Abstract:
An electric cooking assembly includes a main body portion that defines a cooking area. First and second cooking surfaces are contained within the cooking area. A first electric heating element arranged to provide heat to at least a portion of the first cooking surface, and a second electric heating element is arranged to heat at least a portion of the second cooking surface. The main body portion may include first and second hood members. The first hood member defines the cooking area and the second hood member is positioned at least partially within the cooking area and configured to decrease heat lost from the cooking assembly during preparation of food products in the cooking area. The second hood member is configured for adjustment between an open position providing access to the cooking surface and a closed position covering at least a portion of the cooking surface.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application is a continuation of application Ser. No. 10/803,169, filed Mar. 17, 2004, which application is incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention generally relates to grill assemblies for preparing food products, and more particularly relates to electric grill assemblies and to a dual hood configuration for a grill assembly. 
     2. Related Art 
     Grill assemblies for preparing food products are well known in the art. Generally, many existing grill assemblies provide a cooking compartment that defines an enclosed cooking area (e.g., the primary cooking area). The cooking area can include one or more cooking surfaces that support the food articles during cooking. Typically, a source of thermal energy provides heat to the entire cooking area or to targeted portions of the cooking area. Most existing grill assemblies allow large amounts of heat loss to the outside environment and fail to minimize wind currents that can disrupt the cooking process within the cooking area of the grill. Further, most existing grills require a combustible fuel such as natural gas, propane, briquettes, or wood. Although burning a combustible fuel may provide additional flavor to the food being cooked, grill assemblies that combust fuel are typically not suited for use inside living structures and are prohibited in many housing complexes (e.g., condominium and apartment complexes). The use of electric cooking assemblies that generate sufficient heat for grilling purposes typically requires a 220-240V power source, which makes grilling using electricity as a source of heat impractical in many outdoor cooking situations. Improvements in cooking assemblies that address these shortcomings are, therefore, sought. 
     SUMMARY OF THE INVENTION 
     The present invention relates generally to grill assemblies for preparing food products, and more particularly relates to an electric grill assembly and to a dual hood configuration for a grill assembly. 
     One aspect of the invention relates to an electric cooking assembly configured for preparing food products. The cooking assembly includes a main body portion defining a cooking area including a first cooking surface and a second cooking surface, a first electric heating element arranged and configured to provide heat to at least a portion of the first cooking surface, and a second electric heating element configured to heat at least a portion of the second cooking surface. The first and second electric heating elements may be separately controlled such that only one heating element is operable at a given time, or may be controlled in any other combination or sequence of use. 
     Another aspect of the invention relates to a method of manufacturing a grill assembly that includes a main body portion defining a cooking area, first and second cooking surfaces, and first and second electric heating elements. The method includes the steps of arranging the first electric heating element to heat at least a portion of the first cooking surface, arranging the second electric heating element to heat at least a portion of the second cooking surface, and controlling the first and second heating elements independent from each other 
     A further aspect of the invention relates to a method of assembling a cooking apparatus that including a main body portion, first and second cooking surfaces, first and second electric heating elements, and a control member. The main body portion includes a base member and a hood member that together define a cooking area. The method includes positioning the first and second cooking surfaces in the cooking area, positioning the first electric heating element in the cooking area between the first cooking surface and the base member, and coupling the second electric heating element to the second cooking surface. The method also includes coupling the control member to the first and second electric elements to control current flow to the first and second electric elements to maximize heat generation in the cooking area with a minimum amount of current flow. 
     A further aspect of the invention relates to a cooking assembly for preparing food products that includes a main body portion having a base member and a first hood assembly that together define a cooking area, a cooking surface, and a second hood assembly. The first hood assembly is adjustable relative to the base member to provide access to the cooking area, the cooking surface is positioned within the cooking area, and the second hood assembly is positioned at least partially within the cooking area between the cooking surface and the first hood assembly. The second hood assembly may be adjustable between an open position wherein the cooking surface is accessible and a closed position wherein the second hood member covers at least a portion of the cooking surface. 
     Another aspect of the invention relates to an electric grill configured for cooking food products that includes a base member, an electric heating element positioned in the base member, a first hood coupled to the base member thereby defining a cooking area between the base member and the first hood, a cooking surface positioned vertically above the electric element between the base member and the first hood, and a second hood positioned at least partially within cooking area. The second hood may be adjustable between an open position wherein the cooking surface is accessible and a closed position wherein at least a portion of the cooking surface is covered. 
