Patent Publication Number: US-2020275802-A1

Title: Resistive charcoal igniter system and method

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     The present application is related to and claims priority to U.S. Non-Provisional patent application Ser. No. 16/274,221, filed Feb. 12, 2019, pending, which is related to and claims priority to U.S. Provisional Patent Application No. 62/742,219 filed Oct. 5, 2018, both of which are incorporated by reference in their entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     The following includes information that may be useful in understanding the present disclosure. It is not an admission that any of the information provided herein is prior art nor material to the presently described or claimed inventions, nor that any publication or document that is explicitly or implicitly referenced is prior art. 
     TECHNICAL FIELD 
     The present invention generally relates to the field of barbeque cooking of existing art and, more specifically, relates to fuel lighters. 
     RELATED ART 
     Cooking using a charcoal-fired barbecue is an effective and satisfying means of preparing a meal. Proponents of barbecue cooking often prefer the health advantages, taste preferences, or involved technique provided by cooking with a barbecue. However, many people avoid charcoal-fired barbecue cooking simply because they find it difficult, messy, or inconvenient. In particular, lighting the charcoal can present a dreaded chore for many. Charcoal, lump charcoal, or charcoal briquets can be difficult to light merely using a match or other light flame sources, and lighting the charcoal in the basin underneath the barbecue grill may also be messy. Flammable fluids may make lighting easier but can be hazardous and produce an unpleasant taste in the food prepared using those charcoal. The storage and safe use of flammables present a potential fire danger. These consumable materials must be purchased over and over, adding to barbecuing expenses. This difficulty in lighting charcoal, lump charcoal, or charcoal briquets may be one of the primary reasons that barbecuers often choose propane or electric cooking methods over charcoal cooking. A suitable solution is desired. 
     U.S. Pat. No. 5,197,455 to Ross Tessien relates to a charcoal starter. The described charcoal starter includes an improved charcoal starter that employs a grate having a conical shaped charcoal briquet receiving and stacking portion, to permit an enhanced rise of heat to impact the coals to get them to burn. The heat may come from paper kindling as conventionally disposed beneath the grate, or from a resistance heater element built into the grate. The grate may resemble a witch&#39;s hat with the retaining disk being the brim and a conical portion being disposed thereon, both with suitable apertures therein; or the grate can be made of suitable wire. The grate may be permanently mounted within the starter&#39;s cylindrical body or be removable. 
     SUMMARY OF THE INVENTION 
     Because of the disadvantages inherent in the known charcoal ignition art, the present disclosure provides a novel resistive charcoal igniter system and method that is friendlier to the environment. The general purpose of this disclosure is to provide a resistive charcoal igniter system and method. 
     Disclosed is a resistive charcoal igniter device for containing and igniting charcoal, lump charcoal, or charcoal briquets. The device has a cylindrical container with a wire base or tray in the bottom for containing the charcoal. An electrically operated heating element is located within the wire base. When charcoal is placed in the container, and the heating element is energized, the charcoal, lump charcoal, or charcoal briquets ignites after enough time. The device also includes a handle affixed to the container and a heatshield placed between the handle and the container to protect a user&#39;s hand from heat generated within the container while holding the handle. The resistive heater is powered externally and may be electrically connected to a power source by an extension cord integrated into the device. 
     According to another embodiment, a method of igniting charcoal, lump charcoal, or charcoal briquets is also disclosed. The method of igniting charcoal, lump charcoal, or charcoal briquets includes providing the above-described device, inserting charcoal into the cylinder through the top end, depositing charcoal onto the grate, plugging the cord into a power source such as a wall outlet, heating the heating element, igniting the charcoal with the heating element, and dispensing the charcoal into a cooking device. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The figures which accompany the written portion of this specification illustrate embodiments and methods of use for the present disclosure, a resistive charcoal igniter system and method, constructed and operative according to the teachings of the present disclosure. 
         FIG. 1  is a perspective view of the device according to an embodiment of the disclosure. 
         FIG. 2  is a rear perspective view of the device of  FIG. 1 , according to an embodiment of the present disclosure. 
