Note: Descriptions are shown in the official language in which they were submitted.
CA 02613858 2007-12-10
Att'y Docket No.: 18823-10S
APPLICATION FOR LETTERS PATENT
TITLE: TEMPERATURE CONTROL APPARATUS AND METHOD FOR A
BARBEQUE GRILL
INVENTORS:
TO ALL WHOM IT MAY CONCERN:
BE IT KNOWN THAT WE,
Sydney Barkhouse, a citizen of Canada of 988 Fernandez Drive, Mississauga,
Ontario L5V 1W9, Canada
and
Stuart T. McKenzie, a citizen of Canada of R.R. #1, Box 16, Tiny Township,
Wyevale, Ontario LOL 2T0, Canada
1 5 have invented a:
TEMPERATURE CONTROL APPARATUS AND METHOD FOR A BARBEQUE GRILL
of which the following is a specification.
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TEMPERATURE CONTROL APPARATUS AND METHOD FOR A BARBEQUE GRILL
RELATED APPLICATIONS
[0001] This application claims priority to prior Patent Co-operation
Treaty Application
having Serial No. PCT/CA2007/002085, filed November 16, 2007 (published as
International
Patent Publication No. .WO 2009/062281 on May 22, 2009).
FIELD OF THE INVENTION
[0002] The invention relates to a temperature control apparatus for a
cooking apparatus,
and is particularly concerned with a TEMPERATURE CONTROL APPARATUS AND
METHOD FOR A BARBEQUE grill or similar apparatus.
BACKGROUND OF THE INVENTION
[0003] Traditionally, barbecues, grills and other typically outdoor
cooking apparatus
have not included means for automatically managing the temperature of an
interior of the
apparatus. Control of temperature is often managed manually by observation (or
sensing) of a
temperature state of the cooking apparatus, and manually adjusting the
temperature to attempt to
achieve a desired temperature.
SUMMARY OF THE INVENTION
[0004] In accordance with a broad aspect of the present invention
there is provided a
temperature control system for controlling the rate of flow of a flammable
fluid at generally
constant pressure. The system may include a flow control apparatus that is
free of a regulator
mechanism, for affecting the flow of the fluid. The flow control apparatus may
be operable
between at least a first flow rate and a second flow rate, and may have at
least one upstream
opening and at least one downstream opening. The system may also include a
first burner in
fluid communication with the downstream opening of the flow control apparatus
and a conduit in
fluid communication at one end thereof with the upstream opening of the flow
control apparatus,
and configured at the other end thereof for connection to a fuel supply. A
thermocouple may be
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located in the vicinity of the burner, for converting a sensed thermal state
into an electrical
signal. An electronic controller, in communication with the flow control
apparatus, for
activating the flow control apparatus to one of said first and second flow
rates, and being in
communication with the thermocouple for receiving the electrical signal from
the thermocouple
is also provided. An interface connected to the controller for manually
inputting a desired
temperature may be included, wherein the controller is operable to
automatically cycle the flow
control apparatus between the first and second flow rates until the
temperature sensed by the
thermocouple is similar to the desired temperature. The system is free of a
regulator between an
upstream end of the conduit and the burner.
[0005] In an embodiment of the present invention the controller is pre-
programmed with
a first temperature set point and a second temperature set point relative to
the desired
temperature input by the user, and the controller is pre-programmed to
automatically cycle the
flow control apparatus between the first flow rate when the thermocouple
communicates a
temperature above said second set point, and the second flow rate when the
thermocouple
communicates a temperature below said first set point..
[0006] Conveniently, the controller may be pre-programmed with a
first temperature set
point and a second temperature set point relative to the desired temperature
input by the user, and
the controller is pre-programmed to automatically cycle the flow control
apparatus between the
first flow rate when the thermocouple communicates a temperature above said
second set point,
and the second flow rate when the thermocouple communicates a temperature
below said first set
point..
[0007] According to another broad aspect, the system may include at
least one manually
controllable valve located between the upstream end of the conduit and the
burner, the at least
one manually controllable valve having a total minimum flow rate generally
equal to the first
flow rate of the flow control apparatus. The system may also include at least
one of a solenoid
valve and a latch valve.
[00081 The system may be part of a barbecue grill assembly having and
enclosure, the
thermocouple and burner being mounted within the enclosure.
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[0009] According to another aspect, a second flow control apparatus
operable between at
least a third flow rate and a fourth flow rate, and having at least one
upstream opening and at
least one downstream opening may be provided. The second flow control
apparatus may be in
fluid communication at the upstream opening thereof with the fuel supply. The
system may also
include a second burner in fluid communication with the downstream opening of
the second flow
control apparatus, and a second thermocouple, located in the vicinity of the
second burner, for
converting a sensed thermal state into an electrical signal. The controller
may be in
communication with the second flow control apparatus and is capable of
activating said flow
control apparatus to one of said third and fourth flow rates. The controller
may also be in
communication with the second thermocouple for receiving the electrical signal
from the second
thermocouple. The interface may be configured for manually inputting a second
desired
temperature, and the controller may be operable to automatically cycle the
second flow control
apparatus between the third and fourth flow rates until the temperature sensed
by the second
thermocouple is similar to the second desired temperature.
[0010] According to another broad aspect, the system may include a divider
located
adjacent the first and second burners for thermally inhibiting transference of
a thermal output of
the first and second burners through the divider.
100111 In another aspect, the controller may include at least one
additional pair of set
points, each additional pair corresponding to a different possible temperature
input by the user.
[0012] In accordance with another broad aspect, there may be provided a
divider system
for inhibiting heat transfer within an enclosed volume of a gas barbeque,
wherein the enclosed
volume defined by an openable lid and a base, and the base supports a grill
having openings
therein for permitting the passage of thermal energy. The divider may include
a nonflammable
rigid sheet having a low thermal conductivity and a perimeter which is defined
to generally
conform to a cross-section of the enclosed volume in a plane generally
perpendicular to said
grill. The sheet may include at least one rebate therein for receiving at
least one of the grill and
the base to permit placement of the divider into the barbeque and to permit
closure of the lid to
thermally sub-divide the enclosed volume.
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100131 In an embodiment, the divider may include a support feature
mounted thereto for
abutting at least one of an edge of the base and the grill to inhibit lateral
movement of the divider
when installed within the enclosure.
[0014] In a further embodiment, the divider may include the support feature
extends
generally perpendicular to the divider to lie flush with at least one of the
base and the grill when
installed within the enclosure.
