Abstract:
A charcoal igniting device includes an envelope, a chimney, and a base. The envelope has an envelope height and an envelope width, the envelope height is greater than the envelope width. The envelope sidewall defines a series of holes. The envelope has an upper envelope rim and a lower envelope rim. The chimney is disposed co-axially within the envelope. The chimney has a sidewall impregnated with wax, an upper chimney rim, an ignition element disposed upon the upper chimney rim, and a lower chimney rim. The base defines a series of holes disposed through the base. The base has an outer base perimeter mated to the lower envelope rim and an inner base perimeter mated to the lower chimney rim.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a Continuation-In-Part Application and claims priority to U.S. patent application Ser. No. 12/117,481, filed on May 8, 2008, titled “CHARCOAL STARTING DEVICE AND METHOD”, the disclosure of which is incorporated herein by reference in its entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention generally relates to a charcoal ignition device. More particularly, the present invention pertains to a device for storing and ignition of charcoal and a method of fabricating the device. 
       BACKGROUND OF THE INVENTION 
       [0003]    It is generally known that charcoal is utilized as a fuel source for cooking or grilling foodstuffs. Typically, a supply of charcoal is placed on a grating of a grill and ignited. Once the charcoal has formed uniformly alighted coals, the foodstuffs may be grilled. To accelerate ignition, conventional charcoal may include various flammable waxes and/or petroleum distillates. However, even with these accelerants, rapid coal formation is not guaranteed. In addition, rapid, even coal formation is typically facilitated by stacking the charcoal in a pile. Unfortunately, charcoal is generally dusty and this very dark or black dust may be messy or otherwise objectionable to some individuals. Accordingly, it is desirable to provide a device for igniting charcoal that is capable of overcoming the disadvantages described herein at least to some extent. 
       SUMMARY OF THE INVENTION 
       [0004]    The foregoing needs are met, to a great extent, by the present invention, wherein in some embodiments device for igniting charcoal is provided. 
         [0005]    An embodiment of the invention pertains to a charcoal igniting device. The charcoal igniting device includes an envelope, chimney and base. The envelope has an envelope height and an envelope width. The envelope height is greater than the envelope width. The envelope includes an envelope sidewall defining a series of holes, an upper envelope rim, and a lower envelope rim. The chimney is disposed co-axially within the envelope. The chimney includes an n-faceted sidewall impregnated with wax, an upper chimney rim, an ignition element disposed proximate the upper chimney rim, and a lower chimney rim. The base is defined by a series of holes. The base has an outer base perimeter mated to the lower envelope rim and an inner base perimeter mated to the lower chimney rim. 
         [0006]    Another embodiment of the invention relates to an improved charcoal igniting device. The improved charcoal igniting device includes a container, chimney, and base. The container has a container sidewall, an upper container rim, and a lower container rim. The chimney is disposed co-axially within the container. The chimney has a chimney sidewall, an upper chimney rim, and a lower chimney rim. The base is defined by an outer base perimeter mated to the lower container rim and a centrally located orifice having an edge mated to the lower chimney rim. A container volume is defined by the container sidewall, the base, and an exterior surface of the cone sidewall. The improvements of the charcoal igniting device include a series of holes defined by the container sidewall to facilitate an ingress of air therein. The chimney is an n-faceted frustum and a plurality of tabs and corresponding mating slots are included to retain an assembled shape of the container and chimney. In addition, the improved charcoal igniting device includes a supply of wax impregnated in the chimney sidewall to provide a fuel to ignite the supply of charcoal and an ignition element disposed on the upper chimney rim. In response to ignition of the ignition element, the wax impregnated chimney sidewall burns and draws air upwardly through the chimney and inwardly and upwardly through the series of holes in the container sidewall, and a flame front proceeds in an inverted cone downwardly through the container volume. 
