Abstract:
A portable charcoal cooker includes a housing having side doors for loading starting materials and charcoal in separate compartments, a grill rack above the compartment, and a pivoting cover provided with a handle for transporting the cooker. The cooker is placed on end with the top door open to lights the starting materials and ignite the charcoal. After the charcoal is lit, the cooker is placed on its base and the cover opened to present the cooker rack for cooking.

Description:
RELATED APPLICATION 
     This invention claims the benefit under 35 USC 121 of U.S. Provisional Application No. 60/304,831 filed on Jul. 13, 2001 in the name of Cleve E. Nordeen and entitled “Portable Charcoal Grill”. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to outdoors cooking devices and, in particular, to a charcoal fired cooker that may be charged with charcoal and ignition materials, transported to a cooking site, and thereafter ignited and deployed in a plurality of cooking modes. 
     BACKGROUND OF THE INVENTION 
     Charcoal cooking is a popular form of outdoor food preparation. Large and elaborate cooking apparatus is available for cooking at home. There are many occasions away from the home where this cooking form is also desirable, such as camping, picnics, and other such gatherings. The home cooking apparatus is not readily transportable to such sites. Smaller units have been proposed for these activities, generally in the form of smaller, lightweight units. In addition to transporting these cookers, the charcoal fuel and starting materials, such as lighter fluid, must be separately handled. After use, the cooker must be emptied and cleaned, and along with the remaining charcoal fuel and lighter fluid, repacked for the return visit. Because of these attendant problems, inexpensive grills are often left at the site. 
     These grills are generally open configurations, without lids, wherein a grill rack is placed over the ignited coals, and the cooking is done only in a conventional grilling mode. Only a single cooking mode is provided, and, accordingly, accessory cooking units are required for heating, warming, frying and the like. Where such auxiliary equipment is not available, certain foods must be prepared in advance and held until use in insulated containers. 
     To simplify the starting of the charcoal, and eliminate liquid starting fuels, chimney devices have become popular. Therein, a cylindrical container is loaded with a paper source, such as crumpled newspaper, on which the charcoal is layered. Lighting the paper serves to ignite the charcoal, with the convection through the container assisting the process. The ignited coals are then distributed in grills of the above mentioned type. U.S. Provisional Application No. 09/799.716 to Patience discloses a folding charcoal grill that incorporates a folding design wherein a chimney-type orientation is used to start the charcoal, and thereafter rearranged to provide a direct radiant heat grill. 
     In view of the foregoing limitations, it would be desirable to provide an outdoor charcoal cooker that is easy to transport, easy to start, and can perform the various cooking activities associated with outdoor cooking. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention provides a single compact, versatile portable charcoal cooker that may be fully charged at home with charcoal fuel and starting materials, enclosed in an easily transportable unit, transported to the activity sight without risk of spillage or separation, conveniently ignited, and when ready deployed in a plurality of cooking modes including grilling, fiying, heating, warming, griddle cooking, roasting and baking. During startup and cool down, the cooker operates in a self cleaning mode, eliminating the need for conventional scraping and scouring prior to use. After use, the ashes may be conveniently and safely disposed and the unit converted to a sealed carrying mode and stored for the next use. 
