Note: Descriptions are shown in the official language in which they were submitted.
CA 02363985 2001-11-23
SUP'P'ORTED GAS BARBEQUE ASSEMBLY
FIELD OF TIC INVENTION
The present invention relates generally to the field of coolting apparatus,
and more
particularly to barbeques such as outdoor gas fuelled barbeques.
BACKGROUND OF THE INVENTION
To reduce manufacturing, shipping and storage costs, barbeque 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 casting
containing burners
and a grill, shelves, a console for regulating the flow of 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 to one another. For example, a typical
barbeque may
require that over twenty such connections be made by a consumer. Common tools
such as
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screwdrivers and wrenches may also 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 complete.
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 may 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
dexterity with tools. Even unassisted or manual insertion and tightening of
screws or bolts in
this position may be difficult. Alternatively, a consumer may have to
reposition a partially
assembled barbeque numerous times during its assembly process if it is desired
to install screws
or bolts in a more 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
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models for display to potential consumers. This may make retailers reluctant
to assemble floor
models, which could make it more difficult for the unassembled barbeques to be
sold because
consumers 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
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.
Manufacturers also
incur increased labour costs in assembling the barbeque themselves.
Once the barbeque is assembled, connections between two or more of the
assembled
components may become loosened, for example, by moving the barbeque or through
regular use
of the barbeque. Loosening may also be caused thermal contraction and
expansion of the
barbeque components when the barbeque is subject to varying weather conditions
or variation in
the heat output of the barbeque itself. Imperfections in the manufacture of
one or more barbeque
components may lead to a barbeque assembly with one or more loose connections,
even when
the barbeque is intially assembled. Such loosened connections may ultimately
cause joined
components to become separated, impacting negatively on the operation of the
barbeque. For
example, the connection between vertical supports and a bridging member
joining the supports
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may loosen, causing the barbeque grill assembly to be unstable.
Notwithstanding the extent to which components are joined to one another, the
structural
members of the barbeque support assembly may themselves elastically yield to a
limited extent
when a force is applied thereto. This yield may lead to a less rigid barbeque
support structure.
Indeed in an extreme situation, repeated elastic yielding of a component may
lead to its failure.
Based on the foregoing, it would be desirable to develop alternative barbeques
that may
be shipped unassembled to reduce costs, but that may be readily and quickly
assembled by
unskilled consumers. It would also be desireable to develop alternative
barbeques that have
added resistance to loosening of the connections between their components, and
that have
reduced elastic yielding of their support structure components as compared to
barbeques known
in the art.
SUMMARY OF TIC INVEN'TION
The invention consists of a barbeque grill housing support structure.
According to one
broad aspect of the invention, the barbeque assembly may have a first member
and a second
member for supporting the grill housing, and a cross member fastened between
the first and
second members. The first member may be oriented in an initial position
relative to the cross
member, and a biasing member is attached to the first member and the second
member. The
biasing member displaces the first member to a biased position in which the
first member is
displaced from the cross member relative to the initial position.
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In an illustrative embodiment of the invention, respective free ends of the
first and second
members are displaced from one another along an axis substantially parallel to
a longitudinal
axis of the cross member when the first member is biased from the initial
position to the biased
position.
In a further illustrative embodiment, the biasing member is a barbeque grill
housing
attached between the first and second members.
In a yet further illustrative embodiment, the support structure has a friction
system
adapted to support displacement of the first member in the biased position.
The friction system
includes a first friction member on the first member, and a second friction
member on the biasing
member. The first and second friction members fractionally co-operate to
support the
displacement of the first member in the biased position.
In a yet further illustrative embodiment, the first friction member is a post,
and the
second friction member is an edge of a post hole.
In a yet further illustrative embodiment, the first member includes a beam
connection
member having a portion defining a bolt hole therethrough, and the cross
member has portions
defining a bore therethrough for receiving a bolt. Upon placement of the bolt
through the bolt
hole and the bore, a friction fit may be provided between the bolt and an edge
of the bore when
the first member is in the biased position.
According to another broad aspect of the invention, there is provided a
barbeque grill
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housing support structure having a first member and a second member for
supporting the grill
housing, and a cross member fastened between the first and second members to
orient the first
member in an initial position relative to the cross member. There is also
provided a fastener
joining the first member and the cross member, and a biasing member attached
to the first
member and one of the second member and the cross member. The biasing member
may be in
spaced relationship with the fastener, and displacing the first member to a
biased position in
which the first member is displaced from the cross member.
According to another broad aspect of the invention, there is provided a
barbeque grill
housing support struchue, having a first member and a second member for
supporting the grill
housing, and a cross member fastened between the first and second members to
orient the first
member in an initial position relative to the cross member. The cross member
is fastened to the
first member, and a biasing member attached to the first member and one of the
second member
and the cross member maintains the first member in a biased position in which
the first member
is angularly displaced from the cross member relative to the initial position.
This arrangement
provides additional friction between the first member and the cross member.
According to another broad aspect of the invention, there is provided a
barbeque grill
housing support structure having a first member and a second member for
supporting the grill
housing, and a cross member fastened between the first and second members to
orient the first
member in an initial position relative to the cross member. The cross member
may be fastened
to the first member. There is also provided a biasing member attached to the
first member and
the cross member displacing the first member to a biased position in which the
first member is
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displaced from the cross member relative to the initial position.
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 perspective 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
illustrative 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 4A is a partial side view of an end of a bridging member of the
barbeque of Figure
1 showing an alternate welding slot;
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FIGURE 4B is a partial top view of the end of the bridging member shown in
Figure 4A;
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;
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 7B is a perspective view of an alternative embodiment of the beam
connection
member 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 8A is an assembled partial end view of a beam connection member and
bolt of
the barbeque of Figure 1;
FIGURE 9 is an exploded partial perspective view including beam connection
members,
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support members and a cross beam of the 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 of a pin of the barbeque of Figure 1;
FIGURE 12A is side view of an alternative embodiment of the pin of Figure 11;
FIGURE 12B is an exploded partial perspective view of a beam connection
member, leg
extension, caster and legs of the barbeque of Figure 1;
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, with hidden
features
shown in phantom;
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, with hidden features
shown in
phantom;
FIGURE 15 is a perspective view of a partially assembled barbeque of Figure 2;
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FIGURE 16 is a perspective view of an alternative embodiment of the beam
connection
member and tank base of Figare 2;
FIGURE 17 is a perspective view of an alternative embodiment of the tank base
of Figure
16;
FIGURE 18 is a perspective view of the tank base of Figure 17 having
strengtheners;
FIGURE 19 is an exploded perspective view of a fuel source retainer of the
barbeque of
Figure 2;
FIGURE 20 is a perspective view of an alternative embodiment of the fuel
source retainer
of Figure 19;
FIGURE 21A is an end view of a further alternative embodiment of the fuel
source
retainer of Figure 19;
FIGURE 21B is a side view of the fuel source retainer of Figure 21A;
FIGURE 22 is a top view of an alternative embodiment of a shelf of the
barbeque of
Figure 1, with hidden features shown in phantom;
FIGURE 23 is an end view of the shelf of Figure 22, with hidden features shown
in
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phantom;
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 1, with hidden
features
shown in phantom;
FIGURE 26 is an exploded partial perspective view of a shelf and support of
the
barbeque of Figure 1;
FIGURE 27 is an exploded partial perspective view of a shelf and support of
the
barbeque 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;
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
30A
showing the valve clip inserted into the valve opening;
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FIGURE 30C is a perspective view of the valve clip and valve opening of Figure
30A
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 view of the barbeque of Figure 1;
FIGURE 33 is an exploded perspective view of a lower casting and burner of the
barbeque of Figure 1;
FIGURE 34 is a 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
barbeque of Figure 1;
FIGURE 36 is a perspective assembled view of the console and leg members of
Figure
35;
FIGURE 36A is a detailed side view of the console of Figure 36, showing the
console
and the bridging member, with the leg member shown outlined and transparent;
FIGURE 37 is an exploded perspective view of the console and leg members of
the
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barbeque of Figure 2;
FIGURE 38 is a perspective assembled view of the console and leg members of
Figure
37;
FIGURE 39A is a side view of a console bolt of the barbeque of Figure 1;
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
taken along the line 41-41 of Figure 40;
FIGURE 42A is an exploded perspective view of a axle pin and axle lock of the
barbeque
of Figure 1;
FIGURE 42B is an assembled perspective view of an axle pin and axle lock of
Figure
42A;
FIGURE 43A is an exploded perspective view of an axle pin and axle lock of the
barbeque of Figure 2;
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FIGURE 43B is an assembled perspective view of an axle pin and axle lock of
Figwe
43A;
FIGURE 44 is a partial side view of the barbeque of Figure 2 showing an
alternative fuel
source retainer, and showing the beam connection member outlined and
transparent;
FIGURE 45 is a partial end view of the barbeque of Figure 2 showing the
alternative fuel
source retainer of Figure 44;
FIGURE 46A is an isolated bottom view of a mounting bracket of the alternative
fuel
source retainer of Figure 44;
FIGURE 46B is a side view of the mounting bracket of Figure 46A;
FIGURE 46C is an end view of the mounting bracket of Figure 46A;
FIGURE 47A is an isolated end view of an engaging member of the alternative
fuel
source retainer of Figure 44;
FIGURE 47B is a side view of the engaging member of Figure 47A;
FIGURE 47C is an another end view of the engaging member of Figure 47A, viewed
from a direction opposite to the end view of Figure 47A;
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FIGURE 47D is a top view of the engaging member of Figure 47A, with hidden
features
shown in phantom;
FIGURE 47E is a cross-sectional view of the engaging member of Figure 47A
taken along
the line 47E-47E of Figure 47C;
FIGURE 47F is a cross-sectional view of the engaging member of Figure 47A
taken along
the line 47F-47F of Figure 47C;
FIGURE 47G is a perspective view of the engaging member of Figure 47A with an
elongated shim;
FIGURE 47H is another perspective view of the engaging member of Figure 47G
viewed
from a direction opposite to the perspective view of Figure 47G;
FIGURE 48A is a side view of a fuel tank retaining bolt of the barbeque of
Figure 2;
FIGURE 48B is an end view of the fuel tank retaining bolt of Figure 48A;
FIGURE 49 is a transparent isolated side view showing the connection of a beam
connection member and cross beam of the barbeque of Figure 2;
FIGURE SOA is an end view of a wing nut of the barbeque of Figure 2, with
hidden
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features shown in phantom;
FIGURE SOB is a side view of the wing nut of Figure 50A, with hidden features
shown in
phantom;
FIGURE SOC is another end view of the wing nut of Figure SOA viewed from a
direction
opposite to the end view of Figure SOA, with hidden features shown in phantom;
FIGURE 51 is an isolated transparent side cutaway view showing a bolt and wing
nut
joining the beam connection member and cross beam of the barbeque of Figure 2;
FIGURE 52A is an isolated end view of a burner support member of the barbeque
of
Figure 1;
FIGURE 52B is a side view of the burner support member of Figure 52A;
FIGURE 52C is a top view of the burner support member of Figure 52A;
FIGURE 53A is a transparent top view of the burner tray of Figure 28
additionally
including a bracket;
FIGURE 53B is a side view of the burner tray of Figure 53A;
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FIGURE 53C is an end view of the burner tray of Figure 53A;
FIGURE 54 is a detailed view of the burner tray of Figure 53A identified by
the reference
numeral 54 in Figure 53C;
FIGURE 55 is a detailed view of the burner tray of Figure 53A identified by
the reference
numeral 55 in Figure 53C
FIGURE SSA is a top view of the shelf of Figure 22 showing an alternative
conduit of the
shelf in phantom;
FIGURE SSB is an isolated cross-sectional view of the conduit of the shelf of
Figure SSA
taken along the line SSB-SSB;
FIGURE 56 is a side view of the panel of the barbeque of Figure 2, with hidden
features
shown in phantom;
FIGURE 57 is an end view of a bracket of the panel Figure 56, with hidden
features
shown in phantom;
FIGURE 58 is an isolated perspective view of the valve clip of Figure 29;
FIGURE 59 is another perspective view of the valve clip of Figwe 58 viewed
from a
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direction opposite to the perspective view of Figure 58;
FIGURE 60A is an isolated top view of a beam connection member Figure 2;
FIGURE 60B is an end view of the beam connection member of Figure 60A, showing
hidden features in phantom;
FIGURE 60C is a side view of the beam connection member of Figure 60A, showing
hidden features in phantom;
FIGURE 60D is a cross-sectional view of the beam connection member of Figure
60A,
taken along the line 60D-60D of Figure 60A;
FIGURE 61A is an isolated side view of an alternative axle lock of the
barbeque of
Figure 1, with hidden features shown in phantom;
FIGURE 61B is another isolated side view of axle lock of Figure 61A, viewed
from a
direction transverse to the side view of Figure 61A, with hidden features
shown in phantom;
FIGURE 61C is an end view of axle lock of Figure 61A, with hidden features
shown in
phantom;
FIGURE 61D is a cross-sectional view of the axle lock of Figure 61C taken
along the line
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61D-61D;
FIGURE 61E is a cross-sectional view of the axle lock of Figure 61B taken
along the line
61E-61E;
FIGURE 62A is an isolated side view of an alternative axle lock of the
barbeque of
Figure 2, with hidden features shown in phantom;
FIGURE 62B is another isolated side view of axle lock of Figure 62A, viewed
from a
direction transverse to the side view of Figure 62A, with hidden features
shown in phantom;
FIGURE 62C is an end view of axle lock of Figure 62A, with hidden features
shown in
phantom;
FIGURE 62D is a cross-sectional view of the axle lock of Figure 62C taken
along the line
62D-62D;
FIGURE 62E is a cross-sectional view of the axle lock of Figure 62B taken
along the line
62E-62E;
FIGURE 63 is an isolated cross-sectional side view of a wheel and alternative
axle pin of
the barbeque of Figure 1, with hidden features shown in phantom; and
FIGURE 64A is an isolated end view of a burner support member of the barbeque
of
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Figure 1;
FIGURE 64B is a top view of the burner support member of Figure 64.A;
FIGURE 64C is a side view of the burner support member of Figure 64A;
FIGURE 65 is an isolated top view of a lower casting of the barbeque of Figure
1,
showing casting openings for receiving the burner support member of Figure
52A;
FIGURE 66 is an isolated view of a burner support member of Figure 52A, which
includes a member for attaching it to a burner;
FIGURE 67 is an isolated transparent side view of a burner, burner support
member and a
portion of the lower casting defining a casting opening of the barbeque of
Figure l;
FIGURE 68 is an isolated top view of the burner support member and casting
portion of
Figure 67;
FIGURE 69A is a side view of the alternative axle pin of Figure 63;
FIGURE 69B is an end view of the axle pin of Figure 69A;
FIGURE 70A is a side view of an alternative axle pin of the barbeque of Figure
2;
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FIGURE 70B is an end view of the axle pin of Egure 70A;
FIGURE 71A is an isolated side view of an alternative embodiment of a threaded
post of
the barbeque of Figure 1;
FIGURE 71B is an isolated end view of the threaded post of Figure 71A;
FIGURE 72 is an isolated side view of an alternative nut of the barbeque of
Figure 1;
FIGURE 73A is a top view of the valve clip of Figure 29;
FIGURE 73B is an end view of the valve clip of Figure 29;
FIGURE 73C is an side view of the valve clip of Figure 29;
FIGURE 73D is a bottom view of the valve clip of Figure 29;
FIGURE 73E is a cross-sectional view of the valve clip of Figure 29, taken
along the line
73E-73E of Figure 73C;
FIGURE 74 is a side view of support members and cross beam of the barbeque of
Figure
2 wherein the support members are biased towards the cross beam in an initial
position;
FIGURE 75 is a side view of support members and cross beam of the barbeque of
Figure
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2 wherein the support members are biased away from the cross beam in an
alternate initial
position;
FIGURE 76 is a side view of the support members of Figure 74 wherein a biasing
member in the nature of a lower casting is positioned in preparation for
moving the support
members to a biased position; and
FIGURE 77 is a side view of the support members of Figure 76 in a biased
position, and
being maintained in place by the lower casting.
