CA2435868A1

CA2435868A1 - Barbeque assembly

Info

Publication number: CA2435868A1
Application number: CA 2435868
Authority: CA
Inventors: Stuart T. Mckenzie
Original assignee: Fiesta Barbeques Ltd
Current assignee: Wolfedale Engineering Ltd
Priority date: 2003-02-05
Filing date: 2003-07-23
Publication date: 2004-08-05
Also published as: WO2004069015A2; WO2004069015A3

Abstract

A barbeque grill assembly includes a grill housing and a support structure therefor that may be readily assembled. The support structure includes supports or legs which maintain the grill housing in a generally horizontal orientation. A base stabilizes the structure, and locates and supports a fuel container, such as a liquid propane tank. Similarly, a readily installable cross piece or bridging member stabilizes the barbeque support structure and supports the grill housing. The grill housing includes a unitary grill that has an integrated warming rack. A
simplified fuel conduit of the assembly provides a manually mountable passage between a valve or fuel source and a burner. The assembly also includes a removable condiment rack which may be conveniently added or removed from the structure, as required.

Description

Agent Ref: 42502/49 BARBECUE ASSEMBLY
FIELD OF THE INVENTION
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 INVENTION
To reduce manufacturing, shipping and storage costs, harbeque grill manufacturers often ship unassembled barbeques to retailers for subsequent assembly by consumers.
While some manufacturers 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 grill housing, a heat source (such as a burner), a grill and warming rack, shelves, a side burner, a console with valves for regulating the flow of fuel to the burner, and a structure for supporting the grill housing.
Following assembly of the various barbeque components, a fuel source is typically connected to the barbeque. The fuel source may be a tank containing pressl:lrized propane, which should be safely positioned and secured to the barbeque support structure.
Fully assembled barbeques are sometimes 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 a fully assembled barbeque generally requires a larger shipping carton and therefore occupies a greater volume when shipped. As a result, fewer barbeques may be shipped at a time, leading to increased shipping costs. Even a small reduction in the volume required to ship a barbeque assembly can result in significant shipping cost savings. Shipping 21170453.2 _ 1 _ Agent Ref: 42502/49 fully assembled barbeques can also impose a cost on manufacturers because increased labour costs may be incurred to pre-assemble the barbeques before shipping.
In an attempt to reduce shipping, storage and packaging cost;>, barbeque assemblies are frequently shipped in disassembled form. Consumers or end users must perform any required assembly. Accordingly, any further reduction in the disassembled volume of a barbeque assembly can result in cost savings fox a manufacturer. fIowever, a reduction in volume is often correlated with an increase in the number of barbeque components that must ultimately be assembled by an end user. An increase in the number of components, including fasteners, that must be assembled by a consumer may increase chances that an assembling error will be made by the consumer. Such an error may lead to a malfunction of the assembled barbeque, which could cause personal injury or property damage.
Assembly of a barbeque often requires the use of common tools such as screwdrivers and wrenches. 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. If the demands of the assembling task are increased, then consumer frustration may also increase.
One barbeque component that can require assembly by a consumer is a warming rack.
Some warming racks are pivotally attached between the upper and lower grill housings so that they move as the grill housing is opened and closed. These interconnected moving parts can eventually wear or become misaligned following a period of use. Thus barbeque components that are subject to wearing because they move can also contribute to consumer dissatisfaction.
As such, there is a need for a simplified assembly system for a warming rack.
21170453.2 _ 2 _ Agent Ref: 42502149 Side burners are also typically assembled by consumers. Some side burners include a burner element connected to a valve via a venturi that introduces air to a fuel stream from the valve. The venturi is typically placed about an end of the valve, and is fixed at an opposite end to the burner element. The valve is connected using a tube to a fuel source, either directly, or via the console. In either case, multiple connections are required to ultimately join the side burner to a fuel source. Additionally, the connection between the venturi and the valve is not secured. As such, there is a need for a simplified assembly system for side burners to facilitate making secure positive connections to a fuel source.
Safety is also a consideration in the design of a barbeque assembly. For example, regulations in some jurisdictions provide for the positioning and retention of the fuel source, such as a liquid propane tank. Many barbeques strictures known in the art consist of a level shelf for supporting the propane tank. While fixtures are sometimes provided to encourage the location of the tank in a safe position, the tank may often be placed by the consumer at any location on the shelf. This could result in the tank being placed in an undesirable location, or placed contrary to safety standards.
Also, many manufacturers of barbeques produce several different models to appeal to different consumer preferences, both in terms of features and cost. The production of separate models can increase manufacturing costs because the same type of component (e.g., a front panel) is configured differently for each model and therefore rr~ay need to be manufactured independently. Accordingly, there is a need for a simplified assemblying system which can still facilitate different barbeque configurations.
Based on the foregoing, it would be desirable to develop alternative barbeques that may a~n04ss.z _ 3 _ Agent Ref: 4202/49 be shipped in smaller volumes and manufactured inexpensively to reduce costs, but that may be readily and safely assembled by relatively unskilled consumers.
SUMMARY OF TI~IE INVENTION
According to one broad aspect of the present invention there is provided A
conduit for directing flow of a fuel between a fuel source and an burning element of a gas barbeque. The conduit includes a substantially rigid body for permitting passage of the fuel between a first end and a second end of the body and an air intake defined in a side of the body.
The first end has a feature mountable to an inlet of the fuel burning apparatus to permit passage of fuel between the conduit and the inlet, and the second end having a fastener for xigidly mounting the body to the fuel source.
According to a second broad aspect of the present invention, there is provided a brace for a barbeque assembly. The barbeque assembly has a grill housing and at least two supports for the housing. The brace includes a body, the body having a generally planar fuel container support area which is angled relative to a remainder of the body and a flange located in a peripheral area of the body. The brace also includes means for mounting the body between the supports so that the body is generally inclined relative to the grill housing.
According to a third broad aspect of the invention there is provided a receptacle for use in conjunction with a barbeque grill support structure. The support structure includes a panel mounted thereto by panel mounting means. The receptacle has a body defining a hollow, wherein an edge of the body defines an opening to the hollow, and a mount connected to the body, the mount being co-operable with the mounting means o:f the panel to locate the body adjacent the panel to partially obstruct the opening, the body and the panel together defining a z t »o4s3.z _ 4 Agent Ref: 42502149 container, the container being accessible though an unobstructed portion of the opening.
