Patent Publication Number: US-10323846-B2

Title: Safety and convenience system for a gas grill

Description:
CROSS-REFERENCE TO RELATED APPLICATION AND PRIORITY CLAIM 
     This application claims the benefit, under 35 U.S.C. § 119(e), of U.S. Provisional Patent Application No. 62/112,226, filed 5 Feb. 2015, entitled “GAS MONITORING AND SENSOR APPARATUS AND METHODS OF MAKING AND USING THE SAME,” and U.S. Provisional Patent Application No. 62/183,723, filed 23 Jun. 2015, entitled “INTERNET INTEGRATED GAS MONITORING AND SENSOR APPARATUS AND METHODS OF MAKING AND USING THE SAME,” the entire contents and substance of both provisional applications are incorporated herein by reference in their entirety as if fully set forth below. 
    
    
     BACKGROUND 
     Field of the Invention 
     Embodiments of the present invention relate to a safety and convenience system for a gas grill and, more particularly, a system having gas and temperature sensors for determining whether the grill chamber is safe to light, as well as other operating parameters. 
     Description of the Related Art 
     Nearly half of U.S. households own a grill. Each year, these grills cause millions of dollars in damage, injuries, and even deaths. Many of these accidents are the result of an explosion due to an unsafe lighting event or a grill left unattended. Unsafe lighting events occur when the gas or starter fluid buildup in the grill exceeds a safe level, and then an ignition source is activated. When this occurs, flare ups, fireballs, and even explosions may result. Unattended grills can also cause plants, grill covers, or even homes to catch fire. Most of these accidents can be prevented. 
     Gas grills make up a large portion of the grill market, and the basic design has changed very little over the years. These grills use fuel stored in a tank, routed through fuel lines to a burner, and often include adjustment valves and an igniter to control the flow of gas and to provide the spark to ignite the fuel. Features such as electric ignition, multiple burners, ceramic infrared heating elements, and thermometers, each have their own benefits, but none address the safety of the grill. 
     Therefore, what is needed is a system that can be built into, or retrofitted onto a gas grill to provide a measure of safety to prevent unsafe lighting events and/or unattended grill fires. Furthermore, these additional safety measures can also add convenience features to a grill. It is to such a system that this disclosure is directed. 
     SUMMARY 
     Features of the present disclosure include safety features, as well as convenience features. The system can use sensors and actuators to provide automatic or remote shut off, monitoring, or starting of a gas grill. The system can also warn of unsafe conditions, and in some applications, can take active control steps to prevent an unsafe lighting event. A system according to this disclosure may also be able to automatically turn off a grill after a predetermined period of time, if the grill is knocked over, or if it has been left unattended for too long. The increases in both safety and convenience can result in fewer accidents, and an increased ability to grill safely and conveniently. 
     In some embodiments, a grilling system according to the present disclosure can include a grill assembly, a sensor assembly, and a system controller. The grill assembly can be made up of a grill body, a grill lid, a grilling surface, one or more burners, a gas feed line, a grill adjustment valve, and an igniter. The sensor assembly can include a gas sensor, a temperature sensor, and a sensor housing. In some embodiments, the system controller may be connected to the gas sensor and the temperature sensor and be capable of receiving a gas sensor value and a temperature sensor value. The system controller may be capable of indicating a condition of the grill to a user based on the gas sensor value and the temperature sensor value. 
     In some embodiments, an unsafe condition of the grilling system assembly can be identified when the temperature sensor value is less than about 150 degrees Fahrenheit, and the gas sensor value is greater than about 500 ppm; while a safe condition of the grilling system can be identified when the temperature sensor value is greater than about 150 degrees Fahrenheit, and/or the gas sensor value is less than about 500 ppm. The system may further include one or more indicator lights with which to indicate a safe condition or unsafe condition to the user. The grilling system can have an audible alarm so that the system controller can indicates the unsafe condition to the user by activating the alarm. 
     In some embodiments, the sensor housing is removably attached to one or more of the grill body, the grill lid, and the grilling surface. This attachment may be accomplished by the sensor housing being magnetic. A shutoff valve can be located in the gas feed line so that the system controller can actuate the shutoff valve in response to the unsafe condition being identified. In some embodiments, this may be in concert with or alternative to the system controller disabling the igniter in response to the unsafe condition being identified. 
