Ash catcher and support clip for grills

The present inventions are directed to an ash catcher system for use with a charcoal grill and having an ash catcher pan and a plurality of support clips.

FIELD OF THE INVENTION

The present invention relates generally to grills and more particularly, to an improved ash catcher system having an ash catcher pan and support clips for use with charcoal grills.

BACKGROUND OF THE INVENTION

Charcoal grills are well known and very popular. Charcoal grills typically include a lower portion or chamber and an upper portion or lid. The upper portion includes vent openings and a closure mechanism associated with the vent openings to adjust the size of the openings to control temperature and fuel combustion. The lower portion or chamber includes a fuel grate located near the bottom of the chamber to hold the charcoal or other fuel used for cooking. A cooking grate is located near the top of the chamber and above the fuel grate to support the food being cooked. Vent openings are also provided on the bottom of the chamber to provide combustion air for the cooking fuel and to provide a means to clean-out ashes and other debris that accumulates during the cooking process. A plurality of support logs are also provided.

A particularly popular charcoal grill is sold by Weber-Stephen Products LLC and referred to as a Weber Kettle®. A typical Weber Kettle® is shown inFIG. 1. As shown, grill10consists of a generally hemispherical, upwardly open lower chamber12that includes a plurality of vent openings at the bottom (not shown). A lid13having vent holes (not shown) and a vent closure mechanism14is also provided. The lower chamber12is supported by three legs15arranged in a tripod configuration which are attached to the lower chamber12by inserting into sockets16. An ash catcher17is positioned below lower chamber12and is secured to legs15by spring clamps18. In this representative example, the ash catcher17and clamps18are of the type shown and described in U.S. Pat. No. 4,576,140, which is assigned to Weber-Stephen Products LLC and is incorporated herein by reference. An ash disposal damper mechanism19may also be provided to aid in the removal of accumulated ash in the lower chamber12. An example of a typical damper mechanism is shown and described in U.S. Pat. No. 4,416,248, also assigned to Weber-Stephen Products LLC and incorporated herein by reference.

While prior ash catchers have performed satisfactorily, including that shown in U.S. Pat. No. 4,576,140, as well as other types discussed therein, there are certain drawbacks. For example, the prior art ash catcher bowls are shallow. As a result, they hold less ash and are more susceptible to ash being blown out by wind. Moreover, bowl size in the prior devices was limited because of the structure and operation of the clamps, slots or other means to secure them to the legs. In addition, some users found the prior art spring clamps awkward to use, since the spring arm had to be squeezed within the leg structure. And, depending upon the conditions, the clamps were not sufficiently strong and could result in the ash catcher pan becoming unlevel, falling and/or spilling ash.

SUMMARY OF THE INVENTION

The present inventions preserve the advantages of known ash catcher systems and also provide new features and advantages.

Accordingly, it is an object of the present invention to provide an improved ash catcher system having an ash catcher pan and support clip.

It is another object of the present invention to provide a deeper ash catcher pan that has a higher ash capacity and/or is less susceptible to wind blowing out ash.

It is an additional object of the present invention to provide a support clip that securely supports the ash catcher pan, is capable of supporting a deeper pan and is easy to install.

Still another object of the present invention is to provide a support clip that is easy to squeeze and/or may be installed by the user on the outside of the legs of the grill.

Yet an additional object of the present invention is to provide a support clip that effectively secures the ash catcher pan to the legs of the grill and which is efficiently and economically manufactured.

In accordance with the present invention, an ash catcher system is provided for use with a grill, the grill having a plurality of legs. The system includes an ash catcher pan having an upper rim, a lower generally horizontal and downwardly facing outer rim, and a bowl portion. A plurality of support clips, each support clip having a generally circular collar portion, squeeze arms attached to one side of the collar portion and a support flange attached to the collar portion on a side opposite of the squeeze arms are also provided. Each squeeze arm may include an angled portion and a grip portion. Preferably, a squeeze angle between each of the angled portions of the support clip of between approximately 75° and 95° is provided, with a squeeze angle of approximately 94° being most preferred. A preferred ash catcher pan also may also include a lip or bead around an upper circumference. Preferably, the angle between the collar portion and the support flange is approximately 114°.

The present invention also provides a support clip for use in securing an ash catcher pan to the legs of a grill. The support clip includes a generally circular clamping or collar portion; two squeeze arms on said clamping portion; and, a support flange extending from said clamping portion. Each squeeze arm may also include an angled portion. In a preferred embodiment, a squeeze angle between the angled portions of the squeeze arms is between approximately 75° and 95°, with 94° being most preferred. The angled portion of the support clip may include a grip portion, with each grip portion being generally parallel to each other. The preferred embodiment also includes a support flange which extends from said clamping portion and is located opposite the squeeze arms on the clamping portion for supporting the ash catcher pan. Slots may also be provided on the clamping portion.

INVENTOR'S DEFINITION OF THE TERMS

The terms used in the claims of this patent are intended to have their broadest meaning consistent with the requirements of law. Where alternative meanings are possible, the broadest meaning is intended. All words used in the claims are intended to be used in the normal, customary usage of grammar and the English language.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Set forth below is a description of what is currently believed to be the preferred embodiments or best representative examples of the inventions claimed. Future and present alternatives and modifications to the embodiments and preferred embodiments are contemplated. Any alternatives or modifications which make insubstantial changes in function, purpose, structure or result are intended to be covered by the claims of this patent.

