U.S. patent application number 12/222879 was filed with the patent office on 2009-03-26 for cooking device.
Invention is credited to Don McLemore, John D. McLemore.
Application Number | 20090078127 12/222879 |
Document ID | / |
Family ID | 36609907 |
Filed Date | 2009-03-26 |
United States Patent
Application |
20090078127 |
Kind Code |
A1 |
McLemore; Don ; et
al. |
March 26, 2009 |
Cooking device
Abstract
A smoker having a smoke generating material loader which
preferably is insertable and retractable through a housing aperture
and is adjustable between a no dump state and a dump state once
inserted, preferably relative to a receiver tray that is closer to
a heat source, as in an electric heat resistance bar, to cause
smoke generation of smoke generating material received from the
loader when placed in a dump state. The loader preferably has one
or more seal off end caps or sections relative to the receiving
housing aperture to provide a heat retention function. A preferred
embodiment features a nested arrangement between the inserted
loader and receiver tray and preferably the receiver tray is in a
sliding supported relationship with the loader as in a
semi-cylindrical loader main body in contact with one or more
concave supporting surfaces of the receiver tray. The receiver tray
also preferably has opposing shielding walls extending up from
opposite sides of an apertured base receiving tray. The opposing
shields also preferably having an upper constricted opening in
close proximity to a rotating loader main body and at a common
height with the constricting opening brought about by the nesting
arrangement.
Inventors: |
McLemore; Don; (Columbus,
GA) ; McLemore; John D.; (Fortson, GA) |
Correspondence
Address: |
SMITH, GAMBRELL & RUSSELL
1130 CONNECTICUT AVENUE, N.W., SUITE 1130
WASHINGTON
DC
20036
US
|
Family ID: |
36609907 |
Appl. No.: |
12/222879 |
Filed: |
August 18, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11020027 |
Dec 23, 2004 |
7426885 |
|
|
12222879 |
|
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Current U.S.
Class: |
99/482 ; 426/314;
426/523 |
Current CPC
Class: |
A23B 4/052 20130101 |
Class at
Publication: |
99/482 ; 426/314;
426/523 |
International
Class: |
A47J 37/07 20060101
A47J037/07; A23L 1/01 20060101 A23L001/01 |
Claims
1. A method of assembling a smoker, comprising: providing a housing
having a heat-up region and a smoke generating material receiving
area; inserting a smoke generating material loader into said
housing such that said loader is positionable between a non-release
of supported smoker generating material first position state and a
release of smoker generating material for reception in the smoker
generating material receiving area of said housing second position
state.
2. The method of claim 1 wherein said housing includes an aperture
which receives said loader upon said loader being insertable into
the aperture.
3. The method of claim 1 wherein said loader is configured for
rotational adjustment between said position states.
4. The method of claim 3 wherein said aperture is defined by a
circular side wall edge in said housing and said loader has a
circular sliding surface received by the sidewall edge.
5. The method of claim 4 wherein said loader has a first end cap
sized substantially similar to the aperture as to provide a
rotatable plug relationship between said first end cap and the side
wall edge.
6. The method of claim 1 wherein said loader has a main body with
an upward facing, exposed opening and closed bottom section when in
said first state.
7. The method of claim 6 wherein said main body has a
semi-cylindrical configuration.
8. The method claim 6 wherein said loader comprises first and
second end caps at opposite ends of said main body with one of said
end caps having a substantially similar diameter to a housing
aperture configured for insertion and retraction of said loader to
at least partially plug the aperture.
9. The method of claim 1 wherein said housing includes a loader
insertion aperture and further comprises an access door and door
covered access opening for providing an alternate housing access
location.
10. The method claim 1 further comprising a heat source positioned
within the heat-up region of said housing.
11. The method of claim 10 wherein said heat source is an
electrical heart source that comprises a heat resistance bar.
12. The method of claim 11 wherein the smoke generating material
receiving area comprises a receiver tray having an apertured base
and a confining side wall to retain smoke generating material
received from said loader
13. The method of claim 12 wherein said receiver tray is in direct
contact with said heat resistance bar.
14. The method of claim 1 wherein the smoke generating material
receiving area comprises a receiver tray having an apertured base
and a confining wall which retains smoke generating material
received from the loader, and wherein said loader and said receiver
tray assume a nested arrangement when said loader is inserted into
said housing.
15. The method of claim 14 wherein said loader has a main body with
a smoker material reception recess that releases smoke generating
material to said receiver tray when said loader is in said second
position state and is adjustable to substantially seal off a smoker
material reception opening in said receiver tray.
16. The method of claim 15 wherein said confining wall comprises
shields that include constricting upper panel sections which define
the reception opening and between which is positioned said loader
which essentially seals off the reception opening.
17. The method of claim 14 further comprises a heat resistance bar
having an inlet section featuring two generally parallel prong
sections and a loop section defining an overall "L-shaped" heat
resistance bar configuration and the receiving area of said housing
comprises a receiver tray with an apertured base and an outer
peripheral configuration with which said resistance bar generally
conforms in dimension or extends within that outer peripheral
configuration.
18. A smoker, comprising: a housing; a smoke generating material
reception tray in said housing; and a smoke generating material
loader removably supported by said housing and configured to supply
smoke generating material to said reception tray upon rotation from
a no-dump state to a dump state.
19. The smoker of claim 18 wherein said loader comprises a main
body which is insertable and removable relative to an aperture
formed in said housing and includes a loader main body having an
upper opened smoker generating material reception recess and a
smoke generating material support surface with the upper opened
reception recess dumping smoke generating material via gravity upon
rotation of said loader form a no-dump state to a dump state.
20. The smoker of claim 19 wherein said loader has an end cap for
essentially sealing off the side wall aperture in said housing upon
loader insertion into said housing, and said reception tray
includes an apertured receiver tray base and side walls that extend
into a nested arrangement with the inserted loader.
21. A method of using a smoker, comprising: inserting a loader into
an aperture provided in a smoker housing; rotating the loader so as
to release material which provides a source of smoke to a receiving
region within the smoker housing; and heating said material while
in said receiving region to carry out a smoke generation by the
material in a smoking of a food item.
22. The method of loading of claim 21 further comprising inserting
said loader until a section of said loader eventually seals off the
aperture, and the receiving region of said smoker includes a
receiver tray which is closer to a heat source in said housing than
said loader and which receiver tray receives the smoke generating
material from the loader upon rotation of the loader between an
inserted no dump state to a dump state.
Description
CROSS REFERENCE TO RELATED APPLICATION(S)
[0001] The present application is a continuation of U.S. patent
application Ser. No. 11/020,027 filed Dec. 23, 2004, which
application is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention comprises a cooking device with a
release feeder device as in a smoker apparatus with a smoke
generating material loader that is preferably manipulated (e.g.,
dialed) between a storage mode and a release mode, wherein a supply
of wood chips or some other smoke generating material is released
to a receiving area of the cooking apparatus as in a receiver tray
and subjected to a heat source.
BACKGROUND OF THE INVENTION
[0003] Both indoor and outdoor grilling has continued to increase
in popularity and, in the United States alone, it is estimated that
75% of US households have an outdoor cooking grill, which
percentage further increases when indoor grilling is also taken
into consideration. This increased popularity with grilling has led
to more sophisticated cookers who are no longer satisfied with
merely cooking over a bed of charcoal, but have moved into
alternate food preparation techniques as in smoking food to prepare
a delicious, succulent entree.
