Patent Publication Number: US-2016220066-A1

Title: Accessories for barbeque grill

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Application No. 61/727,857 filed Nov. 19, 2012, the contents of which are incorporated by reference herein; U.S. Utility application Ser. No. 14/082,465, filed Nov. 18, 2013; the contents of which are incorporated by reference herein; and U.S. Provisional Application No. 62/147,828, filed Apr. 15, 2015, the contents of which are incorporated by reference herein. 
    
    
     TECHNICAL FIELD AND BACKGROUND OF THE INVENTION 
     This application relates to accessories for use with barbeque grills. In particular, the disclosure of this application relates specifically to accessories designed for use with a kamado-type grill product. The most well-known and popular such grill is marketed under the trademark Big Green Egg. Such grills include a generally egg-shaped outer shell within which are contained various components intended to permit various types of food to be cooked in various ways. This invention provides several interior components that are designed to provide maximum utility of the grill for differing cooking methods while maintaining and maximizing the interior capacity of the grill in a manner not presently available. 
     SUMMARY OF THE INVENTION 
     It is therefore an object of the present invention to provide a grill insert according to several alternatives that permits the level of the charcoal-created fire to be raised to a height closer to the grille grate on which the food is being cooked. 
     According to one preferred embodiment of the invention, a barbeque accessory assembly for use with a barbeque grill is provided. The barbeque grill is of the type having an enclosure within which is contained a fire ring positioned over a fire box, and a grill grate positioned in vertically spaced relation above the fire ring. The accessory assembly includes a deflector plate adapted for being positioned in the enclosure between the grill grate and the fire box, and a plurality of openings extending around the periphery of the deflector plate for permitting heat and smoke to rise along the sides of the grill above the level of the deflector plate into an area of the grille grate where the food is being cooked or smoked. 
     According to another embodiment of the invention, the openings in the deflector plate communicate with an outer peripheral edge of the deflector plate. 
     According to another embodiment of the invention, the openings in the deflector plate communicate with an outer peripheral edge of the deflector plate, and comprise crenellations formed by bending segments of the edge of the deflector plate out of a plane defined by a major surface of the deflector plate. 
     According to another embodiment of the invention, the deflector plate comprises first and second semicircular plate segments. 
     According to another embodiment of the invention, the accessory assembly includes a component base for being positioned in the enclosure above the fire box and below the grille grate, and adapted for receiving and supporting the deflector plate. 
     According to another embodiment of the invention, a component bar is provided for extending across the component base from a first side to a second side. The component bar includes a slot for receiving a mating tab formed on a bottom surface of the deflector plate for being inserted in the slot. 
     According to another embodiment of the invention, the enclosure and the grille grate are circular in horizontal cross-section. 
     According to another embodiment of the invention, the openings in the deflector plate extend in an equally-spaced configuration around the periphery of the deflector plate. 
     According to another embodiment of the invention, the deflector plate is circular and sized to fit into the grille enclosure in a closely-fitting position above the fire box and below the grille grate. 
     According to another embodiment of the invention, a barbeque accessory assembly for use with a barbeque grill is provided, the barbeque grill being of the type having an enclosure within which is contained a fire ring positioned over a fire box, and a grill grate positioned in vertically spaced relation above the fire ring, and comprising a basket adapted for being positioned and supported in the enclosure above the firebox and below the grille grate. 
     According to another embodiment of the invention, the basket is sized to be supported on a top surface of the fire box. 
     According to another embodiment of the invention, the basket includes vertically extending sidewalls adapted to extend upwardly away from the fire box and towards the grill grate. 
     According to another embodiment of the invention, the basket includes vertically extending sidewalls adapted to extend upwardly away from the fire box and towards the grill grate, and a flange positioned on the basket above the sidewalls and adapted to rest on an upper peripheral surface of the fire ring above the fire box and below the grill grate, with a bottom of the basket extending below the upper peripheral surface of the fire ring. 
     According to another embodiment of the invention, the enclosure and the grille grate are circular in horizontal cross-section and wherein the shape of the basket is selected from the shapes consisting of semicircular in horizontal cross-section and circular in cross-section. 
     According to another embodiment of the invention, the accessory assembly includes a support ring adapted for being positioned on an annular top surface of the fire ring and on which the basket is adapted to rest during use. 
     According to another embodiment of the invention, the support ring is formed of two semicircular ring segments. 