DETAILED DESCRIIrTION OF ILLUSTRATIVE EMBODIMENTS OF THE
INVENTION
Referring to Figure 1, a first illustrative embodiment of the claimed
invention is shown in
exploded view. The illustrative embodiment of the claimed invention includes a
barbeque 60
having a support structure which has first and second support members 62, 64,
and a cross
member in the nature of a cross beam 66 rigidly connected therebetween. A
preparation or
storage surface in the nature of first and second shelves 68', 70' may be
included. To provide
limited structural support to the support members 62, 64, a panel such as an
accessory panel 72
may be provided. A grill housing 74, having opposed castings 76 and 78 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 warming rack 84 may also be contained
within the grill
housing 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
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angled bars 88 may also be included. If a self contained fuel source is used,
including a fuel
container, for example, such as a propane tank 90, then a fuel source or
container 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 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 of 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
be used in association as well. The description provided is therefore not
intended to be limited to
the particular combination of variations disclosed.
Support Member
Support member 62 may be configured to be substantially identical to support
member
64, and may have a mirror configuration to support 64. In the embodiment
illustrated in Figure
2, 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 may 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
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diameter of 13/8 inches and a wall thickness of 0.036 inches. Leg members
having other
dimensions may also be used as long as sufficient structural support for
barbeque 60 is provided.
In an alternative embodiment, legs 98 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.
Referring to Figures 3 and 4, leg 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.
Referring to Figure to Figures 4A and 4B, an alternate weld slot such as slot
106a may be
used to strengthen the weld formed between bridging member 102 and leg 98. In
comparison to
the location of slot 106, slot 106a is rotated about its centroid so that the
weld material applied
through slot 106a attaches to leg 98 at both sides of a longitudinal
centerline of leg 98, whereas
slot 106 directs the weld material to an orientation that is substantially
parallel to a longitudinal
centerline of leg 98. The rotation of slot 106a is preferably approximately 10
degrees. An
abutting member or saddle having protrusions or wings 115 for abutting leg 98
may be added to,
or integrally formed with, bridging member 102 so that bridging member 102 is
closer to leg 98
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adjacent the location of a weld. Wings 115 may also facilitate the positioning
of leg 98 relative
to slot 106a before a weld is applied. Wings 115 are preferably stamped,
embossed or otherwise
integrally formed with bridging member 102 so that they protrude from bridging
member 102 to
abut and conform to a portion of the periphery of leg 98. As shown in Figure
4B, wings 115 may
have an arcuate cross section which conforms to a portion of leg 98.
In an alternative configuration (not shown), a weld rnay be applied to both
sides of a
longitudinal centerline of leg 98 to attach bridging member 102 thereto by
including two
substantially parallel slots in bridging member 102, instead of one slot such
as slot 106a. The
two slots are preferably oriented adjacent one another and are generally
parallel to a longitudinal
centerline of leg 98. Bridging member 102 may then be welded to leg 98 through
each slot.
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 100.
When in their operative position, legs 98 and 100 preferably are generally
vertically oriented,
and may rest on their respective base ends 110 and 112. Alternatively, leg
members 98 and 100
may rest on wheels 94, casters 74, leg extensions 114 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 art that a wider spacing for the leg
members 98 and 100 may
20953910.4 - 25 -
CA 02363985 2001-11-23
provide greater stability to barbeque 60, while a narrower spacing could make
barbeque 60 top-
heavy and prone to tipping. For example, if a narrower grill housing is used
(not shown), the
spacing between leg 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.
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
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
two 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 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 may 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 grill
housing 74.
20953910.4 - 26 -
CA 02363985 2001-11-23
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
21/z inches.
Alternatively, beam 66 may have a cross-sectional configuration which is
polygonal, round, or
non-uniform in shape. To reduce costs and material, the beam 66 may be hollow.
A rigid
plastic, or a metal, whether formed by injection moulding, extrusion, bending,
or some other
appropriate process, is preferably used to construct cross beam 66.
While cross beam 66 is generally linear in the illustrative embodiment of the
invention, it
may have angles or curves formed therein for orienting the beam 66 for
attachment to each
support member 62 or 64, 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
Referring 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 of the beam connection members, for
example beam
connection member 122, may be configured to have a fuel source support base 92
for supporting
a fuel container such as a propane tank 90, as described below. If a propane
tank 90 is not used
in conjunction with barbeque 60, for example if a natural gas feed is used,
then beam connection
20953910.4 _ 27
CA 02363985 2001-11-23
members 116 and 122 may alternatively be configured identically to one another
or as mirror
images of one another (not shown). Aside from the possible consideration of a
fuel source
support base 92, the following description of beam receptacle 120, applies to
beam receptacle
124 as well, unless otherwise indicated.
Beam receptacle 120 has an open end 126 for receiving an end 128 of cross beam
66.
Beam receptacle 120 may also have a closed end 130 which is opposed to open
end 126 prevents
cross beam 66 from being inserted into the receptacle 120 any further. Closed
end 130 also
provides feedback by way of abutment of cross beam 66 thereagainst to indicate
that beam 66 is
fully inserted, and 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 configwed 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 or extrusion.
Referring to Figures 2 and 9, an alternative embodiment of beam connection
member
116' is formed as a strut 118' having a generally inverted U-shaped cross-
section. Strut 118' may
20953910.4 _ 28
CA 02363985 2001-11-23
be attached between leg members, such as leg members 98' and 100', as
described below. Arms
136 (whose lower longitudinal edge is shown in a phantom line) and 138 of the
U-shaped cross-
section are preferably substantially at right angles to base 140 of the U-
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
generally parallel 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' (Figure 2).
Arm 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 may be in the form of a substantially perpendicular flange
144 along a free
end 146 (shown as a phantom line) of arm 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'.
20953910.4 - 29 -
CA 02363985 2001-11-23
Furthernnore, opening 142 may additionally have a flange such as a peripheral
flange (not
shown) for abutting cross beam 66'.
To abut a greater portion of beam end 128', base 140 of strut 118' may be
widened at a
mid-section 150 of strut 118'. Mid-section 150 may widened in a direction
generally away from
arm 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 gradually further apart to a maximum when adjacent mid-
section 150. If
mid-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'x. This may enable a support member such as support member 62'
having a shelf
68" 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 a bolt
154, which is inserted through a hole 156 in base 140 and a corresponding bore
158 in beam end
128'. When beam end 128' is inserted into opening 142 to abut arm 136, hole
156 and bore 158
are preferably aligned to receive bolt 154. Hole 156 and bore 158 are aligned
and may be
generally vertically oriented to permit insertion of bolt 154 in a downward
direction. This
arrangement permits bolt 154 to rest within both hole 154 and bore 158, while
also, to a limited
extent, securing base 140 to beam end 128'. Once bolt 154 is inserted through
both hole 154 and
bore 158, it may be secured with a manually securable bolt retainer such as a
wing nut 160 or
20953910.4 - 30 -
CA 02363985 2001-11-23
some other manually tightenable fastener.
In the context of this description the terms "unassisted", "manual",
"manually", "by
hand", or other similar terms, indicate that the component or components
described may be
installed, attached or otherwise arranged without assistance of any mechanical
advantage,
including the use of tools or other implement. However, while unassisted
installation of a
component is preferred, it is not necessary. An appropriate tool or tools may
optionally be used.
As best seen in Figure 49, bolt 154 may have a widened head 157 for abutting a
greater
portion of beam connection member 116'. By contacting a greater portion of
beam connection
member 116', movement of installed bolt 154 may be further inhibited, which in
turn may reduce
movement of retained cross beam 66' relative to beam connection member 116'.
Rotational movement of bolt 154 may be limited by a portion 159 of a bolt
shaft 161
defining a non-rotatable shape. Shaft portion 159 may be located adjacent head
157. At least
hole 156 (see also Figure 9) may be configured to have substantially the same
shape as deftned
by a periphery of shaft portion 159 to permit shaft portion 159 to be located
therein. Because
shaft portion 159 is non- rotatable, and may be located within similarly sized
hole 156, shaft 161
may be inhibited from rotating, for example, when nut 160 is threaded and
tightened thereon.
This may permit additional unassisted or manual tightening of nut 160 to bolt
154 to further
inhibit movement of connected beam end 128' relative to beam connection member
116'. In an
illustrative embodiment, shaft portion 159 has a substantially rectangular
cross section and hole
156 is similarly configured to be generally rectangular in shape.
20953910.4 - 31 -
CA 02363985 2001-11-23
Referring to Figures SOA - SOC, nut 160 is shown with wings 163 extending in a
direction generally perpendicular to nut body 165. Increased leverage for
turning nut 160 may
be obtained by angling wings 163 away from a central axis of nut 160 (not
shown).
Nut 160 may additionally include a nub 167 for gripping sides of a
corresponding rebate
169 in beam end 128'. Nub 167 protrudes from nut body 165 in a direction
substantially
opposite to the direction of the protrusion of wings 163, and may be tapered,
being wider
adjacent nut body 165. Rebate 169 may be similarly tapered but marginally
smaller than nub
167. As nut 160 is threaded onto bolt shaft 161, nub 167 enters rebate 169.
Because rebate 169
is marginally smaller than nub 167, and both rebate 169 and nub 167 are
similarly tapered,
friction between nub 167 and sides of rebate 169 gradually increases. Once nub
167 is tightened
within rebate 169, loosening of nut 160, for example due to movement of
barbeque 40, may be
inhibited. Tapered rebate 169 may also guide nub 167 into position as nut 160
is tightened.
Beam connection member 116' 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.
Referring to Figure 10, a further alternative beam connection member 116",
preferably
made of metal, has twa walls 132" protruding substantially perpendicular to a
strut 118" of beam
connection member 116". Walls 132" are 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
20953910.4 - 32 -
CA 02363985 2001-11-23
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 bolt 164 is inserted, wall holes 162 and
bore 166 are
aligned and preferably generally vertically oriented to ~rmit 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 132" 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 Beam Connection Member to Leg Members
Beam connection member 116, may be rigidly attached to at least one, and
preferably
both, of the leg members 98, 100. If beam connection member 116 is attached to
both leg
members 98,100, then the connection member 116 may provide structural support
to support
member 62. Strut 118 of beam connection 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
w9s39io.a - 33 -
CA 02363985 2001-11-23
conduits 170. Each conduit 170 may be 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 118 to leg members 98 and 100, each leg member 98,100 is
inserted
through a respective conduit 170. The 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 members 98,100. This permits the leg members to be inserted
through 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 strut 118, the axes of conduits 170, are moved along the
longitudinal axis of the
leg members 98, 100.
Conduits 170 may be secured to leg members 98, 100 using pins 172 (see Figure
11).
Each 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 174a,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.
Pin 172 preferably has a head 178, 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
20953910.4 - 34 -
CA 02363985 2001-11-23
to inhibit longitudinal movement of the pin 172 within the holes 174,176.
Catch 180 is located
at 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. An annular rebate 184 may also be provided
in pin 172.
The annular rebate 184 is located adjacent to catch 180, 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
attach 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 188, which is larger than entry 174a to
inhibit movement of
pin 186 along its longitudinal axis within the holes 174, 176. Pin 186 may
also have a catch 189
to inhibit longitudinal mavement 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 exit hole 176b to inhibit pin 186 from being removed
once end 190 is
fully inserted therethrough. To facilitate passage of catch 189 through
marginally smaller exit
hole 174b, end 190 may be tapered. To further facilitate passage of catch 186,
end 190 may have
at least one and preferably three partially transverse slats 192 emanating
from a central
longitudinal axis of pin 186. Each slot 192 is preferably uniformly angularly
displaced from the
other. As end 190 is inserted through the marginally smaller exit hole 174b,
slots 192 permit end
190 to narrow, facilitating passage of catch 186, therethrough. Slotted pin
186 may be made of a
resilient material such as a plastic so that end 190 returns to its original
shape once it passes
20953910.4 - 35 -
CA 02363985 2001-11-23
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
movement 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
made of a metal. To accommodate both rounded and square leg members 98,100,
ends 152' of
strut 118' rnay have concave rebates 194, instead of having conduits 170.
Concave rebates 194
may 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
between edges 196 of the arcuate rebate 194, strut 118' may be welded to leg
members 98',100'
along edges 196.
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 beam 66 is substantially perpendicular to
both strut 118 and
20953910.4 - 36 -
CA 02363985 2001-11-23
legs 98,100. Similar relationships between the analogous structural elements
of the alternative
embodiments are also preferred.