[0004] Various conventional cookers of the smoker type exists and
are typically of the outdoor type. The heat sources for cookers are
based on various fuels as in gas, electric sources (e.g., electric
resistance bars or infrared ceramic plates), charcoal, etc. An
advantage of a smoker cooker is that a desirable smoked flavor is
imparted to the food and the cooking technique is generally carried
out at low to moderate heat levels. The smoking cooking techniques
can also promote basting of the food as the juices from the food
are caught and vaporized to baste the food to keep the food moist
and prevent dehydration while the smoke flavor is imparted to the
food. In addition, with the inclusion of a drip pan the juices can
be captured and this drip pan can also hold fluids such as water
which, in conjunction with the heat source, provide additional
moisture in the food being smoked (e.g., meats, fish, etc.).
[0005] A typical conventional smoker assembly includes a housing
containing one or more grill racks, the above noted pan positioned
below the grill for dripping collection and vapor generation, a
heat source, and a wood chip tray or rack, placed adjacent the heat
source, to hold the smoke producing material (e.g., to generate the
smoke there is typically used materials such as hickory, alder and
mesquite wood in any one of a variety of forms as in chips,
briquettes, and saw dust).
[0006] In addition, the prior art devices include stand alone
smokers as seen, for example, in U.S. Pat. Nos. 5,713,267;
4,417,748; 4,309,938; 4,020,322 and 3,776,127 as well as those that
are designed as an added feature to a grill assembly as seen by
U.S. Pat. Nos. 5,891,498; 5,718,165; 5,167,183 and 4,770,157.
Additionally, the prior art discloses a variety of structures for
generating the smoke and providing the smoke to the food, including
a generally common housing embodiment with both an internalized
firebox (where the material is subjected to heat and initiates
smoke generation) and a smoke/food contact chamber or smoker
location (where the smoke is applied to the food) as seen from U.S.
Pat. No. 4,321,857; those with an exterior fire box with direct
attachment to a smoker housing as exemplified by U.S. Pat. No.
6,209,533; as well as those that are externally connected to the
smoking location via a smoke conduit or the like as seen from U.S.
Pat. No. 5,138,939.
[0007] The above noted references additionally illustrate ways of
supplying the smoke generating material, with U.S. Pat. No.
5,138,939 featuring a supply stack of pellets which are fed via a
motorized pusher assembly to the smoke generation location, U.S.
Pat. No. 3,776,127 illustrating an upper domed cover which provides
access to the interior of the smoker when cool, U.S. Pat. Nos.
5,891,498 and 4,309,938 showing a door access arrangement and U.S.
Pat. Nos. 4,770,157 and 5,718,165 illustrating sliding insertion
drawers.
[0008] Problems associated with the prior art includes difficulty
in accessing the tray or smoke generating material support once
cooking is initiated and the heat level rises to near or at the
cooking temperature, the inability to easily re-supply the smoke
generating source material without seriously disrupting an ongoing
smoking process (e.g., an excessive release of built up smoke
and/or heat), and/or a removal from the firebox housing of at least
some of the currently utilized smoke generating material (which can
also lead to ash material falling out on the cook and/or exterior
environment), and/or the reliance on a highly complex supply
assembly as exemplified by U.S. Pat. No. 5,138,939. In addition,
due to the lower heat, longer time often associated with smoking
food, when the fuel source is of the replenishment type (e.g.,
charcoal or wood fuel), the fuel itself often needs to be
replenished during the course of a single food smoking operation.
This need to resupply also leads to heat release from the firebox
housing and the potential for release of smoke, ashes, etc.
SUMMARY OF THE INVENTION
[0009] The present invention is directed at providing a cooking
apparatus such as a smoker cooking apparatus with a smoke
generating material supply and/or resupply device as in a release
feeder device that is directed at alleviating or reducing the above
noted deficiencies in the prior art by providing an easy to
operate, not unduly complex smoke generating material feeder or
loader that, among other things, preferably allows for a resupply
in an on-going smoking process without serious disruption of that
smoking process and also provides an easy way to initially supply
and/or resupply later the smoke generating material while the
cooking apparatus has heated up (as in the desired smoker cook
temperature level) with a lower chance of operator or environment
burning.
[0010] The loader can be relied upon as the sole source of feeding
the receiving area of the smoke generating material or, more
preferably, as a secondary source of supply as in its use in
combination with an alternate initial supply assembly (e.g., a
pivot or slide door access/a removable top or side cover/a sliding
drawer, etc. which can be used during an initial pre-heat up
stage). Also, the loader of the present invention is preferably
gravity assisted with a rotating arrangement preferred as in one
where the loader is positioned above a wood chip receiver tray that
is closer to the heat source as compared to the loader which is
farther removed from the heat source. To facilitate the rotation
unloading, the loader is preferably in the form of a container
having a bottom and side wall configuration with smoker material
load recess, as in a container that is semi-cylindrical in shape
and insertable through an opening into a reception state with a
rotation support structure providing one or more bearing contact
surfaces that provide bearing contact as the container is adjusted
(e.g., rotated) from a smoker material storage state (opening
facing the top of the smoker or away from the heat source) to an
unloading state, as in one which is 180.degree. removed from the
storage state wherein the load is transferred, preferably by way of
a gravity assisted fall, into a recipient device such as a smoke
generating material "firebox" receiver tray below.
[0011] The cook thus has greater flexibility in the smoking process
in that, upon an apparent depletion of smoke generation material, a
resupply can be carried out either by a pre-loaded and earlier
inserted resupply loader (while cool or prior to reaching the
desired smoker temperature) or one that is removed during the
smoking process and loaded with the desired amount of resupply
smoke generating material reinserted and then dumped. The timing of
resupply can be based on factors such as experience, direct
observation (e.g., a transparent viewing window in the housing or a
preexisting gas access port), sensed parameters (smoke density
detector) or on a pre-established schedule (e.g. a time and release
with a automated loader with time). Enhanced flexibility is also
found in the ability to resupply with an alternate "flavor" smoke
material as in starting with hickory and switching to an alternate
or supplemental smoking flavor closer to completion time of an
ongoing food item or relative to a switched out cooked food item
(e.g., through an access door) and having either a similar smoke
generating material or a different "flavor" smoke generating
material in the loader ready for supplying the firebox tray without
having to remove the higher temperature resupply loader at any
point during the smoking process, or if the loader is removed and
reloaded with smoke generating material it is done so with minimal
disruption to the smoking process. While a fixed in position food
support during the smoking process (e.g., slide in food support
racks) is preferred under the present invention in line with the
desire for avoiding complexity, the present invention also features
alternate food support means such as a mechanized moving food
support that is internalized (e.g., an internal housing set of food
securement means such as skewers which rotate during the smoking
process either individually or in an interconnected (e.g., chain
link)) fashion or an internal to external mechanized moving food
support means as in a timed conveyor system passing in and out of
the smoker housing with appropriate smoke sealing ports.
