Barbecue grill and smoker

A charcoal-fueled barbecue grill and smoker includes a duct system with “volcanoes” on the inside of the lower grill chamber that match holes in a tube fitted to the lower grill chamber, such that a turning of the tube provides precise venting and temperature control during cooking. A rear stabilizer attached to the lower grill chamber allows the grill to be used either with or without a stand, preventing the grill from toppling over when the lid is opened. The grill may include one or more removable shelves. An ash evacuation system includes a frusto-conical ash bucket that attaches at a hole in the lower grill chamber and held in place by the rear stabilizer using an ash bucket hanger.

BACKGROUND OF THE INVENTION

The field of the invention is barbecue grills and smokers for cooking, and in particular charcoal-fueled barbecue grills and smokers.

Outdoor grilling has long been a popular method of cooking meats and other foods due to the desirable flavors that are developed by this cooking method. The development of the modern charcoal briquette in the early twentieth century led to the widespread production of charcoal-fueled grills intended for personal use. Gas-fueled grills, which were first mass produced in the 1950's, compete with charcoal-fueled grills in the modern marketplace. Many gas-fueled grills are powered by the burning of propane from a small adjacent tank, although others use natural gas and are connected to natural gas lines. Although gas-fueled grills are popular due to ease of lighting and use, many barbecue enthusiasts believe that charcoal-fueled grills produce foods with a more desirable taste due to the unique smoke flavors imparted to the food during cooking.

Charcoal-fueled grills come in many sizes and shapes. The simplest are merely pans made of sheet metal to receive the charcoal, with a wire cooking grid placed above the pan and a support stand. Most grills include a lid to hold in smoke and help prevent “flare-ups” from grease dripping onto the charcoal, and many include vents that may be opened or closed to varying degrees in order to control the burn rate of the charcoal, and thus control the cooking temperature within the grill.

Although many types of charcoal-fueled barbecue grills are available, they generally remain less convenient to use than gas-fueled grills, and the cooking or smoking of food in these grills remains more difficult to control than with gas-fueled grills. A charcoal-fueled grill that combines the ease of use and controllability of gas grills with the desirable flavor characteristics of a charcoal-fueled grill would thus be highly desirable.

BRIEF SUMMARY OF THE INVENTION

The present invention is directed to an improved charcoal-fueled barbecue grill and smoker that presents numerous advantages over prior art grills. The invention provides precise venting and temperature control that simplifies and optimizes low-and-slow cooking, hot-and-fast cooking, and dual-zone cooking in a way that is unique and superior to other charcoal or gas barbecue grills.

In certain embodiments, a duct system includes “volcanoes” on the inside of the lower grill chamber that match holes in one or more tubes fitted at the bottom of the lower grill chamber, such that a simple turning of the tubes provides precise venting and temperature control during cooking. Covers fitted over the volcanoes prevent ash, soot, grease, and the like from falling into the volcanos during use, and thereby impeding the flow of air through the tubes.

In certain embodiments, a rear stabilizer attached to the lower grill chamber allows the grill to be used either with or without a stand, preventing the grill from toppling over when the lid is opened, and also may provide a convenient location to hang shelves when not attached horizontally to the grill.

In certain embodiments, an ash evacuation system includes a frusto-conical ash bucket that attaches at a hole in the lower grill chamber. The ash bucket may be held in place by the rear stabilizer using an ash bucket hanger, and thus the rear stabilizer feature of the invention provides an additional function. A removable cover inside the lower grill chamber covers the hole in the lower grill chamber leading to the ash bucket when the grill is in use for cooking.

In certain embodiments, the invention includes a quick-release shelving system that allows for multiple shelf configurations, including, for example, the connection of multiple grills together in a “daisy chain” fashion by means of the various interchangeable shelving components.

In certain embodiments, the lower grill chamber includes a quick-release mechanism to easily and conveniently detach the grill chamber from the stand for transportation or storage. Certain embodiments may also include an alternative portable stand, which includes a folding mechanism for the legs to facilitate transportation and storage of this stand. This allows for convenient use of the grill when, for example, on camping outings or “tailgating” events. Alternatively, in certain embodiments the grill may be used without a stand, such as by placing it on a non-flammable surface such as a concrete picnic table as commonly found in public parks, with the lower grill chamber being made stable by the tube supports of the lower grill chamber and the rear stabilizers.

In certain embodiments, the invention features a pair of upper vents in the upper grill chamber that are positioned over the tube-controlled vents in the lower chamber, thereby providing a dual-zone cooking functionality for the grill.

In certain embodiments, the upper grill chamber may further be raised and lowered during cooking, or removed entirely if desired to cook in a manner more similar to a simple brazier-type grill. This allows for easy access to control the quantity and quality of the charcoal heating.

