CA2348316A1 - Gas barbeque assembly - Google Patents

Abstract

A barbeque assembly including an easy to assembly support structure for a barbeque grill housing. Assembly of the support structure may be completed with few or no tools. The support structure has first and second support members for supporting the grill housing in a generally horizontal orientation, and a cross beam. A manually installable connector is used to manually connect the cross beam at a first end to the first support member and to manually connect the cross beam at a second end to the second support member. The first and second support members and connection member preferably form a substantially rigid structure.

Description

GAS BARBEQUE ASSEMBLY
FIELD OF THE INV>E:NTION
The present invention relates generally to the field of cooking apparatus, and more particularly to barbeques such as outdoor gas fuelled barbeques.
BACKGROUND OF THE INVEN'T10N
To reduce manufacturing, shipping and storage costs, barbeque grill manufacturers often ship unassembled barbe:ques to retailers, for subsequent assembly by consumers. While some nnanufacturers may provide barbeques with a number of components pre-assembled, consumers are generally required to assemble at least some part of the barbeque. This assembly often requires consumers to follow detailed instructions to combine a plurality of barbeque components. These components may include: an upper and lower casting containing burners and a grill, shelves, a console for regulating the flow ofd fuel to the burners, and a structure for supporting the upper and lower castings. Following assembly of the various barbeque components, a fuel source is connected to the barbeque. The fuel source may be a tank containing pressurized propane, which should be safely secured to the barbeque support ;structure.
To assemble the barbeque, the support members and one or more of the other components may be securely fastened 1:o one another. For example, a typical barbeque may require that over twenty such connections be made by a consumer. Common tools such as screwdrivers and wrenches may be required. Since not all consumers have a facility with such tools or with interpreting assembly instructions for the barbeque, assembly of the barbeque may be a relatively complex and frustrating process, which could take a significant amount of time to c~~mplete.
Difficulty may also be encountered due to the required orientation of fasteners during installation. For example, to assemble some barbeques, fasteners such as screws or bolts are required to be installed in a generally upward direction. This rnay necessitate that the consumer crouch beneath a partially assembled barbeque to install additional components or to secure assembled components. Use of tools in this position may be difficult for those who do not have f~exterity with tools. Even manual insertion and tightening of screws or bolts in this position rnay be difficult. Alternatively, a consumer rnay have to reposition a partially assembled barbeque numerous times during its assembly process if it is desired to install screws or bolts in a rnore convenient orientation than in a generally upward direction.
While manufacturers often provide detailed written assembly instructions, including figures, the required orientation of some barbeque components might not be apparent to unskilled consumers. This may lead to improperly assembled barbeques. For example, the grill casting might not be adequately balanced on the support structure which could make the barbeque unstable. Other elements such as the burners, heat deflectors, and the propane tank should also be properly oriented to ensure safe operation of the barbeque.
The above difficulties might also be faced by retailers attempting to assemble floor models for display to potential consumers. 'Chis may make retailers reluctant to assemble floor 20892747.2 _ ') _ models, which could make it more difficult for the unassembled barbeques to be sold because c~~nsumers are deprived of the opportunity to see an assembled model.
Similarly, if retailers assemble floor models improperly, consumers may be discouraged from purchasing the corresponding barbeque model.
Fully assembled barbeques may alternatively be shipped by manufacturers to retailers to avoid problems associated with the assembly of the barbeque by the consumer. A
potential drawback of this approach is that the fully assembled barbeque generally requires a significantly l~~rger shipping carton and therefore c>cc;upies a greater volume when shipped. As a result, fewer b~arbeques may be shipped at a time leading to increased shipping costs.
Manufacturers also incur increased labour costs in assembliing the barbeque themselves.
Based on the foregoing, it would be desirable to develop alternative barbeques that may be shipped unassembled to reduce cost:>, but that may be readily assembled by unskilled consumers.
~~UMMARY OF THE INVENTION
The invention consists of a barbeque assembly. The barbeque assembly has a support :structure for a barbequc: grill housing. 'The support structure includes first and second support members for supportin;a the grill housing in a generally horizontal orientation, and a cross beam.
,A connector is included for manually connecting the cross beam at a first end to the first support member and for manually cormecting the cross beam at a second end to a second support member. The first and second support members and connection member combine to form a '0892747.2 substantially rigid structure.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the; present invention and to show more clearly how it may be carried into effect, reference is now made, by way of example only and not of limitation, to the accompanying drawings in which:
FIGURE 1 is an exploded persp~ectiva view of the barbeque according to an illustrative embodiment of the invention;
FIGURE 2 is an exploded perspective view of the barbeque according to an alternative illlustrative embodiment of the invention;
FIGURE 3 is an exploded perspective view of supports and a lower casting of the barbeque of Figure 1;
FIGURE 4 is a cross-sectional view of the lower casting of the barbeque of Figure 1 taken along the line 4-4 of Figure 3;
FIGURE 5 is a side view of a beam connection member of the barbeque of Figure 1;
FIGURE 6 is an exploded perspective view of beam connection members and a cross beam of the barbeque of Figure 1;

2.0892747.2 FIGURE 7 is an assembled perspective view of the beam connection members and cross beam of Figure 6 showing bolts oriented for insertion;
FIGURE 7A is an exploded partial end view of a beam connection member and bolt of the barbeque of Figure 1;
FIGURE 8 is a partial side view including the beam connection members and cross beam of the barbeque of Figure 1;
FIGURE SA is an assembled partial end view of a beam connection member and bolt of tine barbeque of Figure 1;
FIGURE 9 is an. exploded partial perspective view including beam connection members, support members and a cross beam of tlhe barbeque of Figure 2;
FIGURE 10 is a partial perspective view of an alternative embodiment of the beam connection member and cross beam of the barbeque of Figure 2;
FIGURE 11 is side view o.f a pin of the barbeque of Figure 1;
FIGURE 12A is side view of~ an alternative embodiment of the pin of Figure 1 l;
FIGURE 12B is an exploded partial perspective view of a beam connection member, leg extension, castor and legs of the barbedue of Figure 1;
20892747.2 FIGURE 13A is an end view of a bolt of the barbeque of Figure 1;
FIGURE 13B is a side view of a~ bolt of the barbeque of Figure 13A;
FIGURE 14A is an end view of an alternative embodiment of the bolt of Figure 13A;
FIGURE 14B is. a side view of the bolt of Figure 14A;
FIGURE 15 is a perspective view of a partially assembled barbeque of Figure 2;
FIGURE 16 is a perspective view of an alternative embodiment of the beam connection member and tank base of Figure 2;
FIGURE 17 is a perspective ~=iew of an alternative embodiment of the tank base of Figure :l 6;
FIGURE 18 is a perspective view of the tank base of Figure 17 having strengtheners;
FIGURE 19 is ~~n exploded perspective view of~ a fuel source retainer of the barbeque of higure 2;
FIGURE 20 is a perspective view of an alternative embodiment of the fuel source retainer of Figure 19;
?0892747.2 FIGURE 21 A is an end view of a further alternative embodiment of the fuel source retainer of Figure 19;
FIGURE 21 B is a side view of the fuel source retainer of Figure 21 A;
FIGURE 22 is a side view of an alternative embodiment of a shelf of the barbeque of Figure 1;
FIGURE 23 is an end view of the shelf of Figure 22;
FIGURE 24 is a cross-sectional view of a receptacle the shelf of Figure 23 taken along the line 24-24;
FIGURE 25 is a side view of'a shelf of the barbeque of Figure l;
FIGURE 26 is an exploded partial perspective view of a shelf and support of the barbeque ofFigure 1;
FIGURE 27 is ;gin exploded partial perspective view of a shelf and support of the harbeque of Figure 2;
FIGURE 28 is an exploded perspective view of a side burner of the barbeque of Figure 1;
FIGURE 29 is .an exploded perspective view of a side burner of the barbeque of Figure 2;
20892747.2 _7_ FIGURE 30A is an exploded perspective view of a valve clip and valve opening of the barbeque of Figure 1;
FIGURE 30B is a perspective view of the valve clip and valve opening of Figure showing the valve clip inserted into the valve opening;
FIGURE 30C is a perspective view of the valve clip and valve opening of Figure showing the valve clip :retained within the valve opening;
FIGURE 31 is an exploded perspective view of the panel and leg members of the barbeque of Figure 1;
FIGURE 32 is a perspective vriew of the barbeque of Figure l;
FIGURE 33 is an exploded perspective view of a lower casting and burner of the barbeque of Figure 1;
FIGURE 34 is ~~ side view of°the lower casting and burner of Figure 23 showing the burner attached to the lower casting;
FIGURE 35 is an exploded perspective view of the console and leg members of the lbarbeque of Figure 1;
20892747.2 FIGURE 36 is a perspective assembled view of the console and leg members of Figure 35;
FIGURE 37 is an exploded perspective view of the console and leg members of the barbeque of Figure 2;
FIGURE 3$ is a perspective assembled view of the console and leg members of Figure ?.7;
FIGURE 39A is a side view of a console bolt of the barbeque of Figure l;
FIGURE 39B is an end view of the bolt of Figure 39A;
FIGURE 40 is a partial exploded perspective view of the wheel assembly of the barbeque of Figure l;
FIGURE 41 is a cross-sectional view of the wheel assembly of the barbeque of Figure 1 l:aken along the line 41-.41 of Figure 40;
FIGURE 42A i;s an exploded perspective view of a axle pin and axle lock of the barbeque ~~f Figure l;
FIGURE 42B i;~ an assembled perspective view of an axle pin and axle lock of Figure 42A;
20892747.2 FIGURE 43A is. an exploded perspective view of an axle pin and axle lock of the barbeque of Figure 2;
FIGURE 43B is an assembled perspective view of an axle pin and axle lock of Figure ~l3 A;
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS OF THE
INVENTION
Refernng to Figure 1, a first illustrative embodiment of the claimed invention is shown in Exploded view. The claimed invention includes a barbeque 60 having first and second support members 62, 64, and a rigid connection between the support members 62, 64, such as a cross team 66. A preparation or storage surl:ace in the nature of first and second shelves 68', 70' may lie included. To provide limited structural support to the support members 62, 64, a panel 72 may be provided. A grill housing 74, having opposed castings 76 and 68 that enclose a burner 80, is supported by the support members 62, 64. A cooking surface or cooking grid, in the nature of one or more grill plates 82, and a w~~rming rack 84 may also be contained within the grill lhousing 74. A fuel flow controller, for instance console 86, may be provided to moderate the flow of fuel to the burner 80. To deflect heat produced by burners 80, a heat deflector, such as angled bars 88 may also be included. 1:f a self contained fuel source is used, such as a propane tank 90, then a fuel source support base 92 may be employed to support tank 90. If an external fuel source, such as piped natural gas, is used then base 92 may be omitted, and support members 20892747.2 62 and 64 may have a substantially identical or mirror configuration of one another. Relocation of the barbeque 60 may be facilitated by the addition oi~wheels 94 and/or casters 96.
In the context of describing embodiments of the claimed invention, variations of detail are disclosed, a number of which are shown, for example, in Figure 2. While one such variation is described in conjunction with another particular variation, yet other variations may generally b~e used in association as well. The description provided is therefore not intended to be limited to tl'ne particular combination of variations. disclosed.
Support Member Support member 62 may be conEgured to be substantially identical to support member E~4, and may have a mirror configuration to support 64. In the embodiment illustrated in Figure support members 62. 64 differ in that support member 64 is provided with a fuel source support base 92. Except for the description of support base 92, the description of support member 62 generally applies to support member 64, unless otherwise noted.
Support member 62 has two leg; members 98 and 100. In the illustrative embodiment, the leg members 98, 100 are substantially cylindrical, and rnay be hollow to reduce cost and weight.
if leg members 98, 100 are made of a metal, such as steel tubing, they may have an external diameter of 1 3l8 inches and a wall thickness of 0.035 inches. In an alternative embodiment, legs ~~8 and 100 may have substantially rectangular cross sections. For example, leg members 98 and 100 may be configured as leg members 98' and 100' having a generally square cross-section with one inch sides, as is shown in Figure 2.
20892747.2 Referring to Figures 3 and 4, lei; members 98, 100 may be joined to each other by at least one member, such as bridging member 102. Bridging member 102 may be connected to leg members 98, 100 either by spot welding, bolting, riveting or in some other appropriate manner known to those in this art. In the illustrative embodiment, bridging member 102 has one, and preferably two, slots 106 and 108 therethrough. Slots 106 and 108 laterally traverse bridging member 102 and are positioned to receive a weld therethrough for attaching leg members 98 and 100 to the bridging member 102. To conserve weld material, the width of slots 106 and 108 may be made narrow enough to receive a standard weld. By joining leg members 98 and 100 using bridging member 102, a substantially rigid structure is created, with leg members 98 and 100 preferably oriented generally parallel to one another, and bridging member 102 may be generally perpendicular to leg members 98 and 1 X00. When in their operative position, legs 98 and 100 Imeferably are generally vertically oriented, and may rest on their respective base ends 110 and 1'.12. Alternatively, leg members 98 and 100 may rest on wheels 94, casters 74, leg extensions 1l 14 or other terminating elements as are known to those skilled in the art.
For stability, leg members 98 and 100 may be substantially uniformly spaced from each other by a distance corresponding generally to a width W of the grill housing 74. It will be appreciated by those versed in the arC that a wider spacing for the leg members 98 and 100 may provide greater stability to barbeque 6Ct, while a narrower spacing therefor could make barbeque 60 top-heavy and prone to tipping. For example, if a narrower grill housing is used (not shown), the spacing between le;g members 98 and 100 as configured for a larger housing 74 may be ;appropriate, and may provide greater stability to barbeque 60 than if a spacing approximating the width of the narrower grill housing was used.
20892747.2 While support members 62, 64 each have at least two leg members 98 and 100, they could alternatively each have just one leg member (not shown) if the single leg member is made sufficiently large to provide adequate support and stability to the grill housing 74 and other components of the barbeque 60. Components herein described as being attached or connected S between leg members 98 and 100, could be attached to the single leg member in substantially the same orientation as for the embodiment of support members 62, 64 each having l:wo leg members 98 and 100.
Cross Beam A cross member, in the nature of cross beam 66, joins first support member 62 to second support member 64 to form a substantially rigid structure for supporting grill housing 74, and other components of the barbeque 60. for sake of stability, cross beam 66 may be of a length which is approximately the same as that of the grill housing 74. For example, cross beam 66 rnay be approximately 18 inches long. This ensures that support members 62 and 64 may be attached to grill housing 74 generally below and approximately aligned with opposite sides of the ~~ill housing 74.
Cross beam 66 may have a uniform lateral cross-section that is generally rectangular in :shape, for example, having two respective opposed sides of three inch width and two respective opposed sides of four inch width, or sides all having a similar width such as 2 '/Z inches.
,alternatively, beam 66 may have a cross-sectional configuration which is polygonal, round, or non-uniform in shape. To reduce costs anti material, the beam 66 may be hollow. A rigid 2og92~4~.z plastic, or a metal, whether formed by injection moulding, bending, or some other appropriate yrocess, is preferably used to construct cross beam 66.
While cross beam 66 is generally linear in the illustrative embodiment of the invention, it rnay have angles or curves formed therein for orienting the beam 66 for attachment to each support member 62 or ~i4, as described in greater detail below. For example, Figure 2 shows an alternative cross beam 66' used in an embodiment of the invention.
Beam Connection Member Refernng additionally to Figures 5, 6, 7, 7A, 8 and 8A, a beam connection member 116, having a strut 118 with a beam receptacle 120 defined therein, connects beam 66 to support member 62. A second beam connection member 122, having a beam receptacle 124, connects beam 66 to support member 64. Beam connection members 116 and 122 are similar in configuration except that at least one o f the beam connection members, for example beam connection member 122, may be confil;ured to have a fuel source support base 92 for supporting a fuel container such as a propane tank 90, as described below. Aside from the possible consideration of a fuel source support base 92, the following description of beam receptacle 120, ;applies to beam recept~~cle 124 as well. unless otherwise indicated.
Beam receptacle 120 has an open end 126 for receiving an end 128 of cross beam 66. A
~~losed end 130 of receptacle 120 which is opposed to open end 126 prevents cross beam 66 from lbeing inserted into the receptacle 120 my further. The closed end 130 also provides feedback by way of abutment of cross beam 66 thereagainst to indicate that the beam 66 is fully inserted, and 1089274 7 .2 ready to be secured. In addition to closed end 130, beam receptacle 120 has walls 132 that, in conjunction with closed end 130, define; receptacle 120 as substantially the same shape, and at least the same size as end 128 of cross beam 66. If a beam 66 with a round or curved lateral cross-section (not shown) is used, then receptacle 120 may have one continuous wall. The difference between the size of receptacle 120, as defined by walls 132 and end 130, and cross beam end 128, is preferably configured to be at a minimum to reduce movement of end 128 within beam receptacle 120.
