Barbeque grill

A barbeque assembly for use in the preparation of cooked food having a bottom housing that defines one or more burner chambers, each burner chamber forming a cavity in the bottom housing, wherein each burner chamber has a burner support and a fuel supply opening. Each burner chamber has a burner positioned within the burner chamber, wherein the burner chamber has a plurality of holes that are configured to allow fuel to flow from the burner chamber cavity to the bottom housing. A plurality of retention elements are configured to secure the one or more burners within the bottom housing.

RELATED APPLICATIONS

Incorporation by Reference to any Priority Applications

Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet as filed with the present application are incorporated by reference under 37 CFR 1.57 and made a part of this specification.

BACKGROUND

This disclosure relates generally to barbeques used for cooking food items, and more particularly barbeques using propane or natural gas as their fuel supply.

The grilling of meats like hamburgers, steaks, chicken and the like is favored by many people because of the flavoring and other properties imparted to the food product by the grilling process. This is particularly so in the case of cooking meats where the grease and drippings from the meat are burned or seared to impart onto the meat a smoked flavor. Also, grilling releases fats and hence reduces the caloric content of the food product.

The typical gas barbecue includes a housing and one or more gas burners. These burners typically have a number of apertures or orifices through which gas is released and ignited in order to produce a flame for cooking and heating purposes. The flame area is typically long and narrow, and closely matches the long, narrow shape of the burner. One problem encountered with such barbecues is the inefficiency associated with such burners, as the limited flame area provided by the burners requires excessive fuel for adequate cooking. In addition, such barbeques are difficult to assemble and even more difficult to disassemble once used and food grease has covered the grill's internal parts. Therefore, cleaning such grills is difficult and time consuming.

SUMMARY

Accordingly there is a need in the art for a barbeque system that provides more efficient grilling and a flame area that is wider and more closely matches the shape and area of the cooking surface. Furthermore, a barbeque unit that is easy to clean and service would be desirable, as well. For example, a barbeque system that can be disassembled and placed within a standard dishwashing machine would provide unmatched convenience and cleanability.

In one embodiment, a barbeque assembly for use in the preparation of cooked food is provided. The barbeque assembly includes: a bottom housing having an internal grill area and defining one or more burner chambers, each burner chamber formed as a cavity in the bottom housing, wherein each burner chamber has a chamber cover support and a fuel supply inlet; one or more regulators, each regulator having a gas inlet and a gas outlet stem and defining a fluid flow path between the gas inlet and the gas outlet stem, wherein the regulator is operable to open and close the fluid flow path, wherein the regulator is configured to couple with a fuel supply, wherein the gas outlet stem is configured to be positioned within the fuel supply inlet to supply fuel to the burner chamber; one or more chamber covers, each chamber covers having a first face and a second face and a plurality of passageways extend from the first face through to the second face, wherein the chamber covers is configured to be positioned within the burner chamber, wherein the chamber covers is configured to allow fuel to flow from the burner chamber cavity through the plurality of passageways to the first face; and a plurality of retention elements, wherein the plurality of retention elements are configured to secure the one or more chamber covers within the bottom housing.

In one embodiment, the barbeque assembly also includes one or more gaskets coupled to the one or more chamber cover supports, wherein the chamber cover is positioned adjacent the gasket, wherein the gasket is configured to compress when the retention elements hold the one or more chamber covers in place. In another embodiment, barbeque assembly also includes a support stand coupled to the bottom housing. The bottom housing may be rotatable about the support stand, wherein the support stand is configured to adjust the height of the bottom housing. The barbeque assembly may also include a lid rotatably coupled to the bottom housing, and in some embodiments, the lid includes a glass window.

In some embodiments, the barbeque assembly also includes a grill coupled to the bottom housing, wherein the grill has a plurality of slats and a plurality of crossbars that form a plurality of holes. In other embodiments, the barbeque assembly includes a grill formed of ceramic glass, wherein the grill comprises a solid base and a plurality of slats. In some embodiments, the bottom housing is formed from a single piece of material, such as injection molded aluminum. In some embodiments, bottom housing is formed from more than one piece of material.

In one embodiment, the gas chamber cover is made from ceramic. In one embodiment, each retention element comprises a clip having a first compression surface and a second compressions surface, wherein a spacing between the first compression surface and the second compression surface is larger than the thickness of the gas chamber cover.

In some embodiments, the bottom housing further comprises a plurality of air inlets. In another embodiment, the barbeque assembly also includes at least one accessory tray coupled to the bottom housing. In another embodiment, the bottom housing is configured to be washable in a dishwasher. In yet another embodiment, the plurality of passageways are substantially distributed over the entire surface of the gas chamber cover, and configured such that fuel supplied to the burner chamber is evenly distributed about the entire first face of the gas chamber cover.

In another embodiment, a method of operating a barbeque system for the preparation of cooked food is provided. The method includes: providing a bottom housing having an interior chamber and a burner chamber, wherein the burner chamber has a fuel supply opening and a burner chamber cover support, wherein a gasket is coupled to the burner chamber cover support; positioning a burner chamber cover having a plurality of passageways extending from a top surface of the burner chamber cover to a bottom surface of the burner chamber cover within the burner chamber and adjacent the gasket, wherein the top surface of the burner faces the interior chamber and the bottom surface of the burner faces the burner chamber; supplying fuel to the burner chamber, wherein the fuel flows into the burner chamber and through the plurality of passageways, wherein the fuel flows from the bottom surface of the burner chamber cover to the top surface of the burner chamber cover; and combusting fuel that flows out of the top surface of the burner chamber cover within the interior chamber and substantially at the top surface of the burner chamber cover.

