Abstract:
A portable, multi-level barbecue grill assembly having a base cavity, a lid, a pivot assembly, a lower cooking grid and an upper warming grid. The upper warming rack is pivotally secured to the lid and to the pivot assembly. The pivot assembly comprises a pair of lift arms and a pair of pivot extensions for raising the pivot axis of the upper warming grid. When the grill is opened, the upper grid pivots about an axis above the lower grid, thereby providing an increased amount of space between the upper and lower grids. When the grill is closed, the pivot axis of the upper grid moves towards the lower grid to provide a compact storage condition.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention relates to barbecue grills. More particularly, the present invention relates to a multi-level barbecue grill having improved and more efficient cooking and warming surface structures.  
       BACKGROUND OF THE ART  
       [0002]     Barbecue grills for both indoor and outdoor use are commonly used and are well known in the art. Such grills generally have at least a lower, cooking surface for cooking food thereon and many have an upper, warming surface for keeping food warm, but far enough away from a heat source so as not to overcook or bum the food. Generally, the upper surface pivots on a pivoting system to a relatively close distance to the lower surface when the grill is closed. When the grill is open, the upper surface pivots upwardly and rearwardly, thereby creating a greater distance between the respective surfaces.  
         [0003]     The difference in distances between the upper surface and the lower surface when the grill is closed as compared to when the grill is open tends to be small. This small difference in the distance between the surfaces prevents the person using the grill (the griller) from having adequate access to the rearward area of the lower surface for food placement and retrieval. In order to facilitate access to the rearward area of the lower surface, the conventional upper surfaces tend to be constructed with a relatively small depth between the front and rear ends of the upper surface when compared to the lower surface, at times up to 50% less, thereby having a significantly smaller surface area. The small size of the upper surface facilitates access to the rearward area of the lower surface, but prevents room for sufficient amounts of food to be placed thereon for warming. The lesser the amount of food that can be cooked and warmed on the grill, the less efficient the grill is. This leads to a greater amount of time being spent by the griller to cook food on the grill, thereby causing more fuel to be used over a longer period of time.  
         [0004]     There is a need for a more efficient multilevel barbecue grill having a lower cooking surface/grid and an upper warming surface/grid with greater surface areas, the upper warming surface/grid being pivotable relative to the lower surface.  
       SUMMARY OF THE INVENTION  
       [0005]     The present invention is an improved, easy to assemble, barbecue grill. The grill includes a lower cooking surface situated directly above a heat source, such as a charcoal or briquette pit or a propane gas assembly, and an upper warming surface that is parallel to the cooking surface, but disposed directly above it. The upper surface is pivotally secured to the lid of the grill, and when the grill is opened, the upper surface pivots upwardly and rearwardly in response to the opening of the grill. A pair of pivot extensions are provided for raising the pivot point level of the upper surface. When the grill is closed, the upper surface is at a level above the lower surface that is slightly higher than that of conventional grills. When the grill is opened, the upper surface raises to a level above the lower surface that is significantly higher than conventional grills, by way of the pivot extensions. Because there is a significantly greater space between the upper surface and the lower surface when the grill is opened, the problem of inadequate access to the rearward area of the lower surface is greatly reduced, if not eliminated. The increased space between the surfaces allows the upper surface to have a greater surface area than conventional upper surfaces, thereby increasing the overall efficiency of the grill.  
         [0006]     It is an object of the present invention to provide a barbecue grill having improved efficiency regarding food cooking and warming capabilities.  
         [0007]     It is another object of the present invention to provide a barbecue grill having a lower cooking surface with improved access to the rearward area of the lower surface.  
         [0008]     It is yet another object of the present invention to provide a barbecue grill having an increased distance between the upper surface and the lower surface when the grill is opened and when the grill is closed.  
         [0009]     It is still yet another object of the present invention to provide a barbecue grill having an upper warming surface that raises to a higher level relative to the lower cooking surface than a comparably sized conventional barbecue grill.  
