Patent Publication Number: US-2012024280-A1

Title: Pre-Assembled Barbecue Grill

Description:
FIELD OF THE INVENTION 
     The present invention relates to barbecue grills, and more particularly to barbecue grills that are partially assembled when shipped and sold and can be assembled quickly and easily by a consumer. 
     BACKGROUND OF THE INVENTION 
     Most barbecue grills are shipped and sold in an entirely unassembled state, presumably because the manufacturer does not want to invest cost in making any assembly of the product and because any partial assembly would increase the size of the product and make it more fragile. However, the consumer must assemble the product or pay an extra charge to the retailer to assemble it, and in the latter case must get the assembled product home. Typically, assembly instructions are confusing or complex, assembly takes a long time, and parts may be missing. Some parts or fasteners can be not incorporated, and may create an unsafe condition for the grill, the top case of which is usually quite heavy and could fall during use when an ongoing fire poses a significant safety risk. 
     The above factors weigh in a consumers decision to even purchase the product in the first place. Attempts have been made to offer partially preassembled grills, but they are cumbersome and still require many assembly steps. 
     SUMMARY OF THE INVENTION 
     The present invention provides a partially assembled grill which can be shipped in a box or container on the same order of size as a totally unassembled grill. According the invention, the partially assembled grill needs only a small number of assembly steps and few parts to minimize the burden on a consumer. The partially assembled grill has the potential for making sales to customers who have shied away from a grill purchase due to the complexity and time of assembly of prior grills. 
     Despite being partially assembled when shipped, the fully assembled grill is still strong and safe to operate, especially because the consumer has very few parts to put together and the risk of failing to use all of the intended parts with be minimized. 
     The present invention provides a partially assembled grill comprising a frame unit having a bottom and two sides, one side mounted to pivot on one end of the bottom so that it is folded against the bottom, and the other side mounted to pivot on the other end of the bottom and positioned generally perpendicular to the bottom, to form a partially folded frame, and a grill casing, wherein the partially folded frame unit encloses the grill casing on two adjacent perpendicular surfaces. 
     The present invention provides a partially assembled grill comprising a frame unit having a bottom and two sides, one side mounted to pivot on one end of the bottom so that it is folded against the bottom, and the other side mounted to pivot on the other end of the bottom and positioned generally perpendicular to the bottom, to form a partially folded frame, and a grill casing, wherein the partially folded frame unit encloses the grill casing on two adjacent perpendicular surfaces, wherein the casing has four bottom corners, and wherein each of the four bottom corners includes a pre-mounted fastening element adapted to engage a pre-mounted mating fastening element on each of the four top corners on top of the frame. 
     The invention provides a partially assembled grill comprising a frame unit having a bottom and two sides, one side mounted to pivot on one end of the bottom so that it is folded against the bottom, and the other side mounted to pivot on the other end of the bottom and positioned generally perpendicular to the bottom, to faun a partially folded frame, and a grill casing, wherein the partially folded frame unit encloses the grill casing on two adjacent perpendicular surfaces, wherein the casing has four bottom corners, and wherein each of the four bottom corners includes a pre-mounted fastening element adapted to engage a pre-mounted mating fastening element on each of the four top corners on top of the frame, wherein the fastening element on the grill casing comprises a first type of element comprising a plate which defines a slotted opening and wherein the mating fastening element on the top of the frame unit comprises a first type of mating fastening element comprising a stud adapted to be received in the slotted opening, and a second type of fastening element comprising a latch and wherein the mating fastening element on the top of the frame unit comprises a second type of mating fastening element comprising a hook. 
     The invention provides a partially assembled grill comprising a frame unit having a bottom and two sides, one side mounted to pivot on one end of the bottom so that it is folded against the bottom, and the other side mounted to pivot on the other end of the bottom and positioned generally perpendicular to the bottom, to form a partially folded frame, and a grill casing, wherein the partially folded frame unit encloses the grill casing on two adjacent perpendicular surfaces, wherein the casing has four bottom corners, and wherein each of the four bottom corners includes a pre-mounted fastening element adapted to engage a pre-mounted mating fastening element on each of the four top corners on top of the frame, wherein the fastening element on the grill casing comprises a first type of element comprising a plate which defines a slotted opening and wherein the mating fastening element on the top of the frame unit comprises a first type of mating fastening element comprising a stud adapted to be received in the slotted opening, and a second type of fastening element comprising a latch and wherein the mating fastening element on the top of the frame unit comprises a second type of mating fastening element comprising a hook, wherein two of the first type of fastening elements and mating fastening elements are provided on the front corners of the casing and stand, and wherein two of the second type of fastening elements and mating fastening elements are provided on the back corners of the casing and stand. 