Beam connection member 116 may be made from a metal, plastic or other suitable material known to those in this art. If made from a plastic, it may be integrally formed by injection moulding.
Referring to Figures 2 and 9, an alternative embodiment of beam connection member 1.16' is formed as a strut 118' having a generally inverted U-shaped cross-section. Strut 118' may be attached between leg members, sucru as leg members 98' and 100', as described below. Arms 1'~ 36 (whose lower longritudinal edge is shown in a phantom line) and 138 of the U-shaped cross-I S :section are preferably substantially at right angles to base 140 of the L1-shaped cross-section.
Strut 118' is preferably attached between leg members 98' and 100' adjacent leg member base ends 110' and 112'. When attached between leg members 98' and 100', arms 136 and 138 may be l;enerally parallel to thf: longitudinal axes of the leg members, and the U-shaped cross section preferably opens in the general direction of leg member base ends I 10' and 112' (Figure 2).
:'.0892747.2 Ann 138 may have an opening 142 formed therein for receiving beam end 128'.
Opening 142 preferably is substantially the same size as a lateral cross-section of beam end 128' so as to mate therewith. To facilitate placement: of beam end 128' into opening 142, opening 142 may correspond to the general shape of just three sides of beam end 128', to define a generally right-angled U-shaped opening 142.
Cross beam 66' may be attached to strut 118' by first inserting beam end 128' into opening 142 until beam end 128' abuts .arm 136 of strut 118'. Arm 136 of strut 118' may additionally have a supporting member attached thereto for supporting beam end 128'. The supporting member ma;y be in the form of a substantially perpendicular flange 144 along a free end 146 (shown as a phantom line) ok'ann 136, the flange 144 being generally directed towards opening 142. Beam end 128' may rest on flange 144 once beam end 128' abuts arm 136. When fully inserted into opening 142, movement of beam end 128' is inhibited by arm 136, flange 144 of arm 136, base 140 of strut 118' and edges of opening 142. A transverse indent 148 in base 140 between arm 138 and opening 142 may also receive and align a portion of beam end 128'.
Furthermore, opening 142 may additionally have a flange such as a peripheral flange (not shown) for abutting crass beam 66'.
To abut a greater portion of beam end 128', base 140 of strut 118' may be widened at a raid-section 150 of strut 118'. Mid-section 150 may widened in a direction generally away from gum 136 or away from ;arm 138, or in both directions. While strut 118' maintains its U-shaped cross-section in this configuration, arms 136 and 138 are closer to one another at the ends 152 of strut 118' and become ~;radually further apart to a maximum when adjacent mid-section 150. If 2 0892747.2 rnid-section 150 is widened in a direction away from arm 138 only, beam connection member 116' then projects from the plane of legs 98 and 100 in a similar direction as an attached shelf 68 (or 68' or 68"). This may enable a support member such as support member 62' having a shelf fib" and a beam connection member 116' to occupy a smaller volume when placed in a container such as a shipping box (not shown) than if mid-section 150 projected in an opposite direction.
Beam end 128' may be attached to strut 118' using at least one fastener, such as bolt 154, which is inserted through a hole 156 in base 140 and a corresponding bore in beam end 128'.
'JVhen beam end 128' is inserted into opening 142 and abuts arm 136, hole 156 and bore 158 are preferably aligned to receive bolt 154. Once bolt 154 is inserted therethrough, it may be preferably manually secured with a wing nut or some other manually tightenable fastener.
Before bolt 154 is inserted, hole I 56 arid bore 158 are aligned and preferably generally vertically oriented to permit insertion of bolt 154 in a downward direction. This arrangement permits bolt 154 to rest within hole 154 and bore 158, while also, to a limited extent, securing base 140 to beam end 128'. Wing nut 160 may then be conveniently attached and tightened.
Beam connection member 1 I 6' is preferably made from a single sheet of metal, which may be cut and then bent to define the elements described above. Beam connection member 116' may alternatively be made of plastic or other suitable material, as known to those skilled in this ;art.
Refernng to Figure 10, a further alternative beam connection member 116", preferably made of metal, has two walls 132" prol:ruding substantially perpendicular to a strut 118" of beam 20892747.2 connection member 11 fi". Walls 132" ~u-e respectively preferably located to abut top and bottom opposite sides of end 128" of cross beam 66", as shown in Figure 10. The walls 132" may respectively alternatively be oriented (not shown) to abut opposite sides of cross beam end 128"
other than the said top and bottom opposite sides.
Each wall 132" has at least one hole 162 passing therethrough for receiving a fastener such as bolt 164. Holes 162 have collinear axes and align with a bore 166 (shown in phantom lines) in cross beam end 128". When wall holes 162 and bore 166 are aligned, bolt 164 may be inserted therethrough and manually secured at a free end using a wing nut 168 or some other manually tightenable fastener. Before lbolt 164 is inserted, wall holes 162 and bore 166 are aligned and preferably generally vertically oriented to permit insertion of bolt 164 in a downward direction. This arrangement permits bolt 164 to rest within holes 162 and bore 166, while partially securing walls 132" to beam end 128". Wing nut 168 may then be conveniently attached and tightened causing walls 13'?"' to urge against beam end 128".
Beam connection member 116" may be constructed from a single generally planar sheet of metal having two bends formed therein to define walls 132" and strut portion 118". The beam connection member 116" may then be welded to leg members such as leg members 98 and 100.
Attachment of J3eam Connection Member to Lei Members Beam connection member 116, may be rigidly attached to at least one, and preferably hotly of the leg members 98, 100. If'bnam connection member 116 is attached to both leg members 98, 100, then the connection member 116 may provide structural support to support ?0892747.2 member 62. Strut 118 of beam connec~:ion member 116 spans leg members 98 and 100, and may be secured to leg members 98 and 100 .at its ends 152 which may have portions defining two conduits 170. Each conduit 170 may b~e attached to, or be integral with, the respective ends 170 of strut 118. Strut 118, bridging member 102 and legs 98 and 100, preferably, combine to form a ladder-like configuration.
To attach strut 1.18 to leg members 98 and 100, each leg member 98, 100 is inserted through a respective conduit 170. Tlae conduits 170 preferably have a lateral cross-section substantially equal to or larger than the size and shape of the lateral cross-section of the respective leg member;. 98, 100. This permits the leg members to be inserted through conduits l~ 70. If the cross-sections of the conduits 170 and leg members 98, 100 are substantially the ;game size, then a friction fit may be fornied between the each conduit 170 and leg member 98, :100. To position strut 118, the axes of conduits 170, are moved along the longitudinal axis of the leg members 98, 100.
Conduits 170 rnay be secured t<a leg members 98, 100 using pins 172 (see Figure 11 ).
1?ach conduit 170 has a hole 174 passing laterally therethrough for receiving a pin 172. Hole 174 has an entry 174a and an exit 174b. Similarly, each leg member 98, 100 has a hole 176, passing laterally therethrough for receiving pin 172. Hole 176 has an entry 176a and an exit 176b. To install pin 172, the respective entries 1'74a, 176a and exits 174b, 176b are aligned. The pin 172 may then be inserted therein to hinder movement of the conduit 170 relative to leg member 98, 100.
:!0892747.2 Pin 172 preferably has a head 1'78, which is larger than entry 174a to inhibit movement of pin 172 along its longitudinal axis within the holes 174, 176. Pin 172 may also have a catch 180 to inhibit longitudinal movement of the pin 172 within the holes 174, 176.
Catch 180 is located a.t the insertion end 182 of the pin 172. End 182 is located opposite to head 178. Catch 180 may be marginally larger than exit hole 176b to inhibit pin 172 from being removed once end 182 is fully inserted therethrough. To facilitate passage of catch 180 through marginally smaller exit hole 176b, end 182 may be tapered. ,4~i annular rebate 184 may also be provided in pin 172.
7.'he annular rebate I 84 is located adj agent to catch I 80, and receives a portion of the boundary of marginally smaller exit hole 176b.
Referring to Figure 12A, an alternative fastener, such as slotted pin 186, may be used to aatach strut 118 to leg members 98, 100. In a similar manner as described for pin 172, slotted pin 186 is installed. Slotted pin 186 however has a slightly different configuration than pin 172.
Slotted pin 186 preferably has a head 1.88, which is larger than entry 174a to inhibit movement of yin 186 along its longitudinal axis within the holes 174, 176. Pin 186 may also have a catch 189 to inhibit longitudinal movement of pin 186 within the holes 174, 176. Catch 189 is located at the insertion end 190 of pin 186. End 190 is located opposite to head 188.
Catch 186 may be marginally larger than c;xit hole 176b to inhibit pin 186 from being removed once end 190 is fully inserted therethrough. To facilitai:e passage of catch 189 through marginally smaller exit hole 174b, end 190 may be tapered. 'To further facilitate passage of catch I
86, end 190 may have at least one and preferably three partially transverse slots 192 emanating from a central longitudinal axis of pin 186. Each slot 192 is preferably uniformly angularly displaced from the another. As end 190 is inserted througll the marginally smaller exit hole 174b, slots 192 permit 20892747.2 end 190 to narrow, facilitating passage ofcatch 186, therethrough. Slotted pin 186 may be made of a resilient material such as a plastic s;o that end 190 returns to its original shape once it passes through exit hole 174b to enable catch 189 to inhibit removal of pin 186.
Yet further alternative means may be employed to secure strut 118 to leg members 98, 100. For example, an axial portion of conduit 170 may be removed to form a yoke (not shown).
The yoke may be snapped onto a leg member 98, 100, and pinned in place as described above.
Instead of, or in addition to catch 180, the insertion end 182 of pin 178 may have a lateral hole therethrough for receiving a retaining clip or cotter pin (not shown) which further inhibits nnovement of pin 178 along its longitudinal axis.
Referring again to Figure 9, if beam connection member 116 is made of metal, for example as described above as beam connection member 116', strut portion 118' may be secured to the leg members 98, 100 by one or more welds, as long as legs members 98 and 100 are also nnade of a metal. To accommodate both rounded and square leg members 98, 100, ends 152' of strut 118' may have concave rebates 194, instead of having conduits 170.
Concave rebates 194 nnay be arcuate and have substantially the same radius as leg members 98, 100 which have round cross-sections. Strut 118' may also be welded to leg members having rectangular cross-sections, such as leg members 98' and 100'. As long as the leg member 98', 100' is wider than the distance ~~etween edges 196 of the arcuate rebate; 194, strut 118' may be welded to leg members 76', 78' along edges 196.
20892747.2 In the various embodiments, strut portion 118 is preferably attached so that it is substantially perpendicular to legs 98 and 100. Walls 132 of beam receptacle 120 are preferably oriented so that the received cross beans (i6 is substantially perpendicular to both strut 118 and legs 98, 100. Similar relationships between the analogous structural elements of the alternative S c;mbodiments are also preferred.
In an alternatives embodiment: (not shown), the beam connection members 116, 122 do not have beam recepta<;les 84, 86, nor is a cross beam 66 used. Instead, the beam connection members of each support member 62, fi4 are integral with one another, having a joining portion therebetween. To reduce the size of the combined beam connection members, for example for shipping, the joining portion may be bifurcated. The bifurcation is preferably located equidistant from each connection member 116 and 122. As with other parts of the barbeque 60, the bifurcated joining portion may be assembled using connectors such as threaded receptacles and bolts that may preferably be manually installed. Alternatively, the free ends of the bifurcated joining portion may be configured to have a releasable snap fit or friction fit to permit manual 1 S joining and separation .of the connection members.
Beam Securing Apparatus Referring again to Figures 5, 6, i, 7A, 8, and 8A, and to Figures 13A and 13B, a beam securing apparatus 198 of beam connection member 116 secures beam 66 within receptacle 120.
'Che beam securing apparatus 198 includes a fastener for attaching receptacle 120 to beam 66.
'Che fastener may be a bolt, and is prr:fcrably a bolt 200 (figure 13A and 13B) that may be :!0892747.2 tightened and loosened by hand. The beam securing apparatus 198 also includes an opening, in the nature of a hole 202: defined in one of walls 132 and passing therethrough. A threaded end 2 04 of bolt 200 may be inserted through hole 202, and may be received by a corresponding bore of the beam securing apparatus 198, which may be a bushing 206, fixed in the cross beam 66.
>_3ushing 206 preferably has internal threads 207 for threaded engagement with the threaded end 04. Hole 202 is smaller than head 20F> of bolt 200 to inhibit head 208 from passing through hole 202. As a result, when an end 128 of cross beam 66 is inserted into receptacle 120, it may be secured to a wall 13:? of receptacle; 120 by bolt 200, inserted through hole 202, into bushing 2 06, and tightened by hand. In the illustrative embodiment, at least one of the walls 132 is an attachment wall 210, and the hole 202 passes through attachment wall 210.
While the hole 202 is located in a wall 210, additional holes 202 may be located in other walls 132 to receive additional screws 96. similarly, more than one hole 202 may be included in the same wall 132.
To further secure an end 128 of cross beam 66, the beam securing apparatus 198 may include a raised collar 212 which may be used to limit movement of bolt 200 once the bolt 200 is tightened. The collar 212 is co-axial with hole 202, and protrudes away from the inside 214 of receptacle 120.
Head 208 of bolt 200 has a generally annular void 216 for matingly receiving collar 212.
'void 216 is coaxial with threaded end ~'.04 of bolt 200, and is open adjacent the point of attachment 218 of threaded end 204 and screw head 208. Void 216 has an internal surface 220 defining a shape that is congruent to and substantially the same size as collar 212. The shape of void 216 need not be uniform, nor does it have to correspond precisely to the shape of collar 212.
20892747.2 'Che shape of void 216 and collar 212 need only be sufficiently similar to permit threaded end ''<?04 of bolt 200 to be inserted through the hole 202, into threaded bushing 206, and tightened to cause collar 212 to enter void 216 and 1:o come into sufficient contact with portions of internal :surface 220 to inhibit movement of the bolt 200. If void 216 is slightly smaller than collar 212 then a friction fit may be formed between internal surface 220 and collar 212.
If void 216 is made to be too small, or if it is a substantially different shape than collar 212, then collar 212 may be inhibited from entering void 216 and bolt 200 may not be turned and threaded, or it may only be partially threaded, into bushing; 206, which is undesirable.
Beam securing apparatus 198 rr~ay also include a slot 224 located in attachment wall 210 1:o facilitate increasing the friction between receptacle walls 132 and beam end 128. As slot 224 is narrowed, the internal perimeter of"receptacle 120, as defined by walls 132, decreases, causing the walls 132 to grip the beam end 128. This gripping may reduce movement of receptacle 120 relative to beam 66, and, by connection, movement of support member 62 relative to beam 66.
Slot 224 passes through collar 212 and adjacent attachment wall 210 to create collar pieces 212a and 212b, ;end adjacent wall portions 210a and 210b. Slot 224 may be oriented substantially perpendicular to the internal perimeter of the receptacle 120 as defined by walls 132. While slot 224 may pass through collar 212 at a chord, it preferably bisects the collar 212 into two substantially equal pieces 212;a and 212b. To facilitate movement of collar pieces 212a and 212b relative to one another, so that beam end 128 may be gripped, slot 224 preferably c;xtends to an edge of receptacle 120 adjacent open end 126. Movement of collar pieces 212a and 212b may be further facilitated by increasing the length of slot 224.
Increasing the width of 20892747.2 the slot 224 between adjacent portions 2 10a and 210b may also facilitate movement of collar ~~ieces 212a and 212b. For example, slot 224 may be lengthened and widened adjacent collar pieces 212a and 212b to form a window 226 in attachment wall 210. The window 226 may be generally rectangular, having one inch and three inch sides. Other sizes and shapes created by lengthening and/or widening slot 224 rnay facilitate varying degrees of relative movement of ~~ollar pieces 212a and 212b.
As collar pieces 212a and 212b are moved closer to one another to a proximate position, slot 224 becomes narrower, and adjacent wall portions 210a and 210b move closer to one ;mother to reduce the overall length I~ of' adjacent wall 210. This shortening of wall 210 reduces the overall internal perimeter of the receptacle 120 defined by the walls 132.
Receptacle 120 ~~referably initially has substantially the same perimeter as beam end 128.
This enables a marginal reduction in the receptacle's perimeter to cause the walls I32 to grip the beam end 128.
'To keep collar pieces 212a and 212b po,~oximate to one another, bolt 200 is installed while maintaining the position of pieces 212a and 212b. As bolt 200 is tightened, proximate collar 1 S ~~ieces 212a and 212b enter void 216. 'rhe shape of void 216 is preferably similar to the combined shape of proximate collar pieces 212a and 212b. Once bolt 200 is installed, it limits l:he movement of collar pieces 212a and 2I2b. This arrangement maintains the grip of receptacle ,valls 132 on beam end 128.