     In order to allow the system controller to notify and accept commands from a user, the system can be provided with a wireless radio, such as a Bluetooth or Wi-Fi transceiver. This radio can enable a user to receive notifications on their mobile device or other portable notification device. In some embodiments, the grilling system can be configures such that the wireless radio can receive a user command inputted via a mobile application on a mobile device, such as a request to activate the igniter and/or actuate the shutoff valve. If the system is provided with an adjustment valve actuator, the system controller may be able to engage the adjustment valve actuator to actuate the grill adjustment valve. This can have the effect of adjusting the temperature of the grill assembly. 
     Some embodiments of the disclosed grilling system can use a tank weight sensor positioned underneath the gas tank to determine the amount of gas remaining in the gas tank. The system controller can then indicate the amount of gas remaining to a user via the mobile application. The system controller can also be able to actuate the shutoff valve after an amount of time determined by the user command. In some embodiments, the user can use the mobile app to set a timer or run a heating cycle, such as a higher temperature for a predetermined cleaning time, and then actuates the shut off valve. 
     Further features of systems in accordance with the present disclosure, and the advantages offered thereby, are explained in greater detail hereinafter with reference to specific embodiments illustrated in the accompanying drawings, wherein like elements are indicated by like reference designators. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic depiction of a grilling system according to an embodiment of the present disclosure. 
         FIG. 2  is a front view of a grill assembly according to an embodiment of the present disclosure. 
         FIG. 3  is a top perspective view of a sensor assembly in accordance with an embodiment of the present disclosure. 
         FIG. 4  is a top perspective view of an indicator assembly in accordance with an embodiment of the present disclosure. 
         FIG. 5  is a flowchart describing the logic behind certain safety and warning aspects of a system in accordance with the present disclosure. 
         FIG. 6  is a schematic depiction of a Wi-Fi based communication path between a system controller and a mobile device, in accordance with an embodiment of the present disclosure. 
         FIG. 7  is a schematic depiction of a Bluetooth based communication path between a system controller and a mobile device, in accordance with an embodiment of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     To facilitate an understanding of the principles and features of the various embodiments of the invention, various illustrative embodiments are explained below. Although exemplary embodiments of the invention are explained in detail as being grilling systems that provide safety and/or convenience features, it is to be understood that other embodiments are contemplated, such as embodiments employing additional sensors, actuators, mobile application features, and the like. Accordingly, it is not intended that the invention be limited in its scope to the details of construction and arrangement of components set forth in the following description or examples. The disclosed systems are capable of other embodiments and of being practiced or carried out in various ways. Also, in describing the exemplary embodiments, specific terminology will be resorted to for the sake of clarity. 
     It must also be noted that, as used in the specification and the appended claims, the singular forms “a,” “an” and “the” include plural references unless the context clearly dictates otherwise. For example, reference to a component is intended also to include composition of a plurality of components. References to a composition containing “a” constituent is intended to include other constituents in addition to the one named. 
     Also, in describing the exemplary embodiments, terminology will be resorted to for the sake of clarity. It is intended that each term contemplates its broadest meaning as understood by those skilled in the art and includes all technical equivalents which operate in a similar manner to accomplish a similar purpose. 
     Ranges may be expressed herein as from “about” or “approximately” or “substantially” one particular value and/or to “about” or “approximately” or “substantially” another particular value. When such a range is expressed, other exemplary embodiments include from the one particular value and/or to the other particular value. 
     By “comprising” or “containing” or “including” is meant that at least the named compound, element, particle, or method step is present in the composition or article or method, but does not exclude the presence of other compounds, materials, particles, method steps, even if the other such compounds, material, particles, method steps have the same function as what is named. 
     It is also to be understood that the mention of one or more method steps does not preclude the presence of additional method steps or intervening method steps between those steps expressly identified. Similarly, it is also to be understood that the mention of one or more components in a composition does not preclude the presence of additional or equivalent components other than or in addition to those expressly identified. 
     The materials described as making up the various elements of the invention are intended to be illustrative and not restrictive. Many suitable materials that would perform the same or a similar function as the materials described herein are intended to be embraced within the scope of the invention. Such other materials not described herein can include, but are not limited to, for example, materials that are developed after the time of the development of the invention. 
     To facilitate an understanding of the principles and features of this disclosure, various illustrative embodiments are explained below. In particular, various embodiments of this disclosure are described as a grilling system that provides safety and convenience features. Some embodiments of the invention, however, may be applicable to other contexts, and embodiments employing these applications are contemplated. For example and not limitation, some embodiments of the disclosure may be applicable to various types of cooking or heating systems, both outdoors and indoors. 
