U.S. patent application number 09/893920 was filed with the patent office on 2002-01-31 for tented gas burner for grill.
Invention is credited to Freber, Don, Giebel, Michael, Minor, Robert, Schubert, Henry, Stewart, Daniel M..
Application Number | 20020011244 09/893920 |
Document ID | / |
Family ID | 23474041 |
Filed Date | 2002-01-31 |
United States Patent
Application |
20020011244 |
Kind Code |
A1 |
Giebel, Michael ; et
al. |
January 31, 2002 |
Tented gas burner for grill
Abstract
A grill having a bi-level tent configuration, a burner assembly
and a grill shell. The lower, first tent has an "I"-shaped
configuration. The upper, second tent has a plurality of openings.
The burner assembly is formed from stamped metal. The upper piece
of stamped metal has a raised or embossed area with multi-level
ports. The burner and tent arrangement provides even distribution
of heat to the cooking surface and flare-up control. The use of
stamped metal for the burner assembly provides for a cost efficient
and easy to assemble grill.
Inventors: |
Giebel, Michael; (Joplin,
MO) ; Stewart, Daniel M.; (Joplin, MO) ;
Freber, Don; (St. Louis, MO) ; Minor, Robert;
(Gilbertville, KY) ; Schubert, Henry; (Neosho,
MO) |
Correspondence
Address: |
Kramer Levin Naftalis & Frankel LLP
919 THIRD AVENUE
NEW YORK
NY
10022
US
|
Family ID: |
23474041 |
Appl. No.: |
09/893920 |
Filed: |
June 28, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09893920 |
Jun 28, 2001 |
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09373825 |
Aug 13, 1999 |
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6283114 |
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Current U.S.
Class: |
126/41R |
Current CPC
Class: |
F24C 3/103 20130101;
F23D 14/105 20130101; Y02B 40/166 20130101; A47J 37/0713 20130101;
Y02B 40/00 20130101; F23D 2203/102 20130101; F23D 14/045
20130101 |
Class at
Publication: |
126/41.00R |
International
Class: |
F24C 003/00; A47J
037/00 |
Claims
What is claimed is:
1. A burner tent comprising: a central tent segment; a first
peripheral tent segment, the first peripheral tent segment being
arranged at a first end of the central tent segment and being
substantially perpendicular to the central tent segment; and a
second peripheral tent segment, the second peripheral tent segment
being arranged at a second end of the central tent segment and
being substantially perpendicular to the central tent segment,
wherein each tent segment includes first and second sloping
sides.
2. The burner tent of claim 1, comprising a further burner tent,
wherein the further burner tent is mounted over the burner tent and
wherein the further burner includes sloping sides.
3. The burner tent of claim 2, wherein a plurality of openings are
arranged on the sloping sides of the further burner tent.
4. The burner tent of claim 1 comprising a further surface arranged
between the first and second sloping sides of the central tent
segment.
5. A burner assembly comprising: a burner sub-assembly, wherein the
burner sub-assembly includes a first embossed sheet metal portion
and a second embossed sheet metal portion; and a venturi passage
sub-assembly, wherein the venturi passage sub-assembly includes a
third embossed sheet metal portion and a fourth embossed sheet
metal portion, wherein the venturi passage sub-assembly includes at
least one passage and wherein the burner sub-assembly includes at
least one hollow chamber, the at least one passage being in fluid
communication with the at least one hollow chamber.
6. The burner assembly of claim 5, wherein the venturi passage
sub-assembly is attached to the burner sub-assembly by being
captured between the first and second embossed sheet metal
portions.
7. The burner assembly of claim 5, wherein the first embossed sheet
metal portion and the second embossed sheet metal portion are
staked together and wherein the third embossed sheet metal portion
and the fourth embossed sheet metal portion are staked
together.
8. The burner assembly of claim 5, wherein the first embossed sheet
metal portion comprises a plurality of openings.
9. The burner assembly of claim 8, wherein the openings are
arranged in a plurality of rows.
10. The burner assembly of claim 5, wherein the first and second
embossed sheet metal portions each comprise an elongated
opening.
11. The burner assembly of claim 5 comprising an ignitor
sub-assembly, the ignitor sub-assembly including at least one
ignitor electrode and a collector box, the collector box being
arranged over the at least one ignitor.