     The cooker includes a firebox base having an open top covered by a pivoting lid and open sides covered by sliding, vented doors. A grill rack is fixedly attached to the base at the top opening and defines therebelow a heating chamber. A flat griddle is provided that is carried by the grill rack. The heating chamber is divided into upper and lower sections by a pivoting gate. A starting material such as crumpled newspaper is placed the lower section and charcoal layered in the upper section. The gate is maintained in the closed position by a stop plate on the lower surface of the griddle. After initial preparation, the cooker is closed and locked for transportation to the cooking site. At the site, the cooker is vertically oriented, the newspaper lit and the cooker functions as a chimney type starter for igniting the charcoal. During startup, the convective heat is vertically channeled by the griddle, resulting in elevated temperatures that produce a self cleaning result on both the grill rack and the griddle. After starting, a heating mode is provided whereby cooking vessels may be placed directly on the top door for heating and/or warming. Opening the top door allows a skillet, wok or the like to be directly heated provides a frying mode. For the other modes, the cooker is horizontally positioned. For dual zone griddle cooking, the top is opened and foods may be prepared on the griddle either a hot zone above the coals, or in a cooler zone above the combusted paper. If a uniform heating zone is desired, the griddle is removed to release the gate, and the cooker gently shaken to distribute the coals. The griddle may be replaced or conventional open fire grilling conducted directly on the grill rack. For baking and roasting modes the lid may be closed. Throughout the course of activities, the cooker may be replenished with charcoal as required. At the end of the day, the cooker functions as a heating source for warmth or dessert cooking. For packing or storage, the ashes are removed through the lower door, the griddle replaced, the lid closed; and the self cleaned unit is ready for the next use. 
     Accordingly, it is an object of the present invention to provide a portable charcoal grill that provides a variety of cooking needs suited to outdoor activities. 
     Another object is to provide a portable outdoor grill that may be prepared for use in advance, and avoids the need for separate starting devices, lighting fluid and fuel. 
     A further object of the invention is to provide a self cleaning outdoor grill. 
     Yet another object is to provide a portable grill wherein a single unit can be configured for starting, heating, grilling, frying, and roasting. 
    
    
     DESCRIPTION OF THE DRAWINGS 
     The above and other features of the present invention will become apparent upon reading the following description of the preferred embodiment, taken in conjunction with the accompanying drawings in which: 
     FIG. 1 is a front elevational view of a multiple mode charcoal cooker in accordance with a preferred embodiment of the invention; 
     FIG. 2 is a rear view of the cooker shown in FIG. 1; 
     FIG. 3 is a left end view of the cooker shown in FIG. 1; 
     FIG. 4 is a front cross sectional view of the cooker in the baking mode; 
     FIG. 5 is a partially section side elevational view of the cooker in the starting, frying and heat modes; 
     FIG. 6 is a front cross sectional view of the cooker in the grilling mode; 
     FIG. 7 is a fragmentary cross section view showing the cooker in the roasting mode; 
     FIG. 8 is a front cross sectional view of the cooker in the griddle mode; 
     FIG. 9 is a fragmentary cross sectional view of the mounting flange and door joint; 
     FIG. 10 is a fragmentary side cross sectional view of the grill rack mounting; 
     FIG. 11 is a fragmentary front cross sectional view of the grill rack mounting; and 
     FIG. 12 is a fragmentary cross sectional view taken along line  12 — 12  in FIG.  4 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to the drawings for the purpose of illustrating a preferred embodiment of the invention and not for limiting same, FIGS. 1 through 4 show a portable multiple mode charcoal cooker  10  comprising a rectangular sheet metal housing  12  including a firebox  14  and a lid  16  defining an interior compartment. A longitudinal carrying handle  18  is attached to the top surface the lid  16  for transporting the cooker  10  between locations. As hereinafter described, the cooker  10  may be deployed in a plurality of cooking modes for use in diverse environments. 
     The firebox  14  is a generally rectangular box configuration having an open upper end and carrying sliding doors  20  at the lateral sides thereof. The firebox  14  includes a generally U-shaped center section having a rectangular base wall  26  terminating at the sides with integrally downwardly and outwardly extending support legs  28 , and integrally connected with a transversely spaced front wall  30  and rear wall  32  of generally rectangular configuration. A rectangular heat shield  33  is attached to the support legs  28  for providing additional heat insulation at the support surface. 
