SYSTEMS AND METHODS FOR GRILL SMOKER OR INDIRECT COOKING CONVERSION AND AIRFLOW REDIRECTION DURING SMOKING OR INDIRECT COOKING

Abstract

Improvements regarding aspects of cooking and/or grilling are described, including a grill insert for a grill having a removable lid, the insert facilitating redirection of airflow from normal grill path(s) of up and out of the grill lid to instead flow at least partially down and over or around an indirect grill cooking surface and out the side of the insert.

Claims

1. A grill system, comprising: a kettle-style grill, including a kettle bowl and a kettle lid configured to seat onto or within the upper periphery of the kettle bowl, wherein the kettle bowl includes an air inlet in a lower portion of the kettle bowl and wherein the kettle lid includes an air outlet on an upper portion of the kettle lid, and further wherein the kettle bowl is configured to support at least one grill grate within the periphery of the kettle bowl; and a kettle grill insert, the kettle grill insert comprising a wall having a cylindrical geometry, with a lower edge configured to seat onto or within the periphery of the kettle bowl, and an upper edge configured to engage a lower periphery of the kettle lid, wherein the kettle grill insert includes a side exhaust vent configured to draw grill gasses from an area within the kettle lid back down and out of the side of the kettle grill insert.

2. A grill system in accordance with claim 1, wherein the side exhaust vent is positioned at least partially through the lower half of the kettle grill insert.

3. A grill system in accordance with claim 1, wherein the kettle grill insert further includes at least one grate support surface provided over or above the side exhaust vent at least on the same side as the side exhaust vent.

4. A grill system in accordance with claim 3, wherein the at least one grate support surface is vertically adjustable.

5. A grill system in accordance with claim 2, wherein the kettle grill insert further includes at least one grate support surface provided on the upper half of the kettle grill insert and at least on the same side of the kettle grill insert as the side exhaust vent.

6. A grill system in accordance with claim 1, wherein the side exhaust vent includes an exterior vent pipe with a damper.

7. A grill system in accordance with claim 1, wherein the upper and lower edges of the kettle grill insert include sealing surfaces configured to prevent the outflow of gasses between the bowl to kettle grill insert interface and between the lid to kettle grill insert interface, and wherein the kettle insert wall is a metal material having at least two spaced-apart handles protruding from an exterior surface thereof.

8. A method for redirecting the airflow of a kettle-style grill, comprising: providing a kettle-style grill, including a kettle bowl and a kettle lid configured to seat onto or within the upper periphery of the kettle bowl, wherein the kettle bowl includes an air inlet in a lower portion of the kettle bowl and wherein the kettle lid includes an air outlet on an upper portion of the kettle lid, and further wherein the kettle bowl is configured to support at least one grill grate within the periphery of the kettle bowl; and redirecting the airflow of the kettle-style grill by providing a kettle grill insert, the kettle grill insert comprising a wall having a cylindrical geometry, with a lower edge configured to seat onto or within the periphery of the kettle bowl, and an upper edge configured to engage a lower periphery of the kettle lid, wherein the kettle grill insert includes a side exhaust vent configured to draw grill gasses from an area within the kettle lid back down and out of the side of the kettle grill insert.

9. A method in accordance with claim 8, wherein the upper and lower edges of the kettle grill insert include sealing surfaces configured to prevent the outflow of gasses between the bowl to kettle grill insert interface.

10. A method in accordance with claim 8, wherein the side exhaust vent includes an exterior vent pipe with a damper configured to fully open or to restrict the flow of redirected exhaust gasses therethrough and wherein the kettle insert wall is a metal material having at least two spaced-apart handles protruding from an exterior surface thereof.

11. A method in accordance with claim 10, wherein the kettle grill insert further includes at least one grate support surface provided over or above the side exhaust vent at least on the same side as the side exhaust vent.

12. A method in accordance with claim 11, wherein the kettle grill insert is configured with a higher grill grate on the side of the kettle grill insert with the side exhaust vent than the side opposite the kettle grill insert, and wherein redirecting the airflow of the kettle-style grill includes redirecting air at least partially down over the higher grill grate and through the side exhaust vent.

13. A grill insert for a kettle-style grill, comprising: a wall having a cylindrical geometry, with a lower edge configured to seat onto or within the periphery of a kettle grill bowl and with an upper edge configured to engage a lower periphery of a kettle grill lid, wherein the kettle grill insert includes a side exhaust vent configured to draw grill gasses from an area within the kettle lid back down and out of the side of the kettle grill insert.