     A further aspect of the invention relates to a cooking assembly configured for preparation of food products that includes a housing having a first hood member and a base member that define a cooking area, an electric heating element positioned in the cooking area, a cooking surface positioned in the cooking area, and a second hood member positioned within the cooking area and configured to decrease heat lost from the housing during preparation of food products in the cooking area. The second hood member is configured for adjustment between an open position providing access to the cooking surface and a closed position covering at least a portion of the cooking surface. 
     The above summary of the present invention is not intended to describe each disclosed embodiment or every implementation of the present invention. Figures in the detailed description that follow more particularly exemplify embodiments of the invention. While certain embodiments will be illustrated and described, the invention is not limited to use in such embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which: 
         FIG. 1  is a top perspective view of an example grill assembly made in accordance with principles of the present invention with the hood in a closed position; 
         FIG. 2  is a top perspective view of the grill assembly shown in  FIG. 1  with the hood in an open position; 
         FIG. 3  is an exploded top perspective view of the grill assembly shown in  FIG. 1 ; 
         FIG. 4  is a top view of the grill assembly shown in  FIG. 1 ; 
         FIG. 5  is a front view of the grill assembly shown in  FIG. 1 ; 
         FIG. 6  is a cross-sectional front view of the grill assembly shown in  FIG. 4  taken along cross-sectional indicators  6 - 6 ; 
         FIG. 7  is a side view of the grill assembly shown in  FIG. 1 ; 
         FIG. 8  is a top view of the grill assembly shown in  FIG. 2 ; 
         FIG. 9  is a front view of the grill assembly shown in  FIG. 2 ; 
         FIG. 10  is a side view of the grill assembly shown in  FIG. 2 ; 
         FIG. 11  is a bottom view of the sear plate shown in  FIG. 3 ; 
         FIG. 12  is a front view of the sear plate shown in  FIG. 3 ; 
         FIG. 13  is a cross-sectional view of another example sear plate according to principles of the present invention with the heating element embedded in the plate member. 
         FIG. 14  is a top view of an example hood assembly made in accordance with principles of the present invention with the outer hood closed; 
         FIG. 15  is a front view of the hood assembly shown in  FIG. 14 ; 
         FIG. 16  is a side view of the hood assembly shown in  FIG. 14 ; 
         FIG. 17  is a cross-sectional side view of the hood assembly shown in  FIG. 14  taken along cross-sectional indicators  17 - 17  with the inner hood closed; 
         FIG. 18  is a cross-sectional side view of the hood assembly shown in  FIG. 14  taken along cross-sectional indicators  18 - 18  with the inner hood open; 
         FIG. 19  is a top view of the hood assembly shown in  FIG. 14  with the outer hood open and the inner hood closed; 
         FIG. 20  is a front view of the hood assembly shown in  FIG. 19 ; 
         FIG. 21  is a side view of the hood assembly shown in  FIG. 19 ; 
         FIG. 22  is a cross-sectional side view of the hood assembly shown in  FIG. 18  taken along cross-sectional indicators  22 - 22 ; 
         FIG. 23  is a top view of the hood assembly shown in  FIG. 14  with the outer hood open and the inner hood open; 
         FIG. 24  is a front view of the hood assembly shown in  FIG. 23 ; 
         FIG. 25  is a side view of the hood assembly shown in  FIG. 23 ; 
         FIG. 26  is a cross-sectional side view of the hood assembly shown in  FIG. 19  taken along cross-sectional indicators  26 - 26 ; and 
         FIG. 27  is a front perspective view of the grill assembly shown in  FIG. 1  in combination with an example grill stand assembly. 
     
    
    
     While the invention is amenable to various modifications and alternate forms, specifics thereof have been shown by way of example and the drawings, and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention. 
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The present invention relates generally to grill assemblies for preparing food products, and more particularly relates to an electric grill assembly and grill assemblies having a dual hood configuration. One grill assembly configuration includes first and second cooking surfaces that are heated by separate electric elements. Typically, either the first or the second electric heating element is used at a given time to heat respective first and second heating surfaces in order to provide sufficient heat when using a standard 110 to 120 V power source. The first and second electric heating elements may have different configurations that may relate directly to the structure of the cooking surfaces. For example, when the first cooking surface is a standard grilling grate, the first electric element may be a serpentine shaped electric element that is spaced vertically below the grill grate. This configuration provides heating of the food articles being cooked on top of the cooking surface by heat provided by the electric element through the space between the grate structures and with heat conducted through the grate structure material. When the second cooking surface is a sear plate made from a cast metallic material, and the second electric element may be embedded in the structure of the second cooking surface. This configuration may be well suited for providing high temperatures in the sear plate while using the same or similar amounts of power as is required for an electric element associated with a grill grate cooking structure. Thus, the grill assembly of the present invention may have different heating element configurations and different cooking surface structures while using a common source of power. 