         FIG. 3  is a side perspective view of the device of  FIG. 1 , according to an embodiment of the present disclosure. 
         FIG. 4  is a top perspective view of the device of  FIG. 1 , according to an embodiment of the present disclosure. 
         FIG. 5  is a flow diagram illustrating a method of use for containing and igniting charcoal, lump charcoal, or charcoal briquets, according to an embodiment of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     As discussed above, embodiments of the present disclosure relate to a fuel lighter and more particularly to a resistive charcoal igniter system and method as used to improve the lighting of charcoal, lump charcoal, or charcoal briquets for a barbecue. 
     The resistive charcoal igniter system includes a device for containing and igniting charcoal, lump charcoal, or charcoal briquets. The device includes a cylindrical container with a wire base in the bottom for containing the charcoal. The cylinder may be constructed of galvanized sheet steel and have apertures providing ventilation and airflow. 
     An electrically operated heating element is located within the wire base. When charcoal is placed in the container, and the heating element is energized, the charcoal, lump charcoal, or charcoal briquets ignite after enough time. The device also includes a handle affixed to the container and a heatshield placed between the handle and the container to protect a user&#39;s hand from heat generated within the container while holding the handle. 
     The resistive heater is powered externally and may be electrically connected to a power source by an extension cord integrated into the device. The resistive heating circuit can include an on-off switch. No fan or forced circulation means is necessary; instead, the device uses concentrated heat and passive ventilation to ignite the charcoal. Advantageously, the device incorporates a power supply providing options between four and six hundred watts to the heating element, thereby encouraging reliable ignition. 
     In use, a user may simply connect the device to a voltage source, place charcoal within the cylinder, activate the heating element, and wait for the charcoal to ignite. Thus, the device does not need constant monitoring to verify ignition success. Charcoal is a fuel in barbecue cooking. 
     The novel features of the invention are particularly pointed out in the specification. The present invention is described more fully by referencing the accompanying drawings and specification. The resistive charcoal igniter system may include a cylinder, a handle, a heatshield, an articulated auxiliary handle, a grate, a heating element, a power cord, and ventilation apertures. 
     The cylinder may be a thin hollow shell, preferably constructed of sheet metal. The handle may be coupled to the cylinder, providing a safe and rigid means of holding, lifting, and manipulating the cylinder. The ventilation apertures may be of sufficient size to permit adequate airflow through the cylinder and to encourage combustion within the cylinder. The articulated auxiliary handle may be a metal rod that is bent in a U-shape. The articulated auxiliary handle may attach to the heatshield using two hooks that are integral to the articulated auxiliary handle and may pass through apertures in the heatshield. The hooks may rotate within the apertures enabling the articulated auxiliary handle to move. 
     The power cord may act to electrically couple the heating element to a voltage source. Preferably, the power cord includes a 120-volt type power plug, such as a NEMA-1 or a NEMA-5 plug able to connect to a household wall outlet. Accordingly, the power cord may include internal conduits comprising power, neutral, and ground. The power cord may further include a voltage regulator, a power switch, a transformer, or any combination of these in various embodiments. The power cord may pass directing through an interior of the handle. 
     The handle itself may comprise plastic, metal, or a combination thereof. Preferably, the handle includes a sheet metal core having a first strut and a second strut, which rigidly coupled to the cylinder. In some versions, a plastic handle couple&#39;s the first strut and the second strut, or simply circumscribes the sheet metal core when the first strut and the second strut are integral to each other. The plastic handle may be sufficiently insulating to allow a user to comfortably grasp the handle even when combustion has been occurring within the cylinder for some time. The first and second struts may couple to the cylinder via screws, rivets, or other means. The first and second struts may take the shape of straight, flat bands with angled end pieces connecting to the cylinder. 
     The grate sits within the bottom of the cylinder. In some versions, the grate comprises one or more metal rods bent to form an air-permeable support. But in some versions, the grate spaces are small enough to impede charcoal passing through the grate. In this way, the grate may reliably support charcoal, while also enabling ample airflow through the grate, which encourages combustion within the cylinder. Because the grate in disposed within one end of the cylinder, the other end of the cylinder remains open, such that a user may deposit charcoal within the cylinder via the open end opposite the grate. 