Bolt 200 and collar pieces 212x. and 212b may be configured to cause beam end 128 to be progressively clamped as bolt 200 is ti;~htened. 'Chis may be achieved by configuring the annular ~~oid 216 of the bolt 200 to be narrower at a closed end 228 of void 216, and to be progressively ;!0892747.2 wider at an open end 2:30 of void 21 (i. Annular void 216 has an outer circumferential surface :?22a and an inner circumferential surface 222b. In the illustrative embodiment outer c;ircumferential surface 222a is angled, at 10 degrees for example, relative to the axis of threaded c,nd 204. As a result, outer surface 222a is ficrther from threaded end 204 at open end 230 of the S void than it is at closed end 228. In the illustrative embodiment, the diameter of outer c;ircumferential surface 222a is approximately one inch adjacent open end 230.
Inner c;ircumferential surface 222b may be angled in a direction opposite to that of surface 222x, or it may be parallel to the axis of threaded end 204. Due to the orientation of surfaces 222a and 222b, void 216 tapers to closed end 228.
When collar pieces 212a and 212b are positioned together to form collar 212, they are preferably configured to be substantially the same size and shape, and preferably marginally larger than, annular void 216. Accordingly, collar pieces 212a and 212b have outer c;ircumferential surface portions 232a and 232b. When collar pieces 212a and 212b are positioned apart, free ends 234a and '234b of the respective collar pieces 212a and 212b are preferably positioned for engagement b~y open end 230 of void 216. This permits free ends 234a and 234b to be inserted into void 2lEi as threaded end 204 of bolt 200 is inserted into hole 202.
As bolt 200 is tightened, the c~ul;er circumferential surface 222a of void 216 and the corresponding outer circumferential surface portions 232x, 232b of collar pieces 212a and 212b gradually come into sliding contact with one another. Slot 224 permits collar pieces 212a and :? 12b to move closer to one another as force is exerted on the pieces 212x, 212b by outer c;ircumferential surface 222x. This fort°.e is caused by the tightening of the bolt 200 moving the x:0892747.2 screw head 208 closer to the collar piec;es 212a, 212b. As the pieces 212a and 212b are forced to move closer to one another, the walls 132 of receptacle 120 grip beam end 128 with increasing force, as described above. Bolt 200 rna~y be manually tightened to the point that collar pieces a! 12a and 212b are at least partially retained by void 216. This arrangement permits the cross S beam end 128 to be gripped by walls 1:32 forming a substantially rigid connection between cross beam 66 and support member 62, without the need for tools. Furthermore, the connection may t>e made using one bolt 200 at each end 128 of cross beam 66. Because collar pieces 212a and a! 12b together are marginally larger than void 216, a tight fit is formed between the screw head 208 and collar pieces 212a, 212b to inhibit loosening of bolt 200.
In the illustrative embodiment, slot 224 may be wider at slot portion 236a which is adjacent open end 126 of receptacle 120. As wall portions 210a and 210b are forced closer together by the tightening of bolt 200, a narrow portion 236b of slot 224 may become closed before bolt 200 is fully installed, while wide portion 236a is just narrowed.
As installation of bolt 200 continues, the force exerted by bolt 200 on collar pieces 212a, 212b is increased. This forces slot wide portion 236a to narrow further, reducing the internal perimeter of the receptacle 120, as defined by walls 132, and causing the walls 132 increase their grip on beam end 128 adjacent to receptacle open end 126. In the: illustrative embodiment, slot wide portion 236a may ~~e 0.10 inches across, and slot narrow portion 236b may be 0.06 inches across.
In an alternative embodiment, the outer surface 222a of void 216 may be configured to d:efme other shapes such as a concave or convex taper (not shown) or some other, preferably 20892747.2 uniform, shape that permits the bolt '200 to be installed while at the same time forcing collar pieces 212a and 212b closer to one another so that beam end 128 may be gripped.
Similarly, the configuration of void 216 and the corresponding configuration of collar pieces 212a, 212b may be varied to achieve the same effect as described above.
For example, while it is preferable that outer surface 222a defines void 216 which tapers to closed end 228, the ~;hape of the taper may vary. Surface 222a may taper linearly, or it may follow a somewhat uniform curve, such as a parabolic, or higher order, function. Outer circumferential surface 222a may also be non-uniform as long as it generally tapers sufficiently to engage and force correspondingly configured collar pieces 212a, 212b together.
It is not necessary that collar pieces 212a and 212b be continuous. Portions of the collar pieces 212a and 212b may be removed to leave a number of smaller protrusions (not shown).
Provided that sufficient: portions of the collar 212 remain to engage, without significant deformation, the outer surface 222a of screw void 216, a substantially equivalent function as described above may b~~ achieved. For example, instead of a collar, a plurality of posts may be I>rovided (not shown), .with at least one post on either side of slot 224, and with each post positioned for sliding engagement with outer circumferential surface 222a.
To permit the described movement of collar pieces 212a and 212b so that beam end 128 rnay be gripped as the bolt 200 is tightened, walls 132 defining receptacle 120 may be made of a hendable material, and are preferably made of a resilient material. An appropriate plastic or metal, for example, may be used.
20892747.2 The head 208 of bolt 200 may have external grips, such as knurls (not shown), cross hatches (not shown), or ridges 238, to provide greater friction to facilitate manual installation of bolt 200. In the illustrative embodiment, the head 208 is cylindrical, having a diameter of about 1.5 inches and a thickness of about 0.6:?5 inches, or some other size and shape suitable for manual manipulation. The threaded end 204 protrudes substantially co-axially with the axis of the head 208. A plurality ridges 238, each being substantially parallel to the axis of the threaded e;nd 204, may be located about the circumference of the cylindrical head 208.
Turning of the bolt :'00 about its longitudinal axis may also be improved by using a non-circular or non-uniform shaped head (not shown) with the threaded end 204 preferably protruding from head 208 along am axis passing througl'~ a centroid of head 208.
Head 208 may lie made of any rigid material, such as nylon plastic or a metal.
If constructed from a plastic, bolt 200 may be integrally moulded with head 208.
Referring to Figures 14A and 14B, provide an alternative connection between the threaded end 204 and head ~!08, the threaded end 204 may be part of a bolt 240 having a bolt head 242.
To receive threaded e;nd 204, screw head 208 may be provided with a bore 242 therethrough which is coaxial with the rotational axis of the screw head 208.. A rebate 244 may be added to a side of the head 208 opposite to void 216. Rebate 244 is c;emtered about bore 242, and is substantially the same shape but marginally smaller than bolt head 242. Bolt 200 is assembled by inserting threaded end 204 into rebate 244 and through bore 242. Because rebate 244 is marginally smaller than bolt head 242, force must be applied to the bolt: head 242 in the direction of the threaded end 204, to press fit head 242 into rebate 244. ,A bolt Having a non-round bolt head, such as a '/4-20 hex bolt, is 20892747.2 preferably used to increase rotational resistance between screw head 208 and bolt head 242 within rebate 244.
Tank Support Refernng to Figure 7, beam co~mection member 122 may be similar in configuration to beam connection member 116, except that, in the illustrative embodiment, beam connection member 122, may be configured to have an integral fuel source support base 92 for supporting a :.elf contained fuel source, such as a propane tank 90 (shown in Figure 1 ).
Other aspects of beam connection member 122, such as the beam securing apparatus 198 described above, are configured and operate in substantially the same manner as described for beam connection member 116. However, the relative positioning of receptacle 124 and conduits 170 for securing beam connection member 122 to leg members 98, 100 may require adjustment to accommodate base 92. In addition to supporting a fuel source, base 92 additionally performs a function analogous to strut 118 of beam connection member 116 in joining conduits 170 and having beam receptacle 124 defined therein.
Beam connection member 122 its preferably moulded to have a fuel source support base ~)2, which substantially conforms to the; shape of at least a base rim 246 of a propane tank 90. A
standard domestic use "20 pound" propane tank may be used to determine the dimensions of :support base 92. Base rim 246 is received by a corresponding base rim cavity 248 defined in :support base 92. Because base rim cavity 248 conforms to the shape of base rim 246, tipping or 20892747.2 other movement of tank 90 is hindered by the support base 92. A void 250 may be located in c;avity 248 to save material and to provide drainage for the cavity 248.
Tipping may be further reduced by increasing the dimensions of support base 92 to conform to a greater portion of the tank: 90. Support base 92 has portions defining a lower tank cavity 252 that conforms to a continuous portion of the lower part of tank 90 that is adjacent to base rim 246. Tank cavity 252 preferably does not encompass the entire circumference of tank ~)0. While complete circumferential support may be used to further reduce possible movement of tank 90, it may also make it more difficult to place tank 90 within base 92.
For similar reasons, the portions of base 92 which define tai k cavity 252 are preferably located adjacent beam receptacle 124. Tank 90 may then be placed into base 92 by first approaching a side of base 92 opposite to receptacle 1.24 to avoid encountering cross beam 66 and the portions defining lower tank cavity 252. Base !~2 is preferably moulded from plastic but may moulded from metal as well.
Refernng to Figures 9 and 15, to reduce costs, an alternative beam connection member 122', which is similar in configuration to beam connection member 116', may be used. As with beam connection member 122, beam cormection member 122', may have an integral fuel source :support base 92'.
Beam connection member 122' is formed as a strut 254 having a generally U-shaped cross-section, and may be attached between leg members, such as leg members 98 and 100, or ~)8' and 100'. Arm 256 and arm 258 ( pawn in phantom] of the U-shaped cross-section are 20892747.2 preferably substantially at right angles to base 260 of the U-shaped cross-section. Strut 254 is preferably attached between leg members 98 and 100 adjacent leg member base ends 110 and 112. When attached between leg membe;rs 98 and 100, arms 256 and 258 may be generally f~arallel to the longitudinal axes of the leg members, and the U-shaped cross section preferably opens in the general direction of leg member base ends 110 and 112.
Having a configuration similar to arm 138 of beam connection member 116', arm rnay have an opening 262 (shown in phantom) formed therein for receiving beam end 128'.
(~ening 262 preferably is congruent to and substantially the same size as a lateral cross-section of beam end 128'. To facilitate placement of beam end 128' into opening 262, opening 262 may correspond to the general shape of just three sides of beam end 128, to define a generally right-angled U-shaped opening 262.
Cross beam 66' may be attached to strut 254 by first inserting beam end 128' into opening 2;62 until beam end 128' abuts arm 256 of strut 254. Arm 256 of strut 254 may additionally have a, supporting member attached thereto fir supporting beam end 128'. 'the supporting member 1 S rnay be in the form of a substantially perpendicular flange 264 (shown in phantom) along a free edge 266 of arm 256, flange 264 being generally directed towards opening 262.
Beam end 128' rnay rest on flange 264 once beam end 128' abuts arm 256. When fully inserted into opening f.62, beam end 128' is inhibited by ann 256, flange 264 of arm 256, base 260 of strut 254 and edges of opening 262. Opening 262 may additionally have a flange such as a peripheral flange (not shown) for abutting cross beam ~i6.
zos9z~4~.z To abut a greater portion of beam end 128', base 260 of strut 254 may be widened at a mid-section 268 of strut 254. Mid-section 268 rnay widened in a direction generally away from arm 256 or away from arm 258, or in both directions. While strut 254 maintains its U-shaped cross-section in this configuration, arms 256 and 258 are closer to one another at the ends 270 of strut 254 and become gradually further apart to a maximum when adjacent mid-section 268. If mid-section 268 is widened in a direction away from arm 258 only, beam connection member 122' then projects from the plane of legs 98 and 100 in a similar direction as an attached shelf 70.
'Chis may enable a support member such as support member 64 having a shelf 70 and a beam connection member 122' to occupy a smaller volume when placed in a container such as a shipping box (not shown) than if mica-section 268 projected in an opposite direction.
The widening of mid-section 2Ei8 is preferably sufficient to permit a base rim cavity 248' for receiving at least a portion of a tank. base rim 246 to be defined in mid-section 268. To reduce the amount of material used, rnid-section 268 may be configured to permit a base rim <;avity 248' which receives a segment, for example half; of the base rim 246 of propane tank 90.
If base rim cavity 248' is defined to receive a segment of base rim 246, the cavity 248' is partially defined by an arcuate wall 272 having ,~ similar radius to base rim 24fi.
Arcuate wall 272 may be curved in the general direction of openiing 262, or it may curve in some other direction, such as away from opening 26:?.
Similarly, to save materials, the dimensions of a tank cavity analogous to tank cavity 252 may be reduced so that it encompasses a smaller portion of tank 90 (not shown). Alternatively, the tank cavity may be eliminated, as slhown in Figures 9 and 15.
x:0892747.2 As a result of the reduction or elimination of tank cavity 252, the central axes of openings 1142 and 262 are not collinear when barbeque 60 is assembled as in other embodiments. As a result an alternative non-linear cross beam 66' having a curve or bends 274 and 276 therein orients beam ends 92' for insertion into openings 142 and 262 and attachment to beam S connection members 116' and 122'.
Beam end 128' may be attached to strut 254 using at least one fastener, such as bolt 278, which is inserted through a hole 280 in base 260 and a corresponding bore 282 in beam end 128'.
l-Iole 280 is preferably located to pass through portions of base 260 defining base rim cavity 248'.
When beam end 128' is. inserted into opening 262 and abuts arm 256, hole 280 and bore 282 are preferably aligned to receive bolt 278. Once bolt 278 is inserted therethrough, it may be manually secured with a wing nut 284 .or some other manually tightenable fastener. Before bolt 278 is inserted, hole 280 and bore 282 are aligned and preferably generally vertically oriented to permit insertion ofbolt 278 in a downward direction. This arrangement permits bolt 27$ to rest ~Hithin hole 280 and bore 282, while partially securing beam connection member 122' to beam c,nd 128'. Wing nut 284 may then be conveniently attached and tightened.
Referring to Fil;ure 16, an alternative configuration for supporting a tank 90 is shown. In the illustrated configuration, a beam connection member 286 having substantially the same ~;tructure as beam connection member l 16" is attached between legs 98 and 100 in a similar manner as described for connection member 116". Beam connection member 286 differs from connection member 116" in that it has an arcuate portion 288 having generally the same radius as tank 90. When tank 90 is supported by a stmt 290 spanning legs 98 and 100, a portion of curved x:0892747.2 lank body 292 (shown in Figure I ) is received by arcuate portion 288, and lateral movement of tank 90 in the direction of beam connection member 286 may be inhibited.
Movement of tank ~)0 may additionally be inhibited by one or more of the embodiments of a fuel source retainer described below. To further inhibit movement of tank 90, strut 290 may have a base rim cavity :?48" which conforms to and receives at least a portion of a tank base rim 246, and preferably the lull circumference of base rim 246.
Refernng to Figure 17, an alternative embodiment of a tank support base which is separate from beam connection member 286 is shown. In this embodiment, tank support base !~2" may be made from injection mouldled plastic having a similar form as base 92, or it may be made of wire as shown in Figure 17. Tank support base 92" may also be pivotally attached to legs 98, 100. Pivotal attachment may be achieved using collinear posts 294 protruding from each leg member 98 and 100. Posts 294 reside in aligned holes 296 located in support base 92".
,Aligned holes 296 are preferably generally located at either end of the longitudinal axis of base !~2". If wheels 94 are added to barbeque 60, posts 296 may be extensions of the wheel axle pins described below. Pivotal attachment of base 92" permits base 92" to be angled to receive tank base rim 246. This may make it easier to place tank 90 into base 92". Once tank base rim 246 is placed within base 92", both base 92" a.nd tank 90 may be rotated to a generally upright position.
Movement of tank 90 rnay then be limited by beam connection member 286 and by adding a fuel source retainer, described below.
Base 92" may also have a base rim collar 298 fur receiving tank base rim 246.
For added support, base 92" may lhave one or more sections 300 (see Figure 18) which conform to a portion :!0892747.2 of tank 90 to resist movement of tank S~0 and to strengthen collar 298.
Sections 300 may be located adjacent posts :?94 to limit movement of tank 90 in a direction along the pivotal axis of base 92". Refernng again to Figure 17~ additional retention of tank 90 may be achieved by addition of a tank support 302 which e:~ct:ends from and substantially normal to base rim collar :?98, and is positioned to abut a side of tank 90 when tank 90 is placed in base 92".
Fuel Source Retainer Referring to Figure 1, for increased retention of tank 90 within support base 92, a fuel source retainer such as tank wire 304 may be added to base 92. Tank wire 304 may have an ~rrcuate portion 306 that substantially conforms to a portion of the circumference of tank 90, such ors tank body 292, to provide lateral support to tank 90 in a direction generally opposite to the support provided by portions of tank cavity 252 adjacent beam receptacle 124.