       FIG. 1  illustrates a schematic of an embodiment of a grilling system  100 . Grilling system  100  includes conventional gas grill components such as gas tank  102 , gas feed line  104 , one or more grill adjustment valves  106 , igniter  108 , and one or more burners  110 . Igniter  108 , and burner  110  may be housed in grill body  112 . The function of this combination of components is well known in the art. A user would open a valve on gas tank  102  to start the flow of gas through gas feed line  104 . Then, by opening grill adjustment valve  106 , gas begins to flow to burner  110  in grill body  112 . By actuating igniter  108 , a flame is lit on and around burner  110 , and grill adjustment valve  106  may then be used to control the size and intensity of that flame. 
     Grilling system  100  may be provided with system controller  200 . System controller  200  may be a basic processor of any suitable type known in the art capable of receiving sensory inputs, running logic operations, and outputting control signals in response to those sensory inputs. System controller  200  can be connector to one or more gas sensors  202  and/or one or more temperature sensors  204 . Gas sensor  202  and temperature sensor  204  may be located inside grill body  112 , in order to monitor the conditions therein. System controller may also be connected to a tank weight sensor  206  that is able to weigh gas tank  102 , and determine the amount of gas in tank  102 . 
     Gas sensor  202  may be of any suitable type known in the art, such as semiconductor gas detectors and infrared gas sensors. Sensors may be selected to be robust and heat resistant, due to the rigors of the grill application. Sensors requiring maintenance or frequent calibration may not be ideal, due to the long periods of time that may pass (for example, over the winter) between uses. Appropriate sensor selection may be important for the cost effectiveness and functionality of the system. 
     Sensors  202 ,  204 , and  206  are able to provide system controller  200  with information necessary to determine the safety of the grill as well as the remaining gas in tank  102 . By using this information, system controller  200  can be provided with actuators to adjust the functionality of grilling system  100 . For example, shutoff valve  208  can be connected to system controller  200  to allow for the shutoff of the gas flow from tank  102  to burner  110 . Adjustment valve actuator  210  can also be connected to controller  200  and provide the ability to adjust grill adjustment valve  106 . By controlling actuator  210 , the grilling system can adjust the flow of gas to burner  110 , or to one of multiple burners  110  to control the temperature and temperature profile inside grill body  112 . Igniter  108  may be connected to system controller  200  as well. This connection can allow system controller  200  to provide ignition to burner  110  as needed to light a flame and begin the grilling process. 
     System controller may be powered by power source  212 . Power source  212  may be a battery, plugged into an electrical socket, a solar cell, a thermoelectric generator, any combination thereof, or other suitable power system. While batteries or plug-in power sources may be the more conventional power options, solar and thermoelectric power may be viable in this application. Many grills are stored outside, in or near direct sunlight. This provides the grill with an excellent source of sunlight to power the system. Similarly, because grills generate a great deal of heat, thermoelectric power, particularly if used to charge batteries, may also be viable. Thermoelectric cells use a temperature difference (i.e. the inside of the grill versus the outside) to generate electricity. The waste heat from the grilling process may be capable of providing sufficient power to enable the system controller and/or other components. Depending on the selection of power source and other components, power source  212  can also provide the power necessary for sensors  202 ,  204 , and  206 , actuators  208  and  210 , and igniter  108  to function. Additionally or in lieu of such an arrangement, each component may be powered separately. 
       FIG. 2  illustrates where the many of the components described with respect to  FIG. 1  are located on a conventional grill assembly  300 . Grill body  110  can house sensor assembly  302 , as well as gas tank  102 , gas feed line  104 , grill adjustment valves  106 , igniter  108 , burners  110 , and grilling surface  304 . Grill body  110  may include a hinged or removable grill lid  306 . Sensor assembly  302  can be a single unit or individual sensor components that can include gas sensor  202  and temperature sensors  204 . Shelf portion  308  of grill assembly  300  may house or support indicator assembly  310 . Indicator assembly  310  may include indicator lights  312 , alarm  314 , and indicator screen  316 . System controller  200  may be housed within indicator assembly  308 , or elsewhere in or on grill assembly  300 , depending on the specific application desired. 