100151 In a yet further embodiment, the divider may include a support
feature mounted to
at least one of the base and the grill for abutting the rigid sheet to inhibit
lateral movement of the
divider when installed within the enclosure. The feature may be a slot defined
in the base for
receiving and edge of the rigid sheet. Alternatively, the divider is
permanently mounted to at
least one of the base and grill. The divider may also include a rebate defined
therein for
receiving a feature of the barbeque, and the feature may be a warming rack.
[0016] In a further aspect, the rebate may be defined by a tongue of
the divider, wherein
the tongue extends into a volume defined by the base.
[0017] According to another broad aspect, there is provided a support
for a fuel container
including a base defining a receptacle for receiving an end of the fuel
container, wherein the
receptacle is a shape generally complimentary to the end. There may also be
provided a fuel
level sensor retainer within the base for receiving and positioning a fuel
level sensor in abutting
relationship with the fuel container when the fuel container is placed within
the receptacle.
[0018] According to a yet further broad aspect there is provided a
method for controlling
the rate of flow of a flammable fluid at generally constant pressure using a
flow control
apparatus, and the flow control apparatus is free of a regulator mechanism and
settable at one of
a first flow rate and a greater second flow rate. This may be used to achieve
a desired
temperature within a cooking apparatus having at least one volume defined
therein. The method
may include the steps of:
assessing whether the flow control apparatus is to be automatically
controlled;
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when the flow control apparatus is to be automatically controlled:
assessing the temperature within the cooking apparatus;
maintaining the flow state of the flow control apparatus when the
temperature within the cooking apparatus is within the range of
about:
(i) an upper threshold value, which upper threshold value is greater
than the desired temperature, and
(ii) a lower threshold value, which lower threshold value is less
than the desired temperature;
assessing whether the temperature within the cooking apparatus is
generally higher than the upper threshold value; and
setting the flow control apparatus to the first flow rate when the temperature
within the cooking apparatus is generally higher than the upper threshold
value.
[0019] In an embodiment, the method may further include the step of
assessing whether
the temperature within the cooking apparatus is generally lower than the lower
threshold value;
and setting the flow control apparatus to a second flow rate when the
temperature within the
cooking apparatus is generally lower than the lower threshold value.
[0020] In a further embodiment, the method may further include the step of
assessing
whether a safety condition occurs; and setting the flow control apparatus to a
first flow rate when
the safety condition occurs.
[0021] Conveniently, the method may further include the step of:
assessing whether the
flow control apparatus is to be manually controlled; and setting the flow
control apparatus to a
second flow rate when the flow control apparatus is to be manually controlled.
[0022] Conveniently, the method may further include the step of:
activating an alarm
when a safety condition occurs.
[0023] In another aspect the upper threshold value may be about two
degrees Fahrenheit
greater than the desired temperature.
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100241 One or more of the steps may be repeated.
[0025] Further, one or more of the assessing steps may be repeated
every one to sixty
seconds. Alternatively, one or more of the steps are repeated sequentially.
[0026] In a further aspect, the step of assessing the safety
condition may include at least
one of:
assessing whether the temperature of the cooking vessel is about or higher
than a
predetermined safety threshold temperature;
assessing whether the rate of increase in temperature is about or greater than
a
predetermined safety temperature increase rate; and
assessing whether the rate of decrease in temperature is about or less than a
predetermined safety temperature decrease rate.
[0027] Additionally, the method may further include the step of
making the desired
temperature equal to a lower keep warm temperature after a predetermined
period of time has
elapsed.
[0028] Conveniently, the cooking apparatus may include a second
volume defined
therein, and a second flow control apparatus for achieving a second desired
temperature within
the second volume, the method further include the steps of:
assessing whether the second flow control apparatus is to be automatically
controlled;
when the second flow control apparatus is to be automatically controlled:
assessing the temperature within the second volume;
maintaining the flow state of the second flow control apparatus when the
temperature within the second volume is within the range of about:
(i) an second upper threshold value, which second upper threshold
value is greater than the second desired temperature, and
(ii) a second lower threshold value, which second lower threshold
value is less than the second desired temperature;
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assessing whether the temperature within the second volume is generally
higher than the second upper threshold value; and
setting the second flow control apparatus to the first flow rate when the
temperature within the cooking apparatus is generally higher than
the upper threshold value.
100291
In a yet further broad aspect, there may be provided a temperature control
device
for controlling a flow control apparatus that controls the rate of flow of a
flammable fluid at
generally constant pressure to heat a cooking apparatus to a desired
temperature, the device may
include:
a microprocessor for controlling operation of the flow control apparatus;
an interface connected to the microprocessor for manually inputting the
desired
temperature; and
a memory coupled to the microprocessor;
the temperature control device including a temperature control module resident
in memory for
execution by the microprocessor, the module being configured to:
assess the temperature within the cooking apparatus;
maintain the flow state of the flow control apparatus when the temperature
within the cooking apparatus is within the range of about:
(i) an upper threshold value, which upper threshold value is greater
than the desired temperature, and
(ii) a lower threshold value, which lower threshold value is less
than the desired temperature;
assess whether the temperature within the cooking apparatus is generally
higher than the upper threshold value; and
set the flow control apparatus to the first flow rate when the temperature
within the cooking
apparatus is generally higher than the upper threshold value.
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100301 Additionally, the device may be additionally configured to:
assess whether the
temperature within the cooking apparatus is generally lower than the lower
threshold value; and
set the flow control apparatus to a second flow rate when the temperature
within the cooking
apparatus is generally lower than the lower threshold value.
[0031] In a further embodiment, the device may be additionally configured
to: make the
desired temperature equal to a lower keep warm temperature after a
predetermined period of time
has elapsed. The device may also include a storage device coupled to the
microprocessor.
[0032] According to a yet further broad aspect, there may be provided
a computer
program product having a computer readable medium tangibly embodying code for
activation of
a temperature control device, the computer program product include:
code for assessing the temperature within the cooking apparatus;
code for maintaining the flow state of the flow control apparatus when the
temperature within the cooking apparatus is within the range of
about:
(i) an upper threshold value, which upper threshold value is greater
than the desired temperature, and
(ii) a lower threshold value, which lower threshold value is less
than the desired temperature;
code for assessing whether the temperature within the cooking apparatus is
generally higher than the upper threshold value; and
code for setting the flow control apparatus to the first flow rate when the
temperature within the cooking apparatus is generally higher than
the upper threshold value.