It may be seen that these design features of the present invention, as presented in the various disclosed embodiments, bring much of the convenience of gas-fueled grills to a charcoal-fueled grill. In addition, the modular nature of certain embodiments of the invention allows for use of the grill in a multitude of configurations and in many different locations and at various events. These and other features, objects and advantages of the present invention will become better understood from a consideration of the following detailed description of the preferred embodiments and appended claims in conjunction with the drawings as described following:

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

Before the present invention is described in further detail, it should be understood that the invention is not limited to the particular embodiments described, and that the terms used in describing the particular embodiments are for the purpose of describing those particular embodiments only, and are not intended to be limiting, since the scope of the present invention will be limited only by the claims.

Referring now toFIGS. 1 and 2, an embodiment of the invention may now be described. The grill or smoker (referred to hereinafter simply as a grill, although it could be used for either purpose) is composed of an upper grill chamber10and lower grill chamber12that fit together to provide a closed interior space. In certain embodiments, upper grill chamber10and lower grill chamber12may be constructed of cast aluminum, in order to prevent rust or corrosion of these grill parts and provide more even heating. Because of its high conductivity, a thick aluminum construction provides for even heating within the chamber. Other metals and materials capable of withstanding the heat developed within a charcoal grill may, however, be employed in alternative embodiments.

A handle16is provided to allow the grill to be opened by pulling up on handle16, thereby pivoting upper grill chamber10away from lower grill chamber12at hinge64(seeFIG. 7showing the rear view of grill with hinge64). In this way, convenient access is gained to the interior of the grill in order to place charcoal within the grill, and to perform various operations during cooking or smoking while using the grill. Preferably, upper grill chamber10may be pivoted more than 90° so that it will remain open due to gravity without the user being required to hold it open during use. Handle16may be constructed of a plastic or rubber material, or any other material that is thermally insulative to protect the user's hand from heat during opening of the grill. Hinge64may be molded as an integral portion of upper grill chamber10and lower grill chamber12, such that mating portions of these two pieces come together to form hinge64. Preferably, these are formed as shown inFIG. 7so that upper grill chamber10is easily removable from lower grill chamber12for cleaning or maintenance.

In certain embodiments, the grill is supported by tubular stand22. Tubular stand22is attached to a base with horizontally extending H-shaped “legs” to provide a firm support for the grill and thereby prevent tipping, which would be highly dangerous for the user of this type of device. For ease of movement, stand wheels24may be employed on one of the two legs of tubular stand22, with stand feet26on the other leg to prevent inadvertent movement of the grill. Stand feet26may be composed of rubber or other material that provides a solid grip. It may be seen that the grill may be moved on stand wheels24by gently tipping the grill in the direction of stand wheels24so that stand feet26disengage from the surface upon which the grill is placed, thereby allowing wheeled movement of the grill to any desired location. Tubular stand22is removably locked into lower grill chamber12by stand lock36(seeFIG. 2). Stand lock36may include a pin that fits through mating holes in lower grill chamber12and tubular stand22.

Shelves14are attached at one or both sides of lower grill chamber12. Shelves14are preferably attached in a removable fashion to protrusions extending from lower grill chamber12(seeFIG. 2). Shelves14provide a convenient location for the placement of cooking utensils or plates holding foods to be cooked or smoked on the grill. Shelves14may include extending metal bars for hanging tools, and may have handles molded into them (as shown inFIG. 1) for convenience of removal and replacement. In certain embodiments, the extending metal bars may be used to attach pouches, baskets, or the like (not shown) for holding various tools and accessories used while grilling.

Venting for the grill is provided through vent tubes28at the bottom, and upper vent holes18at the top. As shown inFIG. 5, lower grill chamber12is molded with tubular indentations to receive vent tubes28beneath lower grill chamber12and held in place with vent tube brackets30(seeFIG. 2). Vent tube brackets30may be integrally molded into lower grill chamber12, or formed as separate parts and bolted or otherwise attached to lower grill chamber12. The “volcanoes”40are openings in the bottom of lower grill chamber12that allow for air to flow through the bottom portion of the grill and through matching vent tube holes32in vent tubes28. It may be seen that be turning vent tubes28, the alignment between vent tube holes32and volcanoes40may be changed. When completely aligned, maximum air flow is allowed through lower grill chamber12. When turned 180 degrees from this position, no air is allowed to flow through vent tubes28and into the grill. At positions between these two extreme positions, more or less air may be allowed to flow. Thus the user is able to precisely control air flow through the bottom of the grill by simply turning one or both of vent tubes28. Air flow may be varied between the right and left sides of the grill by turning the two vent tubes28to different positions, thereby providing different heating parameters to these two sections of the grill. This may be desirable when two different foods are being cooked simultaneously. Vent tube grips34, preferably formed of rubber or plastic or another thermally insulating material, are fitted over the ends of vent tubes28to prevent the user from burning his or her hand while turning vent tubes28during operation of the grill. Although three volcanoes40and vent tube holes32are shown in the illustrations, any number could be used in alternative embodiments of the invention.