According to a fourth broad aspect of the present invention tl~lere is provided a grill for a barbeque having a grill housing and a burner located within the housing. The grill includes a generally planar cooking surface mountable to the grill housing, and a warming rack cantilevered from the cooking service, wherein the warming rack is generally parallel to the cooking surface.
According to a fifth broad aspect of the present invention, there is provided a bridging member for a gas barbeque assembly. The assembly has a grill housing and at least two supports for the grill housing. The member includes a generally planar body mountable to at least one support, the body defining a first hole therein, and means for mounting the body to the support; a first rib neck bolt for interlocking with a feature of the barbeqoxe assembly, the ribs engaging and being retained by edges of the first hole which inhibit rotation and removal of the bolt when the bolt is assembled therein. The member also includes a retainer attachable to a free end of the bolt, for retaining the feature after the feature is mounted to the bolt after the free end is inserted through an opening defined in the feature-According to a sixth broad aspect of the present invention there is provided a support member system for a barbeque assembly. The assembly has a grill housing and at least two support members for supporting the grill housing. The support member system includes a body mountable to the at least two support members, the body defining a hole therein at a location such that the hole is alignable with a corresponding hole in one .member of the at least two support members and the body having a feature located about the hole, and a fastener cooperable with the hole, the feature and the corresponding hole to secure the body to the one member, the fastener having a second feature located thereon, the second feature cooperating with the feature 21170453.2 _ 5 _ Agent Ref: 42502/49 of the body to restrict rotation of the fastener when the fastener is operatively engaged in the hole.
Other and further advantages and features of the invention will be apparent to those skilled in the art from the following detailed description of an embodiment thereof, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF TFIE DRAWINGS
For a better understanding of the present invention andl 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 a perspective view of a barbeque with a side burner and a fuel tank according to an embodiment of the present invention;
Figure 2 is a perspective view of a portion of the underside of the barbeque of Figure 1 showing the underside of the side burner;
Figure 3 is a perspective view of a fuel conduit for the side burner of the barbeque of Figure 1;
Figure 4 is an enlarged perspective view of the fuel conduit of Figure 3, additionally illustrating an air sleeve thereof;
Figure 5 is a partially isolated view of a valve associated with the side burner of the barbeque of Figure 1;
Figure 6 is an assembled view of the valve of Figure 5 and the fuel conduit and air sleeve of Figure 4 for the barbeque of Figure l;
21170453.2 _ ( _ Agent Ref: 42502/49 Figure 7 is an enlarged underside perspective view of a fuel conduit and the side burner of the barbeque in Figure 1;
Figure 8 is an isolated perspective view of the side burner of the barbeque of Figure l;
Figure 9 is an isolated perspective view of a burner mount end of a fuel conduit for the side burner of Figure 3 of the barbeque of Figure 1;
Figure 10 is a perspective view of the barbeque of Figure 1 with the fuel tank removed to show a base of the barbeque;
Figure 11 is an isolated top perspective view of the base of the barbeque of Figure 10;
Figure 12 is an isolated bottom perspective bottom view of the base of Figure 11;
Figure 13 is an isolated rear left side view of an attachf;d support member and base of the barbeque of Figure 1;
Figure 14 is an enlarged bottom left perspective view of an attached support and base of the barbeque of Figure 1;
Figure 14A is an isolated perspective view of a fastener for mounting a base to a support of the barbeque of Figure 1;
Figure 14B is a detailed perspective view of part of an alternative arrangement for attaching a leg to a base of the barbeque of Figure 1.
Figure I S is an enlarged bottom right perspective view of an attached wheel and base of the barbeque of Figure 1;
Figure 16 is an isolated top perspective view of a receptacle of the barbeque of Figure l;
Figure 17 is an isolated top rear perspective view of the .receptacle of Figure 16;
21170453.2 _ 7 _ Agent Ref: 42502/49 Figure 18 is an isolated top perspective view of a receptacle of Figure 16 and panel of Figure 17;
Figure 19 is an isolated rear perspective view of the receptacle and panel of Figure 18;
Figure 20 is a perspective view of the barbeque of Figure 1 with a hood removed showing a grill therein;
Figure 21 is an isolated perspective view of the grill of the barbeque of Figure 20;
Figure 22 is an isolated side view of the grill of Figure 21;
Figure 23 is side view of a bridging member and fasteners of the barbeque of Figure 1 wherein a number of elements of the barbeque have been removed for clarity;
Figure 24 is an opposing side view of an alternative embodiment of the bridging member and fasteners of Figure 23;
Figure 25 is an isolated top right perspective view of the bridging member and fasteners of Figure 24;
Figure 26 is an isolated top left perspective view of the bridging member of Figure 24; and Figure 27 is an isolated view of the fasteners of Figures 23 and 24.
DETAILED DESCRIPTION OF ILLITSTRATIVE EMBODIMENTS OF TIIE
INVENTION
In the figures, similar references are used in different figures to denote similar components. Referring to Figures I ; 2 and 10, aspects of a barbeque grill assembly 20 are shown. Assembly 20 includes a grill housing 22 which is mounted to a barbeque housing 21170453.2 _ g _ Agent Ref: 42502/49 support structure 24. The barbeque support housing structure includes one or more supports, such as legs 26a, 26b, 26c, and 26d (collectively xeferred to as supports 26;
support 26d is shown in Figure 2). Supports 26a and 26b, and supports 26c and 26d, respectively, each are bridged, or braced, by cross pieces 28 and 29, respectively. Cross pieces 28 and 29 also support grill housing 22.
Supports 26 are further stabilised by a brace in the natl~re of base 30, mounted therebetween. Base 30 may be used to support a fuel storage container such as a liquid propane tank 32. Tank 32 rests in tank support area 33 of base 30. Movement of tank 32 is inhibited by retainer 34. A fuel line 36 is located between tank 32 and valves 38a, 38b, and 38c (collectively referred to as valves 38). Valves 38 are preferably used to regulate flow of fuel carried in fuel line 36 to grill housing 22 and side burner 40. Valves 38 are mounted to a console 42, which is attached to respective ends of cross pieces 28 and 29. A fuel conduit 44, in the nature of a venturi conduit, directs the flow of fuel from valve 38a to side burner 40, which is located in a side burner shelf 46. A second burner shelf may be included in barbeque grill assembly 20.
Alternatively, a shelf 48 may be employed, as shown in Figure 1.
Further stabilisation of barbeque housing support structure 24 may be obtained by mounting a panel 50 between supports 26. For example, panel 50 may be mounted between supports 26a and 26c. A receptacle 52 for holding condiments, for example, may be mounted to the barbeque housing support structure 24. Receptacle 52 conveniently co-operates with panel 50 when it is mounted adjacent thereto to inhibit lateral movement of items such as condiments supported by receptacle 52.
Wheels 54 are preferably be added to barbeque housing support structure 24 to facilitate 22170453.2 _ 9 _ __.. _.____ __. . .__.~.. , ,_e.< ,.~,~e ~.-,-,~4.. ~~_~...~.r~___~r~~ ~ --,~~~.._ .___..._.__._.__._.._____.