Referring to Figure 7B, in an alternative embodiment, beam connection members
116,
122 extend and combine to form a unitary beam connection member 197. Unitary
beam
connection member 197 does not have beam receptacles 120,124, nor is a cross
beam 66
included. Instead, the beam connection members 116a and 122a of each support
member 62, 64
are integral with one another, having a joining portion 199 therebetween. To
reduce the size of
the combined beam connection members, for example for shipping, the joining
portion may be
bifurcated (not shown). The bifurcation is preferably located equidistant from
each connection
member 116a and 122a. 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 ~t or friction fit to permit unassisted
joining and separation
of the connection members.
Beam Securing Apparatus
Referring again to Figures 5, 6, 7, 7A, 8, and SA, and to Figures 13A and 13B,
a beam
securing apparatus 198 of beam connection member 116 secures beam 66 within
receptacle 120.
Beam connection member 122 may have a similar configuration to beam connection
member
116, and is discussed in greater detail below.
The beam securing apparatus 198 includes a fastener for attaching receptacle
120 to beam
20953910.4 - 37 -
CA 02363985 2001-11-23
66. The fastener may be a manually installable fastener, such as bolt 200
(Figure 13A and 13B)
that may be installed and tightened by hand. Bolt 200 may additionally be
loosened and
removed by hand. The beam securing apparatus 198 also includes an opening or
passage, in the
nature of a hole 202 defined in one of walls 132 and passing therethrough. A
shaft 201 of bolt
200 having a threaded end 204 may be inserted through hole 202, and may be
received by a bolt
retainer in the nature of a corresponding bore of the beam securing apparatus
198, which may be
a bushing 206, fixed in the cross beam 66. Bushing 206 preferably has internal
threads 207 for
threaded engagement with the threaded end 204. Hole 202 is smaller than a head
208 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 132 of
receptacle 120 by bolt 200,
inserted through hole 202, into bushing 206, 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 rnay 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 protrusion in the nature of 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 204 of bolt 200, and is open adjacent
the point of
20953910.4 _ 3g
CA 02363985 2001-11-23
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 2I2. The shape of
void 216 need not be uniform, nor does it have to correspond precisely to the
shape of collar 212.
The shape of void 216 and collar 212 need only be sufficiently similar to
permit threaded end
204 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 to 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 may also include a slot 224 located in attachment
wall 210
to 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, and 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 212a and 212b. To facilitate movement of
collar pieces 212a
20953910.4 _ 3~ _
CA 02363985 2001-11-23
and 212b relative to one another, so that beam end 128 may be gripped, slot
224 preferably
extends 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
the slot 224 between adjacent portions 210a and 210b may also facilitate
movement of collar
pieces 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 may facilitate varying degrees of
relative movement of
collar 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
another to reduce the overall length L 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
preferably initially has substantially the same perimeter as beam end 128.
This enables a
marginal reduction in the receptacle's perimeter to cause the walls 132 to
grip the beam end 128.
To keep collar pieces 212a and 212b proximate to one another, bolt 200 is
installed while
maintaining the position of pieces 212a and 212b. As bolt 200 is tightened,
proximate collar
pieces 212a and 212b enter void 216. The 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
the movement of collar pieces 212a and 212b. This arrangement maintains the
grip of receptacle
walls 132 on beam end 128.
20953910.4 - 40 -
CA 02363985 2001-11-23
Bolt 200 and collar pieces 212a and 212b may be configured to cause beam end
128 to be
progressively clamped as bolt 200 is tightened. This may be achieved by
configuring the annular
void 216 of the bolt 200 to be narrower at a closed end 228 of void 216, and
to be progressively
wider at an open end 230 of void 216. Annular void 216 has an outer
circumferential surface
222a and an inner circumferential surface 222b. In the illustrative embodiment
outer
circumferential surface 222a is angled, at 10 degrees for example, relative to
the axis of threaded
end 204. As a result, outer surface 222a is further from threaded end 204 at
open end 230 of the
void than it is at closed end 228. In the illustrative embodiment, the
diameter of outer
circumferential surface 222a is approximately one inch adjacent open end 230.
Inner
circumferential surface 222b may be angled in a direction opposite to that of
surface 222a, 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
circuxnferential 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 by open end 230 of void 216. This permits
free ends 234a
and 234b to be inserted into void 216 as threaded end 204 of bolt 200 is
inserted into hole 202.
As bolt 200 is tightened, the outer circumferential surface 222a of void 216
and the
corresponding outer circumferential surface portions 232a, 232b of collar
pieces 212a and 212b
20953910.4 - 41 -
CA 02363985 2001-11-23
gradually come into sliding contact with one another. Slot 224 permits collar
pieces 212a and
212b to move closer to one another as force is exerted on the pieces 212a,
212b by outer
circumferential surface 222a. This force is caused by the tightening of the
bolt 200 moving the
screw head 208 closer to the collar pieces 212x, 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 may be manually tightened to the point
that collar pieces
212a and 212b are at least partially retained by void 216. This arrangement
permits the cross
beam end 128 to be gripped by walls 132 forming a substantially rigid
connection between cross
beam 66 and support member 62, without the need for tools. Furthermore, the
connection may
be made using one bolt 200 at each end 128 of cross beam 66. Because collar
pieces 212a and
212b 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
be 0.10 inches across, and slot narrow portion 236b may be 0.06 inches across.
20953910.4 - 42 -
CA 02363985 2001-11-23
In an alternative embodiment, the outer surface 222a of void 216 may be
configured to
define other shapes such as a concave or convex taper (not shown) or some
other, preferably
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
shape 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 be achieved. For example, instead of a collar, a plurality
of posts may be
provided (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
may be gripped as the bolt 200 is tightened, walls 132 defining receptacle 120
may be made of a
20953910.4 - 43 -
CA 02363985 2001-11-23
bendable material, and are preferably made of a resilient material. An
appropriate plastic or
metal, for example, may be used.
The head 208 of bolt 200 may be graspable, having, for example, external
grips, such as
knurls (not shown), cross hatches (not shown), or ridges 238, to provide
greater friction to
facilitate unassisted 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
0.625 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 end 204, may be located
about the circumference
of the cylindrical head 208. Turning of the bolt 200 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 an axis passing through a
centroid of head 208.
Head 208 may be 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
208, the threaded end 204 may be part of a bolt 240 having a bolt head 242. To
receive threaded
end 204, screw head 208 may be provided with a bore 243 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 centered about bore 243, 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 243. Because rebate 244 is marginally smaller
than bolt head
20953910.4 - ~ -
CA 02363985 2001-11-23
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-rotatable bolt head, such as
a 1/4-20 hex bolt, is
preferably used to increase rotational resistance between screw head 208 and
bolt head 242
within rebate 244.
Fuel Source Support
Referring to Figure 7, beam connection 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 sowce support base 92
for supporting a
self 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 is preferably moulded to have a fuel source support
base
92, 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 such as part number G20-28
manufactured by
Wolfdale Engineering Ltd. of Brampton, Ontario, may be used to determine the
dimensions of
20953910.4 - 45 -
CA 02363985 2001-11-23
support base 92. Base rim 246 is received by a corresponding receptacle in the
nature of a base
rim cavity 248 defined in support base 92. Because base rim cavity 248
conforms to the shape of
base rim 246, tipping or other movement of tank 90 is hindered by the support
base 92. A void
250 may be located in cavity 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. For example, support base 92 may
have an abutment
including portions defining a receptacle in the nature of 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 does not need to encompass the entire circumference of tank 90. 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 tank 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 124
to avoid encountering cross beam 66 and the portions defining lower tank
cavity 252. Base 92 is
preferably moulded from plastic but may moulded from metal as well.
Referring to Figures 9,15 and 60A-60D, 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 connection 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
20953910.4 - ~ -
CA 02363985 2001-11-23
cross-section, and may be attached between leg members, such as leg members 98
and 100, or
98' and 100'. The U-shaped cross-section has arms 256 and 258 which are joined
by a base 260
(best seen in Figures 60C and ~D). Arm 256 and arm 258 of the U-shaped cross-
section are
preferably substantially at right angles to base 260. Strut 254 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 256 and 258 may be generally parallel 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
258
may have an opening 262 formed therein for receiving beam end 128'. Opening
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
262 until beam end 128' abuts arm 256 of strut 254. Arm 256 of strut 254 may
additionally have
a supporting member attached thereto for supporting beam end 128'. The
supporting member
may be in the form of a substantially perpendicular flange 264 along a free
edge 266 of arm 256,
flange 264 being generally directed towards opening 262. Beam end 128' may
rest on flange 264
once beam end 128' abuts arm 256.
20953910.4 - 47 -
CA 02363985 2001-11-23
Referring in particular to Figures 60A - 60D, to further inhibit movement of
beam end
128' when inserted into opening 262, one or more projections 267, extending
from base 260, abut
beam end 128'. Projections 267 may be added to base 260 or they may be stamped
from the
same material as base 260, creating holes 269, as shown in Figure 60A. When
fully inserted into
opening 262, beam end 128' is inhibited by arm 256, flange 264 of arm 256,
base 260 of strut
254, projections 267 and edges of opening 262. Opening 262 may additionally
have a flange
such as a peripheral flange (not shown) for abutting cross beam 66.
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 may 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.
This 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 mid-section 268 projected in an opposite
direction.
The widening of mid-section 268 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, mid-section 268 may be configured to
permit a base rim
cavity 248' which receives a segment, for example half, of the base rim 246 of
propane tank 90.
20953910.4 - 48 -
CA 02363985 2001-11-23
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 a similar radius to base rim 246.
Arcuate wall 272 may be
curved in the general direction of opening 262, or it may curve in some other
direction, such as
away from opening 262.
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 shown in Figures 9 and 15.
As a result of the reduction or elimination of tank cavity 252, the central
axes of openings
142 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
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'.
Hole 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 of bolt 278 in a downward direction. This arrangement permits
bolt 278 to rest
20953910.4 - 4,9 -
CA 02363985 2001-11-23
within hole 280 and bore 282, while partially securing beam connection member
122' to beam
end 128'. Wing nut 284 may then be conveniently attached and tightened.
Referring to Figures 48A, 48B and 51, in a manner similar to that described
above for
bolt 154, rotational movement of bolt 278 may be inhibited by a portion 285 of
bolt shaft 289
defining a non-round shape. Shaft portion 285 may be located adjacent bolt
head 367. At least
hole 280 (shown in Figure 9) may be configured to have substantially the same
cross-sectional
shape as defined by a periphery of shaft portion 285 to permit shaft portion
285 to be located
therein. Because shaft portion 285 is non-round, and may be located within a
similarly sized
hole 280, shaft 289 may be inhibited from rotating, for example, when nut 284
is threaded and
tightened thereon. This may permit additional manual tightening of nut 284 to
bolt 278 to
further inhibit movement of connected beam end 128' relative to beam
connection member 122'.
Nut 284 may be configured in a similar manner as described for nut 160, and it
may
likewise co-operate with a corresponding rebate 291, in a similar manner that
nut 160 co-
operates with rebate 169 to form a friction flt when nut 284 is threaded onto
shaft 289.
Referring to Figure 16, an alternative configuratian for supporting a tank 90
is shown. In
the illustrated configuration, a beam connection member 286 having
substantially the same
structure as beam connection member 116" 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 strut 290 spanning legs 98 and 100, a
portion of curved
20953910.4 - 5~ -
CA 02363985 2001-11-23
tank body 292 (shown in Figure 1) 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
90 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
248" which conforms to and receives at least a portion of a tank base rim 246,
and preferably the
full circumference of base rim 246.
Referring 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
92" may be made from injection moulded 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
92". 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" and tank 90 may be rotated to a
generally upright position.
Movement of tank 90 may 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 for receiving tank base rim 246.
For added
support, base 92" may have one or more sections 300 (see Figure 18) which
conform to a portion
20953910.4 - $1 -
CA 02363985 2001-11-23
of tank 90 to resist movement of tank 90 and to strengthen collar 298.
Sections 300 may be
located adjacent posts 294 to limit movement of tank 90 in a direction along
the pivotal axis of
base 92". Referring again to Figure 17, additional retention of tank 90 may be
achieved by
addition of a tank support 302 which extends from and substantially normal to
base rim collar
298, 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
arcuate portion 306 that substantially conforms to a portion of the
circumference of tank 90, such
as 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 the radius of tank body 292 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
20953910.4 - 52 -
CA 02363985 2001-11-23
perpendicular to semi-circular portion 320. The remaining end of wire member
318 may have a
loop 324 defining a generally circular opening, the centroid of which is
located on a line co-axial
with a longitudinal axis of mounting portion 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
opening 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 be 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
minor
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
encompasses greater than half of the circumference of a portion of the leg
member so that the leg
is retained by clip 328. Similarly, if leg 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 members 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
20953910.4 - 53 -
CA 02363985 2001-11-23
place by friction at the interface between the mounting clip 328 and the leg
member 98, 100.
However, 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
leg members 98 and 100 to a position adjacent shelf 70. This positioning
provides clearance for
tank 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
90. Any lateral movement of tank 90 within base 92 causes collar 314 to come
into contact with
valve 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
90.
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 permits passage of a leg member 98 or 100.
Since mounting
clips 328 are preferably made of a generally 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. The respective mounting portions 322 of each curved wire
member 318
may then be inserted into the reserve 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 to one another as they are aligned with their respective
mounting holes 330.
20953910.4 - 54 -
CA 02363985 2001-11-23
Once aligned, the resilient curved portions 320 encourage the respective
mounting members 322
to enter the mounting holes 330.
Curved portions 320 of collar 314 may alternatively have radii marginally
larger than the
radius of tank body 292. 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.
Referring to Figure 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 21B, curved portion 320" may be additionally
configured to
capture 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 316.
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
20953910.4 - 55 -
CA 02363985 2001-11-23
portions 322, may be inserted directly into mounting holes located in each leg
member 98 and
100 for rotational movement therein.
Referring to Figures 44 to 47F, an alternate fuel source retainer 341 is
shown. Unlike the
above-described fuel source retainers, retainer 341 may depend from bridging
member 104 and
engage valve protecting sleeve 316 to inhibit movement of tank 90 when placed
on a support
such as beam connection member 122', having base rim cavity 248'. Retainer 341
may be used
in conjunction with other supports such as fuel source support base 92. In the
present
description, retainer 341 will be described in the context of a tank 90
supported by beam
connection member 122'.
