Abstract:
A grill top for a grill, the grill including a wall and an open cooking area, the grill top adapted to be mounted to the grill such that the grill top extends across at least a portion of the grilling area. The grill top includes a grill frame having at least two opposed sides, and a plurality of grill rods. Each grill rod includes first and second opposed ends, the first end being rotatably mounted to one side of the grill frame and the second side being rotatably mounted to the other side such that each rod is rotatable relative to each adjacent rod and the grill frame. The grill rods are preferably removable for cleaning. Also disclosed are several devices for cleaning the grill rods.

Description:
RELATED APPLICATION  
       [0001]     The present invention is related to and claims priority from U.S. Provisional Application No. 60/831,817, filed on Jul. 18, 2006, the disclosure of which is incorporated herein by reference in its entirety. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The present invention relates to grills and, more specifically, to an improved grill top that includes removable grill rods and associated cleaning devices.  
       BACKGROUND  
       [0003]     Conventional grills include a grill top or grate that has a series of rods welded or otherwise integrally attached to a frame so as to form a unitary cooking surface which positions the items being cooked at a select position over the cooking fire.  
         [0004]     While there have been many advances in grills made over the years, the grill top itself has remained essentially unchanged.  
         [0005]     As food cooks on a grill top, fats, food particles, oils and other cooking by-products accumulate on the surface of the grill rods. These items eventually become baked onto the grill rods, reducing the effectiveness of the metal rod to conduct heat to food being cooked. Thus, over time, it becomes necessary to clean or replace the entire grill top. Currently the process for cleaning the grill top involves scraping or scouring the rods. This is usually performed with a scouring pad or brush. This technique works fairly well, although does not result in cleaning of the entire rod surface. Food can and generally does become trapped or caked on the sides and at the ends of the grill rods. In many cases users opt to simply replace the grill top at the beginning of every cooking season.  
         [0006]     A need exists for a more efficient grill top and cleaning system for reducing food build up on grill tops.  
       SUMMARY OF THE INVENTION  
       [0007]     The present invention relates to an improved grill top for a grill. The grill including a wall and an open cooking area. The grill top is designed to be mounted to the grill such that the grill top extends across at least a portion of the grilling area. The grill top includes a grill frame having at least two opposed side frames. A plurality of grill rods are provided. Each grill rod includes first and second opposed ends. The first end of each rod is rotatably mounted to one side frame and the second end is rotatably mounted to the other side frame such that each rod is rotatable relative to each adjacent rod and the grill frame. A variety of embodiments of the grill frame are disclosed.  
         [0008]     Also disclosed are cleaning devices for scraping food remnants off the rods after grilling. The cleaning devices can be mounted to the grill frame or the grill. Alternatively, the cleaning devices can be hand-held devices which include a scouring pad for scarping the rods and a drive system for rotating the rods to facilitate scouring of all sides of the rods.  
         [0009]     Other objects, aspects and advantages of the present invention will become apparent to those skilled in the art upon reading the following detailed description, when considered in conjunction with the appended claims and the accompanying drawings briefly described below.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]     For the purpose of illustrating the invention, the drawings show a form of the invention that is presently preferred. However, it should be understood that this invention is not limited to the precise arrangements and instrumentalities shown in the drawings.  
         [0011]      FIG. 1  is a side view of one embodiment of a grill according to the present invention.  
         [0012]      FIG. 2  is a partial top cross-sectional view of the grill taken along lines  2 - 2  in  FIG. 1 .  
         [0013]      FIG. 3A  is a partial side view of the grill of  FIG. 2  illustrating one embodiment of a cleaning device according to the present invention.  
         [0014]      FIG. 3B  is a partial top cross-sectional view of the grill illustrating the embodiment of the cleaning device shown in  FIG. 3A .  
         [0015]      FIG. 4A  is an isometric view of a grill top according to another embodiment of the invention.  
         [0016]      FIG. 4B  is a top view of the grill top of  FIG. 4A .  
         [0017]      FIG. 4C  is a front view of the grill top of  FIG. 4A .  
         [0018]      FIG. 4D  is an isometric view of the grill top of  FIG. 4A  illustrating the grill rods being slidably removed from the frame.  
