Abstract:
An adjustable depth grid assembly for a barbecue grid. The assembly includes a grid body which has a plurality of grid cross wires whereby the grid cross wires provide support for food, as well as optionally cooking briquettes, lava rocks, and/or other flavor enhancers, resting thereon. The grid body includes at least one bracket. The grid assembly also includes an outrigger which has a plurality of outrigger cross wires whereby the outrigger cross wire provide support for food resting thereon. The outrigger has at least one locator wire wherein the locator wire is slidably received in the bracket so that the depth of the grid assembly is adjustable.

Description:
BACKGROUND 
     The present invention pertains to an adjustable grid assembly, and in particular, to an adjustable replacement grid assembly for a barbecue grill. 
     One important component of a complete barbecue grill is the grid assembly since the food-to-be-cooked rests on the grid assembly. It is not unusual that the original grid assembly on the barbecue grill is not adjustable. Over the course of time and after continuous use, the grid assembly becomes worn or unusable so that the replacement of the grid assembly becomes necessary. 
     One type of replacement grid assembly comprises a replica of the non-adjustable original grid assembly. While such a non-adjustable replica grid assembly adequately performs its function, it may only be used in conjunction with the original barbecue grill. Hence, the size of the potential market for a non-adjustable replica replacement grid assembly is not as great as the potential market for a grid assembly which could accommodate barbecue grills of various dimensions. 
     Another type of replacement grid assembly is adjustable as to adapt to the depth of the barbecue grill by the use of slidable extension bars which slidably connect through connector tubes to the front edge and/or the rear edge of a grill body. By adjusting the distance the extension bars project from the edges of the grid body, the grid assembly can adjust to the depth of the barbecue grill. Thus, this type of grid assembly (which uses extension bars) can accommodate a number of barbecue grills which have a constant width and varying depths. 
     Even though the replacement grid assembly (which has the extension bars) is adjustable for the depth of the barbecue grill, there remain a number of drawbacks associated with this type of grid assembly. These extension bars do not provide for a cooking (or grilling) surface over the entire depth of the barbecue grill because the extension bars do not comprise a cooking surface. 
     Furthermore, the replacement grid assembly with the extension bars does not readily adapt to coating, especially coating with porcelain, because the connector tubes become filled (or clogged) with the coating material during the coating operation. 
     The extension bars also do not provide for a great deal of support for the grid body since the extension bars comprise only a few bars, widely-spaced apart, connected to a cross-bar. By necessity, these extension bars must be of a size that is small enough so that if they are coated they will still fit within the tube portion of the cooking grid. As a consequence only a few bars at the front edge and rear edge of the grid assembly support the weight of any food on the grid assembly. Hence, the grid assembly with the extension bars cannot typically support any more than about twenty to twenty-five pounds of food before sagging or completely collapsing. 
     It thus becomes apparent that it would be desirable to provide for an improved adjustable grid assembly wherein there is a cooking surface over the entire depth of the barbecue grill so as to utilize the entire cooking capability of the barbecue grill. It would also be highly desirable to provide for an improved adjustable grid assembly wherein the grid assembly has the structural integrity so as to be able support a significant amount of weight (e.g., at least from about fifty to seventy-five pounds) of food-to-be-cooked. 
     It is further desirable to provide ease of porcelain enamel coating, where required, so as to allow for ease of adjustability. 
     SUMMARY 
     In one form thereof, the invention is an adjustable depth grid assembly for a barbecue grill wherein the assembly comprises a grid body which has a plurality of cross wires whereby the cross wires provide support for the food resting thereon. The grid body further includes at least one bracket. The grid assembly also has an outrigger which has a plurality of outrigger cross wires whereby the outrigger cross wire provide support for food resting thereon. The outrigger has at least one locator wire wherein the locator wire is slidably received in the bracket so that the depth of the grid assembly is adjustable. 
     In another form thereof, the invention is an adjustable depth grid assembly for a barbecue grill. The assembly comprises a grid body having a grid cross wire means for supporting food resting thereon, and an outrigger having an outrigger cross wire means for supporting food resting thereon. The outrigger further including a locator wire. The grid body further including a bracket that receives and supports the locator wire. The depth of the grid assembly is adjustable upon the sliding of the locator wire. 