Agent Ref: 42502/49 movement of barbeque grill assembly 20 to alternate locations, Referring to Figure 2, fuel conduit 44 spans valve 38a and burner 40.
Referring additionally to Figure 3, fuel conduit 44, may have one or more angles or bends, such as bend 55 therein. These bends or angles portions permit a fuel source mount end 56 to align with valve 38 (or some other fuel source), and a burner mount end 58 to align with burner 40. The particular location of any bends or curves is dependent upon the geometry of an associated fuel inlet and burner. For example, if valve 38a and burner 40 were linearly aligned, then fuel conduit 44 may be straight, having no bends 55.
Referring to Figure 4, fuel source mount end 56 has an air intake 62 adjacent thereto to permit mixing of fuel with external ambient oxygen. Air intake 62 has an air sleeve 64 associated therewith. Air sleeve 64 has a number of perforations 65 for permitting the passage of external ambient air and inhibiting the passage of undesirable harticul.ate, such as insects. Fuel source mount end 56 includes a fitting assembly 66. Fitting assembly 66 is used to rigidly mount fuel conduit 44 to valve 38a so that burner mount end 58 is located to provide fuel to burner 40.
Fitting assembly 66 includes a retainer in the nature of a nut 67. Nut 67 has an internal diameter dimensioned to cooperate with fuel source mount end 56 enabling nut 67 to be slidingly engaged with fuel source mount end 56, and to be rotatable relative thereto so that it may engage cooperating threads therein.
To manufacture fitting assembly 66, nut 67 is slid over fuel source mount end 56 and an inhibitor 68 is applied to inhibit removal of nut 67 from fuel source mount end ~6, while permitting at least rotational movement thereof As shown in Figure 4, the inhibitor is in the nature of a flared end 68 of fuel source mount end 56. Flared end 68 abuts an internal rim 69 of 21170453.2 ° 1 p Agent Ref 42502/49 nut 67 to inhibit the removal of nut 67.
Referring to Figures 4 and 5, valve 38a has an outlet 70 defined by a male feature or spud 72 for insertion into an inlet 71 of conduit 44. Spud 72, while not essential, serves to inhibit movement of conduit 44 relative thereto. Outlet 70 also has a complimentary fitting to co-operate with fitting assembly 66 to mount conduit 44 to valve 38a. This fitting may be in the nature of female threads 74 about outlet 70 for engaging threads of nut 67.
Referring to Figure 6, to install conduit 44, outlet 70 and inlet 7I are aligned and nut 67 is tightened over female thread 74. I~lut 67 may be knurled or have some other feature for facilitating manual or hand tightening thereof.
Referring to Figures 7 to 9, burner mount end 58 abuts and is retained to burner inlet 75 to permit fuel to pass between conduit 44 and burner 40. Burner 40 is mounted to shelf 46 by a mounting feature in the nature of a burner mount 76. Burner mount 76 may include a stud or post 78, which is welded or otherv,~ise attached to a base 82 of burner 40. A
portion of post 78 may be inserted through a hole defined in shelf 46. Once inserted, the portion is held in place by a retainer, such as nut 80.
More particularly, referring to Figures 8 and 9, to inhibit fuel From escaping from the interface between burner mount end 58 and inlet 75, burner mount end 58 may be dimensioned to fit within the interior perimeter of burner inlet 75. This permits burner mount end 58 to be inserted therein. To mount burner mount end 58 to burner 40, a feature in the nature of a protrusion or flange 86 is crimped, welded or otherwise attached to burner 40.
In a preferred method for attaching burner mound end 58 to burner 40, burner mount end 58 is inserted into burner inlet 75. End 58 is then preferably flared to make a flange such as flange 86, and crimped 2moas3.a - 11 -Agent Ref: 42502/49 to a base portion 82 of burner 40. A cup portion 84 of burner 40 is then crimped or otherwise mounted to burner base 82, the cup 84 and base 82 co-operating to form burner 40. Burner mount 76 thus secures end 58 of fuel conduit 44 via burner base 82. Flange 86 may be added to, or formed integrally with, fuel conduit 44.
Burner mount end 58 may be configured to have a shape, such as a non-round shape, and burner inlet 75 may be correspondingly dimensioned, so that rotation of burner mount end ~8 within burner inlet 75 is further inhibited. For example, mount end 58 and inlet 75 may have an n-sided polygonal shape as shown in Figure 9.
Fuel conduit 44 is installed by installing burner 40, ali~ming fuel source mount end 56 with valve 38a, and tightening retainer 80. ~nce fuel conduit 44 is al'~igned, nut 67 may be tightened to secure fuel conduit 44.
Fuel conduit 44 is preferably made of a fire-resistant material, such as a metal. It is also rigid so that it may be mechanically retained while maintaining a secure and direct connection between a fuel source (or a valve) and a burner. This arrangement permits the convenient location of valve 38a on console 42, instead of on shelf 46. Additional tubing is therefore not required to connect valve 38a to either the console or fuel tank. 32. Fuel conduit 44 is also secured at both ends, which permits it to span a greater distance to burner 40 than if it were merely in abutting relationship with valve 38a, as bs the state of the prior art. The described arrangement also attempts to reduce the number of connections and parts required to provide fuel to a burner from a fuel source (or valve). In the present embodiment., only one connection needs to be made when mounting fuel conduit 44 to barbeque grill 20.
It will be appreciated that the particular fittings described in the present embodiment such 21170453.2 - 12 Agent Ref: 42502/49 as fitting assembly 66, may have connection fittings, such as the malt; and female parts reversed.
For example, nut 67 could be included on a flared outlet similar to outlet 70, for attachment to a threaded fuel source mount end similar to fuel source mount end 56. ~ther connection arrangements may also be used.
Now, aspects of a base of the barbeque 24 are illustrated. Ilelrerring to Figures 10 to 12, a brace in the nature of a base 30 is mounted between at least two, and preferably all, supports 26.
Base 30 has a fuel container or tank support area 33 for supporting a portion of a fuel storage container 32. Support area 33 is pl°eferably generally planar, having a feature, such as a protrusion 90, for abutting tank 32 to inhibit lateral movement thereof.
Further, support area 33 is planar, but it may be angled do~Tnward towards the middle of base 30.
Protrusion 90 is preferably configured to abut a lower rim 92 of container 32 (Figure 1) or other feature of container 32. As is best shown in Figure 1 l, protrusion 90 comforms to a fit against an exterior portion of lower rim 92 and abuts lower rim 92 when it is placed thereagainst.
An additional protrusion in the nature of a locating nub 94 may be added to, or integral with, base 30. Locating nub 94 is preferably spaced from protrusion 90 by at least a thickness of lower rim 92. Lower rim 92 then may be placed between locating nub 94 and protrusion 90 to inhibit lateral movement thereof. While nub 94 may be formed in base 30, for example by stamping, it is manufactured as a separate piece in the present embodiment. As shown, nub 94 has a head and a shaft. The shaft is inserted into a hole defined in base 30, and is maintained in place by a retainer (e.g., a nut) or in some other manner.