     Another aspect of the invention relates to a grill hood assembly that is configured for improved containment of heat within the grill assembly. This improved hood assembly includes an outer hood member that is movable between open and closed positions, and an inner hood member that is positioned within an enclosed space defined by the outer hood member and is also movable between open and closed positions to provide access to the cooking surface covered by the outer and inner hood members. Example hood assemblies of the present invention are described below in further detail with reference to the Figures. Reference to the various embodiments does not limit the scope of the present invention, which is limited only by the scope the claims attached hereto. 
     As used herein, the term “hood” is defined as any structure used to cover or enclose other parts or features such as the cooking surface of a grill assembly. The term “cooking surface” is defined as any surface adapted and configured for cooking or heating different types of food articles. The term “electric element” or “electric heating element” is defined as a structure that generates heat in the presence of an applied current or voltage. The term “cooking area” is a defined space in which sufficient heat exists in order to cook or warm food articles and is typically associated with a cooking surface and a heat source. The term “food products” or “food articles” is generally meant to include any consumable products such as meats, vegetables, fruits, or other food products capable of being cooked and/or heated using a cooking assembly such as a grill. 
     Referring now to  FIGS. 1-12 , an example grill assembly  10  is shown in various views with the hood assembly members in opened and closed positions. The grill assembly  10  includes a hood assembly  12 , a base  14 , first and second cooking structures  16 ,  18 , first and second electric heating elements  20 ,  22 , a spill tray  24 , and a control assembly  26  (see  FIG. 3 ). The hood assembly  12  includes a hood  30 , a base  32 , and a handle  34 . The hood  30  is movable relative to the base  32  in the direction A (see  FIGS. 7 and 10 ) using the handle  34  to provide access to a cooking area  46  (see  FIG. 6 ) between the hood assembly  12  and the base  14 . The base  14  includes a side wall  40  defining an outer circumference of the base, a floor  42 , and an intermediate wall  44  that divides the base  14  into separate cavities sized for the first and second cooking structures  16 ,  18 . 
     The first cooking structure  16  includes a plurality of grate members  50  that are held together with cross supports  52 . The first cooking structure  16  may be made from materials common to grilling assemblies such as, for example, stainless steel. The second cooking structure  18  is a plate-like structure having an upper surface  60  configured for searing food articles, and an opposing lower surface  62 . The second electric heating element  22  may be mounted directly to the lower surface  62  (see  FIGS. 11 and 12 ). In another embodiment (see the cross-sectional view of  FIG. 13 ), a heating element  222  may be embedded within or otherwise permanently coupled to a second cooking structure  218 . The second cooking structure  18  may be made of cast aluminum or other heat absorbing material such as stainless steel or other metal alloy. Preferably, the second cooking structure  18  can obtain cooking temperatures on the upper surface  60  of about 500 to about 800° F. using a power source that provides about 1,000 to 1,400 W using about 10 to about 12 A of current. More preferably, the second cooking structure  18  attains a temperature of about 700 degrees Fahrenheit using up to about 1,100 watts of power and about 10 amps of current. 
     The first electric element  20  preferably defines a shaped structure (for example, a contoured shaped structure) that provides a relatively even amount of heat across the first cooking structure  16 . The first electric heating element  20  is preferably spaced vertically below the first cooking structure  16 , but may be in contact with features of the first cooking structure such as the cross supports  52  (see  FIG. 6 ). The first electric heating element provides cooking temperatures within the cooking area  46  in the range of about 300 to about 500° F. using up to about 1350 W of power at about 10 to 12 A of current. 