Tank wire 304 may be attached to base 92 with two tank wire supports 308 formed at ends 310 of tank wire 304.
'tank wire supports 308 may be oriented substantially normal to the plane arcuate portion 306 and may be inserted in tank wire retaining holes 312 located adjacent to conduits 170.
Referring to Figures 15 and 19, an alternative fuel source retainer such as a collar 314 may be used to inhibit movement of tank 90. Collar 314 has two substantially identical curved wire members 318. Each wire member :318 has a curved portion 320 having a generally uniform radius which is preferably less than tile radius of tank body 29'2 but greater than the radius of a standard valve protecting sleeve 316 attached to tank 90. A mounting portion 322 is formed at an end of wire member 318. Mounting; portion 322 may be linear and substantially '<!0892747.2 perpendicular to semi-circular portion 320. 'The remaining end of wire member 318 may have a hoop 324 defining a generally circular c.~pening, the centroid of which is located on a line co-axial ~,vith a longitudinal axis of maunting pc.~rtian 322. When the respective mounting portions 322 of each wire member 318 are inserted through the respective loops 324 of the other wire member :318, and semi-circular portions 320 are; oriented to lie in substantially the same plane, a circular ripening 326 is formed by the two semi-circular members 320. Collar 314 may be attached to support member 64 so that the collar 314 spans, and is preferably centered, between legs 98 and 100. Each mounting portion 322 may lbe attached to a respective leg member 98, 100 using a mounting clip 328 wherein each mounting portion 322 is inserted into a respective mounting hole 330 in each mounting clip 328 for rotational movement therein. Each mounting clip 328 is attached to a leg member 98 or 100 for sliding movement along a longitudinal axis of the leg member.
The mounting clips 328 are substantially identical to one another and may be mirror configurations of one another. The description of one mounting clip 328 therefore substantially applies to the other. Mounting clip 328 conforms to a portion of leg member 98 or 100. If leg member 98, 100 is has a round or oval lateral cross-section, then mounting clip 328 preferably c,ncompasses greater than half of the circumference of a portion of the leg member so that the leg is retained by clip 32$. Similarly, if 1e;; member 98, 100 has a rectangular lateral cross-section then mounting clip 328 preferably encompasses at least two sides and at least part of both a third side and a fourth side of a portion of the leg member. Mounting clip 328 may be likewise configured to accommodate leg menrbc;rs having other cross sections. Mounting clip 328 preferably conforms to the attached leg, member 98, 100 to the extent that the clip 328 is held in <":0892747.2 place by friction at the interface between the mounting clip 328 and the leg member 98, 100.
lHowever, the friction is preferably not sufficient resist manual positioning of clip 328 by sliding it longitudinally along leg member 98, 100.
To retain fuel tank 90, mounting clips 328 of collar 314 may be slidingly moved along l.eg members 98 and 100 to a position adjacent shelf 70. This positioning provides clearance for hank 90 to be placed within base 92. Once tank 90 is placed into base 92, mounting clips 328 of collar 314 are slidingly moved along legs 98 and 100 towards tank 90, valve sleeve 316 passes through collar opening 326, and curved members 320 may abut a shoulder portion 332 of tank !~0. Any lateral movement of tank 90 within base 92 causes collar 314 to come into contact with ~ralve sleeve 316 thus inhibiting further lateral movement of tank 90. To replace tank 90, one curved member 320 may be rotated toward and over valve sleeve 316 to permit removal of tank !~0.
Mounting clips 328 may be attached to each leg member 98, 100 by simultaneously manually applying generally opposite forces to the ends 334 and 336 of clip 328 to increase the linear distance between them. This hermits passage of a leg member 98 or 100.
Since mounting clips 328 are preferably made of a genc;rally resilient material, such as a plastic, when a force is no longer applied, the ends 334 and 336 return to their initial position to retain a portion of the leg member therein. Tlhe respective mounting portions 322 of each curved wire member 318 may then be inserted into the respective mounting holes 330. In the illustrative embodiment, at least the curved wire member 318 is sufficiently resilient to permit mounting ends 322 to be moved axially closer te~ one another ;as they are aligned with their respective mounting holes 330.
x:0892747.2 nnce aligned, the resilient curved pardons 320 encourage the respective mounting members 322 ~;o enter the mounting holes 330.
Curved portions 320 of collar 314 may alternatively have radii marginally larger than the radius of tank body 29:?. In this configuration (not shown) curved portions 320 are aligned with body 292 and combine to surround tank body 292 to inhibit lateral movement thereof.
Refernng to Fil;ure 20, a yet further alternative fuel source retainer such as a collar 314' may be used to inhibit movement of tank 90. Collar 314' may include a single piece of wire having a curved, and preferably semi-circular, portion 320' formed therein to define two mounting portions 322'. The configuration of both curved portion 320' and mounting portions :322' is substantially the same as described for curved wire member 318 and mounting portion :322 of the embodiment described above. Collar 314' is attached to mounting clips 328, and permits the installation, retention and removal of a tank 90 in a similar manner as described above for collar 314.
Referring to Figures 21A and 21 B, curved portion 320" may be additionally configured to 1 S rapture an edge of valve protecting sleeve 316. For example, curved portion 320" may have a clip 338 formed therein for engaging a portion of sleeve 316. In order to engage sleeve 316 the radius of curved portion 320" is preferably substantially the same as sleeve 316 so that clip 338 may be aligned with sleeve 3 l6.
In a yet further alternative embodiment (not shown), mounting clips 328 may be eliminated and the mounting portions of the various embodiments, for example mounting :!0892747.2 portions 322, may be inserted directly into mounting holes located in each leg member 98 and '100 for rotational movement therein.
Shelves Refernng to Figures 22, 23 and 24, barbeque 60 may have a shelf 68 or two shelves S (second shelf not shown) to provide a surface 339' which may be used for food preparation, or for supporting items such as cooking utensils. Shelves 68 may be configured identically, or configured as a mirror :image of one another.
In the illustrative embodiment, the second shelf has a configuration that mirrors shelf 68.
The description of shelf 68 that follows, therefore substantially applies to the second shelf, as well. Shelf 68 has a generally planar surface 339'. Surface 339' is supported by shelf supporting portion 340 of leg men-iber 98, and supporting portion 342 of leg member 100.
Legs 98, 100 are preferably each bent in a similar manner to form a substantially 90 degree angle therein, creating supporting portions 340, 342 of sufficic;nl: length to support shelf 68. In the illustrative c;mbodiment, each sup~iorting portion 340, 342 is approximately 15.5 inches long, oriented in ~,ubstantially the same direction, and generally parallel to the another.
Shelf 68 may be secured to each of the supporting portions 340, 342 of respective leg members 98, 100 by shelf retainers ..44 and 346 having receptacles 348 and 350, which receptacles each receive a respective free e:nd 352 and 354 of supporting portions 340 and 342. Each receptacle 348 and 202 may be attached to, or integral 'with, shelf 68. In the illustrative embodiment, receptacles 348, 350 are integral with shelf 68. Because shelf reaainers 344 and 346 are substantially similar to one 20892747.2 another, only shelf retainer 344, which attaches supporting portion 340 to shelf 68, will be described.
To attach shelf 68 to supporting; portion 340, free end 352 of supporting portion 340 may I>e inserted into receptacle 348 in a direction of insertion D. Receptacle 348 preferably has a cross-section which, when taken lateral to direction of insertion D, is substantially equal to or larger than the size and shape of the lateral cross-section of supporting portion 340. The relatively larger cross-section permits supporting portion 340 to be inserted into the receptacle ~~48. If the cross-section of the receptacle :348 and corresponding supporting portion 340 is :,ubstantially the same size, then a friction fit may be formed between receptacle 348 and corresponding supporting portion 3411. While generally maintaining its lateral cross-sectional shape and size, receptacle 348 may also be elongated to receive a greater portion of free end 352.
Referring additionally to Figure 24, to secure supporting portion 340 within receptacle ~~48, receptacle 348 may be provided with ;~ shelf retainer such as a protrusion in the shape of a ramp 356 located within receptacle 348. Ramp 356 generally increases along the direction of insertion D. A corresponding void 358 (shown in Figure 25) located in supporting portion 340, receives ramp 356 to inhibit movement of shelf 68 relative to supporting portion 340. Ramp 356 is installed as follows. When inserting free end 352 into receptacle 348, free end 352 encounters a. base 360 of a sloping side 362 of ramp 356. Ramp 356 is preferably made of a resilient material such as a plastic to permit it to deform before entering void 358. As free end 352 is forced along ramp 356, ramp 356 deforms to permit passage of free end 352 into receptacle 348.
\~Vhen void 358 of supporting portion 340 is positioned to correspond with the location of ramp 20892747.2 356, resilient ramp 356 extends therein. Removal of free end 352 in an opposite direction is inhibited by a sheer side 364 of ramp 356 which abuts an edge of void 358.
Further insertion of free end 352 into receptacle 348 is prevented by a stop such as tab 366 attached to shelf 68.
~~lternatively, receptacile 348 may have a closed end (not shown) for preventing further insertion of free end 352. In either configuration, when assembling shelf 68 and supporting portion 340, the stop provides feedback that the free end 352 is fully inserted and assembly of the two parts is complete.
Shelf retainer 344 may additionally have a conduit 368, which is similar in configuration to receptacle 348 and has an axis which is collinear to the axis of receptacle 348. Conduit 368 differs from receptacle 348 in at least that it does not have a stop, such as tab 366. This permits free end 352 to be inserted through conduit 368 in the general direction of insertion D so that it rnay be subsequently inserted into receptacle 348. Conduit 368 thus generally guides free end ~~52 toward receptacle 348. Once free c;nd 3_52 is received by receptacle 348, conduit 368 inhibits the movement of supporting portion 340 relative to shelf 68. Conduit 368 may be 1 S attached to, or integral 'with, shelf 68. In the illustrative embodiment, conduit 368 may have a slot which separates conduit 368 into two conduit portions 368a and 368b.
Conduit portions ?'~68a and 368b are preferably the same sire but may be unequal. By using conduit portions 368a a.nd 368b instead of a contiguous conduit, the conduit portions 368a and 368b may have greater flexibility at their free ends to facilitate insertion of free end 352 and passage of supporting portion 340. To provide greater reter~ti~~n of supporting portion 340, conduit 368 may be Lengthened to meet receptacle 348 to form a single continuous passage.
2D892747.2 Shelf 68 could alternatively be attached to supporting portions 340 and 342 by bolting, welding, or some other attachment means. While shelf supporting portions 340 and 342 are iintegral with legs 98 and 100 in the illustrative embodiment, they may alternatively be made of a separate member or members attached to support member 62.
In the illustrative embodiment, shelf 68 is made of moulded plastic but could be made from some other material such as steel. If shelf 68 is made of plastic, then strengthening ribs 220 may be added to increase the rigidity of shelf 68, potentially reducing the amount of material required to mould shell' 68.
Refernng to Fil;ures 25 and 26, in an alternative embodiment of shelf 68, labelled 68', either a portion or the entirety of shelf surface 339' may be manually removable. This removable portion, or member, 370 may be removed to be used as a tray, to be cleaned, for example in a dishwasher, or it may be put to some oi:her use appropriate for such a member having a substantially flat an rigid surface. A suitable weather resistant material such as plastic, porcelain, steel, ceramic, wood or a combination thereof may be used to construct removable member 370.
1 S Removable member 370 may also have a ridge (not shown) about the perimeter of its surface 339', and a drain (not shown) to pernvit removal of a liquid such as rain water by gravity.
To accommodate removable me;rnber 370, shelf 68' may have a generally U-shaped shelf name 372. An inner perimeter 374 of shelf frame 372 substantially conforms to a portion of the periphery of removable: member to preferably form a friction ftt therebetween.
Removable member 370 may alternatively or additionally be fastened to frame 372 with a fastener (not 2.0892747.2 - 4:3 -s;hown), or held in place by gravity. While frame 372 may define a closed opening, for example a four-sided opening, the partial removal of a portion of frame 372, such as a fourth side of a rectangular frame, permits an edge 3'76 of removable member 370 to be grasped for removal and installation. Movement of removable member 370 in the direction of the open end of U-shaped frame 372 may be inhibited by tabs 378 and 380 projecting generally toward each other from respective free ends 38:? and 384 of arms 386 and 388 of U-shaped frame 372.
Tabs 378 and 380 further encourage a friction fit between frame 372 and removable member 370.
In an alternative embodiment (not shown), the periphery of removable member 370 may be bevelled or provided with a rib (not shown) for engagement 'with a corresponding feature of the frame 372 to permit a snap fit therebetween. Other variations to the configuration of the interface between frame 372 and removable member 370 may be dei:ined to retain member 370 within frame 372 while permitting manual installation and remowal of member 370 therein. Removable member 370 rnay be any generally planar shape s~citable for use as a tray as long as frame 372 is configured to receive that particular shape.
When installed, removable member 370 is supported by receptacles 348 and 350, and corresponding conduits 368' and 390°. Receptacle 350' and conduit 368' may be configured as described for the illustrative embodiment, or they may be formed together as a continuous channel member 392' for slidingly receiving and frictionally retaining supporting portion 340 of leg member 98. A second continuous channel member 394', having a substantially similar configuration as channel member 392', is provided for retaining supporting portion 342 of leg nnember 100. Because channel members 392' and 394' are similar, a description of channel 20892747.2 member 394' will be provided. This dc;scription applies equally to channel member 392' with necessary modifications for receiving supporting portion 340.
Channel memb~:a- 394' may be attached to arm 388 of U-shaped shelf frame 372 along a <;losed side 396 of the c;hannel member 394'. Channel member 394' may alternatively be integrally formed with shelf frame 372. A ramp 356', which has a configuration that is similar to ramp 356 and which operates in a similar manner, is provided along an interior surface 398 of conduit 390' for entering void 358 to retain supporting portion 342. The procedure required to manually attach shelf fi~ame 372 to supporting portions 340 and 342 is similar to that described above for attaching shelf 68 to supporting portions 340 and 342. In encouraging proper alignment and installation of frame 372:, channel member 392' performs a similar function to that of conduits 368, 390 and receptacles 348, 350. Bends 400 and 402 of U-shaped frame 372 may be used as stops to prevent further insertion of supporting portions 340, 342 instead of a tab such as tab 366, or closing an end of channel member 392'.
Channel member 392' may have a generally circular or rectangular cross-section for frictionally receiving and retaining supporting portions having a variety of cross-sections. For example, if channel member 392' has a generally rectangular cross-section, it may receive and retain supporting members having crass-sections of a similar size and shape.
An advantage of some cross-sectional shapes is that they may accommodate supporting members having different cross-sections as long a.s there is sufficient frictional contact between the supporting members amd the inner surface of the channel. A channel having a generally square cross-section, for example, may also receive and retain a supparting member having a circular cross-section with a 20892747.2 diameter that is substantially the same magnitude as the length of the sides of the channel's square cross-section. In this configuration, the circular supporting member contacts the inner :>urface of the conduit along lines defining the mid-points of the channel's sides, and is retained by the channel. In combination with th~.e various configurations of channel and support member, ramp 356' serves to further retain the support member within the channel.
Refernng to Figure 27, in a yet further alternative embodiment of shelf 68, labelled 68", a f=astener in the nature of at least two bolts 404 and wing nuts 406 may be used to attach shelf 68"
to supporting portions 340 and 342. Shelf 68" has at least one slat 408 for spanning the distance between supporting portions 340 and 342. Slats 408 may be bolted directly to supporting portions 340 and 342 using bolts 404 inserted through slat holes 410 and through holes 412 in ;supporting portions 340 and 342, which bolts 404 are secured by wing nuts 406. Slats 408 may also be retained by a shelf bracket 414 at each slat end 416. Each shelf bracket 414 is :substantially identical to the ather. T'he description of one therefore applies to the other.
Shelf bracket 4R4 retains and secures slat ends 416 to a supporting portion, such as supporting portion 340. The shelf bracket 41.4 has a narrow body with a longitudinal bend 418 therein to form to arms 420 arid 422 extending from bend 418 substantially normal to one another. One of the arms, such as arm 420, may have protrusions, such as flanges 424 to inhibit lateral movement of slat ends 416. Flanges 424 may be generally normal to both arms 420 and 422, and may be located at least at eithfr end of bracket 414. Movement of slats 408 may also be inhibited by additional protrusions (not shown) extending from either arm 420 or arm 422, which additional protrusions a.re located to abi.rt slats 408 that are not adjacent the ends of bracket 414.
20892747.2 'Chew additional protru ions may also lie used to evenly space slats 408 from one another. The other arm, arm 422, has at least one, and preferably two holes 426, there through for receiving a bolt 404.
Shelf 68" may be installed by placing slats 408 on support portions 340' and 342' so that c;ach end 416 of each slat 408 is supported by one of support portions 340' and 342'. Each bracket 414 is placed over the slat ends 416 with slat ends 416 located between flanges 424.