         [0010]     It is another object of the present invention to provide a barbecue grill that is easy to assemble.  
         [0011]     It is yet another object of the present invention to provide a barbecue grill that has a compact structure.  
         [0012]     It is still yet another object of the present invention to provide a barbecue grill that is portable.  
         [0013]     These and other objects of the invention may occur to those skilled in the art from the description to follow and from the appended claims. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]      FIG. 1  is a perspective view of the barbecue grill of the present invention in an opened state.  
         [0015]      FIG. 2  is a detailed rear view of the barbecue grill of the present invention showing part of the hinging structure of the cover of the grill and the bowl of the grill.  
         [0016]      FIG. 3  is a top view of the barbecue grill of the present invention showing the grill in a closed state.  
         [0017]      FIG. 4  is a side, internal view of the barbecue grill of the present invention, showing the barbecue grill in both an opened state and a closed state, superimposed on each other, with the grill in its opened state shown in dotted lines.  
         [0018]      FIG. 5  is another perspective view of the barbecue grill of the present invention, with the cover shown in its open condition.  
         [0019]      FIG. 6  is a perspective view of the barbecue grill of the present invention with its legs extended.  
         [0020]      FIG. 7  is a perspective view of the barbecue grill of the present invention with its legs being closed.  
         [0021]      FIG. 8  is a perspective view of the interior components of an alternative embodiment of the barbecue grill of the present invention having the grill in both opened and closed positions being superimposed upon one another, with the components shown in dotted lines in the open condition of the grill. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0022]     The present invention is now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be evident, however, to one skilled in the art that the present invention may be practiced without these specific details.  
         [0023]     Referring now to  FIG. 1 , one embodiment according to the present invention is shown at numeral  10  as a barbecue grill. Grill  10  includes a lid  12  secured to a bowl  14  or base cavity and a plurality of legs  15  extending downwardly from bowl  14 . Lid  12  and bowl  14  may be secured to each other by way of any conventional method known in the art. For example, as shown in  FIG. 2 , lid barrels  16  may be secured to lid  12  at the base of the rear of lid  12  and bowl barrels  18  may be secured to bowl  18  at the top of the rear of bowl  18 , both, for example, by welding or any other comparable method. A cylindrical shaft or post  20  extends through the cylindrical bores of barrels  16  and  18 , about which barrel  16  may pivot or rotate when lid  12  is lifted off of bowl  14  in order to obtain access in bowl  14 .  
         [0024]     Bowl  14  includes a front wall  22 , a back wall  24 , a bottom wall  26  and a pair of sidewalls  28   a, b.  Front wall  22 , back wall  24 , bottom wall  26  and pair of sidewalls  28   a, b  are secured together in a substantially square formation to define a basin  30  for containing a heat source, such as charcoal or a propane gas assembly, with bottom wall  26  forming the floor of bowl  14 . Although bowl  14  and lid  12  are shown as being substantially square, it should be appreciated that grill  10  can have any other shape conventional in the art, such as rectangular or circular. Sidewalls  28   a, b  are substantially straight and are parallel to each other. Front wall  22  is secured to each of sidewalls  28   a, b  at a substantially right angle; however front wall  22  includes a bowed portion  22   a  in order to provide front wall  22  with a curved appearance when viewed from the top view when grill  10  is opened ( FIG. 5 ).  