In some embodiments, the method also includes securing the burner chamber cover to the burner chamber with at least one burner retention member, wherein said securing causes the gasket to compress.

In yet another embodiment, a barbeque assembly that does not include a separate, removable burner is provided. The barbeque assembly includes a bottom housing, an o-ring, a cavity cover, and at least one retention clip. The bottom housing includes at least one side wall and a bottom wall, the bottom wall is shaped to define a gas collection cavity and a cavity cover support positioned above the gas collection cavity, the bottom wall having a gas inlet and at least one retention clip opening. The o-ring is positioned around an opening to the gas collection cavity and supported by the cavity cover support. The cavity cover is positioned in contact with the o-ring and at least partially covers the gas collection cavity. The at least one retention clip has upper and lower extension portions, wherein the lower extension portion is sized to fit within the retention clip opening, and wherein the upper and lower extension portions are sized and spaced from each other sufficiently to retain the cavity cover against the o-ring, covering the gas collection cavity.

DETAILED DESCRIPTION

FIGS. 1 through 3illustrate an embodiment of a gas barbeque100. The gas barbeque100includes a bottom housing40, a lid102, a grill144, a stand150, regulators160, gas chamber covers130, and fuel tanks106.FIG. 1illustrates the gas barbeque100with the lid102open.FIGS. 2 and 3illustrate the gas barbeque100with the lid102closed. The lid102is coupled to the bottom housing40via a hinge (not shown). The hinge allows the lid102to be easily separated and removed from the bottom housing40. The support stand150is coupled to the bottom housing40. The support stand150allows the bottom housing40to be rotated, raised and lowered with respect to the support stand150. The fuel tanks106are coupled to regulators160a-b. Two burners are formed as cavities within the bottom housing40that are covered by the removable gas chamber cover plates130. This embodiment of the gas barbeque100is configured to have two separate burners, although in other embodiments, one, or three or more burners are provided. In one embodiment, the burner is formed from a single cavity that is substantially the entire area of the bottom surface of the bottom housing40. The burners are configured to heat the grill area by combusting fuel supplied by the fuel tanks106. The supply of fuel to each burner is controlled by regulators160a-b. The first regulator160aadjustably controls the fuel supply to the first burner independent of the second regulator160b, and second regulator160badjustably controls the fuel supply to the second burner independent of the first regulator160a.

Bottom Housing

FIGS. 4 through 8illustrate an embodiment of a bottom section or grill housing40of a gas barbeque100. The bottom housing40has a front wall42, sidewalls44, and a back wall46that form an interior section or grill area48. An exterior tray area80is formed in a front section of the housing. The interior section48defines a first burner chamber64aand a second burner chamber64b, and a support stand mount90. The exterior tray portion80has a first regulator housing82aand a second regulator housing82b, beverage holders88, and utensil hooks89. Some embodiments exclude the holders88, hooks89, or both.

The interior section48of the bottom housing is formed by the front wall42, the sidewalls44, the back wall46, and a base50. The back wall46is substantially flat and extends vertically from the base50. The back wall46extends between the sidewalls44. A lid wall47extends above the back wall46and sidewalls44. In this embodiment the lid wall47is thinner than the back wall46and sidewalls44and is configured to fit within the lid102when closed. The upper profile of the lid wall47can have a slight curvature as illustrated inFIG. 7. In some embodiments, the lid wall47is omitted. A pair of mounts52are disposed on the back wall46that are configured to couple with the lid102. In some embodiments, there may be more than two mounts. In some embodiments, the mounts52are used to form one or more hinges.

The sidewalls44extend from the back wall46and curve around to the front side of the bottom housing40and up to the exterior tray portion80. The sidewalls are mirror images of each other. In this embodiment, the sidewall44is divided into a front section44a, a middle section44b, and a back section44cby grooves54that extend downwards from the top of the lid wall47toward the base50. In some embodiments, the grooves54are omitted. The middle section of the sidewall44bhas an inner shelf56and an outer shelf58that are positioned substantially between the grooves54. The inner shelf or grill mount56, extends partially into the interior portion48forming a shelf or ledge. In some embodiments the grill mount56has clips or other mounting hardware configured to secure a grill into position on the grill mount56. The outer shelf58, extends approximately halfway down the outside of the sidewall44. The outer ledge58and inner ledge56form a cavity60in sidewall44. The cavity60extends from the base50of the bottom housing to the top of the sidewall44. The outer shelf58and cavity60form a bottom housing handle59. The bottom housing handle59has a wavy profile, as shown inFIG. 7. In some embodiments the handle59may have a different profile, a rubberized coating, or other coating.

The front section of the sidewall44acurves around to the exterior tray portion80. A plurality of slots or grooves62extends through the front section of the sidewall44a. The illustrated embodiment includes five slots62of substantially the same size and shape. The slots62extend from the base50to approximately ¾ of the height of the sidewall44a. In some embodiments there may be more slots, less slots, or no slots. In other embodiments, the slots may have different configurations, including, different shapes, sizes, and the slots may not be a uniform size and shape. The slots62function as air inlets and allow air to pass between the interior section48and the surrounding environment. The sidewall44top includes a thicker lip section63. The lip section63is thicker than the sidewall44below the lip section63. The lip63is configured so that a bottom edge of a lid102may rest on top of the lip section when the lid102is closed.