[0033] Additionally, the computer program product may further include code
for
assessing whether the temperature within the cooking apparatus is generally
lower than the lower
threshold value; and code for setting the flow control apparatus to a second
flow rate when the
temperature within the cooking apparatus is generally lower than the lower
threshold value.
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[0034] Additionally, the computer program product may further include
code for making
the desired temperature equal to a lower keep warm temperature after a
predetermined period of
time has elapsed.
[0035] Other and further advantages and features of the invention
will be apparent to
those skilled in the art from the following detailed description of
embodiments thereof, taken in
conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
[0036] The present invention will be further understood from the
following detailed
description of embodiments of the invention, with reference to the drawings in
which:
100371 FIG. 1 is an isometric view of a barbecue including a temperature
control
apparatus;
[0038] FIG. 2 is an isometric view of the barbecue of FIG. 1 with a
lid of the barbecue
removed to reveal a grill and divider;
[0039] FIG. 3 is a schematic diagram of components included in the
temperature control
apparatus, and components related thereto;
[0040] FIG. 4A is a cross-sectional view of a solenoid valve in a
closed position;
[0041] FIG. 4B is a cross-sectional view of the solenoid valve of
FIG. 4A in an open
position;
[0042] FIGS 5A to 5P illustrate various features of an embodiment of
a liquid crystal
display of the temperature control apparatus;
[0043] FIG. 6 is an isolated isometric view of the barbecue of FIG. 1
showing a console,
burners, and temperature control apparatus;
[0044] FIG. 7 is a partial rear view of FIG. 6;
[0045] FIG. 8 is an isometric view of the barbecue of FIG. 1 showing
a tank support;
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[0046] FIG. 8A is an enlarged view of a tank sensor of FIG. 8;
10047] FIGS 9A to 9D include various views of a tank sensor of FIG.
8;
[0048] FIG. 10 illustrates an isometric view of the barbecue of FIG.
1 illustrating a tank
support in an extended position;
[0049] FIG. 10A is an enlarged view of the tank support of FIG. 10;
[0050] FIG. 11A is an isolated isometric view of the tank support of
FIG. 10;
[0051] FIGS 11B to 11D present different isolated views of the tank
support of FIG. 10
and a shelf of the barbecue of FIG. 10;
[0052] FIG. 12 is an enlarged cross-sectional view of the tank
support of FIG. 10 having
a tank placed therewithin;
[0053] FIG. 13 is an isometric view of the barbecue of FIG. 1 with a
lid thereof removed
to reveal a divider;
[0054] FIG. 13A is an enlarged view of the divider of FIG. 13;
[0055] FIGS 13B to 13D are various views of the barbecue of FIG. 13
and the divider
therein;
[0056] FIG. 14 is an isolated isometric view of the divider of FIG.
13;
[0057] FIG. 15 is an isometric view of the barbecue of FIG. 1 and a
storage receptacle;
[0058] FIG. 15A is an enlarged view of the receptacle of FIG. 15;
[0059] FIGS 16A to 168 present various isolated views of the storage
receptacle, insert
and slide rails of FIG. 15;
100601 FIG. 17 is an isometric view of the barbecue of FIG. 1 and a
grease receptacle;
100611 FIG. 17A is an enlarged view of the receptacle of FIG. 17;
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[0062] FIGS 18A to 18D are isolated views of a shelf and receptacle
of the barbecue of
FIG. 17;
100631 FIG. 19 is an isolated isometric view of the barbecue of FIG.
2 showing an
infrared burner;
[0064] FIG. 19A is an enlarged view of the infrared burner of FIG. 19;
[0065] FIGS 20A to 20D are isolated views of the infrared burner of
FIG. 19; and
[0066] FIG 21 is a schematic flow diagram of aspects of the function
of the temperature
control device.
DETAILED DESCRIPTION OF THE INVENTION
[0067] Similar references are used in different figures to denote similar
components. The
disclosed temperature control apparatus may facilitate control of an internal
temperature of a gas
fuelled appliance, such as an outdoor gas barbeque. The description herein is
made in the
context of a gas fuelled barbeque, but the disclosed temperature control
apparatus may be
applied to any manner of appliance, including gas fuelled appliances.
[0068] In general, the temperature control apparatus permits a user to
input a desired
temperature set-point. The temperature control apparatus then automatically
controls the flow
rate of gas into the barbeque to achieve the desired temperature. This may
permit greater
precision in the cooking of food with a gas fuelled appliance. For example,
more accurate and
automatic temperature control may permit a barbeque to be used to bake, in
addition to a more
traditional grilling of meat. Even the grilling of meat may be improved given
that an operator or
user has the assistance of a somewhat automated control of the temperature
within the barbeque.
Such greater diversity of food that may be cooked with a barbeque may have
certain advantages,
such as encouraging a greater number of women to use a barbeque for cooking.
[0069] Figure 1 illustrates a barbeque 20, which may be a typical
barbeque. Barbeque 20
may include an openable lid 22 mounted to a base 24.
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[0070] Figure 2 illustrates the barbeque 20 having lid 22 removed for
illustration
purposes. Base 24 supports a grill 26. Grill 26 may be used to support food
for cooking, or
vessels (not shown) containing food for cooking. The particular configuration
of the grill base
and lid may be modified significantly without materially affecting the
operation of the
temperature control apparatus. The grill 26 may even be eliminated if suitable
means, such as a
container (not shown), are employed to support food to be cooked.
100711 Barbeque 20 may also include a console 28 which may be mounted
about base 24.
Console 28 may be used to support one or more control knobs 30, for manual
control of
associated valves, and part of a temperature control apparatus 32. It is not
necessary that
temperature control apparatus 32 be integrally mounted to barbeque 20 via
console 28, or to any
other feature of the barbeque. The temperature control apparatus 32 may simply
be placed upon
any suitable part of barbeque 20 and connected to barbeque 20 as described
herein. Hence,
temperature control apparatus 32 may be used to modify existing barbeques to
provide
temperature control as described herein. Alternatively, the temperature
control apparatus may be
integrated with a purpose built barbeque such as barbeque 20.
[0072] Figure 3 provides a schematic overview of the temperature
control apparatus 32.