[0012] An additional feature of an embodiment of the present
invention is a loader provided with a solid bottom and a receiving
area or firebox receiver tray provided with a perforated base to
facilitate heat contact and ash release. The removal of the loader
is thus made a much cleaner and safer process in that there is
avoided ash dissipation during the removal of the loader from the
confines of the housing, which in prior art systems can require the
removal of still smoldering ash with associated hazards.
[0013] A preferred embodiment of the present invention includes a
smoker such as a stand alone structure (e.g., a box like self
supporting structure) or a structure suited for attachment to a
grill structure (e.g., a box like structure that has means for
engagement with a preexisting grill structure or is otherwise
integrated with the grill). The smoker housing preferably has
rectangular side walls having sides more elongated in the vertical
direction than widthwise and depth wise as to accommodate a
multitude of slidable food support racks (e.g., 2 to 6 racks as in
4 racks spaced at different vertical heights from the base of the
smoker). One of the side walls preferably comprises a door as in
one that extends for more than a majority of the height of the
smoker and is hinged at a border edge between two walls of the
housing (e.g., the door itself and a side wall) so as to provide
ready access to the food racks as well as the preferably included
drip pan and/or liquid vapor generating liquid (e.g., water)
container that is/are provided between the heat source and food
rack(s) as well as an apertured firebox receiver tray in contact
with or closely adjacent the heat source (e.g., in direct
(above/below) contact or with small spacing as in less than two
inches and more preferably less than an inch). The heat source is
preferably a coiled electric heat resistance bar (and thus can be
an indoor device, but in view of the smoke generation and
associated typical indoor ducting requirements, outdoor usage is a
more typical usage of the subject matter of the present
invention).
[0014] The loader preferably extends through an opening formed in
one of the walls of the housing at a vertical height (e.g., mid
level) above the firebox tray and preferably is also aligned along
a vertical plane extending through each of the loader and firebox
tray (although an offset arrangement is also featured under the
subject matter of the invention as in one having a reload slide
shoot to compensate for any vertical non-alignment between the
loader and the firebox receiver tray receiving the smoker material
for initiation of smoke generation). However, the directly above
arrangement is favored in that it provides a less complex
structure. Also, the loader's peripheral profile is preferably made
smaller than the receiver tray (e.g., a smaller length and/or width
relative to the receiver tray) as to better accomplish a
no-spillage interchange during the unloading of the smoke
generating material. In this regard, the loader is provided a short
distance above the receiving opening in the receiver tray as in an
arrangement wherein the loader is placed vertically between the
receiver tray below and the drip pan and food rack above. A
centrally located (relative to sidewall depth) opening is well
suited for good smoke dissipation and the loader extends inward
into the housing, as in inward to a central location relative to a
horizontal cross-section of the housing, with the loader's central
axis of elongation (which coincides with the axis of rotation in
the preferred rotatable loader assembly) being arranged 90.degree.
offset from an axis extending in a front to back direction though a
central region of the door to achieve the preferred side loading
arrangement or an arrangement wherein the loader is in a non-door
wall portion of the smoker housing. The loader is preferably
partially nested relative to the receiver tray in the sense that a
portion of the vertical height of the loader tray overlaps with a
portion of the receiver tray, as in upper side wall edges of the
tray extending vertically up and to opposite sides of the loader at
least to some extent (e.g., a semi-cylindrical loader which
vertically overlaps or nests within the firebox receiver tray below
both when in the pre-dump and the dump position). Further, the
loader preferably provides some degree of covering enclosure
functioning relative to the open upper end of the smoke generating
material receiver tray. Also, the free edge (innermost within
housing) of the receiver tray preferably vertically overlaps with a
closing end cap of the nested loader.
[0015] In a preferred embodiment, the smoker includes a double wall
arrangement, and preferably is in the form of an insulated housing
having a generally mini-bar refrigerator configuration and a door
provided over, for example, a majority or more of one side wall
such as a hinged door with a sealing strip to seal off the doorway.
The sealing strip is formed of a material suitable for handling in
excess of the temperature range-involved with standard smoker
techniques (e.g., 150.degree. F. to 350.degree. F.). The smoke
generated from the smoke generating material can thus be sealed in
and maintained in contact with the food product being smoked at a
higher efficiency which is beneficial for the preferred smoke
processing times of six (6) to twelve (12) hours.
[0016] Also, the housing of the smoker is preferably provided with
a base having a false-bottom configuration with a vertically
downward extending flange peripheral side wall (as in one that is
separate or part of the main body smoker housing structure) and a
bottom (again can be separate or part of the main smoker housing)
and is closed off at the top edge of the peripheral flange with a
plate so as to provide an insulating opening below the false bottom
plate that also preferably functions as a location for providing
control equipment for the heat source as in an electric control
circuit for an electric heater and a gas flow control system for a
gas burner and/or temperature sensing means and timing devices,
etc. In this regard, a heat source control device as in a dial or
touch pad is preferably provided on the external surface of the
smoker housing for user manipulation (e.g., at the base as in the
vertical flange or, more preferably, at a higher location on the
housing with temperature and/or time adjustment communication means
(hardwired or wireless transceiver/receiver signal arrangement
associated with the heat source control)).
[0017] Also, the temperature control and/or timer is preferably a
digital system, and is positioned at the bottom of the refrigerator
in one embodiment and internalized within the double walled main
housing section (e.g., within a door hollow) in another embodiment,
although other positions (separate housing externally attached) are
also featured. There is further preferably provided a remote (e.g.,
wired or wireless connection) between a hand operated control
transmitter and a housing supported control unit with receiver unit
for remote adjustment of smoker apparatus characteristics as in the
above noted temperature and time. For example a 30 feet or less
(e.g. a 20 foot or less as in a Bluetooth.TM. wireless connection)
with press button adjustment signal generators is provided for
altering the temperature setting for smoke processing of the food
and/or for altering a timer or the like for smoking time and/or
another smoker apparatus characteristic as in overall on/off of the
smoker, position adjustment of, for example, food support means
and/or the loader, etc. Thus a person sitting at a patio table can
adjust the cooking apparatus settings at a remote deck location
without having to move from the present location. A feedback
transmitter/receiver arrangement is further preferably provided in
an alternate embodiment for supplying data to a display means on
the remote, as in for example, present temperature status data
output or time left or incurred (based on an internal heat sensor
and timer), preferably associated with a calculated temperature or
time difference relative to a preset temperature or time value,
loader position status information (full, in pre-dump position, in
dump position, etc.), as well as possible other characteristics,
such as door lock status, vent operative opening and air access
opening sizing (when venting is involved as an alternate embodiment
of the invention further includes a no air entry embodiment
operating, for example, at a low temperature setting range of
100.degree. to 250.degree.). An alternate embodiment of the
invention comprises an automated loader assembly such as one having
means for implementing an automated unloading of the loader (e.g.,
loader adjustment turning means) as in gear and chain, electrical
solenoid hydraulic manipulation, etc. to manipulate the loader for
achieving, for example, a pre-dump to dump and return to pre-dump
sequence, although a manual device is preferred for less complexity
reasons. An additional embodiment includes means for automated
withdrawal of the loader external to housing and re-insertion fully
internal in the housing (e.g., a gear rack with motor for sliding
in and out of the loader). The automated loader dumping and/or
loader insertion/retracting means of the present invention are also
preferably associated with the above noted remote control (e.g.,
added functions to the temperature and time altering control
described above). Again, for simplicity and cost production,
however, a hand, operated loader retraction and insertion and dump
and return to pre-dump arrangement are preferred.