14. A grill insert in accordance with claim 13, wherein the side exhaust vent is positioned at least partially through the lower half of the kettle grill insert.

15. A grill insert in accordance with claim 13, wherein the kettle grill insert further includes at least one grate support surface provided over or above the side exhaust vent at least on the same side as the side exhaust vent.

16. A grill insert in accordance with claim 15, wherein the at least one grate support surface is vertically adjustable.

17. A grill insert in accordance with claim 14, wherein the kettle grill insert further includes at least one grate support surface provided on the upper half of the kettle grill insert and at least on the same side of the kettle grill insert as the side exhaust vent.

18. A grill insert in accordance with claim 13, wherein the side exhaust vent includes an exterior vent pipe with a damper.

19. A grill insert in accordance with claim 13, wherein the upper and lower edges of the kettle grill insert include sealing surfaces configured to prevent the outflow of gasses between the bowl to kettle grill insert interface and between the lid to kettle grill insert interface.

20. A grill insert in accordance with claim 19, wherein the sealing surfaces comprise gasket material and wherein the kettle insert wall is a metal material having at least two spaced-apart handles protruding from an exterior surface thereof.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0025] FIG. 1 is a front perspective view of a kettle grill with an exemplary smoker insert, in accordance with exemplary aspects of the disclosure;

[0026] FIG. 2 is a perspective view of a portion of the grill and insert of FIG. 1, with the lid removed and the interior of the exemplary insert shown;

[0027] FIG. 3 is another perspective view of the grill insert of FIG. 1, further illustrating the direct and indirect heat zones;

[0028] FIG. 4 is another perspective view of the grill insert of FIG. 1, showing cooking on both direct and indirect zones; and

[0029] FIG. 5 is a perspective plan view of the interior wall of the indirect zone adjacent the side exhaust vent provided through the interior wall of an exemplary grill insert, with one or more grill support members provided to support a grill at least partially over or above the opening of the side exhaust vent.

DETAILED DESCRIPTION

[0030] As we have noted, the present disclosure describes various improvements regarding aspects of grilling and/or cooking, including with regard to apparatuses, systems and methods for redirecting existing airflow path(s) using an insert.

[0031] FIG. 1 illustrates a first exemplary embodiment, showing a 22″ Weber™ Performer Grill, shown generally at 100 (which includes an attached cart 110) also including an exemplary compatible body insert 110. The exemplary (in this case a kettle) grill includes (as part of the original grill), a removable lid 114, a lid handle 116, a rotary damper 118, offset from the removable (dome) lid 114 by about 6″, a dome thermometer 120 and a circular lower perimeter edge 122, with a flare 124, configured to mate with a rim 126 of the lower bowl 128. While it is not visible in this figure, this particular kettle grill also has a lower flare recess interior of the rim 126 of the lower bowl 128.

[0032] Referring still to FIG. 1, insert 112 is illustrated as an exemplary multi-part configuration, with at least first 130 and second portions 132 joined by one or more fasteners 136. In exemplary embodiments, fasteners 136 may also, as shown, extend beyond the surface of the insert 112 such that it/they form(s) a resting place against one or both of the lower perimeter edge 122 of the lid 114 and/or the rim 126 of lower bowl 128.

[0033] The insert 112 is illustrated nested within the flare 124 of the removable lid 114 and the lower flare of the rim 126 of the lower bowl. As will be shown below, in exemplary embodiments use of a gasket, e.g., a high temperature gasket material for grills on one or both of the upper and lower edges of the insert or on the surfaces of the grill provides a relatively sealed configuration for that (removable) mating.

[0034] Exemplary handle 136 is illustrated as being attached by fastener 138, the handle being wood. For this particular embodiment, handle 136 is also attached by another (lower) fastener 138, though the side exhaust vent 140 (hereinafter “side vent” or “exhaust vent”) blocks that view.

[0035] Exemplary side exhaust vent 140 is illustrated as being attached to the insert 112 (in this case the kettle is circular), so the vent 140 is attached to the insert via a complementary base shape (e.g., as a partially rounded base shape), which can be integral to, screwed to, welded to, etc., the material of the insert 112. The insert also includes a vent outlet 142, which may or may not (i.e., not connected if it is close to the insert/integral to the base) also be connected to the base of the vent 140 via a vent air extension portion 144, having a length away from the insert 112. The shape of that vent air extension portion 144, should it be included may be straight and tubular (as shown) or any other desired shape or configuration, e.g., as an elbow with an upward facing exhaust, as a curved member, etc.