12. The burner assembly of claim 5, wherein the at least one
passage of the venturi passage sub-assembly includes at least one
louver.
13. A grill comprising: a burner assembly; a first burner tent
mounted above the burner assembly; and a second burner tent mounted
above the first burner tent, wherein the first burner tent
comprises a central tent segment, a first peripheral tent segment,
and a second peripheral tent segment, the first and second
peripheral tent segments being substantially perpendicular to the
central tent segment and each tent segment including first and
second sloping sides and wherein the burner assembly comprises a
venturi sub-assembly and a burner sub-assembly, each of which is
comprised of sheet metal.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to gas barbecue grills
generally and more particularly to burners and tented burners for
grills.
BACKGROUND INFORMATION
[0002] In general, it is known to use tented burners in barbecue
grills. However, presently available barbecue grills have several
disadvantages. For example, known tented burner arrangements are
ineffective in providing an optimum and even distribution of heat
to the cooking surface of the grill. In addition, presently
available grills do not effectively control flare-ups, as are
commonly caused by drippings onto the burner or the tent arranged
above the burner.
SUMMARY OF THE INVENTION
[0003] The present invention provides a grill having a tent
structure mounted over a gas burner. The tent structure is
configured in such a way as to allow the periphery of the cooking
surface to achieve a higher temperature than that allowed by
conventional tented burner arrangements, thereby providing an even
distribution of heat to the cooking surface of the grill.
[0004] The present invention also provides a grill having a tent or
combination of tents to provide improved flare-up control.
[0005] In addition, the present invention provides a gas grill
having a stamped sheet metal burner assembly with top-side,
multi-level porting to enhance even distribution of heat across the
cooking surface. This results in a low-volume, efficient burner
having a longer operating lifespan. Moreover, the use of sheet
metal components provides substantial cost and assembly
benefits.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is an exploded perspective view of an exemplary
embodiment of a grill in accordance with the present invention.
[0007] FIG. 2 is an exploded perspective view of the burner
assembly of FIG. 1.
[0008] FIG. 3A shows an exploded perspective view of a venturi
sub-assembly in accordance with the present invention. FIGS. 3B and
3C are bottom and side views, respectively, of a portion of the
venturi sub-assembly.
[0009] FIG. 4 is a cross-sectional view of the gas grill of FIG.
1.
[0010] FIG. 5 is a cross-sectional view of a further embodiment of
a gas grill of the present invention.
DETAILED DESCRIPTION
[0011] The present invention is directed to a burner arrangement
for a gas grill. As shown in FIGS. 1-3 an exemplary embodiment of
the gas grill comprises a bi-level tent configuration, a burner
assembly 1, and a main grill shell 2.
[0012] A lower, first tent 3 is generally configured in the shape
of the letter "I". A main, central portion of the first tent 3
comprises a first sloped surface 4 and a second sloped surface 5
which meet along a ridge 6. In the exemplary embodiment shown, the
sloped surfaces 4 and 5 are arranged with an angle of approximately
120 degrees therebetween. On each end of the main portion of the
first tent 3 is a transverse tent-like structure 7a, b. Each
transverse tent segment 7a, b comprises an outer sloped surface 8a,
b and a medial sloped surface 9a, b which meet along a ridge 10a,
b. The ridges 10a, b are substantially perpendicular to the central
ridge 6. A mounting tab 11a, b for mounting the tent 3 to the grill
shell 2 is arranged at a lower end of each sloped surface 8a, b.
Each mounting tab 11a, b may comprise a hole for receiving a
fastener therethrough. Proximate to the ends of the medial sloped
surfaces 9a, b, openings 12a, b, c, d are provide for securing an
upper tent structure 15, described below.
[0013] The first tent 3 maximizes heat distribution, especially to
the corners and to the periphery of the cooking surface. The tent 3
also prevents grease or other food drippings from contacting the
burner 1, thus protecting the burner 1 and effectively eliminating
or controlling flare-ups. By thus protecting the burner 1, it
becomes possible to provide flame ports on the top side of the
burner 1, which substantially improves the longevity of the
burner.
[0014] An upper, second tent 15 comprises a first sloped surface 16
and a second sloped surface 17 on opposite sides of a ridge 18. The
second tent preferably comprises a plurality of openings 19
arranged through the first and second sloped surfaces 16 and 17.