       FIG. 3  shows a closer view of an embodiment of sensor assembly  302 . Sensor assembly  302  may be made up of sensor housing  318 , gas sensor  202 , and temperature sensor  204 . In some embodiments according to the present disclosure, sensor housing  318  may be a heat resistant housing, and be provided with a means of attaching or otherwise securing itself inside grill body  110 . Examples of such attachment mechanisms include hooks, a shelf system, or a magnetic attachment system. Because many gas grills are made of metal, a magnetic housing may allow for easy, reliable, and removable installation of sensor assembly  302 . 
       FIG. 4  shows a closer view of an embodiment of indicator assembly  310 . Indicator assembly  310  may be made up of indicator housing  320 , indicator lights  312 , alarm  314 , and indicator screen  316 . In some embodiments, indicator lights  312  can include a “Grill is On” light, a “Safe to Light” light, and an “Unsafe to Light” light. Other lights can also be included to indicate that a cleaning mode or other program is running, or that a mobile device is connected via Wi-Fi or Bluetooth (discussed further below). Indicator screen  316  can include information such as grill assembly temperature, remaining fuel level, remaining grilling time, or the like. In some embodiments, indicator assembly  310  may house other components, such as system controller  200  and power source  212 . Indicator assembly  310  may be integrally installed in grill assembly  300 , or may be a modular unit. Wires can connect indicator assembly  310  to sensor assembly  302  as well as other components; however wireless communication mechanisms can also be used in appropriate applications. 
     Because indicator housing  320  does not have to be located inside of grill body  110 , it need not necessarily be as heat resistant as sensor assembly  302 . However in some embodiments according to the present disclosure, sensor assembly  302  and indicator assembly  310  are combined in a unitary device. This device could be placed on grilling surface  304  during grill operation, and a user may rely on alarm  314  for an unsafe to light warning, as opposed to lights  312  (when grill lid  306  is closed). 
       FIG. 5  illustrates the logic  500  behind system controller  200  as it relates to safety indicators and safety controls. Starting at  502 , the first question at  504  is whether or not the temperature is above a particular threshold, for example and not limitation, 150 F. If temperature sensor  204  indicates that this is the case, the next step at  506  is to determine if the temperature has experienced a rapid drop recently, for example and not limitation, a drop of more than 50 degrees in the past minute. If temperature sensor  204  indicates that it is not the case that the temperature is above the temperature threshold ( 508 ), this is an indication that the grill is not on, and the system should proceed to checking gas sensor  202 . If the temperature has experienced a rapid drop recently ( 510 ), this may also indicate that the grill is off, and as before, the system should proceed to checking gas sensor  202 . If the temperature is both above the threshold and has not experienced a rapid drop ( 512 ), the grill is likely on and lit. In this case system controller  200  may indicate this condition by turning on the appropriate indicator light  312 , or by another suitable means. 
     If the grill is off, gas sensor  202  can be monitored to detect an unsafe condition ( 516 ). In the event that gas sensor  202  indicates the presence of gas above a safe concentration, for example and not limitation, 500 parts per million (ppm), the grill may be unsafe to light ( 518 ). If gas sensor  202  indicates the presence of gas below the upper safe concentration limit, the grill may be safe to light ( 520 ). In the event that the grill is safe, system controller  200  may indicate this condition by turning on the appropriate indicator light  312 , or by another suitable means ( 522 ). If lighting the grill may be unsafe, system controller  200  may indicate this condition by turning on the appropriate indicator light  312 , activating alarm  314 , or by another suitable means ( 524 ). As an additional or alternative safety measure, system controller  200  can shut off the gas flow by actuating shutoff valve  208  and/or preventing igniter  108  from functioning ( 526 ). This may not only warn of an unsafe condition, but also actively take steps to eliminate it. 
     In some embodiments, grilling system  100  is provided with network connectivity.  FIGS. 6 and 7  depict Wi-Fi and Bluetooth communication architectures, respectively. Wi-Fi arrangement  600  shows system controller  200  in communication with a wireless radio  602 . Wireless radio  602  may communicate using Wi-Fi (or other suitable protocols) with wireless router or server  604 . Wireless router  604  can then communicate as is known in the networking field with the internet  606 . A user can then send and receive messages by connecting a mobile device  608  to internet  606 , including by accessing wireless router  604  or another suitable internet connection. Arrangement  600  can allow for grill control and monitoring both nearby and remotely, allowing an unsafe condition to alert a grill owner even while away from home. This can be beneficial if a child or other family member is using the grill in an unsafe manner, and allows a user to initiate safety measures and alerts remotely. 