     Referring additionally to FIG. 9, the ends of the walls  30 ,  32  are provided with inwardly turned retaining flanges  34  for slidably capturing the sides of the doors  20  to permit movement between the lowered closed positions, and raised open positions. A pair of L-shaped traverse reinforcing ledges  36  are connected between the tops of the front wall  30  and the rear wall  32  for strengthening the base  26  (FIG.  11 ). A pair of L-shaped longitudinal reinforcing ledges  38  are attached to the inner surfaces of the front and rear walls and aligned with the ledges  36  for supporting a grill rack as described below (FIG.  10 ). 
     The lid  16  has a generally inverted U-shaped center section  40  and longitudinally spaced end walls  42 . The lower rear longitudinal end of the center section  40  is pivotally connected by a piano hinge  44  to the upper end of the rear wall  32  of the base  26  for movement between a lower closed position, and an open position approximately 180° therefrom. The front wall  46  of the center section  40  is provided with a downwardly depending lip  48  overlying the upper end of the front wall in the closed position. A toggle lock assembly  50  is attached to the front walls of the firebox  14  and the lid  16  for releasably maintaining the closed position in use and during transport. 
     Referring to FIG. 2, the rear wall of the firebox  14  is provided with a circular ignition opening  52  adjacent the hinge  44  and the bottom door  20  for igniting the fuel supply as described below. The front wall  30  of the firebox  14  is provided with a pair a longitudinally spaced, vertically aligned mounting slots  54  for supporting a griddle in a serving position as also described below. 
     As shown in FIGS. 3 and 4, the side doors  20  are provided with a plurality of horizontally aligned circular vent openings  56  adjacent the lower ends thereof. The doors  20  are provided with integrally formed, outwardly extending lifting handles  58  at the upper ends thereof for effecting movement of the doors between the open and closed positions. In a rotated vertical position, the base leg  28  and the handle  18  support the cooker  10 , for the lighting, heating, and frying modes. 
     Referring to FIGS. 4 and 5, the interior of the cooker  10  includes a cooking rack  60  horizontally fixed to the ledges  38  and dividing the interior into an upper cooking zone and a lower heating zone. As additionally shown in FIG. 12, a vertical charcoal gate  66  divides the heating zone into an ignition compartment  70  carrying a starter material  72 , such as crumpled newspaper or like, and a fuel compartment  74  carrying charcoal  76  or other ignitable material suitable for heating and cooking. A rectangular griddle  78  is supported on the rack  60 . 
     The rack  60  comprises a plurality of longitudinally spaced, laterally extending rods  80  connected to a pair of laterally spaced, longitudinally extending runners  82 . The ends of the rods  80  are attached to the ledges  38  for securing the rack  60  in place. The charcoal gate  66  includes a pair of juxtaposed gate sections  84 . Each gate section  84  includes a plurality of laterally spaced rods  86  interconnected by top and bottom runners  88 . The outer rods  86  adjacent the front and the rear wall  32  of the firebox  14  are pivotally supported at apertures in the ledges  56  and the base wall  26 . The gate sections  84  may accordingly pivot between an in-line closed position transverse to the walls  30 ,  32  isolating the charcoal  76  and starting material  74 , and a closed position overlying the walls and permitting a spreading of ignited charcoal on the bottom wall  26 . 
     The griddle  78  is provided with a downwardly extending stop plate  90 , which projects between the rods of the rack and engages the bottom surface of the gate sections  84  to maintain the closed position of the gate  66  during transport and ignition. The griddle  78  has a rectangular center section  92  overlying the rack  60  bounded by an upwardly turned rim  94 . A pair wire loop lifting handles  96  are attached at the sides of the griddle  78 . Referring to FIG. 2, the rear edge of the griddle  78  is provided with a pair of support hooks  98  that are received in the slots 54  in the front wall  30  for mounting the griddle in a serving position. 
     The handle  18  has an elongated shape of desired cross section and is formed of an insulating material. The handle  18  extends longitudinally over the center of the top wall of the lid  16 , and is connected thereto and spaced therefrom by standoff legs  100 . A cylindrical wood handle is satisfactory. Alternative materials such as high temperature plastics may also be used. 