     The heating element may mount to or be integral with the grate. In some versions, the grate includes three extensions mounted at one end to the cylinder and disposed proximally to the heating element. In some versions, these extensions regulate the proximity of the charcoal to the heating element. These three extensions may connect to two concentric rings, which provide strength and rigidity to the grate. The heating element may produce heat when energized by a voltage source. The heat may be sufficient to ignite charcoal in contact with or in proximity to the heating element. Preferably, the heating element has an output of approximately four to six hundred watts. 
     The heatshield may sit between the handle and the cylinder, and may rigidly mount to the handle, the cylinder, or both. The heatshield comprises a material having a low emissivity, such as sheet steel or aluminum, in some embodiments. The heatshield may help shield a user&#39;s hand from heat generated within the cylinder when the user is grasping the handle. The heatshield may be contoured around the cylinder to isolate heat away from the handle more effectively. Preferably, the cylinder is perforated, the perforations being the afore-mentioned ventilation apertures. The exact specifications, materials used, and method of use of the resistive charcoal igniter system may vary upon manufacturing. 
       FIGS. 1-4  show various views of a device  100 . 
       FIG. 1  shows a device according to an embodiment of the present disclosure. The device  100  may be useful for containing and igniting charcoal, lump charcoal, or charcoal briquets. The device may include cylinder  110 , handle  120 , heatshield  130 , articulated auxiliary handle  140 , grate  150 , heating element  160 , and power cord  170 . Cylinder  110  may have bottom end  112  and top end  114 . Bottom end  112  and top end  114  are opposite each other and represent circular apertures in the side of cylinder  110 . The interior of cylinder  110  is substantially hollow. Grate  150  and heating element  160  sit inside cylinder  110 . Handle  120  may rigidly couple to cylinder  110 . Handle  120  may have first strut  122  affixed to cylinder  110  proximally to top end  114 , and second strut  124  affixed to cylinder  110  proximally to the bottom end, and handle-grip  126  may bridge first strut  122  to second strut  124 . In some embodiments, handle-grip  126  may comprise plastic, with first strut  122  and second strut  124  molded into handle-grip  126 . Alternatively, first strut  122  may connect to or be integral with second strut  124 , and handle-grip  126  may surround first strut  122  and second strut  124 . In some versions, a single strut connects to the cylinder at an upper region and a lower region and passes through the handle. Handle  126  is split longitudinally with half of each part of handle  126  on either side of the strut. In some versions, handle  126  parts are on the front and back sides of the strut. 
     Yet further, handle-grip  126  may be constructed of alternate materials or affixed to first strut  122  and second strut  124  by other means. Heatshield  130  may rigidly couple to handle  120 . In some versions, heatshield and handle  120  connect to cylinder  110  by fasteners which pass through apertures in cylinder  110 , handle  120 , and heatshield  130 . Articulated auxiliary handle  140  may pivotably attached to heatshield  130  and may sit beneath handle  120 , such that the combination of articulated auxiliary handle  140  and bottom end  112  of cylinder  110  can stably support device  100  on a surface. Grate  150  may be disposed interior to cylinder  110  and proximally to bottom end  112 . Grate  150  may have a plurality of wire members  152  spaced sufficiently tightly to prevent the charcoal from passing out through bottom end  112  of cylinder  110 . Grate  150  may be circular and may be concentric to cylinder  110 . Heating element  160  may mount interior to cylinder  110 . Heating element  160  may be close enough to grate  150  to heat and ignite charcoal when charcoal is resting upon grate  150 . Power cord  170  able to selectively apply an electric current to heating element  160 . “Selectively” may mean when a control system such as a switch activates heating element  160 . Alternatively, “selectively” may merely mean when power cord  170  is plugged into a power source. 
