Patent Description:
The present invention relates generally to systems, methods, and devices for grilling and warming food products. In particular, the present invention relates to systems and devices for feeding fuel into a grilling device.

Consumers use a variety of grilling devices for cooking, grilling, and warming food products. Some grilling devices, including smokers and pellet grills, burn solid fuel. This solid fuel may be in the form of wood pellets or other pelletized solid fuel materials. Pellet grills and smokers burn solid fuel to generate heat and smoke, which enters a grilling chamber to cook food residing therein. Such grilling devices typically include an externally accessible cavity, which holds solid fuel pellets and feeds them into the grilling device to be burned. Those skilled in the art often refer to this externally accessible cavity as a hopper. Various examples of a hopper are shown in <CIT>, <CIT>, <CIT> and <CIT>.

The hopper typically connects to an auger system, which slowly removes fuel pellets from the hopper and feeds them into a firepot. In conventional grilling devices, the auger system connects to the bottom of the hopper at one end and to the firepot at another end. In such a configuration, the auger system moves the pellets from the hopper to the firepot, which is situated within the grilling device. When the fuel pellets reach the firepot, a heating element ignites the fuel pellets, thus providing heat with which to cook and/or warm food products.

Along these lines, auger feeder systems can feed fuel pellets into the firepot at different rates, depending on the needs of the user. For example, increasing the rate at which fuel pellets are fed into the firepot results in higher cooking and smoking temperatures. Conversely, decreasing the rate at which fuel pellets are fed into the firepot decreases cooking and smoking temperatures. Thus, to effectively cook with a pellet grill as described above, the auger system of the grilling device must be able to maintain the necessary flow rate of fuel pellets from the hopper into the firepot. However, in typical pellet grills and auger systems, a number of obstacles can cause fuel pellets to clog or get stuck, resulting in fuel pellets backing up in the system and hindering fuel flow.

When fuel pellets get stuck within hopper or auger systems of typical pellet grills, users are often required to unclog the fuel pellets themselves. Such unclogging may require the user to remove the fuel pellets, open the auger system, identify where the fuel pellets are stuck, and manually unclog the system. Manually unclogging pellet grills in this way takes time and causes frustration and inconvenience for the user.

Ultimately, the pellet grill cannot produce the necessary levels of heat and smoke when the hopper and auger system fail to feed fuel pellets into the firepot at an appropriate rate. Accordingly, there are a number of disadvantages in grilling devices and systems that can be addressed.

The present invention provides a pellet hopper assembly in accordance with claim <NUM>.

In order to describe the manner in which the above-recited and other advantages and features of the invention can be obtained, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof, which are illustrated in the accompanying drawings. Understanding that these drawings depict only typical embodiments of the invention and are not, therefore, to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:.

The present invention relates generally to systems, methods, and devices for grilling and warming food products.

The pellet hopper of the present invention includes smooth pellet drop features that increase the evacuation efficiency of the pellet hopper, thus reducing the incidence of pellet evacuation failure. The embodiments disclosed herein, where implemented, may reduce the frequency of temperature loss during the processes of grilling and warming food products. Users are therefore able to use pellet grills without scrupulously overseeing the evacuation status of the fuel pellets into the auger system. Users can also avoid the need to restart the pellet grill in response to an interrupted pellet evacuation. Additionally, in some instances, the aforementioned benefits are available to existing pellet grills via after-market modification, as described below.

Turning now to the figures, <FIG> illustrates a perspective view of a pellet hopper <NUM> disposed within a pellet grill <NUM> according to an embodiment of the present invention.

The pellet hopper <NUM> is disposed within a cavity <NUM> positioned to the side of the pellet grill <NUM>. The pellet grill <NUM> also includes a hopper lid <NUM> that a user may open to selectively access the pellet hopper <NUM> inside the cavity <NUM>.

<FIG> illustrates the pellet grill <NUM>, including the pellet hopper <NUM>, cavity <NUM>, and hopper lid <NUM> of <FIG> in an exploded view. During use, a user opens the hopper lid <NUM> and inserts fuel, such as solid fuel pellets, into the cavity <NUM> of the pellet grill <NUM>. The pellet hopper <NUM> directs the flow of pellets down through a pellet evacuation opening <NUM> and into an auger feeder system <NUM> (see <FIG>). The auger feeder system then feeds the fuel pellets into a firepot for ignition and heat production.

