Abstract:
A charcoal grill ( 10 ) providing a rapid ignition and heating of the charcoal, by means of an electric fan ( 30 ) that is coupled to the body ( 12 ) of the grill. The fan decreases the overall time required to heat the charcoal to proper cooking temperature by increasing the flow of air provided to the charcoal. The increased airflow created by the incorporated fan accelerates the firing-up and heating of the charcoal by channeling air across and through the charcoal. The decreased time required to heat the charcoal to a temperature suitable for cooking, further more ensures more efficient use of the charcoal.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This patent application is a continuation-in-part of PCT Patent Application No. PCT/IL06/00805, filed Jul. 12, 2006, which is based upon and claims the benefit of Israel Patent Application No. 170823, filed Sep. 12, 2005 entitled “Portable Charcoal Grill with Incorporated Fan,” both of which are incorporated herein by reference. 
     
    
     FIELD OF INVENTION 
       [0002]    This invention relates generally to charcoal grills, and specifically to such devices that also have incorporated electric fans. 
       BACKGROUND OF THE INVENTION 
       [0003]    Barbequing over charcoal grills is enormously popular the world over. To that end, consumers are able to choose from a seemingly endless array of charcoal grills that come in all shapes and sizes. In spite of great availability of charcoal grills and in spite of the bells and whistles that may accompany them, these grills universally face one great set back. Charcoal grills require approximately 30 minutes or more to heat the charcoal to a temperature suitable for safe and effective cooking. 
         [0004]    Accelerants, like lighter fluid, may be used to decrease the igniting and heating time. However, such additives emit noxious fumes that contribute to ozone pollution. Because toxic chemicals may also enter the food and affect the flavor, one must take additional care to ensure that the additives are fully burned off before placing food on the grill. 
         [0005]    Chimney starters are another option for decreasing charcoal heating time, wherein the charcoal is heated in a separate container and when sufficiently heated, is poured into the grill&#39;s cook box. 
         [0006]    A safer and more practical option is to employ a fan. Traditionally, the tiring method of waving any available planar object, such as sheets of paper or a paper plate, is used. Using an electric fan is much less strenuous. Illustrative of such fans include U.S. Pat. No. 6,571,788 and German Patent 4423862, which disclose hand-held electric fans; German Patent 1245710, which discloses a fan that attaches to the bottom of a grill; U.S. Pat. No. 6,615,820, which discloses a fan through which air is blown from the upper side of the grill; and U.S. Pat. No. 3,933,145, which discloses a fan that is incorporated into the hood of a grill. 
         [0007]    However, such devices, for reasons that will become apparent, do not provide a simple and easy to use device that generates an airflow that travels through the charcoals, allowing accelerated ignition and heating of the charcoal without creating potential contaminants or blowing ashes into the cooking food, in accordance with the principle of the present invention. 
       SUMMARY OF INVENTION 
       [0008]    Presented herein is a portable charcoal grill with the added advantage of providing rapid ignition and heating of the charcoal, by means of an electric fan that is coupled to the body of the grill. The fan decreases the overall time required to heat the charcoal to proper cooking temperature by increasing the flow of air to the charcoal. 
         [0009]    In accordance with exemplary embodiments of the present invention, the increased airflow created by the incorporated fan aids in heating and firing up the charcoal by channeling air up through the charcoal. 
         [0010]    Because the fan blows the air into the cooking box below the level of the charcoal, thereby effectively providing additional air for the fire, while allowing the air to circulate naturally and uniformly up through the charcoal, ashes and charcoal dust are not blown up into the air or onto the food. 
         [0011]    The decreased time required to heat the charcoal to a temperature suitable for cooking that results from the use of the present invention furthermore ensures more efficient use of the charcoal. 
         [0012]    Another novel feature of some embodiments of the present invention is that charcoal can be placed on the entire surface of the cooking grid, without concern for providing entry for oxygen. This is because an attached air chamber allows air to enter from below the charcoal plate and flow up through the charcoals. 
         [0013]    Yet another useful feature offered by the present invention relates to a protective screen that prevents charcoal and ashes from escaping from the grill area, onto the fan. 
