Abstract:
A portable grill easily carried as components, which may be stacked as generally flat parts, to be carried in a compact container, and may be easily assembled without tools and used in various modes. Upper and lower reflectors which are flat rectangular parts when disassembled, are flexed and held in arcuate shapes upon assembly, to form the cooker lid and body, respectively, by rods that engage the edges of the reflectors and mount in holes in the legs. After use, the cooker may be disassembled and transported again. By installing, removing and substituting various parts, the cooking unit may be used as, for example, a grill, a baker, a boiler, a smoker, a steamer, a deep fryer and the like. Provision is made for propane as well as charcoal, wood and other consumable fuels.

Description:
FIELD OF THE INVENTION 
     The invention relates generally to a cooking system and, more particularly, to a versatile outdoor cooking system which permits rapid assembly and disassembly for easy storage and transportation 
     BACKGROUND OF THE INVENTION 
     Cooking outdoors is well-known and many system&#39;s have been developed to facilitate cooking outdoors. However, the systems that are available either are limited in desirable features or, if they are provided with many desirable features, are heavy and cumbersome to store and difficult to transport, for example, by one hiking through a wilderness area. 
     Therefore, what is needed is a lightweight outdoor cooking system which provides desirable features and which may also be easily stored and readily transported. 
     Many available systems are inefficient by design. Deficiencies include: 
     Inadequate draft control. 
     No fire grate. 
     No Combustion air control. 
     Open lid designs lose heat, do not reflect heat to food being cooked. 
     No radiant heat. 
     Not rain proof or wind proof. 
     Square shapes are less efficient than parabolic or semi circular shapes. 
     Painted surfaces absorb heat while unpainted aluminum reflects heat. 
     Grills with short legs may start grass fires. 
     Grills with short legs are inconvenient, requiring the user to stoop or squat. 
     No place to hang implements. 
     SUMMARY OF THE INVENTION 
     The present invention, accordingly, provides a system for cooking outdoors which permits rapid assembly and disassembly with the feature that when disassembled all the pieces lie flat for easy storage and transportation. Additionally, the system includes a number of additional features which enable it to be used in a number of different cooking modes as, for example, a grill, a baker, a boiler, a smoker, a steamer, a deep fat fryer, and the like. Some of these modes may be carried out simultaneously. A dutch oven may be utilized in the present invention, without a ground fire, and can be used despite rain or wind. Improved draft control makes possible starting of charcoal fire, even in rain, by positioning body and lid ends to control draft. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which: 
     FIG. 1 is a perspective view of an outdoor cooking system embodying features of the present invention; 
     FIG. 2 is a perspective view of the cooking system of FIG. 1 in which a top reflector is open; 
     FIG. 3 is an exploded view of the outdoor cooking system of FIG. 1; 
     FIG. 4 is a plan view of a reflector used in the cooking system of FIG. 1; 
     FIG. 5 is a side view of a reflector used in the cooking system of FIG. 1 taken along the line  5 — 5  of FIG. 4; 
     FIG. 6 is a side view of a reflector used in the cooking system of FIG. 1 taken along the line  6 — 6  of FIG. 4; 
     FIG. 7 is a fire grate configured for use with the cooking system of FIG. 1; 
     FIG. 8 is a cooking grate configured for use with the cooking system of FIG. 1; 
     FIG. 9 is a cross-sectional partially broken-away view of a portion of one and of the cooking system of FIG. 1 taken along the line  9 — 9  of FIG. 1, and showing the engagement of a leg-pair with two rods, two reflectors, and two windscreens; 
     FIG. 10 is an exploded side view of the cooking system of FIG. 1 taken along the line  10 — 10  of FIG.  1  and showing how two reflectors flex in the assembly and disassembly of the cooking system of FIG. 1; 
     FIG. 11 is a side end view of the cooking system of FIG. 1 showing in phantom selected elements that may be positioned within the interior of the cooking system of FIG. 1; 
     FIG. 12 is an elevation view of a support bracket configured for use with the cooking system of FIG. 1; 
     FIG. 13 is an exploded perspective view of a Dutch oven comprising a lid/griddle and pan that may be used in conjunction with the cooking system of FIG. 1; 