Along these lines, <FIG> illustrates a schematic view of a pellet hopper <NUM>, auger feeder system <NUM>, and firepot <NUM> within a pellet grill <NUM>. As shown, the pellet hopper <NUM> is disposed above the auger feeder system <NUM>, which receives fuel pellets <NUM> through the pellet evacuation opening <NUM> of the pellet hopper <NUM>. The auger feeder system <NUM> then feeds the fuel pellets <NUM> into the firepot <NUM> for combustion and heat production within the pellet grill <NUM>.

The fuel pellets <NUM> pass from the pellet evacuation opening <NUM> of the pellet hopper <NUM> and into the auger feeder system <NUM> at the interface <NUM> therebetween. In one or more embodiments of the present invention, the interface <NUM> between the pellet hopper <NUM> and the auger feeder system <NUM> may also include one or more interface components such as gaskets, seals, connection means, or the like. Such interface components will be described in more detail below with reference to FIGS. In embodiments described in the present invention, the interface <NUM> is substantially free of any obstacles that may interrupt the transfer of fuel pellets <NUM> from the pellet hopper <NUM> to the auger feeder system <NUM>.

For example, <FIG> illustrates a perspective view of a hopper bottom <NUM> according to an embodiment of the present invention.

The hopper bottom <NUM> may be one component of a pellet hopper assembly. The hopper bottom <NUM> illustrated in <FIG> includes a first bottom panel 205a, a second bottom panel 205b, and a third bottom panel 205c. The first bottom panel 205a is connected to the second bottom panel 205b at a first interface 210a and the second bottom panel 205b is connected to the third bottom panel 205c at a second interface 210b.

In one or more embodiments, the hopper bottom <NUM> may also include a fourth bottom panel (not shown in <FIG>) that is connected to the third bottom panel 205c at a third interface and the first bottom panel 205a at a fourth interface. This fourth bottom panel may also be angled at a nonzero angle relative to the horizontal plane defined by the pellet evacuation opening <NUM>. Like the other bottom panels 205a-205c, the fourth bottom panel of an alternative embodiment may also include an inner edge that partially defines the pellet evacuation opening <NUM>.

Also, as will be described below with reference to subsequent figures, one or more embodiments of the hopper bottom <NUM>, such as the hopper bottom <NUM> illustrated in <FIG>, may also include one or more vertical walls extending vertically downward from one or more of the inner edges 215a-215c of the bottom panels 205a-205c. These vertical walls may extend downward to, or through, the interface <NUM> between the pellet hopper <NUM> and auger feeder system <NUM> shown in <FIG>. Again, more detail regarding inner edges 815a-815d and outer edges 825a-825d is given below with reference to <FIG>. It is simply noted here that the embodiment of the hopper bottom <NUM> illustrated in <FIG> may also include these additional vertical walls.

In addition, it is important to note that in one or more embodiments of the pellet hopper <NUM> described herein, one or more vertical surfaces <NUM> may extend from up from an outer edge of each bottom panel 205a-205c. <FIG> illustrates one such vertical surface <NUM> extending up from the first bottom panel 205a. In one or more embodiments, similar vertical surfaces may interface with the interior of cavity <NUM> of the grill <NUM> shown in <FIG>. The vertical surfaces <NUM> may be separately formed with one or more bottom panels 205a-205c or integrally formed therewith.

Also, of note, one or more bottom panels 205a-205c of the present invention may include a secondary evacuation opening <NUM> extending therethrough. <FIG> illustrates such a secondary evacuation opening <NUM> extending through the third bottom panel 205c. A user may manipulate a door that removably covers the secondary evacuation opening <NUM> to selectively evacuate fuel pellets <NUM> out through the secondary evacuation opening <NUM> when necessary. In one or more embodiments, one or more secondary evacuation openings <NUM> may also serve as an overflow evacuation opening.

Each bottom panel 205a-205c includes a respective inner edge 215a-215c that at least partially defines a pellet evacuation opening <NUM>, which lies in a horizontal plane defined by the inner edges 215a-215c. In addition, each bottom panel 205a-205c is disposed so as to form a nonzero angle relative to the horizontal plane. In this way, each of the bottom panels 205a-205c is tilted downward toward the pellet evacuation opening <NUM>.