[0018] Further, just above the base plate or floor at the lower
region of the smoker housing there is preferably provided an ash
tray that can be readily removed upon opening the door (or some
alternate access means as in a sliding drawer ash tray slot
arrangement) once the smoker has sufficiently cooled. With a
preferred electrical heater bar embodiment, the ash tray is
positioned below a heat source such as a heat resistance bar and
below the apertured receiver tray's bottom plate.
[0019] A preferred loader support structure features a reception
aperture provided in the housing wall which is generally configured
commensurate with the shape of the end of the loader that is
positioned closest to that wall following full insertion of the
loader into the housing. For example, with the preferred
semi-cylindrical loader configuration, a circular aperture is
provided in a side wall of the housing which is dimensioned to be
generally of the same size as the circumference associated with the
support end of the loader as in a slight friction contact
arrangement or a slight gap (e.g., less than 1/8 inch with or
without sealing means) to preclude excessive heat and smoke release
while still providing for loader dump rotation. The support end of
the loader is thus preferably a circular disk as the end of the
partially open cylindrical dumper body that preferably has some
axial thickness about its sealing periphery (e.g., a flange
arrangement as analogous to a sealant tube dispenser gun tube
reception housing). The side wall defining the aperture provides
structural support to the loader as in sole reliance on the
aperture edging to provide cantilever base support for the freely
suspended remainder of the loader or a combination of support
plates supported with the housing by through rods at one or both
ends. These additional supports can further include an extended
portion of the receiver tray below. In a preferred embodiment a
pair of support rods extend through spaced support plates that are
axially spaced apart and fixed to the rods. The receiver tray is
attached to opposing inner faces of the axially spaced support
plates. Also, the receiver tray preferably has one or both end
shield plates that are shaped to provide rotation support to the
inserter loader.
[0020] The receiver tray also preferably is arranged so as to
extend horizontally within the housing with a fixed end fixed to
the interior of the same wall in which the loader aperture is
formed and the opposite end extending inward into the interior of
the housing for about the same distance as the loader when fully
inserted. The loader is preferably supported by way of the wall
edge(s) defining the side wall aperture and, at its inter-most end,
by an end wall of the receiver tray. Also the interiormost end of
the loader is preferably positioned just past the corresponding end
of the loader to complete the partial nesting arrangement (e.g., a
receiver tray end wall with a concave upper edge receiving in
sliding contact the main body of the loader in a border region
between the main body and interiormost loader end cap).
[0021] In a preferred embodiment there is provided a sheet metal
receiver tray having side walls supported in cantilevered fashion,
an apertured bottom base plate and a free interiormost end wall. In
addition, there is one or more support rods extending from one end
interior side wall surface to an apposite side wall (e.g., a pair
of support rods extending in parallel fashion and positioned just
below the receiver tray). Sandwiched between the support rods lying
on a horizontal plane and the receiver tray base plate is a coiled
resistance heater bar that is also preferably in a direct contact
arrangement with the bottom base plate. In other words, the
illustrated "wood chip" tray and/or the supporting side plates
and/or rods are preferably placed in direct contact with the
resistance heater bar to facilitate conductive heat transference
from the resistance bar to the apertured plate supporting the
smoker material in the receiver tray.
[0022] An embodiment at the invention features a border region of
the housing extending about the loader aperture that provides a
light friction seal arrangement between the end region of the
loader and the side wall of the smoker housing. The border region
also preferably includes positioning indicia or some form of
markings to designate the setting position, although a non-indicia
embodiment is also featured under the present invention. An
alternate embodiment features proper tray position alignment means
as in a key-hole-slot arrangement in the loader and border region
to help an operator determine proper initial orientation which
clears following sufficient axial insertion of the loader into the
smoker housing (e.g. an L-shaped loader slot which allows axial
insertion relative to a housing supported key projection extending
into the slot area which L-shaped slot provides for rotation once
sufficiently inserted. The opposite end loader cap preferably has a
similar substantial sealing arrangement that provides for
retraction of the loader (preferably a supported, but not
completely withdrawn retraction setting) which provides retracted
loader support for facilitating a reloading of smoker material
while the smoker is heated up.
[0023] The providing of a sealing strip around the door also helps
to maintain a previously achieved smoke/temperature setting. This
sealed in relationship also facilitates the low temperature, long
time period the food is heated (e.g., it is not uncommon for
smoking periods to exceed 8 hours in one setting). With such
prolonged times it is also helpful to have the loader tray
available to restock the smoke generating material due to complete
usage during a first period of the overall smoking period. This can
be done in a retraction setting while the smoker is fully heated or
can involve an initial dump and then a refill and insertion of the
loader while the smoker is cool or before full heat up into a
stand-by state until a desired point in time arises wherein the
pre-loaded loader is dumped.
[0024] For situations where the heating source is charcoal or some
other loose material supplied to the receiver tray (as compared to
a gas or electric heat source), the fuel can also be restocked by
the smoke material loader as in a process comprising supplying wood
chips directly to a pile of burning charcoal in a receiver tray
followed by a restocking of the charcoal to the receiver tray and
then again supplying additional flavor supplying smoke generating
material. In an embodiment where the heat source is an electric
resistance bar and the wood chip loader is provided at the upper
end of a receiving nesting wood chip tray support assembly,
preferably the wood chip loader forms an upper closed off section
of the receiving receiver tray.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 shows a perspective view of the smoker of the present
invention with front door closed;
[0026] FIG. 2 shows a perspective view of the smoker with front
door open;
[0027] FIG. 3 shows a right side perspective view of the smoker
with front door removed and loader removed;
[0028] FIG. 4 shows a partially cut-away left side perspective view
of the smoker with loader removed;
[0029] FIG. 5 shows an enlarged view of the smoker of FIG. 4 with
loader inserted;
[0030] FIG. 6 shows an interior view of the smoker with left and
front wall removed;
[0031] FIG. 7 shows a cut-away view of the smoker taken along
cross-section line VII-VII in FIG. 3;
[0032] FIG. 8 shows in cut away a portion of that which is shown in
FIG. 7;
[0033] FIG. 9 shows a right side elevational view with tray
position indicia shown;
[0034] FIG. 10 shows a cutaway view of the bottom front right
corner of the smoker with loader removed, filled and aligned for
insertion;
[0035] FIG. 11 shows a view similar to FIG. 10 with the loader
inserted and rotated into a dumping release mode (wherein smoke
generating materials falls into the receiver tray below);
[0036] FIG. 12 shows a close up view of the loader load/unload dial
positions for an embodiment of the invention;
[0037] FIG. 13 shows more detailed view of the loader for supplying
wood chips or the like in position for insertion into the smoker
housing;
[0038] FIG. 14 shows the smoke material loader in the process of
being inserted into the housing (in an empty state for illustration
of a wood chip reception cavity as it would be typically filled
with smoke generating material and/or some other material as in
fuel supply material);
[0039] FIG. 15 shows the loader in a full insertion state and in a
non-dumping mode;
[0040] FIG. 16 shows the loader being dialed into a dump or "load"
position relative to a smoker material reception tray;
[0041] FIG. 17 shows the interior of the smoker housing with the
loader in a non-dump, standby state (and with an alternate heater
configuration);
[0042] FIG. 18 shows a view similar to FIG. 17 with the loader
being positioned between its no-dump and full dump states, relative
to the smoker material reception tray there below.
