Abstract:
A gas grill burner apparatus is provided that fits within barbecue grill cooking chambers of varied configurations and sizes. In accordance with one embodiment of the present invention, a gas grill burner apparatus includes a center manifold configured to form two hollow gas tubes, the gas tubes being substantially parallel. The gas grill burner apparatus also includes first and second C-shaped hollow gas tube end portions slideably engaged within opposing ends of the parallel hollow gas tubes. The apparatus further includes a center grease tent mounted atop the center manifold and first and second telescoping grease tent members mated with the center grease tent. The telescoping grease tent members are configured to move laterally with the first and second gas tube end portions.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]    This application claims the benefit of U.S. Provisional Patent Application serial No. 60/370,966 dated Apr. 8, 2002, which is incorporated herein by reference in its entirety. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    The invention is generally related to barbecue grills, and, more particularly, is related to an adjustable gas grill burner apparatus.  
         BACKGROUND OF THE INVENTION  
         [0003]    Gas-fired barbecue grills typically incorporate one or more gas burners, which are mounted within the interior of a cooking chamber. The gas burners typically are mounted in a lower portion of the cooking chamber below a cooking surface, such as a grill or grate, and are provided with a flow of gas, such as from an LP gas tank, for providing heat for cooking food items placed upon the cooking surface.  
           [0004]    Typical gas burners are formed of metal and are configured with an interior chamber which is adapted to receive a flow of gas from one or more gas feed lines. The interior chamber of a gas burner is adapted to distribute the flow of gas from the gas feed lines about the gas burner so that the gas may be distributed and expelled through a series of gas orifices.  
           [0005]    Typically, the gas orifices are formed about a periphery of the gas burner so as to provide a relatively large flame pattern. In some embodiments, the gas orifices are downwardly directed and typically are formed along a lower portion of the outer periphery of the gas burner. Gas burners incorporating these downwardly-directed gas orifices also typically incorporate a protruding edge or flange which is positioned above the gas orifices and which overhangs the gas orifices so that drippings exuded from food items being cooked on the cooking surface of the grill disposed above the burners, and other materials, do not fall or drain into the gas orifices.  
           [0006]    In other embodiments, gas burners have incorporated gas orifices about an upper surface of the gas burner. This particular configuration of the gas burners typically requires the use of a cover or shield which is disposed between the gas orifices and the cooking surface for preventing drippings and other materials from falling or draining into the gas orifices, and thereby potentially clogging the gas orifices.  
           [0007]    Typical gas burners and shields are a fixed size. An array of different barbecue grills; however, typically are not configured with cooking chambers of standard size or shape. The size and configuration of the cooking chamber typically varies from one barbecue grill to another. As such, manufacturers of barbecue grills must either manufacture or obtain a variety of gas burners and shields each designed specifically for the grill in which it will be installed. This results in higher manufacturing and inventory costs.  
           [0008]    Further, an original gas burner installed in a grill at the time of purchase can malfunction and need to be replaced in order to sustain the useful life of the grill. Currently, in order to replace a gas burner, one must obtain a specific gas burner designed to fit in the particular barbecue grill needing the replacement burner. As such, the proper replacement burner may be difficult to find and more costly to purchase than necessary. Such a lack of standardized sized and shaped cooking chambers has led to the expenditure of considerable funds in designing, producing, and maintaining inventories of numerous sizes and configurations of gas burners.  
           [0009]    U.S. Pat. No. 4,561,419 to Koziol, incorporated by reference herein in its entirety, discloses an adjustable burner assembly for a gas grill. The Koziol burner assembly includes a gas intake member in communication with an adjustable-length bar burner. The bar burner includes telescoping body members that can extend laterally to fit a variety of gas grill base portions. A drawback of this type of design is that heat is not evenly distributed throughout the base of the grill portion. The bar burner structure has a narrow footprint relative to the bases of many gas grills. As such, heat is often concentrated outwardly of the central region of the grill atop the bar burner, but does not project outwardly far enough and does not heat the central region of the grill surface.  
           [0010]    Another drawback of the Koziol assembly is its relative difficulty in manufacturing. Generally, flat pieces of steel that are crimped together require significant effort during the manufacturing process. Furthermore, singular pieces of steel can become warped over time. Generally, tube structures are easier to manufacture and also provide extra strength to any structure.  
           [0011]    Therefore, there is a need for improved devices and systems which address these and other shortcomings of the prior art.  
         SUMMARY OF THE INVENTION  
         [0012]    In accordance with the present invention, a gas grill burner apparatus is provided that fits within barbecue grill cooking chambers of varied configurations and sizes. In accordance with one embodiment of the present invention, a gas grill burner apparatus includes a center manifold configured to form two hollow gas tubes. The gas tubes are substantially parallel. The gas grill burner apparatus also includes first and second C-shaped hollow gas tube end portions slideably engaged within opposing ends of the parallel hollow gas tubes. The apparatus further includes a center grease tent mounted atop the center manifold and first and second telescoping grease tent members mated with the center grease tent. The telescoping grease tent members are configured to move laterally with the first and second gas tubes end portions.  