     In some versions, heating element  160  is substantially flat and is not conical. This shape provides cylinder  110  with a larger volume useful for holding charcoal. In some versions, grate  150  is substantially flat and is not conical. This shape provides cylinder  110  with a larger volume useful for holding charcoal. In some versions, heating element  160  sits beneath grate  150 . In some versions, grate  150  and heating element  160  are the same component. That is, heating element  160  is structured to impede charcoal from falling through heating element  160  into the region beneath heating element  160 . In some versions, heating element  160  is above portions of grate  150  and below other portions of grate  150 . In some versions, heating element  160  attaches to the top or bottom of grate  150 . In some versions, heating element  160  is within 3, 2, 1, or ½ inches of grate  150 . In some versions, grate  150  supports charcoal during ignition. That is, grate  150  is charcoal-supporting. 
     In some embodiments, cylinder  110  comprises galvanized sheet steel. Other highly reflective and radiant materials, such as aluminum or stainless steel, may be used alternatively. Heatshield  130  may sit between handle  120  and cylinder  110 . And Heatshield  130  may comprise highly reflective metals. Highly reflective metals may include metals having an emissivity ratio under 0.2. Device  100  may also include a plurality of circular ventilation apertures  116  perforating cylinder  110 . A plurality of circular ventilation apertures  116  may provide sufficient passive airflow in cylinder  110  to enable the combustion of charcoal within cylinder  110 . Preferably, power cord  170  passes directly through an interior of handle  120 , as illustrated. 
       FIG. 2  shows device  100  of  FIG. 1 , according to an embodiment of the present disclosure. As shown, articulated auxiliary handle  140  may include straight base strut  142 , first hook  144 , second hook  146 , first leg  148 , and second leg  149 . Straight base strut  142  may provide a secondary gripping location when articulated auxiliary handle  140  is deployed. First hook  144  may pivotably engage heatshield  130 , and second hook  146  may likewise pivotably engage heatshield  130 . First leg  148  and second leg  149  may each be perpendicularly arranged with straight base strut  142 , forming a squared U-shape. Each of first hook  144  and second hook  146  may also be formed into a square U-shape as illustrated. This may be useful to prevent accidental removal of articulated auxiliary handle  140  from heatshield  130 . First leg  148  may rigidly couple to first hook  144  to straight base strut  142 , and second leg  149  may likewise rigidly couple second hook  146  to straight base strut  142 . This may be done with each element at such an orientation that first hook  144  mirrors second hook  146  across handle  120 , and first leg  148  mirrors second leg  149  across handle  120 . 
     Heatshield  130  may also include first-aperture  136  and second-aperture  138  perforating heatshield  130 . First-aperture  136  may be dimensioned and positioned to receive first hook  144  of articulated auxiliary handle  140 , and second-aperture  138  may likewise be dimensioned and positioned to receive second hook  146  of articulated auxiliary handle  140 . First-aperture  136  and second-aperture  138  may mirror each other over handle  120 , with one disposed on a left side of heatshield  130 , and the other on the right. 
       FIG. 3  may be a side perspective view of the device of  FIG. 1 , according to an embodiment of the present disclosure. First strut  122  and second strut  124  may each include, or be constructed of, a flat strip of metal, with each of the flat strips of metal having first-bend  123  and second-bend  125 . Each of the first-bends  123  may be affixed to cylinder  110 , and each of second-bends  125  may be affixed to handle-grip  126 . Each of first strut  122  and second strut  124  may be fastened to cylinder  110  using fasteners  190 , such that each of fasteners  190  passes through first-bend  123  of first strut  122  and first-bend  123  of the second strut. The same fasteners  190  may also pass through cylinder  110 . Fasteners  190  may be bolts, screws, rivets, or other fasteners. 