         [0014]    An additional unique feature disclosed in the present invention is providing an add-on air chamber that is incorporated within the grill box. The ability to disassemble the air chamber of the grill provides a new portability option and diversity to the charcoal grill. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0015]    These and further features and advantages of the invention will become more clearly understood in light of the ensuing description of a preferred embodiment thereof, given by way of example only, with reference to the accompanying drawings, wherein— 
           [0016]      FIG. 1  is a perspective view of an exemplary embodiment of the present invention; 
           [0017]      FIG. 2  is a perspective view of the same embodiment, with the fan door open; 
           [0018]      FIG. 3  is an exploded view of the same embodiment; 
           [0019]      FIG. 4  is a cross-sectional view of an exemplary embodiment of the present invention with the ash catcher open; 
           [0020]      FIG. 5  describes the- direction of airflow into and through the grill of the present invention; 
           [0021]      FIG. 6  describes the direction of airflow through and out of the grill of the present invention. 
           [0022]      FIGS. 7   a, b , and  c  illustrate two isometric views of an add-on air chamber in accordance with a preferred embodiment of the present invention as well as a cross sectional view of the air chamber. 
           [0023]      FIG. 8  illustrates a grill partially installed with the add-on air chamber shown in  FIG. 7 . 
           [0024]      FIG. 9  illustrates a grill provided with the add-on air chamber in accordance with another preferred embodiment of the present invention. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0025]    The description presented here relates to an exemplary embodiment of the present invention as shown in  FIGS. 1 ,  2 , and  3 , wherein a grill  10  substantially comprises a grill body  12  that houses the cooking components of the invention, an air chamber  24  that is attached at one end to body  12 , and an electric fan  30  that is set into the second end of air chamber  24 . When fan  30  of portable grill  10  is in the “ON” position, -the airflow generated by fan  30  causes the charcoal to heat more quickly and efficiently by providing additional oxygen to feed the flames. 
         [0026]    Portable grill  10  can be used repeatedly and the components are made of any durable, heat-resistant materials that will stand up to repeated use. 
         [0027]    Grill body  12  is the cook box that houses the cooking components of portable grill  10 . In an exemplary embodiment, grill body  12  is of a rectangular box shape. Other embodiments may have other shapes, for example, a square or circular container. In accordance with some embodiments of the present invention, there may be openings  58  scattered across the lateral surfaces of grill body  12 , an aesthetic feature that allows the flames to be viewed, a feature seen in  FIG. 1 . 
         [0028]    In some embodiments of the present invention, grill body  12  is constructed as two parts, an upper part and a lower part. In such embodiments, the upper part of grill body  12  may be separable from the lower part of grill body  12  and replaced. Preferably, the upper part includes grill plate  50 . 
         [0029]    Portable grill  10  may be equipped with at least three legs  14  that extend down from grill body  12 . These legs  14  serve to provide added stability when grill  10  sits on the ground. Legs  14  may be rigidly affixed to grill body  12  and positioned on grill body  12  in any configuration that will allow grill  10  to rest soundly on a surface. There is the option of encasing one or all of legs  14  with rubber or other heat resistant material for increased handling comfort. 
         [0030]    A pair of carry handles  16  allows the user to transport easily portable grill  10  from one location to another. In the exemplary embodiment, carry handles  16  are rigidly affixed to grill body  12 , on opposing short sides of grill body  12 . In alternative embodiments, carry handles  16  may be attached elsewhere in grill  10 . Furthermore, in alternative embodiments, carry handles  16  may be flexibly attached to grill body  12 . Carry handles  16  are heatproof and there is the option of encasing one or both carry handles  16  with rubber or other heat resistant material for increased handling comfort. 
         [0031]    A protective screen  18  ensures that charcoal and ashes from portable grill  10  may not reach the area of fan  30  and also prevents the heat generated by portable grill  10  from adversely affecting the user while operating fan  30 , lever  38 , and heat vent  34 . In the exemplary embodiment, protective screen  18  is securely coupled to grill body  12 , between grill body  12  and air chamber  24 . Protective screen  18  may be constructed from any rigid planar material. 
         [0032]    In some embodiments of the present invention, there is also an isolation layer  56  located between grill body  12  and air chamber  24 , seen in  FIG. 1 . Isolation layer  56  may be constructed of wool surrounded by any rigid, planar material. Isolation layer  56  prevents the transfer of heat from grill body  12  to air chamber  24 , thus protecting fan  30  from heat damage, and also preventing lever  38  and heat vent cover  35  from getting too hot to be safely handled. 
         [0033]    An ash catcher  20  provides both a convenient location to collect the ashes that accumulate during the course of using portable grill  10  and a simple disposal method. In the exemplary embodiment, ash catcher  20  is a removable drawer that is tapered at the bottom and is opened by means of a handle located on the exterior end of ash catcher  20 . In other embodiments, the drawer of ash catcher  20  may have other forms, for example, a flat or rounded bottom. 