     The invention provides a method of packaging a partially assembled grill comprising locating a frame unit having a bottom and two sides, so that one side mounted to pivot on one end of the bottom so that it is folded against the bottom, and the other side is mounted to pivot on the other end of the bottom and positioned generally perpendicular to the bottom, to form a partially folded frame, and locating a grill casing so that the partially folded frame unit encloses the grill casing on two adjacent perpendicular surfaces. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a grill and stand folded in a packed configuration for shipping; 
         FIG. 2  is a perspective view like that of  FIG. 1 , but exploded; 
         FIG. 3  is a perspective view of the stand in its folded and shipped position; 
         FIG. 4  is a perspective view of the stand in a further stage of unfolded assembly than in  FIG. 3 ; 
         FIG. 5  is a perspective view of the stand in a further stage of assembly than in  FIG. 4 ; 
         FIG. 6  is a perspective view of the stand in a further stage of assembly than in  FIG. 5 ; 
         FIG. 7  is a perspective view of the stand in a further stage of assembly than in  FIG. 6 ; 
         FIG. 8  is a perspective view of the stand in a final stage of assembly; 
         FIG. 9  is a side view of the stand with the firebox casting unattached above; 
         FIG. 10  is a side view like that of  FIG. 9  with the firebox on top of the stand but not yet in a final mounted position; 
         FIG. 11  is a side view like that of  FIG. 10  with the firebox on top of the stand in a final position; 
         FIG. 12  is a side view like that of  FIG. 11 , with a locking latch in an unlatched position; 
         FIG. 13  is a side view like that of  FIG. 12 , with a locking latch in a latched position; and 
         FIGS. 14-18  show an alternate arrangement for a stand different from the arrangement in  FIGS. 3-8 . 
     
    
    
     DESCRIPTION OF THE EMBODIMENT 
     An embodiment of the present invention will now be described, but the invention is not limited to this embodiment. 
     The present invention provides a partially assembled grill comprising a frame unit having a bottom and two sides, one side mounted to pivot on one end of the bottom so that it is folded against the bottom, and the other side mounted to pivot on the other end of the bottom and positioned generally perpendicular to the bottom, to form a partially folded frame, and a grill casing, wherein the partially folded frame unit encloses the grill casing on two adjacent perpendicular surfaces. 
     The frame unit comprises at least one side bar to connect the ends of the two sides away from the bottom. The frame of the side bar is connected at one of its ends to an end of one of the sides. The grill casing includes at least one fastening element pre-mounted to one of its bottom corners adapted to engage a pre-mounted fastening element on the top of the frame unit. The casing has four bottom corners, and wherein each of the four bottom corners includes a pre-mounted fastening element adapted to engage a pre-mounted mating fastening element on each of the four top corners on top of the frame. The fastening element on the grill casing comprises a first type of element comprising a plate which defines a slotted opening, and wherein the mating fastening element on the top of the frame unit comprises a first type of mating fastening element comprising a stud adapted to be received in the slotted opening The fastening element on the grill casing comprises a second type of fastening element comprising a latch and wherein the mating fastening element on the top of the frame unit comprises a second type of mating fastening element comprising a hook. Two of the first type of fastening elements and mating fastening elements are provided on the front corners of the casing and stand. Two of the second type of fastening elements and mating fastening elements are provided on the back corners of the casing and stand. 
     The present invention provides a partially assembled grill comprising a frame unit having a bottom and two sides, one side mounted to pivot on one end of the bottom so that it is folded against the bottom, and the other side mounted to pivot on the other end of the bottom and positioned generally perpendicular to the bottom, to form a partially folded frame, and a grill casing, wherein the partially folded frame unit encloses the grill casing on two adjacent perpendicular surfaces, wherein the casing has four bottom corners, and wherein each of the four bottom corners includes a pre-mounted fastening element adapted to engage a pre-mounted mating fastening element on each of the four top corners on top of the frame. 
     The fastening element on the grill casing comprises a first type of element comprising a plate which defines a slotted opening, and wherein the mating fastening element on the top of the frame unit comprises a first type of mating fastening element comprising a stud adapted to be received in the slotted opening. The fastening element on the grill casing comprises a second type of fastening element comprising a latch and wherein the mating fastening element on the top of the frame unit comprises a second type of mating fastening element comprising a hook. Two of the first type of fastening elements and mating fastening elements are provided on the front corners of the casing and stand. Two of the second type of fastening elements and mating fastening elements are provided on the back corners of the casing and stand. 
     The invention provides a partially assembled grill comprising a frame unit having a bottom and two sides, one side mounted to pivot on one end of the bottom so that it is folded against the bottom, and the other side mounted to pivot on the other end of the bottom and positioned generally perpendicular to the bottom, to form a partially folded frame, and a grill casing, wherein the partially folded frame unit encloses the grill casing on two adjacent perpendicular surfaces, wherein the casing has four bottom corners, and wherein each of the four bottom corners includes a pre-mounted fastening element adapted to engage a pre-mounted mating fastening element on each of the four top corners on top of the frame, wherein the fastening element on the grill casing comprises a first type of element comprising a plate which defines a slotted opening and wherein the mating fastening element on the top of the frame unit comprises a first type of mating fastening element comprising a stud adapted to be received in the slotted opening, and a second type of fastening element comprising a latch and wherein the mating fastening element on the top of the frame unit comprises a second type of mating fastening element comprising a hook. 