Tank support area 33 is preferably located at an end of base 30. When tank 32 is mounted therein, tank 32 is located at a fixed, spaced distance from grill housing 22 (which contains at least one burner element; not shown) and side burner 40. This arrangement serves to 211'70453.2 _ 13 Agent Ref: 42502/49 comply with the safety regulations of some jurisdictions, which mandate that a fuel source and a burner of a barbeque grill assembly be located at specific spaced distance to each other. Further, the location of tank 32 in tank support area 33 is encouraged by a pre:Eerred orientation of base 30 when it is mounted to supports 26. As shown in Figures 1 and 10, base 30 is preferably mounted so that it is generally laterally inclined relative to the grill housing, and consequently, relative to the ground. When base 30 is so mounted, support area 33 will be les s offset from ground level.
Such a preferred orientation is further encouraged by having rr~ounting holes 108 and 112 arranged in a plane which is slightly offset from vertical in a direction away from support area 33. This inclined assembly discourages placement of fuel storage container 32 in an area other than in tank support area 33, because an alternative generally Level surface is not provided in base 30 for supporting fuel tank container 32. The generally inclined orientation of base 30 may also provide increased lateral support to barbeque rotating support stricture 24.
Base 30 is made of a single generally rigid piece of material. 'This rigidity can serve to stabilise any barbeque assembly components attached thereto, such as supports 26. While base 30 may be moulded from a plastic or other material, it is preferably stamped from a single sheet of metal such as a deep drawn or double deep drawn cold rolled steel.
To increase the rigidity of the sheet, raised areas or deformations such as embossments 96 may be added or stamped therein. To increase longitudinal rigidity, raised portions 96 preferably extend centrally and longitudinally of the base 30. l~,ateral reinforcement may also be obtained by including raised portions in a non-longitudinal direction. In the present embodiment, raised portions 96 extend longitudinally and then merge into a generally arcuate shape to both reinforce tank support area 33, and to define protrusion 90.
raised portions may additionally be tapered or ramped to further increase rigidity of base 30.
Additional 2117043.2 - 14 -Agent Ref: 42502/49 reinforcement may be obtained, and material may be saved, by constructing base 30 to have one or more non-linear, and preferably inwardly arcuate, sides 98a and 98b.
Further strengthening of base 33 may be obtained by including a rib or flange, such as flange 102.
While flange 102 may be added to base 30, it is preferably stamped integrally therewith to reduce the need for welds in the barbeque grill assembly 20. Flange 102 is preferably located adjacent a perimeter of base 30, and preferably extends about the entire perimeter of base 30.
Now, further detail is provided on mounting arrangements of base 30. Referring additionally to Figures 13 to 15, base 30 may be mounted to supports 26 using one or more fasteners 104, located adjacent tank support area 33, and one or more fasteners 106 located adjacent an end of base 30, generally opposite to tank support area 33. While base 30 may be attached to supports 26 by welding or some other permanent ataachmE;nt, a releasable fastener is preferably used so that barbeque grill assembly 20 may be conveniently packaged disassembled, to reduce packaging required, and then assembled and disassembled a.s needed.
Fastener 104 may include a bolt, such as a carriage bolt, and a retainer in the nature of a wing nut. Fastener 104 is preferably configured for manual or hand tightening.
Flange 102 has at least one hole 108 for receiving fastener 104. Similarly, an associated support, such as support 26b, defines at least one hole 109 for receiving fastener 104 as well. ~fhe bolt is inserted through holes 108 and 109, and is retained by the wing nut. A pronged spacer 111 may be used to inhibit rotation of support 26 relative to base 30. Pronged spacer 111 has dowel-like protrusions 113 (see Figure 14A) projecting therefrom. These protl-usions 113 are received by holes such as holes 109 and 108 of support 26 and base 30, respectively. As the wing nut of fastener 104 is tightened, protrusions 113 are held in place in both holes 109 and 108 to inhibit shearing 21170453.2 - 15 _ Agent Ref 42502/49 movement of support 26 relative to base 30.
Fastener 104 may alternatively be a wing bolt having tlhree prongs (not shown) therein.
The three prongs would be inserted through holes 109 and 108 with the middle prong being retained by a wing nut, for example. Base 30 or support 26 could alternatively have integral or extruded protrusions, similar to protrusions 113. An example of such.
protrusions are labelled I I3' in Figure 14B. To assemble base 30 to support 26, the protrusions are inserted through holes 109 and 108, with a carriage bolt and wing nut securing 'the connection.
Referring in particular to Figure 14, fastener 106 is used to mount base 30 to a different support 26 in a similar manner as described for fastener 104. Fastener 106 is preferably configured for manual or hand tightening. Holes 115 located in support 26 are positioned to encourage base 30 to be inclined, as described above. At least one of holes 115, such as hole 115a, may be non-round to inhibit rotational movement of a similarly configured retainer. Holes 109 and 115 may be included in thf: same support member 26 so that the support member may be used to mount either end of base 30 thereto. This configuration permits multiple uses for a support.
As best shown in Figure l5, fastener 104 may also be used to retain a wheel 54 to the barbeque housing support structure 24. It should be appreciated that additional holes 108 and 109 may be added to base 30 and supports 26 to enable base 30 to be attached to supports 26 at different locations as may be needed for a particular installation of barbeque grill assembly 20.
The arrangement described above can reduce the munber of welds required to manufacture barbeque grill assembly 20, because base 30 may be stamped from a single sheet of material. The use of removable fasteners, such as fasteners 104 and 106, permits barbeque grill 2a mods~.2 - 16 Agent Ref: 42502/49 assembly 20 to be shipped in unassembled form, which may reduce the amount of packaging required for shipping.
Turning now to Figure 16, details of a receptable for barbeque 20 are provided. As shown, receptacle 52 has a portion in the nature of bottom 116 for supporting items stored therein. Receptacle 52 also has three sides 118 which co-operate with bottom 116 to form a four-sided partial enclosure. Sides 118 could be formed as one continuous side in the shape of an arc or some other shape that would cooperate with bottom 116 to create a partial enclosure.
Sides 118 terminate at free edges 120. Similarly, bottom 116 terminates at a free edge 122 thereof. Bottom free edge 122 may additional include a flange 138 for providing rigidity to bottom 116 and for providing support to clip 134.
As best seen in Figures 17 and 18, side edges 120 and bottom 116 together define an opening in the shape of a portion of panel 50. As best shown in Figure 18, when receptacle 52 and panel 50 are aligned with panel 52 located to abut bottom 116 and to span free edges 120, then bottom I 16, sides 118, and front panel 50 cooperate to form a five-sided partially enclosed container, shelf or rack for the convenient storage of items such as condiments and barbeque grill accessories (not shown). In this configuration, sides 118 and panel 50 together define the boundary of an opening 123 which provides access for placement and removal of items in receptacle 52. It will be appreciated that the particular shape of the receptacle is not limited to the present embodiment. Other shapes that are convenient for the storage of barbeque-related items may also be used. For example, a receptacle having one continuous, generally spherical side, forming an enclosure and having an opening, could also be used, with panel 50 completing the side thereof. Sides 1 I 8 may further be provided with a rim 124 for added strength about 21170453.2 _ I'~ "