         [0034]    In alternative embodiments, ash catcher  20  may be an integral component of grill body  12 , wherein the ashes are accessed by alternative means. For example, a sliding panel or a door that is flexibly attached to grill body  12  and rotates away from grill body  12  may be located at the lowermost portion of one side of grill body  12 . 
         [0035]    An air chamber  24  provides an enclosed area through which air may flow. Air chamber  24  is fixedly attached to one side of grill body  12  and houses the airflow regulating components of portable grill  10 . 
         [0036]    An aperture  28  located at the side of grill body  12  is connecting the grill to air chamber  24 , and is positioned so that the upper edge of aperture  28  is parallel to or below the level of charcoal plate  50 . Air chamber  24  covers aperture  28 . Aperture  28  provides the opening necessary to allow air to flow between grill body  12  and air chamber  24 . There may also be a corresponding aperture  28  in ash catcher  20 . 
         [0037]    A fan  30  is positioned at the second end of air chamber  24 , situated such that when the blades rotate and create an airflow, said air flows into grill body  12 . Fan  30  is comprised of a plurality of blades that extend from a central base and an electrical motor that is attached to the base to drive fan  30 . 
         [0038]    Fan  30  expedites the heating process by increasing the flow of air to the igniting charcoal. The air is then able to flow up and circulate through the charcoal to efficiently stimulate the heating process. Because fan  30  causes air to flow under the charcoal rather than down or across, there is no need to place a cover, hood, or lid over portable grill  10  when igniting and heating the charcoal. 
         [0039]    In the exemplary embodiment, fan  30  is firmly affixed to a fan door  32 , which is flexibly attached to air chamber  24  by means of a hinge or other connection device. Fan door  32  allows access to fan  30  for maintenance, repair, etc. 
         [0040]    A unique feature of the present invention is an inner flap  36 , which is located within air chamber  24 , situated in front of fan  30 . The feature can be seen in  FIG. 4 . Inner flap  36  is of the same shape as air chamber  24 , in order to completely close off the airflow from fan  30 . Inner flap  36  acts as a choke, providing the user with a means to adjust the amount of air flowing from fan  30  into grill body  12 , and thereby allowing the user to control the heat of the charcoal. This feature will be useful not only during the ignition phase, but also if the user wishes, for example, to re-ignite the charcoal or control the heat of the burning charcoal. 
         [0041]    In the exemplary embodiment, a lever  38  is used to rotate inner flap  36  to the desired position. Lever  38  extends through air channel  24  and is fixedly attached to inner flap  36 . Inner flap  36  is moved to the opened position when the user wishes to ignite the charcoal. In the closed position, inner flap  36  completely blocks the airflow created by fan  30 . 
         [0042]    Another unique feature of the present invention is a heat vent  34  located on the upper surface of air chamber  24 , between inner flap  36  and aperture  28 . Heat vent  34  provides an outlet for the heat from grill body  12  when inner flap  36  is partially or completely closed. 
         [0043]    In an exemplary embodiment of the present invention, heat vent  34  is covered by a heat vent cover  35  that is flexibly connected to the top of air chamber  24  by any means. Heat vent cover  35  helps prevent ash or other contaminants from reaching fan  30 . In some embodiments of the present invention, heat vent  34  may by covered other methods, for example, a sliding panel. 
         [0044]    In the exemplary embodiment, inner flap  36  and heat vent  34  may operate independently. In alternative embodiments, inner flap  36  and heat vent  34  may operate in tandem, wherein a single lever  38  operates both, such that when inner flap  36  is completely open, heat vent cover  35  is completely closed, when inner flap  36  is partially open, heat vent cover  35  is correspondingly partially open, and when inner flap  36  is completely closed, heat vent cover  35  is completely open. Yet other embodiments may allow for inner flap  36  and heat vent  34  to operate in other configurations. 
         [0045]    A power cable  42  extends out from fan  30  and leads to a power source in order to provide power to fan  30 . In one embodiment, fan  30  may be powered by a replaceable battery. In other embodiments, the power may originate from other sources, including, for example, a car battery, an electrical wall outlet, or solar power. A power switch  44  of any kind allows the user to activate or turn off fan  30 . The rotation of the fan can be controlled. 