     In still another form thereof, the invention is an adjustable depth grid assembly for a barbecue grill. The assembly comprises a grid body having a plurality of grid cross wires whereby the grid cross wires provide support for food resting thereon. The grid body further includes at least a first bracket and an opposite second bracket. The grid cross wires includes one edge grid cross wire and an opposite edge grid cross wire. The grid assembly further includes one outrigger having a plurality of outrigger cross wires whereby the outrigger cross wires provide support for food resting thereon. The one outrigger has at least one locator wire wherein the locator wire is slidably received in the first bracket so that the depth of the grid assembly is adjustable relative to the one edge grid cross wire. The grid assembly further includes another outrigger having a plurality of outrigger cross wires whereby the outrigger cross wires provide support for food resting thereon. The other outrigger has at least one locator wire wherein the locator wire is slidably received in the second bracket so that the depth of the grid assembly is adjustable relative to the other edge grid cross wire. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The following is a brief description of the drawings which form a part of this patent application: 
     FIG. 1 is an isometric view of a first specific embodiment of the grid assembly of the invention wherein the grid assembly, which comprises a grid body and an outrigger, rests on supports on the interior walls that define, at least in part, the firebox of the barbecue grill; 
     FIG.  2 . is a top view of the grid body of the grid assembly of FIG. 1; 
     FIG.  3 . is an end view of the grid body of FIG. 2; 
     FIG. 4 is a top view of the outrigger of the grid assembly of FIG. 1; 
     FIG. 5 is an end view of the outrigger of FIG. 4; 
     FIG. 6 is a top view of the grid assembly of FIG. 1 wherein the outrigger extends inwardly into the grid body so as to present a grid assembly with a predetermined depth; 
     FIG. 7 is a cross-sectional view of the grid assembly of FIG. 6 taken along section line  7 — 7  of FIG. 6; 
     FIG. 8 is a top view of the grid assembly of FIG. 6 wherein the outrigger has been extended outwardly from the grid body so as to provide for a grid assembly with a depth greater than that illustrated in FIG. 6; 
     FIG. 9 is a top view of a second specific embodiment of the grid assembly wherein there is a grid body with two outriggers wherein one outrigger extends from the front edge of the grid body and the other outrigger extends from the rear edge of the grid body; 
     FIG. 10 is an enlarged view of the area indicated by the dashed circle “ 10 ” in FIG. 6; 
     FIG. 11 is an enlarged view of the area indicated by the dashed circle “ 11 ” in FIG. 7; and 
     FIG. 12 is an enlarged view of the area indicated by the dashed circle “ 12 ” in FIG.  8 . 
    
    
     DETAILED DESCRIPTION 
     Referring to the drawings, there is illustrated a barbecue grill, generally designated as  20  (see FIG.  1 ). Barbecue grill  20  includes a generally rectangularly-shaped firebox  22  and a grid assembly generally designated as  24 . 
     The grid assembly  24  includes a grid body  28  which comprises a plurality of mediate cross wires  30  wherein all of the mediate cross wires  30  are generally parallel to one another. The grid body  28  further includes an edge cross wire  32  which defines one edge of the grid body  28  and another edge cross wire  34  which defines the other, opposite edge of the grid body  28 . The mediate cross wires  30 , the one edge cross wire  32 , and the other edge cross wire  34  are generally parallel to each other. 
     The grid body  28  further includes a front brace wire  36  which has a top surface  38  and a bottom surface  40  (see FIGS.  2  and  3 ). The grid body  28  also includes a rear brace wire  42  and a mediate brace wire  44 . The front brace wire  36 , the mediate brace wire  44 , and the rear brace wire  42  are each generally perpendicular to the grid cross wires ( 30 ,  32 ,  34 ). The front brace wire  36 , the rear brace wire  42  and the mediate brace wire  44  are attached to all of the cross wires, i.e., all of the mediate cross wires  30 , the one edge cross wire  32  and the other edge cross wire  34 . A trio of U-shaped (or omega-shaped) brackets  46 ,  48 ,  50  are affixed to the bottom surface  40  of the front brace wire  36 . As is apparent from the drawings, each bracket ( 46 ,  48 ,  50 ) presents a passage through which a wire may pass as will be described hereinafter. Furthermore, each bracket is of a dimension so as to provide for ample volume in the passage after the application of a coating material (e.g., porcelain enamel, nickel, chrome, etc.) to the bracket which permits the smooth and easy passage of the outrigger  60  through the bracket (as will be described hereinafter) whether in the coated or uncoated condition. 