     FIG. 14 is an exploded perspective view of a Dutch oven pan and grill, that may be used in conjunction with the cooking system of FIG. 1; 
     FIG. 15 is a perspective view of the system of FIG. 1 showing how two brackets of FIG. 12 may be assembled to the system to support a container of a fuel connected to a burner for cooking food on a griddle positioned in the cooking system of FIG. 1; 
     FIG. 16 is a perspective view of the system of FIG. 1 showing how two brackets of FIG. 12 may be assembled to the system to support a container of a fuel connected to a burner for cooking food in the Dutch oven lower pan of FIG. 13 positioned in the cooking system of FIG. 1; 
     FIG. 17 is a perspective view showing how a rotisserie and spit may be mounted to brackets of FIG. 12; 
     FIG. 18 is cross-sectional view of the rotisserie and spit of FIG. 17 taken along the line  18 — 18  of FIG. 17; 
     FIG. 19 is a perspective view of an alternate embodiment of the cooking system of FIG. 1 in which two cooking systems are configured to operate together; 
     FIG. 20 is a perspective view of the cooking system of FIG. 19 wherein top reflectors are open and a container of fuel is positioned along one end thereof for cooking on a griddle on one side of the cooking system, and a charcoal grill is used on the other side; 
     FIG. 21 is a perspective view of the cooking system of FIG. 19 configured with a fire grate on one side and a cooking grate on the other side; 
     FIG. 22 is a perspective view of the cooking system of FIG. 19 configured with a rotisserie and spit mounted thereon; and 
     FIG. 23 is a perspective view of the cooking system of FIG. 19 showing how one top reflector may be open while the other top reflector is closed so that different cooking modes may be isolated from each other. 
     FIG. 24 is a plan view of an alternate embodiment grill. 
     FIG. 25 is an exploded elevation view of the alternate embodiment grill of FIG. 24 adapted for use over an open camp fire, and also including an accessory propane burner assembly including legs and support rods. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to FIG. 1, the outdoor cooking system embodying features of the present invention is generally illustrated at  10 . A body reflector  12  forms a portion of the body of the cooker, and another reflector  14  forms a portion of the lid assembly  15 . A body end  16  at each end of reflector  12  closes the ends of the body portion of the cooker. Body end  16  lifts up to access fire or baking area below grill. Lid ends  18  and  19  (see FIG. 2) at each end of reflector  14  close the ends of lid  15  of the cooker. Rods  20  and  22  join and support reflector  12 , as will be described hereinafter. Rods  28  and  30  join with and support reflector  14 , as will be described hereinafter. Rod  20  also acts as a hinge pin about which lid  15  pivots for access to any heat source or food in the cooker. 
     Referring to FIG. 2, the cooker  10  is shown with the lid  15  open, showing lid end  19 , without the cooking grill. 
     FIG. 3 shows an exploded parts relationship between some of the parts of cooker  10 . Rods  20  and  22  insert through conduits formed in the edges of reflector  12  and into hole  44  in lid end  18  and a similar hole in lid end  19 , not shown in FIG. 3, and into holes  32  and  34 , respectively, in leg stand  24 ; and into holes  36  and  38 , respectively, in leg  26 . Rods  28  and  30  insert through conduits formed in the edges of reflector  14  and into holes  40  and  42  in lid end  18  and similar holes in lid end  19 . In the preferred embodiment, lid ends  18  and  19  are identical. Grill  46  is positioned atop rods  20  and  22 . Grate  48  is positioned inside reflector  12  to support charcoal or other flammable material burned to supply heat for cooking. Grate  48  has a front edge and a back edge, the edges engaging and supported by the body reflector. Grate  48  is usually placed in a generally horizontal position as shown, but may be placed in an angular position in order to place the flame closer to the grill to attain greater heat for cooking. Grate  48  is supported for supporting flammable fuel in the cooker, the grate having a width less than the width of the grill, the grate having a first edge and a second opposite edge, the edges located inside of and engaging the interior of the body reflector to support the grate beneath the grill. The grate may be placed in a horizontal position by the grate edges engaging the body reflector, or may be tilted with the first edge higher than the second edge to place some of the fire closer to the food to speed up the cooking process. 