     Power cord  170  may include a 120-volt type Nema-1 or Nema-5 power plug. This 120-volt type power plug may be able to removably couple to a household wall outlet and receive current thereby. In some versions, power cord  170  mounts at or through the top of handle  126  and is sometimes the male side of the plug. In some embodiments, power cord  170  may also include voltage regulator  172  configured to limit the voltage applied to heating element  160 , power switch  174  able to turn heating element  160  on and off, and, in some versions, transformer is  176  able to convert an alternating current signal to a direct current signal. Device  100  may also include a power supply adapter to provide four hundred watts to heating element  160 . Power supply adapter may be composed of one of the following, or a combination thereof: power cord  170 , voltage regulator  172 , power switch  174 , and transformer  176 . Various electric and electronic combinations or additions may be implemented. A system imparting four hundred watts to heating element  160  is an unexpectedly useful solution and is the preferred method. Various electric and electronic control or timer components may be added. The heating element may use up to 600 W in various configurations. For example, some embodiments do not require either voltage control or on/off switches. 
       FIG. 4  may be a top perspective view of the device of  FIG. 1 , according to an embodiment of the present disclosure. Grate  150  may include at least two concentric wire rings  154  and at least one cross-member  156 . At least one cross-member  156  may rigidly couple at least two concentric rings  154  to each other. At least one cross-member  156  may also rigidly couple at least two concentric rings  154  to cylinder  110 . At least one cross-member may also include at least three extensions  158 . Each of the three extensions  158  may rigidly couple at least two concentric rings  154  to cylinder  110 , each of the three extensions  158  having bent terminus  159 . Bent terminus  159  may space the charcoal from heating element  160 . Bent terminus  159  may angle by approximately forty-five degrees from each of the extensions  158  in some embodiments. Heatshield  130  may also include first-corrugation  132  and second-corrugation  134 , wherein each of first-corrugation  132  and second-corrugation  134  protrude laterally from either side of handle  120 , respectively. And each of first-corrugation  132  and second-corrugation  134  have a concave side disposed toward cylinder  110 . Heatshield  130  may help prevent heat produced within cylinder  110  from burning a user&#39;s handle when holding handle  120 . Preferably, first-corrugation  132  mirrors second-corrugation  134  across handle  120 . 
       FIG. 5  is a flow diagram illustrating a method for lighting or igniting charcoal, lump charcoal, or charcoal briquets for a barbecue, according to an embodiment of the present disclosure. In particular, the method for lighting charcoal, lump charcoal, or charcoal briquets for a barbecue  500  may include one or more components or features of the device  100 , as described above. As illustrated, the method for lighting charcoal, lump charcoal, or charcoal briquets for a barbecue  500  may include the steps of: step one  501 , providing a device for containing and igniting charcoal, lump charcoal, or charcoal briquets, the device comprising a cylinder having a bottom end and a top end, a handle rigidly coupled to the cylinder, the handle having a first strut affixed to the cylinder proximally to the top end, and a second strut affixed to the cylinder proximally to the second end, and a handle-grip bridging the first strut to the second strut, a heatshield rigidly coupled to the handle, a grate disposed interior to the cylinder proximally to the bottom end, the grate having a plurality of wire members spaced sufficiently tightly to prevent charcoal from passing out through the bottom end of the cylinder, a heating element mounted interior to the cylinder, the heating element being sufficiently proximal to the grate to heat and ignite the charcoal when the charcoal is resting upon the grate, and a power cord able to selectively apply an electric current to the heating element; step two  502 , inserting at least one of the charcoal into the cylinder through the top end; step three  503 , depositing the at least one of the charcoal onto the grate; step four  504 , coupling the power cord to a power source; step five  505 , heating the heating element; step six  506 , igniting the at least one of the charcoal in proximity to the heating element; and step seven  507 , dispensing the charcoal into a cooking device. 
     It should be noted that the steps described in the method of use can be carried out in many different orders according to user preference. The use of “step of” should not be interpreted as “step for”, in the claims herein and is not intended to invoke the provisions of 35 U.S.C. § 112(f). It should also be noted that, under appropriate circumstances, considering such issues as design preference, user preferences, marketing preferences, cost, structural requirements, available materials, technological advances, etc., other methods for lighting charcoal, lump charcoal, or charcoal briquets for a barbecue, are taught herein. 
     The embodiments of the invention described herein are exemplary and numerous modifications, variations and rearrangements can be readily envisioned to achieve substantially equivalent results, all of which are intended to be embraced within the spirit and scope of the invention. Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientist, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application.