This disclosure relates to outdoor cooking in general and, more specifically, to solid fuel smokers.
Current solid fuel smokers have a firebox and a cooking chamber. A smokebox or firebox is placed adjacent to the cooking chamber in an offset position. There is a cutout on the wall shared between the firebox and cooking chamber. The cutout allows for the travel of the combustion products from the offset firebox into the cooking chamber. The cutout also allows for transfer of the heat from the burning solid fuel inside the firebox into the cooking chamber. However, this radiation is highly concentrated on the single side of the cooking chamber that shares a wall with the firebox. In fact, excess radiative heat makes a portion of the cooking chamber near the firebox too hot and unsuitable for most cooking purposes. The offset positioning of the firebox also contributes to lack of even distribution of the temperature in the cooking chamber. It also leads to substantial loss of energy—about two-third of the energy generated in the firebox is lost through its walls.
There are horizontal smokers with the firebox mounted under the cooking chamber. These may reduce heat loss. However, these systems still suffer from excessive radiative heat at the cooking region neighboring the firebox and the lack of adjustment mechanism.
What is needed is a device, system, and methods for overcoming these and related issues.
The invention of the present disclosure, in one aspect thereof, comprises a cooking device having a cooking chamber, and a firebox affixed to a bottom of the cooking chamber and in fluid communication with the cooking chamber. The firebox has an internal fuel grate, and an air intake receiving combustion air from outside the firebox.
Some embodiments include a baffle system controlling fluid flow from the firebox into the cooking chamber. The baffle system may comprise a pair of rotatable stacked plates, each having a plurality of cutouts defined therein such that the rotatable plates maybe rotated with respect to one another to alter a degree of fluid flow allowed through the pair of plates. The baffle system further may comprise a pair of nested cylindrical walls with one of each of the pair of nested cylindrical walls affixed to one of each of the pair of rotatable plates and extending upwardly therefrom.
In some cases, the pair of nested cylindrical walls defines a plurality of cutouts such that the nested cylindrical walls rotate with their respective affixed plates to alter a degree of fluid flow allowed laterally through the nested cylindrical walls. The degree of fluid flow laterally through the pair of nested cylindrical walls may decrease as the degree of fluid flow through the pair of plates increases. The degree of fluid flow laterally through the pair of nested cylindrical wall may increase as the degree of fluid flow through the pair of plates increases.
The baffle system may further include a perforated wall extending below the nested cylindrical walls and/or a diffuser inside the pair of nested cylindrical walls above the pair of plates.
The invention of the present disclosure, in another aspect thereof, comprises a cooking device having a cooking chamber defined by upper and lower portions between end walls, a cooking grate inside the cooking chamber, a firebox attached to the lower portion of the cooking chamber spaced apart from the end walls, the firebox being in fluid communication with the cooking chamber, and a damper interposing the firebox and a center portion of the cooking grate, the damper being adjustable to allow combustion products to rise from the firebox to the center portion of the grate, and to diffuse combustion products rising from the firebox.
In some instances, the damper comprises a radial damper. The radial damper may have first and second stacked components, each defining a set of cutouts with a degree of overlap that is altered by rotation of one of the first and second stacked components to alter fluid flow through the radial damper.
The cooking device may further include a pair of nested cylindrical walls, a first one of the pair being connected to and extending upwardly from the first stacked component, a second one of the pair being connected to and extending upwardly from the second stacked component. In some cases, the first and second nested cylindrical wall walls each define at least one cutout, the at least one cutout of the first cylindrical wall being adjustable by rotation to overlap or not overlap with the at least on cutout of the second cylindrical wall to alter fluid flow through the first and second nested cylindrical wall walls.
The cooking device can include: a diffuser plate inside the pair of nested cylindrical wall walls above the damper; a perforated wall supporting radial damper and nested cylindrical walls inside the cooking chamber, spaced apart from the firebox; and/or a pair of adjustable smoke stacks spaced apart on the upper portion of the cooking chamber, each of the pair of adjustable smoke stacks having and adjustable damper to control fluid flow from the smokestacks. When present each of the pair of adjustable smoke stacks may be further adjustable for height.
The invention of the present disclosure, in another aspect thereof, comprises a cooking device with a cooking chamber defined by an upper portion, a lower portion, and two spaced apart end portions, a firebox attached to the lower portion of the cooking chamber and in fluid communication with the cooking chamber, and a baffle system inside the cooking chamber controlling direction of combustion gases from the firebox toward a food support inside the cooking chamber. The baffle system includes a radial damper that is adjustable by a handle extending outside the cooking chamber and the firebox to pass combustion products therethrough and to diffuse combustion products radial away from the radial baffle; a pair of nested cylindrical walls extending upwardly from the radial damper and defining an opening therethrough that adjusts with adjustment of the radial baffle to allow combustion products to pass through the pair of nested cylindrical walls or be impeded from passing through the pair of nested cylindrical walls, a diffuser plate above the radial baffle, and a perforated wall extending downwardly from the radial damper.