     In the preferred embodiment leg stands  24  and  26  are identical. The projecting ends of rod  30  provide handles for lifting the lid to access the food in cooker  10 . The projecting ends of rods  20  and  22  provide convenient places to hang tongs, forks or other cooking accessories. The flexibility of the body reflector and body rods allow the leg stands  24  and  26  to adjust to irregular terrain. In the preferred embodiment, the body reflector  12  is sufficiently flexible to allow the grill  10  to twist enough to allow the leg ends to move so that one leg end may move to at least 2 inches from a plane defined by the other three leg ends. 
     FIGS. 4,  5  and  6  show plan, side and front views of reflector  12 . In the preferred embodiment, reflectors  12  and  14  are identical. Conduits  50  and  52  are formed in alignment on one edge of reflector  12  to accept one of rods  20 ,  22 ,  28  or  30 . Conduits  50  and  52  each define a central axis central and longitudinal to the lengths therethrough. Conduits  54  and  56  are formed in the opposite edge of reflector to accept any of the rods,  20 ,  22 ,  28  or  30 . Tabs  51  and  55  are positioned alternate to conduits  50  and  52 , and  54  and  56 . A portion of reflector  12  preferably extends beyond conduits  50 ,  52 ,  54  and  56 , coplanar with the main portion of reflector  12  and with tabs  51  and  55 . Referring to FIGS. 2 and 3, tabs  51  and  55  extend above rods  20  and  22  to guide and contain grill  46  and prevent grill  46  from becoming displaced from the desired position, as for example, if meat should stick to grill  46  during cooking, a fork or spatula may be pushed between the meat and grill  46  to free the meat for turning or removal from the grill. 
     FIG. 7 shows the fire grate  48  which may be placed in the assembled cooker to support the fire spaced away for the reflector  12  to provide heat insulation from reflector  12  and provide air draft to support combustion of the fire. The grate  48  is of a selected length to fit within the length of reflector  12  and sized in width to fit within the reflector  14  and below rods  20  and  22 . Preferably, the width of the grate  48  positions the grate of a suitable distance below rods  20  and  22 , which in the preferred embodiment, the width is substantially 70% of the center distance between the holes in leg stands  24  and  26 . Depending on the proportions of reflector  12  and leg stands  24  and  26 , the width of the grate  48  may vary between 65% and 75% of this center distance, and possibly between 60% and 80% of this center distance. The fire grate illustrated is made of “expanded metal” sheet which has multiple slits in an alternating pattern, which are stretched to provide diamond shaped openings. A wire rack may also be used for the fire grate  48 . 
     FIG. 8 shows the grill  46  which is of a selected length to fit within the length of reflector  12  and sized in width to fit atop rods  20  and  22 , and within tabs  51  and  55 . The grill  46  in the preferred embodiment has a width substantially equal to the center distance between the holes in leg stands  24  and  26 , plus the diameter of rod  22 . 
     FIG. 9 shows relationships of cooker  10  parts as assembled. Rod  28  has been inserted into conduits  50  and  52  in one edge of reflector  14 , and through hole  40  in lid end  18 . Rod  20  has been inserted into conduits  50  and  52  in one edge of reflector  12 , through hole  44  in lid end  18  and through hole  32  in leg stand  24 . Body end  16  is inserted between reflector  12  and leg stand  24  and supported by rods  20  and  22 . Rod  22  is not shown in FIG.  10 . Since rod  20  is inserted through hole  44  in lid end  18 , lid assembly  15  is supported in a pivotal relation about support rod  20 , and may be closed as in FIG. 1, and may be lifted to an open position as shown in FIG.  2 . Angle X may be selected between 60° and 90°. In the preferred embodiment, X is 85°, to provide stability to the cooker. 