[0043] FIG. 19 shows the loader of FIG. 17 in its full dump state;
and
[0044] FIG. 20 shows an alternate smoker device with an alternate
fuel source.
DETAILED DESCRIPTION OF THE INVENTION
[0045] FIGS. 1 and 2 illustrate smoker cooking apparatus 20
("smoker") with FIG. 2 showing door 29 swung open for viewing the
interior 21 of housing 22 comprised of main housing section 23 and
base housing section 24. In the illustrated embodiment, smoker
cooking apparatus 20 has a rectangular side wall configuration
comprised of side walls 25, 26, 27 and 28. Side wall 28 is partly
(or entirely) comprised of door 29 shown in FIG. 2 as having
grasping handle 30 (upper edge positioning) and is supported by an
upper and lower hinge assembly 31, 32 with the lower edge of the
door being shown below the border between the base housing section
24 and the main housing section 23 in refrigerator door
fashion.
[0046] As shown in FIG. 2, the periphery 33 of door 29 and/or
corresponding edging 34 of housing 22 are designed for an airtight
fit which is facilitated by seal 36 which preferably is secured
within a recessed edge 29' of the door's periphery cavity. Seal 36
is arranged to partially extend out of the cavity of door 29 to
assume a compression seal relationship relative to the contacting
edging 34 of housing 22. Door 29 is also preferably maintained shut
by an engagement device as in a magnetic attraction arrangement
with a preferred embodiment being an internalized magnetized
sealing strip as in an integrated magnetic material and elastic
seal material combination that comes into releasable engagement
with a magnetic attraction material at housing edging 34.
Alternatively or in addition thereto, a magnetic or non-magnetic
assembly is provided at a corresponding peripheral location on the
door and housing main body for door closure-retention as in a
mechanical latch assembly or electronic solenoid clasp bar, etc. In
one embodiment an electronic, preferably with a local and/or remote
operation function and/or mechanical key code device, is utilized.
This arrangement provides a childproof safety function.
[0047] FIGS. 1 and 2 further illustrate two foot pad sets 35, 35'
of two different types extending down into ground contact from the
corner undersurface of base housing section 24 and one or more are
preferably individually adjustable to accommodate uneven ground
support surfaces (e.g., threaded post and fixed not support). The
foot pads in the front are preferably provided with covers for
improved appearance and user contact protection.
[0048] As represented by the partial cut-away views in FIGS. 4 and
5, each of the walls (front (including door), back, left and right
sides, top, and bottom) preferably are each in the form of a double
wall panel assembly with, or without insulation therebetween such
as one or more sheets of insulating and heat resistant foam (e.g.,
a blown-in foam insulation panel) or non-woven fiber material
(e.g., See FIG. 7) or some alternative solid insulation means or,
alternatively, reliance is placed on an air pocket alone. The outer
wall is preferably formed of a material suitable for the high heat
environment and potential outdoor use as in stainless steel or a
plastic or a composite material. The interior wall material is
formed of a heat resistant material which can be of a similar or a
different material as its exterior counterpart.
[0049] FIGS. 2 to 4 illustrate food rack slide supports 48 each
comprised of an upper and a lower slide slot defining rung 48a, 48b
with the upper rung preferably having an inner, downwardly
extending capture projection 48c. The rung sets on each wall are
preferably formed together with a common back base (50, 50')
secured with screws to respective interior wall surfaces of housing
22. Back bases 50, 50' supports a lower positioned pan support rung
sets 51, 53 that support opposite sides of water/drip collection
pan 52. A preferred pan 52 support arrangement features left and
right pan support rung sets 51, 53 each having front and rear outer
sections 56, 57 and a dipped central section 58 which receive
corresponding sized flanged extensions 54, 54' of pan 52 for
securing in position pan 52. Pan support rungs 51, 53 are also
preferably integrated with the back base 50, 50' to provide
monolithic rack bodies for securement to the noted opposing
interior walls. Four individual food racks 62 are shown slidingly
received within opposing food rack slide supports sets 48 above pan
52.
[0050] With reference to FIGS. 3 and 4 there is shown through hole
or port 60 formed in an upper, back region of side wall 25 which
provides exhaust and/or intake port means for exhausting combustion
waste gases and/or providing an oxygen intake. Although not shown,
an additional embodiment of the inventions includes an aperture
opening and adjustment cover assembly as in one having an inner
aperture plate that is fixedly supported and a second aperture
plate that is pivotably adjustable (e.g., with an outer finger
flange and central pivot relative to the first aperture plate). In
this way an adjustment to a desired full opening setting with fully
corresponding apertures or a partial setting with partially
corresponding apertures or a closed off setting wherein the
apertures of the outer plate are between apertures of the inner
plate is made possible. In addition port 60 also provides a
suitable ducting location for gas passageway as in a duct extending
from an internal relatively closed off environment (e.g., house or
shed) to a less closed in environment. An alternate embodiment
includes an essentially sealed off arrangement free of
intake/exhaust port like port 60.
[0051] FIGS. 1 and 2 further illustrates control panel assembly 64
having front panel face 65a and a rear (internal) panel face 65b
(control panel assembly 64 probably comprises both visual
indicators (e.g., temperature and time visual indicators) 65c
(e.g., LED displays or mechanical dials, etc.) and smoker character
adjustment means 65d to alter, for example, the smoker duration
time, the desired temperature setting(s), an "on/off" functioning
arrangement, a key code if an electronic door lock is utilized,
etc.). The time settings and temperature settings are also
preferably adjustable via a remote device (e.g., activator) 66
shown in FIG. 1, which sends (e.g., digital systems based signals)
direction signals either directly to control panel assembly 64 or
indirectly via control assembly 68 (FIG. 8) with the latter
preferably including electronic components for time adjustment
means, power line input etc. Control assembly 68 is shown in FIG. 8
as being within the false bottom compartment 70 formed between
floor panel 71 forming the bottom of main housing section 23 and
panel 72 forming the bottom of base housing section 24, and with
control assembly 68 shown mounted to panel 72 of base housing
section 24. As shown in FIG. 2, there is further provided base pan
81 (e.g., an ash pan) which provides a final drip and ash capture
means and can be slid in and out along the upper surface of floor
panel 71 when the door is open and the smoker sufficiently
cooled.
[0052] For remote activation, transceiver/receiver assembly 73
shown in FIG. 8 is provided as part of control assembly 68,
although various alternate signal receiver and/or transmitter
arrangements are featured as in a combination transmitter/receiver
or an independent transceiver and receiver arrangement fully
positioned within the door supported control panel 64. Preferably a
wireless communication system is utilized to achieve the adjustment
and monitoring of the smoker characteristics as in time,
temperature and on/off status, loader adjustment, etc. as described
above through use of either or both of control assembly 68 and
control panel 64. Further, the transmission reception function is
preferably bi-directional with, for example, the remote 66, having
a display to provide smoker characteristic displays on a real time
basis as in status information of the current smoker temperature
and/or for smoker time remaining there is featured a single
directional arrangement wherein the display is not present on the
remote, only on the housing as in front panel face display 65c.