     According to the configuration of the first and second electric heating elements  20 ,  22 , at least two separate cooking conditions can be provided within the grill assembly  10  using the same power source (e.g., a common 110 to 120 V power source). Because the available power using a 110 to 120 V source is relatively low while the desired cooking temperatures for the first and second cooking structure  16 ,  18  is relatively high, it may be necessary to use only one of the first and second electric heating elements  20 ,  22  at any given time. However, if a greater power source is available (e.g. 220 to 240 V power source), it may be possible to power both electric heating elements at the same time while providing the desired temperatures. A greater power source may also make possible the use of larger heating elements for a larger cooking area or a greater number of heating elements. In either case, the example grilling assemblies disclosed herein provide improved heat generating efficiency for the power source provided. 
     In some embodiments, the power being supplied to the first and second heating elements  20 ,  22  can be regulated with, for example, a rheostat, to control the temperature being used to cook the food article. For example, the food article may require a lower or specific cooking temperature and the power can be regulated to reach that temperature. 
     The spill tray  24  is positioned below the first cooking structure  16  and includes a side wall  70 , a floor  72 , and a handle  74 . The spill tray  24  is configured for collecting grease and other by-products that fall from the food articles being cooked. The spill tray  24  may be made from a material having a high reflectivity so as to reflect heat that is emanating from the first electric heating element  20  towards the floor  42  of the base  14  back toward the food articles being cooked on the first cooking surface  16 . The spill tray  24  may be easily removable from the base  14  using the handle  74 . A heat reflective member (not shown) that is separate from or replaces the spill tray  24  may be positioned within the base  14  (e.g., below first electric element  20 ) or may be positioned adjacent to the hood  30  and base  32  of the hood assembly  12  to reflect heat generated by the first and second electric heating elements  20 ,  22  back toward the cooking structures  16 ,  18 . 
     The control assembly  26  includes a panel member  80 , first and second temperature controls  82 ,  84 , an on/off power switch  86  and a power allocation switch  88 . The switches and controls  82 ,  84 ,  86  and  88  are merely exemplary of those control features that may be necessary and useful with the grill assembly  10 . The first and second temperature controls  82 ,  84  may be used to control the amount of power provided to the respective first and second electric heating elements  20 ,  22 . The power allocation switch  88  may be used to allocate power to one or the other or both of the first and second electric heating elements  20 ,  22 . If power is allocated to both the first and second electric heating elements  20 ,  22 , a differential power can be used to provide, for example, more power to the first heating element  20  to increase the temperature of the first electric heating element  20  and less power to the second electric heating element to lower the temperature of the second electric heating element  22 . The on/off power switch  86  may be used as master power control to the grill assembly  10  for safety purposes in the event that the first and second temperature controls  82 ,  84  are not turned to the off position at the completion of cooking the food articles. 
     In some embodiments, the second electric heating element  22  may be configured so that there is no variation in the temperature of the second cooking structure  18 . In such a configuration, the power allocation switch  88  may be used to either turn the second electric heating element on or off, and when in the off position power is allocated to the first electric heating element  20 . According to this configuration, the second temperature control  84  may be a timer rather than a temperature control. In one embodiment, the timer can be used simply to measure cooking time. In another embodiment, the timer can be coupled to the power source to regulate the length of time the first and second heating elements  20 ,  22  are supplying heat in the grill. For example, the timer can be set to a thirty minutes and at the end of the thirty minutes power is shut off to the first and second heating elements  20 ,  22 . 
     In still further embodiments, the grill assembly may include a temperature gauge (not shown) that monitors the temperature within the cooking area  46 . The control assembly  26  may further include a controller that includes a programmable microprocessor and memory and is capable of automatically controlling certain features of the grill assembly  10 . For example, such a controller may be used to monitor the temperature within the cooking area  46  and automatically alter the power allocation to the first and second electric heating elements  20 ,  22  to maintain a pre-determined temperature within the cooking area. In another example, the controller may be used to provide cooking options and cooking information at a display screen (e.g., options for cooking times and temperatures) that can be viewed and implemented upon selection by the user. 
     The grill assembly  10  may be used in combination with a grill stand assembly  90  as shown in  FIG. 27 . Stand assembly  90  includes a base  92  in the form of a refrigerator, first and second trays  94 ,  96 , and a light fixture  98 . The refrigerator  92  may include wheels  100 , a door  102 , a handle  104 , and a casing  106  sized to receive food articles. The refrigerator  92  and light fixture  98  may be powered by the same power source (e.g., a 110 to 120 V power source) used to power the grill assembly  10 . In order to provide the necessary power requirements for the heating elements of the grill assembly, the refrigerator  92  may be automatically powered off in when the grill assembly features are turned on. In most instances, turning off the refrigerator  92  should not be problematic for keeping the refrigerated food articles cold because grill assemblies are commonly used for only a short period of time (e.g., about an hour or less) when preparing food articles. 