The angle at which each bottom panel 205a-205c is tilted downward toward the pellet evacuation opening <NUM> affects the transfer of fuel pellets <NUM> from the cavity <NUM>, through the pellet evacuation opening <NUM>, and into the auger feeder system <NUM>. For example, the smaller the angle of each bottom panel 205a-205c relative to the horizontal plane defined by the inner edges 215a-215c of each bottom panel 205a-205c, the less inclined the fuel pellets will be to travel down each bottom panel 205a-205c toward the pellet evacuation opening <NUM> due to gravity.

In contrast, and along the same lines, the greater the angle of each bottom panel 205a-205c relative to the horizontal plane (i.e., the steeper the bottom panels), the more inclined the fuel pellets will be to travel down the bottom panels 205a-205c toward the pellet evacuation opening <NUM>. Thus, the manufacturer can select the angles at which each bottom panel 205a-205c tilted to ensure effective evacuation of fuel pellets <NUM> through the pellet evacuation opening <NUM>. When determining these angles, the manufacturer may take into account a number of factors that also affect the transfer of fuel pellets <NUM> toward the pellet evacuation opening <NUM>.

For instance, one factor the manufacturer may consider is the frictional properties of the materials used to form the bottom panels 205a-205c. The manufacturer may also consider the frictional properties of the fuel pellets <NUM> a user will likely use to heat the pellet grill <NUM>. Also, the manufacturer may consider the environment in which the user grills food with the pellet grill <NUM>.

For example, moisture can affect the frictional properties of the fuel pellets <NUM> and the bottom panels 205a-205c and make each stickier. Thus, the manufacturer may form the bottom panels 205a-205c at steeper angles when the user is likely to expose the fuel pellets <NUM> and/or bottom panels 205a-205c to water from outdoor sprinklers, rain, dew, humidity or the like.

With this in mind, there are a number of angles, and ranges thereof, at which to dispose each bottom panel 205a-205c that may be advantageous to promote fuel pellet evacuation. These nonzero angles of the bottom panels 205a-205c are illustrated in <FIG>, which illustrate front and side views of the hopper bottom <NUM> illustrated in <FIG>. For example, in one or more embodiments, as seen in <FIG>, the first bottom panel 205a may form a first nonzero angle θ<NUM> relative to the horizontal plane H of between about <NUM> degrees and <NUM> degrees. In one or more embodiments, the first nonzero angle θ<NUM> may be between about <NUM> degrees and <NUM> degrees, and preferably about <NUM> degrees.

Also, as shown in <FIG>, in one or more embodiments, the second bottom panel 205b may form a second nonzero angle θ<NUM> relative to the horizontal plane H of between about <NUM> degrees and <NUM> degrees. In one or more embodiments, the second nonzero angle θ<NUM> may be between about <NUM> degrees and <NUM> degrees. In one or more embodiments, the second nonzero angle θ<NUM> is preferably about <NUM> degrees.

As seen in <FIG>, in one or more embodiments, the third bottom panel 205c may form a third nonzero angle θ<NUM> relative to the horizontal plane H of between about <NUM> degrees and <NUM> degrees, or between about <NUM> degrees and <NUM> degrees. Preferably, in one or more embodiments, the second nonzero angle θ<NUM> is about <NUM> degrees.

Along these lines, <FIG> illustrate an embodiment of a hopper bottom <NUM> having bottom panels 305a-305c disposed at various other angles α<NUM>-<NUM> relative to the horizontal plane H. In the embodiment illustrated in <FIG>, the angles of the first, second, and third panels 305a-305c may be less than the angles of respective bottom panels 205a-205c illustrated in <FIG>. In this way, the volume may be maximized within the hopper bottom <NUM>. This extra volume may be advantageous depending on where the manufacturer disposes the pellet hopper <NUM>.

For example, with reference back to <FIG>, in one or more embodiments, the manufacturer may dispose the cavity <NUM> and pellet hopper <NUM> on a front side of the pellet grill <NUM>. In such a front-loaded hopper configuration, it may be advantageous and convenient for the user to reduce the horizontal depth of the cavity <NUM>, and thus the cavity volume, that extends out in front of the pellet hopper <NUM>. One will appreciate that the volume of the cavity <NUM> may vary depending on where the manufacturer places the cavity <NUM> and pellet hopper <NUM> on the pellet grill <NUM>.