Boles 426 of arm 422 are then aligned with both the hole 410 in the adjacent slat 408 and hole ~E12 in the associated support portion 340 or 198. Bolt 404 may then be inserted through the three holes 426, 410 and 412 and manually secured with a wing nut 406. Once bracket 414 is installed, lateral movement of slat ends 416 is inhibited by protrusions such as flanges 424.
Lifting or otherwise moving barbeque 60 may be facilitated by providing a handle hole X128 (shown in Figure 22) defined in shelf fib for gripping shelf 68. Shelf 68 may also have an indentation defining a c;up holder 430. Similarly, at least one utensil rebate 432 for holding utensils (not shown), may be provided along an edge of shelf 68. A handle hole (not shown), c;up holder (not shown) and utensil rebate (labelled 432' on shelf 68' and 432" on shelf 68") may also be added to shelves 68' or 68".
Side Burner Referring to Figure 28, one or both of the shelves may be substituted with a side burner 434. Side burner 434 may have a burner frame member 436 which has substantially the ::ame configuration as shelf frame 37:2, arid a burner apparatus 438 which may include a burner 20892747.2 - 4'7 -tray 440 having a similar configuration to removable member 370. Burner tray 440 may also be installed and retained within burner f'ca~me 436 in a manner similar to that described for removable member 37C~. Similarly, hurner frame 436 may be installed and retained in substantially the same manner as described for shelf frame 372. Burner frame 436 may be additionally retained by installing at least one fastener in the nature a bolt 442 inserted through a hole (not shown) in channel member 392' and into an aligned threaded bore in support portion ~~40 or 342. Bolt 442 preferably has a head that may be gripped and manually tightened (not shown).
In the illustrative embodiment, burner frame member 436 is generally L-shaped having just one arm 386' which has a configuration similar to arm 386 of shelf frame 372. In place of a second arm, burner frame 436 has a i~lange 444 for receiving a fastener such as bolt 446 for fastening burner frame 436 to burner tray 4417.
Burner tray 440 has a burner pan 448 in which a standard burner, such as burner 450 may reside. Burner pan 448 may be formed from the same piece of material as burner tray 440 if a metal burner tray is used. In the illustrative embodiment, burner pan 448 is a separate piece made of a heat resistant metal which is attached to burner tray 440 using a fastener such as a bolt and wing nut (not shown). As shown in Figure 29, a v~u-iation of burner pan 448, labelled 448', rests within a burner pan opening (not shown) and is supported by a peripheral flange 452.
Burner 450 has a burner element 454 that is attached to a fuel conduit 456.
Burner element 454 may have ~~ fastener in tlue nature of a threaded post 458 attached thereto. Threaded 2 X892747.2 post 4S8 may be inserted through a post hole 460 in burner pan 448 and manually secured using a wing nut 462 or some; other manually tightenable fastener. Fuel conduit 4S6 extends through a conduit hole 464 in pan 448 and may receive in its input end 466 a fuel output conduit 468 of a burner valve 470. Conduit hole 464 is preferably smaller than element 4S4 to inhibit passage of S element 454 therethrough. Proper placement of conduit 4S6 within conduit hole 464 may be facilitated both by threaded post 4S8 arid post hole 460, and by an arcuate rebate 472 at an edge of conduit hole 464 which may abut conduit 456. Arcuate rebate 472 preferably conforms to a portion of fuel conduit 4S6 and may have substantially the same radius of conduit 456. An optional spider guard 4'74 may be included at input end 466 to inhibit entry of spiders and other insects therein.
A burner grill 4'76 may be located adjacent burier element 454, and is preferably located t~o receive heat from burner 4S0 when burner 4S0 is operational. Burner grill 476 may have a protrusion such as a leg; 478 to inhibit movement of burner grill 476 relative to burner tray 440.
Ln the illustrative embodiment, burner grill 476 has four legs 478 which may be received by four 1 S l~~g holes 480 in burner tray 440. Wlien legs 478 are inserted into leg holes 480, lateral movement of burner gr~:ll 476 is limited.. A.t least one, and preferably two, of burner legs 478 have a curved end 482. Curved ends 482 are first inserted into respective leg holes 480 with burner grill 476 oriented substantially perpendicular to burner tray 44U. Once curved ends 482 are inserted, burner grill 476 may be rotated about curved ends 482, which reside in leg holes 4.80, to a position generally parallel tc> burner tray 440. The remaining legs 478 may then be inserted into leg holes 480 in the manner described above. In this configuration movement of burner grill relative to burner tray 440 rnay be further inhibited.
20892747.2 Burner valve 470 may be inserted into valve opening 484 from a side of burner tray opposite to that of barrier pan 448, and may be attached to burner tray 440 with a valve securing apparatus, such as valve clip 486. Valve; opening 484 is preferably round and has one or more c;ngaging members in t:he nature of fins. 488 which extend into valve opening 484. Fins 488 are preferably identical in shape and are located in a plane parallel to that of burner tray 440. Each fin 488 extends from an opposite side c>f valve opening 484 towards the other, and has a curved portion 490 which abuts and is connected to a corresponding portion of a wall 492 of valve opening 484. A free end 494 of each fin 488 is substantially linear and defines a generally straight edge 496. Free; ends 494 may be parallel to each other.
Referring additionally to Figures 30A, 30B and 30C, valve clip 486 may have a planar portion having curved ends 500 and generally linear parallel sides 502 which together define a shape which is substantially the same as valve clip opening 484 defined by fins 488. Planar f~ortion 498 also has an opening, such a~s valve stem opening 504, passing therethrough. Valve stem opening 504 permits insertion of a valve stem 506 of burner valve 470.
Valve clip 486 may 1 S be attached to a standard burner valve such as burner valve 470. Because valve clip 486 is preferably attached to burner valve 470 by a manufacturer, it may be fastened to burner valve 4170 using screws inserted through borf;s (not shown) of valve clip 486.
Manually tightenable fasteners may also be used (not shown). The bores may additionally pass through posts 510 of valve clip 486. Posts 510 are preferably ofa length to ensure that valve stem projects through valve stem opening 504 a sufficient distance to engage a valve knob S 12 once burner valve 470 is attached to burner tray 440. Valve knob 512 facilitates turning of valve post 506 about its axis to control fuel flow through burner valve 470.
20892747.2 Once burner valve 470 is attachc;d to valve clip 486, the planar portion 498 of valve clip 486 may be inserted through valve clip opening 484, as shown progressively in Figures 30A and 30B. Further insertion of valve clip 48(i may be inhibited by at least one, and preferably two, tabs 514, wherein each tab 514 extends from a linear edge 502 of valve clip 486. Tabs 514 may lie in a plane parallel to, but displaced from, the plane of the surface 516 planar member 498.
Once valve clip 486 is inserted into valve clip opening 484 to the point that it is inhibited from further insertion by tabs 514, it may be rotated about its central axis by preferably 90 degrees (as shown in Figure 30C). This rotation aligns the curved portions 490 of fins 488 and the curved ends 500 of valve clip 486 to inhibit removal of valve clip 486 from valve clip opening 484.
Valve clip 486 rnay be additionally configured to retain fins 488. Curved ends 500 of planar member 498 ma:y be provided with a slot 518 which bisects the curved ends 500 to form two parallel curved ends 500a and 500b for retaining fins 488. In this configuration, planar nnember 498 is installed by insertion into valve clip opening 496, as shown in Figures 30A and 30B. Tabs 514 extend :from each linear side 502b to permit only curved end 500a to pass through valve clip opening 484. In this position, slots 518 are aligned with straight edges 496 of fins 488. Rotation of valve clip 486 by 90 degrees causes fins 488 to enter respective slots 518.
Once fins 488 enter slots 518, curved ends 500a and 500b retain respective fins 488 therebetween (as shown in Figure 30C).
To secure valve clip 486 within valve clip opening 484, tabs 514, which are preferably coplanar with linear sides 502b, may be provided with a retainer such as a protrusion in the shape of a ramp 520. Ramp 520 generally increases opposite to the direction of rotation R and projects 20892747.2 into the plane of slot 518. When valve clip 486 is inserted into valve clip opening 484, ramps 520 abut fins 488. As valve clip 486 is forced marginally further into valve clip opening 484, t;~bs 514 deflect away fxom the plane ol'slot 518. This deflection permits rotation of valve clip 486 and fins 488 may enter slot 518. Once valve clip 486 is rotated 90 degrees, tabs 514, and ramps 520, enter valve clip opening 484 to clear fins 488 and return to their original position, as i~~ best shown in Figure 30C. Further rotation of valve clip 486 is inhibited by sheer side 522 of each ramp 520 which abuts straight edge 496 of fin 488. 'This inhibited rotation provides feedback that valve clip 486 is installed. Tabs 514 are preferably made of a resilient material such as a plastic to enable them to resiliently return to their initial positions after being deflected during installation. Thc; thickness of each tab 514 may be reduced to facilitate temporary deflection of tab S 14 from its initial position. Once burner valve 470 is installed, burner knob ~~24 may be attached to valve stem 506, and conduit 456 may be oriented to cause valve output 4E68 to be inserted into conduit input end 466. Valve clip 486 may be removed by manually deflecting tabs 514, for example by fml;er pressure, and concurrently rotating valve clip 486 in a direction opposite to direction D.
To permit a snug fit between valve clip 486 and fins 488, an apex 526 (shown in phantom in Figure 30C) of slot 518 which is co-planar with slot 518, has a curved portion 528 and a tangent portion 530. When valve clip 486 is fully installed, as described above, tangent portion ~~30 abuts fin straight edge 496 to inhibit transverse movement of valve 470 relative to fin straight edge 496. Tan;?ent portion 5.3Cn originates at a Linear edge 502 of valve clip 486 and merges with curved portion 528 which gradually curves toward valve stem opening 504 and terminates at an opposite linear edge 5(>2 of valve clip 48fi adjacent tab 514. When valve clip 20892747.2 486 is installed, curved portion 528 first meets fin straight edge 496, and as valve clip 486 is rotated, curved portion 528 guides tangent portion 530 into alignment with fin linear edge 496.
Once tangent portion 530 and linear edge 496 are aligned, ramped tabs 514 clear fin 488 and snap into place. To further facilitate alignment of fin 488 with slot 518, curved edges SOOa and SOOb may be rounded in a direction generally normal to the plane of the curves of curved edges SOOa and SOOb.
While the illustrative embodimf;nt describes fins 488 having straight edges 496, edges defining other shapes rmay also be used as long as the configuration of valve clip 486 is adjusted accordingly.
Valve clip 486 may be made of any preferably weather resistant material such as a plastic or a metal. In the illustrative embodiment, valve clip 486 is injection moulded as a single piece using a plastic that enables tabs S 14 to be resilient.
Referring to Figure 29, a side burner 434' is configured for use with shelf bracket 414.
7.'he configuration and installation of valve clip 486 and the other elements of side burner 434 is substantially the same as described above for side burner 434, and are not described further.
One shelf bracket 414 rnay be used to secure burner tray 440. Shelf bracket 414 is installed in substantially the same mancu:r as described above in the context of shelves 68" and 70". Bolts 404 are inserted into bracket holes 426, through holes 532 in burner tray 440, and then through holes 412 in support portion 340' or 342' (side burner 434' may also be attached to support portions 340 and 342 in a similar manner). Bolts 404 may then be secured with wing 20892747.2 nuts 406. Burner tray 440 may be attached to the remaining support portion 340' or 198' with at least one bolt 404 inserted through holes 532 in tray 440 and holes 406 in the support member.
Bolts 404 may then be secured with wing nuts 406.
Panel Refernng to Figure 31, a cross piece, in the nature of a generally rectangular panel 72, is mounted between support members 62 and 64, and is preferably mounted between a leg member !~8 or 100 of support member 62 and a leg member 98 or 100 of support member 64. The generally planar panel '72 substantially conforms to the shape of opening 534 (see Figure 32) which is generally defined by the support members 62 and 64, cross beam 66 and console 86.
1?anel 72 may also be curved or bowed. or some other shape that substantially spans opening 534, and may have a flange or other protrusion (not shown) to at least partially obscure an adjacent l.eg member 98 or 100. Panel 72 is preferably mounted to be substantially parallel to cross beam 66.
A pocket 536 rnay be integrally formed in panel 72. Pocket 536 may be used for holding condiments or utensils (not shown). When panel 72 is installed, pocket 536 may have a substantially level bottom 538 and vertical sides 540. In the illustrative embodiment, pocket 536 extends along substantially the entire length of panel 72. To better retain items stored within ~~ocket 536, pocket sidca 540 may be angled inwards, for example by three degrees relative to pocket bottom 538. Furthermore, placement of items into pocket 536 may be facilitated by ~.ilting pocket 536 away from the plane of panel '72, for example by 12 degrees. The location of 20892747.2 pocket 536 may be varied relative to longitudinal edges 542 and 544 of panel 72. For example, a.s shown in Figure 2, pocket 536' may be located adjacent longitudinal edge 544' of an alternate panel 72'.
Panel 72 has at least one mounting member, and preferably two mounting members, in the nature of mounting pins 546, each of which extends from an edge thereof.
Each pin 546 extends from an edge 548 of panel 7 ~ tlhat is substantially perpendicular to the longitudinal axis of pocket 536. Pins 546 may be coaxial and are oriented for insertion into corresponding mounting holes 550 located in support :members 62 and 64. Mounting holes 550 are preferably located in one of legs 98 or 100 of each, support member 62, 64. In the illustrative embodiment, c;ach pin 546 projects from an edge of panel 72, adjacent a corner thereof, and each corresponding mounting hole 550 is located adjacent a respective bridging member 102 and 104.
Pins 546 may also lie in substantially the; same plane as panel 72.
Panel 72 may have an additional mounting member in the nature of a retaining clip 552.
Retaining clip 552 may be located along edge 548 of panel 72, and located at a distance, for c;xample ten inches, from pin 546. Additional retaining clips 552 may be added. Each retaining clip 552 is preferably located to correspond to the location of a leg member 98, 100 when the panel 72 is installed. Retaining clip .552 may be made of a resilient material, and may be shaped to conform to a portion, and preferably at least a semi-circular half, of the lateral perimeter of a corresponding leg merr~ber 98, 100. 'To conform to leg member 98 or 100, clips 552 may have a semi-circular surface 554 corresponding to the shape of leg member 98, 100.
Retaining clip 552 is attached to, or integral with, panel 7~'. at a mid-point of the curved retaining clip 552. In this x:0892747.2 configuration, each clip 552 receives anal retains a portion of a respective leg member 98 or 100, and limits movement of panel 72 in a direction substantially transverse to the plane of panel 72.
In an alternative embodiment, e;~ch clip 552 may be attached to panel 72 at an end 556 of clip 552 instead of a mid-section (not shown). In this embodiment, surface 554 of clip 552 is f~referably configured to conform to a greater portion of the circumference of leg member 98, 100 than in the embodiment described above. This permits a snap fit to be formed after resilient clip 552 is attached to a leg member 98, 100. For example, as clip 552 is attached, a resilient free of clip 552 must be; forced away from panel 72 to accommodate the wider diameter of leg member 98, 100. Once leg member')8, 100 is placed within clip 552 the free end resiliently returns to its initial position to engage a~ portion of leg member 98, 100 substantially corresponding to the shape of clip surface 554. T'he illustrative embodiment of clip 552 may be likewise configured to :form a snap fit v~ith leg member 98, 100 by extending free ends 556 to encompass a greater portion of the lateral perimeter of legs 98, I 00.
In a preferred configuration, the: mounting members, including pins 546 and clips 552, :,ubstantially secure panel 72 between support members 62 and 64 to provide at least some resistance to movement of support members 62 and 64 relative to one another.
Pins 546 and clips 552 are both preferably integrally formed with panel 72, which may be made of a plastic or metal.
:0892747.2 Castin Referring to Figures 1, 3 and 4, grill housing 74 has opposed castings 76 and 68 that may f;nclose burner 80, grill plates 82, warnaing rack 84 and angled bars 88. In operation, the castings '~6 and 68 may be aligned vertically so that casting 76 is located generally above casting 68. In the following description each respective casting will be referred to as an upper casting 76 and a lower casting 68.
Lower casting fib supports burner 80 and grill plate 82. Angled bars 88 for deflecting heat may also be supported by lower casting 68. The casting 68 preferably has an interior >urface 558 that defines a volume, which volume may be generally box-shaped.