Many of the components described herein may be substituted by suitable
components that are
functionally similar. Temperature control apparatus 32 may include an input
device 34. Input
device 34 may be a touch sensitive LCD screen (as illustrated), but may
alternatively include
some other suitable input device, such as a keypad or dial(s).
[0073] Temperature control apparatus 32 also includes a
microprocessor 36.
Microprocessor 36 may be electrically connected to input device 34 for
receiving input from a
user. Microprocessor 36 is also operatively connected to at least one valve
38. Valve 38 may be
any type of electrically or mechanically controlled valve suitable for
changing the flow of a gas.
In the present embodiment, valve 38 is an electrically controlled valve. For
example, valve 38
may be a latching or latch valve. A latch valve having at least two settings,
being open and
closed or high and low-flow, may be used either in place of or in addition to,
another latch valve
or a different type of valve such as a solenoid valve. It is preferable that a
latch valve having a
high and low-flow setting be used, as will be explained below. The latch valve
advantageously
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requires power to change from one setting (e.g., high) to another (e.g., low),
but does not require
power to maintain any particular setting. This may advantageously reduce the
amount of power
required for the temperature control apparatus 32. This characteristic may be
particularly useful
if the temperature control apparatus is powered by battery (not shown) or
other portable or
limited power supply. If power supply is lost or runs out, then a capacitor
(not shown) may be
included in temperature control apparatus 32 to enable the latch valve to be
switched one (or
more) times in or to put it in a desired flow state. For example, if power is
lost when the latch
valve is in a low flow state, the capacitor may be used to switch it to a high
flow state so that
barbeque 20 may be then used as a conventional barbeque.
[0074] Alternative valves such as solenoid valve 40, as shown in Figures 4A
and 4B,
may be used. Any suitable solenoid valve may also be used, and not just the
valve illustrated in
Figures 4A and 4B. Figure 4A shows solenoid valve in a closed position. Figure
4B shows the
solenoid valve in an open position. Valve 40 may have an opening 41 to
encourage a low flow
rate when the valve is "closed". In an embodiment, solenoid valve 40 is
switchable between at
least a low-flow rate and a high-flow rate. A solenoid valve may be less
suitable for uses where
power is at a premium because a solenoid valve typically requires power to
maintain the valve in
at least one of its flow states. This may cause a draw on power, such as
battery power.
However, if the solenoid valve requires power to enter a low flow rate, then
when power is lost,
it will automatically revert to a high flow rate, enabling barbeque 20 to be
used as a conventional
barbeque, without the need for additional power or a capacitor. Valves such as
38 and 40 may
alternatively include two valve mechanisms within a single unit, which may
provide a more cost
effective and/or compact arrangement when more than one valve is employed.
100751 Referring again to Figure 3, microprocessor 36 may be
operatively connected to a
thermocouple, such as thermocouple 42. Additional thermocouples may be used,
as needed. For
example, if temperature control apparatus 32 is used to control the
temperature of more than one
barbeque, or more than one area or zone within a given barbeque, then multiple
thermocouples
may be used. Additionally, multiple thermocouples may be used to obtain a more
accurate
reading within a single barbeque enclosure. In one embodiment just one valve
may be used to
control temperature in a single barbeque enclosure or zone.
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[0076] In the embodiment described herein, a second thermocouple 44
is employed so
that temperature control apparatus 32 may be used to control the temperature
within two
different zones of barbeque 20 (this is described in further detail below).
Optionally, an
additional thermocouple, such as meat probe 46 may be connected to
microprocessor 36 to
permit the monitoring of the temperature of a food, such as meat being cooked
within barbeque
20.
[0077] Temperature control apparatus 32 may receive power from a
power supply 48.
Power supply 48 preferably provides 12 volts AC. Temperature control apparatus
32 may also
be configured to run on some other suitable voltage, including DC current,
provided that suitable
circuitry is included with temperature control apparatus 32 to accept such
power. Using DC
power may permit a battery or other portable form of power to be used.
Typically, a 120 volt
AC power supply is used and is then converted by a transformer to 12 volt AC
power.
[0078] Microprocessor 36 may accept other inputs such as from a tank
level sensor 50.
Tank level sensor 50 provides a signal to microprocessor 36 to indicate the
level of a connected
fuel supply, which may be used to calculate the time remaining before
additional fuel is needed
either at the current fuel usage rate, an average fuel usage rate, or some
other appropriate
measure. This may done by monitoring the rate of change over time and
predicting
(extrapolating) the time when the tank will be out of fuel. If another gas
source is used, for
example from a natural gas line, then the tank sensor functionality may be
removed or
eliminated.
[0079] The various connections between the components of the
temperature control
apparatus 32 may be wired or wireless, and may include standard connectors,
such as 2.5
millimetre audio style connectors, or may be hard-wired or use some other
connection, as
desired.
[0080] Input device 34 may have any of a number of suitable configurations
as noted. At
its simplest, input device 34 may be a dial, switch or lever that may be moved
to select a higher
or lower desired temperature for the barbeque 20. In the illustrated
embodiment, input device 34
includes an LCD screen 52 that may be backlit (or may have a sensor or timer
to limit or
eliminate the amount of back light in order to conserve power, if needed). LCD
screen 52 may
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be touch sensitive, or may be activated using some other input device such as
a keypad, a
keyboard, a light pen, a mouse, or some other device. The particular layout
and style of the
graphics for the interface of LCD screen 52 may be configured as needed. No
particular layout
is required. Aside from the functionality to input a set-point temperature,
all other functionality
is optional. However, some configurations, such as those described herein, may
facilitate inputs
to be made and readings to be displayed.
100811 The temperature control apparatus 32 may be activated by
pressing the on/off
button 53 of the LCD screen 52 (when temperature control apparatus 32 is not
activated,
barbeque 20 may operate as a conventional barbeque). Once activated, a desired
temperature
may be set by pressing the temperature area 54 of the LCD screen 52. A set-
point temperature
may then be entered using up and down arrows 56 and 58 to increase or decrease
the desired
target temperature. The barbeque 20 may be configured to achieve a wide range
of temperatures.
For example, the barbeque 20 may be configured to achieve temperatures between
40 C and
200 C, or 35 C to 300 C, or 50 C to 350 C, or to any suitable combination of
temperature
ranges. The barbeque 20 may also be purpose built for a very narrow
temperature range such as
between 200 and 300 C. The temperature control apparatus 32 may be configured
to achieve
any range of temperatures depending on the barbeque 20 configuration.