     The grid assembly  24  further includes an outrigger generally designated as  60 . The outrigger  60  contains a plurality of mediate outrigger cross wires  62  along with an edge outrigger cross wire  64  which defines one edge of the outrigger  60  and another edge outrigger cross wire  66  which defines the other, opposite edge of the outrigger  60 . All of the cross wires, i.e., the mediate cross wires  62 , the one edge cross wire  64  and the other edge cross wire  66 , are generally parallel to one another. The outrigger  60  further includes a brace wire  68  which has an orientation that is generally perpendicular to the cross wires ( 62 ,  64 ,  66 ). The outrigger also has a spacer wire  72  spaced inwardly from the brace wire  68 . The spacer wire  72  has an orientation that is generally perpendicular to the cross wires ( 62 ,  64 ,  66 ). The brace wire  68  and the spacer wire  72  are each attached to the outrigger cross wires ( 62 ,  64 ,  66 ). The spacer wire  72  provides for spacing between the cross wires ( 62 ,  64 ,  66 ), as well as the locator wires ( 74 ,  76 ,  78 ) as described hereinafter. The spacer wire  72  also controls the warpage (or the tendency to warp) of the grid assembly which may occur during the enamelling (coating) process. The spacer wire  72  should be of such a size that it provides for good strength against such warpage. In this regard, the diameter of the spacer wire  72  is larger than the diameter of the brace wire  68 . 
     The outrigger  60  has two edge locator wires ( 74 ,  76 ) and one mediate locator wire  78 . The locator wires ( 74 ,  76 ,  78 ) are attached to the spacer wire  72 . The one edge locator wire  74  has a spring clip  82  (or some type of stop member) attached thereto. The other edge locator wire  76  also has a spring clip  84  (or some type of stop member) attached thereto. Spring clips  82  and  84  are movable along the locator wires so that their position may vary. Applicants contemplate that the spring clip may be permanent (i.e., not movable along the length of the locator wire). Furthermore, when the assembly has an enamel coating thereon, there is sufficient frictional resistance so as to provide for resistance against any movement even in the absence of spring clips. 
     In regard to the assembly of the grid assembly, the grid body  28  has a width “A” (see FIG. 2) which corresponds to the width “B” (see FIG. 1) of the firebox  22  of the barbecue grill  20 . Typically, the grid body  28  fits in the firebox  22  by resting upon supports  90  that project from the inside walls of the firebox  22 . The outrigger  60  has a width “C” (see FIG. 4) that corresponds to the width of the grid body  28  and the width of the firebox  22  so that the outrigger  60  functions with the grid body  28  to form a complete grid assembly for use with a barbecue grill  20  having a firebox  22  of a width “B”. 
     To assemble the grid assembly, the locator wires ( 74 ,  76 ,  78 ) on the outrigger  60  are passed through the passages defined by the U-brackets ( 46 ,  48 ,  50 ), respectively. The outrigger  60  may then be moved (or slid) relative to the grid body  28  so as to selectively vary the depth “E” (see FIG. 6) of the grid assembly. Because the outrigger  60  is adjustable relative to the grid body  28 , the grid assembly  20  is able to adjust to accommodate barbecue grills of different depths and having a width “B”. 
     Referring to the adjustability feature of the grid assembly, FIG.  6  and FIG. 7 illustrate the grid assembly in a position so that it is adjusted to present a pre-selected depth. In this position, the outrigger is moved toward the grid body to the maximum extent possible; however, it should be appreciated that the minimum depth of the grid assembly occurs when using the grid body alone. In FIG. 6 no spring clips (or stop members) are on the locator wires; however, it should be appreciated that the presence of stop members would limit the extent to which the outrigger can be moved toward the grid body in that the distal ends of the locator wires would abut against the stop members. 
     FIG. 8 illustrates the grid assembly in a condition wherein the outrigger is positioned so as to maximize the depth “F” of the grid assembly. 
     After assembly and as shown in FIG. 1, it should be appreciated that the outrigger slopes slightly toward the firebox bottom so that utensils will remain unobstructed on the grid surface. In this regard, the angle “G” between the surface of the outrigger and the horizontal plane is about two degrees. 
     Referring to FIG. 9, there is illustrated another specific embodiment of the invention wherein the grid assembly is generally designated as  100 . Grid assembly  100  includes a grid body  102  and a pair of outriggers  104  and  106 . 