As illustrated in Figures 44 and 45, retainer 341 includes a mounting member
in the
nature of mounting bracket 343 and an engaging member 345. Mounting bracket
343 and
engaging member 345 abut opposite sides of tank collar 316 to inhibit movement
of collar 316
and, by connection, tank 90. Bracket 343 may be secured at an end to another
component of
barbeque 60 so that movement of bracket 343 is minimized. For example, bracket
343 may be
attached to bridging member 104. If bracket 343 is attached to bridging member
104 it may be
welded or otherwise connected to a flange 602 thereof. While bracket 343 may
be attached to a
side of flange 602, it may also be attached to an edge of flange 602.
In an illustrative configuration, bracket 343 may be generally L-shaped,
having a first
arm 347 for attachment to flange 602 and a second arm 349 which, when
installed, projects away
from bridging member 104 so that it may abut tank collar 316 when tank 90 is
placed in base rim
20953910.4 _ $6
CA 02363985 2001-11-23
cavity 248'. One or more protrusions in the nature of longitudinal flanges 335
and 337 may be
added to or integrally formed in bracket 343. Flanges 335 and 337 are
preferably angled from
bracket 343 so that they are positioned to contact tank collar 316. This
configuration encourages
at least two points of contact between bracket 343 and tank collar 316. If
flanges 335 and 337
are not included then there might be only one point of contact between bracket
343 and tank
collar 316. In addition to, or instead of, flanges 335 and 337, bracket 343
could have a generally
arcuate shape (not shown) to conform to arcuate tank collar 316. In any
embodiment, bracket
343 is preferably constructed of a substantially rigid material such as a
metal, and may
additionally be strengthened by forming a longitudinal indent 351 therein.
Referring in particular to Figures 46A - 47F, engaging member 345 co-operates
with
bracket 343 to engage and retain tank collar 316 therebetween. Engaging member
345 includes
at least one slot 353, and preferably a pair of slots 353, which receive edges
355 of an opening
357 in bracket 343. Opening 357 may be oriented generally co-axially with a
longitudinal axis
of second arm 349, with edges 355 running generally parallel to the
longitudinal axis. Slots 353
are preferably parallel to one another, and may slidingly engage edges 355 to
permit movement
of engaging member 345 along edges 355 from an engaged position (see Figures
44 and 45),
where tank collar 316 is retained, to a disengaged position (not shown) where
tank collar 316 is
not retained. Slots 353 may define in engaging member 345 a head portion 361
and a body
portion 363, having a stem 365 therebetween. To reduce play in collar 316,
when retained by
fuel source retainer 341, body 363 may be curved to correspond to the
curvature of collar 316.
Head 361 preferably has a shape that is generally similar to, but smaller
than, that of opening
357, and slots 353 run generally transverse to a longitudinal axis of head
361. This configuration
20953910.4 _ $7 _
CA 02363985 2001-11-23
permits head 361 to be inserted into opening 357. Further insertion may be
inhibited by
configuring body 363 to be larger than opening 357. As engaging member 345 is
rotated about
stem 365, with head 361 inserted in opening 357, edges 355 enter slots 353.
When engaging
member 345 is rotated in this manner by approximately 90 degrees, portions of
edges 355 are
retained within slots 353, inhibiting movement of engaging member 345 in a
direction transverse
to opening 357, but permitting sliding movement along a longitudinal axis of
opening 357.
Sliding movement permits engaging member 345 to be moved from an engaged
position to a
disengaged position. To facilitate this sliding movement, slots 353 preferably
have a width that
is at least the same as the combined thickness of mounting bracket 343 and
tank collar 316. This
permits collar 316 to be retained, having body 363 on one side and mounting
bracket 343 on the
other. However, this width of slot 353 may permit play between engaging member
345 and
mounting bracket 343. Addition of a shim 373, projecting into slot 3S3 to
narrow at least a
portion of slot 353, may reduce this play. Figures 47G and 47H show engaging
member 345
with an elongated shim 373' which may further reduce play in engaging member
345.
Engaging member 345 may additionally be provided with a protrusion in the
nature of a
tab 359 for grasping and moving engaging member 345 between engaged and
disengaged
positions. Tab 359 preferably projects from a side of body 363, and may have a
generally
arcuate shape to facilitate grasping and moving of body 363 by hand.
Engaging member 345 is preferably moulded from a plastic, and may include a
hole 375
to encourage cooling during the moulding process.
20953910.4 _ 5g _
CA 02363985 2001-11-23
To retain tank collar 316, tank 90 is first placed onto beam connection member
122', but
held with collar 316 tilted away from fuel source retainer 341. Engaging
member 345 may then
be moved to a disengaged position to permit placement of collar 316 adjacent
or abutting
mounting bracket 343. Once tank 90 is tilted toward fuel source retainer 341
to locate collar 316
adjacent or abutting mounting bracket 343, engaging member 345 may be slid
into an engaged
position by grasping tab 359 and moving the engaging member 345 to retain
collar 316.
Referring to Figure 44, movement of tank 90 may be further inhibited by using
bolt 278
as a fuel tank retaining bolt to retain tank rim 246 within cavity 248'. To
retain tank rim 246, a
head 367 of bolt 278 may be located adjacent arcuate wall 272 with
substantially the thickness of
tank rim 246 therebetween. In this configuration, lateral movement of tank rim
246 when placed
between head 367 and arcuate wall 272, may be inhibited by arcuate wall 272
and bolt head 367.
If bolt head 367 is tapered, being narrower at its free end 369, a generally V-
shaped opening 371
is formed between head 367 and arcuate wall 272. As tank rim 246 is placed
between head 367
and arcuate wall 272, it may be guided into position by the narrowing V-shape.
Shelves
Referring to Figures 22, 23 and 24, barbeque 60 may have a shelf 68 or two
shelves
(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.
20953910.4 - 59 -
CA 02363985 2001-11-23
The description of shelf 68 that follows therefore substantially applies to
the second shelf, as
well. Shelf 68 includes a body 333 having a generally planar surface 339. Body
333 may be
supported by at least one arm in the nature of a shelf supporting portion 340.
Shelf supporting
portion 340 may be formed from leg member 98, and a second shelf supporting
portion 342 may
be formed from 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 sufficient
length to support shelf 68. In the illustrative embodiment, each supporting
portion 340, 342 is
approximately 15.5 inches long, oriented in substantially 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 344 and 346 having
receptacles 348 and 350,
which receptacles each receive a respective free end 352 and 354 of supporting
portions 340 and
342. At least free ends 352 and 354 may be frictionally retained within shelf
retainers 344 and
346. 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 retainers
344 and 346 are substantially similar to one 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
be 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
348. If the cross-section of the receptacle 348 and corresponding supporting
portion 340 is
20953910.4 - 6
CA 02363985 2001-11-23
substantially the same size, then a friction fit may be formed between
receptacle 348 and
corresponding supporting portion 340. 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
348, receptacle 348 may be provided with a 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 hole or 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. When void 358 of supporting portion 340 is positioned to
correspond with the
location of ramp 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. Alternatively, receptacle 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
20953910.4 - 61 -
CA 02363985 2001-11-23
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
may be subsequently inserted into receptacle 348. Conduit 368 thus generally
guides free end
352 toward receptacle 348. Once free end 352 is received by receptacle 348,
conduit 368
inhibits the movement of supporting portion 340 relative to shelf 68. Conduit
368 may be
attached to, or be formed integrally with (for example, by moulding), 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 368a and 368b are
preferably the
same size but may be unequal. By using conduit portions 368a and 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.
Referring to Figures 55A and 55B, conduit 368 alternatively may be generally J-
shaped.
Furthermore, as shown in Figure 55A, conduit 368 may be displaced from
receptacle 348 by a
greater distance than is shown in Figure 22. This increased spacing may
provide greater
resistance to a release of an attached leg member 98 from conduit 368 when
shelf 68 is in an
operative position and a generally downward force is applied to a free end 377
of shelf 68.
Alternatively, to provide a greater area of contact for retention of
supporting portion 340, conduit
368 may be lengthened to meet receptacle 348 to form a single continuous
passage (not shown).
Shelf 68 could alternatively be attached to supporting portions 340 and 342 by
bolting,
20953910.4 - 62 -
CA 02363985 2001-11-23
welding, or some other attachment means. While shelf supporting portions 340
and 342 are
integral 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 shelf 68.
Referring to Figures 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 ~ cleaned, for
example in a
dishwasher, or it may be put to some other 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.
Removable member 370 may also have a ridge (not shown) about the perimeter of
its surface
339', and a drain (not shown) to permit removal of a liquid such as rain water
by gravity.
To accommodate removable member 370, shelf 68' may have a generally U-shaped
shelf
frame 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 fit therebetween.
Removable
member 370 may alternatively or additionally be fastened to frame 372 with a
fastener (not
shown), or held in place by gravity. While frame 372 may define a closed
opening, for example
20953910.4 - 63 -
CA 02363985 2001-11-23
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 376 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 382 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 defined to retain member 370 within frame 372
while
permitting unassisted installation and removal of member 370 therein.
Removable member 370
may be any generally planar shape suitable 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
member 100. Because channel members 392' and 394' are similar, a description
of channel
member 394' will be provided. This description applies equally to channel
member 392' with
20953910.4 - ~ -
CA 02363985 2001-11-23
necessary modifications for receiving supporting portion 340.
Channel member 394' may be attached to arm 388 of U-shaped shelf frame 372
along a
closed side 396 of the channel 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 frame 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-sectian
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 cross-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 as there is sufficient frictional contact between the
supporting members
and the inner surface of the channel. A channel having a generally square
cross-section, for
example, may also receive and retain a supporting member having a circular
cross-section with a
diameter that is substantially the same magnitude as the length of the sides
of the channel's
20953910.4 - 65 -
CA 02363985 2001-11-23
square cross-section. In this configuration, the circular supporting member
contacts the inner
surface of the conduit along lines defining the mid-points of the channel's
sides, and is retained
by the channel. In combination with the various configurations of channel and
support member,
ramp 356' serves to further retain the support member within the channel.
Referring to Figure 27, in a yet further alternative embodiment of shelf 68,
labelled 68", a
fastener 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 other. The description of one therefore applies
to the other.
Shelf bracket 414 retains and secures slat ends 416 to a supporting portion,
such as
supporting portion 340. The shelf bracket 414 has a narrow body with a
longitudinal bend 418
therein to form to arms 420 and 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 either 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 are located to abut slats 408 that are not adjacent the
ends of bracket 414.
These additional protrusions may also be used to evenly space slats 408 from
one another. The
20953910.4 - 66 -
CA 02363985 2001-11-23
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
each 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.
Holes 426 of arm 422 are then aligned with both the hole 410 in the adjacent
slat 408 and hole
412 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
428 (shown in Figure 22) defined in shelf 68 for gripping shelf 68. Shelf 68
may also have an
indentation defining a cup 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),
cup 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 same
configuration as shelf frame 372, and a burner apparatus 438 which may include
a burner tray
440 having a similar configuration to removable member 370. Burner tray 440
may also be
20953910.4 _ 67
CA 02363985 2001-11-23
installed and retained within burner frame 436 in a manner similar to that
described for
removable member 370. Similarly, burner frame 436 may be installed and
retained in
substantially the same manner as described for shelf frame 372.
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 flange 444 for receiving a fastener such as
bolt 446 for
fastening burner frame 436 to burner tray 440.
Referring additionally to Figure 54, to inhibit movement of burner tray 440
relative to
burner frame 436, at least one fastener in the nature a bolt 442 may be
inserted through a hole
such as hole 443 in channel member 392' and into an aligned threaded bore 445
in burner tray
440. As described, flange 444 may also be used for fastening burner frame 436
to burner tray
440. The combined burner tray 440 and frame 436 may then be attached to shelf
supporting
portion 340 in the manner described above, namely by inserting shelf
supporting portion 340 into
channel member 392'. While a head 447 of bolt 442 may protrude into the
channel defined by
channel member 392', it is preferably located or otherwise configured to clear
supporting portion
340. Referring to Figure 53A., a projection in the nature of a stop 449 may be
located adjacent
channel member 392' to inhibit further insertion of supporting portion 340
therein.
Burner tray 440 has a burner pan 448 in which a standard burner, such as
burner 450 may
reside. For example, a burner manufactured by Lincoln Brass Works of
Waynesboro, Tennessee
may be used. Burner pan 448 may be formed from the same piece of material as
burner tray 440
20953910.4 _ 68 _
CA 02363985 2001-11-23
to form one integral piece. For example, burner pan 448 and tray 440 may be
stamped from a
single piece of sheet metal. As shown in Figure 29, a variation of burner pan
448, labelled 448',
is illustrated. Burner pan 448' may be manufachued as a separate part that
rests within a burner
pan opening (not shown) and that is supported by a peripheral flange 452.
Referring to Figures 53A - 55, burner tray 440, may additionally include an
abutting
member in the nature of a burner tray bracket 453 for attaching tray 440 to a
leg member, such as
cylindrical leg member 100 (attachment to leg shelf supporting portion 342 is
shown in Figure
55). Burner tray bracket 453 abuts shelf supporting portion 342 to inhibit
movement of burner
tray 440 relative to supporting portion 342.
Burner tray bracket 453 may be integrally formed with burner tray 440, and may
project
from tray 440 to abut shelf supporting portion 342. While bracket 453 may
tangentially abut
cylindrical shelf supporting portion 342, if a shelf supporting portion having
a non-rounded
profile is employed, such as shelf supporting portion 342', then bracket 453
may abut the
supporting portion substantially flush, along a corresponding surface thereof
(not shown).
A fastener, including a nut and bolt, or a bolt having a serrated neck (not
shown) which is
similar to bolt 612", may be used to connect burner tray bracket 453 to shelf
supporting portion
342. The bolt may be inserted through a hole 455 in bracket 453, and into a
corresponding pair
of aligned holes 457 and 459, located in shelf supporting portion 342. Once
inserted, the bolt
may be secured by a manually tightenable retainer, such as a wing nut. If a
shelf supporting
portion having a non-rounded profile is employed, such as shelf supporting
portion 342', then the
20953910.4 - 69 -
CA 02363985 2001-11-23
fastener may be inserted through a hole 463 in bracket 453, and a
corresponding hole in
supporting portion 342', which is located to align with hole 463 (not shown).
Burner tray bracket 453 may include an additional member, in the nature of an
angled
flange 461, which may be configured to tangentially abut shelf supporting
portion 342 to further
inhibit movement of burner tray 436. Even if bracket 453 is not attached to
supporting portion
342 using a fastener, flange 461 serves to inhibit removal of tray 448 from
supporting portion
342 in at least a direction generally transverse to the plane of tray 448.