     The Bluetooth arrangement  700 , depicted in  FIG. 7  is somewhat simpler. System controller  200  can still be in communication with a wireless radio  602 . In this instance, wireless radio  602  may communicate using Bluetooth (or other suitable short-range protocols) directly with a user&#39;s mobile device  608 . This arrangement has the advantages of not requiring a functional wireless network or internet service; however the range of a Bluetooth connection may be limited to between 10 and 100 feet, depending upon the environment and obstructions. This limited range will often not be an issue, since it may actually be desirable (for safety reasons) to require the grill operator/monitor to be within Bluetooth range. In some embodiments, a Bluetooth connected mobile device may be required to operate certain grill features, such as a cleaning mode, so that the system controller can be assured that a user is nearby. 
     The basic architecture discussed above with regard to sensors, actuators, and networking provides a number of additional feature options for both safety and convenience. For example, a user may be able to preheat a grill while preparing the food to be cooked. No longer will a griller have to make a trip outside to turn on and light the grill, and then return inside to continue food preparation. This capability can also address the issue of flame loss (or flame blowout). A grill may sometimes have its flame blown out by the wind, causing the temperature to drop and the food to stop cooking. Because the gas keeps flowing, it may lead to an unsafe lighting condition. A system as described may be able to not only alert a user of the flame loss, but also allow a safe remote relighting. Similarly, a user may be able to turn off an unused grill without returning to the grill itself. This can be beneficial when a meal is to be eaten away from the grill, or if the grill is left on in case additional food is requested or desired. 
     In some embodiments, a mobile application may even allow for the temperature to be varied over time, or in response to a food temperature sensor. This can allow a user to have a great deal of control over the heat at which food is to be started, cooked, and finished/kept warm. Tank weight sensor  206  can allow a user to remotely check to make sure they have enough fuel for their planned grilling without being home. This may prevent repeated trips to the store, or worse, a gathering being interrupted by having to make a trip for additional fuel or ended due to an inability to get additional fuel (such as on a holiday). Increasing the versatility and convenience of the grilling process while also increasing the safety can result in significant improvements to a user&#39;s satisfaction with their grill. 
     The ability to light, adjust the temperature, and/or shut off the grill remotely can also allow for a simpler cleaning cycle. Many grill users prefer to clean their grills by turning the temperature up on the grill with no food inside to burn off any debris. If left alone in this condition, the grill may cause a fire with something that comes into contact with it, or something adjacent to it. The disclosed system can allow for this cleaning cycle to run on a timer, and to be monitored and aborted if necessary, without requiring a user to be within an arm&#39;s reach of a hot grill. 
     The disclosed system can include a number of additional sensors or actuators to provide other safety or convenience features. For example, a tilt sensor may be provided to cut the flow of gas in the event that the grill is knocked or blown over. This may prevent an accidental fire, without requiring a user to be dangerously near a hot, overturned grill. Another sensor that may be provided is a lid sensor for indicating the position of the grill&#39;s lid. Such an input may allow for a cleaning cycle to be aborted should the grill be opened during the cycle. Due to the very high heat used for grill cleaning, this may be beneficial. Relatedly, a lid lock may be included such that the grill can be remotely latched or unlatched. This may prevent unauthorized use, the interruption of a cleaning cycle, or other such issues that may arise. 
     From the foregoing, it can be seen that the invention provides a grilling system that provides features designed to both improve safety and make grilling more convenient. It will be appreciated by those skilled in the art, however, that the invention can be embodied in other specific forms without departing from the spirit or essential characteristics thereof. For example, while the invention has been described in the context of an outdoor grilling system, the concepts described herein need not be limited to this illustrative embodiment. For example, other devices involving open flames such as ovens, turkey fryers, heating devices, and other such appliances would enjoy many of the same benefits as described above. Additionally, the specific configurations, choice of materials, and the size and shape of various elements, including the chosen sensors and actuators, could be varied according to particular design specifications or constraints requiring a grilling system to meet additional of different design parameters. Such changes are intended to be embraced within the scope of the invention. 
     The presently disclosed embodiments are, therefore, considered in all respects to be illustrative and not restrictive. The scope of the invention is indicated by the appended claims, rather than the foregoing description, and all changes that come within the meaning and range of equivalents thereof are intended to be embraced therein.