     Two of the first type of fastening elements and mating fastening elements are provided on the front corners of the casing and stand. Two of the second type of fastening elements and mating fastening elements are provided on the back corners of the casing and stand. 
     The invention provides a partially assembled grill comprising a frame unit having a bottom and two sides, one side mounted to pivot on one end of the bottom so that it is folded against the bottom, and the other side mounted to pivot on the other end of the bottom and positioned generally perpendicular to the bottom, to form a partially folded frame, and a grill casing, wherein the partially folded frame unit encloses the grill casing on two adjacent perpendicular surfaces, wherein the casing has four bottom corners, and wherein each of the four bottom corners includes a pre-mounted fastening element adapted to engage a pre-mounted mating fastening element on each of the four top corners on top of the frame, wherein the fastening element on the grill casing comprises a first type of element comprising a plate which defines a slotted opening and wherein the mating fastening element on the top of the frame unit comprises a first type of mating fastening element comprising a stud adapted to be received in the slotted opening, and a second type of fastening element comprising a latch and wherein the mating fastening element on the top of the frame unit comprises a second type of mating fastening element comprising a hook, wherein two of the first type of fastening elements and mating fastening elements are provided on the front corners of the casing and stand, and wherein two of the second type of fastening elements and mating fastening elements are provided on the back corners of the casing and stand. 
     The invention provides a method of packaging a partially assembled grill comprising locating a frame unit having a bottom and two sides, so that one side mounted to pivot on one end of the bottom so that it is folded against the bottom, and the other side is mounted to pivot on the other end of the bottom and positioned generally perpendicular to the bottom, to form a partially folded frame, and locating a grill casing so that the partially folded frame unit encloses the grill casing on two adjacent perpendicular surfaces. 
       FIG. 1  shows the preassembled grill in its shipped state, removed from a box or container.  FIG. 2  is an exploded view of  FIG. 1 , showing a stand  10 , a firebox casing  12 , and two shipping inserts  14  and  16 , which may be made of foam, polystyrene, cardboard or the like. 
     The stand  10  has three major parts, which are a bottom  20 , a first side  22  and another second side  24 . The side  22 , which is positioned perpendicular to the bottom  20  fits on the outer, left side of the insert  14  when shipped, while the second side  24  is folded generally flat against the bottom  22  in  FIGS. 1 and 2 . 
       FIG. 3  shows the stand  10  alone in the same configurations as  FIGS. 1 and 2 . In  FIG. 4 , the second side  24  has been unfolded to be perpendicular to the bottom  20 , similar to the first side  22 . In  FIG. 5 , a first side bar  30  is being attached to join the first and second sides  22  and  24 . In  FIG. 5 , the side bar is first placed in contact with both first and second sides  22  and  24 , and then slid along into final position, and indicated by the arrows. Appropriate fasteners can secure the side bar its final position. The fasteners can be located already in the fastening holes and then tightened so that the consumer does not have to find and insert them into the first and second sides  22  and  24 . 
       FIG. 6  shows the stand in an upright position with one side bar  30  attached, and  FIG. 7  shows the other side bar  32  being placed into position.  FIG. 8  shows the other side bar fastened into position. 
       FIG. 9  shows a side view of the stand with the firebox casing  12  in contact with the stand  10 , but not yet in its final assembly position. After the firebox casing is in the position shows in  FIG. 10 , it is slid to the left to the final assembly position shown in  FIG. 11 . A partial blow up of  FIG. 11  shows a first type of connector  40  on the stand having a side slot  42  which receives stud  44  on the firebox casing  12 . In  FIGS. 9-11 , each of the four corners of the stand and firebox casing has the same first type of connector  40  and stud  44 . 
     Although  FIG. 11  shows the firebox casing  12  in its final assembly position, the firebox casing  12  is not yet fully attached to the stand  10 .  FIG. 12  shows a second type of connector in the form of a latch mechanism  50  comprising a latch  52  on the stand  10  and a hook  54  on the firebox casing  12 . The opposite side of the stand  10  and the firebox casing  12  have a similar latch mechanism.  FIG. 12  shoes the latch mechanism fully engaged, which keeps the firebox casing  12  secure on top of the stand  10 . In this position, the loop  56  on the lever  58  of the latch  52  engages the hook  54 .  FIGS. 9-11  also show wheels  60  mounted to the lower ends of a stand side. 
       FIGS. 14-18  show an alternative arrangement for a stand, in which the bottom  70  has a ring  72  for receiving and holding a propane tank, and wherein at least one of the side bars  74  has one of its ends pre-mounted to one side of the stand during shipment, and the other end of the side bar has a slot to engage a fastener at stud on the other side of the stand, thereby avoiding having a loose side bar, and loose fasteners, during shipment. Having pre-mounted components including fasteners makes the assembly quicker and easier, and avoids having to find, match, and assemble loose parts. 
     Although a preferred embodiment has been described, the present invention is not limited to the embodiment illustrated. The scope of the invention is limited only by the following claims.