Referring again to Figure 28, burner 450 has a burner element 454 that is
attached to a
fuel conduit 456. Burner element 454 may have a fastener in the nature of a
threaded post 458
attached thereto. Threaded post 458 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 456 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 454 to inhibit passage of element 454 therethrough. Proper placement
of conduit 456
within conduit hole 464 may be facilitated both by threaded post 458 and 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 456 and may have
substantially the
same radius of conduit 456. An optional spider guard 474 may be included at
input end 466 to
inhibit entry of spiders and other insects therein.
A burner grill 476 may be located adjacent burner element 454, and is
preferably located
20953910.4 _ 7
CA 02363985 2001-11-23
to receive heat from burner 450 when burner 450 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.
In the illustrative embodiment, burner grill 476 has four legs 478 which may
be received by four
leg holes 480 in burner tray 440. When legs 478 are inserted into leg holes
480, lateral
movement of burner grill 476 is limited. At 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 440. Once
curved ends 482
are inserted, burner grill 476 may be rotated about curved ends 482, which
reside in leg holes
480, to a position generally parallel to 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 may be further inhibited.
Burner valve 470 may be inserted into valve opening 484 from a side of burner
tray
opposite to that of burner pan 448, and may be attached to burner tray 440
with a valve mounting
apparatus, such as valve clip 486. Valve opening 484 may be generally circular
and may have
one or more engaging members in the 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 of 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 - 30C, 58, 59 and 73A - 73E, valve clip
486
20953910.4 _ 71 _
CA 02363985 2001-11-23
includes a body 487 which 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 in part by fins 488. Planar portion 498 also has an
opening, such as
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 be attached to a standard burner valve, such as burner
valve 470,
which is manufactured by Lincoln BIaSS Works of Waynesboro, Tennessee. Because
valve clip
486 is preferably attached to burner valve 470 by a manufacturer, it may be
fastened to burner
valve 470 using screws 508 inserted through bores 509 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 of a length to ensure that valve stem
projects through
valve stem opening 504 a sufficient distance to engage a valve knob 512 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.
Once burner valve 470 is attached 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 486 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
20953910.4 _ 72 _
CA 02363985 2001-11-23
shown in Figure 30C). This rotation aligns the curved portions 490 of fms 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 may be additionally configured to retain fins 488. Curved ends
500 of
planar member 498 may be provided with a slot 518 which bisects the curved
ends 500 to form
two parallel wings or curved ends 500a and 500b for retaining fms 488. In this
configuration,
planar member 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
fms 488. Rotation of valve clip 486 by 90 degrees causes edges 496 of fms 488
to enter
respective slots 518. Once fms 488 enter slots 518, curved ends 500a and 500b
retain respective
fins 488 therebetween (as shown in Figure 30C). If one or both slots 518 is
narrowed to
substantially the same thickness as fms 488, fms 488 may be frictionally
retained therein.
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
into the plane of slot 518. When valve clip 486 is inserted into valve clip
opening 484, ramps
520 abut fms 488. As valve clip 486 is forced marginally further into valve
clip opening 484,
tabs 514 deflect away from the plane of 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
is best shown in Figure 30C. Further rotation of valve clip 486 is inhibited
by sheer side 522 of
20953910.4 _ '~3 _
CA 02363985 2001-11-23
each ramp 520 which abuts straight edge 496 of fm 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. The thickness of each tab 514 may be reduced to
facilitate temporary
deflection of tab 514 from its initial position. Once burner valve 470 is
installed, burner knob
524 may be attached to valve stem 506, and conduit 456 may be oriented to
cause valve output
468 to be inserted into conduit input end 466. Valve clip 486 may be removed
by manually
deflecting tabs 514, for example by forger 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
530 abuts fin straight edge 496 to inhibit transverse movement of valve 470
relative to fln
straight edge 496. Tangent portion 530 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 502 of valve clip 486 adjacent tab 514.
When valve clip
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 fm
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 fm 488 with slot 518,
curved edges 500a and
500b may be rounded in a direction generally normal to the plane of the curves
of curved edges
20953910.4 _ 74 _
CA 02363985 2001-11-23
SOOa and SOOb.
While the illustrative embodiment describes fins 488 having straight edges
496, edges
defining other shapes may 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 514 to be resilient.
Referring to Figure 29, a side burner 434' is configured for use with shelf
bracket 414.
The 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 may be used to secure burner tray 440. Shelf bracket 414
is
installed in substantially the same manner 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
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.
20953910.4 _ 75 _
CA 02363985 2001-11-23
Panel
Referring 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
98 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.
Panel 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
leg member 98 or 100. Panel 72 is preferably mounted to be substantially
parallel to cross beam
66.
A pocket 536 may be integrally formed in panel 72. Pocket 536 may be used for
holding
condiments or utensils (not shown). Pocket 536 may have a bottom 538 which
projects from
panel 72. Sides of pocket 536 may be defined by a portion of panel 72 and at
least one wall 540
which traverses bottom 538. Additional walls such as wall 541 may be added to
define a four-
sided pocket 538 having a bottom 538. In the illustrative embodiment, pocket
536 extends along
substantially the entire length of panel 72. To better retain items stored
within pocket 536, at
least one of pocket sides 540, 541 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
tilting pocket 536 away from the plane of panel 72, for example by 12 degrees.
The location of
pocket 536 may be varied relative to longitudinal edges 542 and 544 of panel
72. For example,
as shown in Figure 2, pocket 536' may be located adjacent longitudinal edge
544' of an
20953910.4 _ 76
CA 02363985 2001-11-23
alternative panel 72', described below.
Panel 72 has at least one mounting member, and preferably two retaining or
mounting
members, in the nature of mounting posts or pins 546, each of which extends
from an edge
thereof. Each pin 546 extends from an edge 548 of panel 72 that 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, and
each pin 546 may
rest, and may additionally be frictionally retained, therein. Mounting holes
550 are preferably
located in one of legs 98 or 100 of each support member 62, 64. In the
illustrative embodiment,
each 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
example 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 have a
shape that conforms to a portion, and preferably at least a semi-circular
half, of the lateral
perimeter of a corresponding leg member 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 integrally formed with, panel 72 at a
mid-point of the curved
retaining clip 552. In this configuration, each clip 552 receives and retains
a portion of a
20953910.4
CA 02363985 2001-11-23
respective leg member 98 or 100, and limits movement of panel 72 in a
direction substantially
transverse to the plane of panel 72. If a leg member, such as leg 98', having
a non-round cross-
section is used, then retaining clip 552 may be configured accordingly.
In an alternative embodiment, each 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
preferably 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 end of clip 552 must be forced away from panel 72 to accommodate the
wider diameter of
leg member 98,100. Once leg member 98,100 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. The illustrative embodiment of
clip 552 may be
likewise configured to form a snap fit with leg member 98,100 by extending
free ends 556 to
encompass a greater portion of the lateral perimeter of legs 98, 100.
In a preferred configuration, the mounting members, including pins 546 and
clips 552,
substantially 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.
Referring to Figures 56 and 57, alternative panel 72' has a general
configuration similar
ao9s39io.a _ 78 _
CA 02363985 2001-11-23
to that of panel 72. Panel 72' differs in that it may be disassembled
permitting it to fit within a
smaller volume than in its assembled state for storage or shipping. Panel 72'
may be generally
planar, and may be mounted to legs 98', between support members 62' and 64',
using panel
mounting brackets 557. Brackets 557 may be identical, but are preferably
mirror images of one
another. Accordingly, the description of one bracket 557 applies to the other.
Bracket 557 has a mounting pin 546', which is configured and operates in a
similar
manner as described for mounting pin 546, for mounting the bracket 557 to leg
member 98'.
Similarly, a clip 552', which is configured and operates in a similar manner
as described for clip
552, may be added to one or both brackets 557 for mounting the bracket 557 to
leg member 98'.
Bracket 557 may be injection moulded or otherwise formed from a plastic, or
moulded from a
metal.
Panel 72' may additionally have an integral pocket 536'. Pocket 536' may be
defined on
one side by panel 72', and on another side by a generally opposed side 540',
which is joined to
panel 72' by a bottom 538'. Bottom 538' may located at substantially right
angles to both panel
72' and side 540' to form a three-sided pocket. Alternatively, bottom 538' may
be angled to a
greater or lesser degree relative to panel 72' and/or side 540' to change the
orientation of an item
contained within pocket 536', as described above for pocket 536. A single
sheet, for example, of
a metal such as steel, may be used to form panel 72' and pocket 536' by making
two folds therein
to define panel 72', bottom 538' and wall 540', respectively. The sheet thus
formed may have a
generally right angled J-shaped cross-section which cross-section terminates
at opposed edges
559 and 561 which generally trace the J-shaped cross-section. Alternatively,
panel 72' may be
20953910.4 _ 79 -
CA 02363985 2001-11-23
formed to have a rounded generally J- or U-shaped cross-section, or some other
shape defining
an integral pocket (not shown), by bending a single sheet of metal or other
appropriate material,
accordingly. In the present embodiment, bottom 538' may include one or more
holes (not
shown) to permit drainage of a liquid such as rain water from pocket 536'.
Pocket 536' may additionally be bounded by panel mounting brackets 557
adjacent
respective opposed edges 559 and 561 to define a five-sided pocket including
wall 540', panel
72', mounting brackets 557, and bottom 538'. Brackets 557 may be removably
attached to wall
540', panel 72', and bottom 538' along edges thereof. Each bracket 557 abuts
respective edges
559 or 561 to removably retain wall 540', panel 72', and bottom 538'
therebetween. Brackets 557
may additionally include one or more flanges for abutting a surface of one or
more of wall 540',
panel 72', and bottom 538', to inhibit movement thereof. The flanges of
bracket 557 preferably
abut the respective wall 540', panel 72', or bottom 538', adjacent edge 559
(or 561, as the case
may be).
In the illustrative embodiment, bracket 557 has a flange 563 for abutting a
surface of wall
540' adjacent edge 559. Similarly, flanges 565 and 567 abut panel 72' and
bottom 538',
respectively. To further inhibit movement of wall 540', panel 72', and bottom
538', additional
flanges may be added to bracket 557 to abut an opposite surface of wall 540',
panel 72', and
bottom 538'. For example, discontinuous flange 569, having flange portions
569a, 569b, 569c,
and 569d, may abut a surface of panel 72' opposite to flange 567. In this
configuration, a portion
of edge 559 may rest between discontinuous flange 569 and flange 567.
Similarly, a flange 571
may abut a surface of wall 540' opposite to flange 563. Flanges 571 and 563
may be joined at
20953910.4
CA 02363985 2001-11-23
ends thereof by a rounded or angled flange 585, which may reinforce the
connected flanges 571
and 563.
One or more of the flanges may also have reinfarcements. For example, flange
569a may
have a reinforcing flange 573. Reinforcements may also increase the overall
rigidity of bracket
557.
Panel 72' may additionally include one or more holes 575 located adjacent one
or both
edges 559 and 561 for receiving one or more respective tabs 577 which project
from a flange of
bracket 557, such as flange 567. When tab 577 is inserted through hole 575,
tab 575 inhibits
movement of panel 72' in a direction generally transverse to the projection of
tab 577 to inhibit
removal of bracket 557 from panel 72'.
Panel 72' may additionally have an angle 579 formed therein for directing a
free end 581
of panel 72' to locate adjacent console 86 when barbeque 60 is fully
assembled. Angle 579 may
traverse panel 72' between edges 559 and 561 causing free end 581 to be
displaced from the
plane of panel 72'. Free end 581 is preferably displaced to the same side of
panel 72' that side
540' is located. Brackets 557 may be likewise angled to accommodate angle 579.
For example,
bracket 557 may have angle 583 formed therein.
To assemble brackets 557 with the integral wall 540', panel 72', and bottom
538', portions
of edge 559 are inserted between opposed flanges 567 and 569, and between
flanges 571 and
563, with a portion of bottom 538' abutting flange 565. Edge 561 is similarly
inserted between
the flanges of the remaining bracket 557. As each edge 559 and 561 is
inserted, tab 577 enters
20953910.4 _ g 1
CA 02363985 2001-11-23
and locates within hole 575. Tab 577 may additionally be ramped, to permit
edge 559 (or 561)
to be guided over tab 577 before tab enters hole 575. Ramped tab 577
preferably has a generally
right-angle triangle cross-section so that a snap fit may be formed as ramped
tab 577 enters hole
575. Brackets 557, including panel 72' held therebetween, may then be attached
to support
members 62' and 64' in a manner similar to that described for panel 72.
In an alternative embodiment (not shown), brackets 557 may have a slot or
groove
instead of, or in addition to, flanges, for receiving edge 559 or 561.
Casting
Referring to Figures 1, 3 and 4, grill housing 74 has opposed castings 76 and
78 that may
enclose burner 80, grill plates 82, warming rack 84 and angled bars 88. In
operation, the castings
76 and 78 may be aligned vertically so that casting 76 is located generally
above casting 78. In
the following description each respective casting will be referred to as an
upper casting 76 and a
lower casting 78.
Lower casting 78 supports burner 80 and grill plate 82. Angled bars 88 for
deflecting
heat may also be supported by lower casting 78. The casting 78 preferably has
an interior
surface 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 casting 76 preferably has an interior surface
(not shown) that
defines a volume, which volume may be generally box-shaped. The interior
surface terminates
20953910.4 _ g2 _
CA 02363985 2001-11-23
at an edge 564 which defines an opening 568. Opening 568 is preferably
generally rectangular,
with edge 564 substantially conforming to edge 560 of lower casting 78 to
reduce spaces or gaps
therebetween. This may reduce heat loss from within the grill housing 74 when
castings 76 and
78 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 volumes and openings. For example,
each of the
interior surfaces could define a hemispherical volume and the edges could each
define a
generally circular opening.
As shown in Figure 32, castings 76 and 78 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 78
inhibit heat transfer from within the grill housing 74 to the surrounding
environment. Castings
76 and 78 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 78. Hinge 570
has a bolt 572
(shown in phantom) which is connected to upper casting 76, and semi-circular
receiving
members 574 and 576, which are connected to lower casting 78 and are
configured to receive
bolt 572. Bolt 572 may be slidingly inserted between semi-circular receiving
members 574 and
576, to form hinge 570. 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
20953910.4 _ g3 -
CA 02363985 2001-11-23
relative to lower casting 78. Handle 582 is preferably made of a heat
resistant material such as
wood or an appropriate plastic so that it remains relatively cool to the touch
even when the
castings 76 and 78 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
582 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 handle 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, to install handle 582', the generally parallel threaded
posts 586 are inserted
into handle holes 590 passing through upper casting 76. As noted above, a
gasket or gaskets 584'
may be placed between handle 582' and 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, for example, using wing nuts
592 or speed
nuts (not shown).