[0036] Additionally, exemplary vent 140 includes a closing member 146, in this case closed via a pivot over a tensioned screw 148 (which may be a tightly held member pushable for increments between fully closed and fully open positions relative to the vent outlet 142).

[0037] FIG. 2 illustrates generally at 200, an exemplary insert grate 210, a hot zone 212, with charcoal 214 and/or wood therein, with this grate including a hinged component 216 to allow fuel feeding. FIG. 2 also shows an exemplary smoking or indirect zone 218 that extends from the base grate 220 and/or drip pan 222 (which can help restrict airflow from below the smoking/indirect zone) thereon, to an area above the insert grate, or as will be shown below, a possible movable grate insert elevated above the base grate 220 or drip pan 222). In this illustrated exemplary embodiment, the cooking area within the smoking/indirect zone 218 is above the insert grate 210 that is nested on the upper inner fasteners 134 of the insert. In this case, the airflow provided by the grill directs the lower air from the hot coals 214 of the hot zone 212 upwards towards the (spaced apart) grill dome, which cannot vent (or at least fully vent) the air via a closed (or at least partially closed) damper 118 and back down over the food (e.g., see the pineapple 224 and chicken breasts 226) to the side vent, which in this case is well below the cooking grate on the smoking/indirect zone 218.

[0038] FIG. 3 illustrates an exemplary embodiment with a lower grate 310, covering a hot zone 312 (optionally with an openable grate portion for feeding fuel to the hot zone). In this case, the removable insert 314 is movable around the circumference of the shown exemplary kettle; and the side vent 316 and is positioned slightly off center of the opposite side of the hot zone to create an airflow path over a portion of the positioned packer brisket 318 (note, that this can be adjusted at any time via use of handle(s) 320, e.g., to position the point, join between the point and flat, or flat closer to the vent 316). We also note that in this case, vent 316 is fully open.

[0039] Additionally, in exemplary embodiments where a movable elevated grill surface 322 is used, the elevated grill itself or any associated attached/elevated drip pans, e.g., drip pan 324, may be moved or positioned to adjust the position of the food (possibly without moving the insert 314) or to shield any portion or portions of the meat (e.g., by pulling drip pan slightly towards the hot zone 312) to tailor the cook and to adjust the airflow from the hot zone 312/coals up to the (exemplary) dome lit and down over the illustrated brisket to the side vent 316. In this example, good color/char 326 can be seen around the flat 328 as well as on the point 330 of the brisket 318 due to the airflow curving over the brisket to the side vent 316. Note that in this particular illustrated example, movable elevated grill surface 322 allows the brisket 318 to also be spaced a bit from the side vent 316, with attached drip pan 324 being extendable to also shield the brisket 318 a bit more from direct heat, promoting that up and over and out the side airflow that creates the nice cook. That being said, this could also be reproduced using movable shield elements on the cooking grill to adjust the difference/line between the hot zone 314 and an indirect zone 218, as well as upwards or downwards adjustable grates within the insert to fine tune the level of exposure of the cooking grate to the redirected air.

[0040] FIG. 3 also shows at least one exemplary gasket 332, provided around an upper periphery of insert 314 to provide sealing of airflow.

[0041] With further reference to FIG. 4, which shows a cooking evolution of the embodiment of FIG. 2 generally at 400, a full circle elevated insert cooking surface grate, such as 210 in FIG. 2 (or indeed use of plural movable elevated cooking grates, such as 322 in FIG. 3 or otherwise (e.g., half moon or quarter grate pieces that may be placed or removed)) allows for direct cooking over the hot zone 312 as well as for concurrent continual cooking over the smoking and/or indirect zone 218, with movement of heat (with the lid on) up and past the broccoli 410 (for direct heat cooking), to the lid and at least partially across and down over the chicken 226 (and pineapple 224), for continued indirect and/or smoked cooking. This also provides flexibility for cooking, where a side, such a charred broccoli, can be finished near the end of a planned slow cook such that they can be presented together. In the alternative, an elevated cooking surface/grate may be provided for the smoking and/or indirect side, and direct grilling may be done at a lower level, partway down to or on the lower grate.