100821 Once a desired temperature is set, microprocessor 36 compares
a signal received
from thermocouple 32. The signal indicates the temperature in the vicinity of
thermocouple 42.
If the temperature conveyed by thermocouple 42 is within a given range of the
set-point
temperature, then nothing is done by microprocessor 36. The range within which
the
temperature conveyed by thermocouple 42 may differ from the desired set-point
may be as low
as a fraction (for example, 0.1 of a degree) or as large as one or more
degrees, including plus or
minus 5 or 10 (Celsius or Fahrenheit) . Improved accuracy may be obtained by
reducing the
range by which the temperature conveyed by thermocouple 42 may differ from the
desired
temperature set via input device 34.
100831 The range of variation relative to the desired temperature may
have a first or
lower threshold value, and a second or upper threshold value. While the
difference between the
lower and upper threshold values may be small, in order to more closely
achieve the desired
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temperature, a small difference in these values may cause the valves, and
possibly other
components to operate more frequently. This frequent operation may reduce the
effective
lifetime of such components. Such frequent use may also increase the power
consumption,
which may be undesirable if there is a limited or restricted power supply.
While a greater
difference between upper and lower threshold values may produce greater
variation in the actual
temperature of the barbeque 20, less energy may be used and a longer life may
be obtained from
at least some of the components of barbeque 20.
100841 For example, a lower/upper difference of 10 F (i.e., plus or
minus 5 F about the
desired temperature) may provide suitable results. Alternatively, ranges as
small as 1 F or as
large as 50 F, or larger depending on the cooking needs. The upper and lower
limits for the
range may be static relative to the temperature set-point. For example, they
may be set to always
be within 5 F of the desired temperature. Alternatively, the upper and lower
set-points may vary
depending of the temperature set-point. For example, the upper and lower
limits may be within
10 F of the desired temperature at a lower temperature such as 40 F, whereas
they may define a
smaller range, for example, plus or minus 3 F, relative to a higher set-point
temperature, such as
200 F.
100851 This dynamic variation of upper and lower set-points may be
used advantageously
to take advantage of the thermal dynamic characteristics of the barbeque
assembly 20.
100861 When microprocessor 36 receives a signal from thermocouple 42
indicating a
temperature greater than (or optionally, equal to) an upper limit value,
microprocessor 36 sends a
signal to valve 38 to cause it to enter a low or no-flow state.
10087] In the present embodiment, valve 38 enters a low-flow state.
Microprocessor 36
compares temperature information from thermocouple 42 and compares it with the
upper and
lower limits as frequently as once per second, or fraction of a second, or as
infrequently as every
several minutes. The typical range for this comparison may be between 0 to 30
seconds. This
provides sufficient time for a change in the temperature of the barbeque 20 to
stabilize after a
change in the state of valve 38.
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[0088] When microprocessor 36 determines that the temperature
conveyed by
thermocouple 42 has fallen below a lower threshold (or alternatively, is equal
to a lower
threshold), then it may signal valve 38 to turn on or to switch to a high-flow
state. This may
cause the temperature within barbeque 20 to increase above the lower
threshold. Microprocessor
36 may continue to receive signals from thermocouple 42, and to cycle valve 38
between high
and low (or, in some embodiments, off) states in order to achieve a desired
temperature within
barbeque 20. For example, when microprocessor 36 compares the temperature of
thermocouple
42 against the lower and upper temperature thresholds every 5 seconds, and the
upper and lower
threshold values are separated by a range of 10 F, the temperature within
barbeque 20, having a
closed lid 22, has been found to be maintainable within as little as one or
two degrees Fahrenheit
of the desired temperature.
100891 A safety feature may be included in the temperature control
apparatus 32.
Microprocessor 36 may include memory (not shown), if needed, for example, for
storing
historical temperature data. In an embodiment, at least the previous reading
from thermocouple
42 may be stored for comparison with a subsequent reading. If a difference
between the
previous and subsequent readings relative to the time between readings is
sufficiently great or
sufficiently small, then an alarm may sound. Furthermore, if the differences
in the previous and
subsequent temperatures is great enough, microprocessor 36 may signal valve 38
to change into
an off or low-flow state. This may occur, for example, if there is a flare-up
or fire within the
barbeque 20, causing a rapid increase in the temperature therein.
Alternatively, if there is a rapid
decrease in temperature, then the flame may have gone out and the flow of fuel
may need to be
shut off or reduced. In either case, an alarm may sound to alert the user to
an error condition.
[0090] As noted, more than one thermocouple may be employed within a
single barbeque
assembly 20. In such case, microprocessor 36 may take an average or weighted
reading of the
various thermocouples to determine the temperature of the barbeque 20.
Alternatively, barbeque
20 may be divided into two or more zones (or additional barbeques may be
connected to
temperature control apparatus 32), with at least one thermocouple being placed
in each zone or
barbeque.
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100911 When temperature control apparatus 32 is connected to
thermocouples in two or
more thermally separated zones of barbeque 22, different temperature states
may be achieved
within barbeque 20. For example, a desired temperature may be set for
thermocouple 44 in a
manner similar to that set for thermocouple 42. Thermocouple 44 may be set at
a temperature
the same as, higher than, or lower than the zone in which thermocouple 42 is
placed (for
example, zones 1 and 2 are illustrated in Figure 3). Zones 1 and 2 may be
thermally separated by
a physical divider (as described in further detail below) or they may simply
represent different
areas within barbeque 20. If zones 1 and 2 are not physically divided, then
achieving
significantly different temperatures between thermocouple 42 and thermocouple
44 may be more
difficult. Nevertheless, barbeque 20 may include a generally warmer area and a
generally less
warm area. When more than one zone or barbeque is to be controlled using the
temperature
control apparatus 32, then at least one additional (or integrated) valve
assembly 60 may be used
for each zone controlled by temperature control apparatus 32. Microprocessor
36 may then be
configured to independently control each respective valve, such as 38 and 60,
in response to
temperatures encoded by thermocouples 32 and 44.
[0092] Temperature control apparatus 32 may also operate in
conjunction with a
thermocouple 46. Input device 34 may be used to enter a type of meat (such as,
pork, beef,
chicken, or lamb) and a desired doneness (e.g., well done, medium, medium-
rare, or rare).
Microprocessor 36 may then control the temperature of barbeque 20 employing
one or both
thermocouples 42, 44, to achieve a pre-determined temperature in order to cook
the meat to a
desirable extent.