         [0007]    Yet another embodiment of the invention pertains to a method of fabricating a charcoal igniting device. In this method, an envelope is generated from a envelope pattern. The envelope includes mating tabs and corresponding slots to retain the envelope in an assembled shape. An n-faceted frustum is generated from a frustum pattern. The frustum includes an ignition element disposed at an upper opening of the frustum. The frustum is infused with wax. A bottom panel is affixed to the envelope. The bottom panel includes an outer diameter corresponding to a bottom rim of the envelope. The bottom panel includes an inner orifice having a diameter corresponding to a width of a lower rim of the frustum. The lower rim of the frustum is affixed to the inner orifice of the bottom panel. 
         [0008]    There has thus been outlined, rather broadly, certain embodiments of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional embodiments of the invention that will be described below and which will form the subject matter of the claims appended hereto. 
         [0009]    In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of embodiments in addition to those described and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting. 
         [0010]    As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]      FIG. 1  is a hidden line, perspective view of a charcoal igniting device according to an embodiment of the invention. 
           [0012]      FIG. 2  is an exploded view of the charcoal igniting device according to an embodiment of the invention. 
           [0013]      FIG. 3  is a plan view of the pre-cut and pre-scored blanks suitable for use in the charcoal igniting device according to an embodiment of the invention. 
           [0014]      FIG. 4  is a cross sectional view of the charcoal igniting device during the ignition process according to an embodiment of the invention. 
           [0015]      FIG. 5  is a perspective view of the charcoal igniting device according to an embodiment of the invention. 
           [0016]      FIG. 6  is a plan view of the pre-cut and pre-scored blanks suitable for use in the charcoal igniting device according to another embodiment of the invention. 
           [0017]      FIG. 7  is an exploded view of the charcoal igniting device according to the embodiment of  FIG. 6 . 
       
    
    
     DETAILED DESCRIPTION 
       [0018]    The present invention provides, in some embodiments, a charcoal starting or igniting device and a method of fabricating the charcoal igniting device. In general, the charcoal igniting device includes an envelope or container configured to retain a supply of charcoal. For the purpose of this disclosure, an envelope is defined as a structure to enclose or partially enclose a space, volume, or item. This envelope includes a fiber-based sheet stock such as, for example, fiberboard, corrugated fiberboard, and the like. For the purpose of this disclosure, the term, “fiberboard” is defined as at least including, for example, paper, paperboard, cardboard, corrugated cardboard, cellulosic, and/or resinous material which is similar in character to fiberboard, and which is manipulated in the same or similar manner as fiberboard. This includes any suitable material capable of being folded from a blank. In this regard, the term “blank” refers to at least a piece or unit of fiberboard that is cut or scored and/or suitable for folding into a particular conformation such as a box, base, cone, lid, or tube. 
         [0019]    In another embodiment, the invention provides for a method of fabricating the charcoal igniting device. In this method, the various components of the charcoal igniting device may be assembled and packaged for storage, transport, and sales. 
         [0020]    The invention will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. As shown in  FIG. 1 , a charcoal ignition device  10  includes an outer container or envelope  12 , chimney  14 , and base  16 . Together, these components define a volume suitable for retaining a supply of charcoal  18 . 
         [0021]    The envelope  12  is optionally cylindrical in shape and is relatively taller than it is wide. The envelope  12  may be fabricated from any suitable sheet good. In a particular example, the envelope  12  may be fabricated from paperboard or the like. The envelope  12  includes a set of holes or vents  20  disposed at or near a lower rim of the envelope  12 . As described herein, the vents  20  provide for an ingress of air to provide oxygen for the burning charcoal  18 . 
         [0022]    In various examples, the set of vents  20  may include one or more individual vents. The vents may be round or rounded, square, rectangular, polygonal, or the like. Generally, the set of vents  20  are sized and shaped to reduce the likelihood that the charcoal will spill out therefrom. The set of vents  20  may be arranged about the circumference of the envelope  12  in one or more rows. 
         [0023]    In various embodiments the chimney  14  includes a frusto-conical structure or frustum of a pyramid and generally tapers from a relatively wide base to a relatively more narrow upper rim. As used herein, the term a ‘frustum’ and its derivatives refers to a portion of a cone or n-sided pyramid disposed between two planes intersecting the cone or pyramid. The chimney  14  includes the side surface(s) of the frustum and may be open at the top and/or bottom. 