The openings 19 provide improved heat distribution and allow for
controlled flare-ups.
[0015] The second tent 15 is arranged over the center section of
the lower tent 3 with an air gap therebetween. In the exemplary
embodiment shown, the sloped surfaces 16 and 17 are arranged with
an angle of approximately 130 degrees therebetween and the tents 3
and 15 are spaced apart at their ridges (e.g., 0.02" to 0.50"). The
air gap between the tents 3 and 15 cools the tents, particularly
the upper tent 15, which helps control flare-ups. The gap between
the tents also prevents drippings and food particulates from
becoming trapped between the tents. The arrangement of the second
tent 15 over the tent 3 also promotes an even distribution of heat
to the cooking surface and allows grease to drain from the cooking
surface, thereby reducing flare-ups.
[0016] At its corners, the second tent 15 preferably comprises tab
extensions 20a, b, c, d. When the tent 15 is placed on the lower
tent 3, the tab extensions 20a, b, c, d sit in the openings 12a, b,
c, d on the first tent 3. The tent 15 is readily removable from the
lower tent 3 such as for cleaning.
[0017] The burner assembly 1 will now be described. As shown in
FIG. 1, the burner assembly 1 comprises a burner sub-assembly 40
and a venturi sub-assembly 25, each of which is comprised of
stamped sheet metal components. As shown in FIG. 2, the burner 1 is
assembled by capturing the venturi sub-assembly 25 between upper
and lower halves of the burner sub-assembly 40. The lower half of
the burner sub-assembly 40 is comprised of a stamped piece of sheet
metal 21. The upper half of the burner sub-assembly 40 is comprised
of a complementary piece of stamped sheet metal 22. The two halves
are preferably joined by staking or hemming the two pieces
together.
[0018] The upper piece of sheet metal 22 comprises raised or
embossed features 26a and 26b, whereas the lower piece 21 comprises
corresponding embossed features 27a and 27b. Each feature 26a, b
and 27a, b is formed as a channel arranged in an elongated oval
loop. The peripheries of the features 26a and 26b substantially
correspond to the peripheries of the features 27a and 27b,
respectively. When the two pieces 21 and 22 are joined, the
features 26a, b and 27a, b form two hollow burner halves 41a and
41b, as shown in FIG. 1.
[0019] As shown in FIG. 2, the features 26a, b of the upper burner
portion 22 comprise a plurality of holes or ports 24. The ports 24
preferably are arranged in a plurality of rows on each of the
features 26a, b. In one embodiment, a first row of ports 24 is
located on side walls of each feature 26a, b and a second row of
ports 24 is located above the first row, near the junction of the
side walls and a substantially flat top surface of the feature 26a,
b. The ports 24 arranged in the second row are preferably smaller
than the ports in the first row. Such multi-level porting improves
the efficiency of the burner and provides better heat distribution
at the cooking surface of the grill. Furthermore, locating the
ports 24 on the top side of the burner also improves burner
performance and efficiency and substantially improves the longevity
of the burner, as compared to conventional burners which are ported
on their undersides.
[0020] The gas burner sub-assembly 40 also may comprise elongated
slot-like openings 30 through the two pieces of stamped metal 21,
22. The elongated slot-like openings 30 provide additional
secondary air to enhance the performance of the gas burner assembly
1, in particular improving the burning which occurs through the
ports 24 located on or near the essentially horizontal top surfaces
of the features 26a, b of the burner sub-assembly 40.
[0021] In the exemplary embodiment shown in FIG. 2, the lower and
upper pieces 21 and 22 of the burner sub-assembly 40 comprise tabs
28a, b and 29a, b, respectively, at opposite ends. When the pieces
21 and 22 are joined, the tabs 28 and 29 are joined and may be used
to mount the burner 1 to the grill shell 2. As shown in FIG. 1, the
grill shell 2 may comprise openings 33 for receiving the tabs 28
and 29.
[0022] The gas burner assembly 1 also comprises a venturi
sub-assembly 25. As shown in FIG. 3, the venturi sub-assembly 25
preferably comprises two pieces of stamped metal 25t and 26b which
are joined, such as by hemming or staking, to form two fuel-air
passages, one for each burner half 41a, b. Each passage provides a
conduit for providing an air-fuel mixture to each burner half.