         [0025]     Referring now to  FIGS. 6 and 7 , plurality of legs  15  is shown with legs  15  opened and extending downwardly from the underside of bowl  14 . Legs  15  can extend directly downwardly from bowl  14 , or they can alternatively extend downwardly at an angle in order to better stabilize grill  10  on the ground. A bracket  17 , shown in detail in  FIG. 6   a,  having a hole  19 , being secured to the underside of bowl  14  on each corner of bowl  14  by way of welding or the like, extends downwardly from the underside of bowl  14 . When grill  10  is not being used, or when legs are not required as when grill  10  is seated on a ledge or the like, legs  15  are able to be manually released from a locked position and folded inwardly to rest along the underside of bowl  14 , as demonstrated in  FIG. 7 . An outwardly biased pin or button  21  is provided which can be pushed in order to release legs  15  from the locked position. When legs  15  are extended outwardly into a locked position for use of grill  10 , pin  21  extends through hole  17  and through aligned holes in legs  15  in order to lock legs  15  into place. It should be appreciated that any other comparable type of locking mechanism may be used in order to secure legs  15  into a locked position during use of grill  10 .  
         [0026]     Referring back to  FIGS. 1 and 4 , lid  12  includes a lid front wall or front rim  32 , a lid back wall  34 , a top wall  36  and a pair of lid sidewalls  38   a, b.  As seen in  FIG. 1 , each of walls  32 ,  34 ,  36  and  38   a, b  have substantially the same shape as the respective corresponding walls  22 ,  24 ,  26 , and  28   a, b  of bowl  14  so that when grill  10  is closed, the lower ends of each of the walls of lid  12  abuts with the corresponding upper ends of the walls of bowl  14  to form a secure seal. Front wall  32 , back wall  34 , bottom wall  36  and pair of sidewalls  38   a, b  are secured together in a substantially square cross-sectional formation which corresponds to the top of bowl  14 , with top wall  36  forming the ceiling of lid  12 . Sidewalls  38   a, b  are substantially straight and are parallel to each other. Front wall  32  is secured to each of sidewalls  38   a, b  at a substantially right angle; however front wall  32  also includes a substantially bowed portion in order to provide front wall  32  with a curved appearance when viewed from the top view when grill  10  is closed ( FIG. 3 ).  
         [0027]     Grill  10  still further includes a pair of grids, one being a lower, cooking grid  40  and the other being an upper, warming grid  42 . Both of grids  40  and  42  are made of any conventional material known in the art, such as stainless steel, and are composed of a plurality of diagonally disposed rungs  44   a, b,  which are shown as being slightly curved. The plurality of rungs  44   a, b  are shown in  FIG. 1  as extending diagonally from a central rung  46   a, b  towards the back and either to the left or right side of either lower grid  40  or upper grid  42 . This of course is just one grid design of a variety of known designs, any one of which may be incorporated into grids  40  and  42 , none of which have any bearing on the improved functionality of grids  40  and  42 .  
         [0028]     Lower grid  40  includes a curved front edge  48  generally corresponding to the curve of portion  22   a  of bowl front wall  22 , a straight rear edge  50  and a pair of straight, substantially parallel side edges  52   a, b.  Upper grid  42  also includes a curved front edge  54  parallel to the curve of front edge  48  of lower grid  40 , a straight rear edge  56  and a pair of straight, substantially parallel side edges  58   a, b.  Each of the respective edges of lower grid  40  and upper grid  42  are disposed so as to correspond to the respective adjacent sides of either bowl  14  or lid  12 . Each of the edges of grids  40  and  42  are able to be placed as close to the respective sides of bowl  14  and lid  12  as possible so as to ensure that grids  40  and  42  contain maximum surface areas, thereby ensuring a maximum cooking surface area and a maximum warming surface area. At least one pair of oppositely disposed supports  74   a, b  are placed in bowl  14 , secured to sidewalls  28   a, b,  for supporting lower grid  40  in place within the cooking area of bowl  14 . Alternatively, lower grid  40  may be supported by upwardly extending flanges of a sear grid if grill  10  is a gas barbecue grill.  
