Patent ID: 12238828

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Set forth below is a description of what are currently believed to be the preferred embodiments or best representative examples of the inventions claimed. Future and present representations or modifications to the embodiments and preferred embodiments are contemplated. Any alterations or modifications which make insubstantial changes in function, purpose, structure, or result are intended to be covered by the claims of this patent. The present inventions may be used as part of an electric grill, or may be adapted for use in any other electronic outdoor device.

FIG.1provides context for embodiments of the invention, showing components of an electric grill assembly, including a removable controller100, a mounting bracket200, and an electric grill's housing300. Throughout this disclosure, components of electronic controller100are referred to by reference numerals in the100's; components of mounting bracket200are referred to by numerals in the200's; and electric grill housing300components are referred to by numerals in the300's.

Embodiments of the inventions provide a mounting bracket200which allows a controller100to be easily attached and removed from an electric grill's housing300. Mounting bracket200may be affixed to the electric grill housing300—which is typically formed of a metal, such as steel-via a bolt or screw201. Rivets, or welding techniques, may also be used. Mounting bracket200may receive and engage electronic controller100, thereby connecting or disconnecting the electronic controller100to electric grill housing300. Furthermore, mounting bracket200electrically connects controller100to the housing300to act as ground with respect to the housing300. Moreover, embodiments of the inventions provide a hollow mounting bracket200. A thermal barrier forms in the hollow air space and protects the electronic controller's internal circuitry.

Electronic controller100's exterior is preferably formed of a plastic housing. Other materials may be used, but it is preferred that controller100be formed of a material that does not conduct electricity or heat. Controller100has a power cord110, which supplies electricity which can be converted to heat for cooking. Moreover, power cord110may plug into a wall outlet and provide an electrical ground for controller100. Therefore, in embodiments where controller100is in electrical contact with housing300, controller100may act as an electrical ground. Stated another way, current may travel from housing300through mounting bracket200, to controller100, and then to ground via extension cord110. For example, manufacturing mounting bracket200from steel, or any other conductive material, will electrically connect controller100with housing300. In such embodiments, any stray or leaked currents in the electric grill housing300dissipate through the electronic controller100and to the ground. Providing an electrical ground to the housing300is an important safety feature. Scenarios exist in which electric currents may inadvertently reach the housing300, for example as a result of unsafe use. The result of an electric current reaching the housing300creates a risk of electric shock to a user. It is therefore desirable to provide a path for any current that inadvertently reaches housing300to flow to ground.

Controller100's exterior further includes one or more engagement members170,180. For example,FIG.2A, which shows controller100from a rear view, shows two engagement members170,180in the form of raised edges. Both engagement members170,180inFIG.2Afurther include a spring element190,195, respectively. As described further below, engagement members170,180and spring elements190,195are used to align controller100in mounting bracket200, and to securely fasten controller100to mounting bracket200. For example, when controller100is inserted into mounting bracket200, engagement members170,180are guided by mounting bracket200's lower lip271and upper lip272until spring elements190,195align with, and engage, mounting bracket's tabs280,281. Engaging spring elements190,195with tabs280,281secures controller100to mounting bracket200.

Spring elements190,195may be metallic and capable of conducting electricity. In such embodiments, engaging spring elements190,195with steel mounting bracket200(and more specifically, steel tabs280,281) establishes an electrical connection. Spring elements190,195may be connected to power cord110, thereby completing the electrical connection from housing300, through mounting bracket200, and power cord110.

Further yet, controller100may have one or more temperature probes, such as thermocouples120. By way of example,FIGS.1and2Ashow two thermocouples120protruding from controller100's back side. As will become apparent herein, when controller100is engaged with mounting bracket200, thermocouples120may extend through the mounting bracket200and into one or more openings310in the electric grill housing300. From this position, temperature probes such as thermocouples120may measure the temperature inside the housing300. Such temperature feedback may be used by electronic controller100in regulating a cooking temperature.

In alternative embodiments, seen for example inFIG.2B, controller100has only one thermocouple120and one engagement member170, with two spring elements190,195mounted to engagement member170.

It should be understood that embodiments of the inventions may encompass electronic, digital, and/or electro-mechanical controllers. For example, embodiments of an electro-mechanical controller may include a bi-metal controller for regulating the electricity delivered to a heating element. In embodiments of the inventions using a digital controller, controller100may further include one or more user input devices130, such as a control knob, for activating, adjusting, and/or controlling a cooking temperature. For example,FIG.3shows an exemplary schematic of electrical components of controller100. Electricity is drawn via power cord110, shown as line111and neutral112. Optionally, power converters113convert a wall outlet's AC current to various steps of DC current. Further optional internal circuitry includes a microprocessor140, which may control the temperature of an electric grill by controlling TriAC Drivers150. It should be understood that TriAC Drivers150may be used to control heating elements positioned within electric grill housing300. Embodiments may further include a wireless communication controller160for allowing wifi, Bluetooth, or other wireless communication with remote devices, such as cell phones, tablets, and/or computers.

