may be equipped with adjustable supporting arms to facilitate movement of baskets  38  and racks  48 . 
     As an alternative, support frames  42 ,  46  and bars  44  can be positioned to align the center of baskets  38  and racks  48  with the center line  82  of inner cavity  32 . This configuration provides for an even air gap between baskets  38  and racks  48  and the surfaces of inner cavity  32 . 
     Referring now to FIGS. 1 and 12, a plurality of support arms  84  are fastened or welded to the outer surface of lower body portion  26 . Support arms are positioned to rest on frame  14  to support body  12  of grill  10 . This feature allows body  12  to be lifted out of frame  14  Without the need for tools. The easy removal of body  12  allows for easy cleaning of grill  10  and its components and should replacement parts be required, this feature allows for easy replacement of such parts, such as replacing frame  14 . Moreover, removal of body  12  allows for convenient access to body  12  and its components for cleaning and replacement of parts. 
     While an illustrative embodiment of the invention has been described, various modifications will be obvious to those skilled in the art. Such modifications are within the spirit and scope of the present invention which is limited and defined only by the appended claims.