In an embodiment having a front-loaded hopper with a reduced volume cavity <NUM>, bottom panels 305a-305c of the hopper bottom <NUM> within the cavity <NUM>, such as the hopper bottom <NUM> shown in <FIG>, may have reduced angles α<NUM>-<NUM> relative to corresponding angles θ<NUM>-<NUM> shown in <FIG>. These reduced angles α<NUM>-<NUM> result in a larger volume within the cavity <NUM> available for loading fuel pellets <NUM>.

For example, the first bottom panel 305a may form a first nonzero angle α<NUM> relative to the horizontal plane H of between about <NUM> degrees and <NUM> degrees. In one or more embodiments, the first nonzero angle α<NUM> may be between about <NUM> degrees and <NUM> degrees. In one or more embodiments, the first nonzero angle α<NUM> is preferably about <NUM> degrees.

Also, as shown in <FIG>, the second bottom panel 305b may form a second nonzero angle α<NUM> relative to the horizontal plane H of between about <NUM> degrees and <NUM> degrees. In one or more embodiments, the second nonzero angle α<NUM> may be between about <NUM> degrees and <NUM> degrees. In one or more embodiments, the second nonzero angle α<NUM> is preferably about <NUM> degrees.

In one or more embodiments, the third bottom panel 305c shown in <FIG> may form a third nonzero angle α<NUM> relative to the horizontal plane H of between about <NUM> degrees and <NUM> degrees. In one or more embodiments, the third nonzero angle α<NUM> may be between about <NUM> degrees and <NUM> degrees. In one or more embodiments, the third nonzero angle α<NUM> is preferably about <NUM> degrees.

Again, as noted above, one or more embodiments of a hopper bottom may include bottom panels 205a-205c, 305a-305c disposed at various different angles θ, α or combination thereof, as described herein. The manufacturer may determine those angles θ, α based on a number of factors discussed above to optimize the transfer of fuel pellets <NUM> from the pellet hopper <NUM> to the auger feeder system <NUM> in a variety of different environments and configurations.

<FIG> illustrates a perspective view of a pellet hopper <NUM> according to the invention. Pellet hopper <NUM> includes a first bottom panel 405a, a second bottom panel 405b, and a third bottom panel 405c, similar to those shown in other embodiments described herein. In addition, pellet hopper <NUM> includes a wall panel <NUM> connected to the first and third bottom panels 405a, 405c at third and fourth interfaces 415a, 415b, respectively.

The wall panel <NUM> includes a main surface <NUM> and a bottom angled surface <NUM>. The main surface <NUM> of the wall panel <NUM> extends vertically upward from the first and third bottom panels 405a, 405c and interface with the inside of the cavity <NUM> of the pellet grill <NUM> (as shown in <FIG> and <FIG>). The bottom angled surface <NUM> of the wall panel <NUM> is connected to the main surface <NUM>. The bottom angled surface <NUM> includes a fourth inner edge <NUM> that at least partially defines the pellet evacuation opening <NUM>.

Similar to the bottom panels 405a-405c of the illustrated pellet hopper <NUM>, the bottom angled surface <NUM> of the wall panel <NUM> is also angled at a nonzero angle relative to the horizontal plane defined by the pellet evacuation opening <NUM>. In this way, the bottom angled surface <NUM> of the wall panel <NUM> is tilted downward toward the pellet evacuation opening <NUM>. The bottom angled surface <NUM> thus promotes the transfer of fuel pellets <NUM> from the pellet hopper <NUM> through the pellet evacuation opening <NUM>.

Along these lines, <FIG> illustrates a perspective view of just the wall panel <NUM> illustrated in <FIG>. As shown, the bottom angled surface <NUM> of the wall panel <NUM> connects to the main surface <NUM> and extends at a nonzero angle β relative to the horizontal plane H. The horizontal plane H is defined by the pellet evacuation opening <NUM> shown in <FIG>. Like the other nonzero angles α, θ described herein with reference to bottom panels 205a-205c, 305a-305c shown in <FIG>, nonzero angle β may vary in different embodiments. For example, nonzero angle β may be similar to any of the angles α, θ described above with reference to other embodiments.

Also, nonzero angle β may be different than any of the angles α, θ described above with reference to other embodiments. For example, angle β may be between about <NUM> degrees and <NUM> degrees or between about <NUM> degrees and <NUM> degrees. Again, the manufacturer can form the bottom angled surface <NUM> at any number of angles depending on the frictional and environmental factors noted above to optimize the transfer of fuel pellets <NUM>.