Agent Ref: 42502/49 opening 123.
Panel 50 is preferably generally planar and serves to stabilize barbeque housing support structure 24. Panel 50 is mounted between adjacent supports 26, and may be made of plastic, metal or some other appropriate material.
Mounts 126 for receptacle 52 are provided adj scent free terminal edges 120.
Mounts 126 cooperate with a fastener which may be in the nature of a carriage bolt assembly 130, that is also used to attach panel 50 to supports 26. The fastener is preferably configured for manual or hand tightening. In this configuration, the same fasteney-s are used t~o mount both front panel 50 and receptacle 52, which can help to reduce the number of parts required for barbeque grill assembly 20. This co-operation between panel 50 and receptacle 52 permits receptacle 52 to be added to or removed from barbeque assembly 20, as needed. For example, one model of barbeque assembly produced by a manufacturer could include a receptacle 52, while another model may not. Since the configuration and mounting of the panel 50 is essentially the same in either case, only one version of panel 50 would need to be manufactured for both models of barbeque assembly. Furthermore, the same carriage bolt assembly 130 that is used to mount panel 50 to barbeque assembly 20 can be used to optionally mount receptacle 52, as well.
Mount 126 may include a flange 128. Flange 128 may be angled to conform to an exterior of shape of support 26. Support 26 may be any convenient shape, having a cross-section, for example, that is round or rectangular. In the present embodiment, supports 26 have a rectangular cross-section. Accordingly, flange 128 has a right angle formed therein for abutting support 26. Carriage bolt 130 is inserted through a hole (not shown) in flange 128. It is then inserted through a hole passing through support 26 (not shownl, and a hole defined in front panel 21170453.2 _ 1 g Agent Ref 42502/49 50 (not shown). Carriage bolt 130 is held in place by a retainer, which may be in the nature of a wing nut 132. When wing nut 132 is tightened to carriage bolt 130, then flange 128, support 26, and panel 50 are mounted to one another. Mount 126 may additionally include a clip 134 to further retain receptacle 52 to support 26. Clip 134 may be configured as a resilient finger having a toe 136 for engaging a portion of support 26. In the preferred embodiment, angled flange 128 abuts two sides of support 26, and clip 134 abuts the other two sides of support 26 so that at least a portion of each side of support 26 is retained by the combined clip 134 and flange 128.
Receptacle 52 is preferably made as a unitary molded product. For example, it may be injection molded from a resilient plastic. Any resiliency in the plastic material can permit free ends of angled flange 128 and clip 134 to be manually bent away from one another to permit support 26 to be located therebetween prior to carriage bolt 130 being installed. Alternatively, receptacle 52 could be made as a metal part or welded or otherwise assembled from a series of some sub-components to achieve the functions described above.
The above-described cooperation between receptacle 52 and panel 50 permits receptacle 52 to be included with barbeque grill assembly 20 as an optional feature.
Unlike receptacles known in the art, which tend to be constructed integrally with an associated panel, the structural functionality of panel 52 is not lost by the removal of receptacle 52.
Now referring to Figure 20, aspects of a grill housing fir barbeque 20 are provided. As shown, grill housing 22 has upper grill housing or hood 140 removed to reveal grill 141 (hood 140 is illustrated in Figures 1 and I0). Grill 141 is mountable to lower grill housing 143, having a burner or other heat source located therein (not shown). Grill 141 relay be mounted to lower 21170453.2 - 19 -Agent Ref: 42502/49 grill housing 143 in a manner known in the art. For example grill 141 may be supported by a ledge or tabs (not shown) of lower grill housing 143 and may be held in place by gravity or friction.
Referring additionally to Figures 21 and 22, grill 141 includes a cooking surface 142 and a warming rack 146, cantilevered thereto. Cooking surface 142 is made of a series of connected rods 144, but may alternatively be made of any material in a configuration that permits the transfer of heat from a heat source located within lower grill housing 143 to food items which are supported by cooking surface 142. For example, grill 141 could be made from a single sheet of metal, which may additionally have perforations therein (not shown). In the preferred embodiment, metal rods 144 made of cold rolled steel are preferably parallel and evenly spaced, to form cooking surface 142. Rods 144 are preferably interconnected by one or more transverse rods 145 attached thereto. Transverse rods 145 may be connected by welding or in any other suitable manner known in the art.
Grill 141 includes warming rack 146. Warming rack 146 pref erably is interconnected to cooking surface 142. Both cooking surface 142 and warming rack 146 are preferably co-planar so that they can support food products to be cooked or warmed. Cooking surface 142 and warming rack 146 are preferably generally opposed to one another and are generally parallel to one another. While warming rack 146 may have the same area as cooking surface 142 (provided that its size does not prevent hood 140 from closing), warming rack 146 is preferably smaller in area than cooking surface 142. This arrangement permits access to food products being cooked or warmed on cooking surface 142. Fox example, if warming rack 146 and cooking surface 142 were opposed and had the same area, then it could be difficult to access or tum food products 21174453.2 - 20 -Agent Ref: 42502!49 located on cooking surface 142.