The cooking device can include a pair of height and flow adjustable smoke stacks affixed to the upper portion of the cooking chamber spaced apart from one another.
Referring now to
The grill 100 and other embodiments of the present disclosure may comprise a cooking chamber 102. The cooking chamber 102 may be defined by an upper portion 130, a lower portion 132, and a pair of spaced apart end pieces 134. The cooking chamber 102 may be generally cylindrical but is not necessarily strictly so, and other geometries are possible. A firebox 108 may be attached to the cooking chamber and in fluid communication therewith. Unlike prior systems, the firebox 108 is attached to the lower portion 132 rather than communicating through the end pieces 134. The firebox 108 may be centrally located (front to back, and/or side to side) on the lower portion 132. In some embodiments, the firebox 108 and/or some components associated with the firebox 108 may extend into the cooking chamber 102 or be contained in the cooking chamber 102. The cooking chamber 102 and/or firebox 108 may be supported on a stand 110.
An adjustable baffle system 112 may control both radiative and convective heat transfer from the firebox 108 into the cooking chamber 102 where food is placed for cooking. Adjustable smokestacks or flue pipes 106 may be provided to control flow of gases out of the cooking chamber 102. Some embodiments may have smokestacks configured differently such as the smokestack 800 shown in
The cooking chamber 102 may have an openable lid 104 on the upper portion 130 allowing access to interior components and placement and removal of food items. Various racks, grates, hooks, and other implements for retaining food during smoking or cooking operations may be provided (these may be referred to generally as “food supports”). For simplicity and illustrative purposes, a single food support is shown as the single grate 120 (removed from its place in the cooking chamber 102 above the baffle system 112). A central sear zone 122 may be directly over the baffle system 112 for searing operations as discussed in greater detail below.
The firebox 108 may comprise an openable door 109 on one side thereof (e.g., the front) that may allow access to a fuel chamber 114 above an ash receptacle 116. The fuel chamber 114 and ash receptable 116 may be arranged as drawers for ease of access.
Referring now to
Referring now to
Smokestacks 106 may be adjustable with respect to the amount of exhaust flow allowed from the cooking chamber 102.
Referring now to
In a smoking mode, the air damper 202 is partially open allowing limited air to be supplied to the solid fuel (on grate 204) resulting in the smoldering of the fuel. The baffle system 112 is arranged in a manner to reduce or prevent vertical or upward flow of smoke. Smoke is instead directed it into the cooking chamber 102 via perforated side walls 610. The closed baffle system 112 also acts as a radiation shield, preventing the center of the cooking chamber 102 from overheating or otherwise getting too hot for desirable smoking operations.
In a searing or grilling mode (e.g.,
Referring now to
In some embodiments, a diffuser plate 606 may be placed or affixed on or within the inner cylindrical wall 604 to further diffuse smoke and combustion products selectively allowed to pass upward through the inner cylindrical wall 604. The diffuser plate 606 may be on a vertical level below the openings 603, 605. The diffuser plate 606 itself may define a number of openings 607, which may be angled or form louvres for directing gas flow. The openings 607 are illustrated as being configured to direct gas or fluid flow in a radial direction, which may further the effect of the cylindrical walls 602, 604, but could be configured to direct or allow gas flow primarily vertically, for example. Functionally, the diffuser plate 606 may also serve to more evenly distribute heat proximate the sear zone.
Below the cylindrical walls 602, 604 may be perforated side walls 610. The side walls 610 may descended generally vertically from the cylindrical walls 602, 604 but terminate along a curve conforming to the shape of the bottom interior of the lower portion 132 of cooking chamber 102. In some embodiments, a single sidewall may descend from the cylindrical walls 602, 604 and be perforated along all of part of its circumference.
Referring now to
Referring now to
Depending on relative positioning of the inner cylindrical wall 604 and outer cylindrical wall 602, direct transfer of radiative and convective heat vertically upward may be limited to created more smoke and/or limited or diffused heat as might be useful in smoking or baking. This configuration can be seen in operation in
On the other hand, when the baffle system 112 is configured for grilling or searing (as in
It will be appreciated that the plates 612, 614 could be affixed to outer cylindrical wall 602 and inner cylindrical wall 604, respectively, such that the openings 603, 605 align when the openings 613, 615 align. In such an embodiment smoke and gases may not readily flow back into an upper portion of the baffle system 112 (e.g. above the diffuser 606) during smoking or baking operations but more heat may be transferred to the entire grate 120 during grilling/searing operations as gas and heat could flow outward through the openings 603, 605 when the openings 613, 615 in the plates 614, 612 are aligned.