<FIG> illustrates a bottom perspective view of another embodiment of a pellet hopper <NUM> that also includes a shelf plate <NUM>. The shelf plate <NUM> may be disposed below the bottom panels 510a-510c of the pellet hopper <NUM>. In one or more embodiments, the shelf plate <NUM> is connected to at least one of the bottom panels 510a-510c of the pellet hopper <NUM> and forms a horizontal surface <NUM> disposed below the bottom panels 510a-510c. In one or more embodiments, the horizontal surface <NUM> may be parallel to a horizontal plane in which the pellet evacuation opening <NUM> lies. Additionally, or alternatively, in one or more embodiments, the horizontal surface <NUM> of the shelf plate <NUM> is parallel and coplanar with the horizontal plane in which the pellet evacuation opening <NUM> lies.

<FIG> shows a top perspective view of an embodiment of a shelf plate <NUM> according to the present disclosure. In the illustrated embodiment, the shelf plate <NUM> includes a horizontal surface <NUM> extending around and at least partially defining a shelf plate opening <NUM>. One or more vertical surfaces 530a-530d extends upward from the horizontal surface <NUM>. In one or more embodiments, the vertical surfaces 530a-530d of the shelf plate <NUM> may extend up from the horizontal surface <NUM> at various heights.

In one or more embodiments, the height of each vertical surface 530a-530d may extend up to the bottom surface of a respective bottom panel 510a-510c of the pellet hopper <NUM>. Because each bottom panel 510a-510c of the pellet hopper <NUM> may form a different nonzero angle, as discussed above, each respective vertical surface 530a-530d of the shelf plate <NUM> may necessarily extend upward to varying heights in order to extend between the horizontal surface <NUM> of the shelf plate <NUM> and the bottom surface of the corresponding bottom panel 510a-510c. Accordingly, one will appreciate that the height of each vertical surface 530a-530d of the shelf plate <NUM> may therefore vary depending on the angles of the bottom panels 510a-510c to which the shelf plate <NUM> is connected.

In one or more embodiments, the shelf plate <NUM> is connected to the pellet hopper <NUM> where the upper edge <NUM> of each vertical surface 530a-530d of the shelf plate <NUM> contacts the bottom surfaces of the bottom panels 510a-510c of the pellet hopper <NUM>. Additionally, or alternatively, the perimeter edge <NUM> of the shelf plate opening <NUM> may be connected to the inner edges <NUM> of respective bottom panels 510a-510c.

<FIG> illustrates a side view of the pellet hopper <NUM> illustrated in <FIG>. In the illustrated embodiment, the vertical surface 530b of the shelf plate <NUM> extends from the bottom surface of the bottom panel 510b to the horizontal surface <NUM> of the shelf plate <NUM>. Additionally, one will note that the embodiment of the pellet hopper <NUM> illustrated in <FIG>, <FIG>, includes a wall panel <NUM>. In such an embodiment, a vertical surface 530d of the shelf plate <NUM> may extend from the horizontal surface <NUM> of the shelf plate <NUM> to the main surface <NUM> of the wall panel <NUM>.

Thus, in one or more embodiments, the vertical surface 530d of the shelf plate <NUM> may span the vertical height of the bottom angled surface <NUM> of the wall panel <NUM>, shown in <FIG>. As such, as shown in <FIG>, the vertical surface 530d of the shelf plate <NUM> corresponding in position with the wall panel <NUM> may be connected to the main surface <NUM> of the wall panel.

Additionally, or alternatively, in one or more embodiments, the upper edge 535b of the vertical surface 530d of the shelf plate <NUM> corresponding in position with the wall panel <NUM> may be connected to the interface <NUM> between the main surface <NUM> and the bottom angled surface <NUM> of the wall panel <NUM>.

The horizontal surface <NUM> of the shelf plate <NUM> provides a surface on which a manufacturer can place a gasket or seal between the pellet hopper <NUM> and auger feeder system <NUM>. In such a configuration, the horizontal surface <NUM> of the shelf plate <NUM> provides a flat, level surface with which a gasket or seal can effectively interface. This may advantageously provide an improved, water-tight seal between the pellet hoppers <NUM> and auger feeder system <NUM> of the present disclosure. As such, moisture is not likely to enter the pellet hopper <NUM> and affect the frictional properties of the pellet hopper <NUM> and fuel pellets <NUM>, or otherwise negatively affect the pellet hopper <NUM> through material corrosion and the like.