     According to another embodiment of the invention, a basket is provided, and is adapted for being placed in a barbeque grill of the type comprising an enclosure within which is contained a fire ring positioned over a fire box, and a grill grate positioned in vertically spaced relation above the fire ring, the basket further adapted for being positioned and supported in the enclosure above the firebox and below the grille grate. 
     According to another embodiment of the invention, the basket is sized to be supported on a top surface of the fire box. 
     According to another embodiment of the invention, the basket includes vertically extending sidewalls adapted to extend upwardly away from the fire box and towards the grill grate. 
     According to another embodiment of the invention, the basket includes vertically extending sidewalls adapted to extend upwardly away from the fire box and towards the grill grate, and a flange positioned on the basket above the sidewalls and adapted to rest on an upper peripheral surface of the fire ring above the fire box and below the grill grate, with a bottom of the basket extending below the upper peripheral surface of the fire ring. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will be more fully understood when taken in connection with the following drawings: 
         FIG. 1  is an exploded view of one embodiment of a grill with which the invention is used; 
         FIG. 2  is an exploded view of the component bar and component bar receiving bracket according to one embodiment of the invention; 
         FIG. 3  shows two views of the placement of the component bar receiving bracket between the fire ring and the firebox; 
         FIG. 4  is a top view of the firewall deflector plate according to one embodiment of the invention; 
         FIG. 5  is a side view of the firewall deflector plate according to one embodiment of the invention; 
         FIG. 6  is a top view of a deflector plate according to one embodiment of the invention; 
         FIG. 7  is a side view of the deflector plate shown in  FIG. 6  according to one embodiment of the invention; 
         FIG. 8  is a top view of a drip pan rack according to one embodiment of the invention; 
         FIGS. 9 and 10  are perspective views of the firewall deflector plate and component bar in a drip pan rack configuration; 
         FIG. 11  is a perspective view showing the firewall deflector plate and component bar in a full deflection configuration; 
         FIG. 12  is a side elevation showing placement of the deflector plates in the component bar in the full deflection configuration; 
         FIG. 13  is a perspective view of a roasting tower attachment for cooking food items; 
         FIG. 14  is a perspective view of a rib tower arrangement for ribs in a vertical orientation. 
         FIG. 15  is a composite view of an assembly base, deflector plate and component bars according to an embodiment of the invention; 
         FIG. 16  is a perspective view of a divider plate that fits into the component bar and sits on the assembly base, shown in a fragmentary view; 
         FIG. 17  is an exploded, fragmentary view of a basket support bracket assembly that fits onto the assembly base, shown in a fragmentary view; 
         FIG. 18  is an exploded view, with parts broken away and certain components separately illustrated for clarity, of an alternative embodiment of a grill including accessories according to a preferred embodiment of the invention; 
         FIG. 19  is a top plan view of the interior of the grill shown in  FIG. 18 ; 
         FIG. 20  is a top plan view according to  FIG. 19  with a basket in place on one side of the grill; 
         FIG. 21  is a top plan view according to  FIG. 20  with a grill grate positioned over the basket; and 
         FIG. 22  is view looking into the fire box, showing the support rings in position on the top rim of the fire box, the charcoal basket in position on the support rings and the grille grate on which the food is placed positioned on the fire ring. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring now to  FIG. 1 , a kamado-type barbeque grill  10  of one type with which the accessories according to the invention can be used is described. Grill  10  includes a lid  20 , a base  30 , a damper top  40 , and a fuel assembly  50 . 
     Lid  20  includes a chimney  21 , a bottom edge  22 , and a handle  23 . Lid  20  is substantially dome shaped. Chimney  21  protrudes outwardly from the top of lid  20  and defines a cylindrical opening  24 . Opening  24  communicates with the interior of lid  20 . 
     Base  30  is an inverted dome-shaped structure including a flat bottom  31  and an annular upper edge  32 . 
     Damper top  40  is releasably connectable with chimney  21  and aligns with opening  24 . When connected to chimney  21 , damper top  40  is used to regulate the upward flow of heated air, and/or smoke through opening  24  of chimney  21 . In a closed position, damper top  40  can completely or substantially prevent the flow of heated air, and/or smoke outwardly from the interior of lid  20 . 