100931 Temperature control apparatus 32 may additionally be connected
to a tank level
sensor 50 for determining the amount of fuel left in a connected fuel
reservoir, such as a liquid
propane tank 66. An icon, such as icon 67 may graphically or numerically
illustrate the amount
of fuel remaining. Microprocessor 36 may be connected to a tank level sensor
(described
below), and may be configured to shut off valves such as valve 38 when the
tank is low or
empty.
10094] Tank 66 may be provided with a regulator 68 for ensuring that
the pressure of the
fuel provided to barbeque 20 is at a constant pressure, regardless of the flow
setting of the valves
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(such as valve 38). Hence, even though valve 38 may be in a low-flow state,
the pressure of the
fuel transmitted therethrough to barbeque 20 may be at generally the same
pressure as the fuel
transmitted when valve 38 is in a high-flow state. The valves, such as valve
38 and valve 60, do
not include a regulator or have a regulator associated therewith. This may be
advantageous
because it may reduce the chance that a "flame-out" occurs within barbeque 20
due to
insufficient fuel pressure. It may also reduce the cost of valves 38 and 60.
Since fuel flow is not
regulated by pressure, the valves need not include a regulator. A fuel
pressure of about 11 inches
water column (WC) may be employed for propane and about 7 inches WC for
natural gas. This
may vary depending on requirements and government or other regulations which
may vary by
jurisdiction.
100951 Figures 5A to 5T illustrate an example of a configuration for
a LCD screen 52 of
the temperature control apparatus 32. As noted, the particular layout, font,
figures, and
functionality included may be varied, added to, or removed. For example,
functionality relating
to a meat probe or tank level sensor may be eliminated or removed to reduce
cost or for some
other reason. At a minimum, means for inputting a desired temperature set-
point may be
included, unless the system is designed to always maintain the same
temperature, such as for a
commercial application. Features highlighted for LCD display 52 are shown
darkened in the
figures for ease of illustration. The various features may be darkened or not
in an embodiment.
Different colours and lighting, including back-lighting, may be employed to
improve readability
and usability.
[0096] Figure 5A shows an on/off button graphic 53. Pressing screen
52 about this
graphic, causes the temperature control apparatus 32 to switch off and on, as
desired. As noted,
when temperature control apparatus is in an "off' state, barbeque 20 may
operate as a
conventional barbeque. Alternatively, barbeque 20 may be configured without
one or more, or
all of knobs 30. In this configuration, temperature control apparatus 32 may
control all fuel flow
to barbeque 20. Valves 38 may be configured to include an "off' setting, or
fuel flow may be
switched off, for example manually, at tank 66, or at some other fuel source
that is connected to
barbeque 20. In this alternative configuration, barbeque 20 may be difficult
to achieve a desired
temperature without turning temperature control apparatus 32 on.
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[0097] Figure 5B illustrates a countdown timer that may be included.
The countdown
timer may be set in a manner similar to that described for the temperature
setting. The
countdown timer may be used to turn off or change fuel flow after a certain
period of time.
Alternatively, it may be used as a simple timer. This feature may be activated
by pressing the
hour glass icon 70 and adjusting the desired time by pressing the arrow keys
56 and 58.
[0098] Figure 5C illustrates icons of display 52 that may be used to
set a temperature, as
described above. If temperature control apparatus 32 is configured to control
two zones (it may
be used for just one zone or barbeque), then zone control button 54 may be
pressed, followed by
increase/decrease arrows 56 and 58 in order to enter a desired temperature set-
point. A similar
operation may be followed for a second zone by pressing second zone button 72.
If both zones
are to have the same temperature set-point, then button 74 may be pressed and
both zones
desired temperatures will be set at the same time by pressing
increase/decrease arrows 56 and 58.
[0099] Figure 5D includes a food-type entry input 76. This may be
used to toggle or
scroll through different meat types, and to enter a desired doneness for the
food as illustrated at
62. Microprocessor 36 may be encoded with any variety of food types and
characteristics to be
entered via display 52.
1001001 Figure 5E illustrates setting of a clock feature 78.
Microprocessor 36 may be
configured to maintain display of clock 78 even when display 52 has been
switched off Clock
78 may be set by pressing in the area of clock 78 and the up or down arrow at
the same time in
order to increment or decrement the clock setting. It should be noted that all
functions are
preferably configured to require simple single button sequential pressing to
avoid the need for a
separate clock icon. Both the clock and arrow areas of display 52 are pressed
at the same time
for setting. However, an alternative configuration could be employed so that a
clock icon is
pressed and the arrow keys subsequently pressed in order to set the clock.
[00101] Figure 5F illustrates employing the increase icon 56, and Figure 5G
illustrates
using the decrease icon 58. These icons are used to increase and decrease
values associated with
the various functions of the temperature control apparatus 32.
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[00102] Figure 5H illustrates a preheat function that may be encoded
into microprocessor
36. A preheat button 80 of display 56 may be pressed. This causes
microprocessor 36 to
activate valve 38 to a high setting so that zone 1 (and any other zone
activated, in which case
additional valves are activated). Valve 38 is activated to a high flow rate so
that the associated
zone in barbeque 20 quickly achieves a predetermined preheat temperature. In
the present
example, a preheat temperature of 400 F is pre-programmed in microprocessor 36
as the preheat
temperature. Any other temperature may be pre-programmed as a preheat
temperature.
Alternatively, temperature control apparatus 32 may be configured, including
screen 52, to have
a manually settable preheat temperature. Once the preheat temperature is
reached, the
temperature control apparatus may beep one or more times, at intervals if
desired. For example,
the temperature control apparatus 32 may beep for a period of 5 seconds every
minute for 5
minutes.
1001031 Figure 5M illustrates a food-specific function that may be
coded into
microprocessor 36 and implemented into display 52. A food icon 76 may be used
in conjunction
with a probe such as a thermocouple meat probe 46 (see Figure 3). When the
meat probe reaches
a desired temperature, the temperature control apparatus 32 may issue a beep.
When the probe
reaches a temperature over the set-point (for example, 5 over the set-point,
a continuous or
repeated beep may issue). A sample table of goal temperatures for various food
items follows.
These values may be pre-programmed into microprocessor 36. Any other of a wide
range of
values may be pre-coded for use with different types of foods or cooking
scenarios. Optionally,
temperature control apparatus 32 may be configured to enable coding of values
by a user. In
such case, a random access memory, such as a stable flash memory may be
employed in the
temperature control apparatus.