Warming rack 146 is connected to cooking surface 142 via riser 148. As shown, riser 148 comprises a series of bars linking bars of cooking surface 142 with corresponding bars of warming rack 146. Riser 148 may be integral with cooking surface 142 and warming rack 146.
For example, riser 148 may be mounted between cooking surface 142 and warming rack 146. In the preferred embodiment, riser 148, cooking surface 142 and warming rack 146 are integrally formed.
The combined cooking surface 142, riser 148, and warming rack 146, preferably together have a generally U-shaped or J-shaped profile (see Figure 22). ThesE;
components may alternatively have some other convenient profile such as a C-shaped or a more arcuate shape.
Alternatively, riser 148 may be stepped or have some ather configuration that maintains warming rack 146 at a distance from cooking surface 142. This displacement attempts to reduce the amount of heat provided to food supported by warming rack 146 compared to food located in lower grill housing 143.
Grill 141 is preferably made from a generally planar unitary piece having transverse rods 145 at either end thereof. The unitary piece then has at least two bends 150 and 152 formed therein. Bends 150 and 152 may each form internal angles of 90 degrees. In the preferred embodiment, bend 150 has an acute internal angle and bend 152 has an obtuse internal angle so that warming rack 146 is generally parallel and opposed to cooking sl:lrface 142. Additional bends may be provided, as long as warming rack 146 is not too skewed relative to cooking surface 142 to cause food products to slide or otherwise fall the;refrom.. In an alternative embodiment (not shown), a single arcuate bend may be formed in a sheet of interconnected rods 21170453.2 _ 21 --Agent Ref: 42502/49 so that the grill has an arcuate C-shape or J-shape. A third bend 154, adjacent bend 152 may be included to inhibit food from rolling off warming surface 146, particularly when food is removed using a spatula. Third bend 154 also acts as a spring to increase stability and encourage resilient bending at bend 154.
It will be appreciated that the dimensions of warming rack 146 are determined by the number and length of rods 144 used. Rods 144 can include shorter rods 156 and longer rods 158.
For example, in the preferred embodiment, four rods 156 located to either side of the rods 158 (which are used to form warming rack 146) are shorter in length and only form part of cooking surface 142. The combination of rods 156 and 158 can be used to determine the area of warming rack 146. Similarly, if rods longer than rods 158 are employed, then warming rack can have a greater area.
Alternatively, the height of riser 148 can be adjusted b:y forming bend 152 at a different location. A longer riser 148 can be expected to reduce the heating of food products supported on warming rack 146, because warming rack 146 will be further from the heat source located in lower grill housing 143. In any embodiment or variation desca~ibed herein, the materials used for constructing grill I41 may be enamelled with porcelain.
Now referring to Figures 23 and 24, detail on a cross piece of barbeque 20 is provided.
As shown, a cross piece or bridging member 29 spans legs 26d and 2fic and inhibits movement thereof. Cross member 29 also supports grill housing 22, and console 42 (as seen in Figure 1).
Cross member 28 (Figure 24) is similar in function and configuration to cross member 29, but it differs in that it additionally supports slideable retainer 34 for tank 32., Cross member 28 also differs in that it does not include a rebate such as rebate 160 of cross member 29. A rebate, such 21170453.2 _ 22 Agent Ref: 42502/49 as rebate 160, may be added to a cross member to facilitate the location of other components of the barbeque assembly 20, such as conduit 44 (see Figure 2 for example).
Rebate 160 may be stamped from cross member 129, and is preferably rounded, or has a flange, to temper any sharp edge remaining after the formation of rebate 160.
Referring to Figures 25 and 26, cross piece 28 is shown in isolation. Please note that the description provided herein for cross piece 28 applies mutatis mutandis to cross piece 29, except as otherwise noted.
Cross piece 28 includes a generally planar body 162, having at least one hole 163 defined therein. Hole 163 receives fastener 164 for attachment to a feature of'barbeque assembly 20.
Fastener 164 is a bolt 166 having ribs 168 comprising longitudinal fins radially projecting in a spaced relationship from the shaft of bolt 166 and located about the base of bolt 168. In the preferred embodiment, bolt 166 is a 1/4-20 rib neck bolt having 11, 12 or 13 ribs. However, larger or smaller bolts having a greater or fewer number of rib: may also be used as appropriate.
Hole 163 is sized to have a diameter similar to that of bolt 166 (not including ribs 168). Bolt 166 is press fit to body 162. This is accomplished by inserting a free end 172 of bolt 166 into hole 163 until further insertion is inhibited by ribs 168. At this point, greater force is applied to the head 172 of bolt 166 to force ribs 168 to deform edges of hole 163 so that ribs 168 bite, grip, or are otherwise engaged with, the edge of hole 163. Bolt head 172 inhibits further insertion of bolt 166 into hole 163. Removal of bolt 166, or rotation thereof, is inhibited by the engagement of ribs 168 with the edges of hole 163. It is expected that consumers would not assemble bolt 166 to body 162 due to the added force required to insert bolt 166 and engage body 162. Instead, these two components would be preassembled. Bolt 166 may be alternatively mounted to cross piece 28 by welding (not shown). For example, a stud or bolt having point on its head may be 21170453.2 - 23 Agent Ref: 42502/49 projection welded to crass piece 28 about the points.