     The cooker  10  may be conveniently stored until use, filled with charcoal and starting materials, and transported to a desired site, requiring only an ignition source, such as a match, to begin starting of the charcoal prior to cooking, thereby avoiding the need for on-site handling of fuel materials. To charge the cooker, the firebox  14  is placed on a horizontal surface, the bottom door  20  moved to the open position, and the gate sections  84  pivoted to the closed position. The griddle  78  is placed the rack  60  with the stop plate  90  engaging the gate sections  84  to maintain the closed position thereof. Thereafter, the lid  16  lowered to the closed position and the lock assembly  50  latched. A sufficient supply of starting material  74  such as crumpled newspaper is stuffed into the starting chamber and the lower door  20  closed. The cooker  10  is moved to a vertical position, the upper door  20  opened and a desired supply of charcoal  76  placed on the charcoal gate  66 . The upper door is closed and the cooker is thereafter preset for transport to the cooking site. 
     For starting the cooker in chimney fashion, the cooker  10  is located on a suitable supporting surface, and spaced therefrom by the leg  28  and the door handle  18  as shown in FIG.  5 . The top door is then opened, and the starting material ignited through the ignition opening  52 . During ignition, air is drafted upwardly between the door ventilation holes  56 , resulting in a vertical convection path adjacent the rack  60  and the griddle  78 , which has been determined to be of sufficient temperature to effect self cleaning of the cooking surfaces. For alternative self cleaning at the completion of use, additional charcoal may be added to the fuel compartment, and post use self cleaning effected in the above vertical position. For additionally cleaning the griddle surfaces, the griddle may be inverted to place the cooking surface directly adjacent the rack  60 . 
     After ignition of the charcoal, the cooker  10  may be deployed in a plurality of modes for preparing foods using a variety of cooking techniques throughout the day, as well as providing environmental heating during inclement weather. At the start of the day, the cooker  10  may be vertically oriented as shown in FIG. 11 with the upper door closed. In this position, the upper door functions as a heating plate for cooking activities such as preparing coffee or heating foods in smaller cooking vessels. Alternatively, the upper door may be opened to provide a direct heating cooking burner for use, by way of example, in frying foods in a skillet, wok or like equipment. In this mode, the charcoal is supported on the gate, in closer proximity to the cooking implement. 
     For midday cooking, the lid  16  is opened and the griddle  78  removed, thereby releasing the gate sections  84  and allowing the ignited charcoal to be distributed over the bottom surface. Charcoal distribution may be assisted by gentle shaking. For multiple zone cooking, the gate may be maintained in the closed position. For griddle cooking on a heated solid surface, the griddle  76  is replaced, and a variety of foods prepared by direct cooking on the griddle center section. 
     Later in the day, for grilling and roasting of foods, the griddle  76  is removed and hung on the front wall  30  at the mounting slots  54  whereat the griddle  76  may be used as a preparation or storage shelf. Desired foods may be placed on the rack, and simply grilled with the lid  16  in the open position. Alternatively, the lid may be closed for roasting and baking foods. 
     At the conclusion of the day, the cooker may be placed on end, the top door opened, and dessert foodstuffs roasted over the open coals. Adding additional charcoal, the cooker effectively functions as a campfire heater. 
     At the conclusion of activities, as discussed above, the cooker may be reassembled, the lid closed and additional charcoal added. With the top door closed, the cooker will effect self cleaning of the rack and griddle, in a manner previously described. After the coals are extinguished, the bottom door is opened and the ashes disposed in a safe manner. The bottom door is then closed, and the cooker is compactly organized for transportation and storage until next use. 
     Having thus described a presently preferred embodiment of the present invention, it will now be appreciated that the objects of the invention have been flly achieved, and it will be understood by those skilled in the art that many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the sprit and scope of the present invention. The disclosures and description herein are intended to be illustrative and are not in any sense limiting of the invention, which is defined solely in accordance with the following claim.