In addition, in one or more embodiments, the shelf plate opening <NUM> is at least as large as the pellet evacuation opening <NUM> of the pellet hopper <NUM>. In this way, the horizontal surface <NUM> of the shelf plate <NUM> extends around and away from the pellet evacuation opening <NUM>. Thus, the shelf plate <NUM> does not occlude the pellet evacuation opening <NUM> or hinder the fuel pellets <NUM> flowing therethrough during use.

The top perspective view of the pellet hopper <NUM> illustrated in <FIG>, which is similar to the pellet hopper <NUM> of <FIG>, includes a shelf plate <NUM> disposed below the bottom panels 510a-510c. However, as illustrated from the top perspective view, no portion of the shelf plate <NUM> obstructs, extends into, or otherwise physically interferes with the pellet evacuation opening <NUM>.

However, in one or more embodiments of a pellet grill, the opening to the auger feeder system <NUM> may be smaller than the pellet evacuation opening with which the auger feeder system <NUM> interfaces. Additionally, or alternatively, one or more sealing components, such as a gasket or other type of seal, may at least partially occlude the pellet evacuation openings described herein. For example, <FIG> shows an embodiment of a pellet hopper <NUM> having a partially occluded pellet evacuation opening <NUM>.

As noted above, and as shown in <FIG>, a number of obstacles may occlude the pellet evacuation opening <NUM>. These obstacles may include a sealing gasket or other component of an auger feeder system <NUM> to which the pellet hopper <NUM> is connected. In addition, in one or more embodiments, as shown in <FIG>, a pellet grill may include a pellet hopper <NUM> that includes one or more horizontal features <NUM> extending from the inner edges <NUM> of the bottom panels <NUM>.

In the illustrated embodiment of <FIG>, a horizontal feature <NUM> extends inward from the inner edges <NUM> of the bottom panels <NUM> to at least partially occlude the pellet evacuation opening <NUM>. In such an embodiment, it may be advantageous to minimize the negative affect these horizontal features <NUM> may have on the flow of fuel pellets <NUM> through the pellet evacuation opening <NUM>. For example, the horizontal feature <NUM>, or any other pellet evacuation opening <NUM> occlusion feature (whether horizontal or not), may cause fuel pellets <NUM> flowing through the pellet evacuation opening <NUM> to build-up and clog within the pellet hopper <NUM>.

Accordingly, one or more embodiments of a pellet hopper <NUM> may include a pellet evacuation insert <NUM>. As seen in <FIG>, a manufacturer or user may dispose the pellet evacuation insert <NUM> within the pellet hopper <NUM>. The pellet evacuation insert <NUM> may sit over and around the pellet evacuation opening <NUM> and on top of a bottom portion of the bottom panels <NUM>. The pellet evacuation insert <NUM> may advantageously cover any occlusion of the pellet evacuation opening <NUM>, such as the horizontal features <NUM> illustrated in <FIG>, and provide smooth, angled surfaces extending from the bottom panels <NUM> to the pellet evacuation opening <NUM>.

Along these lines, <FIG> illustrates a top perspective view of an embodiment of a pellet evacuation insert <NUM>. The pellet evacuation insert <NUM> includes a first insert panel 805a connected to a second insert panel 805b at a first interface 810a and a third insert panel 805c connected to the second insert panel 805b at a second interface 810b. In addition, in one or more embodiments, the pellet evacuation insert <NUM> includes a fourth insert panel 805d connected to the third and first insert panels 805c, 805a at third and fourth interfaces 810c, 810d, respectively.

In addition, each insert panel 805a-805d includes a corresponding inner edge 815a-815d that at least partially defines a pellet evacuation insert opening <NUM>. In one or more embodiments, each insert panel 805a-805d is trapezoidal. Also, in one or more embodiments, the pellet evacuation insert opening <NUM> formed by the inner edges 815a-815d is rectangular. One will appreciate that the shape of the pellet evacuation insert opening <NUM> and the insert panels 805a-805d may vary depending on the number of insert panels 805a-805d included in the pellet evacuation insert <NUM>.