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 78 may be
modified from a
general box-shape, as described below.
Referring to Figure 2, lower casting 78 may rest on support members 62 and 64.
A
fastener such as bolt 596 may be used to inhibit movement of lower casting 78
relative to support
members 62 and 64. Bolt 596 may be inserted into a hole or casting bore 598
passing through
20953910.4 _ g4
CA 02363985 2001-11-23
lower casting 78, wherein bore 598 is substantially coaxial with a threaded
bore 600 in bridging
member 102 or 104 when lower casting 78 is aligned for assembly to member 62,
64. To
connect lower casting 78 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 78 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
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 limit repetition, only one half of the symmetrical bridging members
is described. It will
be understood that the undescribed other half of the symmetrical bridging has
as similar
structure.
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 78. In its operative position, support surface
604 is preferably
generally horizontally oriented and located at about waist height. For
example, support surface
604 may be located 26 inches from the base ends 110, 112 of leg members 98,
100. Increased
rigidity of bridging member 102 may be achieved by including at least one, and
preferably four,
protuberances 606 formed therein. Protuberances 606 preferably protrude by a
distance that is
20953910.4 _ 85 _
CA 02363985 2001-11-23
substantially the same as the thickness of the material from which bridging
member 102 is made,
and have a generally symmetrical shape such as a rectangle or oval. At least
two protuberances
606 straddle each bend 608 (which is formed by flange 602) so that bend 608
lies along a
longitudinal centerline of each protuberance 606. Instead of including
protuberances 606,
increased rigidity of bridging member 102 may be achieved by attaching at
least one, and
preferably four, gussets (not shown) thereto in locations similar to those
described for
protuberances 606.
Bolt 596 is preferably configured so that it may be manually installed and
tightened. Bolt
596 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 shaft 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
612 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
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
manually
tightenable fastener in the nature of a nut 610' having a threaded bore 616
through its axis,
instead of threaded shaft 612. A member in the nature of a post or a threaded
post 612' may be
20953910.4 _ 86 _
CA 02363985 2001-11-23
partially threaded into the threaded bore 600 of flange 602 so that it
protrudes from support
surface 604. Threaded post 612' 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 78.
Threaded post 612', and therefore casting 78, may then be secured to support
62, 64 by threading
and tightening nut 610' about the threaded post 612', whereby the casting 78
is sandwiched
between nut 610' and flange 602. Because the threaded post 612' is preferably
first connected to
flange 602, it may further serve as a locator for positioning the lower
casting 78 relative to the
bridging members 102 and 104. Threaded post 612' may additionally have a head
to form a bolt
618 which may be threaded through threaded bore 600, with its free end
protruding from support
surface 604.
Referring additionally to Figures 71A-72, an alternative threaded post in the
nature of a
bolt 612" may be inserted into bore 600 of flange 602. Bolt 612" additionally
has a serrated neck
613 for gripping edges of marginally smaller bore 600. Nut 610" may be
threaded onto bolt 612"
to retain lower casting 78 therebetween.
In the illustrative embodiment, the casting 78 may be guided to a preferred
alignment
relative to the support members 62 and 64, by employing an alignment device or
structure in the
nature of at least one, and preferably four, alignment or guide members such
as 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 and threaded therethrough. Guide posts
620 protrude from
grill housing 74, and preferably protrude from lower casting 78, in a
direction away from interior
surface 558. Openings or holes in the nature of guide bores 622, located in
flange 602 of
20953910.4 _ g7
CA 02363985 2001-11-23
bridging member 102, may receive the guide posts 620. The flanges 602 of each
bridging
member 102,104 preferably each have two spaced-apart guide bores 622 for
receiving the
respective guide posts 620.
The guide posts 620 may protrude from a side, such as bottom 624, of lower
casting 78,
bottom 624 being located generally opposite to the opening 562 of the lower
casting 78. 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
78 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 guide 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 78 is aligned relative to the
supports 62, 64, and the edges
632 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 78 relative to the
supports 62, 64.
As 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
20953910.4 _ 8g
CA 02363985 2001-11-23
protrude from support surface 604 into bores in lower casting 78 (not shown).
A hollow 636 may be provided in support surface 604 to encourage edges 632 of
guide
bores 622 to grip guide posts 620. Hollow 636 is defined by adjacent
protuberances 606 that are
displaced from one another along support surface 604 with an exposed portion
of support surface
604 therebetween. Hollow 636 is located adjacent threaded bore 600. In an
alternative
embodiment, hollow 636 is located with threaded post 612', passing
therethrough. When lower
casting 78 is placed onto protuberances 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 78. As bolt 596 (or nut 610' in an alternative embodiment) is
installed and tightened, bolt
596 is drawn into casting bore 598, and the gap narrows due to a partial
deformation of support
surface 604 (and flange 602) as it is moved towards lower casting 78 at hollow
636. This
deformation of surface 604 may create longitudinal tension in support surface
604 causing
portions of edges 632 of guide bores 622 to grip guide posts 620, thereby
biasing flange 602 to
lower casting 78.
The lower casting 78 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
preferably located in the bottom 624 of lower casting 78, and may be arranged
beneath burner
80. The lower casting 78 may further be provided with an ignition hole 287
therethrough for
igniting fuel by external means, such as a lighted match (not shown) inserted
therein. Burner 80
may alternatively be ignited using an ignition, described below.
20953910.4 _ 89
CA 02363985 2001-11-23
To provide a drain for grease and other drippings from food cooked within the
grill
housing 74, lower casting 78 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 78. When in operative position, bottom
624 may be
sloped downwards at between five and 15 degrees from the horizontal towards
drain opening
638. A cup, tube or other means (not shown) 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
inserted into and retained by a hole 642 in lower casting 78 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
78 for
supporting a rotisserie (not shown). The rebates 644 are preferably generally
located at the mid
points of opposite sides of edges 560.
Biased Supports
Increased frictional retention of at least one of the components of the
barbeque assembly
may be achieved by altering the orientation of two components relative to one
another after they
have been assembled to a new orientation, and then maintaining the components
in the new
orientation. Changing the relative orientation of connected components causes
the components
to bear against each other with greater force in the area of interconnection.
This may increase
20953910.4
CA 02363985 2001-11-23
the friction between components which may make it more difficult to further
move the
components relative to each other. This additional force may also cause the
connected
components to bear on any fastener used to connect them which in turn may make
the engaged
fastener more difficult to remove. As a result, the connected components are
more tightly
coupled than connected components to which a force has not been applied.
Altering the orientation of two connected components may also cause elastic
deformation
of at least one of the components. A proportionately greater force may then be
required to
further deform the component. Accordingly, a component subject to a force
becomes stiffer and
more resistant to further deformation provided that the yield point for the
material has not been
reached.
Referring to Figures 2, and 74 to 77, in the embodiment, a cross member such
as cross
beam 66' may be connected to a first support member 62' to orient first
support member 62' in an
initial position relative to cross beam 66'. These components 62' and 66' are
preferably fastened
to one another so that free movement of the two components about their common
connection is
limited. Once the two components are connected, support member 62' may be
moved to a
second or biased position by applying a force thereto to angularly displace it
from beam 66'
about the common connection between them, for example at connection area 642.
Because beam
66' and support member 62' are already connected, movement of support member
62' from an
initial to a biased position causes the components 62' and 66' to bear on each
other adjacent their
common connection, for example at connection area 642 or adjacent beam end
128'. Once
secured in this biased position, for example by a biasing member (described
below), friction
20953910.4 - (~1 -
CA 02363985 2001-11-23
between the support member 62' and beam 66' is increased which may make it
more difficult to
separate them once they are assembled and positioned in this manner. At the
same time, at least
one of components 62' and 66' may be elastically deformed and are more
resistant to further
deformation than when in an initial position. The structure of the combined
components
including cross beam 66', first support member 62' and the biasing member may
therefore be
stiffer than a similar arrangement having support member 62' in an initial,
unbiased, position.
In the embodiment support member 62' and beam 66' are connected using a
fastener. The
fastener may be in the nature of a bolt such as bolt 154. Bolt 154 may be
received by a hole 156
in a beam connection member 116' of support member 62', and may be further
inserted through a
bore 158 in beam 66'. Bolt 154 may also be secured by a bolt retainer in the
nature of a nut or
wing nut 160. While this connection may be sufficient, stronger coupling of
support member 62'
to beam 66' may be achieved by angularly displacing support member 62'
relative to beam 66'
from this initial position to a biased position. For example, support 62' may
be displaced from its
initial position by a degrees towards beam 66' (see, for example, Figure 74)
or it may be
displaced by ~i degrees away from beam 66' (see, for example, Figure 75).
Minimal
displacement is generally required to achieve increased frictional resistance
between the
connected components. For example, an angle a or [3 of less than one degree
may be sufficient
depending on the relative sizes of the joined components and the amount of
play therebetween
when in the initial position. In Figures 74 to 76, a and [3 are shown as
approximately two
degrees. This displacement is emphasized in the Figures for illustrative
purposes only. The
displacement would typically be smaller than depicted, and may be in the range
of 0.5 to 5
degrees. However, different angles may be appropriate for members having
different dimensions
20953910.4 - (~2 -
CA 02363985 2001-11-23
and/or different material properties. If there is play between connected
components in
connection area 642 when they are in an initial position, then some or all of
any additional play
or slack existing between the components may be reduced when the components
are moved to a
biased position. However, a degree of play in any connection between
components is not
essential.
As support member 62' and beam 66' are moved from an initial position to a
biased
position, bolt 154 may also be subject to increased forces in a number of
directions. For
example, bolt 154 may experience increased shear force as support member 62'
is moved relative
to beam 66'. Shear forces may be caused by edges or boundaries of hole 156 and
bore 158 acting
on bolt 154. If bolt 154 is secured with nut 160, then bolt 154 may also be
subject to tensile
forces as connected support member 62' and beam 66' are moved. Any one or more
of these
forces acting on bolt 154 may inhibit the removal of bolt 154 from within its
associated hole 156
and bore 158. For example, any shear force acting on bolt 154 will increase
the friction between
bolt 154 and the shear surfaces. Likewise, a tensile force on a secured bolt
154 can increase
friction between the engaged threads of bolt 154 and nut 160.
In a similar manner to that described above, beam 66' may be connected to
second
support 64' to similar effect. In the preferred embodiment, first and second
support members 62'
and 64' are connected to cross beam 66' using fasteners 154 and 278. In this
configuration, both
support members 62' and 64' are in an initial position (see, for example,
Figure 74 or Figure 75).
Support members 62' and 64' are preferably moved to a biased position by
moving them either
towards each other or away from each other at a similar angular displacement
relative to cross
20953910.4 - 93 -
CA 02363985 2001-11-23
beam 66'. Once located in a biased position, support members 62' and 64' may
be held in place
by a biasing member such as lower casting 78, which is in spaced relationship
with fasteners 154
and 278, as shown, for example, in Figure 77. Lower casting 78 may be secured
between
support members 62' and 64' in the manner described above.
In this configuration, one or more of the connected components (i.e., first
and second
support members 62' and 64', cross beam 66', lower casting 78) are elastically
deformed. As
noted above, this elastic deformation can lead to a stiffened and resilient
structure because a
proportionately greater force than the biasing force is required to further
deform the one or more
components. A biasing force that causes any component, including fasteners 154
and 278, to
approach its proportional limit should not be applied to the structure. The
connected components
are preferably elastically deformed well within their respective yield limits.
This permits the
components to resist various additional forces during regular use of the
barbeque 60 without
plastically deforming, while maintaining a substantially rigid structure.
If lower casting 78 is secured in the manner described above then the
connections
between support members 62' and 64' and lower casting 78 form at least one
friction system that
may also be subject to additional forces. For example, one or more first
friction members in the
nature of guide posts 620 and bolt 612' (which may also be a friction member)
may be subject to
additional forces as they resist the deflection of the biased supports 62' and
64'. This in turn may
encourage increased frictional retention of guide posts 620 and bolt 612'
within their respective
bores 622 and 598. In particular, there rnay be increased forces experienced
by guide posts 620
than if supports 62' and 64' are not biased. For example, guide posts 620 may
experience greater
20953910.4 - ()4 -
CA 02363985 2001-11-23
forces at their interface with associated second friction members, which may
include edges 632
of guide bores 622, when guide posts 620 frictionally co-operate to maintain
displacement of
supports 62' and 64' in a biased position. Bolt 612' may subject to additional
forces in a similar
manner as described for guide posts 620. These additional forces are applied
at one or more
points of connection between lower casting 78 and supports 62' and 64',
whether supports 62' and
64' are biased towards cross beam 66' or away from it.
While lower casting 78 is preferably used as a biasing member, alternatively,
one or more
members such as a strut (not shown) may be used to maintain two components
(such as support
62' and cross beam 66~ in a biased position relative to each other.
Alternatively, console 86 or
panel 72' may act as a biasing member.
In the embodiment, supports 62' and 64' are attached to cross beam 66' in an
initial
position. In this initial position the combined components form a generally U-
shaped structure,
with the arms of the "U" (i.e., supports 62' and 64~ forming an angle of less
than 90 degrees with
the base of the "U" (i.e., cross beam 66~, as shown in Figure 74. Supports 62'
and 64' may then
be biased away from cross beam 66' to a biased position wherein the arms of
the "U" are
generally perpendicular to the base, as shown in Figure 77. For example,
respective free ends of
supports 62' and 64' may be displaced from one another along an axis
substantially parallel to a
longitudinal axis of cross beam 66' when supports 62' and 64' are biased from
an initial position
to a biased position. Referring to Figure 76, this biasing is preferably
achieved by aligning guide
posts 620 with the guide bores 622 of one support member, for example support
member 62', and
inserting the guide posts 620 therein. Because supports 62' and 64' are still
in an initial position,
20953910.4 - 9$ -
CA 02363985 2001-11-23
the remaining guide posts 620 that are associated with the guide bores 622 of
support 64' are
misaligned. Support 64' may be manually moved to a biased position to align
guide bores 622
with guide posts 620. At the same time support 62' is encouraged to a biased
position as well.