[0023] As shown in FIG. 3A and enlarged in FIGS. 3B and 3C, the
venturi sub-assembly 25 preferably also comprises louvers 251
proximate to the inlets of the fuel-air passages. The louvers 251
comprise openings which allow primary air to be drawn into the
passages. The primary air is mixed with fuel applied to the passage
inlets and the fuel-air mixture is conducted to the burner halves
where it is combusted. The use of primary air helps make it
possible to reduce the volume of the burner. The louvers 251 are
preferably arranged on the lower portion 25b of the venturi
sub-assembly so as to shelter them from the elements (e.g., wind,
rain). Moreover, the louver openings preferably should be
sufficiently small so as to prevent insects from entering the
passages and nesting in the burner assembly 1.
[0024] When the burner assembly 1 is assembled, the venturi
sub-assembly 25 is captured between the two pieces 21 and 22 of the
burner sub-assembly. The venturi passages align with the burner
halves 41a, b thus formed. An opening 37 in the venturi
sub-assembly aligns with openings 36 in the pieces 21 and 22 so as
to provide an opening in the completed burner assembly 1 for
receiving one or more ignitors, as described below.
[0025] The stamped metal configuration of the burner assembly 1
allows for reduced manufacturing costs and ease of assembly
compared to tubular steel.
[0026] As shown in FIGS. 4 and 6, the burner assembly 1 may also
comprise an ignitor sub-assembly which preferably is located in the
middle of the burner assembly 1. The ignitor sub-assembly may
comprise a pair of ignitors 34 placed through an opening 36 located
between the burner halves 41a and 41b. For ignition, an arc is
developed between the electrodes of the ignitors 34. As shown in
FIG. 6, the electrodes of the ignitors 34 are offset, thereby
increasing the spacing between the electrodes. The increased
spacing results in the generation of longer arcs which improves
ignition. Moreover, a collector box 50 is arranged over the
electrodes to improve the distribution of gas to the electrodes and
to act as a windscreen. As shown in FIG. 4, the box 50 has an open
back side which allows gas from the burner halves 41a and 41b to
enter the box where it is trapped and ignited by the electrodes 34.
To further improve the ignition operation, there may be an
increased density of ports 24 on the burner halves 41a, b proximate
to the collector box 50. The use of the collector box 50 and the
dual ignitors 34 allows consistent, reliable and fast ignition.
[0027] Although a dual-burner embodiment has thus far been
described, other configurations, such as a single-burner or a
three-burner configuration are possible within the scope of the
present invention.
[0028] The grill shell 2 is generally rectangular comprising two
sets of opposing walls and a floor. A front wall 30a comprises one
or more openings 31 through which the venturi sub-assembly 25 may
pass. A bottom surface of the shell 2 comprises two rectangular
openings 35 which allow secondary air to flow up through the bottom
of the shell over the burner 1. The shell 2 may also comprise
features for suspending one or more grease catches (not shown)
below the openings 35. In the dual-burner embodiment shown it is
preferable to provide two smaller catches as opposed to one larger
catch so as to provide better grease collection and air flow
through the openings 35. The improved air flow helps cool the
shell, thereby reducing flare-ups caused by grease trapped in the
shell, and improves the provision of secondary air to the burner
1.
[0029] The grill shell 2 may comprise a tent pedestal 32 on each
end. Each mounting tab 11a, b on the first tent 3 rests on, or
alternatively, is attached to a tent pedestal 32, positioning the
first tent 3 above the gas burner assembly 1, as shown in FIG.
4.
[0030] FIG. 5 shows a further embodiment of a grill in accordance
with the present invention. In the embodiment of FIG. 5, the tent 3
comprises a horizontal plate 13 arranged at the base of the tent
between the sloped surfaces 4 and 5. The plate 13 helps spread the
heat generated by the burner, keeping the tent 3 cooler.
Additionally, refractory elements, which absorb and re-radiate heat
such as ceramic "hot blocks," may be placed between the tent 3 and
the plate 13 on the top side of the plate 13, to assist in the
distribution of heat.
[0031] While several preferred embodiments of a tented gas burner
for a grill have been described herein, it is to be understood that
variations may be made in the tented gas burner assembly without
departing from the spirit and scope of the invention as defined by
the appended claims.
* * * * *