Moreover, controller100may interface directly with heating elements (not shown) positioned within housing300in order to deliver electric current for heating. For example, there may be electric contacts which allow line111and neutral112(seeFIGS.2A and2B) to interface and deliver electricity with one or more heating elements in an electric grill's housing300. For example, electric contacts for line111and neutral112may be aligned with openings340in housing300(see e.g.FIG.9). Through these openings340, line111and neutral112may contact and interface a heating element, and deliver electricity to (and from) the heating element. Using digital or electro-mechanical means, controller100determines and controls the appropriate amount of electricity to deliver in order to achieve a desired cooking temperature.

Additional disclosure of exemplary controller100's circuitry and functionality is provided in Applicant's co-pending U.S. patent application Ser. No. 15/200,687, entitled “Electric Grill with Current Protection Circuity,” Ser. No. 15/493,611 entitled “Wireless Control And Status Monitoring For Electric Grill With Current Protection Circuitry,” Ser. No. 15/200,759, entitled “Digital Power Supply,” and Ser. No. 15/493,696, entitled “Digital Power Supply with Wireless Monitoring and Control.” Each of these applications is hereby specifically incorporated by reference, in its entirety.

Components of controller100(including without limitation those components shown inFIG.3) may be sensitive to heat generated in the electric grill housing300. Thus, in embodiments of the inventions, mounting bracket200serves to protect and shield controller100from heat generated by cooking in electric grill housing300by providing a thermal barrier290between controller100and housing300.

Turning now toFIGS.4and5A and5B, isometric views of mounting bracket200are shown.FIG.4shows mounting bracket200affixed to an electric grill housing300, whereasFIGS.5A and5Bshow an isometric view of the mounting bracket200alone. Mounting bracket200is three dimensional and generally hollow. It has a front surface210, a top surface220, a bottom surface230, a left side240, and a right side250. Throughout this disclosure, mounting bracket200is shown to have tapered sides, though such tapered sides are not a limitation of the invention. It is understood that mounting bracket200's shape may vary and the tapered sides are not limiting.

Mounting bracket200's back260is a plane which opposes the front surface210. The back260plane is generally open and may include flanges261,262,263, and264, seen for example inFIGS.5A and5B, which are isometric review views of mounting bracket200.FIGS.5C and5Dshow the mounting bracket200from the lower left perspective. Flanges261,262,263, and264are used to screw, bolt, or otherwise fasten mounting bracket200to electric grill300. Embodiments having an open back260are preferable because the open back260reduces the contact area between mounting bracket200and electric grill housing300. For example, the only points of contact may be the flanges261,262,263, and264. This can be seen inFIG.4, where mounting bracket200contacts housing300through flange262(additional flanges are not visible from the angle shown). Reduced surface contact results in reduced heat transfer. Reduced heat transfer is an important consideration because it reduces and/or eliminates the need for insulating materials inside mounting bracket200. Moreover, reduced contact area allows mounting bracket to be made of a material such as steel, which has relatively high heat conductivity.

Reduced heat transfer resulting from reduced contact area is one feature by which mounting bracket200protects controller100's circuitry from overheating. An additional thermal management feature is mounting bracket200's hollow shape. As described further herein, when controller100is engaged with mounting bracket200, the hollow shape allows for an air gap, which in turn forms a thermal barrier290(see e.g.FIG.8) protecting controller100from heat when controller100is engaged with mounting bracket200via slot270.

More specifically, turning again toFIG.4, mounting bracket200's front surface210includes an elongated slot270through which electronic controller100(and specifically, engagement members170,180) may be received. Slot270is shown to be generally rectangular, with rounded corners, extending generally the length of mounting bracket200's front surface210. Slot270is sized and aligned to mate with corresponding engagement members170,180. In some embodiments, slot270mates with a controller having only one engagement member170(see e.g.FIG.2B). It should be understood that slot270and its corresponding engagement member(s) may take various shapes and sizes. For example, instead of being generally rectangular, an oval slot (and corresponding oval engagement member(s)) may be used.

A lower lip271extends generally the length of the slot's bottom edge. Lower lip271provides support to electronic controller100when it is engaged with mounting bracket200. An upper lip272(see e.g.FIGS.5C,5D, and8) may also be provided. Both are perpendicular to front surface210and parallel with respect to each other.

Together, lower lip271and upper lip272guide controller100's engagement members170,180into slot270to a fastened position in which controller100's spring element(s)190,195engage corresponding tabs in the mounting bracket200. For example, mounting bracket200may include tabs280,281, which mate with a corresponding spring element190,195on controller100, thereby securely fastening controller100to mounting bracket200when inserted. Throughout this disclosure, tabs280,281are shown to extend generally perpendicular to slot270and along the left and right edges of slot270, but it should be understood that tabs280,281may be configured in any number of positions, including for example along the top and/or bottom edge.

Spring elements190,195, which are aligned with tabs280,281, are shown in the fastened position inFIGS.7A,7B, and7C. In particular,FIGS.7A,7B, and7Cshow controller100in the fastened position, which is to say that spring elements190,195are engaged with tabs280,281.FIG.7Ashows controller100mounted on mounting bracket200and extending into housing300. InFIGS.7B and7C, housing300is cut-away to provide a closer perspective of engagement members170,180and spring elements190,195engaging tabs280,281.