           [0013]    Another embodiment of the present invention may be construed to be a gas grill that includes an adjustable gas grill burner apparatus. The adjustable gas grill burner apparatus includes a center manifold configured to form two hollow gas tubes. The gas tubes are substantially parallel. The burner apparatus also includes first and second C-shaped hollow gas tubes end portions slideably engaged within opposing ends of the parallel hollow gas tubes. The burner apparatus further includes a center grease tent mounted atop the center manifold and first and second telescoping grease tent members mated with the center grease tent. The telescoping grease tent members are configured to move laterally with the first and second gas tubes end portions. The gas grill also includes at least a first gas feed line for providing gas to the hollow gas tubes.  
           [0014]    Yet another embodiment of the present invention may be construed to be an adjustable gas grill burner apparatus. The apparatus includes a continuous hollow gas tube burner formed in an elongated ovular shape. The apparatus also includes a grease tent. The continuous hollow gas tube burner includes a center manifold and first and second C-shaped telescoping end portion. The grease tent includes a center tent member mounted above the center manifold and first and second end members mated with the center tent member and mounted to the first and second C-shaped telescoping end portions. The first and second end members extend with the first and second C-shaped telescoping end portions.  
           [0015]    Other systems, features, and advantages of the present invention will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, features, and advantages be included within this description, be within the scope of the present invention, and be protected by the accompanying claims. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0016]    [0016]FIG. 1A illustrates an exploded view of an embodiment of a gas grill burner apparatus of the present invention.  
         [0017]    [0017]FIG. 1B illustrates a front view of the gas grill burner apparatus of FIG. 1A disposed in a closed position.  
         [0018]    [0018]FIG. 1C illustrates a front view of the gas grill burner apparatus illustrated in FIG. 1A disposed in an open position.  
         [0019]    [0019]FIG. 2 illustrates a perspective view of a center grease tent of the gas grill burner of FIG. 1A.  
         [0020]    [0020]FIG. 3 illustrates a perspective view of a side grease tent member of the gas grill burner apparatus of FIG. 1A.  
         [0021]    [0021]FIG. 4 illustrates a top view of a C-shaped hollow tube end portion of the gas grill burner apparatus of FIG. 1A. 
     
    
     DETAILED DESCRIPTION  
       [0022]    Referring first to FIG. 1A, an exploded view of an embodiment of a gas grill burner apparatus  10  is illustrated. The burner apparatus  10  may be adjusted in size to fit within a variety of gas grills. In this embodiment, the length of the burner apparatus  10  may be adjusted. However, in other embodiments both length and width may be adjusted to fit most gas grills.  
         [0023]    A center manifold  40  and mating C-shaped tube end portions  30  form a closed-loop burner  15  arranged in a substantially elongated ovular shape. The burner  15  has a substantially circular cross-sectional configuration defining a hollow internal, tube-like, chamber. A plurality of orifices are disposed through the tube of the gas burner  15 , such as around the outside periphery. It should be understood, however, that the orifices can be arranged in any suitable manner. It should also be understood that the adjustable gas burner apparatus  10  can comprise any suitable cross-section configuration and be arranged in any suitable substantially continuous shape. The gas burner  15  can comprise any heat-tolerant, rust-resistant material, such as stainless steel, or the like.  
         [0024]    The center manifold  40  forms a pair of center portions of the continuous burner  15 , arranged substantially parallel to each other and spaced apart from each other. Each center portion is a substantially elongated linear tube having opposing ends. The center manifold  40  is formed of an upper manifold  42  and a lower manifold  44  coupled together. Formed in the lower manifold  44  are two port holes  46  for coupling to two gas feed lines  20 . Two baffles  45  are welded into place in the lower manifold  44  to divide the gas burner  15  into left and right burners. Accordingly, either one side or both sides of the burner may be used at any given moment. Two gas feed lines  20  are desired in order to provide split control of the burner  15 .  
         [0025]    The C-shaped end portions  30  are disposed toward opposing ends of the pair of center portions. The ends of each end portion  30  are fixed one to each of the pair of center portions, thereby providing continuous fluid communication between the center portions and the end portions  30 . As illustrated this gas burner apparatus  10  comprises a substantially elongated oval shape. It should be understood, however, that the gas burner apparatus  10  can comprise any suitable shape, such as a rectangle, square, or the like.  