It should also be understood that greater or lesser degrees of opening may be achieved between the openings 603, 605 as well as between the openings 613, 615 (e.g., cylindrical walls 602, 604 and/or plates 612, 614 may be partially openable as well as fully opened or closed). In some embodiments, the outer cylindrical wall 602 may rotate with respect to the inner cylindrical wall 604 rather than the inner cylindrical wall 604 being rotatable within the outer cylindrical wall 602.
Referring now to
The upper piece 702 and possibly the lower piece 710 may be fitted in or to a top 701 of the cap 700. The aligned central openings 712, 704 allow gas flow into the cap but exit from the cap is controlled by the damping or alignment of the upper piece 702 and lower piece 710.
Referring now to
It will be appreciated that embodiments of the present disclosure provide more accurate and better control of the temperature and heat in the cooking chamber 102 by adjusting the means of radiative and convective heat transfer from the firebox 108 into the cooking chamber 102. Adjustable air damper 202 and smokestacks 116 (or flue pipes 800) allows for fine-tuning of each desired cooking mode from low temperature smoking to high temperature searing.
It is to be understood that the terms “including”, “comprising”, “consisting” and grammatical variants thereof do not preclude the addition of one or more components, features, steps, or integers or groups thereof and that the terms are to be construed as specifying components, features, steps or integers.
If the specification or claims refer to “an additional” element, that does not preclude there being more than one of the additional element.
It is to be understood that where the claims or specification refer to “a” or “an” element, such reference is not be construed that there is only one of that element.
It is to be understood that where the specification states that a component, feature, structure, or characteristic “may”, “might”, “can” or “could” be included, that particular component, feature, structure, or characteristic is not required to be included.
Where applicable, although state diagrams, flow diagrams or both may be used to describe embodiments, the invention is not limited to those diagrams or to the corresponding descriptions. For example, flow need not move through each illustrated box or state, or in exactly the same order as illustrated and described.
Methods of the present invention may be implemented by performing or completing manually, automatically, or a combination thereof, selected steps or tasks.
The term “method” may refer to manners, means, techniques and procedures for accomplishing a given task including, but not limited to, those manners, means, techniques and procedures either known to, or readily developed from known manners, means, techniques and procedures by practitioners of the art to which the invention belongs.
The term “at least” followed by a number is used herein to denote the start of a range beginning with that number (which may be a range having an upper limit or no upper limit, depending on the variable being defined). For example, “at least 1” means 1 or more than 1. The term “at most” followed by a number is used herein to denote the end of a range ending with that number (which may be a range having 1 or 0 as its lower limit, or a range having no lower limit, depending upon the variable being defined). For example, “at most 4” means 4 or less than 4, and “at most 40%” means 40% or less than 40%.
When, in this document, a range is given as “(a first number) to (a second number)” or “(a first number)-(a second number)”, this means a range whose lower limit is the first number and whose upper limit is the second number. For example, 25 to 100 should be interpreted to mean a range whose lower limit is 25 and whose upper limit is 100. Additionally, it should be noted that where a range is given, every possible subrange or interval within that range is also specifically intended unless the context indicates to the contrary. For example, if the specification indicates a range of 25 to 100 such range is also intended to include subranges such as 26-100, 27-100, etc., 25-99, 25-98, etc., as well as any other possible combination of lower and upper values within the stated range, e.g., 33-47, 60-97, 41-45, 28-96, etc. Note that integer range values have been used in this paragraph for purposes of illustration only and decimal and fractional values (e.g., 46.7-91.3) should also be understood to be intended as possible subrange endpoints unless specifically excluded.
It should be noted that where reference is made herein to a method comprising two or more defined steps, the defined steps can be carried out in any order or simultaneously (except where context excludes that possibility), and the method can also include one or more other steps which are carried out before any of the defined steps, between two of the defined steps, or after all of the defined steps (except where context excludes that possibility).
Further, it should be noted that terms of approximation (e.g., “about”, “substantially”, “approximately”, etc.) are to be interpreted according to their ordinary and customary meanings as used in the associated art unless indicated otherwise herein. Absent a specific definition within this disclosure, and absent ordinary and customary usage in the associated art, such terms should be interpreted to be plus or minus 10% of the base value.
Thus, the present invention is well adapted to carry out the objects and attain the ends and advantages mentioned above as well as those inherent therein. While the inventive device has been described and illustrated herein by reference to certain preferred embodiments in relation to the drawings attached thereto, various changes and further modifications, apart from those shown or suggested herein, may be made therein by those of ordinary skill in the art, without departing from the spirit of the inventive concept the scope of which is to be determined by the following claims.
This application claims the benefit of U.S. provisional patent application Ser. No. 63/320,034, filed on Mar. 15, 2022, and incorporates such provisional application by reference into this disclosure as if fully set out at this point.
Number | Date | Country | |
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63320034 | Mar 2022 | US |