The front wall42is divided into three sections that extend around the exterior tray area80. The side sections of the front wall42amirror each other and extend from the end of the front section of the sidewall44atoward the interior section48of the bottom housing40. The middle section of the front wall42bis substantially parallel to the back wall46. The middle section of the front wall42bhas a step formed at the top of the wall. A first regulator opening43aand a second regulator opening43bare formed in the front wall42b. The regulator openings43correspond to the positions of the regulator housings82. The openings43are formed so that a regulator outlet stem165can be inserted through the opening43when a regulator160is placed in the regulator housing82.

The bottom housing40has a first burner chamber64aand a second burner chamber64b. The burner chambers64are substantially the same size and shape. The burner chambers64a-bare divided by a center divider49. Each burner chamber64is substantially rectangular in shape and forms a cavity in the bottom housing40. The chamber has an outer wall66, an inner wall72, a burner support68, a fuel supply opening74, and a plurality of retention clip openings76. The outer chamber wall66extends vertically from the base50. The shelf is substantially perpendicular to the outer chamber wall66and positioned below the top edge of the outer chamber wall66. In this embodiment, the burner support forms a shelf68that is substantially the same width and extends substantially around the burner chamber64. In some embodiments the burner support may not extend substantially around the burner chamber64. In some embodiments, the burner support68may consist of a plurality of support struts that are substantially the same height. In other embodiments, there may not be a support shelf.

The illustrated embodiment includes a groove70formed on the shelf68. The groove70is formed to accommodate a gasket or seal. The groove70is substantially the same size and shape along the entire length of the groove70. In some embodiments there is no groove70on the burner support68. An inner chamber wall72extends down to substantially the same level as the base50of the bottom housing40.

The inner chamber wall72has a fuel supply opening or cutout74. The fuel supply opening74is sized and shaped such that a regulator gas stem165can be accommodated within the opening74. In this embodiment, there are four retention clip openings76. The retention clip openings76are positioned on opposite sides of each other with two on each of the long sides of the outer chamber wall66. The width of the opening76is sized and shaped to fit a retention clip110. The opening76extends through the outer chamber wall66to the underside of the bottom housing41. In some embodiments there may be no retention clip openings. The burner chamber64may have a plurality of holes configured to support mounting hardware such as screws or pegs to secure a burner.

The bottom housing40has a support stand mount90. The support stand mount90is a cylindrical mount with two square shaped mounting holes92that extend through the bottom housing40. A cylindrical-shaped recess94extends into the underside of the bottom housing41. The top surface of the support stand mount90is substantially level with the top surface of the center divider49and the top surface of the burner chamber64. Within the recess94, there are two stand mounting tabs96that extend out from the wall of the recess94. Each tab has a hole98. The tabs96and holes98are located on opposite sides of the recess94and correspond to the mounting holes92. The tabs and mounting holes are sized and shaped to be compatible with mounting equipment for a support stand150.

The exterior tray portion80, or tray, is substantially perpendicular to the front wall42. A plurality of cup or beverage holders88is formed in the tray80. The beverage holders88are cylindrical and extend into the tray80. The diameter of the cup holders88are sized such that a typical cup, can, or bottle could fit within the circumference of the cup holder88. A utensil hook89is formed in front of each cup holder88.

A first regulator housing82aand a second regulator housing82bare formed on the tray80. The regulator housings82a-bare substantially the same and correspond to the first burner chamber64aand the second burner chamber64b. The regulator housing82is a cylinder having a diameter and a wall thickness that may extend above and below the tray80. The housing82has a first or top opening85and a second or bottom opening86. At the bottom opening of the cylinder86there is a regulator support lip84. The diameter of the bottom opening86can be less than the diameter of the top opening85. The regulator housing82is configured so that the regulator160is inserted through the top opening85and the regulator160is supported by the support lip84. The bottom opening86is sized and configured such that the fuel tank106can couple to the regulator160through the bottom opening86.

The bottom housing can be formed40from a single piece of material. The housing can be manufactured using injection molded aluminum. Aluminum injection molding can produce parts with thinner walls and more intricate shapes. The bottom housing can be produced as a single unit, which may be lightweight and more economical than assembling the housing from multiple pieces. In this embodiment the bottom housing is formed from a single piece of material. In some embodiments the bottom housing may be formed and assembled from multiple pieces of material. The bottom housing may be configured to have a single burner chamber or may be configured to have three or more burner chambers.

Gas Chamber Covers

FIGS. 9 and 10illustrate an embodiment of a burner's gas chamber cover130. The gas chamber cover130is rectangular in shape and has a length138, a width136, and a thickness134. The gas chamber cover130can be formed as a single ceramic unit. In some embodiments other materials may be used for the burner, or multiple ceramic pieces may be coupled together. The gas chamber cover130can be formed from metal such as stainless steel, etc. The gas chamber cover130has a first side or top surface140and a second side or bottom surface142. The top surface140and the bottom surface142are substantially parallel. The gas chamber cover130has a solid body. The burner has a plurality of holes or channels132that extend through the gas chamber cover130from the top surface140to the bottom surface142. The plurality of holes or channels132are substantially the same size and shape. The holes132are arranged in a predetermined pattern on the gas chamber cover130. In this embodiment the holes132are arranged in a repeating pattern, where every other row has the same hole pattern lengthwise along the gas chamber cover130. In other embodiments the hole pattern may be different.