[0042] FIG. 5 is a top perspective view of one half of an exemplary circular/cylindrical kettle insert, shown generally at 500, bisected at line 502, with a cylindrical wall 510, upper and lower gaskets 512, 514 to provide a good seal between a kettle grill lid and a kettle grill bowl, and an internal portion of a side exhaust vent 516 positioned on a lower portion of the insert 500 (at least partially below illustrated exemplary insert grill/grate support members 518 (shown as a continuous support around the interior of the illustrated half of the kettle insert 500) and 520 (shown as plural grill/grate support tabs or channels, which may be the same or different lengths at least partially around the interior of the illustrated half of the kettle insert). The non-illustrated half of the insert 500 may mirror the illustrated exemplary grill support components or may include different grill support configurations (given that the non-illustrated half would rest over the hot zone of the grill, and thus may benefit from lower grill heights than would be provided over the illustrated/indirect zone).

[0043] Referring still to FIG. 5, any of the insert grill/grate support members 518, 520 may also include varying mechanisms to adjust height, e.g., the sliding tracks 522 shown with grill support member 518, which is configured to allow the grill height to be raised or lowered according to preference (note that the term “grill height” refers to the height(s) of the grill cooking surface(s), or grate(s)). The tracks 22 may include sliding support for the member 518 to allow adjustment of the entire member 518, with one or more locking members, such as wingnuts, set screws, etc., to finalize the position prior to loading it with food. Any of support members 520, should the kettle insert 500 be equipped with support members of that type in lieu of or along with support members of the type shown at 518, may also utilize height adjustment aspects described herein. We note that the tracks 522, in this illustrated exemplary embodiment, are configured to position the grill grate in one or more positions above the bottom of side exhaust vent 516, further facilitating the redirection of air flow over the food and out the side vent during indirect cooking or smoking.

[0044] Support members 518 and/or 520 may provide a simple ledge for grill grate support, or may be configured as a slotted (e.g., c-shaped) configuration to more securely hold a grate or to facilitate rotation of a grate provided thereon or therein, e.g., to have an upper half moon grate rotated so that part of the surface now rests higher up over the direct heat/hot zone.

[0045] As we have noted, cooking conditions can advantageously be tailored not just using internal components of an apparatus, system or method, but also using relative positioning of the three airways, inclusive of the bottom inlet (which is adjustable), the upper damper (in many cases a kettle dome damper) and the side vent, which in embodiments is movable, particularly in a kettle/circular configuration, as desired. In many instances, establishing operative temperatures can be done with the upper damper completely closed, with the lower vent open sufficiently to provide combustible air, and with the side vent open to provide the venting pathway (for both air and moisture). During use, it may be beneficial to open the dome damper slightly and/or adjust the positioning to produce more output, e.g., when coals burn down and before the grill is refueled, and/or to provide more aggressive heating to one or more portions of the cook surface (with the side vent still pulling down airflow over or across the indirect heat cooking surface). Additionally, where round kettles are used, the insert itself or supported grill grate(s) provided therein can be rotated (or in exemplary embodiments, raised or lowered via adjustment of the grill grate support member(s)) to provide airflow over select portions of cooking surfaces or cooking food to further tailer the cook.

[0046] Exemplary aspects described herein advantageously allow, where standard round kettles are used, an inexpensive insert that is configured to redirect the natural flow of exhaust, which for kettles is up and out, to instead provide for airflow, heat and moisture to flow back down from the headspace of the grill, over the top and/or sides of the food and out the side of the insert, providing an airflow path not previously used for kettle grills, which themselves are an inexpensive, commonly owned type of grill.

[0047] It should be understood that various aspects disclosed herein may be combined in different combinations than the combinations specifically presented in the description and accompanying drawings. It should also be understood that, depending on the example, certain acts or events of any of the processes or methods described herein may be performed in a different sequence, may be added, merged, or left out altogether (e.g., all described acts or events may not be necessary to carry out the techniques). In addition, while certain aspects of this disclosure are described as being performed by a single apparatus for purposes of clarity, it should be understood that the techniques of this disclosure may be performed by a combination of the apparatus associated with, for example, a cooking device, system or method including described accessories or additional accessory cooking or airflow sensing devices, the latter being either single sensing devices or positioned (e.g., as part of temperature probes seen discretely in the brisket) separately over the cooking surface.