The biased position of both supports 62' and 64' may be maintained by
inserting remaining guide
posts 620 within the guide bores 622 of support 64', as shown in Figure 77.
Heads 610' may then
be attached to bolts 612' to secure the lower casting 78 to supports 62' and
64'. Lower casting 78
may be similarly attached to supports 62' and 64' if supports 62' and 64' have
an initial position in
which they are angled away from cross beam 66'.
Supports 62' and 64' may be oriented in different initial positions by
changing the angle at
which beam connection member 116' is welded to legs 98' and 100'.
Alternatively, different
initial positions may by configured by adding one or more bends or curves to
either one or more
of supports 62' and 64' and cross beam 66' (not shown). The relative location
of guide posts 620
and/or guide holes 622 rnay additionally or alternatively be modified so that
supports 62' and 64'
have to be moved from to a biased position to permit the posts 620 and holes
622 to engage. As
the above examples illustrate, there are many modifications or adjustments
that may be made to
any one or more of the components to be connected to ensure that at least one
of the components
is moved from an initial position to a biased position to impart additional
force on at least one of
the connections between that component and a second component.
Other components of the barbeque assembly 60 may be likewise assembled
according to
the principles described above. Other embodiments of barbeque 60, such as
those illustrated in
20953910.4 _ ()6 _
CA 02363985 2001-11-23
Figure 1, may also be configured and assembled in the manner described.
Burner Support Member
Referring to Figures 33 and 34, lower casting 78 contains at least one burner
80. Burner
80 may be an H-shaped burner 80, a bar-shaped burner 80' (see Figure 2), or
some other
appropriate barbeque burner known in the art. To satisfy government standards,
such as ANSI
Z21-58 in the U.S. and CGA 1.6 in Canada, support members 646 are attached to
burners to
retain and maintain the burner in a preferred orientation within lower casting
78. The support
members 646 of the illustrative embodiments described below permit the burner
to be manually
installed in and removed from barlaeque 60 without tools. Support members 646
may be used in
combination with many different burner configurations, including the H-shaped
burner 80 and
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
conjunction
with an H-shaped burner 80 is an example and may 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
80. When in a preferred orientation, the four arms 648 of burner 80 are
generally horizontal. At
least one support member 646 is attached 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 78. Each support member 646
has a generally
planar strip portion 650. Strip portion 650 may be rectangular, and is
preferably constructed
20953910.4 _ 97 _
CA 02363985 2001-11-23
from a resilient heat resistant material such as a metal. For example,
aluminized steel may be
used. 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 or some other securing
means that is
not significantly affected by high temperatures. Alternatively, strip 650 may
have a bend therein
to form a toe 652 protruding more or less normal to a longitudinal axis of
strip 650. Toe 652
may be welded to arm 648, thereby providing a larger area for attachment to
arm 648 than along
an edge of strip 650. As shown in Figures 66 - 68, in an alternative
embodiment of burner
support, burner support member 646' (described below), a toe 652' may
additionally include a
attachment member 655 for attaching the support member 646' to burner 80.
Attachment
member 655 may also be applied to toe 652 in a similar manner.
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 opening 658 in the
bottom 624 of lower
casting 78. Catch 656 is preferably generally rectangular in shape, and may be
formed from strip
650 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 662 of three-
sided catch 656 away from strip 650 to form a bend 660 where catch 656 meets
strip 650. Bend
660 is preferably adjacent 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
90 degrees from an opening 664 formed by the bending of catch 656 away from
snip 650. An
angle of about 30 degrees may be defined, for example. In the illustrative
embodiment, the
material used for strip 650 may be sufficiently pliable to permit the
formation of bend 660, but is
20953910.4 _ 9g _
CA 02363985 2001-11-23
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 it towards opening 664 in support
member 646, catch free
end 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 78 adjacent to
casting opening 658 to
prevent further insertion of support member 646 into casting opening 658. In
the illustrative
embodiment, support member 646 has two shoulders 666. Shoulders 666 define a
neck 669 for
insertion into casting opening 658. 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 from arm 648 by
between 0.5 and 1
inch, and preferably by 0.65 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 650. 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 670, 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 inhibit insertion of support
member 646 into
opening 658 beyond a desired threshold (not shown). In the above embodiments,
the tabs 668,
being located in planes generally perpendicular to the plane of strip 650, may
also add rigidity to
strip 650.
20953910.4 _
CA 02363985 2001-11-23
Burners, such as burner 80, typically have at least one, and frequently two,
fuel input
ducts 672. Free ends 674 of ducts 672 have guards, such as spider guards 474,
to prevent insects
from entering ducts 672. Guards 474 engage outlets of console 86 (described
below) to receive a
mediated flow of fuel which is supplied to the burner 80 via ducts 672.
To manually install burner 80 into lower casting 78, free ends 674 of each
duct 672 are
inserted through separate burner duct passages 676 and 678, located in lower
casting 78.
Passages 676 and 678 permit fuel to be delivered from an external source, such
as propane tank
90, via ducts 672 to burner 80. Once duct free ends 674 are inserted through
passages 676 and
678, 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 646 is further inserted into opening
658, catch 656
encounters an edge of opening 658, and is deformed and caused to move closer
to strip 650 to a
depressed or deformed position (not shown) to permit further insertion of
support 646. When
catch free end 662 passes through opening 658, the resilient catch 656 returns
to its initial angled
displacement from strip 650, and is positioned adjacent to opening 658. In
this configuration, a
snap fit may be formed between catch 656 and lower casting 78. In this
position, the free end
662 of catch 656 is adjacent to, and preferably abuts, lower casting 80 to
hinder removal of
support 646 from opening 658. Once catch 656 passes through opening 658,
shoulders 666 abut
portions of interior surface 558 of lower casting 78 adjacent to casting
opening 658 to inhibit
further insertion of support 646 into opening 658. To manually remove support
646 from
20953910.4 - 1~0 -
CA 02363985 2001-11-23
opening 658, catch 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 may additionally each have a
hole 680
therethrough. Holes 680 are coaxial with one other, and may optionally receive
a pin such as a
cotter pin to further inhibit removal of support member 646 from opening 658.
In the illustrative embodiment, during installation of support 646, shoulders
666 abut the
lower casting 78 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 78 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
646 with catch 656 in a depressed position, yet sufficiently small to prevent
removal of support
646 with catch 656 in its initial position. The casting openings 658 which
receive each support
646 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 an edge 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 contact 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
such 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
20953910.4 -101-
CA 02363985 2001-11-23
least two supports 646 to abut edges of their respective holes to limit
transverse movement of the
burner 80.
Referring to Figures 52A - 52C, in an alternative embodiment of burner support
member
646, labelled 646', catch 656 may be formed by bending the free end 654' of
strip 650' to form a
catch 656' and a bend 660' with similar characteristics to those described
above. Shoulders 666'
may be formed by cut-outs or rebates 667' in strip 650'. Rebates 667' also
define free parallel
sides 670' of a neck 669' of strip 650', from which catch 656' depends.
Referring additionally to Figures 65-68, support member 646' is installed into
casting
opening 658, and operates, in a similar manner as described above for support
member 646. In
particular, bend 660' enters opening 658 and is followed by neck 669' and
catch 656', which
angles away from strip 650' and may guide neck 669' into proper alignment
within opening 658.
As catch 656' is inserted further into opening 658, it encounters an edge of
opening 658 and is
caused to move closer to neck 669' to a depressed position to permit further
insertion. When
catch 656' clears opening 658 it resiliently returns to its initial position
and is positioned adjacent
opening 658. In this position, catch 656" inhibits removal of neck 669' from
opening 658.
Opening 658 may be generally rectangular in shape, having a length of
approximately
0.45 inches and a width of approximately 0.3 inches, wherein its length runs
generally parallel to
an axis of bend 660' when neck 669' is installed therein. To limit movement of
burner 80, neck
669' may have a width of marginally less than 0.45 inches so that free
parallel sides 670' abut or
are adjacent to opposed parallel edges of opening 658 when neck 669' is
located within opening
20953910.4 - 102 -
CA 02363985 2001-11-23
658. Similarly, to limit movement of burner 80, supports 646' may be
positioned to co-operate
so that neck 669' of each support 646' abuts or is adjacent to another edge of
opening 658. For
example, if two supports 646' are used and one support 646' is positioned to
abut a longitudinal
edge of a first opening 658, then the second support 646' is preferably
located to abut an opposite
longitudinal edge of a second opening 658. In a similar manner as described
for support member
646, support member 646' may additionally have a hole therethrough (not shown)
for optionally
receiving a removable pin such as a cotter pin which further inhibits removal
of support member
646' from opening 658.
Referring to Figures 64A - 64C, burner support member 646' may additional
include an
indent or embossment 659 which may increase the rigidity of strip 650'.
Embossment 659 may
be substantially linear and may run along a longitudinal centerline of strip
650'. It may
additionally traverse a portion of neck 669'.
In a further alternative embodiment (not shown), the rectangular catch may be
fashioned
from the strip by making two incisions in the 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 the 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 yet alternative embodiment, the catch may be added to the strip
by welding or
other connection means to provide a catch with the preferred properties
described above.
20953910.4 - 103
CA 02363985 2001-11-23
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 646 into opening 658, 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.
Similarly, 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 by burner 80 is preferably a pressurized combustible gas, such
as propane,
that is appropriate for gas barbeques. Because 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
flow of fuel is mediated by console 86, described below. Fuel openings 682
permit fuel to be
released into the interior 684 of lower casting 78. The fuel may then be
ignited. The fuel
openings 682 are preferably located adjacent 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
692, is attached to console 86, and connected to igniter 686 via igniter wire
694 (see Figure 1).
Heat Deflectors
Referring to Figure 1, a heat deflector in the nature of angled bars 88 may be
installed
within casting 78, to encourage heat dissipation within barbeque 60. Burner 80
is sandwiched
20953910.4 _ 1(~, _
CA 02363985 2001-11-23
between casting bottom 624 and angled bars 88. Angled bars 88 may be formed
from a single,
substantially rectangular sheet of metal. Longitudinal peaks 696 and valleys
698 may be formed
therein, to create angled sides 700 for dissipating 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.
When 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.
At least one and preferably two support struts 704 for supporting angled bars
88, traverse
the interior 684 of lower casting 78, and are located between burners 80 and
angled bars 88.
Support struts 704 may be uniformly displaced from casting bottom 624 by fins
706
which project from interior surface 558. 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
fm 706 which inhibits movement of the strut 704 when the fm 706 is placed
therein. The fins
706 may be integral with casting 78, 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
20953910.4 - 105 -
CA 02363985 2001-11-23
strut 704, once angled bars 88 are installed.
Referring to Figure 2, in an alternative embodiment, a heat deflector such as
lava rocks
714 or ceramic briquettes (not shown) may be provided instead of or in
addition to angled bars
88. If these alternatives are used then an appropriate support structure, such
as grate 716, for the
lava rocks 714 or ceramic briquettes may be provided. Grate 716 may be
supported directly by
fins 706, and support struts 704 may be 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 78 (only
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 (not shown) or may rest in rebates 644 located in edges 560 of lower
casting 78. Either, or
both, grill plate 82 and warming rack 84 may be made from wire, chrome wire,
heavy duty
20953910.4 _ 1~
CA 02363985 2001-11-23
porcelain coated wire, porcelainized metal, cast iron or porcelainized cast
iron.
Console
Referring to Figures 35, 36, 36A, 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 732. Appropriate valves for
controlling the flow
of a gaseous fuel as are known in the art may 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
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.
Referring in particular to Figures 36 and 36A, 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, and, when barbeque 60 is fully
assembled, may lie in a
plane that is parallel to cross beam 66. Lateral edges 754 of console 86 may
have at least one
rebate in the nature of a notch 756 and preferably two notches, including
notch 758, for receiving
20953910.4 - 1~'~ -
CA 02363985 2001-11-23
tabs 750 and 752. Tab 750 preferably lies in a plane generally transverse to
the plane of notch
756, and tab 752 preferably lies in a plane generally transverse to the plane
of notch 758.
Notches 756 and 758 receive edges 760 and 762 of tabs 750 and 752 to support
console 86
thereon. One or both of notches 756 and 758 may additionally have a slot 764
therein for
receiving an edge 760 or 762 of a corresponding tab, for example tab 750, when
the tab is placed
therein. Slot 764 preferably is substantially the same thickness as tab 750,
and is sufficiently
wide to permit entry of an edge 760 of tab 750 but is sufficiently narrow to
limit movement of
console 86 relative to tab 750. The remaining tab 752 when placed within notch
756 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.
A side 765 of notch 758, which lies between slot 760 and edge 754, may be
configured to
form an angle of less than 90 degrees with adjacent edge 754 to guide tab 750
into slot 760.
When side 765 is angled in this manner, and placed upon tab 750, tab edge 760
may come into
sliding contact with side 765. Since side 765 terminates at slot 760, tab edge
760 is guided by
side 765 into slot 760. Notch 756 may be similarly configured.
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,
and 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
fastener inserted through a corresponding hole 772 in console side 768. The
fastener may be a
20953910.4 - 1~g -
CA 02363985 2001-11-23
screw, and is preferably a bolt 774 (see Figure 39A and 39B) that may be
installed and removed
by 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.
Refernng to Figure 39A and 39B, a head 776 of bolt 774 may have external
grips, such
as knurls or cross hatches 778 to provide greater friction to facilitate
unassisted installation of the
bolt 774. In the illustrative embodiment, the head 776 is cylindrical, having
a diameter of about
5/8 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
778. Turning of the bolt 774 about its longitudinal axis may also be improved
by using a non-
circular or non-uniform shaped head (not shown) with the threaded end 780
preferably
protruding along an axis passing through a centroid of the head 778. The head
778 may be made
of any rigid material, such as nylon plastic or a metal.
Referring 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
104. When installed, flange 780 preferably traverses the distance between
support members 62
20953910.4 - 1~ _
CA 02363985 2001-11-23
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
extend generally perpendicularly from flange 780, and abut, or may be attached
to, console sides
768'. While tabs 784 may 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
768' 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
example leg member 98, to maintain console 86 in a preferred orientation
before it is secured.
Threaded 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 772', 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 to receive fastener 382 to secure console 86' to
bridging members 102,
104.