The number of holes can be used to control the temperature of the barbeque. The arrangement of the holes132helps determine the distribution of the heat over the surface of the gas chamber cover130and the barbeque. The even distribution helps to provide a uniform distribution of heat in the grill area when operated. In other embodiments, the arrangement of the holes and/or the size of the holes can vary to achieve different heat intensities and temperatures. The heat intensity of a gas burner cover can be in part controlled by increasing or decreasing the number of holes on the surface of the cover130. For example, in some embodiments, a gas chamber cover130is configured to provide high intensity, medium intensity, or low intensity heating. The medium intensity cover can have more holes, or a greater hole density, than the low intensity cover, and the high intensity cover can have more than the medium intensity cover. In some embodiments, the medium intensity cover can have about 3%, 5%, 7% or 10% fewer holes, or lower hole density (e.g., holes per grill surface area) than the high intensity burner, and the low intensity cover can have about 7%, 10%, 12%, or 15% fewer holes, or lower hole density, than the high intensity burner. The different intensity covers can be configured to provide intensities and ranges of temperatures that are appropriate for cooking specific types of food. For example, a low intensity cover could be used to cook fish, a medium intensity cover could be used to cook poultry, and a high intensity cover could be used to cook steaks.

Regulator

FIGS. 11 and 12illustrate an embodiment of a regulator160. The regulator includes a manifold body161, a gas inlet166, a gas outlet164, a regulator control knob162, and a fuel tank interface168. The manifold body161has a fluid flow passage that connects the gas inlet166and the gas outlet164. The fluid flow rate of fuel through the fluid flow passage is controlled by the regulator control knob162. The regulator control knob162is operable to open and close the fluid flow passage. The fluid flow rate can be adjusted between zero, when the fluid flow passage is closed, up to a maximum flow rate. Adjusting the fuel flow rate through the regulator directly controls the amount of fuel consumed and heat generated in the barbeque unit. Therefore, the regulators provide a mechanism for user control over the grilling temperature. The fuel tank interface168includes a cylindrical recess with a bottom surface or base169. The fuel tank interface168has a threaded region on the inner wall that is configured to couple with a fuel source, such as propane or natural gas tank. Preferably the fuel tank is securely coupled to the regulator160such that fuel does not leak out of the fuel tank interface168. The gas inlet166extends vertically downward from the manifold body161. The stem of the gas inlet166and may extend beyond the base169of the fuel tank interface168. The gas inlet166is configured to couple with a fuel supply and form a fluid flow passage between the inlet166and the fuel supply. The gas outlet164extends horizontally from the manifold body161. The gas outlet164has a stem165that is configured to extend into a burner chamber64when assembled as part of the barbeque assembly100. Preferably, the length of the outlet stem165can vary to accommodate different barbeque assemblies. Additionally the length of the stem165can vary to be positioned at different positions within the burner chamber165. The pressure of the gas within the burner chamber can be controlled, in part, by the diameter of the gas outlet stem165. In some embodiments the length and diameter of the outlet stem165can differ to modify the operating pressure within the barbeque.

Gasket

FIG. 13illustrates an embodiment of a gasket or seal170(sometimes referred-to as an o-ring170). In this embodiment the gasket170is substantially rectangular in shape and has a substantially circular cross sectional shape. In some embodiments the gasket170can have a different cross sectional shape, such as a square, rectangular, oval, or other shape. The gasket170can be formed from a fire-retardant material, such as Nomex®. The gasket170is sized and configured to fit substantially within the groove70on the burner support68and to provide a seal between the burner's gas chamber and cover130. The diameter or height of the gasket170may be greater than the depth of the groove70so that a portion of the gasket170extends above the burner chamber shelf68when the gasket170is positioned within the burner chamber groove70. The gasket170can be coupled to the burner chamber groove70using a heat resistant adhesive. The gasket170may be formed from an elastomeric material. Preferably the material is compressible, so that the gasket170can help form a seal with the burner130. The gasket170and the spacing between the outer chamber wall66and the outer edge of the gas chamber cover130, allow the gas chamber cover130to move with respect to the bottom housing40while maintaining a seal. In addition, the gasket170and the spacing between the outer chamber wall66and the outer edge of the gas chamber cover130allow for thermal expansion movement in the gas chamber cover130.

Retention Clips

FIG. 14illustrates an embodiment of a retention clip110. The retention clip110has a first or inner surface112and a second or outer surface114. In this embodiment the clip has a uniform width124. The width124of the clip is sized to fit within the retention clip opening76in the burner chamber64. The clip is divided into a handle portion120, a top or upper compression surface116, a bottom or lower compression surface118, and a foot portion122. The retention clip110is configured to move between a compressed state and an expanded state. The expanded state is shown inFIG. 14. In the compressed state, the upper compression surface116is curved downward and the lower compression surface118is curved upwards.

When the retention clip is in the expanded state, the upper compression surface116exerts a downward force upon the surface adjacent to the upper compression surface116and the lower compression surface118applies an upward force to the surface adjacent to the lower compression surface118to squeeze the gas chamber cover130against the gasket170(sometimes referred to as a seal or o-ring170). The upper compression surface116and the lower compression surface118apply opposite forces to the area between the surfaces when the retention clip110is in the expanded state. Preferably, the retention clip110is formed from a single piece of material, such as aluminum.

The retention clip110can be manipulated into the expanded position by pulling upward on the handle portion120and securing the foot portion122and bottom compression surface118against the underside of the bottom housing41. Manipulating the retention clip110into the expanded position increases the area between the upper compression surface116and the lower compression surface118and allows the retention clip110to be positioned about the gas chamber cover130. The opening or spacing between the upper and lower clip surfaces116,118is large enough to accommodate the gas chamber cover130and the bottom housing40wall thicknesses, as shown inFIG. 17.

FIG. 17illustrates a cross section of a burner assembly, which illustrates the use of the retention clip110to secure the gas chamber cover130to the burner chamber64without the use of any screws. The retention clip110is configured so that when a gas chamber cover130is positioned above a burner chamber64, the upper compression surface116exerts a downward force on the top surface140of the gas chamber cover130and the lower compression surface118exerts an upward force on the underside of the bottom housing41, thereby, securing the gas chamber cover130to the burner chamber64. Preferably, the retention clips are configured to allow the shifting and slight movement caused by different rates of thermal expansion and contraction of the gas chamber cover130, housing40, and retention clips110during operation of the barbeque assembly100.