         [0019]      FIG. 5A  is an isometric view of an alternate embodiment of a grill top according to the present invention.  
         [0020]      FIG. 4B  is a top view of the grill top of  FIG. 5A .  
         [0021]      FIG. 4C  is a front view of the grill top of  FIG. 5A .  
         [0022]      FIG. 5D  is a side view of the grill top of  FIG. 5A .  
         [0023]      FIG. 5E  is an isometric view of the grill top of  FIG. 5A  illustrating the grill rods being slidably removed from the frame.  
         [0024]      FIG. 6A  is an isometric view of an alternate embodiment of a grill top according to the present invention.  
         [0025]      FIG. 6B  is a top view of the grill top of  FIG. 6A .  
         [0026]      FIG. 6C  is a front view of the grill top of  FIG. 6A .  
         [0027]      FIG. 7A  is an isometric view of an alternate embodiment of a grill top according to the present invention with the grill rods shown removed from the grill frame.  
         [0028]      FIG. 7B  is a top view of the grill top of  FIG. 7A .  
         [0029]      FIG. 7C  is a front view of the grill top of  FIG. 7A .  
         [0030]      FIG. 8A  is an isometric view of an alternate embodiment of a grill top according to the present invention  
         [0031]      FIG. 8B  is a top view of the grill top of  FIG. 8A .  
         [0032]      FIG. 8C  is a front view of the grill top of  FIG. 8A .  
         [0033]      FIG. 9A  is an isometric view of an alternate embodiment of a grill top according to the present invention.  
         [0034]      FIG. 9B  is a top view of the grill top of  FIG. 9A .  
         [0035]      FIG. 9C  is a front view of the grill top of  FIG. 9A .  
         [0036]      FIG. 9D  is a side view of the grill top of  FIG. 9A .  
         [0037]      FIG. 9E  is an isometric view of the grill top of  FIG. 9A  illustrating the grill rods removed from the frame.  
         [0038]      FIG. 10A  is a top view of an alternate embodiment of a grill top according to the present invention.  
         [0039]      FIG. 10B  is a side cross-sectional view of the grill top of  FIG. 10A  taken along lines  10 B- 10 B.  
         [0040]      FIG. 11  is an isometric view of an alternate embodiment of,a grill top according to the present invention.  
         [0041]      FIG. 12A  is a partial side view of a rod from the embodiment of  FIG. 11 .  
         [0042]      FIG. 12B  is a partial cross-sectional view of the rod of  FIG. 12A  taken along lines  12 B- 12 B.  
         [0043]      FIG. 13  is an isometric view of an alternate embodiment of a grill top according to the present invention.  
         [0044]      FIG. 14A  is a partial side view of a rod from the embodiment of  FIG. 13 .  
         [0045]      FIG. 14B  is a partial cross-sectional view of the rod of  FIG. 14A  taken along lines  14 B- 14 B.  
         [0046]      FIG. 15A  is a front view of a cleaning device according to an alternate embodiment of the invention for cleaning the rods.  
         [0047]      FIGS. 15B and 15C  are top views of the cleaning device of  FIG. 15A  illustrating the rod being inserted into the device.  
         [0048]      FIG. 16A  is a top view of a hand-held cleaning device according to an alternate embodiment of the invention for cleaning the grill top.  
         [0049]      FIG. 16B  is a side cross-sectional view of device of  FIG. 16A .  
         [0050]      FIG. 17A  is a top view of an alternate embodiment of a grill top according to the present invention.  
         [0051]      FIG. 17B  is a side cross-sectional view of the grill top of  FIG. 17A  taken along lines  17 B- 17 B.  
         [0052]      FIGS. 17C, 17D  and  17 E are enlarged partial side cross-sectional views illustrating the louvers in open, partially-open and closed positions, respectively.  
         [0053]      FIG. 18  is an isometric view of an alternate embodiment of a cleaning device according to the present invention.  
         [0054]      FIG. 18A  is side view of the cleaning device of  FIG. 18 .  
         [0055]      FIG. 18B  is front view of the cleaning device of  FIG. 18 .  