         [0024]    The chimney  14  serves as a conduit or conveyance device to draw air from below the charcoal ignition device  10  and bring fresh, oxygenated air into the interior of the charcoal ignition device  10 . The chimney  14  may be fabricated from any suitable sheet good. In a particular example, the chimney  14  may be fabricated from paperboard or the like. In addition, this paperboard cone may be infused or coated in a fuel or accelerant such as wax, resin, petroleum distillate, or the like. In a particular example, the cone is infused with paraffin wax. The chimney  14  optionally includes a wick or ignition element  22  disposed on or proximate to the upper rim. If included, the ignition element  22  provides a device or convenient location to initiate ignition of the charcoal ignition device  10 . Alternatively, the upper rim of the chimney  14  may be lit directly to initiate ignition. 
         [0025]    The base  16  is generally shaped as an annular disk and provides a bottom panel that connects the bottom rim of the envelope  12  to the bottom rim of the cone  16 . The base  16  may include any suitable sheet good. In a particular example, the base  16  may be fabricated from paperboard or the like. Optionally, the base  16  includes a set of bottom openings or vents  24 . If included, the set of bottom vents  24  provide for an ingress of air to provide oxygen for the burning charcoal  18 . 
         [0026]    In various examples, the set of bottom vents  24  may include one or more individual vents. The vents may be round or rounded, square, rectangular, polygonal, or the like. Generally, the set of bottom vents  24  are sized and shaped to reduce the likelihood that the charcoal will spill out therefrom. The set of bottom vents  24  may be arranged in a circular or other such pattern upon the base  16 . 
         [0027]      FIG. 2  is an exploded view of the charcoal igniting device  10  according to an embodiment of the invention. As shown in  FIG. 2 , the various components of the charcoal igniting device  10  may include a plurality of tabs  26  to provide bonding surfaces. In a particular example, the lower rim of the envelope  12  and the lower rim of the chimney  14  may include the tabs  26  to facilitate bonding to the base  16 . In this regard, the base  16  may include an inner base  16 A and an outer base  16 B. The tabs  26  may be sandwiched between the inner base  16 A and outer base  16 B to provide greater bonding strength. 
         [0028]    To generate the bond, an adhesive may be applied to the tabs  26  and/or to one or both of the inner base  16 A and outer base  16 B. With the tabs  26  disposed between the inner base  16 A and outer base  16 B, the inner base  16 A and outer base  16 B may be urged together and held thusly until the adhesive sets. 
         [0029]    Also shown in  FIG. 2 , the wick  22  may include a plurality of wicks  22   a . In a particular example, a series of cuts may be made into the upper rim of the chimney  14  to generate a series of wicks  22   a  circumscribing the upper rim of the chimney  14 . More particularly, a series of eight cuts may be made about the circumference of the upper rim of the chimney  14 . The resulting tabs are configured to provide a relatively greater surface area that is made available to ignite the charcoal igniting device  10 . To further facilitate ignition, one or more of the wicks  22   a  may be folded outwardly. Optionally, an accelerant may be added to one or more of the wicks  22   a . In a particular example, an end user may place a wax, petroleum distillate, or other such accelerant on or around the wicks  22   s  to facilitate ignition. 
         [0030]      FIG. 3  is a plan view of a pre-cut and pre-scored blank suitable for use in the charcoal igniting device  10  according to an embodiment of the invention. As shown in  FIG. 3 , the blank for the envelope  12  may include a strip of paperboard that is rolled upon itself to generate a cylinder. Adhesive may be applied to all or a portion of the blank to affix the envelope  12 . In a particular example, the adhesive may be applied to one or more gluing areas  28 . In addition, to generate a uniform diameter, the blank for the envelope  12  may be wrapped around a form (not shown). 
         [0031]    Similarly, the blank for the chimney  14  may include the gluing areas  28  for the application of the adhesive. The blank for the chimney  14  may also be wrapped around a form (not shown) to generate a consistently sized component. Subsequently, the formed chimney  14  may be immersed in wax or other such accelerant to infuse the accelerant therein. 