Support Stand

An embodiment of a support stand150is illustrated inFIGS. 1 through 3. In the illustrated embodiment, the support stand is a floor mount stand and is about 30″, 36″, or 42″ tall. The stand includes a bottom housing engagement interface152, a vertical support154, a base156, and a plurality of legs158. The vertical support154can include a telescoping support to allow adjustability of the grill height. The vertical support154extends between the bottom housing engagement interface152and the base156. The vertical support154can be a cylindrical column. The support can be another geometric shape or design that his configured to support the barbeque assembly100. In some embodiments the support154may include telescoping functionality that allows the support154to move up and down along the vertical axis. A telescoping support152may be spring based, pneumatic based (e.g., a pneumatic gas cylinder), a manual height adjustment mechanism that is secured into position using a fastener (e.g., a bolt, pin, or thumb-screw, etc.), or other system that allows the adjustment of the vertical height of the bottom housing40. The plurality of legs158extend out from the base156support to provide support for the for the barbeque assembly100. In this embodiment there are five legs158that extend out from the base156. The legs158are identical and are spaced circumferentially about the base156. The bottom and/or ends of the legs may have textured surfaces or anti-slip coatings or pads to prevent movement of the barbeque assembly100. In some embodiments, wheels are coupled to the legs to allow the barbeque assembly100to roll. The wheels may be plastic, casters, or other device that facilitates movement. In some embodiments the support base150is a fixed height. In some embodiments the support stand150can rotate about its vertical axis. The rotation may be up to 360°. This allows the barbeque assembly100to rotate without moving the base156of the support stand150. In some embodiments the engagement region152can be locked in place so that the bottom housing40does not rotate.

In some embodiments, the bottom housing40of the barbeque100is pivotably mounted to the stand150to allow the bottom housing40, grill, etc., to be tilted with respect to the stand150. The ability to tilt the bottom hosing40with respect to the stand allows the user to keep the bottom housing40and grill substantially horizontal when the stand150is placed on a non-horizontal surface. In addition, the bottom housing40may be center mounted to the stand150such that the stand150is positioned at or near the center of the bottom housing40. Center mounting allows the bottom housing40to be rotated with respect to the stand150.

The engagement interface152is configured to fit within the support stand mount90The engagement interface152has a plurality of mounts (not shown) that are configured to engage a screw, bolt, quick disconnect, or other engagement apparatus that functions to couple the support stand150to the bottom housing40. The engagement mounts (not shown) align with the mounting tabs96.

In another embodiment, the support stand is a table mounted support stand. The table mounted support can smaller and configured to mount on a table top or other surface. For example, the support can be about 6″, 12″ or 18″ tall. The table mounted support can utilizes the same bottom housing engagement interface as the floor mounted stand and may be vertically adjustable. The table mounted configuration can improve accessibility and usability for persons with physical disabilities.

The stand150allows complete adjustability of the barbeque housing and gills. For example, one the stand150is placed at the desired location, the housing40may be raised or lowered, rotated and/or tilted with respect to the stand150. Furthermore, the stand150provides only a single point of contact for support between the stand150and the housing40. The barbeque unit is balanced with respect to the stand150such that the housing40only has a single “leg” (e.g., the stand150), instead of the typical four-leg or three-leg support found on most grills. The single-leg support allows the user to easily adjust not only the barbeque height, but also allows the barbeque to be easily rotated, swiveled, and tilted, to the right or left, clockwise or counterclockwise, with respect to the stand150.

Grill

FIG. 1illustrates an embodiment of a grill144for use with the barbeque assembly100. The grill is configured in a repeating pattern of parallel slats or bars146that are connected by a plurality of perpendicular slats or crossbars148. The pattern of slats146and crossbars148creates openings in the grill144for the flames and heat to come up from the burners130, and allows grease drippings to fall through the grill144and into the bottom housing40. The grill144may be formed from stainless steel, aluminum or other material. The grill can be mounted on grill shelves56.

FIGS. 20 and 21illustrate another embodiment of a grill244. In this embodiment the grill244is formed from treated glass, ceramic, ceramic glass, metal or other material that is suitable for cooking. The grill244has a solid base248and a repeating pattern of parallel slats246. There are no openings in the grill244to the interior portion of the bottom housing40. In other words, the grill is substantially solid, having no passages through its entire wall thickness. The grill144can be formed from a glass ceramic with low thermal expansion, such as Schott ROBAX®.

During operation of the barbeque, the grill is heated244by the gas chamber covers130. The grill244prevents grease drippings or other food from falling into the bottom housing40and onto the gas chamber covers130, which is instead collected in the valleys formed by the slats246. The grill can be easily removed for cleaning. In some embodiments, the grill244is configured such that its shape and geometry improve heat intensity by directing or focusing energy to desired locations. For example, the ceramic glass and the parallel slat geometry246can function as an infrared grill, by optically focusing energy to the grill's cooking surface. Indeed, in some embodiments the heat intensity is increased by approximately 20% over conventional grills. Additionally, infrared grilling uses less fuel and produces a smaller carbon footprint on the environment. For example, an infrared barbeque can use 40% less gas and have a 40% smaller carbon footprint.