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Well-Done Medium Medium-Rare Rare
Beef 170 F 160 F 145 F 135 F
Lamb 170 F 160 F 145 F 135 F
Veal 170 F 160 F 145 F 135 F
Chicken 180 F
Turkey 180 F
Pork 170 F
Fish 160 F
Hamburger 160 F
[00104] Figure 5K illustrates entering a food type by repeatedly
pressing the food icon 76.
Figure 5K at the right side thereof illustrates the various food types that
will be displayed as
food-type icon 76 is pressed.
[00105] Figure 5L illustrates display 52 after it has been set to cook beef
medium-rare.
Figure 5L illustrates that the probe temperature is below the set temperature
of 145 F.
[00106] Figure 51 further illustrates temperature control setting. In
the present example,
temperature may be set in five degree increments. However, the temperature
control apparatus
32 may be configured to enable other increments including fractions of a
degree. The
temperature control apparatus 32 may be configured to sound an alarm or to
flash a light once a
target temperature has been reached.
[00107] Figure 5J illustrates a condition when the target temperature
cannot be reached
after a certain period of time. The period of time may be predetermined by
encoding
microprocessor 36 accordingly. For example, if a set-point temperature is not
achieved within
10 minutes, then an alarm, whether visual, auditory or other sensory
indicator, may be activated
to indicate to a user that the target temperature cannot be achieved, either
because the
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temperature is too high or too low. The goal temperature may then be reset
accordingly or the
barbeque 20 may be examined to determine whether there is a fault.
[00108] Figure 5N illustrates that up button 56 may be used in
conjunction with automatic
temperature control button 82 to toggle between different temperature units,
such as Celsius and
Fahrenheit.
[00109] Figure 50 illustrates the fuel tank level icon 67 described
above. Icon 67 may be
configured to illustrate a progressively empty fuel vessel as illustrated in
Figure 5P. Processor
36 may be programmed to query the tank level sensor 50 at a predetermined
interval such as 30
seconds. Tank level icon 67 may then include one or more bars corresponding to
a
predetermined level. Depending on the tank level value returned by tank level
sensor 50, a given
number of bars may be activated in icon 67 to illustrate graphically the
amount of fuel
remaining. Alternatively, a number corresponding to the level of the fuel tank
may be illustrated.
An alarm may be activated when the fuel tank 66 reaches a predetermined level,
such as 10%.
[00110] Figure 6 is an isolated view of barbecue base 24 and console
28. Figure 6
illustrates that the barbecue 20 may include an auxiliary burner (not shown)
connected by
conduit 84. The present embodiment may include three burners 86, 88 and 90.
Barbecue 20
may be configured to have any number of burners, including just one burner, or
multiple burners.
If just one burner, such as burner 86, or 88, is employed, then temperature
control apparatus 32
will typically include just one valve assembly, such as valve assembly 38.
Each burner 86, 88
and 90 may define separate heating zones within barbecue 20. In such case,
barbecue 20 may be
thermally separated into three different zones. In the embodiment shown in
figure 6, barbecue
20 includes just two heating zones. Burners 86 and 88 may be associated with
heating zone I
and burner 90 may be associated with heating zone 2. Heating zones 1 and 2 may
be separated
by a divider (discussed below) that is resistant to thermal transmission. This
may ensure that
zones 1 and 2 may be controlled independently to have different temperatures,
or they may be
controlled relatively independently to have the same temperature. Burners 86,
88 and 90 may
have different configurations, or the same configuration, and they may include
the burner types
illustrated, or any other burner known in the art, including those
conventionally used for gas
fuelled appliances, such as barbecues.
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1001111 Figure 7 illustrates an isolated rear view of console 28 and
associated components
of barbecue 20, including components of the temperature control apparatus 32.
Figure 7 should
be viewed in conjunction with figure 6. When temperature control apparatus 32
is off or not
activated, control knobs 30, 92 and 94, each associated with a respective
burner 86, 88 and 90,
may be used to control in a conventional manner the flow of a combustible fuel
in a conventional
manner. Each control knob includes an associated valve. Any suitable control
knob and valve
combination may be used, including those well known in the art. Additional
control knobs may
be included, such as control knobs 96 (e.g., for a rotisserie), 98 and 100.
Control knob 98 may
be used to control the flow of fuel to an additional burner or other appliance
via conduit 102
which connects to conduit 84 (shown in figure 6).
1001121 Each valve, such as valve 38, associated with a zone may have
a minimum flow
rate that is similar to or equal to the sum of the flow rates of the
associated controls, such as
controls 30 and 92. For example, if controls 30 and 92 each have a minimum
flow rate of 5,000
BTUs, then valve 38 preferably has a minimum flow rate of 10,000 BTUs (i.e.,
5,000 + 5,000).
This configuration permits valve 38 to supply a minimum amount of fuel to
controls 30 and 92.
If the minimum flow rate of valve 38 is made lower than the sum of the minimum
flow rates of
the associated control or controls, then it is possible for any associated
burner, such as burner 86
or 88 to "flame out" due to an insufficient fuel supply. The minimum flow rate
for valve 38 may
be in the range of 10,000 BTUs, and the maximum flow rate may be in the range
of 25,000
BTUs. Higher and lower values may also be suitable depending on the
configuration such as the
volume of the barbeque to be heated.
1001131 Control 30 may be configured to include an off position in
which the flow of fuel
to burner 86 is inhibited. The off position may be a discreet position. For
example, control 30
may click or snap into an off position. Control 30 may also have discreet or
continuous high and
low positions, permitting high and low rates of fuel flow to burner 86. In an
embodiment,
control 30 must be pushed when it is in an off position before it may be
turned to a high or low
position. Once in a high, low, or intermediate position, it may be released.
Control 30 may then
be rotated between high and low positions, without pushing it, in order to set
a fuel flow rate that
is high, low or at some intermediate position. To return to an off position,
control 30 may be
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pressed and turned to the off position. The other valves 92, 94, 96, 98 and
100 may be similarly
configured.