         [0032]      FIG. 4  is a cross sectional view A-A of the charcoal igniting device  10  during the ignition process according to an embodiment of the invention. As shown in  FIG. 4 , following ignition of the ignition element  22 , a flame  30  proceeds downwardly via the wick towards the chimney  14 . During an initial phase, a flame front proceeds through the volume of charcoal as indicated by the region  32 . That is, flame  30  proceeds further downwardly along the chimney  14  and outwardly into the supply of charcoal  18  in a generally inverted cone shape. It is an advantage of embodiments of the charcoal igniting device  10  that the envelope  12  remains largely or entirely unconsumed during the initial and into an intermediate phase. During this intermediate phase, the flame front proceeds through the volume of charcoal as indicated by the region  34 . In this manner, the supply of charcoal  18  remains confined within the charcoal ignition device  10  and is therefore more likely to ignite. In contrast, if the envelope  12  were to ignite during the initial phase, the structural integrity of the envelope  12  may be compromised and the supply of charcoal  18  may fall from the charcoal ignition device  10  without first being ignited. 
         [0033]    During a later phase the flame front proceeds through the volume of charcoal as indicated by the region  36  and the envelope  12  is largely consumed by the flame  30 . However, the consumption of the chimney  14  may progress relatively faster and thereby increases the likelihood that the supply of charcoal  18  will fall inwardly. This inward settling of the supply of charcoal  18  consolidates the supply of charcoal  18  and facilitates rapid, even coal combustion development. Also shown in  FIG. 4 , the chimney  14 , set of vents  20 , and set of bottom vents  24  provide a supply of fresh, oxygenated air to the flame  30  as indicated by flow lines  38 . 
         [0034]      FIG. 5  is a perspective view of the charcoal igniting device  10  according to an embodiment of the invention that is wrapped or covered in a wrapper  40 . In general, the wrapper  40  provides an envelope to retain the supply of charcoal  18  and any dust from the supply of charcoal  18 . In addition, the wrapper may provide a surface upon which to place a label. Also shown in  FIG. 5 , the wrapper  40  may include a handle  42 . The handle  42  may provide a ready surface to grasp and carry the charcoal ignition device  10 . In a particular example, the handle  42  may include a flat or storage conformation and a carrying conformation. 
         [0035]    The wrapper  40  may further include a tear strip  44  configured to facilitate tearing the wrapper  40  open. For example, the tear strip  44  may include a string disposed below the wrapper  40 . By pulling on the tear strip  44 , the wrapper  40  may be torn about the circumference of the charcoal ignition device  10 . Thereafter, the wrapper  40  may easily be removed in preparation for ignition. 
         [0036]      FIG. 6  is a plan view of a pre-cut and pre-scored blank suitable for use in the charcoal igniting device  10  according to another embodiment of the invention. As shown in  FIG. 6 , the blank for the envelope  12  may be fabricated using one or more sheets  50  of fiberboard. In a particular example, two sheets  50  of fiberboard are used as stock to die cut the various components of the charcoal igniting device  10 . In the particular example illustrated in  FIG. 6 , the charcoal igniting device  10  includes a first envelope portion  12 A and a second envelope portion  12 B and the inner base  16 A that are cut as a single piece. The charcoal igniting device  10  also includes a chimney  14 ′ and outer base  16 B. 