         [0056]      FIG. 18C  is a cross-sectional view of the rod of  FIG. 18A  taken along lines  18 C- 18 C. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0057]     Referring now to the drawings, various currently preferred embodiments of the invention are depicted, wherein like reference numerals refer to similar items throughout the views.  FIG. 1  illustrates a schematic side view and  FIG. 2 a  schematic partial top view of a grill  10  with a grill top  12  according to one embodiment the invention.  
         [0058]     The grill top  12  includes a series of individual grill rods  14  which are independently separable from one another. As shown in the figures, the grill  10  includes a series of openings  16  formed in a side wall  18  of the grill  10 . The holes  16  are sized to be slightly larger than the diameter of the rods  14  such that the rods  14  can be inserted into the holes  16 . The rods  14  are sufficiently long so as to extend across the cooking area with their free ends  14 E engaging with a frame support  20  on the opposite side. In the illustrated embodiment, the free end  14 E of each rod  14  engages with a corresponding hole  22  formed in the frame support  20 . However, it should be readily apparent that the free ends of the rods can be supported in a variety of ways, such as resting in notches formed in the frame support or extending through holes formed in the opposite side of the grill.  
         [0059]     The spacings of the holes  16 ,  22  are preferably equal and designed to provide conventional spacing between rods, e.g., approximately 0.75 inches. However, it is also contemplated that different hole spacings may be used to provide the grill top with different rod spacings in different areas.  
         [0060]     Each rod  14  preferably includes a handle  24  formed on the end opposite the free end. The handle  24  may be made from the same material as the rod  14 , or may be made from a different material, such as a material that reduces conduction of heat like rubber.  
         [0061]     The rods  14  can be made from any material suitable for use in forming a grill top, including metal (e.g., stainless steel, cast iron, aluminum), ceramic or porcelain. Other materials can also be used. In one embodiment, the rods have a diameter of approximately 0.25 inches, however any suitable size (and shape) may be used. For example, the rods may be square or triangular in cross-section.  
         [0062]     As shown in  FIG. 2 , each rod  14  is preferably individually separable from the other rods and capable of being removed from the grill  10  so as to facilitate cleaning of the rod. For example, rod  14 A is shown being slid out of the holes  16 ,  22 . Once removed, the rod can be cleaned in a variety of different ways, such as by placing the rod  14  into a dishwasher. Alternately, as will be discussed below, the rod could be cleaned by running the rod through a separate cleaning device.  
         [0063]     Referring to  FIGS. 3A and 3B , one embodiment of a cleaning device  30  is shown. In this embodiment, scrapers  32  are mounted around each rod  14 . The scrapers  32  in the illustrated embodiment are each shaped so as to have an edge  34  that preferably conforms to a portion of the contour of the rod  14 . As shown, since the rods are cylindrical in shape, the scrapers each preferably have an edge  34  that has an arcuate shape that is less than one quarter of the circumference. As such, four scrapers  32  per rod would, in combination, provide an effective scraping surface covering approximately the entire circumference of the rod  14  as depicted in  FIG. 3A . Of course, if the scrapers  32  have an edge defining a larger portion of the circumference of the rod (e.g., one half), less scrapers  32  would be needed. It should be readily apparent that if the rods have a different cross-sectional shape, a different shape or the edge and arrangement of the scrapers would be needed.  
         [0064]     The scrapers  32  are preferably positioned such that the edges engage with and scrape along the circumference of the rod  14 . As shown in  FIG. 3B , as the rod  14  is pulled out, the scrapers  32  scrape caked on food (identified as F in  FIG. 3B ). To facilitate the scraping, the scrapers  32  are preferably formed from spring steel or similar strong, yet slightly flexible material that can withstand high temperatures. In the illustrated embodiment, the scrapers  32  include a bent leg  36 , the end of which includes the edge  34 . In this configuration, the bend in the scraper  34  provides a tight fit about the rod  14 . Since the rod  14  is inserted in the direction of the bend, the bent leg  36  will flex as the rod  14  is inserted, yet maintain the shape of the scraper when the rod is pulled out.  