FIGS. 1 through 3illustrate an embodiment of the lid102. The lid102of the barbeque is shaped and configured as shown. The lid102has two mounts104that have corresponding mounts52on the bottom housing. The mounts104are used to couple the lid102to the bottom housing40. The lower edge of the lid102matches the curvature of the bottom housing40. The matching curvature ensures a good fit between the lid102and bottom housing40. The lid102rotates about the mounts104. Preferably the lid is configured to rotate to a specific point. For example the stop may prevent the lid102from rotating beyond the position shown inFIG. 1. In some embodiments an upper grill rack may be coupled to the lid102. In another embodiment, the lid102has a glass viewing area. In some embodiments, the entire lid102is formed of a transparent material, such as an heat insulating glass. A user can view the interior portion48of the barbeque through the viewing area. In some embodiments the entire lid can be formed from a transparent material. In some embodiments, the glass use to form the viewing window or the lid102is constructed from a low thermal expansion glass, such as Pyrex®.

Side Mount Accessories

The barbeque assembly100may include trays or accessories mounted to the sidewalls44of the bottom housing40. The trays can be mounted to the bottom housing40via the grooves54. Preferably, the trays or accessories have a standardized engagement interface for mounting to the grooves54. The accessories engage the grooves54and slide into position within the bottom housing40, thereby coupling the accessory to the bottom housing40. In some embodiments, the sidewall44does not have grooves54and the sidewall44has another engagement interfaces, such as a series of slots on the outer ledge58. The accessories may be configured to match the outer curvature of the sidewall44. The side mount accessories can include trays, burners, containers, and other accessories.

Bottom Housing Assembly

An embodiment of the bottom housing assembly180is illustrated inFIGS. 15 and 16. The bottom housing assembly includes the bottom housing40, the grill144(not shown), regulators160, fuel tanks106, gaskets170, gas chamber cover130, and a plurality of retention clips110. The burner chamber64may be formed as part of and integral with the bottom housing40.

The regulator and burner chamber assembly follows the same general procedure for the first and second chambers64a-b. The gasket170is coupled to the groove70on the burner chamber shelf68. The gasket170may be coupled to the groove70using a thermally resistant adhesive. Preferably the gasket170is sufficiently secured so that it does not shift during operation of the barbeque. Preferably, the gasket170and groove70are configured so that when the gasket170is coupled to the groove70a portion of the gasket extends above the burner support68. Preferably the portion of the gasket that extends above the shelf is substantially uniform in height. The gasket170and groove70may have different cross sectional shapes and sizes than those shown in this embodiment. The height that the gasket170extends above the groove can vary. In some embodiments the shelf68may not have a groove and a gasket may be mounted directly on the burner support68of the burner chamber.

Each retention clips110is inserted into a retention clip opening76in the burner chamber64. The retention clip110is manipulated so that the foot portion122and the lower compression surface118are positioned on the underside of the bottom housing41and adjacent the outer surface of the burner chamber64. The retention clip110is not secured into this position and is free to move about. In this position the retention clip110does not interfere with the initial positioning of the gas chamber cover130above the burner chamber64.

A gas chamber cover130is inserted into the burner chamber64and above the shelf68. A cross-section of the gas chamber cover130positioned within the burner chamber64is illustrated inFIG. 17. The gas chamber cover130is configured to fit substantially within the outer chamber wall66. The gas chamber cover130is positioned such that it is supported by and rests on the gasket170. Preferably the bottom face142of the gas chamber cover130is in contact with the gasket170and not in contact with the shelf68. Preferably there is a gap between the bottom face142and the burner support68. Preferably there is another gap between the outer edge139of the gas chamber cover130and the outer chamber wall66. Portions of the outer edge139of the gas chamber cover130may contact the outer chamber wall66. Preferably the thickness134of the gas chamber cover130is such that the top surface140of the gas chamber cover130is at substantially the same height as the top edge of the burner chamber64. The gas chamber cover130is secured to the burner chamber64using only hand installed clips110; no screws or tools are utilized. Removal of the gas chamber cover130is easily accomplished by following the reverse procedure. For example, releasing the clips110by pulling their top portions towards the center of each respective burner chamber64. Once the clips110are released, the gas chamber cover130is removed and the entire assembly may be cleaned. For example, in one embodiment, the lid102, the grills144, the gas chamber covers130, the stand150, regulators160and tanks106are removed from the bottom housing40, and the bottom housing,40, lid102, grill144, and possibly other parts, may be placed inside of a standard dishwashing machine for cleaning, as discussed in greater detail below.

After the gas chamber cover130is positioned within the burner chamber64, the retention clips110secure the burner130within the burner chamber64. Each retention clip is manipulated so that the upper compression surface116is adjacent the top surface140of the burner130and the lower compression surface118is adjacent the underside of the bottom housing41. The clips110can be manipulated into position by applying an upward force on the handle portion120of the clip110. The foot portion122and the lower compression surface118are relatively constrained by their position on the underside of the bottom housing41, as such, an upward force applied to the handle portion120causes the gap between the lower compression surface118and the upper compression surface116to expand. The expansion allows the upper compression surface116to be moved into position onto the top surface140of the ceramic gas chamber cover130. The gas chamber cover130is secured when the upper compression surface116is positioned substantially on the top surface140and the lower compression surface118is positioned substantially on the underside of the bottom housing41, as illustrated inFIG. 17. The upper compression surface116works in conjunction with the lower compression surface118to hold the gas chamber cover130in place. Specifically, the upper compression surface116applies a downward force on the top surface140and the lower compression surface116applies an upward force on the underside of the bottom housing41. The compression forces applied to the ceramic gas chamber cover130secure the gas chamber cover130within the burner chamber64. Preferably the forces asserted by the retention clips cause the gas chamber cover130to slightly compress the gasket170, thereby forming a seal between the bottom surface142and the gasket170. Preferably the seal formed between the gasket170and the bottom surface142is sufficient to prevent gas from flowing out the edges of the gas chamber cover130during operation. Each clip110is secured following substantially the same procedure and provides substantially the same downward force on the gas chamber cover130. Compression of the gasket causes the size of the gap between the bottom surface142and the burner shelf68to decrease. Preferably there is still a gap between the bottom surface142and the shelf68after the clips110have been secured to the burner chamber64. The gas chamber cover130may shift laterally and horizontally from its original position, resulting in portions of the gas chamber cover130contacting the outer chamber wall66. Preferably, there is a still a gap between a substantial portion of the outer edge139and the outer chamber wall66. The clips110may be unsecured by applying an upward force to the handle portion120and moving the upper compression region116off of the gas chamber cover130.