Once bolt 166 is retained within hole 163, a componer~l: of barbeque assembly 20 may be mounted to bolt free end 170, and may be retained by a retainer such as a manually tightenable nut 174. Nut 174 is threaded onto bolt 170. Figure 27 provides an isolated view of fastener 164, including bolt 166 and retainer I74. It should be noted that various fasteners, including fastener 164, are shown in Figures 25 and 26. They each are preferably configured for manual or hand tightening. Some of the fasteners are shown without their associated retainers, and some fasteners are shown having retainers mounted thereon. However, no components of barbeque assembly 20 are shown mounted by fasteners to cross piece 28 to more clearly illustrate cross piece 28 and its associated fasteners in situ. In assembled fornn, cross piece 28 would have components mounted thereto with retainers installed.
Referring to Figures 25 and 26, cross piece 28 includes a flange I76 formed in body 162.
Flange 176 orients fastener 164 to a desired orientation, and can be used to impart rigidity to body 162. One or more indents or dimples 178 may also be included along an interface or bend 179, which defines flange 176 in body 162.
Fastener 164 may be used to mount lower grill housing 143 to cross piece 28.
This is accomplished by inserting free end I70 of bolt 166 into a corresponding hole (not shown) defined in lower grill housing I43. Once inserted, free end I70 is retained by nut I74, which is attached thereto. Lower grill housing 143 may be further retained and mounted to cross piece 28 using one or more additional fasteners, such as fastener 180, having a configuration similar to that described for fastener 164.
Additional components of gas barbeque assembly 20 may also be attached to cross piece 21170453.2 _ 24, Agent Ref: 42502/49 28. For example, a fastener 181 may be used to slideably engage tank retainer 34 (see figure 24).
A transverse indent 182 may be included in body :162 to further reinforce body 162 and to provide a guide for tank retainer 34 as it is moved between engaged and disengaged positions (not shown) with a top of tank 32.
Body 162 of cross piece 28 may also include a flange X183 for engaging and supporting console 42. Flange 183 preferably has a similar profile to that of an interior surface of console 42 (not shown) so that there is limited play between console 42 and flange 183 when console 42 is mounted thereon. Due to the similar profile, flange 183 can act as a side of console 42. A
ridge 190 in flange 183 provides an abutting surface for an edge of flange 183 to further assist in locating console 42 upon flange 183.
A fastener 186 (illustrated in isolation in Figure 27) is used to secure console 42 to cross piece 28. Fastener 186 includes a retainer or nut 187 mounted to flange 183.
Nut 187 may be mounted by welding, for example, and is centered about a hole (not shown) defined by flange 183. Fastener 186 also includes a bolt 192 for insertion through a hole defined in console 42 and retention by nut 187. Bolt 192 is configured to be manually tightenable. For example, it may have a knurled surface to facilitate the gripping thereof.
In the preferred embodiment, cross member 28 spans and stabilizes supports 26a and 26b.
Cross piece 28 is mounted at both ends to supports 26a and 26b, respectively, by employing fasteners 194 and 196. Fasteners 194 and 196 are configured and provide a similar function as described for fastener 164. For example, a bolt 198 of fastener 194 is mounted to cross piece 28 as described above. Support 26a may then be mounted thereto by inserting a free end of bolt 198 into a hole defined through support 26a (not shown). Free end 200 is then engaged by a retainer 21 no4s3.2 - 25 Agent Ref: 42502/49 202 of fastener 194, and tightened to mount support 26a to cross piece 28.
Support 26b is similarly mounted to cross piece 28. It should be Doted that body 162 may alternatively be welded to supports 26a and 26b respectively. However, cross piece 28 is preferably mounted to supports 26a and 26b in the manner described above so that supports 26a and 26b and cross piece 28 may be disassembled, and therefore packaged or stored in a smaller volume.
Cross piece 28 may additionally include one or more tabs 204. Tabs 204 may be attached to or integrally formed in body 162. For example, tabs 204 may be stamped and bent from body 162. Tabs 204 are located and positioned to abut supports 26a. and 26b to encourage a preferred alignment of supports 26a and 26b relative to cross piece 28 when they are mounted to cross piece 28.
Body 162 may be made from any substantially rigid material, such as metal cold rolled steel. The area about the interface between the fasteners and cross piece 28 may be deformed to form bosses 206. Bosses 206 provide a greater land area to for the fastener ribs to grip cross piece 28. Bosses 206 also create a clearance for the fastener ribs so that when a fastener is tightened, it is more difficult for the ribs to go through a thickness of cross piece 28.
As will be noted from the above description, cross piece 28 permits the convenient manual attachment of various components of barbeque assembly 20, without requiring any welds. This can serve to reduce the cost of manufacturing such an assembly, and permits baxbeque assembly 20 to be stored, shipped, or packaged in a smaller volume.
By including the various fasteners such as fastener 164, as part of cross piece 28, generally fewer loose pieces are included in the disassembled barbeque 20, and fewer pieces need to be assembled by a consumer when putting barbeque assembly 20 together.
21170453.2 - 26 Agent Ref: 42502/49 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 which fall within the spirit and scope thereof. For example, various embodiments of a barbeque of the present invention may include different combinations of the embodiments of the component parts thereof.
27170453.2 _ 27