         [0065]     This embodiment of the invention provides a quick mechanism for cleaning the rods  14  after use. The user simply pulls a rod outward and the scrapers remove the caked on food. The rod can then be reinserted. It is contemplated that the rods may be designed so as to inhibit their complete removal. This can be done by adding a stop or shoulder near the free end that cannot readily fit past the scrapers. Also, it is possible to attach several, if not all, of the rods together to a single handle allowing a user to pull all of the rods through the scrapers at the same time.  
         [0066]     While the scrapers  34  are shown as separate components, it is also contemplated that the scrapers can be interconnected for easy attachment to the grill wall. Also, the scrapers can be designed to be replaceable.  
         [0067]     The above discussion has focused on an embodiment of the invention in which that the grill top  12  is attached to the grill  10  such that the rods  14  extend out of holes  16  formed in the side  18 . It is also contemplated that the grill top  12  can be constructed such that it can be placed down into or onto the grill  10  like conventional grill tops. In this embodiment, the grill top is supported by brackets or other supports mounted to the grill  10  in a conventional manner.  
         [0068]     Referring now to  FIGS. 4A-4D , one embodiment of a removable grill top  112  is shown. In this embodiment, the grill top  112  includes a grill frame  120  which is preferably designed to extend across the heating area of the grill during use. In the illustrated embodiment the grill frame  120  is substantially rectangular. The frame is preferably made from a heat resistant material, such as stainless steel, iron, ceramic or porcelain. Other types of materials can be used. The cross-sectional shape of the individual frame members can have any suitable shape that provides sufficient support for grill rods  114 .  
         [0069]     The grill top  112  includes a plurality of individual grill rods  114 . The grill rods  114  are similar to the grill rods  14  discussed above. The grill rods in the embodiment illustrated in  FIG. 4A  are cylindrical in shape. Other shapes, of course, are possible. The rods  114  extend through holes  116  formed in the frame  120 . The holes  116  are similar to the holes  16  described above and are slightly larger in shape than the size of the rods  114 . As shown, there are holes formed on opposite sides of the frame  120  such that one end of the rod  114  extends through one hole and the other end extends through the other hole. As discussed above, the rods may include handles (not shown) at one end to limit the passage of the rod into the hole and provide an easy way to remove the rods for cleaning. Other mechanisms can be used to limit the movement of the rods within the holes.  
         [0070]     In the illustrated embodiment, the frame  120  includes two spaced apart side frames  121 . The ends of the side frames are preferably connected by lateral frames  123  so as to form a rigid box structure. The frame  120  is preferably made stainless steel with a thickness of about 0.125 inches and a cross-sectional height of about 0.5 inches. The frame has an overall shape of about 16 inches and about 24 inches. The hole spacings are about 0.75 inches on center.  
         [0071]      FIG. 4D  illustrates that rods  114  in a state of partial removal with the rods still engaged with one hole but one free end removed from the other hole.  
         [0072]     Referring now to  FIGS. 5A-5D , a further embodiment of the removable frame top is shown. In this embodiment the grill top  212  includes a frame  220  and a plurality of rods  214 , each rod again being removable from the frame  220 . The primary difference between this embodiment and the prior embodiment is that the frame  220  does not include holes. Instead, the frame has a series of rod support  222  that are attached to the frame  220  and form cradles or support seats for the rods  214 . In the illustrated embodiment, the supports are substantially U-shaped and have an inner shape that complements the shape of the rod  214 , at least at portions of the rod  214  that are intended to seat on the support. For example, if the rod has a round cross section at its ends, the supports  222  preferably have a semicircular inner surface so that the rods seat onto the inner surface of the supports.  
         [0073]     However, if it is desired that rotation of the rods be inhibited when mounted to the frame, that the ends of the rods may be formed with a non-circular cross-section (e.g., square). The support  222  would have a inner surface shape that complements the end of the rod so as to prevent rotation (e.g., a square shape).  
         [0074]     The supports  222  are preferably fixedly attached to the frame  220 , such as by welding, so as to form an integral unit. The supports are preferably made from the same material as the frame  220 .  