Each insert panel 805a-805d forms a nonzero angle relative to the horizontal plane in which the inner edges 815a-815d lie. In this way, each insert panel 805a-805d tilts downward toward the pellet evacuation insert opening <NUM> to promote the flow of fuel pellets <NUM> down into the auger feeder system <NUM>. When the pellet evacuation insert <NUM> is disposed within a pellet hopper <NUM>, such as that shown in <FIG>, the outer edges 825a-825d of the insert panels 805a-805d come into contact with the upper surfaces of respective bottom panels <NUM> of the pellet hopper <NUM>.

In this way, a fuel pellet <NUM> flowing down one of the bottom panels <NUM> may smoothly transition from the surface of the bottom panel <NUM> and across the upper surface of the insert panel 805a-805d. Then, the fuel pellet <NUM> can flow down through the pellet evacuation insert opening <NUM> and thus through the pellet evacuation opening <NUM>. In order to form the smooth transition between the bottom panels <NUM> and the insert panels 805a-805d, the nonzero angles formed by the insert panels 805a-805d must be less than the nonzero angles θ of the bottom panels <NUM>.

For example, <FIG> illustrates a front view of the pellet evacuation insert <NUM> shown in <FIG>. In addition, <FIG> illustrates a cross-sectional view of the bottom panels <NUM> illustrated in <FIG> on which the pellet evacuation insert <NUM> is disposed. The bottom panels <NUM>(a,c) may also include an obstructing feature of horizontal features <NUM> that at least partially occludes the pellet evacuation opening <NUM>, similarly as shown in <FIG>. In such a configuration, the nonzero angles µ<NUM>, µ<NUM> of the first and third insert panels 805a, 805c relative to the horizontal plane H are less than the nonzero angles θ<NUM>, θ<NUM> formed by the first and third bottom panels <NUM>, respectively.

As a non-limiting example, the embodiment shown in <FIG> may have a first bottom panel <NUM> disposed at a nonzero angle θ<NUM> of <NUM> degrees. In such an embodiment, the nonzero angle µ<NUM> of the first insert panel 805a is less than <NUM> degrees. In this way, the first insert panel 805a of the pellet evacuation insert <NUM> can span the horizontal feature <NUM> occluding the pellet evacuation opening of the pellet hopper and provide a transition surface over which fuel pellets <NUM> may flow into the pellet evacuation opening.

Likewise, as shown in <FIG>, the non-zero angles µ<NUM> - µ<NUM> of insert panels 805b-805d are less than the non-zero angles θ<NUM>-<NUM> of the bottom panels <NUM> with which the insert panels 805b-805d come into contact. For example, in one embodiment where θ<NUM> is <NUM> degrees, then µ<NUM> is less than <NUM> degrees. Likewise, for example, in one embodiment where θ<NUM> is <NUM> degrees and θ<NUM> is <NUM> degrees, then µ<NUM> is less than <NUM> degrees and µ<NUM> is less than <NUM> degrees.

The foregoing are not meant to be limiting in any way. Rather, the foregoing examples are given to illustrate that the nonzero angles µ<NUM> - µ<NUM> of each insert panel 805a-805d are less than the angles θ<NUM> - θ<NUM> of corresponding bottom panels <NUM> on which the pellet evacuation insert <NUM> rests. In this way, the pellet evacuation insert may be configured such that each insert panel 805a-805d contacts the upper surfaces of a corresponding bottom panel <NUM> of a pellet hopper and spans any physical occlusions of horizontal features <NUM> blocking a pellet evacuation opening. Accordingly, the pellet evacuation insert may advantageously promote the flow of fuel pellets <NUM> down to the auger feeder system <NUM>, even if a one or more occlusions of horizontal features <NUM> partially blocks the pellet evacuation opening.

One will appreciate that the nonzero angle µ<NUM> -µ<NUM> of each insert panel 805a-805d may vary between embodiments depending on the nonzero angles θ<NUM> - θ<NUM>, α<NUM> - α<NUM> of the bottom panels 715a-715d. Since the nonzero angles θ<NUM> - θ<NUM>, α<NUM> - α<NUM> of the bottom panels 715a-715d vary between pellet hopper embodiments as described herein, the nonzero angle µ<NUM> -µ<NUM> of each insert panel 805a-805d of various embodiments of the pellet evacuation insert <NUM> may also vary accordingly.