     Fuel assembly  50  includes a fire box  55 ; a fire grate  65 , a fire ring  70 , and a grill grate  80 . When assembled, the fuel assembly  50  fits inside the base  30  and is covered by lid  20 . Fire box  55  includes a bowl  56 , supports  57 , and a flange  58 . Bowl  56  has several openings  59  in its side walls to allow for the flow of air into and out of fire box  55 . 
     Fire grate  65  is substantially disc-shaped and has a plurality of perforations  66 . Fire grate  65  provides a durable surface for igniting and burning heating fuel such as, for example, charcoal and wood. Perforations  66  allow air to flow through grate  65  in order to support combustion of the fuel. 
     Fire ring  70  sits on top of the flange  58  of the fire box  55  and provides the proper amount of spacing between the fuel and the food being cooked. The upper edge of fire ring  70  may include several recesses  71 . 
     The grill grate  80  is a substantially circular structure formed of parallel bars  81  held in position by perpendicular cross bars  82 , with an outer diameter that permits it to rest on the top edge of fire ring  70 . 
     Referring now to  FIGS. 2 and 3 , principal components of the novel interior assembly include a component bar receiving bracket  90 , of which two are required, and a component bar  100 , each fabricated from suitable steel or iron material. Each bracket  90  includes a pair of outwardly-extending curved arms  91 ,  92  attached to a curved central body  93  in which is formed a transversely-extending notch  94  and a curved slot  95 . 
     The component bar  100  is elongate and includes two parallel slots  101  and  102 . As shown in  FIG. 2 , one end of the component bar  100  is shaped and sized to fit into the notch  94  of the bracket  90 . 
     Two brackets  90  are positioned with their respective arms  91 ,  92  resting on the top edge of the fire box  55  and held in position by the weight of the fire ring  70  which sits on top of the arms  91 ,  92 . The two brackets  90  are positioned opposite each other on the fire box  55  in the manner described immediately above. The component bar  100  is positioned with opposite end edges fitted into the notches  94  and therefore bisects the interior annular space of the base  30 . Note also in  FIG. 3  that the body  93  of the bracket  90  extends radially-inwardly into the volume of the base  30 . The component bar  100  is thus used to support various attachments that are provided with flanges that fit into the slots  101 ,  102 , as described below. 
       FIG. 4  illustrates a firewall deflector plate  110  that includes a solid steel or iron heat deflector  111  and a support flange  112  that, in one configuration, is inserted into one of the slots  101  or  102  in the component bar  100 . Note that the firewall deflector plate  110  has a bottom edge  113  and a top edge  114  that are parallel to each other. 
       FIG. 5  is a side view of the firewall deflector plate  110  showing deflector  111  and the support flange  112 . 
       FIG. 6  illustrates a deflector plate  120  that includes a solid steel or iron heat deflector  121  and a support flange  122  that, in one configuration, is inserted into one of the slots  101  or  102  in the component bar  100 . Note that the deflector plate  120  has a bottom edge  113  that is arcuate, whereas the top edge  114  is straight. 
       FIG. 7  is a side view of the deflector plate  120  showing deflector  121  and the support flange  122 . 
       FIG. 8  shows a drip pan rack  130  formed of iron or steel bars  131 - 133  varied in length and captured between a support flange  134  and an arcuate bar  135 . 
     Use of the structures shown in  FIGS. 2-8  is illustrated in  FIGS. 9-12 . In  FIG. 9 , the firewall deflector plate  110  is shown, with the deflector  111  inserted into slot  101  of the component bar  100  and supported in a vertical, depending position by the support flange  112 . The deflector  111  has the effect of dividing the fire box  55  in half. If indirect cooking is desired, the fuel can be placed on one side of the deflector  111  and the food placed on the half of the grill grate  80  positioned over the other side of the deflector  111 . As shown in  FIG. 10 , if use of a drip pan is desired, the support flange  134  of the drip pan rack  130  can be placed in the slot  102  of the component bar  100  so that the support bars  131 - 133  extend horizontally outwardly. A drip pan can be placed on the drip pan rack  130  to collect drippings from the food being cooked above on the grill grate  80 . 
     Referring now to  FIGS. 11 and 12 , if full indirect cooking is desired, the two deflector plates  110  and  120  are positioned with the respective support flanges  114  and  124  in the slots  102  and  101  of the component bar  100 . Both deflector plates  110 ,  120  extend horizontally outward and cover the fire box  55 , allowing heat from the fire box  55  to flow upwardly only through a gap around the edge of the base  30  formed by the peripheral edges of the deflector plates  110 ,  120  and the inner surface of the base  30 . 