         [0029]     Grill  10  further includes a pair of pivot extensions  60   a, b  and a pair of lift arms  62   a, b.  As seen in  FIGS. 1, 4  and  5 , pivot extensions  60   a, b  are triangular structures, preferably comprised of the same material as grids  40  and  42  (i.e., stainless steel). Lower grid  40  can further include a pair of oppositely disposed indentations  64   a, b  on each side of lower grid  40 . Indentations  64   a, b  provide an indented area on side edges  52   a, b  to accommodate the securing of pivot extensions  60   a, b  thereon. Pivot extensions  60   a, b  are secured to lower grid  40  and extend upwardly therefrom in a vertical orientation so that pivot extensions  60   a, b  are substantially perpendicular to the plane in which lower grid  40  is disposed.  
         [0030]     In further detail, each pivot extension assembly includes a rod  65   a, b  extending partly across each of indentations  64   a,    64   b  and parallel to side edges  52   a,    52   b.  Pivot extensions  60   a,    60   b  include metal rods  67   a, b  extending upwardly at an angle from the opposite ends of rods  65   a, b  and coming together at a first pair of pivots  66   a, b  (discussed below).  
         [0031]     Still referring to  FIGS. 1, 4  and  5 , grill  10  will be described while in an opened position. First pair of pivots  66   a, b  are disposed on the top of pivot extensions  60   a, b.  For example, pivot  66   a  is secured to the top of pivot extension  60   a  and pivot  66   b  on top of pivot extension  60   b.  Pivots  66   a, b  are movable as discussed below. First pair of pivots  66   a, b  is preferably any type of conventional pivot known in the art and is preferably of the same type of material as grids  40  and  42  and pivot extensions  60   a, b  (i.e., stainless steel). Pivots  66   a, b  are formed in part by the intersections  67   a,    67   b.  Pivot extensions  60   a, b  are provided so as to raise the pivot point of first pair of pivots  66   a, b;  that is, the pivot between a lift arm (described below) and pivot extension  60   a, b  from a level that is even with that of lower grid  40  to a level that is above the level of lower grid  40 . By way of pivot extensions  60   a, b,  first pair of pivots  66   a, b  are raised to a level higher than that of lower grid  40 , such as by about three inches in the preferred embodiment. First pair of pivots  66   a, b  are, in other words, about three inches higher than a conventionally disposed pivot would be, which would be at the level of lower grid  40 . By employment of pivot extensions  60   a, b  to raise the level of pivots  66   a, b,  the space between lower grid  40  and upper grid  42  is increased, both while grill  10  is opened and closed. For example, a conventional grill having a grill height of about 10 inches (when the grill is closed) employs a lower grid having a surface area of about 243 in 2  and an upper grid having a surface area of about 112 in 2 . The distance between the upper grid and lower grid in the aforementioned conventional grill would be about 3.75 inches when the grill is opened and about 2 inches when the grill is closed. Employment of pivot extensions  60   a, b  increases this distance between lower grid  40  and upper grid  42  to about 6.75 inches when the grill is opened and about 2.5 inches when the grill is closed. The increased space between the lower grid  40  and upper grid  42  does not affect the overall grill package height. In this case, it would be about 8.25 inches. Additionally, the distance between upper grid  42  and lid  12 , while grill  10  is closed, would be a maximum distance of about 3.5 inches (about one inch at the front of upper grid  42 ), while the same maximum distance in a comparably conventional grill would be about 2 inches.  
         [0032]     As shown in  FIG. 5 , extending upwardly from pivot  66   a  is a first lift arm  68   a  and extending upwardly from pivot  66   b  is a second lift arm  68   b.  Lift arms  68   a, b  are in turn secured to a second pair of pivots  70   a, b,  respectively, which provide a pivot point between lift arm  68  and upper grid  42 . Second pair of pivots  70   a, b  are secured to upper grid  42  at the foremost comers of upper grid  42 . It should be appreciated that second pair of pivots  70   a, b  are the same type and of the same material as first pair of pivots  66   a, b,  which can be any type of pivot conventional in the art. Lift arms  68   a, b  each comprises a metallic rod twisted or configured into a substantially rectangular loop. Each lift arm  68   a, b  can alternatively comprise a single straight metallic rod, multiple metallic rods or a metallic rod twisted into any other shape so long as the lift arms can easily pivot between the open and closed position of barbecue grill  10 .  