         [0026]    The end portions  30  are fixed to the center portions in a slidable or telescoping manner either directly or with additional extension members (not shown) slidably disposed between the center portions and the end portions  30 . In an embodiment where no extension member is included, the gas burner apparatus  10  is adjustable between a closed position (See FIG. 1B) and an open position (See FIG. 1C). The gas burner apparatus  10  may be adjusted to positions intermediate the two extremes illustrated in FIG. 1B and FIG  1 C. The end portions  30  can be moved toward and away from each other to decrease and increase the length L, respectively. It should be noted that the same technology is applicable to altering the width W of the burner apparatus  10 , by providing telescoping function for the end portions  30  and the corresponding burner tent  100 .  
         [0027]    Two gas feed lines  20  are provided in fluid communication with and extend from the two port holes  46  in the lower manifold  44 . The two port holes  46 , although illustrated generally in the center of the lower manifold  44 , may be positioned anywhere along the lower manifold  44  as long as fluid communication is provided to the center portions of the burner  15 . The gas feed lines  20  can be connected to the lower manifold  44  in any suitable manner, such as being press fit, welded, or the like.  
         [0028]    Each gas feed line  20  comprises an elongated venturi tube  24  having a receiving end and a delivery end. The receiving end of the venturi tube  24  is arranged and configured to receive a flow of gas fuel from a fuel source, such as an LP tank (not shown), or the like, through aspirator  26 , which is firmly crimped into place. The delivery end of the venturi tube  24  may be coupled to the lower manifold  44  with a venturi gasket and flange structure  22  as is well known in the art. It should be noted that although a pair of venturi tubes  24  is illustrated, the continuous gas grill burner apparatus  10  of the present invention can comprise any suitable number of venturi tubes  24  without departing from the spirit of the invention.  
         [0029]    The gas grill burner apparatus  10  also includes a grease tent  100  disposed above and along the length L and width W of the continuous burner  15 . It is preferable that the grease tent  100  is defined by a length L substantially corresponding to the length L of the gas burner  15  and a width W substantially corresponding to the width W of the gas burner  15 . The grease tent  100  comprises multiple members, such as a center member  60  and a pair of end members  50 . The end members  50  are disposed toward opposing ends of the center member  60  and are substantially linearly aligned therewith. The end members  50  are fixed to the center member  60  in a slidable or telescoping manner. The end members  50  are movable between a closed position, where a substantial portion of the center member  60  is covered (FIG. 1B) and an expanded position, where a substantial portion of the center member  60  is exposed (FIG. 1C). One or both of the end members  50  can be slidably moved along the center member  60  in order to alter the length L of the grease tent  100 . It should be also noted that although a pair of movable end members  60  is disclosed herein, the grease tent  100  can comprise only one movable end member  50  without departing from the spirit of the present invention.  
         [0030]    The grease tent  100  is configured such that grease drippings fall atop the grease tent  100  and run off the sides of the tent  100 . In this manner, the burner  15  remains protected from the falling grease thereby preventing the gas orifices of the burner  15  from getting clogged, as well as reducing the possibility of a grease fire.  
         [0031]    The side members  50  of the grease tent  100  may be coupled to the end portions  30  of the burner  15  with rivets  72 . In this manner, the side tent members  50  may be moved concurrently with the end portions  30  of the burner  15 . End stops  70  may be included and coupled to the side tent members  50 . The end stops  70  may be used to position the side tent members  50  and end portions  30  about the gas chamber of the grill.  
         [0032]    Burner feet  74  may also be included in the burner apparatus  10  and may be coupled to the end portions  30  or the lower manifold  44 . The burner feet  74  may be installed, as needed, by the user.  
         [0033]    In use, the gas grill burner apparatus  10  can be positioned in a cooking chamber  200  of a gas barbecue grill regardless of size or configuration of the cooking chamber. The end portions  30  and end members  50  of the gas burner  15  and grease tent  100 , respectively, are moved laterally relative to the center manifold  40  and center tent member  60 , respectively, to adjust the size of the gas grill burner apparatus  15 .  
         [0034]    The apparatus  10  is reduced in length L to a measurement that is readily received by the cooking chamber  200  of the gas grill. The apparatus  10  is disposed in the cooking chamber  200  of the barbecue gas grill. The burner apparatus  10  is disposed in the cooking such that the apex of the grease tent  100  is pointing upward and the gas feed line(s)  20  is extending downward. The length of the apparatus  10  is expanded to a measurement substantially corresponding to the length of the cooking chamber. The aspirator(s)  26  of the gas feed line(s)  20  is connected to a gas fuel source (not shown), such as an LP tank, or the like. Upon turning on the flow of gas to the gas feed line(s)  20 , gas flows through the gas burner  15  and out the orifices disposed throughout. The gas is ignited with flame or a spark and the burner apparatus  10  produces heat for cooking.  