Claims

1. A conduit for directing flow of a fuel between a fuel source and an burning element of a gas barbeque, said conduit comprising:
a substantially rigid body for permitting passage of said fuel between a first end and a second end of said body;
an air intake defined in a side of seed body;
said first end having a feature mountable to an inlet of said fuel burning apparatus to permit passage of fuel between said conduit and said inlet;
said second end having a fastener for rigidly mounting said body to said fuel source.

2. The conduit of claim 1, wherein the horning element is a burner for a gas barbeque.

3. The conduit of claim 1, wherein the fuel source is a valve assembly.

4. The conduit of claim 1, wherein said first end is mountable to said burning element by crimping.

5. The conduit of claim 1, wherein said body is tubular.

6. The conduit of claim 3, wherein said fastener is a nut rotatably mounted to said second end, said nut being configured to engage threads of the valve assembly.

7. The conduit of claim 6, further comprising a retainer for inhibiting removal of said nut.

8. The conduit of claim 7, wherein said nut is knurled for manual tightening thereof to the valve assembly.

9. A brace for a barbeque assembly, the barbeque assembly having a grill housing and at least two support for said housing, said brace comprising:
a body, said body having a generally planar fuel container support area which is angled relative to a remainder of said body;
a flange located in a peripheral area of said body;

and means far mounting said body between the supports so that said body is generally inclined relative to the grill housing.

10. The brace of claim 9, further comprising an embossment for strengthening said body.

11. The brace of claim 9, further comprising an embossment for defining said fuel container support area.

12. The brace of claim 9, wherein said flanges are integrally formed by stamping.

13. The brace of claim 9, wherein said flange extends about an entire periphery of said body.

14. The brace of claim 11, further comprising a fuel container locating nub projecting from sand tank support area to cooperatively receive and inhibit lateral movement of an edge of the fuel container.

15. The brace of claim 9, wherein said mounting means includes fastener inserted through a hole defined in said flange.

16. A receptacle for use in conjunction with a barbeque grill support structure, the support structure including a panel mounted thereto by panel mounting means, said receptacle comprising:
a body defining a hollow, wherein an edge of said body defines an opening to said hollow: and a mount connected to said body, said mount being co-operable with said mounting means of the panel to locate said body adjacent said panel to partially obstruct said opening, said body and said panel together defining a container, the container being accessible though an unobstructed portion of said opening.

17. The receptacle of claim 16, wherein said body has a bottom portion and a wall portion.

18. The receptacle of claim 16, further comprising a hole defined therein for receiving a fastener of the mounting means.

19. The receptacle of claim 16, wherein said mount includes a clip for engaging said assembly.

20. The receptacle of claim 17, wherein said bottom portion is rectangular and said wall portion extends along three sides of said bottom portion.

21. The receptacle of claim 20, wherein free ends of said walls and said bottom together are configured to conform to the panel.

22. The receptacle of claim 21, wherein said wall free ends have stablizers which abut the barbeque assembly.

23. A grill for a barbeque having a grill housing and a burner located within the housing, said grill comprising:
a generally planar cooking surface mountable to said grill housing;
a warming rack cantilevered from said cooking service, wherein said warming rack is generally parallel to said cooking surface.

24. The grill of claim 23, wherein said warming rack is smaller in area relative to said cooking surface.

25. The grill of claim 23, wherein said warming rack is cantilevered at an edge thereof to said cooking surface.

26. The grill of claim 23, wherein said grill is coated in porcelain enamel.

27. The grill of claim 23, wherein said cooking surface and cantilevered warming rack are integrally formed.

28. The grill of claim 27, wherein said warming rack and cooking surface are formed from same piece.

29. The grill of claim 28, wherein said integrally formed warming rack and cooking surface are made by forming at least one bend in said grill.

30. The grill of claim 23, wherein said grill consists of a series of generally parallel joined rods.

31. The grill of claim 23, wherein said warming rack is in opposed relationship to said cooking surface.

32. The grill of claim 30, further comprising reinforcements in the nature of transverse bars span said rods.

33. The grill of claim 23, further comprising a protrusion adjacent said warming rack for inhibiting movement of items stored on said warming rack.

34. A bridging member for a gas baxbeque assembly, the assembly having a grill housing and at least two supports for said grill housing, said member comprising:
a generally planar body mountable to at least one support, said body defining a first hole therein;
means for mounting said body to the support; a first rib neck bolt for interlocking with a feature of the barbeque assembly, said ribs engaging and being retained by edges of said first hole which inhibit rotation and removal of said bolt when said bolt is assembled therein; and a retainer attachable to a free end of said bolt, for retaining said feature after said feature is mounted to said bolt after said free end is inserted through an opening defined in the feature.

35. A support member system for a barbeque assembly having a grill housing and at least two support members for supporting said grill housing, said support member system comprising:
a body mountable to said at least two support members, said body defining a hole therein at a location such that said hole is alignable with a corresponding hole in one member of said at least two support members and said body having a feature located about said hole; and a fastener cooperable with said hole, said feature and said corresponding hole to secure said body to said one member, said fastener having a second feature located thereon. said second feature cooperating with said feature of said body to restrict rotation of said fastener when said fastener is operatively engaged in said hole.