[0053] Control assembly 68 further preferably includes a heating
temperature control system such as those used to control the
temperature of conventional ovens (e.g. via current to resistance
adjustments). Heating temperature control 69 (FIGS. 6 and 8) is
placed in communication with a heat source as in the illustrated
heat resistance bar 76 preferably by direct wiring between control
assembly 68 and heat resistance bar 76 as shown in FIG. 8, heat
resistance bar 76 has an L-shape loop configuration with a shorter
bar section 78 comprising two parallel bar sections 78a, 78b
extending out from support plate 79 and has electronic connection
terminals (not shown) extending into communication with control
assembly 68 which includes means for altering the current supply in
the bar to alter the temperature of the heater and preferably also
a temperature level sensor to compare to and maintain a preset
temperature once a desired level is set.
[0054] The first leg set 78 of resistance bar sections (78a, 78b)
is shown in FIGS. 6 and 7 as extending internally into the smoker
apparatus away from back wall 26. The second leg 84 of the heat
resistance bar 76 comprises a second set of parallel resistance bar
sections (84a, 84b) extending transversely off from unequal length
sections 76a, 76b to define the overall L-shape loop construction.
Bar sections 84a, 84b extend toward side wall 25 near where the
L-shaped heat resistance bar coil is completed by way of an end cap
heat resistance bar loop section 84c (FIG. 2) extending between the
free ends of 84a, 84b. Heat resistance bar 76 extends out from its
support location at support plate 79 into a suspended, cantilever
state within smoker chamber 21 relative to the interior surface of
the housing walls. The cantilever arrangement is preferred together
with a direct contact relationship with the smoker material recover
tray 89 but not preferably a resistance bar support of the receiver
tray arrangement. Rather, additional support rods 88 and 90 are
preferably provided to provide the bulk of support to the receiver
tray. While a heat resistance coil embodiment is preferred for an
electrical based embodiment of the present invention, alternate
electrical based heating units such as infrared ceramic plates
heaters or electromagnetic wave heaters (e.g., infrared and
microwave spectrum wave levels) are also featured under the present
invention. Alternate heat sources such as non-electric heat sources
(e.g., combustion as in charcoal and coal with associated
combustion material support tray or the like) are also featured
under the present invention.
[0055] As shown in FIGS. 2, 3 and 6 support rods 88, 90 extend
parallel with section resistance bar sections 84a, 84b and into
fixed engagement at opposite ends of housing walls 25 and 27 and
are shown spaced away from sections 84a, 84b to avoid direct
contact therewith. Support rods 88, 90 provide a stable base for
supporting smoker material receiver tray 89. As shown in FIGS. 2
and 7, interior brackets 92, 93 extend across at respective spaced
apart locations along the length of fixed support rods 88, 90, with
the main internal bracket 92 being in a central region of the
housing chamber and bracket 93 being closer to the interior wall as
in a direct contact relationship. As shown in FIG. 7, at a lower
end of bracket 92, rods 88, 90 extend through receiving apertures
provided in bracket 92 to support the bracket 92. The upper region
of bracket 92 is secured to interior end wall plate 96 of receiver
tray 89. Although bracket 92 and plate 96 are shown as secured
individual components alternate load support means are also
featured under the present invention as in monolithic plate
structure, vertically extends support bars, etc. There is also
preferably provided a corresponding end tray plate 97 shown in FIG.
7 in a preferred direct contact arrangement with the interior
surface of wall 25. FIGS. 5 to 8 illustrate a preferred arrangement
for base plate 95 of receiver tray 89, which includes a series of
apertures 80 to provide for ash drop into base pan 81. First and
second brackets 92, 93 are shown secured to the ends of apertured
base tray plate 95, with bracket 93 shown as an angle bracket with
flange extension providing below plate 95 support and bracket 92
fixed either directly or indirectly via end tray plate or end
shield 96 in transverse fashion to the horizontally oriented base
tray plate 95. The support arrangement is also such that the smoker
material receiver tray 89 is in direct contact with heat resistance
bar 76 which facilitates heat transfer with side wall shields 98,
100 extending upwardly up from or the elongated sides of apertured
base plate 95. Thus a preferred arrangement for smoker material
receiver tray 89 comprises an enclosure defined by one or more end
tray plates or end shields 96, 97 (e.g., the interior surface of
wall 25 can be used in place of plate 97 if sufficiently robust)
side shields 98, 100 extending between and in contact with end
plates 96, 97 and base plate 95 which is preferably apertured to
provide for gravity release of waste products as in ash from smoker
material combustion (preferably a slow smoldering smoke generating
combustion). Apertured base plate on which smoke generating
material is placed is preferably positioned in close proximity with
the heat generating source as in 0 to 6 inches with 0 representing
the aforementioned direct contact relationship and more preferably
0 to 2 inches as in less than 1 inch spacing. For situations where
non electric heat generating means material is utilized as in a
heat supply based on a combustible such as charcoal, the support
surface in the housing which receives the combustible material is
arranged so as to place the combustible in close spacing with the
smoke generating means as in 0 to 6 inches with "0" including
either direct contact with the combustible in use with the
apertured plate 80 or alternatively the common usage of apertured
plate and receiver tray 89 in general as recipient of both the
combustible and smoke generating material in a direct contact,
intermingled, relationship.
[0056] The preferred heat resistance bar/tray contact arrangement
places each of the long edges of an apertured, rectangular base
tray plate 95 in contact along their full length with the
respective, adjacent resistance bar sections 84a, 84b and/or
shields 98, 100, which extend vertically up from the tray plates
long edges. In this way, there is an extended length of direct
contact heat conduction to base plate 95, and/or shields 98, 100
(depending on relative positioning of each). Shields 98, 100 are
shown to be multi-paneled shields, that include opposing, mirror
image opposing panel schemes. The illustrated shields 98, 100 each
comprise panel sections (101, 102, 103) which are best shown in
FIGS. 6 and 8, as well as an upper, outer breakout panel section
104 which, in conjunction with the immediately below supporting
panel 103, defines elongated "V" shaped shield rims on each side
with apex edges 106 (FIG. 7). The opposite end of shields 98, 100
is preferably fixed (e.g., directly or integrated as in a
monolithic stamped plate) to the interior surface of wall or to an
adjacent bracket. Base plate 95 is further shown to be the upper
component in overhead stacking arrangement of rods 88, 90 at the
lower level, and intermediate heat resistant coil 76 preferably
spaced above rods 88,90 and an above positioned base plate 95 shown
in contact with heat resistance coil 76.