         [0035]    [0035]FIG. 11B illustrates a front view of the continuous gas grill burner apparatus  10  of FIG. 1A disposed in a closed position  12 . In this manner, the burner apparatus  10  may be placed in a first, smaller gas grill chamber  200 . As mentioned, the end stops  70  may be positioned up against or relatively close to the side walls of the gas grill chamber  200 . Furthermore, the burner feet  74  may rest atop the base of the gas grill chamber  200 .  
         [0036]    [0036]FIG. 1C illustrates a front view of the continuous gas grill burner apparatus  10  illustrated in FIG. 1A disposed in an open position  14 . The burner apparatus  10  may be placed in a second, relatively larger, gas grill chamber  300 . It should be understood that the end portions  30  of the burner&#39;s need not be extended symmetrically. For example, the left end portions  30  may be extended more so than the right end portion  30 , or vice-versa.  
         [0037]    [0037]FIG. 2 illustrates a perspective view of a center grease tent member  60  of the gas grill burner apparatus  10  of FIG. 1A. In this embodiment, the grease tent  100  is formed in an A-frame cross-sectional shape. The grease tent  100  is positioned over the gas burner  15  in order to prevent grease from cooking food disposed above the gas burner  15  on the cooking surface (not shown) from dripping on the gas burners  15 . It should be noted that although the A-frame configuration grease tent  100  is illustrated herein, the grease tent  100  can comprise any suitable configuration. The grease tent  100  preferably comprises a heat-tolerant, rust-resistant material, such as stainless steel, or the like.  
         [0038]    The center grease tent member  60  also includes a plurality of detents  62 . In this embodiment, the center grease tent member  60  includes eight detents  62 ; four on each lateral side of the center member  60 . The detents  62  may be used as reference markers for the side tent members  50 , so as to evenly adjust the length of the burner apparatus  10 . FIG. 1B and FIG. 1C best illustrate the functionality of the detents  62 . In the closed position illustrated in FIG. 1B, the side members  50  are at the center-most detents  62 . In the open position illustrated in FIG. 1C, the side members  50  are extended to the outermost detents  62 . More or less than eight detents  62  could be formed in the center tent member  60 . The detents  62  are simply depressions formed in the center tent member  60  and have solid surfaces.  
         [0039]    [0039]FIG. 3 illustrates a perspective view of a side grease tent member  50  of the gas grill burner apparatus  10  of FIG. 1A. As noted with regard to the center tent member  60  of FIG. 2, the grease tent  100  is formed in an A-frame cross-sectional shape. An apex  54  is formed at a lateral center line to provide a graded slope for grease run-off. Two holes  56  are provided for the rivets  72  (See FIG. 1A). Although not shown, an end stop  70  may be welded to the end of the side member  50 .  
         [0040]    [0040]FIG. 4 illustrates a top view of a C-shaped hollow tube end portion  30  of the gas grill burner apparatus  10  of FIG. 1A. Gas orifices  32  are provided around the periphery of the end portion  30 . In this embodiment, the orifices  32  are positioned in a slightly upward direction so as to direct the flames directly upward. In other embodiments, the orifices  32  may be positioned differently, for example in a slightly downward direction.  
         [0041]    Two holes  36  are provided on the top of the end portion  30  for receiving rivets  72  (See FIG. 1A). The holes  36  are positioned to align with the holes  56  of the side tent members  50 . The side tent members  50  are aligned such that they provide complete cover for the end portions  30 . Holes for the burner feet  74  (See FIG. 1A) may also be provided on the underside of the end portion  30 .  
         [0042]    The ends  34  of the end portion  30  may be outwardly swaged so as to meet with the ends of the center manifold  40 , which are inwardly swaged. In this manner, the tube ends  34  prevent the user from extending the end portion  30  beyond the ends of the center manifold  40 . Furthermore, the swaged ends  34  of the burner end portion  30  provide for a better seal to prevent gas leakage. The end portion  30  is formed such that the ends  34  are relatively flush with the interior of the hollow tubes of the center manifold  40 . It will be appreciated that the seal need not be airtight, but rather sufficient enough to avoid significant gas leakage. Any gas that may leak through the seal will bum within the tube.  
         [0043]    Once heated, the metal of the end portions  30  and the manifold  40  may oxidize. This process may substantially lock the end portions  30  in place. However, once a user has positioned the burner apparatus  10  in place, it would seem unlikely to adjust the burner apparatus  10  after use. A significant amount of force, such as with a hammer or some other tool may be utilized to break the lock formed between the end portion  30  and the center manifold  40 .  
         [0044]    The foregoing description has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obvious modifications or variations are possible in light of the above teachings. For example, a third, center, hollow gas tube may be formed in the center manifold  40 . In this manner, the C-shaped end portions  30  would be configured with an extra tube, to form a fork-like shape. The embodiment or embodiments discussed, however, were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are intended to be included herein within the scope of this disclosure and the present invention.