         [0033]     Referring to  FIGS. 1, 4  and  5 , a third pair of pivots  72   a, b  extends outwardly from side edges  58   a, b  of upper grid  42  and are disposed towards the rear edge  56  of upper grid  42 . The two pivots of third pair of pivots  72   a, b  are disposed opposite each other on upper grid  42  and extend outwardly from upper grid  42  towards sidewalls  38   a, b  and through a hole  73   a, b  of lid  12  to pivotably secure upper grid  42  to lid  12 . Third pair of pivots  72   a, b  provides a pivot point for upper grid  42  relative to lid  12 . Pivots  72   a, b  both comprise a rod  75   a, b  secured to opposite sides of upper grid  42  and extend outwardly therefrom and through respective holes  73   a, b  on the sidewall of lid  12 . Rod  75   a, b  can be secured by a nut, such as a wing-nut, can be snap-fit into place, or secured by any other comparable securing method or apparatus to facilitate pivoting of upper grid  42  in response to movement of lid  12  between an open and closed position.  
         [0034]     Turning now to  FIG. 4 , the opened and closed positions of grill  10  are shown in a superimposed manner. For the sake of clarity and brevity, only one of any of the aforementioned pairs of features included in grill  10  will be discussed below. While grill  10  is in a closed position, lift arm  62   a  extends outwardly from first pivot  66   a  in a horizontal manner, substantially parallel to both lower grid  40  and upper grid  42 . While in this position, second pivot  70   a,  the pivot between the top of lift arm  62   a  and upper grid  42 , is in a first position C′, which is a relatively low position within grill  10 , resting just above lower grid  40 . While grill  10  is closed, upper grid  42  is resting just above lower grid  40  with a distance between the two of about 2.5 inches, as explained above. It is again emphasized that this distance is variable depending on the particular grill size with which the present invention is being employed. Third pivot  72   a,  which is the pivot that pivotably secures upper grid  42  with lid  12 , is at a first position D′.  
         [0035]      FIG. 4  also shows grill  10  in an open position. When grill  10  is opened in a clockwise direction as illustrated, second pivot  70   a  travels along a first path  76  to a second position, shown at C″. Likewise, third pivot  72   a  travels along a second path  78  to a second position, shown at D″. While grill  10  is closed, the distance between first pivot  66 , which is stationary relative to a vertical and horizontal direction, and second pivot  70   a  is shown at distance A from first pivot  66   a.  The distance between third pivot  72   a  and the pivot (i.e. the longitudinal axis of shaft  20 ) between lid  12  and bowl  14  at the back of grill  10  is shown as B. According to all embodiments of the present invention, distance A is substantially equal to distance B and the angle between the pivots involved with distance A must be substantially equal to the angle between the pivots involved with distance B in order to ensure level lifting of upper grid  42  while grill  10  is in the process of being opened. Substantially equal distances and angles will ensure that upper grid  42  remains parallel to lower grid  40  while grill  10  is being opened. In other words, it is preferred that there be no more than a 10% difference between distance A and distance B and there be no greater than a 10° difference in the angles between the pivots of distance A and distance B to ensure level lifting of upper grid  42 . It should be appreciated that the actual distance of A and B are not relevant to the level lifting of upper grid  42  of the present invention because the actual distance of A and B will vary depending on the size of the grill with which the present invention is being employed.  
         [0036]     Pivot extension  60   a  enables upper grid  42  to lift to a higher level relative to lower grid  40  than it would when compared to the upper and lower grids of a conventional grill. This increased distance between grids  40  and  42  allows grids  40  and  42  to be constructed having surface areas that are about 18% greater than grids used in a comparably sized conventional grill. For example, when comparing grill  10  according to the present invention having an overall package height of about 8.25 inches with a comparably sized conventional grill, upper grid  42  has a surface area of 166 inches 2  and lower grid  40  has a surface area of 255 inches 2 , whereas the grids of a comparably sized conventional grill would have surface areas of 112 inches 2  and 243 inches 2 , respectively.  