Regulator Assembly

FIGS. 18 and 19illustrate the assembly of the regulator160and fuel tank106and attachment to the bottom housing40. The regulator assembly includes a regulator160and a fuel tank106. The regulator160is positioned by inserting a gas outlet stem165through an opening43in the front wall42and through the fuel supply opening74in the burner chamber64. The outlet stem165is constructed so that the tip of the outlet stem165extends into the burner chamber64. In some embodiments the burner chamber opening74may have an elastomeric membrane or seal with an opening for the outlet stem165. The outlet stem165can be inserted through the seal and into the burner chamber64, which can elastically deforms around the outlet stem165and substantially seal the burner chamber64from ambient air. In some embodiments the seal may not prevent all ambient air from entering or exiting the burner chamber64. In other embodiments, the seal is omitted. The length of the outlet stem165can vary, in some embodiments it may extend only partially into the burner chamber64and in other embodiments it may extend substantially into the burner chamber. For example, in some embodiments the stem165extends into the middle of the burner chamber. In other embodiments, the stem165extends a predetermined distance past the opening74, such as about 0.5″, 1″, 2″, or 6″ beyond the opening74.

The manifold body161is positioned within the regulator housing82with the base of the fuel tank interface169resting on the regulator support lip84. The fuel tank106is inserted through the bottom opening86of the regulator housing82and coupled to the regulator160. For example, in one embodiment, the fuel tank106is screwed into the fuel tank interface168. The gas inlet166is inserted into the fuel tank106and forms a fluid connection between the fuel tank106and regulator160. As the fuel tank106is rotated and secured to the regulator160, the regulator160and fuel tank106are tightened and secured to each other on opposite sides of the tray80. The position of the regulator160and tank106may be fixed with respect to the tray80by attaching the tank106to the regulator160with the tray80positioned between them, for example, as shown inFIG. 19. Once the regulator160and tank106are attached to each other, they are secure and do not move with respect to the tray80or other parts of the barbeque housing. In one embodiment, the regulator160and tank106may be removed from the tray80only after the tank106is decoupled from the regulator160.

In one embodiment, the regulator160is initially positioned by sliding outlet stem65into the burner chamber64through the opening74. When positioned in this manner, the regulator160rests on the shelf80. The regulator160may be secured in place by attaching the fuel tank106to the regulator160. The fuel tank106serves as a lock to prevent movement or removal of the regulator160.

The flow of fluid through the manifold161is controlled by a regulator control knob162. The regulator control knob162opens and closes the fluid passage. When the fluid passage is open, fuel flows from the fuel tank to the burner chamber64. The weight of the fuel tank106is supported by the regulator support lip84. In some embodiments a gas line may be connected to the regulator. In this embodiment each regulator160has an independent fuel supply. In some embodiments a single fuel source may be connected to the first and second regulators160a-b. Each regulator160a-bindependently and separately controls the fuel supplied to each burner chamber64a-b.

Each regulator control knob162is mounted in a substantially horizontal plane such that they each rotate about a substantially vertical axis. This unique mounting allows the operator better visibility of the regulator setting (e.g., low, medium, high heat, etc.) when viewed from above.

The present configuration and front-style tank loading allow unique quick-connection and disconnect and removal of each fuel tank106and regulator160from the barbeque assembly. Further the assembly process does not utilize screws or similar fasteners. Indeed in many embodiments, no tools are used to assembly the barbeque assembly or to attach or remove the fuel tanks106and regulators160. This further provides simplicity in assembly and operation, and disassembly for efficient and complete cleaning.

Barbeque Assembly

The support stand150is coupled to the bottom housing40. The table mounted and floor mounted support stands couple to the bottom housing the same general methodology. The engagement interface152of the support stand150is inserted into the mount90in the bottom housing40. The mounting tabs96on the bottom housing40are aligned with engagement mounts on the support stand150. The appropriate hardware is inserted through the mounting holes92, the engagement mounts, and mounting tab holes98and secured into place. For example, in one embodiment, quick release pins are used to secure the support stand150to the bottom housing40. Preferably the bottom housing40is securely mounted on the support stand150such that it does not rock or tilt. Preferably, the bottom housing40is substantially level and stable after being secured to the support stand150. After the bottom housing40has been secured to the support stand, the housing can be moved and positioned as needed. In some embodiments, the support stand may have a vertical height adjustment, which allows the height of the bottom housing40to be adjusted after the support stand150and the bottom housing40are coupled together. By adjusting the height the support stand150, the height of the grilling surface may be adjusted to an appropriate height. In some embodiments, the bottom housing40can rotate about the vertical axis of the support stand150.