         [0075]     Referring to  FIG. 6A-6C , another embodiment of the removable grill top  312  is shown. In this embodiment, the frame  320  includes V-shaped notches  322  to support the rods  314 . The shape of the notch permits the rod  314  to roll within the notch. Of course, the shape of the notches  322  can be other than V-shaped, such as U-shaped.  
         [0076]      FIGS. 7A-7C  show a similar embodiment of the grill top  412 , except that the frame  420  is not designed to be removable from the grill  10 . Instead, the frame  420  is formed from two separate frame members  420  that are mounted to the inside of the grill  10  (not shown).  
         [0077]      FIGS. 8A-8C  show a variation of the grill top in the embodiment of the invention shown in  FIGS. 6A-6C . In this embodiment, the frame includes a lock  350  to prevent or inhibit removal of the rods  314 . Any suitable lock can be used. In the illustrated embodiment, the lock includes a pivotable locking frame that is hinged or pivotably attached to the frame  320 . When the locking frame is pivoted down (as shown on the left side of  FIG. 8A  and the bottom of  FIG. 8B ), the rod ends can be removed from the frame  320 . To lock the device, the locking frame  350  is rotated up (as shown on the right side of  FIG. 8A  and the top of  FIG. 8B ). This position prevents the ends of the rods from being removed from the frame  320 .  FIGS. 9A-9E  shows a similar locking mechanism  450  when used with the embodiment of the invention shown in  FIGS. 7A-7C .  
         [0078]     A further variation of the present invention is shown in  FIGS. 10A and 10B . In this embodiment, at least the ends of the rods  514  are hollow so as to form a recess  515 . The frame  520  includes two frame members  522  which each have rod supports  524  that extend from one side of the frame member  522 . The supports  524  include a plug with a shape designed to engage with the recess  515  in the rod to secure the rod  514  to the frame  520 . When all the rods  515  are attached to the frame  520 , the grill top  512  is a complete unit. Preferably the recesses are circular in diameter and the supports  524  are cylinders that slidingly engage with the recesses. However, a variety of other complementary shapes can be used in the present invention.  
         [0079]      FIG. 11  illustrates another embodiment of the invention where the rod  614  includes removable ends  616 . This allows a hollow rod center portion  618  to be used that is larger and/or different in shape than the ends  616 . The removable ends  616  are attached to the center portion as described in the prior embodiment. Once attached to the center portion, the other portion of the end  616  engages with the frame as in any of the various embodiments described above.  FIGS. 12A and 12B  illustrate one form of rod  614  according to this embodiment of the invention.  
         [0080]     It is also envisioned that the rods in the present invention can be formed with holes for providing heat passage or, more preferably, for cooking enhancement. Referring to  FIGS. 13 and 14 A and B, the rods  714  are shown as having a series of holes  730  formed in the body of the rod. The holes  730  can be formed on one side or opposite sides of the rod depending on the desired use of the rod.  
         [0081]     For example, if the holes are formed along the upper surface of the rods, with no holes on the bottom, it is possible to fill the rods with a liquid, such as water or a flavor enhancing liquid like steak sauce, mesquite flavoring, barbeque sauce, etc. Thus, during cooking, when the rod heats up, the heat causes the liquid inside the rod to evaporate into a gas. The moist gas rises through the holes and enters into the item being cooked or into the chamber formed inside the grill cover. This greatly enhances the cooking of the foods. To fill the rod, at least one end of the rod preferably can be opened as described previously.  
         [0082]     It is also contemplated that, instead of a liquid, a solid can be inserted into the rod, such as a flavor enhancing stick. For example, the flavor stick may be made from or include mesquite or hickory. As the rod heats up, the flavoring from the hickory or mesquite enters the food or the cooking chamber, thereby enhancing the flavor of the food. In this embodiment, the holes can be formed on both sides of the rod as shown in  FIG. 14B .  