         [0037]    Also shown in  FIG. 6 , rather than gluing areas  26  as shown in  FIG. 3 , the first envelope portion  12 A and second envelope portion  12 B and chimney  14 ′ include tabs  52 A- 52 E configured to mate with slots  54 A- 54 E. In this or other embodiments, the chimney  14 ′ may include one or more openings  56  to allow the tab  52 E to pass through the chimney  14 ′ to engage or mate with the slot  54 E. In this regard, to assemble the chimney  14 ′, the blank for the chimney  14 ′ is folded at score lines  58 A to  58 N starting at end  60 , rolling the blank of the chimney  14 ′ upon itself, and proceeding towards end  62 . As the chimney  14 ′ is folded along the score line  58 A to  58   n , the openings  56  may be aligned to provide an opening from the outside of the cone to the inside. Of note, the chimney  14 ′ fabricated using the blank as shown in  FIG. 6  may be shaped as or defined an n-faceted frustum of a pyramid. In a particular example, the chimney  14 ′ may include a frustum of a hexagonal pyramid with 6 facets or sides. The chimney  14 ′ may include one or more of the tabs  26  to facilitate securing the chimney  14 ′ to the base  16  or between the inner base  16 A and the outer base  16 B. As described herein, some or all of the chimney  14 ′ may be coated in wax or other such flammable material. In a particular example, an upper 70% to 95% of the chimney  14 ′ may be immersed in a container of hot, liquid paraffin wax, removed from the container, and aloud to cool and harden. In another example, liquidus wax may be applied via a brush or other such applicator. Optionally, another layer of fiberboard, paper, release coating, powder and/or membrane may be applied to the chimney  14 ′ to serve as a barrier configured to reduce or prevent stacked charcoal igniting devices from sticking to one another. 
         [0038]    To assemble the charcoal igniting device  10 , the blank for the first envelope portion  12 A and second envelope portion  12 B and the inner base  16 A may be removed from the sheet  50  and folded along a plurality of score lines  64 . The tabs  52 A and  52 B of the first envelop portion  12 A may be inserted into the corresponding slots  54 A and  54 B of the second envelop portion  12 B. The tabs  52 C and  52 D of the first envelop portion  12 A may be inserted into the corresponding slots  54 C and  54 D of the second envelop portion  12 B. The tabs  26  of the first and second envelop portions  12 A and  12 B may be folder at score lines  66 . A sufficient amount of glue may be placed upon one or both of the tabs  26  and inner base  16 A to affix the tabs  26  to the inner base  16 A. The chimney  14 ′ is assembled as described above and the tabs  26  are folded at corresponding score lines  58 . The chimney  14 ′ may be inserted up through the central opening of the inner base  16 A until the tabs  26  of the chimney  14 ′ rest upon the inner base  16 A. Alternatively, the tabs  26  of the cone  16 A may be inserted down through the inner base  16 A and then the tabs  26  of the chimney  14 ′ may be pressed outward to rest upon the inner base  12 A. The tabs  26  of the chimney  14 ′ may be affixed to the inner base  12 A with a sufficient amount of glue. 
         [0039]    Glue may be placed on one or both of the inner base  16 A or outer base  16 B and the inner base  16 A and outer base  16 B may be affixed together while sandwiching the tabs  26  of the first and second envelop portions  12 A and  12 B and the chimney  14 ′ therebetween. As described herein, the supply of charcoal  18  (shown in  FIG. 1 ) may be placed in the charcoal igniting device  10 . In addition, the wrapper  40  (shown in  FIG. 5 ) may be used to cover the charcoal igniting device  10 . 
         [0040]      FIG. 7  is an exploded view of the charcoal igniting device according to the embodiment of  FIG. 6 . The  FIG. 7  is similar to the  FIG. 2  and thus, for the sake of brevity, those elements already described hereinabove will not be described again. As shown in  FIG. 7 , the container  12  is retained in shape via the action of the tabs  52 A- 52 D disposed in the respective slots  54 A- 54 D. Also shown in  FIG. 7 , the outer base  16 B is integrated into or unitary with the container  12 . 
         [0041]    The particular chimney  14 ′ shown in  FIG. 7  is in the form of a frustum of a hexagonal pyramid. It is an advantage of this and other embodiments that faceted sidewalls of the chimney may facilitate an ease of assembly. The chimney  14 ′ includes a plurality of tabs  26  to provide bonding surfaces to secure the chimney  14 ′ to the outer base  16 B and/or the inner base  16 A. In a particular example, the tabs  26  may be sandwiched between the inner base  16 A and outer base  16 B to provide greater bonding strength. 
         [0042]    Also shown in  FIG. 7 , a central axis of the container  12  and a central axis of the chimney  14 ′ are aligned. That is, in this and/or other embodiments, the container  12  and chimney  14 ′ are co-axial or co-axially aligned. 
         [0043]    The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.