Also, as shown in <FIG>, in one or more embodiments of the pellet evacuation insert <NUM>, one or more vertical walls 830a-830d extend from the inner edges 815a-815d of the pellet evacuation insert <NUM>, respectively. The vertical walls 830a-830d extends vertically downward into the pellet evacuation opening of a pellet hopper during use. In one or more embodiments, each wall may extend through a pellet hopper opening and into the auger feeder system <NUM> to which the pellet hopper <NUM> is connected. Alternatively, in one or more embodiments, the vertical walls 830a-830d may extend only partially through a pellet evacuation opening toward the auger feeder system <NUM>.

Also, in one or more embodiments, each vertical wall 830a-830d may extend downward to varying degrees. In one or more embodiments, the vertical walls 830a-830d may extend downward through a pellet evacuation opening so as to shield flowing fuel pellets <NUM> from encountering any components between a pellet hopper and auger feeder system <NUM>. Such components may include the shelf plates, auger feeder system opening, gaskets, or seals described herein. These interface components may reside at or near the interface <NUM> between the pellet hopper <NUM> and auger feeder system <NUM>, such as those shown in <FIG>.

Interface components positioned at the interface may present edges, crevasses, or other non-smooth contours through the interface <NUM>. These non-smooth features of any interface components may occlude the pellet evacuation opening or otherwise occlude fuel pellets <NUM> flowing into the auger feeder system <NUM>. Accordingly, the vertical walls 830a-830d of the pellet evacuation insert <NUM> may extend at least partially through the interface <NUM> and provide sidewalls having smooth surfaces through the interface. In this way, the vertical walls 830a-830d of the pellet evacuation insert <NUM> may further reduce the chance of fuel pellets <NUM> clogging and backing up as they flow through the pellet evacuation opening of a pellet hopper <NUM>.

In addition, in one embodiment according to the present invention, a manufacturer can form the pellet evacuation insert <NUM> separately from the pellet hoppers <NUM> described herein. In such an embodiment, a user or manufacturer can separately and selectively combine the pellet evacuation insert <NUM> into a pellet hopper <NUM> when needed. Alternatively, in one or more embodiments of pellet hoppers <NUM> described herein, the manufacturer may form the pellet evacuation insert integrally with a pellet hopper <NUM> as one piece. In this way, the manufacturer can ensure the effective flow of fuel pellets <NUM> as provided by the pellet evacuation insert <NUM> described herein.

One will also appreciate, as noted above, that in one or more embodiments, the vertical walls 830a-830d of the pellet evacuation insert <NUM> may also extend from the inner edges of the bottom panels described herein, rather than a separate pellet evacuation insert <NUM>. This may be the case in an embodiment where the pellet evacuation insert <NUM> is formed integrally with a pellet hopper <NUM>, as described above. In such an embodiment, the vertical walls 830a-830d extending from inner edges of the bottom panels of a pellet hopper <NUM> may serve the same function and provide the same advantages as the vertical walls 830a-830d extending from the inner edges 815a-815d of the various insert panels 805a-805d of the pellet evacuation insert <NUM>.

Claim 1:
A pellet hopper assembly, comprising:
a hopper bottom, comprising:
a first panel (405a) connected to a second panel (405b) at a first interface and the second panel connected to a third panel (405c) at a second interface, wherein a first inner edge of the first panel, a second inner edge of the second panel, and a third inner edge of the third panel together define a pellet evacuation opening (<NUM>), and wherein:
the first panel (405a) forms a first nonzero angle with respect to a horizontal plane such that the first panel tilts downward toward the pellet evacuation opening;
the second panel (405b) forms a second nonzero angle with respect to the horizontal plane such that the second panel tilts downward toward the pellet evacuation opening; and
the third panel (405c) forms a third nonzero angle with respect to the horizontal plane such that the third panel tilts downward toward the pellet evacuation opening; and
a wall panel (<NUM>) extending between and connected to the first and third panels at third and
fourth interfaces, respectively, the wall panel comprising:
a main surface (<NUM>) extending vertically upward from the third and fourth interfaces; and
a bottom angled surface (<NUM>) connected to the main surface, the bottom angled surface including a fourth inner edge (<NUM>) that at least partially defines the pellet evacuation opening, the bottom angled surface forming a fourth nonzero angle with respect to the horizontal plane such that the bottom angled surface tilts downward toward the pellet evacuation opening.