     Referring now to  FIG. 13 , a roasting tower assembly  140  is illustrated, and includes a pair of tower panels  141 ,  142  that are mounted to the component bar  100  and fit into the respective notches  94  in the two component bars receiving brackets  90 . A support rod  145  is suspended through one of the slots  101 ,  102  in the component bar. A nut or other enlargement on the support rod  145  maintains the support rod  145  at the desired vertical position. As shown, two roasting baskets  147 ,  149  are mounted on the support rod  145  within the area formed by the height of the tower panels  141 ,  142 . Any suitable number of baskets may be used, and if two or more are used, may be stacked on each other or vertically spaced-apart for better air flow. Also, a hole or enlargement of either or both slots  101 ,  102  may be formed in the component bar  100  to receive the support rod  145 , and the tower panels  141 ,  142  may be formed with a curved profile permitting them to be placed in the slots  95  of the component bar receiving brackets  90 . 
     Referring now to  FIG. 14 , a rib tower assembly  150  is illustrated, and includes a pair of curved tower panels  151 ,  152  the bottom ends of which are mounted to the component bar  100  and fit into the respective slots  95  in the two component bars receiving brackets  90 . The top ends of the tower panels  151 ,  152  support the component bar  100 . A support rod  155  is suspended through one of the slots  101 ,  102  in the component bar  100 . A nut or other enlargement on the support rod  155  maintains the support rod  155  at the desired vertical position. Also, a hole or enlargement of either or both slots  101 ,  102  may be formed in the component bar  100  to receive the support rod  155 . 
     The support rod  155  supports a rib rack carousel  160  constructed of suitable iron or steel bar stock and formed as a circle with a peripheral rim  161  on which may be suspended one or more rib racks  164 . Each rib rack  164  includes hooks  166  on which may be fastened food items such as rib sections for cooking. Suspending the ribs vertically enhances cooking time and flavor by permitting the ribs to be basted during cooking as juices drain down the sides of the ribs. 
     Referring now to  FIGS. 15-17 , further accessories for use with the grill are shown. 
     An assembly base  170  is provided for fitting on and being supported by the flange  58 . See  FIG. 1 . The assembly base  170  includes a pair of upwardly extending tabs  172 ,  174  adapted to receive and support a component bar  176  that includes a pair of mating slots  178 ,  180  for receiving the tabs  172 ,  174 . The component bar  176  also includes an elongate slot  182  extending down its length that can be used to support any desired attachment. 
     For example, a deflector plate  190  may be inserted into the slot  182 . The deflector plate  190  includes two deflector segments  190 A,  190 B that include downwardly-extending flanges  192 A,  192 B that extend into the slot  192 . The deflector plate  190  also includes a series of crenellations  194  that permit heat and smoke to rise indirectly and along the sides of the grill above the level of the deflector plate  190  into the area where the food is being cooked or smoked. 
       FIG. 16  illustrates a further embodiment of the invention. An assembly base  200 , shown fragmentarily, includes an interior slot  202  that supports the component bar  176 . The slot 178  fits into the slot  202  of the assembly base  200  and is retained by the upwardly-extending tab  204  in the slot  202 . The other side of the assembly base  200  mirrors the slot  202  and supports the other end of the component bar  176 . As also shown in  FIG. 16 , the component bar  176  can be used to support a divider plate  210  that includes a divider portion  212  that separates the area of the grill  10  below the component bar  200  into two zones. One zone may contain either no combustible material, or the two zones may contain differing amounts of combustible material in order to permit different amounts of heat to rise upwardly in different areas of the grill  10 . The divider portion is supported by a support  214  that rests on the top surface of the component bar  176 . 
     As shown in  FIG. 17 , an assembly base  220  with a slot  222  in its upper side is provided for supporting a bracket  224  that includes a tab  226  that fits into the slot  222 . The bracket  224  has a curve that extends radially-inwardly into the central area of the grill  10 , and includes a notch  228  in its end that supports a vertically-extending post  230 . The post  230  has a series of openings  234  vertically-spaced along its length from which accessories may be suspended. The post is supported in the notch  228  by an enlarged head  236 . The other side of the assembly base  220  mirrors the slot  222  and supports the other end of the component bar  176 . 