         [0037]     Referring now to  FIG. 8 , a second embodiment of the barbecue grill of the present invention is shown and referred to at numeral  100 . Grill  100  includes each of the same features as the grill described above, including a lid  112 , a bowl  114  having a pair of sidewalls  128 , a lower grid  140 , an upper grid  142 , a pair of pivot extensions  160 , a pair of lift arms  162 , a first pair of pivots  166 , a second pair of pivots  170  and a third pair of pivots  172 . The remaining features of grill  10  described above are incorporated below, however a detailed description thereof is omitted for the sake of brevity. As was done above, just one of the pair of features will be discussed below for the sake of clarity.  
         [0038]     In this embodiment, lower grid  140  is pivotably secured to sidewalls  128  by way of first pivot  166 , each of first pivots  166  being disposed on an opposite side of lower grid  140 . As explained earlier with respect to pivots  66   a, b,  pivots  166  include a pivot assembly interconnecting a lift arm  162  and pivot extension  160 . When grill  100  is closed, lift arm  162  extends from first pivot  166  in a substantially horizontal fashion to a second pivot  170 . Second pivot  170  pivotably secures lift arm  162  to pivot extension  160 , which when grill  100  is closed, extends substantially upwardly from second pivot  170  so that lift arm  162  and pivot extension  160  are substantially perpendicular to each other. Again as discussed earlier with respect to second pivots  70   a, b,  second pivot  170  is comprised of a pivot assembly comprising a rod extending between lift arm  162  and pivot extension  160 , and having a securing apparatus securing the rod in place. Pivot extension  160  in turn is fixedly secured to the underside of upper grid  142 . Third pivot  172  pivotably secures upper grid  142  to a sidewall  138  of lid  112  in the same fashion described above for pivots  72   a, b,  towards the rearward portion of lid  112 , by way of a rod  175  secured to opposite sides of upper grid  142  and extending outwardly therefrom and through respective holes  173  of upper lid  112 , rod  175  being secured in place by a lock-nut (not shown), snap-fit into place, etc. Rod  175   a, b  can be secured by a nut, such as a wing-nut, can be snap-fit into place, or secured by any other comparable securing method to facilitate pivoting of upper grid  142  in response to movement of lid  112  between an open and closed position.  
         [0039]     When grill  100  is closed, second pivot  170  and pivot  172  are in first positions E′ and F′ respectively. As a griller manually opens lid  112  clockwise as shown, upper grid  142 , which is pivotably secured to lid  112 , pivots upwardly with the opening of lid.  112 . When lid  112  is fully opened, pivot  170  and pivot  172  travel upwardly and rearwardly (towards shaft or pivot  120 ) into second positions E″ and F″ respectively. When lid  112  is opened, lift arm  162  and pivot extension  160  are substantially in alignment, as lift arm  162  pivots upwardly in the clockwise direction around pivot  166 , which is fixed relative to bowl  114 , and pivot extension  160  pivots about second pivot  170  which is itself pivoting about first pivot  166  with lift arm  162 . Employment of pivot extension  160  allows upper grid  142  to pivot upwardly to a higher level relative to lower grid  140 , thereby allowing a greater amount of space between upper grid  142  and lower grid  140  in the open position.  
         [0040]     What has been described above are preferred aspects of the present invention. It is of course not possible to describe every conceivable combination of components or methodologies for purposes of describing the present invention, but one of ordinary skill in the art will recognize that many further combinations and permutations of the present invention are possible. Accordingly, the present invention is intended to embrace all such alterations, combinations, modifications, and variations that fall within the spirit and scope of the appended claims.