For convenience, the present inventions are herein described in relation to a typical Weber Kettle® sold by Weber-Stephen Products LLC, the Assignee of this patent. However, it will be understood that the present inventions may be used with a variety of charcoal grills of other manufacturers. For example, the Weber Kettle® has three support legs15that are arranged in a tripod configuration as shown generally inFIG. 1. It will be understood that the present inventions may be used with grills10having three legs15of a different configuration or leg angles, or with grills10having a different number of legs15or other support members.

Turning toFIG. 2, a preferred embodiment of the ash catcher system20of the present invention may be seen. The system20generally includes an ash catcher pan21and a plurality of support clips30. As will be understood, the number of support clips30coincides with the number of legs15of the grill10.

A preferred embodiment of ash catcher pan21may best be seen by reference toFIGS. 2 and 3. Pan21includes an upper rim22, a lower generally horizontal and downward facing rim23and a bowl portion24. A generally vertical edge25may be provided that extends between upper rim22and lower outer rim23. As best shown inFIG. 3, pan21may also include a bead or lip26around the upper circumference of pan21. Lip26may function to aid in the stability of pan21when installed to provide a point of contact with legs15to wedge pan21against legs15and support clip30as hereinafter described.

A preferred embodiment of support clip30may be seen by reference toFIGS. 4-6. Clip30includes a generally circular collar or clamp portion31that may optionally be provided with one or more slots39. Collar portion31is sized to fit over and frictionally grip leg15using a spring or clamping force when installed. Slots39may be provided to adjust the spring force as hereinafter described or to reduce the material and cost in the manufacture of support clip30. Depending upon the spring force desired, those of skill will understand that the size and spacing of any slots39may be adjusted accordingly.

Support clip30is also provided with two squeeze arms32. In a preferred embodiment, squeeze arms32include an angled portion33and a grip portion34. As best shown inFIG. 6, there is an angle X or squeeze angle defined between the interior of the two angled portions33. In the preferred embodiment, squeeze angle X is approximately 94°. In addition, it has been determined that the preferred range of squeeze angle X is between approximately 75° and 95°. Although other squeeze angles may be used, it has been determined that the stated range provides the best and easiest spring force for the user during installation. In addition, grip portion tabs34may optionally be provided so that the user may squeeze the two flat tab surfaces34and not be subject to possible sharp edges or scratching. Thus, in the preferred embodiment, grip portion tabs34are generally parallel to each other. When the squeeze arms32are squeezed together, the opening of clamping portion31is increased so that clip30may be installed and/or moved along leg15.

Preferred clip30also includes a support flange35which preferably extends from an upper surface of clamp portion31. Flange35includes an upper surface36that supports pan21as hereinafter described. It is preferred that flange35is on the opposite side of clamp portion31from squeeze arms32to aid in use. A downwardly facing chamfer or radiused portion37may also be provided at the end of flange35to reduce or eliminate sharp edges.

As shown inFIG. 5, an angle Y is defined as the angle between the outer edge38of clamp portion31and support flange35. In a preferred embodiment, angle Y is approximately 114°. Using this angle, the upper surface36of flange35is in a generally horizontal position when attached to an angular leg15of a typical Weber Kettle® to support pan21as shown generally inFIG. 3. It will be understood by those of skill in the art that different angles Y may be used for grills having legs15attached to grill10at different angles. Thus, depending upon the angle of legs15, angle Y may be calculated and adjusted so that upper surface36of flange35is generally horizontal to support pan21.

It will be further understood by those of skill that a variety of materials may be used for pan21and support clips30. For example, spring steel, stainless steel and/or aluminum may be used for either component.

The use and operation of a preferred embodiment of the ash catcher system20of the present inventions may be seen by reference toFIGS. 2 and 3. When assembling grill10, support clips30are positioned over legs15which may then be secured in sockets16attached to lower chamber12. To move support clip30along leg15, the user squeezes grip portion34which opens clamping portion31. When in the proper position, the user releases grip portion34and the support clip30is frictionally secured to leg15. Since the grip portions34are on the outside of the legs15, their activation is less awkward for the user. Pan21may then be installed.

Specifically, upper surface36of support flange35engages lower outer rim23of pan21. Upper rim portion22and optional lip26are forced to abut leg15. Lower outer rim23is supported by upper surface36of support flange35. In this manner, pan21is securely attached to and wedged against the three legs15of grill10using support clips30. As a result, the present inventions are easier to use than the prior art, enable the use of a higher capacity pan21and securely hold the ash catcher system20to grill10.

The above description is not intended to limit the meaning of the words used in or the scope of the following claims that define the invention. Rather, it is contemplated that future modifications in structure, function or result will exist that are not substantial changes and that all such insubstantial changes in what is claimed are intended to be covered by the claims. Thus, while preferred embodiments of the present inventions have been illustrated and described, it will be understood that changes and modifications can be made without departing from the claimed invention. In addition, although the term “claimed invention” or “present invention” is sometimes used herein in the singular, it will be understood that there are a plurality of inventions as described and claimed.

Various features of the present inventions are set forth in the following claims.