         [0083]     As discussed above, there are various ways to clean the rods of the grill tops described above. Another cleaning device  800  is shown in  FIG. 15A . The cleaner  800  includes a frame  802  onto which is mounted scrapers or scouring pads  804 , such as ScotchBrite® pads. (ScotchBrite® is a registered trademark of the 3M company.) The pads  804  are preferably positioned so as to contact substantially the entire circumference of the rods  14 . In the illustrated embodiment, the pads  804  have an arcuate shape and sized so as to cover approximately one third of the rod  14  circumference. Other shapes and sizes are, of course possible. The pads may be attached to the frame  802  through supports  806 . The pads  804  are preferably replaceable such that the pads can be changed when the pads wear down or become clogged with debris.  FIGS. 15B and 15C  illustrate a rod  12  with caked on food being inserted into the cleaning device. As the rod passes through, the scouring pads scrape off the food that is on the rod.  
         [0084]     It should be readily apparent that, instead of the scouring pads  804 , it is also possible to mount a scraper similar to the scraper described with respect to embodiment illustrated in  FIGS. 3A and 3B .  
         [0085]     Referring to  FIGS. 16A and 16B , an embodiment of the cleaning device is shown for use on the grill top. In this embodiment, the cleaning device  900  is a handheld device that has a handle  902  mounted to a base  904 . A cleaning pad  906 , such as a scouring pad, is mounted to the bottom of the base  904 . One or more drive wheels  908  are attached to the base  904 . The mounting and size of the wheels  908  is designed to position the scouring pad  906  in contact with the rods  12 . A motor (not shown) is preferably mounted to the base  904  and connected to one or more of the drive wheels such that activation of the motor causes the drive wheels  908  to rotate. The drive wheels are preferably made from a material that produces a sufficient degree of friction between the rods  12  and the drive wheels  908  such that the drive wheels  908  cause the rods to rotate. One preferably material is urethane. If the cleaning device  900  is intended to be used when the rods are hot, then the material selected such be able to withstand the typically level of heat to which the rods are exposed.  
         [0086]     As the drive wheels  908  are rotated by the motor, their contact with the rods causes the rods to rotate as well. Since the rods are in contact with the scouring pad  906 , the rotation of the rods causes scouring of the rods  12  by the scouring pad, thus effecting cleaning of the rods.  
         [0087]     The motor can be powered by any suitable power source such as AC power (such as from an outlet) or DC power (such as from batteries mounted in the handle or the base.)  
         [0088]     An alternate embodiment of the cleaning devise is shown in  FIGS. 18 and 18 A- 18 C. In this embodiment, the cleaning device  920  includes a housing  921  with a handle  922  mounted to a base  924 . A cleaning pad  926 , such as a scouring pad, is mounted to the bottom of the base  924 .  
         [0089]     One or more drive belts  925  are rotatably mounted to the housing  921 . Preferably there are two drive belts  925  mounted on either side of the housing. The drive belts  925  project out from the bottom of the base  924  on either side of the pad  926  at a position suitable for engaging with the rods of the grill. Each drive belt is mounted about at least two wheels  927  rotatably attached to the base  924 . As shown, a motor  928  is mounted to the housing and engaged with at least one wheel for rotatably driving the belt  925 . Preferably, the motor is position between the two drive belts and is configured to engage one wheel for each belt. As in the previous embodiment, the motor can be powered by any suitable power source such as AC or DC power. The belts are preferably made from a material suitable for frictionally engaging with the rods.  
         [0090]     A further variation of the invention is shown in  FIGS. 17A-17E . This embodiment of the invention includes a louver system  950  as part of the rods  952  for providing directional control over heat and/or smoke. More particularly, the rods  952  preferably include an eccentric flap  954  that extend from the rod  952 . As such, rotation of the rod  952  determines the orientation of the flap  954  (see  FIGS. 17C-17E ). By placing the flap in the proper orientation, the heat from the heat source can be directed in a desired manner. When the rod is completely rotated, the flaps or louvers  954  block the space between the rods, thus effectively blocking or reducing the passage of heat current through the rods to the food being cooked (see  FIG. 17E ).  
         [0091]     This embodiment is particularly beneficial for a smoker. The louvers permit control over the directional flow of the smoke.  
         [0092]     While the present invention has been described with respect to various preferred embodiments, it should be readily apparent to those skilled in the art that a variety of modifications are possible in light of the teachings provided herein.