FIG. 6illustrates volcano covers42in place in lower grill chamber12, along with grate44that is used to hold charcoal. The purpose of volcano covers42is to prevent ash, soot, grease, and the like from falling into volcanos40during use, and thereby impeding the flow of air through vent tubes28.FIG. 5illustrates ash hole46, which allows for the removal of ash from the grill. Ash hole cover48, shown inFIG. 3and positioned within lower grill chamber12as shown inFIG. 6, is fitted into place at all times other than when ash is being removed, in order to prevent charcoal from falling through during use of the grill, as well as to prevent unwanted air from entering the grill chamber.

Air flow through upper grill chamber10is controlled by upper vent plates20at upper vent holes18, as shown inFIG. 1. Upper vent plates20are generally circular, with cut out sectors that allow for air flow when the cut-out sectors are turned to match the openings of upper vent holes18. The operation of this type of vent is thus similar to openings commonly used on packaging for spices, parmesan cheese, and the like to control the rate at which material is dispensed from the packaging. The combination of precisely controlling airflow through lower grill chamber12with vent tubes28and through upper grill chamber10with upper vent plates20allows for very fine adjustments to the airflow through the grill during cooking. In addition, the air flow at the right side of the grill may be controlled independently from the flow at the left side, and thus two different cooking environments may be maintained for different foods being cooked simultaneously. In alternative embodiments, any number of vent tubes28and/or upper vent plates18could be employed, thereby creating any number of independently controllable cooking zones within the grill.

FIG. 4illustrates rear stabilizer bars38in an embodiment of the invention. Rear stabilizer bars38serve multiple functions. If the user desires to use the grill without tubular stand22, such as by placing it on a concrete picnic table as commonly found in public parks and as illustrated inFIG. 12, rear stabilizer bars38prevent the grill from tipping over when upper grill chamber10is opened using handle16. In addition, and as illustrated inFIG. 7, rear stabilizer bars38provide a convenient location for hanging removable shelves14when their use is not desired, such as when space around the grill is limited or for storage. Finally, rear stabilizer bars38can be used to hold ash bucket58(shown inFIGS. 13 and 14) in place for convenient removal of ash and soot from the grill. Ash bucket58is preferably of a frusto-conical shape, with an opening at the top that mates with ash hole46. Ash bucket hanger62of ash bucket58attaches to rear stabilizer bars38to hold ash bucket58locked into position just beneath and aligned with ash hole46. With ash hole cover48removed, ash and soot can then be conveniently swept into ash bucket58without the user being required to simultaneously sweep ash into ash bucket58and hold ash bucket58in place. Once the ash and soot are cleared from the grill, ash bucket58can be removed by lifting ash bucket hanger62off of rear stabilizer bars38, and ash hole cover48may be returned to its position covering ash hole46so that the grill is again ready for use. Ash bucket58may then be conveniently used to transport the ashes for disposal.

In certain embodiments, multiple grills may be connected in “daisy chain” fashion as shown inFIGS. 8 and 9. InFIG. 8, arcuate shelf connector50is used to connect two grills by substituting arcuate shelf connector50in place of the standard shelves14that would be attached at the adjacent sides of each grill. This configuration is desirable, for example, where the grill is placed in the corner of an outdoor cooking area and two different grills are desired for cooking. Alternatively, as shown inFIG. 9, straight shelf connector52may be used when two grills are desired to be placed in horizontal alignment with each other. The best configuration will depend upon the outdoor cooking space available to the user. Since each of shelves14, arcuate shelf connector50, and straight shelf connector52are easily removable, one or more grills may be reconfigured in many different configurations using these various optional parts, as desired by the user.

In certain embodiments, the portability of the grill may be improved by the use of an optional folding stand54in place of tubular stand22, as shown in FIGS.10and11. Each of the folding stand legs56of folding stand54are hinged such that they fold flat against each other when not in use, as illustrated inFIG. 11. Thus folding stand54is desirable for use when the grill will be carried to a different location for use, such as, for example, camping or “tailgating” events. Folding stand54is held onto lower grill chamber12and locked into place using stand lock36, just as with tubular stand22. In other applications, it may be desirable to dispense with the stand entirely, as shown inFIG. 12where the grill is positioned on a concrete picnic table as are common at many parks. In this configuration, it is the vent tube brackets30that provide steady, four-corner support for the grill. As noted earlier, rear stabilizer bars38prevent the grill from tipping over when upper grill chamber10is pivoted to the open position in this configuration, because rear stabilizer bars38extend rearwardly from lower grill chamber12and provide a balance point against the weight of upper grill chamber10when in the fully opened position.

Unless otherwise stated, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present invention, a limited number of the exemplary methods and materials are described herein. It will be apparent to those skilled in the art that many more modifications are possible without departing from the inventive concepts herein.

All terms used herein should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. When a grouping is used herein, all individual members of the group and all combinations and subcombinations possible of the group are intended to be individually included. When a range is stated herein, the range is intended to include all subranges within the range and all particular points within the range. All references cited herein are hereby incorporated by reference to the extent that there is no inconsistency with the disclosure of this specification.