The interior ;surface 558 terminates at an edge 560 defining an opening 562 which may be generally rectangular. A closure such as upper' casting 76 may be provided to inhibit loss of the heat produced by burners 80. Upper castin~; 76 preferably has an interior surface (not shown) that defines a volume, which volume may be generally box-shaped. The interior surface terminates pit an edge 564 which defines an opening 568. Opening 568 is preferably generally rectangular, ~,vith edge 564 substantially conforming to edge 560 of lower casting 68 to reduce spaces or gaps l:herebetween. This may reduce heat lass from within the grill housing 74 when castings 76 and 68 are in a closed position, as shown in Figure 32, for example. Interior surface 558 of lower casting 78 and the interior surface of upper casting 76, and their respective edges 560, 564 may ;alternatively be configured to define other valumes and openings. For example, each of the iinterior surfaces could define a hemispherical volume and the edges could each define a generally circular opening.
20892747.2 As shown in Figure 32, castings 76 and 68 combine in a closed position to enclose a generally box-shaped volume when they are oriented with their openings 562 and 568 facing each other, and their edges 560, 564 are; aligned. In this closed position, the castings 76 and 68 inhibit heat transfer from within the grill housing 74 to the surrounding environment. Castings 76 and 68 are separable. from one another to provide access to at least the grill plate 82. At least one hinge 570 preferably joins upper casting 76 to lower casting 68. Hinge 570 has a bolt 572 (shown in phantom) which is connected to upper casting 76, and semi-circular receiving members 574 and 576 'Nhich are connected to lower casting 68 and receive bolt 572. Bolt 572 rnay be slidingly inserted between semi-circular receiving members 574 and 576 to form hinge '.>70. A free end of bolt 572 may receive a -bolt clip 578 to inhibit removal of bolt 572 from its position between receiving members 574 and 576. An axial groove or head 580 may be included at the bolt free end to inhibit axial removal of bolt clip 578.
A handle 582, connected to upper casting 76, may be gripped to move upper casting 76 relative to lower casting 68. Handle 58.2 is preferably made of a heat resistant material such as 'NOOd or an appropriate plastic so that it remains relatively cool to the touch even when the castings 76 and 68 are hot. Heat resistant: gaskets 584, sandwiched between handle 582 and casting 76, may be installed to inhibit heat transfer between casting 76 and handle 582. Handle :i82 may be attached to casting 76 using at least one, and preferably two, fasteners in the nature of threaded posts 586 projecting from ends of hurdle 582' (shown in Figure 2) or bolts 588 for insertion into handle 582 (as shown in figure 1). The installation of either handle 582 or 582' is similar. For example,1:o install handle 582', the generally parallel threaded posts 586 are inserted into handle holes 590 passing through c.rpper casting 76. As noted above, a gasket or gaskets 584' 2 0892747.2 rnay be placed between handle 582' anal casting 76. Once inserted through handle holes 590, threaded posts 586 may be manually secured by either wing-nuts 592 or in some other manner to hold handle 582 fixed adjacent to casting 76. A temperature gauge 594 may also be attached to upper casting 252 in a similar manner as described for handle 582. In particular, temperature gauge 594 may be manually installed and fastened using wing nuts 592.
To accommodate various internal components, such as burners 80, grill plate 82, warming rack 84 and angled bars 88, the shape of the castings 76 and 68 may be modified from a general box-shape, as described below.
Referring to Figure 2, lower casting 68 may rest on support members 62 and 64.
A
fastener such as bolt 596 may be used to inhibit movement of lower casting 68 relative to support members 62 and 64. Bolt 59fi may be inserted into a casting bore 598 passing through lower casting 68, wherein bore 598 is substantially coaxial with a threaded bore 600 in bridging member 102 or 104 when lower casting; 68 is aligned for assembly to member 62, 64. To connect lower casting 68 to bridging member 102 or 104, bolt 596 is inserted through casting bore 598, starting adjacent interior surface 558. Bolt 596 is then received by threaded bore 600 and tightened to attach lower casting 68 to bridging member 102 or 104.
As the bridging members 102 and 104 are preferably identical to one another, the description for one applies to the other. Bridging members 102 and 104 may also be symmetrical about their longitudinal centrelines. This configuration permits identical bridging member configurations to be used for both bridging member 102 and 104, which may reduce :!0892747.2 tooling and manufacturing costs. For example, to use a bridging member 102 as bridging member 104, the bridging member need only to be rotated 180 degrees about its longitudinal axis. To avoid redundancy, only one h;al f of the symmetrical bridging members is described.
Each bridging member, for example member 102, may be provided with at least one flange 602 having the threaded bore 600. Flange 602 additionally provides a support surface 604 for supporting lower casting 68. In its .operative position, support surface 604 is preferably ~;enerally horizontally oriented and located at about waist height. For example, support surface (i04 may be 26 inches fiom the base ends 110, 112 of leg members 98, 100.
Increased rigidity of bridging member 102 nnay be achieved by attaching at least one, and preferably four, gussets 606 thereto. In the illustrative embodiment, at least two gussets 606 straddle each bend 608 formed by flange 602.
Bolt 596 is preferably configured so that it may be manually installed and tightened. Bolt '.i96 includes a head 610 that may be gripped. Head 610 may be cylindrical, having an oval cross-section, wherein the minor axis of the oval cross-section is greater than the thickness of the head 610. A threaded ;;haft 612 extends from the center of the oval head 610 along the cylinder axis, and may be integrally formed with head 610. For enhanced gripping, a protrusion from head 610, such as posts. 614, may be added. Posts 614 protrude from a side of head 610 opposite to threaded shaft 612. Posts 614 are preferably spaced apart and equidistant to the axis of shaft tilt to permit increased torsional leverage about the axis of shaft 612 when the bolt 596 is tightened or loosened. Due to the heat produced by the burners 80, bolt 596 is preferably made :!0892747.2 of a material, such as cold forged steel, that does not deform when subjected to high temperatures.
Refernng to Figures 1 and 4, head 610 may alternatively be configured as a nut 610' having a threaded bore 616 through its .axis, instead of threaded shaft 612. A
threaded post 612' rnay be partially threaded into the threaded bare 600 of flange 602 so that it protrudes from support surface 604. Threaded post (i 12' may alternatively be welded directly to flange 602. A
free end of the threaded post 612' is inserted into the bore 598 passing through the lower casting E.8. The casting 68 may then be secured by threading and tightening nut 610' about the threaded post 612', whereby the casting 68 is sandwiched between the nut 610' and the flange 602.
Hecause the threaded post 612' is preferably first connected to flange 602, it may further serve as a~ locator for positioning; the lower casting 68 relative to the bridging members 102 and 104.
'hhreaded post 612' may additionally have a head to form a bolt 618 which may be threaded through threaded bore fi00, with its free end protruding from support surface 604.
In the illustrative embodiment, the casting 68 may be guided to a preferred alignment 1 S relative to the support members 62 and 64, by employing an alignment structure in the nature of apt least one, and preferably four, guide posts 620. The alignment structure also encourages alignment of threaded bore 600 with casting bore 598 so that bolt 596 may be readily inserted amd threaded therethrough. Guide posts 620 protrude from lower casting 68 in a direction away from interior surface 558. Guide bores 622 located in flange 602 of bridging member 102 receive the guide posts 620. ~fhe flanges 602 of each bridging member 102, 104 preferably each have two spaced-apart guide bores 622 for receiving the respective guide posts 620.
2089274%.2 The guide posts 620 may protrude from a side, such as bottom 624, of lower casting 68, bottom 624 being located generally opposite to the opening 562 of the lower casting 68. Each post 620 may be located adjacent an extremity of bottom 624, such as at corners 626. The location of guide posts 620 and corresponding bores 622 orients lower casting 68 so that it straddles support members 62, 64 and is generally balanced, thus reducing the possibility of barbeque 60 tipping. Additional guide bores, such as guide bore 628, may be included to accommodate different spacings of guide posts 620 on castings of different size.
Guide posts 620 may be tapered, being narrower at their distal ends 630. The bases 634 of guide posts 620 are preferably larger than the guide bores 622. The narrower distal ends 630, being smaller than the ;;uide bores 622, may fit more readily within the guide bores 622, reducing the need to precisely align the posts 620 with the bores 622. As the guide posts 620 are inserted into the bores 622, the casting 68 is aligned relative to the supports 62, 64, and the edges tS32 of the guide bores come into contact: with the respective bases 634 of guide posts 620 to preferably form a friction fit between the guide bore edges 632 and guide posts 620. This arrangement further inhibits movement of the lower casting 68 relative to the supports 62, 64.
~~s noted above, the alignment structure also serves to align the threaded bores 600 and casting bores 598, to permit insertion and tightening of bolt 596. The guide posts may alternatively protrude from support surface 604 into bores in lower casting 68 (not shown).
A hollow 636 may be provided in support surface 604 to encourage the edges 632 of the l;uide bores 622 to grip the guide posts 620. Hollow 636 is defined by adjacent gussets 606 that are displaced from one another along support surface 604 with an exposed portion of support x:0892747.2 surface therebetween. l-follow 636 is located with threaded bore 600, or threaded post 612', passing therethrough. When lower casting 68 is placed onto gussets 606 which overlap support surface 604, a gap (not shown) is formed at hollow 636 between support surface 604 and the bottom 624 of lower casting 68. As bolt 596, or nut 610', is installed and tightened, the gap narrows due to a deformation of support surface 604 towards lower casting 68 at hollow 636.
This deformation of surface 604 may create longitudinal tension in support surface 604 causing portions of guide bores 622 to grip guide posts 620.
The lower casting 68 may be provided with a plurality of holes in the nature of vents 286 that permit oxygen to be drawn for use by burners 80 to combust fuel. Air holes 286 are yreferably located in the bottom 624 of lower casting 68, and may be arranged beneath burner F~O. The lower casting ti8 may further b~e provided with an ignition hole 287 therethrough for igniting fuel by external means, such as a lighted match (not shown) inserted therein. Burner 80 rnay alternatively be ignited using an ignition, described below.
To provide a drain for grease and other drippings from food cooked within the grill housing 74, lower casting 68 may have a drain in the nature of at least one drain opening 638.
Drain opening 638 is preferably centrally located in the bottom 624, and passes therethrough.
Bottom 624 may be sloped towards drain opening 638 to encourage draining from substantially the entire bottom 624 of lower casting 68. When in operative position, bottom 624 may be sloped downwards at between five and 15 degrees from the horizontal towards drain opening Ei38. A cup, tube or other means (not: sihown) for collecting the drippings may be located beneath drain opening 638. For example, as shown in Figure Figures 1 and 2, a cup holder 640 may be 20892747.2 42502/'7 inserted into and retained by a hole 642 in lower casting 68 adjacent drain opening 638. Cup holder 640 may be made of a section of pliable wire configured to receive and support a cup below drain opening 638.
A pair of rotisserie rebates 644 may be provided in edges 560 of lower casting 68 for ~~upporting a rotisserie (not shown). The rebates 644 are preferably generally located at the mid points of opposite sides of edges 560.
Burner Support Member Refernng to Figures 33 and 34, lower casting 68 contains at least one burner 80. Burner f~0 may be an H-shaped burner 80, a bar-shaped burner 80' (see Figure 2), or some other appropriate barbeque burner known in t:he art. To satisfy government standards, such as, support members 646 are attached to burners to retain and maintain the burner in a preferred orientation within lower casting 68.. The support members 646 of the illustrative embodiments described below permit the burner to be manually installed in and removed from barbeque 60 without tools. Support members 646 may be used in combination with many different burner configurations, including the H-shaped burner 80 arid bar-shaped burner 80'.
The attachment and use of the support members 646 is similar in each case. Accordingly, the following description of support members 646 as used in cogjunction with an H-shaped burner 80 is an example and rnay apply in substantially the same manner to burners having different configurations.
H-shaped barbeque burners typically have four coplanar arms, such as arms 648 of burner f~0. When in a preferred orientation, the four arms 648 of burner 80 are generally horizontal. At 20892747.2 least one support member 646 is attachc;d to each arm 648. Each support member 646 generally uniformly displaces the arms 648 of burner 80 from the lower casting bottom 624 and inhibits movement of burner 80 relative to lower casting fib. Each support member 646 has a generally ylanar strip portion . Strip portion 650 may be rectangular, and is preferably constructed from a resilient heat resistant material such as a metal. Strip portion 650 is attached along an edge (not shown) to arm 648 to generally form a right angle with arm 648. Attachment may be by welding ar some other securing means that is not significantly affected by high temperatures.
~~lternatively, strip 650 may have a bend therein to form a toe 652 protruding more or less normal to a longitudinal axis of strip 650. 'foe 652 may be welded to arm 648, thereby providing a larger area for attachment to ann 648 than along an edge of strip 650.
Adjacent a free end 654 of strip 650 is a catch 656 for securing strip 650 (and by connection burner 80) when catch 656 is inserted into an apening 658 in the bottom 624 of lower casting 78. Catch 656 is preferably generally rectangular in shape, and may be formed from strip fi50 by making three incisions in strip 650, or stamping strip 650, to define three sides of rectangular catch 656. A fourth side of catch 656 is defined by bending a free end 654 of three-sided catch 656 away from strip 650 to form a bend 660 where catch 656 meets strip 650. Bend fi60 is preferably adjacf,nt strip free end. 654, and has an axis which is generally parallel to the plane of arms 648. As a result of bend 660, catch free end 662 is displaced from strip 650. Once bend 660 is formed, catch free end 662 is preferably displaced by greater than zero and less than ~>0 degrees from an opening 664 fornaed by the bending ofcatch 656 away from strip 650. An angle of about 30 degrees may be defined, for example. In the illustrative embodiment, the material used for strip fi50 may be sufficiently pliable to permit the formation of bend 660, but is 2 0892747.2 of sufficient resilience that when a force is applied to catch free end 662 to move it through an arc about the axis of bend 660 to move i1: towards opening 664 in support member 646, catch free e,nd 662 returns substantially to its original position at about 30 degrees displacement from opening 664 of support member 664 when the force is no longer applied.
Support member 646 also has at least one protrusion, such as a shoulder 666 which contacts portions of interior surface 558 of lower casting 68 adjacent to casting opening 658 to prevent further insertion of support member 646 into casting opening 658. In the illustrative Embodiment, support rr~ember 646 has two shoulders 666. Shoulders 666 are located at a predetermined distance from arm 648 to provide a preferred displacement of burner arms 648 from lower casting interior surface 558. For example, shoulders 666 may be displaced by inches.
;shoulders 666 may be formed by bending portions of the free parallel sides 670 of strip 650 adjacent free end 654 to form tabs 668 which are preferably perpendicular to the plane of strip fi50. The creation of tabs 668 forms shoulders 666 at portions of the free parallel sides 670, adjacent tabs 668. To facilitate bending; of tabs 668, a transverse cut to define shoulder 666 may be made in each side 6 7 0, before tabs 668 are bent. Alternatively, shoulders 666 may be added to strip 650 by welding or by otherwise connecting one or more metal tabs or pieces to strip 650 to limit insertion of support member 646 into opening 658 beyond a desired threshold (not shown). In the above embodiments, thc: tabs 668, being located in planes generally perpendicular to the plane of strip 65t:>, rnay also add rigidity to strip 650.
Burners, such as burner 80, typically have at least one, and frequently two, fuel input ducts 672. Free ends 6'74 of ducts 672 leave guards, such as spider guards 474, to prevent insects 2089274 7.2 from entering ducts 672. Guards 474 engage outlets of console 86 (described below) to receive a mediated flow of fuel which is suppli.eal to the burner 80 via ducts 672.
To manually install burner 80 into lower casting 68, free ends 674 of each duct 672 are inserted through separate burner duct passages 676 and fi78, located in lower casting 68.
Passages 676 and 678 permit fuel to lae delivered from an external source, such as propane tank ~)0, via ducts 672 to bw-ner 80. Once duct free ends 674 are inserted through passages 676 and (i78, support member free ends 654 are each inserted, preferably concurrently, into their respective lower casting openings 658. Because the manner in which each support 646 is installed and removed is similar, a description for the installation of just one support 646 is provided. Bend 660 enters opening 658 and is followed by catch 656 which angles away from strip 650, as described above. As support (i46 is further inserted into opening 658, catch 656 encounters an edge of opening 658 and, is caused to move closer to strip 650 to a depressed position (not shown) to permit further insertion of support 646. When catch free end 662 passes l:hrough opening 658, the resilient catch 656 returns to its initial angled displacement from strip 650, and is positioned adjacent to opening 658. In this position, the free end 662 of catch 656 is ;rdjacent to, and preferably abuts, lower casting 80 to hinder removal of support 646 from opening 658. Once catch 656 passes t>7~rough opening 658, shoulders 666 abut portions of interior surface 558 of lower casting 68. adjacent to casting opening 658 to inhibit further insertion of support 646 into opening 658. To manually remove support 646 from opening 658, hatch free end 662 is moved toward strip 650 to permit support 646 to clear the edges of opening 658 and be removed. The tabs 668 ma;y additionally each have a hole 680 therethrough. Holes 20892747.2 fi80 are coaxial with one other, and may optionally receive a removable pin such as a cotter pin to further inhibit removal of support mc;mber 646 from opening 658.