     Referring now to  FIG. 18 , Referring now to  FIG. 1 , a kamado-type barbeque grill  250  of one type with which the accessories according to the invention can be used is described. Grill  250  includes a lid  260 , a base  270 , a damper top  280 , and a fuel assembly  290 . 
     Lid  260  includes a chimney  262 , a bottom edge  264 , and a handle  266 . Lid  260  is substantially dome shaped. 
     Base  270  is an inverted dome-shaped structure including a flat bottom  272  and an annular upper edge  274 . 
     Damper top  280  is releasably connectable with chimney  262 . When connected to chimney  262 , damper top  280  is used to regulate the upward flow of heated air, and/or smoke through the chimney  262 . In a closed position, damper top  280  can completely or substantially prevent the flow of heated air, and/or smoke outwardly from the interior of lid  260 . 
     Fuel assembly  290  includes a fire box  292 ; a fire grate  294 , a fire ring  296 , and a grill grate  298 . When assembled, the fuel assembly  290  fits inside the base  270  and is covered by lid  280 . Fire box  292  has several openings  300  in its side walls to allow for the flow of air into and out of fire box  292 . 
     Fire grate  294  is substantially disc-shaped and has a plurality of perforations  302 . Fire grate  294  provides a durable surface for igniting and burning heating fuel such as, for example, charcoal and wood. Perforations  302  allow air to flow through fire grate  294  in order to support combustion of the fuel. 
     Fire ring  296  sits on top of a flange  304  of the fire box  292  and provides the proper amount of spacing between the fuel and the food being cooked. The upper edge of fire ring  296  may include several recesses  306 . 
     The grill grate  298  is a substantially circular structure formed of parallel bars  308  held in position by perpendicular cross bars  310 , with an outer diameter that permits it to rest on the top edge of fire ring  296 . 
     As shown in  FIG. 19 , first and second support rings  312 ,  314  are sized and shaped in an arcuate configuration to fit on the upper lip of the fire box  292 , as shown. 
     As shown in  FIG. 20 , a charcoal basket  320  is positioned into the fire box  292  and is supported on the support rings  312 ,  314 . The basket  320  has a semicircular bottom  322  with slots  324  to allow air flow through the bottom  322 . The basket  320  also has slotted sidewalls  326  that extend upwardly from the bottom  322 , and which conform generally in shape to the shape of the semicircular bottom  322 . 
     Charcoal is placed in the basket  320  and is lit to create a fire much closer to the food-supporting grill grate  298  than is typical, therefore allowing quicker cooking and/or searing of the food, when desired, and with less charcoal usage. In the configuration shown in  FIG. 21 , the grill grate  298  is placed on top of the fire ring  296 , so that half of the grill grate  298  is exposed to heat from the charcoal, if any, in the bottom of the base  270  and half is exposed to heat from the closer fire in the basket  320 . Alternatively, no charcoal need be lit in the bottom of the base  292 . 
     A further alternative is to place two baskets  320  on the support rings  312 ,  314  so that the entire grill is used with a fire that is closer to the food on the grill grate  298 , allowing quicker cooking, and/or searing of the food. 
     Alternatively, a pan can be placed in the basket  320  with water when cooking indirectly. 
     Alternatively, two baskets  320  can be placed on the support rings  312 ,  314  so that pans with water can be placed in both pans for indirect cooking. 
     Alternatively, as shown in  FIG. 22 , a basket  330  is shown, fabricated with a bottom  332 , sidewalls  324  and a raised, arcuate support rim  326 . In this arrangement, the support rim  326  is positioned on the upper lip of the fire ring  296  and the bottom  332  and the sidewalls  324  are suspended into the fire ring  296 . The basket  330  can be used as described above, namely to hold charcoal and to place the fire closer to the grill grate  298 . This allows much less fuel to be consumed, and creates a hotter fire that can place a quick sear onto the meat being grilled. Then, the meat can be moved to the other side of the grill grate  298  to allow the meat to cook more slowly to the desired degree of doneness. The basket  330  can also be used to support a pan of water while indirect cooking is taking place. In this example, the charcoal is located on the grate  294  near the bottom of the base  270 . Basket  330  is shown in place in the grill  250  of  FIG. 18 . 
     Barbeque grill accessories according to the invention have been described with reference to specific embodiments and examples. Various details of the invention may be changed without departing from the scope of the invention. Furthermore, the foregoing description of the preferred embodiments of the invention and best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation, the invention being defined by the claims.