     FIG. 10 shows an exploded end elevation of selected parts of cooker  10 . Rod  20  is inserted in conduits  50  and  52  of reflector  12 , then into hole  40  in a lid end at each end of reflector  14 , then into holes  32  and  36  in legs stands  24  and  26 , respectively. Rod  22  is inserted into conduits  54  and  56  in reflector  12 , then reflector  12  is flexed as illustrated to align and insert rod  22  into holes  34  and  38 , in leg stands  24  and  26 , respectively. Likewise, rod  28  is inserted in conduits  52  and  54  reflector  14 , then into holes hole  40  in lid end  18  and the like hole in lid end  19 . Rod  30  is inserted into conduits  54  and  56  in reflector  14  then reflector  14  is flexed as illustrated to align and insert rod  30  into hole  42  in lid  18  and the like hole in lid end  19 . One body end  16  is inserted between reflector  12  and leg stand  24  and is supported atop rods  20  and  22  by tabs  58  and  60 . The other body end  16  is inserted between reflector  12  and leg  26  and is supported atop rods  20  and  22  by tabs  58  and  60 . Lid ends  18  may be slid along rods  28  and  30  to vary the distance from lid  14  to vary flow of draft air for the fire. Body ends  16  may be slid along rods  20  and  22  to vary the distance from reflector  12  to vary flow of draft air for the fire. 
     In the preferred embodiment, the center distance between the first hole and the second hole in the leg stand is 10 inches; the center distance between the conduits  50  and  54  is substantially 17.6 inches, that when the body reflector is flexed for assemble, the center distance is reduced to substantially 57% of the relaxed distance. A range of dimensions for the center distance between the conduits could range from 15 to 20 inches. For the center distance of 10 inches between the holes in the leg stands, the body reflector could by 50 to 67% for this range of distances. 
     DESCRIPTION OF ALTERNATE EMBODIMENTS 
     FIG. 11 shows a cross section of the cooker in a different configuration. Referring to FIG. 13, also, pan  62  with close fitting pan lid  64  is placed with flanges  66  and  68  on pan  62  extending above and supported by rods  20  and  22 . The body of pan  62  is of a width less than the center distance between the holes in leg  26 , minus the diameter of rod  22 . Charcoal briquets  70  are placed on grate  48  to provide heat to cook food in pan  62 , as well as bake a potato  72  placed on reflector  12  below grate  48 . Pan lid  64  has an upstanding rib  65  around the periphery to contain charcoal briquets  74  which may be placed atop lid  64  to aid in baking food in pan  62 . The upstanding extends 0.88 inches in the preferred embodiment, although any dimension between 0.30 and 1.50 inches would be useable. Pan lid  64  has an flanges  67  and  69  which closely fit to flanges  66  and  68  on pan  62 . 
     FIGS. 12 and 17 show support bracket  76  with holes  78  and  80  to fit interchangeably on the ends of rods  20  and  22 . Holes  78  and  80  have the same center distance apart as holes  32  and  34  in leg stand  24  and as holes  36  and  38  in leg  26 . A larger hole  82  is sized and positioned to accept and support a propane burner as will be described hereinafter. Slot  84  is positioned to accept and support a rotary spit  90  on which food may be mounted and rotated during cooking. Straight sides  86  and  88  are sized and positioned to accept and support a motor assembly  92  adapted to support and rotate the rotary spit  90 . FIG. 18 illustrates the spit  90  engaged with motor assembly  92  for rotation of the spit  90  while cooking. Angle Y defines an apex angle of 90° to 170° between the axis connecting the centers of hole  78  and the hole  82  and the axis connecting centers of hole  82  and hole  78 . In the preferred embodiment the angle Y is substantially 130°. 