In the illustrative embodiment, during installation of support 646, shoulders 666 abut the lower casting 68 immediately after catch free end 662 passes through opening 658. This configuration attempts to minimize movement of support 646 along an axis parallel to the direction of insertion, by retaining lower casting 68 between shoulders 666 on one side and catch free end 662 on the other.
Casting opening 658 is preferably made sufficiently large to permit insertion of support fi46 with catch 656 in a depressed position, yet sufficiently small to prevent removal of support fi46 with catch 656 in its initial position. T'he casting openings 658 which receive each support fi46 are also preferably of a size and location to inhibit movement of burner 80 in a direction transverse to the direction of insertion. For example, transverse movement may be inhibited by configuring the edges of opening 658 to be located immediately adjacent strip 650. In this configuration, if a transverse force is applied to burner 80, movement of the burner 80 is hindered by strip 650 coming into cont;~ct with an edge of opening 658.
Alternatively, the location of the edges of the openings relative to the inserted support members 646, may be made ~;uch that any two or more of the four support members 646 abut an edge of their corresponding opening 658 when subjected to a force transverse to the direction of insertion, which in turn hinders transverse movement of burner 450. Any transverse force applied to burner 80 causes at least two supports 646 to abut edges of their respective holes to limit transverse movement of the burner 80.
2 0892747.2 In an alternative. embodiment {not shown), the rectangular catch may be fashioned from t:he strip by making two. incisions in tlae strip at right angles to one another to define adjacent sides of the rectangular catch. A third side of the catch is a portion of an edge of the strip, and t:he fourth side of catch is defined by bending the three-sided catch away from strip to form a bend where the catch is attached to the strip. As with other embodiments, the axis of the bend is generally parallel to the plane of arms 648.
In a further alternative embodirrzent, the catch may be added to the strip by welding or other connection means. to provide a catch with the preferred properties described above.
In a yet further alternative embodiment, the catch rnay be formed by bending the free end E~54 of strip 650 to forrr~ a catch with similar characteristics to those described above.
In any embodiment, the shape of the catch may differ from a rectangular shape as long as the catch is resilient and has a free end that may be moved to a depressed position to permit insertion of support 64Ei into opening 6:>8, and that returns to its initial position to inhibit removal of support 646 from opening 658 once a free end of support 646 is inserted therein.
~~imilarly, support 646 may be of any shape, having shoulders and a catch, that affords insertion of the support into an opening, the support being inhibited from further insertion by the shoulders, and removal of the support, being inhibited by an attached or integral catch.
The fuel used b:~ burner 80 is preferably a pressurized combustible gas, such as propane, that is appropriate :for gas barbedues. E~ecause the fuel is pressurized, it is forced into the burner 80 and may be released via a plurality of fuel openings 682 in the walls of the burner 80. The 20892747.2 42502/'7 slow of fuel is mediated by console 86, described below. Fuel openings 682 permit fuel to be released into the interior 684 of lower casting 68. The fuel may then be ignited. The fuel openings 682 are preferably located adj acent to a plane that bisects all arms 648 of the H-shaped burner 80. A standard igniter, such as electronic ignition 686 is attached and retained by igniter clip 688 to burner 80 adjacent the fuel openings 682 of at least two arms 648 having a common longitudinal axis. Igniter activation ;assembly 690, which includes an igniter activation knob (i92, is attached to console 86, and comiected to igniter 686 via igniter wire 694 (see Figure 1 ).
Heat Deflectors Refernng to Figure 1, a heat ciealector in the nature of angled bars 88 may be installed within casting 68, to encourage heat dissipation within barbeque 60. Burner 80 is sandwiched between casting bottom 624 and angled bars 88. Angled bars 88 may be formed from a single, >ubstantially rectangular sheet of metal. Longitudinal peaks 696 and valleys 698 may be formed therein, to create angled sides 700 for dlissipating heat within the grill housing 74. Grill plate 82 is preferably located above angled bars 88. In this arrangement, the angled sides 700 may also reduce the accumulation of grease and other drippings from food within the grill housing 74.
'then drippings from food supported by grill plate 82 encounter an angled side 700, they may be heated to a higher temperature and partially vapourized, which vapour may add flavour to food located within the grill housing 74. Openings 702 located adjacent to valleys 698 permit drippings that are not vapourized to drop to lower casting bottom 624, to be drawn by gravity to drain opening 638.
zos~z~4~.z _70_ At least one and preferably two support struts 704 for supporting angled bars 88, traverse the interior 684 of lower casting 68, and are located between burners 80 and angled bars 88.
Support struts 704 may be uniformly displaced from casting bottom 624 by fins which project from interior surface 5.58. Fins 706 are each located to support the respective ends 708 of each strut 704. .Strut ends 708 preferably have a longitudinal groove 710 for receiving a iin 706 which inhibits movement of thc; strut 704 when the fin 706 is placed therein. The fins '706 may be integral with casting 68, or otherwise attached thereto, and may be located to orient support struts 704 in a plane parallel to the plane of the arms 648 of burner 80, and both are preferably horizontal when operational. At least one and preferably two locating tabs 712 projecting from each strut 704 may enter an opening 702 of angled bars 88 to encourage a preferred orientation of angled bars 88, and to inhibit movement of angled bars 88 relative to strut 704, once angled bars 88 are installed.
Refernng to Fi~;ure 2, in an alternative embodiment, a heat deflector such as lava rocks 'l14 or ceramic briquettes (not shown) nay be provided instead of or in addition to angled bars 1 S 88. If these alternatives are used then an appropriate support structure, such as grate 716, for the lava rocks 714 or ceramic briquettes m;a:y be provided. Grate 716 may be supported directly by fins 706, and support sl:ruts 704 may bc; excluded.
Grill and Warming Rack Referring again to Figure 1, grill plate 82, of a configuration known in the art, is supported by a pair of substantially parallel ledges 718 that may be formed in casting 68 (only ;!0892747.2 one ledge is shown). Ledges 718 may be located to orient grill plate 82 in a plane parallel to the plane of the arms 648 of burner 80. When in operative position, grill plate 82 is substantially horizontal and is located above angled bars 88.
Barbeque 60 may also be provided with a warming rack 84, that may be in the form of at least one cantilevered shelf 720 for supporting food at a greater distance from burners 80 than food located on grill plate 82. As a result of this greater distance, food supported by warming rack 84 receives less heat than food located on grill plate 82. Warming rack 84 may be installed by inserting mounting pins 722 into mounting pin holes 724 located in upper casting 76. Once the pins 722 are inserted, toes 726 of warming rack support legs 408 may be inserted into toe holes 728 or may rest in rebates (not shown) located in edges 560 of lower casting 68. Either, or both, grill plate 82 and warming rack 84 may be made from wire, chrome wire, heavy duty porcelain coated wire, porcelainized metal, cast iron or porcelainized cast iron.
Console Refernng to Figures 35, 36, 37 and 38, console 86 has a control valve 730 for stopping or varying the flow of fuel to burner 80. Alternatively, the flow of fuel to burner 80 may be controlled by separate valves 730 and 7 32. Appropriate valves for controlling the flow of a ~;aseous fuel as are known in the art rna.y be used. Valves 730 and 732 are attached to console body 734 (or 734'). Console body 734 is preferably "drawn" from a single sheet of metal to form a substantially rectangular cavity (not shown) for receiving valves 730 and 732. The console body 734 is made using a die (not shown) which imparts shape to console body 734, by 20892747.2 impressing the single sheet of metal into a corresponding mould to produce the desired form of console body 734. Holes 736 and 738 in console body 734 permit knob stems 740 and 742 to protrude therethrough. Knob stems 740 and 742 may then be inserted into respective receptacles in control knobs 744 and 746, forming ;a friction or mechanical fit.
To aid in the proper attachment of console 86 to barbeque 60, ends 748 and 749 of bridging members 102 .and 104 each have at least one, and preferably two, spaced-apart tabs 750 and 752 protruding in a similar direction from an edge thereof. Tabs 750 and 752 may both lie in a. plane that is substantially perpendicular to the plane of bridging member support surface 604, a.nd, when barbeque 60 is fully assembled, rnay lie in a plane that is parallel to cross beam 66.
Lateral edges 754 of console 86 may have notches 756 and 758 for receiving tabs 750 and 752.
rJotches 756 and 758 need only provide a surface or edge 760 and 762 that may be placed onto, a.nd be supported by, tabs 750 and 75'2. One or both of notches 756 and 758 may further have a slot 764 for receiving an edge 760 or 762 of a corresponding tab, for example tab 750. Slot 764 preferably is substantia:tly the same thickness as tab 750, and is sufficient to permit entry of edge 760 to limit movement of console 86 relative to tab 750. The remaining tab 752 also inhibits movement of console 86. This arrangement permits console 86 to be placed upon and supported by tabs 750 and 752 to maintain console 86 in a preferred orientation before it is secured.
Each bridging member 102 and 104 has a securing protrusion 766 for securing console 86 thereto. Protrusion 766 may be perpendicular to both support surface 604 and tabs 750 and 752, a.nd is parallel and adjacent to console side 768 when console 86 is placed on tabs 750 and 752.
Protrusion 766 lies on the concave side of'console 86 and has a threaded bore 770 for receiving a 20892747.2 fastener inserted through a corresponding hole 7?2 in console side 768. The fastener may be a :'.crew, and is preferably a bolt 774 (see Figure 39A and 39B) that may be installed and removed t>y hand. Once partially inserted into hole 772, bolt 774 is inserted into bore 770 and tightened to secure console 86 to bridging member 102. 'The same operation is completed to attach console 86 to bridging member 104. It should be noted that any form of protrusion may be used as long as receiving bore 770 is positioned to receive fastener 774 to secure console 86 to bridging members 102, 104.
Referring to Figure 39A and 39B, a head 776 of bolt 774 may have external grips, such as knurls or cross hatches 77$ to provide greater friction to facilitate manual installation of the bolt 774. In the illustrative embodiment, the head 776 is cylindrical, having a diameter of about .'i/8 inches and a thickness of about 0.2 inches, or some other size and shape suitable for manual manipulation. A threaded end 780 protrudes substantially co-axially with the axis of the head ',~78. Turning of the bolt 774 about its longitudinal axis may also be improved by using a non-circular or non-uniforrr~ shaped head (not shown) with the threaded end 780 preferably protruding along an axis passing throu~;h a centroid of the head 778. The head 778 may be made of any rigid material, such as nylon plastic or a metal.
Refernng to Figures 37 and 38 an alternative console 86' and bridging member ends 748' and 749' is illustrated. In the alternative embodiment, ends 748' and 749' do not have tabs 750 and 752 for supporting a console. Instead, console 86' has a longitudinal flange 782 which may be placed at either end onto the respective support surfaces 262 of bridging members 102 and 2:0892747.2 1;04. When installed, flange 780 preferably traverses the distance between support members 62 and 64.
Flange 780 may additionally have tabs 784 at either end thereof. In this configuration console 86' is supported on support surfaces 262 along edges 786 of tabs 784.
Tabs 784 each c;xtend generally perpendicularly from flange 78U, and abut, or may be attached to, console sides ',~68'. While tabs 784 nray be co-planar with sides 768', they preferably lie in a planes parallel to sides 768', and are marginally closer to one another than if they were co-planar with sides 768'.
Because they are in marginally different parallel planes, each tab 784 meets a respective side ',~68' at a radiused boundary 788. The displacement of tab 784 from side 768' permits protrusion 766 to lie on the concave side of console 86', in a similar manner as described for console 86'.
To attach console 86' to bridging members 102' and 104', tabs 784 of console 86' may be placed upon support surface 604, with sides 768' each abutting an adjacent leg member, for c;xample leg member 98, to maintain console 86 in a preferred orientation before it is secured.
'Chreaded bore 770 of protrusion 766 may then receive a fastener inserted through a corresponding hole 772' in console side 768'. The fastener may be a screw, and is preferably bolt 774. Once partially inserted into hole i'72', bolt 774 is tightened into bore 770 to secure console 86' to bridging member 102. The same operation is completed to attach console 86' to bridging member 104. It should be noted that any form of protrusion may be used as long as receiving bore 770 is positioned t:o receive fastener 382 to secure console 86' to bridging members 102, 1. 04.
20892747.2 A fuel hose (not shown) may be; connected to control valves 730, 356 via a conduit in the nature of tubing. The fuel hose has a connector, for example as manufactured by Marshall Gas of San Marcos, Texas, that may be hand tightened to tank 90, or some other fuel source.
In an alternative: embodiment. (not shown) console 86 may be attached to barbeque 60 by fasteners for attaching console 86 to corresponding ends of bridging members 102 and 104. The fasteners are preferably bolts 774. Openings, in the nature of holes, pass through the bridging member ends, and receive a threaded end 780 of bolt 774. The threaded end 780 may be further received by a corresponding bore in console 86, ~Nhich may be a bushing, fixed in the console body, the bushing having internal threads for threaded engagement with the threaded end 780.
'The holes in the bridging member ends. are smaller than the head 778 of bolt 774 to inhibit head '778 from passing therethrough. To attach console 86 to bridging members 102 and 104, bolts '774 may be inserted through the holes ~of the bridging members, into the console bushings, and tightened by hand. In this embodiment, to inhibit console 86 from pivoting about the bolted connections at the bridging member ends, each end may be provided with flanges. The flanges ;ire preferably located to abut a side 1>f console 86 that is substantially parallel to an axis of rotation that is coaxial with the console; bolts 774 connecting console 86 to bridging members 102 and 104.
In a further alternative embodinnent, bolt 774 may be a nut (not shown). A
threaded post may be partially threaded into each of the bushings as described for the previous embodiment, to protrude from the console 86. Console 86 may then be secured by inserting the threaded posts into the bridging member holes, and then tightening the nuts about the threaded posts. Because ?0892747.2 the threaded post is preferably first connected to console 86, it may further serve as a locator for positioning the console 86 relative to the bridging members 102 and 104.
In the illustrative embodiments. console 86 and panel 72 may be configured and installed ;.o that corresponding edges thereof abut each other to inhibit movement of one relative to the other.
Leg Extensions and Casters Base ends 110 and 112 of leg members 98 and 100 respectively may include either wheels 94, casters 96 or leg extensions 114 to support barbeque 60. Base ends 110 and 112 of ~;upport member 64 preferably have wheels 94 attached thereto. If base ends 110 and 112 of ;support member 62 have casters 96 then barbeque 60 may be moved by applying a generally horizontal force to barh~eque 60 to roll it in the direction of the force along wheels 94 and casters ~)6. If base ends 110 arid 112 of support member 62 have leg extensions 74, then leg extensions ',~4 must be lifted from .a surface supporting barbeque 60 before a generally horizontal force is applied to barbeque 60 to permit rolling; motion with attached wheels 94.
Movement of barbeque (i0 may be discouraged by adding leg extensions 114 to all leg members 98 and 100. Wheels 94, casters 96 and leg extensions 114, regardless of which combination of them is used, are preferably attached so that grill plate 82 is substantially horizontal when barbeque 60 is assembled and in an operative position.
Referring to Fi~;ure 12B, leg ~;x~tensions l 14 support barbeque 60 and protect base ends ;l 10 and 112 of leg members ~)8 and 100. The height of grill plate 82, and the other components x,0892747.2 _7'J_ of barbeque 60 may be varied by attaching leg extensions 114 having a desired length to all legs ~)8, 100, and not attaching any wheels 94 or casters 96 to barbeque 60.
Because leg extensions l!,14 are attached to legs 98 and 100 in the same manner, description for the attachment of one extension is provided.
A plug end 790 of leg extension 114 substantially conforms to the size and shape of a void (not shown) in base end 110 of lei; member 98. The void is the internal space typically defined by a hollow leg; member, such as leg member 98, having a generally tubular, rectangular or other cross-sectional shape. Plug end 790 terminates at a peripheral shoulder 792 defined by a :,upport end 794 of leg extension 114. 'Varying the length of support end 794 affects the horizontal displacement of barbeque 60.
Leg extension 114 may be installed by inserting plug end 790 into the void of leg member 98 until shoulder 792 encounters leg member 98 to prevent further insertion of the extension 114. Because plug end 790 preferably substantially conforms to the void in leg member 98, it may be retained in place by friction. To permit easier insertion of plug end 790, plug end 790 may have longitudinal rebates 796, for example forming ribs 798, to reduce the frictional interface betv~/een plug end 79(1 and leg member 98. Figure 2 shows leg extension 114' having an alternative configuration for insertion into a leg member 98' having a void with a rectangular cross-section. The cross-sectional shape of support end 794 may be varied and does not have to be similar to that of plug end 790.