[0057] Receiver tray 89 is arranged for receipt of smoker material
from loader 105 with loader 105 preferably being in a nested
arrangement within receiver tray 89 as well as preferably in a
support relationship as with end receiver tray plate 96 providing
an interior support surface (e.g., in a sliding contact concave
upper edge support arrangement). The housing itself also preferably
provides additional support to the loader as in opposite loader end
contact via the loader reception surface of housing 22 defining
aperture (61, FIG. 3), which aperture 61 further provides an
insertion and retraction location for loader 105. Aperture 61 is
shown provided in wall 25 to have a degree of vertical height
overlap relative to shields 98, 100 once inserted. For example,
with a preferred circular aperture 61, the aperture's positioning
is preferably arranged relative to the shields such that the
shields extend up to the upper half way point of a vertically
oriented diameter line defining aperture 61. In addition, the
shields 98, 100 preferably are spaced apart greater than that
diameter, with the upper rims 104 defining a receiver tray
constricted portion (minimum spacing location) which is preferably
slightly larger than the aperture diameter (e.g., less than a 1/2
inch and more preferably less than a 1/4 inch) and which define a
limited clearance space an each side for a centered circle defined
by said diameter and positioned an equal amount to opposite sides
of the mirror image rims 104 with constricting edges 106. The
constricted arrangement provides a degree of heat containment
relative to inserted loader and receiver tray combination 80 (FIG.
2), which are preferably arranged with nesting components.
[0058] As shown in FIG. 3, loader 105 of combination 80 includes
loader main body 107 which features a recessed load area 109
designed to receive smoker material for introduction to receiver
tray 89. In a preferred embodiment the loader's main body 107
comprises a semi-cylindrical vessel 106 with an upward facing
concave cross-section and end caps 108, 110 designed to generally
conform to the aperture size 61 as to allow for a sliding in of the
loader 105 without extensive spacing. For example, a smooth sliding
arrangement wherein the end cap is designed for a sliding friction
fit and a general sealing effect once loader 105 is inserted into
its dump ready or fully inserted position shown in FIG. 5 (absent
smoker material to dump for added visual clarity). The preferred
supporting arrangement for loader 105 involves end cap 108 in a
supporting relationship with housing edging defining aperture 60 in
wall 25 (e.g., a double wall panel with or without or partially
bridging flanging with a full bridging flange 61' shown in FIG. 3).
Preferably, the axially spaced edging of the interior and exterior
wall panels for wall 25 provides a spacing which results in the end
caps 108, 110 extending across the respective wall panel spacing of
wall 25 or therepast.
[0059] End caps 108 and 110 (FIG. 3) also preferably have an axial
thickness so as to assume a cylindered ring from such as one
conforming to the axial thickness of the double wall panel
cylindrical aperture 61. In a preferred embodiment end cap 110 is a
two stage end cap with a first cylindrical ring 112 and a second
cylindrical ring 114 larger in diameter from the first ring with
the larger diameter ring having the above described generally
conforming diameter to that of aperture 61 to provide support and
also sufficient surface area to provide a secure location for
handle 1160 (FIG. 3) which in the illustrated embodiment comprises
a U-shaped bracket 1180 having extended legs 1190 and 1200 fixed
(e.g., a weld or some other permanent or releasable (screw)
securement means) to the interior annular surface of cap section
114 (so as to avoid interference with a smooth rotation and
substantially sealed off arrangement between the exterior surface
of cap section 114 and the receiving surface defining aperture 61).
The central bridging portion of U-shaped bracket 1180 provides an
attachment base for handle grasp 1220, preferably formed of a lower
heat conductivity material as in a wood or plastic grasp. Handle
1160 also preferably has an elongated configuration with a length
preferably equal to the maximum housing loader reception aperture
width (e.g., diameter of aperture 61), which length provides for
full hand grasping between legs 1180 and 1200).
[0060] In addition, side wall shields 98, 100 extend up to
vertically overlap (e.g., a partial or full overlap) both main body
107 (e.g., the upper side edges of body 107 which are substantially
horizontally coincident with the mirror image V-shaped rims' apex
edges 106) representing the innermost extension portion of shields
98, 100).
[0061] As seen from FIGS. 3 and 7, loader main body 107 preferably
has a true semi or half cylindrical configuration with the smoker
material supporting main body 107 occupying 1/2 of a full cylinder
which is designed to provide a smoker material loader capacity
sufficient for handling intended usage for the preferred single
load dump for resupply during a smoker cycle (e.g., a 1/2 to 5 lb.
bag smoker material reception volume (e.g., one or two) 13/4 lb.
smoker chip bag insertion capacity without overflow from the
recessed loading area 109 of the loader main body 107. For example,
a 3 inch to 1 foot diameter main body with 1/2 foot to 2 foot axial
extension between end caps (108, 100) is illustrated of a preferred
loader body size, although various other sizes are featured under
the present invention based on desired needs of the operator and
configuration of the smoker in general. End cap 108 extends deepest
into the smoker when loader 105 is fully inserted in a rotary
support arrangement. With loader 105 fully inserted, the opposite
end cap 110 is designed to plug insertion/retraction aperture 61
and generally seal off aperture 61. End cap 110 is preferably sized
either the same as ring 114 for easy initial insertion or of common
size with the larger ring 114 to provide a retracted loader (but
not removed from housing) support and plug seal arrangement.
[0062] As shown in FIGS. 5, 6 and 8 for added stability, extension
rods 116, 118 are provided and extend within the confines defined
by shields 98, 100 and are further preferably arranged to extend
from a first fixed support location at the interior surface of wall
25 (or end tray plate 97) to end tray plate 96 supported by the
vertically extending bracket 92 through which rods 98, 100 extend.
Extension rods 116, 118 are spaced apart so as to be positioned in
lower quadrant regions of the loader tray main body and are
designed to not obstruct rotation freedom for main body 109 or
interfere with the smoker material unloading process described
below. The extension rods 116, 118 provide an added degree of
structural integrity to receiver tray 89 and are preferably spaced
away (e.g., within a 1/2 inch) but relatively close to loader main
body 107. A closer, slide contact arrangement (not shown) is also
featured under the present invention to provide additional body
support to the rotating main body 107.
[0063] FIGS. 9 to 12 illustrate somewhat schematically, and in
cut-away fashion, a filled loader 105 insertion and dumping of
smoker material SM (e.g., wood chips) into reception tray 89 with
an alternate solid handle 1160' embodiment with central grasping
knob 1220' which represents an alternate form of handle for
dialing, but the load handle discussion above is applicable to this
embodiment. The embodiment of FIGS. 9-12 also show an alternate
temperature and/or timer adjustment control unit CD at the base of
smoker 20. The embodiment of FIGS. 9-12 further illustrate position
and instructional indicia ID provided on the exterior of wall 25
with "load" and "unload" being representative and being 180.degree.
apart, with the handle grasp itself having a reference marker RM to
show whether load or unload is currently applicable (e.g. an arrow
designation or an inherent in grasp handle shape arrangement or
both.
[0064] Handle 1160', having grasp portion 1220' (preferably a low
heat conduction type as in a wood dowel with direction indicia RM
(FIG. 12), is grasped by an operator at the grasp portion 1220'
without too much heat conduction passed to the grasping hand. The
operator is aware of the present state of the loader based on
reference indicia RM and the status indicing (e.g., "load" and
"unload" indicia ID provided on wall 25). The axial extension of
the handle grasp 1220' out away from loader end 108 also
facilitates rotation of the loader between ready to dump state
shown in FIG. 10 and the actual dump state shown in FIG. 11.