     FIG. 14 illustrates grill  46  placed on pan  62  which is placed with flanges  66  and  68  on pan  62  extending above and to be supported by rods  20  and  22 . Water may be put in the pan  62  in this configuration for steam cooking food placed on the grill  46 . 
     FIG. 15 shows the cooker  10  outfitted with an accessory propane cooking mechanism. The pair of support brackets  76  are mounted, one on each end of rods  20  and  22  with the slots  84  extending downwardly. A propane burner  94  is positioned in the apex atop support brackets  76 . A propane tank  96  is connected to, and supported by the burner  94  to provide cooking heat. The body ends  16  are omitted in this configuration to allow for access for the burner  94  to extend through the cooker. The pan lid  64  is placed atop rods  20  and  22  to provide a griddle. 
     FIG. 16 shows the cooker  10  outfitted with accessory propane cooking apparatus. A pair of support brackets  76  are mounted, one on each end of rods  20  and  22  with the slots  84  extending downwardly. A propane burner  94  is positioned in the holes  82  in support brackets  76 . A propane tank  96  is connected to, and supported by the burner  94  to provide cooking heat. The pan  62  is placed atop rods  20  and  22  to deep fry, boil or steam food. 
     FIG. 19 illustrates a double width cooker, generally at  102 , This double width cooker is provided with support rods  120 ,  122  and  128  which are longer than rods  20 ,  22 ,  28  and  30 , and are assembled and used in a similar manner to rods  20 ,  22  and  128 . Two each rods  30  are assembled with two reflectors  14  and four lid ends  18 . The reflectors  14  and two reflectors  12  are assembled on rods  120 ,  122 ,  128  and two rods  30 . In this configuration, each lid assembly may be lifted independently to tend to the food or fire at that end of the cooker. 
     FIG. 20 illustrates a double width cooker, generally at  104 , respectively. This double width cooker is provided with support rods  120 ,  122 ,  128  and  130 , which are longer than rods  20 ,  22 ,  28  and  30 , and are assembled and used in a similar manner to rods  20 ,  22 ,  28  and  30 . Two each reflectors  12  and  14  are assembled on rods  120 ,  122 ,  128  and  130 . Two or three lid ends  19  as illustrated may be used. Brackets  76  are used to support a propane burner  94  and propane tank  96 . In this embodiment, one can griddle and grill simultaneously. 
     Cooker  102  may be assembled with body ends  16  for use with one or two grates  48  to support fuel such as charcoal or wood. 
     Cooker  104  may be assembled with brackets  76 , propane burner  94  and propane tank  96  and without body ends  16  to provide propane heat for cooking. 
     FIG. 21 illustrates a double width cooker similar to the cooker in FIG. 20, except without brackets  76 , with propane burner  94  and propane tank  96  with burner  94  simply positioned in the bottom of reflector  12  to provide propane heat for quickly starting a charcoal fire, after which the propane burner  94  is removed and body end  16  installed. In this embodiment, bracket  121  and  123  engage rods  130  and  128  and  120  and  122  to maintain the shape of reflectors  12  and  14 . By controlling draft with lid ends  19  and body ends  16 , and by having heat source on one side and food on the other side, one can slow smoke food with indirect heat. 
     FIG. 22 illustrates a double width cooker assembled with support rods  120 ,  122 ,  128  and  130 , similar to FIG. 19, except without reflectors  12  so that the cooker may be placed above a camp fire or other heat source on the ground. Two or three brackets  76  may be placed with the conduit slot  84  above rods  120  and  122 . A long spit  190  may be assembled with a rotisserie motor assembly  92  to turn food, for example, chicken or game birds for cooking above a fire below the cooker. Lid ends  118  are similar to lid ends  18  except that slot  119  in each lid end  118  provide clearance to close the lid around the spit  190 . 