20892747.2 _78_ Leg extension 114 may be secured to leg member 98 using a fastener, such as slotted pin 186 (see Figure 12B). Leg member ~)8 has a hole 800 passing laterally therethrough for receiving slotted pin 186. Hole 800 ha;s an entry 800a and an exit (not shown). Similarly, plug <,nd 790 of leg extension 114, has a hole 802, passing laterally therethrough for receiving pin 186. Hole 802 has an entry 802a anti an exit (not shown). To install pin 186, the respective c,ntries 800a, 802a and the exits are aligned. Slotted pin 186 may then inserted therethrough to hinder movement of the leg extension ll 14 relative to the leg member 98.
The slotted pin 186 preferably has a head 188, which is larger than entry 800a to inhibit movement of pin 186 along its longitudinal axis within the holes 800, 802. Pin 186 may also have a catch 189 to inhibit longitudinal movement of the pin 186 within the holes 800, 802.
(batch 189 is located at the insertion end 190 of pin 186. End 190 is located opposite to head :188. Catch 189 may be; marginally lar~;er than the exit of hole 800 of leg 98 to inhibit pin 186 from being removed once end 190 is fully inserted through the exit hole. To facilitate passage of marginally larger catch 189 through the exit hole, end 190 may be tapered. To further facilitate passage of catch 189, end 190 may have at least one and preferably three partially transverse allots 192 emanating from a central longitudinal axis of pin 186. Each slot 192 is preferably uniformly angularly di:~placed from the another. As marginally larger end 190 is inserted through the exit of hole 800, slots 19'2 permit end 190 to narrow facilitating passage of catch 1.89, therethrough. Slotted pin 186 may be made of a resilient material such as a plastic so that e,nd 190 returns to its original shape c>nce it passes through the exit of hole 800 and catch 189 inhibits removal of pin 186.
20892747.2 4202%7 Caster plugs 804 receive caster;; 96 to permit rolling movement of barbeque 60 as described above. As with the description of leg extensions 114, a description for the attachment of one caster plug 804 :is provided and applies to the attachment of all caster plugs 804.
The configuration and installation of caster plug 804 is similar to that of the plug end 790 of leg extension 114, acid the description above for plug end 790 substantially applies to caster plug 804. As with leg extension 114, caster plug 804 has a shoulder 806 to inhibit further insertion of the caster plug 804 into the void (not shown) in base end 110 of leg member 98.
',ihoulder 806 is preferably of sufficient: thickness to prevent deformation of shoulder when in use. For example a shoulder thickness of may be used. Unlike leg extension 114, caster plug has an axial bore 808 for receiving a caster post 810 of a standard caster, for example caster 96.
,axial bore 808 may have a circumferential rib (not shown) for engaging a corresponding c;ircumferential groove 812 of caster post 810 to inhibit removal of caster post 810. Caster plug 804 may be further retained using a slotted pin 186 in substantially the same manner as described i:or retention of the leg extension 114. The general configuration of caster plug 804 may also be ~raried to accommodate: leg members of different cross-sectional shapes. For example, a caster plug (not shown) may he configured for use with rectangular leg member 98'.
If casters 96 or leg extensions 114 are attached to the same leg members to which tank base 92 is attached (not shown), then slotted pins 186 may perform the additional function of securing tank base 92 to the adjacent leg members 98, 100. In this configuration, slotted pins 186 are installed in a similar manner as. described above, except each pin 186 also engages a conduit 170 of tank base 92, as described below.
20892747.2 To attach tank base 92 to leg members 98, 100, each leg member 98, 100 is inserted through a respective conduit 170 attached to or, preferably, integrally formed with base 92.
(conduits 170 preferably have a lateral moss-section substantially equal to or larger than the size and shape of the lateral cross-section oar the respective leg members 98, 100.
This permits the leg members to be inserted through the conduits 170. If the cross-sections of the conduits 170 and leg members 98, 100 are substantially the same size, then a friction fit may be formed between the each conduit 170 and leg member 98, 100. To position tank base 92, the conduits 170, may be moved along leg members 98, 10(1. C",onduits 170 are attached to leg members 98, 100 using :;lotted pins 186 in substantially the same manner as described above for attaching strut 118 to leg members 98, 100, with the additional step of inserting leg extensions 114 or caster plugs 804 before inserting pin 18(i.
WIIPPtC
Refernng to Figures 40, 41, 42 and 43, wheels 94 may be attached to legs 98 and 100 of a support member, such as support member Ei4. Each wheel 94 is attached to a leg member 98 or 1.00 in substantially the same manner. 'The description of the attachment of wheel 94 to leg member 98 applies to the attachment of other wheels 94 to other leg members, such as leg member 78.
Wheel 94 may attached to leg rrmmber 98 using an axle, such as axle pin 814, inserted through hole 800 in leg member 98. This may be the same hole used to retain caster plugs 804 20892747.2 and leg extensions 114. Once attached, wheel 94 may freely rotate about axle pin 814 to facilitate moving of barbeque 60, as described above.
Wheel 94 is attached to leg member by first inserting an end 816 of axle pin 814 into an ;axial bore 818 passing through wheel 94. Once inserted through bore 818, end 816 is received lby entry 800a, passes through the void in the hollow leg member 98, and extends through the exit of hole 800 hole. Further insertions of axle pin 814 is inhibited by a circumferential shoulder 820 which has a larger diameter than entry hole 800a, and abuts leg 98 or 100.
Wheel 94 is retained by axle pin 814 with an axle head 822 at an end of axle pin 814 opposite to insertion end 816. Head 822 is larger than hole 8(?0. The displacement along axle 814 between shoulder 820 sand head 822 is preferably marginally ;greater than the length of bore 818.
This permits free movement of wheel 94 about axle 8 I4, while discouraging binding of the walls of bore 818 on .axle 814.
Referring additionally to Figure, 42, axle 814 may be secured in place with an axle ~~ecuring apparatus such as an axle locks 824. Axle lock 824 has a body 826 that is preferably ~~imilar in shape to caster plug 804 but has a transverse, generally C-shaped channel 828 at an ~~nd thereof for engaging a securing povrtion 830 of axle pin 814. Securing portion 830 is located lbetween end 816 and shoulder 820 of axle pin 814. Because channel 828 is C-shaped it lpreferably forms a snap fit with axle pin 814.
Axle lock 824 is attached by first inserting C-shaped channel 828 into the void of hollow leg member 98. The C-shaped channel is aligned and brought into contact with securing portion ?0892747.2 830 of axle 814. As increased force is applied to axle lock 824 to urge securing portion 830 into channel 828, resilient edges 832 of channel 828 part to permit securing portion 830 to enter channel 828. Resilient edges 832 then return to their initial position to retain securing portion 830 within channel 828. To further inhibit movement of axle pin 814 along its longitudinal axis, securing portion 830 may be provided with a groove in the nature of a circumferential groove 834 that receives a stop in the nature of an arcuate rib 836 of channel 828.
Axle lock 824 is preferably constructed from a resilient plastic or metal. If axle lock 824 is made of a plastic them body 826 may have a cross-section marginally larger than the cross-section of the void in leg member 98 so that axle lock 824 may be better retained therein. As the marginally larger axle lock 824 is inserted into the void of leg member 98, edges 832 of the void entrance preferably engage and peel back or otherwise remove peripheral portions of body 826 before it is able to enter the void. While this installation may require added force to be applied to axle lock 824, it may lead to a more precise mating of the axle lock 824 and the void.
As illustrated in Figures 43A arid 43B, alternative axle locks, such as axle lock 824', may be configured to fit voids in legs 98, 100 having alternative cross-sections such as a rectangular cross-section.
If wheel 94 is attached to a leg member 98 or 100 which also supports tank base 92, then axle pin 814 is installed in a manner similar to that described above for attachment of the leg c;xtension 114 and caster plug 804. In particular, axle pin 814 is inserted additionally through <':0892747.2 conduit entry hole 174a and exit hole 17~4b to also retain conduit 170 about leg member 98 or 100.
Wheel bore 818 may be protectc:<i to some degree from dirt and other matter that may interfere with the rotation of wheel 94 about axle pin 814. For example, a cover in the nature of a~ circular hub cap 838 may be attached to head 822 of axle pin 814 to inhibit passage of matter t~etween axle 814 and bore 818. Head 8'?2 may have a circumferential flange 840 for c,ngagement by a hub cap clip 842 having two or more arms 844 which protrude from a side of hub cap 838. Arms 841 extend in the same general direction, normal to the plane of hub cap 838, and may have protrusions 846 at their distal or free ends 848 for engaging flange 840 of head 822. Arms 844 may be located to engage flange 840 while being generally equidistant from one another and generally equidistant from the axis of hub cap 838. Free ends 848 are preferably resilient to permit grasping of flange 840, as described below.
Hub cap 838 may be attached to head 822 by bringing free ends 848 into alignment with the periphery of pin head flange 840. The protrusions 846 extend from free ends 848 generally toward the axis of hub c:ap 838, and inhibit passage of flange 840 therebetween. In this orientation the axes of axle pin 814 and hub cap 838 are generally collinear.
A force may be applied to hub cap 838 in the direction of axle pin 814 and along its axis to cause free ends 848 to bend away from each other as protrusions 846 pass over flange 840. Once protrusions 846 clear flange 840, resilient ends 848 return to their initial shape and protrusions 846 are adjacent to or abut a side of flan,~e 840 to inhibit hub cap 838 from being separated from axle 814. To further inhibit passage of matter betwecw axle pin 814 and bore 818, hub cap 838 may have at 20892747.2 least one circumferential flange 850 for engagement by a corresponding circumferential groove 852 of wheel 94.
All components of barbeque fi0, as described above, are preferably made of weather resistant material and/or heat resistant material, as appropriate.
Assembly The following generally describes the preferred steps that a consumer would be required to follow to assemble a barbeque 60. In many cases the order of these steps may be varied from that described, but to substantially the same effect as the preferred order.
Particular details regarding the assembly of components may be found in the appropriate descriptions above. To minimize the skill required for assembly and to eliminate the need for any tools, a number of components may be pre-assembled b~;f~re they are made available for purchase by consumers.
For example, bridging members 102 and 104 may be welded to legs 98 and 100, and beam connection members, such as beam cormection member 116, may also be pre-assembled to legs ~)8 and 100 to form ladder-like supports 62 and 64. Control valves 730 and 356 may be installed within console body 734, handle 582 m.ay be attached to upper casting 76, and wheels 94 and casters 96 (or leg extensions 114) may be attached to legs 98 and 100. While a partially pre-assembled barbeque 60 may occupy a greater volume than a conventional unassembled barbeque, the potential corresponding increase in labour and shipping costs, will generally be nominal.
2.0892747.2 In the preferred method of assembly of barbeque 60, the ladder-like supports 62 and 64 ~~re placed on a generally level surfacewith free ends 204 and 206 of supporting portion 340 and 1.98 pointing generally upwards. Shelves 68 and 70 may then be assembled thereon in the manner described above to form a snap fit. A snap fit may be achieved by manually exerting a force in a generally downward direction at an edge of the shelves 68, 70 opposite the direction of insertion D. If applicable, shelf frame :I72 and or burner frame 436 may be similarly installed.
Support members 62 acrd 64 may then be oriented on the .flat surface with base ends 110 and 112 pointing upwards with support members 62 and 64 supported by shelves 68 and 70. Beam receptacles 84 and 86 may then be oriented towards each other. Ends 92 of cross beam 66 may be inserted into the respective receptacles 84 and 86 with the threaded bushings 102 of cross team 66 aligned with holes 100. Holes 100 receive screws 96, which may be inserted in a generally downward direction, and which may be manually tightened to secure beam ends 92 to receptacles 84 and 86, i:n the manner described above. The rigid three-sided structure, having two ladder-like supports 62 and 64, ancf a cross beam 66, may be re-oriented so that the support members 62 and 64 rest on their base ends 110 and 112 (or wheels 94, casters 96, and/or leg extensions 114, if pre-assembled). If'shelves 68' and 70' are configured with removable tray members 370, the removable members 370 may be placed within frames 372 and encouraged to frictionally or snap fit within frame 372 by application of a downward force thereon when they ~u-e aligned within frame 372. If a gravity fit is used, the removable members 370 need only be placed within frame 372 in a downward direction.
Front panel 72 may then be assembled between support members 62 and 64. In the present state of assembly, there may be some play in supports 62 and 64. This play permits 20892747.2 425U2i7 bridging members 102 and 104 to be moved away from one another. The displacement of bridging members 102 and 104 permits mounting pins 546 to be consecutively mounted into their respective mounting holes 550 in the leg members 98 and 100. Support members 62 and 64 may then be returned to their original position to retain pins 546 in holes 550. Once the pins 546 acre located, panel 72 may be pivoted about pins 546 into position as mounting clips 552 are <.snapped in place onto their respective legs 98 and 100.
Alternatively, front panel 72 may be installed by concurrently sliding both clips 552 onto legs 98 and 100. Clips 552 may then be slid into place and mounting pins 546 can then be inserted into their respective holes 550. This mounting method for panel 72 may be preferable over the former method if the clip 552 is mounted at a mid-point of clip 552, making it difficult to bend a free ends 556 of clip 552 sufficiently to permit passage of leg member 98, 100 into clip '.i 52.
The next step in assembling barbeque 60 is attaching console 86 to the bridging members '.102 and 104 in the manner described above. In particular, the console 86 is placed onto tabs 750 and 752 so that slots 764 receive a corresponding tab '750 and 752. Bolt 774 may then be secured by manually inserting it into hale 772 and tightening it in threaded bore 770. In the preferred orientation of bore 770, bolt '~ 74 may be installed horizontally.
This step may be alternatively be completed after installation of the lower casting 68, or any of the components thereof.
x:0892747.2 _ 87 _ Tapered guide posts 620 of lower casting 68 may then be aligned with and inserted into guide bores 622. The lower casting (i8 may be retained by a generally downward insertion and manual tightening of bolts 254 through casting bores 258 and into threaded bores 256. If post 612' is used then nut 610' is tightened an to post 612' in a generally downward direction. Burner 80 may then be installed in the manner described above. In particular, burner 80 may be placed within lower casting 68, and free ends 6'74 of each duct 672 are inserted through separate burner duct passages 316 and 318. Support members 646 are then inserted and secured within openings ~i58 by applying a generally downward farce to form a snap fit with lower casting 68.
If not pre-installed, the components of the ignition assembly may be installed by i°astening, for example with bolts or screws, the igniter activation assembly 690 to the concave side of console 86. Igniter activation knob 692, is attached to igniter activation assembly 690 from the convex side of console 86. Tlie igniter activation assembly 690 is then connected to igniter 688 via igniter wire 694. Igniter 694 may be clipped or otherwise attached to burner 80.
In the next step of assembly of lbarbeque 60, support struts 704 are placed onto fins 706, and one or more openings 702 of angled bars 88 are placed over locating tabs 346 of the support struts 704. One or more grill plates 82 may then be placed to be supported by ledges 718. The hinge bolts 572 of upper casting 76 are aligned and slidingly engaged with receiving members 574 and 576 of the lower casting 68, and may then be retained by clip 578.
Cantilevered warming rack 84 may then be installed by inserting mounting pins 722 into mounting pin holes 'l24 located in upper casting 76. Once the pins 722 are inserted, toes 726 of warming rack support legs 408 may be inserted into toe holes 728 or may rest in rebates (not shown) located in :!0892747.2 _ 8g _ edges 240 of lower casting 68. If not pre-installed, handle 582 may be attached through holes >90 in upper casting 7E1, using hand tightened bolts 588, and temperature gauge 594 may be attached through holes 595 in upper casting 76, using hand tightened wing nuts 592. If applicable, shelf tray 3'70, shelf slats 4(18, and/or the elements of burner 222 or 222' may be attached in the manner described above;. Finally, tank 90 may be placed in base 92, and attached t:o a fuel connector, which is tightened manually. If an alternate fuel source is used, this may be attached to control valves 730, 732.
As will be noted from the abovt~ description, the method of assembly described above permits most of the barbeque components to be conveniently installed from a generally top down or horizontal direction. Installation of components requiring fastening from a bottom up direction is limited.
It will be understood by those. skilled in the art that this description is made with reference to the illustrative embodiments and methods, and that it is possible to make other embodiments and to make use of other methods, while employing the principles of the invention 1 S ~Nhich fall within the spirit and scope thereof: For example, various embodiments of a barbeque of the present invention may include different combinations of the alternative embodiments of i:he component parts thereof.
:!0892747.2

Claims

CLAIMS:

What is claimed is:

1. A barbeque assembly comprising:
support structure for a barbeque grill housing, said support structure having:
first and second support members for supporting said grill housing in a generally horizontal orientation;
a cross beam;
a connector for manually connecting said cross beam at a first end to said first support member and for manually connecting said cross beam at a second end to said second support member, the first and second support members and connection member farming a substantially rigid structure.