It should be understood that tabs280,281may take various forms that can engage with spring elements190,195, and the inventions are not limited by the form of engagement between tabs280,281and spring elements190,195.

For example,FIG.5Ashows tab280having an opening for receiving and engaging a spring element190. In other words, spring element190expands into tab280's opening, thereby fastening controller100to bracket200. An alternative embodiment is shown inFIG.5B, wherein tab280is a bent tab, also called an S-tab, which may engage spring element190. Using an S-tab may provide better control of the force required to engage and disengage a spring element, as S-tabs provide less friction than tabs with openings. This is because S-tabs have only rounded edges, and no leading edges, providing a smoother interface when engaging a spring element.

It can be seen that spring elements190,195are positioned on controller100, and more specifically on engagement members170,180, in a configuration that aligns with tabs280,281when in the fastened position. In other words, spring elements190,195are aligned opposite tabs280,281such that spring elements190,195and tabs280,281mate when electronic controller100is in the fastened position. Preferably, spring elements190,195have an angled leading edge191and trailing edge192(See e.g.FIG.7B). Forcing an angled leading edge191against a tab280,281causes the spring element190,195to depress. In such embodiments, a user may insert electronic controller100into slot270, and, with enough force, spring elements190,195will engage their corresponding tabs280,281. Likewise, electronic controller100can be disengaged from slot270by pulling with sufficient force. It should be understood that the elasticity of spring elements190,195determines the force required to secure (and remove) electronic controller100.

Preferably, spring elements190,195are made of a conductive metal to establish an electrical contact with tabs280,281, and by extension, with housing300. Electricity can then be conducted from spring elements190,195to power cord110and to a wall outlet (e.g., ground). Spring elements190,195are one means for fastening controller100to mounting bracket200, but embodiments of the inventions may incorporate any known fastening means.

Once controller100is engaged with mounting bracket200, a gap, or air pocket, referred to as a thermal barrier290, is formed in the hollow space created by the depth between mounting bracket200's front surface210and back plane260. Turning now toFIG.8, a side-view cross section is shown in which controller100is seen secured to mounting bracket200via screws201. Engagement members170,180are contacting upper and lower lips270,271. Thermal barrier290is formed in an air gap in hollow mounting bracket200, between controller100on the one side, and housing300on the other. Thermal barrier290acts to insulate controller100(and its internal electronics) from heat generated within the housing300during cooking. Thermal barrier290may replace the need for traditional heat insulation. In some embodiments of the inventions, the thermal barrier290may be between 1.3 and 1.5 inches thick, though the insulation effect is proportional to the thermal barriers thickness

For example, applicant's testing has revealed that thermal barrier290provides 30%-50% insulation when compared to embodiments having no thermal barrier. That is to say, adding the thermal barrier290lowers the temperature on the controller100side by 30%-50%. This temperature reduction means there is no need for any traditional insulating materials inside controller100. Traditional controllers are made from a high-temperature plastic, such as polyphenylene sulfide (sometimes referred to as “Ryton”), but embodiments of the inventions can be made with lower rated plastics. Moreover, thermal barrier290makes it possible to use electronics which are rated for lower temperatures. This provides the benefit of allowing a mounting bracket200to be formed of sheet metal (including, without limitation, steel), which makes the manufacturing process faster and cheaper, and provides a more durable product. Thus, embodiments of the inventions have the unexpected result of providing high thermal insulation despite mounting bracket200being formed of sheet metal, such as steel, which typically conducts heat (as opposed to providing insulation). In other words, persons of skill in the art, without having the benefit of this disclosure, would not be motivated to use sheet metal for develop a mounting bracket having a thermal barrier290.

Turning now toFIG.9, an exemplary electric grill's housing300is shown alone. The housing300has one or more openings310for receiving thermocouples120, and holes320,330for screwing, bolting, or otherwise affixing mounting bracket200's flanges261,262,263, and264.

To use an electric grill embodying the present inventions, a user inserts electronic controller100into mounting bracket200's slot270. Optional lip271extends along slot270's bottom edge and guides electronic controller100, and optional upper lip272extends along the slot270's upper edge. In embodiments where electronic controller100has one or more thermocouples120, thermocouples120extend into housing300for measuring a cooking temperature. As electronic controller100is being inserted into mounting bracket200, the leading edge of spring elements190,195contact their corresponding tabs280,281. As seen for example inFIG.7B, the user's pressure causes the spring element195to become depressed as it travels underneath tab280, until it travels to an opening285in tab280. The spring element195's spring force causes spring element195to expand into tab opening285and in this way the electronic controller100becomes securely fastened to mounting bracket200. In embodiments where mounting bracket200and spring elements190,195are made of electrically conductive materials, such as steel, engaging spring elements190,195with tabs280,281establishes an electric contact between controller100, mounting bracket200, and housing300. Moreover, hollow mounting bracket200creates a thermal barrier290which allows controller100's internal electronics to function without being degraded by heat from housing300during cooking.