     FIG. 23 illustrates a double with cooker with reflectors  14  assembled with support rods  120  and  122 . The lids are assembled with two reflectors  14 , rod  128 , two support rods  30 , and four lid ends  18 , as illustrated. Rods  120  and  122  connect and support reflectors  12  as described hereinbefore. In this configuration, it is possible to open only one lid section at a time to reduce the loss of heat while attending to the food or fire at one end of the double width cooker. 
     FIGS. 24 and 25 illustrate an alternate embodiment grill. In this embodiment, grill  146  is illustrated as a welded wire assembly, with a multiplicity of cross members  147  positioned closely enough together in a first plane to support food to be cooked without allowing the food to fall through the grill. In a second plane, longitudinal rods  148 ,  150 ,  152  and  154  are welded to the cross members  147 . In the preferred embodiment, rods  148 ,  150   152  and  154  are the same diameter. Rods  148  and  150  fit parallel to and between rods  20  and  22 , to hold grill  146  in place, even when used without reflector  12 . Rods  152  and  154  are spaced apart substantially 0.3 inches apart to allow a ¼″ bolt  156  to pass through and engage the head of bolt  156 . Bolt  156  screws into propane burner  158  to support one or more burners  158  from grill  146 . Cross members  147  are spaced apart far enough to allow the head of bolt  156  to fit between cross members  147 . By allowing the head of bolt  156  to fit down between cross members  147 , the bolt head is below the top of grill  147 , where the bolt head will not interfere with a pot or pan placed on grill  147 . This provides means for suspending a propane burner from the grill. These means may also include a washer attached to the grill. Top of grill  147  is level with top of legs stand  24 . By sliding leg stands  24  outward on rods  20  and  22 , legs  24  serve as additional support for large pots and pans. 
     FIG. 25 illustrates an exploded elevation view of the alternate embodiment grill of FIG. 24 including an accessory propane burner  158  with propane tank  160 . In this alternate embodiment, for example, over an open camp fire, one could cook with accessory propane burner  158  with propane tank  160 . Support rods  20  and  22  are assembled into holes  32  and  34  in two legs  24  as described hereinbefore. Longitudinal rods  148  or  150  are positioned at a center distance at a center distance between holes  32  and  34  in leg  24  less the diameter of rod  20 , less the diameter of rod  148 . 
     The grill according to this invention may be assembled without the body reflector  14  and placed above a campfire to perform cooking. For the purpose of this specification, a campfire includes any fire built on a non-combustible surface, whether indoors or outdoors, other than on a grate supported in a body reflector  14  of this invention. 
     The grill according to this invention may have at least one of the body front rod or body back rod of sufficient length to hang one or more cooking utensils, or to act as handles to lift the cooker. In the preferred embodiment, the grill according to this invention has the lid front rod of sufficient length to extend substantially 1 inch beyond each lid end to act as handles to lift the lid. In any embodiment of this invention, both of the body front rod and body back rod may have a first and a second end and are of sufficient length to extend beyond each of the leg stands to provide a handles for moving the grill. I have disclosed a portable grill wherein the lid ends, each having the lid front hole, each lid end having the lid back hole, each lid end having a hinge hole through which the body back rod is insertably located, providing rotatable attachment of the lid ends and lid reflector about the body back rod when rotated about the body back rod, brings the lid back rod into engagement with the leg stands, thereby limiting rotation of the lid ends and thereby the lid assembly to 60° to 120° about the body back rod. In the preferred embodiment, rotation of the lid ends is substantially 90° about the body back rod although 75 to 105 could be a useful range. Another feature of this invention is that both of the body front rod and body back rod have first and second ends and are of sufficient length to extend beyond each of the leg stands to provide a handles for moving the grill. 
     For purposes of this specification, flammable fuel is defined as wood or charcoal, or other flammable material that can be used as fuel for cooking. 
     Even though several embodiments of the invention have been illustrated in the accompanying drawings and described in the foregoing Description it will be understood that the invention is not limited to the embodiments disclosed, but is capable of rearrangements, modifications, and substitutions and reversals of parts and elements without departing from the spirit of the invention.