     The first and second trays  94 ,  96  may be movable between upright positions as shown in  FIG. 27  and retracted positions in which they lay flat against sides of the refrigerator  92 . In other embodiments, the trays  94 ,  96  may have integrated therein separate heating elements such as a hot plate style heating element for preparing food outside of the cooking area  46 . Thus, the stand assembly  90  may provide multiple functions and may be movable via the wheels  100  to convenient cooking locations both inside and outside of a living structure, while also providing additional refrigerator space. 
     Another example grill assembly embodiment (not shown) that incorporates principles of the present invention includes an adjustable electric heating element that is movable within the cooking area between different positions relative to the cooking structures. 
     Referring now to  FIGS. 14-26 , an alternate hood assembly  112  is shown in various open and closed positions. Hood assembly  112  includes first and second outer hood member  120 ,  122  and first and second inner hood members  130 ,  132 . The first outer hood member  120  includes a handle  124  and a temperature gauge  126  mounted thereon and is movable in a direction B (see  FIGS. 18 and 22 ) relative to the second outer hood member  122 . The first inner hood member  130  is movable in the direction C (see  FIGS. 17 and 18 ) relative to the second inner hood member  132  and may include a flap/cover member  134  coupled to an end thereof. 
       FIGS. 14-18  illustrate the first outer hood member  120  in a closed position in which the first and second outer hood members  120 ,  122  would preferably completely cover the cooking surfaces of the grill assembly (not shown) associated with the hood assembly  112 . For example, hood assembly  112  may take the place of hood assembly  12  and be configured to cover the first and second cooking surfaces  16 ,  18  in the grill assembly  10  shown in  FIGS. 1-12  described above. Hood assembly  112  may also be used with the grill assembly shown and described in U.S. patent application Ser. No. 09/885,360 filed on Jun. 20, 2001, and entitled COOKING ASSEMBLY HAVING MULTIPLE COOKING MODALITIES, which application is incorporated herein by reference in its entirety. 
     The first and second outer hood members  120 ,  122  define a first cooking area  140  within which the first and second inner hood members  130 ,  132  are positioned. When the first outer hood member  120  is in a closed position, the first inner hood member  130  is movable between a closed position as shown in  FIG. 17  and an open position as shown in  FIG. 18 . When both the first outer hood member  120  and first inner hood member  130  are in a closed position and the flap  134  is in a horizontal position covering the otherwise uncovered cooking surface in the space defined by distance X in  FIG. 17 , the hood assembly  112  provides a dual hood configuration in which the cooking area  150  has two insulating layers. Hood assembly  112  can sustain higher temperatures within cooking area  150  with less power or heat because there is less heat loss than in typical grill assemblies. These advantages can result in shorter cooking times and lower operating costs. 
     To gain access to a cooking surface within the second cooking area  150 , the first outer hood member  120  must be raised as shown in  FIGS. 19-22 , and then the first inner hood member  130  must be raised as shown in  FIGS. 23-26 . In some types of cooking applications it may be advantageous to close one or the other of the first hood members  120 ,  130  depending on a number of factors including, for example, the desired size of the cooking surface to be used, the desired cooking time and/or temperature, or the convenience or inconvenience of opening one versus two hood members to gain access to the cooking surface. 
     As mentioned above, the flap  134  may be used to cover specific portions of the cooking surface over which the hood assembly  112  is positioned. The flap  134  may be adjusted from a retracted position as shown in  FIGS. 17-22  to a downward, covering position (not shown) to cover a portion of the cooking surface. 
     In some embodiments, the first and second inner hood members  130 ,  132  may extend across only a portion of the hood assembly width (not shown) rather than extending across the entire width W as shown in  FIGS. 14-26 . Such a reduced width inner hood assembly may be useful in combination with a grill assembly that includes separate cooking surfaces such as grill assembly  10 , wherein there may be a preference to provide a dual hood configuration for either the first or second cooking surface  16 ,  18 . 
     The present invention should not be considered limited to the particular examples or materials described above, but rather should be understood to cover all aspects of the invention as fairly set out in the attached claims. Various modifications, equivalent processes, as well as numerous structures to which the present invention may be applicable will be readily apparent to those of skill in the art to which the present invention is directed upon review of the instant specification.