A fuel hose (not shown) may be connected to control valves 730, 732. The fuel
hose has
20953910.4 - 110 -
CA 02363985 2001-11-23
a connector, for example as manufactured by Marshall Gas of San Marcus, 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, which 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
are preferably located to abut a side of 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 embodiment, 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
the threaded post is preferably first connected to console 86, it may further
serve as a locator for
20953910.4 - 111 -
CA 02363985 2001-11-23
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
so 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 sup~rt barbeque 60. Base ends
110 and 112 of
support 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 barbeque 60 to roll it in the direction of the force along
wheels 94 and casters
96. If base ends 110 and 112 of support member 62 have leg extensions 74, then
leg extensions
74 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
60 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 Figure 12B, leg extensions 114 support barbeque 60 and protect
base ends
110 and 112 of leg members 98 and 100. The height of grill plate 82, and the
other components
of barbeque 60 may be varied by attaching leg extensions 114 having a desired
length to all legs
20953910.4 -112 -
CA 02363985 2001-11-23
98, 100, and not attaching any wheels 94 or casters 96 to barbeque 60. Because
leg extensions
114 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 leg 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
support 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 ?90 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 between plug end 790 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.
Leg extension 114 may be secured to leg member 98 using a fastener, such as
slotted pin
186 (see Figure 12B). Leg member 98 has a hole 800 passing laterally
therethrough for
20953910.4 -113 -
CA 02363985 2001-11-23
receiving slotted pin 186. Hole 800 has an entry 800a and an exit (not shown).
Similarly, plug
end 790 of leg extension 114, has a hole 802, passing laterally therethrough
for receiving pin
186. Hole 802 has an entry 802a and an exit (not shown). To install pin 186,
the respective
entries 800a, 802a and the exits are aligned. Slotted pin 186 may then
inserted therethrough to
hinder movement of the leg extension 114 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.
Catch 189 is located at the insertion end 190 of pin 186. End 190 is located
opposite to head
188. Catch 189 may be marginally larger 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
slots 192 emanating from a central longitudinal axis of pin 186. Each slot 192
is preferably
uniformly angularly displaced from the another. As marginally larger end 190
is inserted
through the exit of hole 800, slots 192 permit end 190 to narrow facilitating
passage of catch
189, therethrough. Slotted pin 186 may be made of a resilient material such as
a plastic so that
end 190 returns to its original shape once it passes through the exit of hole
8()D and catch 189
inhibits removal of pin 186.
Caster plugs 804 receive casters 96 to permit rolling movement of barbeque 60
as
described above. As with the description of leg extensions 114, a description
for the attachment
20953910.4 - 114 -
CA 02363985 2001-11-23
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, and 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.
Shoulder 806 is preferably of sufficient thickness to prevent deformation of
shoulder when in
use. For example, a shoulder thickness of 0.04 inches may be used. Unlike leg
extension 114,
caster plug 804 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 circumferential 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 for retention of the leg extension 114. The general
configuration of caster
plug 804 may also be varied to accommodate leg members of different cross-
sectional shapes.
For example, a caster plug (not shown) may be 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.
20953910.4 - 115 -
CA 02363985 2001-11-23
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 cross-section substantially equal to or
larger than the size
and shape of the lateral cross-section of 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 98,100. Conduits 170 are attached to leg members
98,100 using
slotted 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 186.
Wheels
Referring to Figures 40, 41, 42, 43A and 43B, wheels 94 may be attached to
legs 98 and
100 of a support member, such as support member 64. Each wheel 94 is attached
to a leg
member 98 or 100 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 100.
Wheel 94 may attached to leg member 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
and leg extensions 114. Once attached, wheel 94 may freely rotate about axle
pin 814 to
20953910.4 - 116 -
CA 02363985 2001-11-23
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
by entry 800a, passes through the void in the hollow leg member 98, and
extends through the
exit of hole 800 hole. Further insertion of axle pin 814 is inhibited by a
circuxnferential 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 800. The displacement along axle 814 between
shoulder 820
and head 822 is preferably marginally greater than the length of bore 818.
This permits free
movement of wheel 94 about axle 814, while discouraging binding of the walls
of bore 818 on
axle 814.
Referring additionally to Figures 42A and 42B, axle 814 may be secured in
place with an
axle securing apparatus such as an axle lock 824. Axle lock 824 has a body 826
that is
preferably similar in shape to caster plug 804 but has a transverse, generally
C-shaped groove or
channel 828 at an end thereof for engaging a securing portion 830 of axle pin
814. Securing
portion 830 is located between end 816 and shoulder 820 of axle pin 814.
Because channel 828
is C-shaped it preferably forms a snap fit with axle pin 814.
Axle lock 824 may be attached to barbeque 60 by first inserting axle pin 814
through hole
800 in leg member 98. Axle lock 824 may then be attached by inserting C-shaped
channel 828
into the void of hollow leg member 98. C-shaped channel 828 may be aligned and
brought into
20953910.4 - 117 -
CA 02363985 2001-11-23
contact with securing portion 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
deform and 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 (shown in
Figure 42B). 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 transverse or circumferential groove
834 that receives a
stop in the nature of an transverse rib 836 of channel 828. Rib 836 may be
arcuate,
corresponding to the shape of channel 828 and may laterally traverse channel
828.
Axle lock 824 is preferably constructed from a resilient plastic or metal. If
axle lock 824
is made of a plastic then 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 and 43B, alternative axle locks, such as axle
lock 824"',
may be configured to fit voids in leg members such as leg members 98' and 100'
having
alternative cross-sections such as a rectangular cross-section.
Referring to Figures 61A-63 and 69A-70B, a further alternative axle and axle
lock
arrangement may be employed. Alternative axle 814' may be secured in place
with an alternative
20953910.4 - 118 -
CA 02363985 2001-11-23
axle lock 824'. Axle lock 824' has a body 826' that is preferably similar in
shape to axle lock
824, but body 826' differs in that it has a transverse, bore 828' therethrough
adjacent an end
thereof for engaging a securing portion 830' of axle pin 814', instead of C-
shaped channel 828.
Securing portion 830' is located between end 816' and shoulder 820' of axle
pin 814'.
Axle lock 824' may be attached to barbeque 60 by first inserting body 824'
having bore
828' into the void of hollow leg member 98. Bore 828' may be aligned with hole
800 in leg
member 98. Axle pin 814' may then be inserted into an entrance of hole 800 and
into bore 828'.
Pin 814' preferably has a tapered end 829 to guide pin 814' into bore 828'.
Bore 828' may have a
corresponding tapered opening 831 which co-operates with tapered end 829 to
guide axle pin
814' into bore 828'. Pin end 829 may then exit bore 828' at a second opening
833' of bore 828',
and may pass through an exit of hole 800 in leg 98 to inhibit removal of axle
lock 824' from leg
member 98.
Second opening 833 may be marginally smaller than a cross section of axle pin
end 829.
To facilitate passage of end 829 through marginally smaller second opening
833, end 829 may be
tapered. Bore 828' may additionally have a co-operating taper 837, adjacent
second opening
833, to direct pin 814' therethrough.
To further facilitate passage of end 829, portions of body 826' adjacent
second opening
833 may be resilient. For example, second opening 833 may have at least one
and preferably
three slots 835 emanating from a central longitudinal axis of bore 828'. Each
slot 835 is
preferably uniformly angularly displaced from the other. As end 829 is
inserted through the
20953910.4 - 119 -
CA 02363985 2001-11-23
marginally smaller opening 833, slots 835 permit opening 833 to widen,
facilitating passage of
end 829 therethrough. Axle lock is preferably made of a resilient material
such as a plastic so
that second opening 833 returns to its original shape once axle pin end 829
passes therethrough,
and so that significant manual force is not required to encourage pin end 829
through second
opening 833.
To inhibit removal of axle pin 814' from bore 828', axle pin 814' may be
provided with an
indent or groove in the nature of circumferential groove 834' for receiving
retaining portions 839
of body 826' which generally define second opening 833. Once axle pin end 816'
passes through
second opening 833, resilient retaining portions 839 enter groove 834' to
inhibit removal of pin
814' from bore 828'.
As illustrated in Figures 62A - 62E, alternative axle locks, such as axle lock
824", may
be configured to fit voids in leg members such as leg members 98' and 100'
having alternative
cross-sections such as a rectangular cross-section. Alternative axle lock 824"
may co-operate
with alternative axle pin 814" (shown in Figures 70A and 70B) to retain wheel
94.
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
extension 114 and caster plug 804. In particular, axle pin 814 is inserted
additionally through
conduit entry hole 174a and exit hole 174b to also retain conduit 170 about
leg member 98 or
100.
Wheel bore 818 may be protected to some degree from dirt and other matter that
may
20953910.4 - 120 -
CA 02363985 2001-11-23
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
between axle 814 and bore 818. Head 822 may have a circumferential flange 840
for
engagement by a hub cap clip 842 having two or more arms 844 which protrude
from a side of
hub cap 838. Arms 844 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 cap 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 flange 840 to inhibit hub cap 838 from being separated
from axle 814. To
further inhibit passage of matter between axle pin 814 and bore 818, hub cap
838 may have at
least one circumferential flange 850 for engagement by a corresponding
circumferential groove
852 of wheel 94.
All components of barbeque 60, as described above, are preferably made of
weather
zo9s39io.4 - 121-
CA 02363985 2001-11-23
resistant material and/or heat resistant material, as appropriate.
Assembly
The following generally describes the preferred steps that a consumer would
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 before 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 connection member 116, may also be pre-assembled to legs
98 and 100
to form ladder-like supports 62 and 64. Control valves 730 and 732 may be
installed within
console body 734, handle 582 may 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, may be nominal.
In the preferred method of assembly of barbeque 60, the ladder-like supports
62 and 64
are placed on a generally level surface with free ends 204 and 206 of
supporting portion 340 and
198 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, opposite the direction of insertion
D, at a free end 377
20953910.4 - 122 -
CA 02363985 2001-11-23
of shelf 68, 70. If applicable, shelf frame 372 and or burner frame 436 may be
similarly
installed. Alternatively, shelves 68 and 70, or shelf frame 372 or burner
frame 436, may be
attached after the combined supports 62 and 64 and a cross beam 66 are re-
oriented so that the
support members 62 and 64 rest on their base ends 110 and 112, as described
below.
Support members 62 and 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.
Accordingly, supports 62 and 64 are generally vertically oriented. Beam
receptacles 120 and
124 may then be oriented towards each other. Ends 92 of cross beam 66 may be
inserted into the
respective receptacles 120 and 124 with the threaded bushings 102 of cross
beam 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 120 and
124, in the manner described above. If not pre-assembled, wheels 94, casters
96, and/or leg
extensions 114, may be installed either before or after cross beam 66 is
attached to support
members 62 and 64.
Once cross beam 66 is attached, the rigid three-sided barbeque grill housing
support
structure, having two ladder-like supports 62 and 64, and 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 previously assembled). The support members
62 and 64, and
cross beam 66 combine to form a self-supported frame or barbeque support
structure. Other
components of the barbeque 60 may then be conveniently attached to the support
structure.
20953910.4 -123
CA 02363985 2001-11-23
As described, support members 62 and 64, and cross beam 66, are assembled by
joining
one side of the structure (support member 62) to the other side (support
member 64). This
generally differs from many barbeques known in the art which are assembled
from the bottom
up, beginning with a lower shelf or base and then bolting individual vertical
leg members thereto
(not shown).
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 are 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.
If used, 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
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
are 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
20953910.4 _ 1~ _
CA 02363985 2001-11-23
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 ieg
member 98,100 into clip
552.
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 hole 772 and tightening it in threaded
bore 770. In the
preferred orientation of bore 770, bolt 774 may be installed horizontally.
This step may be
alternatively be completed after installation of the lower casting 78, or any
of the components
thereof.
Tapered guide posts 620 of lower casting 78 may then be aligned with and
inserted into
guide bores 622. The lower casting 78 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 on to post 612' in a generally
downward direction.
Alternatively, lower casting 78 may be installed after installation of front
panel 72.
Burner 80 may then be installed in the manner described above. In particular,
burner 80
may be placed within lower casting 78, and free ends 674 of each duct 672 are
inserted through
separate burner duct passages 316 and 318. Support members 646 are then
inserted and secured
within openings 658 by applying a generally downward force to form a snap fit
with lower
20953910.4 - 125
CA 02363985 2001-11-23
casting 78. Alternatively, burner 80 may be installed after both lower casting
78 and console 86
are installed, in which case igniter wire 694 may be attached to console 86
after burner 80 is
installed.
Side burner assembly 434 may then be installed in the manner described above.
Side
shelf 68 may alternatively be installed after burner assembly 434 is
installed.
If not pre-installed, handle 582 and temperature gauge 594 may be attached to
upper
casting 76. Upper casting 76 may then be attached to lower casting 78, or
installed at a later step
as described below.
If not pre-installed, the components of the ignition assembly may be assembled
by
fastening, 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. The igniter activation assembly 690 is
then connected to
igniter 688 via igniter wire 694. Igniter 694 may be clipped or otherwise
attached between
burner 80 and console 86.
In the next step of assembly of barbeque 60, support struts 704 are placed
onto fms 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 78, 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
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CA 02363985 2001-11-23
724 located in upper casting 76. Once the pins 722 are inserted, toes 726 of
warming rack
support legs 408 may be placed into rebates 644 located in edges 240 of lower
casting 78. If not
pre-installed, handle 582 may be attached through holes 590 in upper casting
76, 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 370,
shelf slats 408,
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 to 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 above 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. For example, the following connections may be made in
a generally top
down direction: attaching cross beam 66 to beam connection members 116 and 122
using bolts
200; installing leg extensions 114 or caster plugs 804 to leg 98 or 100;
attaching shelf 68 to shelf
supporting portions 340 and 342; positioning lower casting 74 relative to
bridging member 102;
securing nut 610' to bolt 612' to attach lower casting 74 to bridging member
102; attaching
burner 80 to lower casting 74; and moving engaging member 345 to engage tank
collar 316.
Because many components may be installed in a downward direction, gravity may
assist in the
positioning and connecting of parts. For example, console 86 may be placed
upon and supported
by tabs 750 and 752 to maintain console 86 in a preferred orientation before
it is secured.
Installation of components requiring fastening from a bottom up direction is
limited.
By enabling the manual and generally top down installation of many components
of the
20953910.4 - 127 -
CA 02363985 2001-11-23
barbeque 60, the various features described above may enable manufactures to
ship unassembled
barbeques to reduce costs, while providing a barbeque that may be readily and
quickly
assembled by unskilled consumers.
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 alternative
embodiments of
the component parts thereof.
20953910.4 - 128 -