[0065] FIG. 10 illustrates loader 105 filled with smoker material
SM in a ready-to-insert into housing 22 state. FIG. 10 further
illustrates the lining up of the filled loader (e.g., "wood tray"
in this particular embodiment) aligned for insertion into the
smoker chamber 21 via aperture 61 in side wall 25. As shown, the
central axial axis of loader 95 (commensurate with the dumping axis
of rotation of loader 105) preferably falls on a common vertical
plane VP with the parallel, central bisect axial line of receiver
tray 89. In other words, the noted central axis of loader 105 and
the central bisect axis of tray 89 preferably substantially
coincide with the denoted vertical plane (e.g., within
.+-.10.degree. of VP at 0.degree.). Alternate, non-aligned
arrangements as in .+-.10.degree. to 30.degree. offset from VP at
0.degree. is also an arrangement featured under the present
invention with or without an added guide (not shown) as in an added
slide chute slopping between the loader and below positioned
receiver tray for guiding smoker material from an unloading loader
to the receiving area of the receiving tray 89.
[0066] FIGS. 13 to 16 provide an external view showing the supply
or resupply process for smoker material (and/or combustibles) with
loader 95 which includes, for example: [0067] a) Supplying smoker
material SM to loader 105 (not shown in FIG. 13 to 16 for added
visual clarity of loader) as in opening a bag of SM and pouring
smoker material into the main body 107; [0068] b) aligning the
rotation axis of the loader with the center of aperture 61 with the
loader positioned for smoker material retention (e.g. the
semi-cylindered main body's top opening facing upwards); [0069] c)
sliding loader into aperture 61 and into chamber 21 of smoker
housing 22 which involves, with the loader position continuing to
be in a smoker material retention position, sliding of the loader
into the housing until receiving a preferred or plug aperture
relationship wherein aperture 61 is essentially closed off by end
cap 110 of loader 105; [0070] d) adjusting (e.g., rotating) loader
105 (as in a 180.degree. rotation) to remove smoker material SM
from loader 105 for receipt within receiver tray 89 (e.g., a
turning upside down of loader 105 through rotation to enable smoker
material SM to drop of freely out into a below position and
receiver tray 89) and preferably continuing to return loader 105
back into its original "no dump" insertion orientation; [0071] e)
retaining the inserted loader in position during the smoking
process (preferably while retaining a sealing plug relationship
return to aperture 61) following dumping and either following a
return to the original no-dump loader position or while the loader
remains in the dump orientation.
[0072] The present invention also comprises retracking the loader
following the above sequence (e.g., a complete withdrawal and
removal of loader 105 from the housing or a non-full withdrawal or
retraction as in a switching of locations of end caps 108 and 110
relative to the side wall 25 section defining aperture 61. The end
caps preferably having a common exterior maximum section (e.g.,
diameter) to provide a common plugging effect at each position.
Following loader retraction additional smoker material SM can be
loaded either for use in a subsequent smoker process or cycle (the
loader preferably being sufficiently spaced at both an inserted
state and a retracted state from heat source 76 to avoid smoking of
the smoker material SM until dumped to receiver tray 89 or a
resupply dumping process is scheduled in accordance with the above
described receiver tray resupply of smoker material during a common
food smoking cycle.
[0073] As also seen from FIG. 10 and the sequence shown in FIGS.
13-16, the smoker material SM is loaded within main body 107 and
generally below the upper edge of the end caps or sufficiently low
enough to avoid insertion complication relative to aperture 61.
Once inserted, the handle grasp indicia (e.g., RM) reference (e.g.,
points) to the load status based on a readily observable (smoker
material on top of main body 109) user insertion. To achieve an
unloading of the wood chips, an operator grasps the handle grasp
1160 and rotates the loader sufficiently to have the smoker
material SM contents drop into the receiver tray below such that
the smoker material smokes (e.g., smolders) due to the heat
provided by the heat source as in heat resistant coil 76' and the
low oxygen environment in the smoker chamber 21. The open top of
the main body 102 provides for ready release in the illustrated
embodiment and a 180.degree. rotation is preferred with or without
rotation stops (e.g., a 180 one-way as in clockwise, then 180 the
opposite way, as in counterclockwise sequence, or a continuous 360
turning cycle in going from loaded-unload-ready to load status). In
addition, the arrangement of the heat shields 98, 100 as in the
above described nesting relationship helps avoid smoker material
spill outs as the closeness and configuration of the tray 89 (e.g.,
V-shaped rim arrangement 104) helps retain the smoker material SM
until the desired point of loader dump positioning (e.g., fully
rotated upside down so that the wood chips fall directly into tray
89 with the bottom surface of the loader main body capping the
reception region). As shown in FIG. 9, the central axial axis of
loader 95 (commensurate with the illustrated rotation axis)
preferably falls on common vertical plane with the central bisect
axial line for tray 89 such that the smoker material drops along
the vertical plane once the open topped loader is flipped.
[0074] FIGS. 17 to 19 show an interior housing chamber 21 viewpoint
of the adjustment of loader 105 with FIG. 17 corresponding to the
exterior load (pre-dump) state of the loader in FIG. 15, and the
interior view of FIG. 18 corresponding to the exterior view of FIG.
18 showing the rotation of loader 105 from its load position toward
an unload or dump position. FIG. 19 shows an unload or dump state
shown schematically in FIG. 11. FIG. 19 also illustrates the
formerly bottom positioned vessel 106 of loader 105 having rotated
to the top to act as a cover over the receiving tray 89 which
facilitates a "closed box" heat and smoker material supply
retention arrangement in the receiver tray and loader
combination.
[0075] FIGS. 17 to 19 further illustrate a modified heater element
76' which includes additional coil loop sections extending beyond
the peripheral confines of the receiver tray so as to extend over
essentially all of the bottom wall of the housing chamber 21. The
embodiment shown in FIG. 3 with the heat resistance bar being
configured to be the same or less than the periphery of the
apertured base plate 95 except for the lead in branch set extending
in from the wall support is preferred (e.g., from the standpoint of
a more efficient heat application through avoidance of extraneous
heat production in the smoker).
[0076] In other words, by confining the hear resistance bar's loop
extension to conform or be inward of the periphery of the receiver
tray 89 there is facilitated a more direct hear approach,
preferably with a direct contact heat conduction element in
addition to the radiant and convection heat exchange used to
sufficiently heat the smoker material SM to achieve the smoke
generation.
[0077] FIG. 20 illustrates an alternate embodiment of the invention
which is similar to that of FIG. 1 but features an alternate smoke
generating hear source involving combustibles "C", as in charcoal,
coal, etc. to generate sufficient hear relative to the receiver
tray to generate smoke in smoker material in the tray. A suitable
support tray or grill "T" is preferably provided and the heat
source is preferably positioned directly adjacent the tray 89 to
heat the tray and smoker contents sufficiently. Also, in an
alternate embodiment (not shown) the combustible and smoke
generating material can be placed in direct contact as in a common
tray supporting both, with the smoke generating material preferably
supplied on top of the combustible. For this embodiment, the loader
can be used to initially position or to resupply either the smoke
generating material or the combustible depending upon the relative
combustion rate for the intended use.
[0078] It should be emphasized that the above-described embodiments
of the present invention, particularly, any "preferred"
embodiments, are merely possible examples of various possible
implementations embodying the principles of the invention. In other
words, many variations and modifications may be made to the
above-described embodiment(s) of the invention without departing
substantially from the spirit and principles of the invention. All
such modifications and variations are intended to be included
herein within the scope of this disclosure and the present
invention and protected by the following claims.
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