     The main grid body  102  presents a plurality of mediate grid cross wires  110 . The grid body  102  further includes an edge grid cross wire  112  which defines one edge of the grid body  102  and another edge grid cross wire  114  which defines the other, opposite edge of the grid body  102 . The grid cross wires ( 110 ,  112 ,  114 ) are generally parallel to one another. The grid body  102  further includes a front brace wire  118  and a rear brace wire  120  and a mediate brace wire  122  wherein these brace wires ( 118 ,  120 ,  122 ) are generally parallel to one another, as well as generally perpendicular to the grid cross wires. These brace wires ( 118 ,  120 ,  122 ) are attached to the grid cross wires ( 110 ,  112 ,  114 ). The grid body  102  includes a trio of brackets  126  attached to the cross wires and a trio of brackets  128  attached to the cross wires in a fashion like the brackets are attached to the grid body in the embodiment of FIG. 1 wherein each bracket defines a passage. The brackets are designed for easy adjustment of the outrigger relative to the grid body, whether in the coated or the uncoated condition. 
     The grid assembly  100  further includes one (or a first) outrigger  104 . The outrigger  104  contains a plurality of mediate cross wires  130  along with an edge cross wire  134  which defines one edge of the outrigger  104  and another edge cross wire  136  which defines the other edge of the outrigger  104 . All of the outrigger cross wires, i.e., all of the mediate cross wires  130 , the one edge cross wire  134  and the other edge cross wire  136 , are generally parallel to one another. The outrigger  104  further includes a brace wire  138  which has an orientation that is generally perpendicular to the cross wires ( 130 ,  134 ,  136 ). The outrigger  104  also has a spacer wire  140  which also has an orientation that is generally perpendicular to the cross wires ( 130 ,  134 ,  136 ). The outrigger  104  has two edge locator wires ( 141 ,  142 ) and one mediate locator wire  143  that are attached to the spacer wire  140 . The locator wires ( 141 ,  142 ,  143 ) are generally parallel to the outrigger cross wires. 
     The grid assembly  100  further includes another (or second) outrigger  106 . The outrigger  106  contains a plurality of mediate cross wires  144  along with an edge cross wire  146  which defines one edge of the outrigger  106  and another edge cross wire  148  which defines the other edge of the outrigger  106 . All of the outrigger cross wires, i.e., all of the mediate cross wires  144 , the one edge cross wire  146  and the other edge cross wire  148 , are generally parallel to one another. The outrigger  106  further includes a brace wire  150  which has an orientation that is generally perpendicular to the cross wires ( 144 ,  146 ,  148 ). The outrigger  106  also has a spacer wire  152  which also has an orientation that is generally perpendicular to the cross wires. The outrigger  106  has two edge locator wires ( 156 ,  158 ) and one mediate locator wire  160  that are attached to the spacer wire  152 . The locator wires ( 156 ,  158 ,  160 ) are generally parallel to the outrigger cross wires. 
     In regard to the assembly of the grid assembly  100 , the outriggers  104  and  106  slide into the passages defined by the brackets attached to the cross wires in a fashion like that for the first specific embodiment. Hence, the second embodiment provides for the accommodation of fireboxes of different depths with a constant width. 
     For both embodiments it should be appreciated that the grid body and the outrigger(s) provide a cooking surface over the entire firebox. The presence of the grid cross wires and the outrigger cross wires also provide adequate support for the food resting upon the cross wires so as to be able to accommodate about fifty to eighty pounds of food resting on the grid assembly. In addition, it should be appreciated that the cooking grid has a smaller spacing to accommodate smaller foods and has additional strength when the cross wires of the outrigger overlap with the cross wires of the grid body. 
     The design of the grid assembly also provides for the easy and effective application of a protective coating, e.g., porcelain enamel, metals (e.g., metallic nickel-chrome) and the like thereto. When the grid assembly is coated with porcelain enamel, the entire grid assembly is cleanable in a dishwasher. By being cleanable in a dishwasher, the porcelain enamel-coated grind assembly does not require lengthy and tedious hand cleaning. When used to support lava rocks or the like, the grid assembly may be used in the uncoated (or raw) condition. 
     It is apparent that the present invention provides for an improved adjustable grid assembly wherein there is a cooking surface over the entire depth of the barbecue grid so as to utilize the entire cooking capability of the barbecue grid. It is also apparent that the present invention provides for an improved adjustable grid assembly wherein the grid assembly has the structural integrity so as to be able to support a significant amount of weight (e.g., at least from about fifty pounds to about seventy-five pounds) of food-to-be-cooked. 
     The patents and other documents identified herein are hereby incorporated by reference herein. 
     Other embodiments of the invention will be apparent to those skilled in the art from a consideration of the specification or practice of the invention disclosed herein. It is intended that the specification and examples be considered as illustrative only, with the true scope and spirit of the invention being indicated by the following claims.