The lid102is coupled to the bottom housing40by mounts52on the bottom housing40and mounts104on the lid102. The mounts52and mounts104are coupled together using appropriate hardware. The hardware may be a quick release pin that allows the lid102to be easily and quickly attached and detached from the bottom housing. The hardware may also limit range of rotation of the lid102relative to the bottom housing40. Preferably the lid102rotates until the bottom edge of the lid102is approximately vertical, as shown inFIG. 1. In some embodiments an upper grill surface may be couple to the lid and the bottom housing.

Barbeque Operation

The barbeque assembly100functions by supplying fuel to the burner chamber64and combusting the fuel in the interior or grill area48of the bottom housing40. The combusting fuel heats the grill area48and cooks food on the grill144. The supply of fuel to the burner chamber64is controlled by the regulator160. The fuel flows along a fluid passage from the fuel tank106, to the regulator160, and out the gas outlet stem165to the burner chamber64. The fuel flows through the plurality of holes132in the gas chamber cover130and into the grill area48. The fuel is ignited substantially on the top surface140of the gas chamber cover130. For example, the user may ignite the fuel by opening the regulators and dropping a lit match through the grate and onto the gas chamber cover130. The control of fuel through the first and second gas chamber cover130a-bis independently controlled by the first and second regulators160a-b. The combusting fuel raises the temperature of the grill area48to a sufficient temperature for preparation of meat and other foods. The geometry and shape of the gas chamber cover130allows the gas to be evenly is dispersed over a much larger area than a typical barbeque burner. For example, the flame area (e.g., the area in which a flame is formed) will substantially match the area of the gas chamber cover130and grills.

The front air inlets62can provide additional ambient air to the grill area48. Negative pressure created by the combusting fuel can cause ambient air to be brought in through the air inlets.

As the temperature heats up the different components of the barbeque100, each component can thermally expand and contract. Different rates of thermal expansion and contraction of the separate components can cause stresses. The barbeque100compensates for the effects of thermal expansion and contraction by removing rigid couplings between the components that can detrimentally affect the life of the components. Different components with different material properties expand and contract in different amounts and at different temperatures. For example, the thermal expansion and contraction of a ceramic gas chamber cover130is different than the thermal expansion and contraction properties of aluminum. Rigid connections and couplings between ceramic and aluminum components can cause the components to separate, crack, and deteriorate over time. As such the barbeque100utilizes a system that can help to account for differences in the thermal characteristics of the different components. Specifically the gas chamber cover130are suspended within the burner chamber64such that the gas chamber cover130is not in substantial contact with the burner chamber64or bottom housing40. The ceramic gas chamber cover130rests on the gasket170and there is a gap between the bottom surface118and the burner chamber shelf68and a gap between the outer edge139of the ceramic gas chamber cover130and the wall of the burner chamber66. The ceramic gas chamber cover130are secured into place by the retention clips110. The gap between the bottom surface118and the shelf68and the gap between the outer edge139and the wall of the burner chamber66allows the gas chamber cover130to shift and move when thermal expansion and contraction occurs. Since it is not rigidly fixed into place, the gas chamber cover130will not be subject to stresses by being pressed up against the bottom housing that could contribute to the breakdown and failure of the gas chamber cover130. Preferably the gas chamber cover130will shift in position as it comes in contact with burner chamber wall66rather than applying significant stress at the contact points to the bottom housing40and the gas chamber cover130. As such, the spatial positioning of the gas chamber cover130relative to the burner chamber64is such that the thermal expansion and contraction of the burner chamber does not cause significant stresses to the gas chamber cover130.

Over time grease drippings and other food drop down through the grill144onto the bottom housing40and the gas chamber cover130. The bottom housing40and gas chamber cover130can become dirty and needed to be cleaned to operate at optimal efficiency. Clogged burners can result in an uneven distribution of heat on the grill144. However, the high temperatures reached by the gas chamber cover130typically carbonized such drippings to an easily-cleanable powder.

The barbeque100typically operates at temperatures at or near 1700° K. The barbeque100operates efficiently and provides the same level of heat as a traditional barbeque at approximately 40-50% less fuel consumption and 40-50% less carbon footprint. The high temperatures and high efficiency of the barbeque100allows for quicker food cooking and better tastes.

After use the ceramic burners and bottom housing can be easily and efficiently cleaned. The barbeque can be easily disassembled by following the reverse process of the assembly described above. The ceramic burners can be cleaned by scraping the burners down with a scraping tool.

The bottom housing40can be quickly and efficiently cleaned. Everything in the bottom housing40with the exception of the gasket can be decoupled and removed. After the bottom housing40has been disassembled, the entire bottom housing40can be placed in a dishwashing machine and cleaned. The bottom housing40is dishwasher safe and can be cleaned quickly and easily. Gas chamber covers are easily removable and cleanable, as well.

The embodiments set forth above are illustrative of inventive principles and features, and these principles may be applied to barbeque systems that have different constructions that doe not match the embodiment of the barbeque assembly illustrated in the Figures. For example the bottom housing may have additional burner chambers. The burners may have different sizes and shapes, circular burners. In other embodiments, the burners may be placed on top of the burner chambers and not within the burner chambers. As such, the principles and features discussed herein can be applied in embodiments of various shapes, sizes and configurations.

Although this invention has been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the invention and obvious modifications and equivalents thereof. In addition, while a number of variations of the invention have been shown and described in detail, other modifications, which are within the scope of this invention, will be readily apparent to those of skill in the art based upon this disclosure. Accordingly, Applicants contemplate that various features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form varying modes of the disclosed invention. Thus, it is intended that the scope of the present invention herein disclosed should not be limited by the particular disclosed embodiments described above, but should be determined only by a fair reading of the claims that follow.