         [0046]    Cooking grid  48  provides a cooking surface on which food can be placed. An added feature of the present invention is that the entire area of cooking grid  48  may be used, without having to leave gaps for air circulation, because air is provided by fan  30  from underneath cooking grid  48 . 
         [0047]    A charcoal plate  50  equipped with a plurality of grid-like openings, is situated inside grill body  12  and below cooking grid  48 . Charcoal plate  50  holds the charcoal required for cooking and creates a partitioned area to separate the airflow area from the charcoal. 
         [0048]      FIGS. 5 and 6  describe the airflow created by fan  30 , wherein the heavy arrows represent the direction of the airflow  54  through grill  10 . 
         [0049]    During the ignition phase, shown in  FIG. 5 , heat vent cover  35  is closed, and inner flap  36  is open. The charcoal is ignited in any suitable manner, and power switch  44  is moved to the “ON” position. When fan  30  is activated, ambient air is drawn in by fan  30 . The increased airflow created by fan  30  causes air to flow along air chamber  24 , through apertures  28  into grill body  12 . Once within grill body  12 , the air flows up and out through the plurality of openings in charcoal plate  50 , circulating air through the charcoal, and causing the charcoal to quickly reach a suitable cooking temperature. 
         [0050]    Shown in  FIG. 6  is an exemplary configuration of heat vent  34 , heat vent cover  35 , and inner flap  36  during the cooking phase, wherein the charcoal has reached cooking temperature. During this phase, heat vent cover  35  is opened and inner flap  36  is closed. The user may alternatively regulate the airflow by, for example, turning off fan  30 . In alternative embodiments, fan  30  may be equipped with a variable speed option. Heat vent  34  is provided to allow heat to escape from body  12  when fan  30  is not in use, without damaging fan  30 . 
         [0051]    There is the option of adding openings  58  to grill body  12  or ash catcher  20  or both in order to allow the flames to be viewed. An example of an embodiment with such an option is seen in  FIG. 1 . 
         [0052]    While the exemplary embodiment of the present invention is of a portable size, there is also the option of manufacturing the present invention in other sizes. Additionally, the present invention may or may not include a cover that is flexibly attached to grill body  12  or elsewhere on grill  10 , or is completely removable. 
         [0053]      FIGS. 7   a, b  and  c  illustrate two isometric views of an add-on air chamber in accordance with a preferred embodiment of the present invention as well as a cross sectional view of the air chamber. Air chamber  100  provided with a fan  102  can be incorporated onto a grill in an add-on manner wherein the chamber  100  is provided with an opening  104  having lips  106  that are slidably inserted through a corresponding receiver  108  surrounding a corresponding opening  110  in grill  112  as shown in  FIG. 8 .  FIG. 8  illustrates a grill partially installed with the add-on air chamber  100 . 
         [0054]    Basically, in the exemplary embodiment of the present invention, air chamber  100  is provided with similar features as the air chamber shown herein above in the other exemplary embodiments. In order to complete the portability feature of the grill, batteries  114  can be provided to the air chamber body wherein the batteries are activating fan  102  through switch  114 . Fan  102  can be connected to the air chamber through a hinge in a manner shown herein above. 
         [0055]    Similarly to the above mentioned exemplary embodiment, air chamber  100  is provided with an outer flap  118  and an inner flap  120  that are movable using a lever  122  as shown herein before. 
         [0056]    A bottom opening  124  is also provided in air chamber  100  so as to allow liquids from the cooking process or other liquids that may enter the air chamber to drain. 
         [0057]      FIG. 9  illustrates a grill provided with the add-on air chamber in accordance with another preferred embodiment of the present invention. Grill  112  that is shown in  FIG. 8  is provided with a cover  126  for covering the grill when it is not in use. In the exemplary embodiment, Grill  112  is provided with two openings  110  in both sides of the grill so as to allow the air chamber to be connected in one of the sides. When the opening is not used, a closure  130  is provided so as to block the opening that is not in use. 
         [0058]    Optionally, a drawer  132  is provided in the bottom portion of grill  112  so as to allow cooked materials to be kept warm. 
         [0059]    The fan can be operated in various ways such as mechanical or electrical and the means to operate the fan by no means limits the scope of the present invention. 
         [0060]    While the invention has been described with respect to a limited number of embodiments, these should not be construed as limitations on the scope of the invention, but rather as exemplifications of some of the preferred embodiments. Those skilled in the art will envision other possible variations, modifications, and applications that are also within the scope of the invention. Accordingly, the scope of the invention should not be limited by what has thus far been described, but by the appended claims and their legal equivalents.