[00114] In the illustrated embodiment, the controls, such as controls
30, 92 and 94, that
are associated with the temperature control apparatus 32, may also be used at
the time that the
temperature control apparatus 32 is activated. For example, when control 30 is
put to an
intermediate flow position, temperature control apparatus 32 may operate valve
38 to cycle gas
flow between the low flow rate of valve 38 and the intermediate flow rate as
set by control 30. If
control 30 is placed to a high flow rate setting, then the temperature control
apparatus 32 may
operate to achieve and maintain temperatures within a broader range. When
temperature control
apparatus 32 is used, all associated valves (30, 92 and 94) will typically be
placed by a user to a
high flow position to provide the temperature control apparatus 32 with the
largest possible range
of operation.
[00115] Temperature control apparatus 32 may also operate if all
control knobs, such as
control 30 are eliminated. In such case, flow of the fuel may be turned off as
a shut-off valve
106 of regulator 68. All control knobs may be conveniently connected via a
manifold 108. When
the temperature of more than 1 zone is to be controlled, then the controls and
associated burners
for a given zone may be connected via separate manifolds. In the present
example, a second
manifold 110 may be included for zone 2. This can be seen in figure 7.
Manifold 108 may
connect burners 86 and 88, and associated controls 30 and 92. Manifold 108 may
also be
connected with valve 38. In this way, the temperature control apparatus 32 may
separately
control the burners in zone 1 via valve 38, and the burners in zone 2 via
valve 60
[00116] Temperature sensors such as thermocouples 42 and 44 may be
located within each
of zones 1 and 2. The thermocouples may be mounted to a side of base 24, or
any other location.
Thermocouples 42 and 44 are preferably placed to avoid contact with any
drippings or splatter
from food cooked within barbecue 20.
[00117] Barbecue assembly 20 may additionally include an ignitor for
igniting fuel
communicated to the burners, such as burner 86. Alternatively, a match or
other suitable means
may be used to ignite the burners.
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[00118] Figure 8 shows barbecue 20 without closure members 112 (as
shown in figure 1).
Figure 8 illustrates a possible placement of tank sensor 50. Tank sensor 50 is
illustrated in
greater detail in figures 9A to 9D. Tank sensor 50 may be used to determine
the fuel level in a
tank 66 associated therewith. Tank sensor 50 may be connected to temperature
control apparatus
32 via a connector 114. A sensor such as that manufactured by Sensotech Inc.
of 1250 Rene-
Levesque Boulevard, Montrol, Quebec may be suitable, or as disclosed in Patent
Corporation
Treaty application no. PCT/CA2005/001935 (International Publication No. WO
2006/072160)
and United States Patent application No. 11/029, 415 (U.S. Patent Publication
No. US 2006-
0169055 Al) and other applications claiming sensor devices and which are owned
Sensotech
Inc.
[00119] Figures 10 and 10A illustrate a support for a fuel reservoir
such as fuel reservoir
66 (see also figure 12). As further illustrated in figures 11A to 11D, support
116 includes at least
1 protrusion 118 that corresponds to a lower portion 120 (see figure 12) of
tank 66. Support 116
may additionally include portions defining a void 122 for receiving a stand
124 of tank 66. Void
122 may be configured as a continuous slot (not shown) for receiving an edge
of stand 124.
[00120] Tank support 116 may additionally include a rebate 126 for
receiving sensor 50.
Rebate 126 may be configured to conform to a perimeter of sensor 50 so that
sensor 50 engages
edges defining rebate 50 in a snap fit. Alternatively, rebate 126 may be
configured for a friction
fit, or may simply retain sensor 50 by gravity fit.
[00121] Tank support 116 may be formed integrally with a shelf 128 of
barbecue
assembly 20. This may make it difficult to install, remove, and replace tank
66. Accordingly,
tank support 116 may be configured as a separate member movable relative to
shelf 128. Tank
support 116 may be mounted to two shelf 128 on rails, sliders or some other
suitable
arrangement. As illustrated in figure 10A, tank support 116 may be configured
to slidably
engage shelf 128. A stabilizer, such as rail 130, may be included to provide
additional support
and guidance to tank support 116 when it is moved relative to shelf 128.
[00122] Tank support 116 may also include a guide in the form of a rib
for engaging a
complimentary feature of shelf 128. Rib 132 may be located upon either side of
tank support
116 to permit generally linear movement of tank support 116 relative to shelf
128. Rib 130 and
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rib 132 serve to discourage displacement or tipping of tank support 116
relative to shelf 128
when shelf 128 is moved for removal or replacement of tank 66.
1001231 Tank support 116 may additionally include a retainer or a lock
such as latch 134.
Latch 134 may be movable within tank support 116 so that it engages shelf 128
or a
complimentary feature in shelf 128. As shown in figure 12, latch 134 extends
generally
perpendicular to a plane of movement of tank support 116 so that it may engage
a corresponding
feature (not shown) of shelf 128. Latch 134 discourages movement of tank
support 116 relative
to shelf 128 when tank support 116 is in engagement with shelf 128, and tank
66 is positioned
for use. This arrangement may further discourage movement of tank 66 when
barbecue 20 is
operated.
1001241 Figure 12 is a cross sectional view providing further
illustration of both tank
support 116 and the positioning of tank level sensor 50. Tank level sensor 50
preferably contacts
tank 66 sufficiently that it may communicate and receive signals therewith in
order to determine
the amount of fuel within tank 66.
1001251 Figure 13 illustrates barbecue 20 configured to have multiple
zones, described
above. By differentially controlling two or more of burners 86, 88 and 90 (see
for example,
figure 7), barbecue 20 may be provided with thermally differentiated zones
therein. As shown in
Figures 13A to 13D, and in an isolated view shown in Figure 14, a divider such
as divider 136
may be included with barbecue 20 to encourage or facilitate thermal
differentiation between the
various zones. In the example shown in figure 13, thermally differentiated
zones 1 and 2 are
illustrated. Even without divider 136, thermally differentiated zones may
exist, for example, if a
high flow rate fuel is provided to one burner, such as 86, and a low flow rate
of fuel is provided,
for example, to burner 90, then zone 1 may be generally warmer than zone 2.
However, when lid
22 is closed, heat from the wanner zone will tend to transfer to the less warm
zone, thus
inhibiting differentiated cooking between zone 1 and zone 2.
1001261 Employing a divider, such as divider 136, in order to
thermally separate two or
more zones within barbecue 20 may permit thermally differentiated cooking. For
example, a
steak or other meat requiring a higher cooking temperature may be included in
zone 1, whereas
vegetables requiring a lower temperature may be included in zone 2. This may
permit the
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cooking of both meat and vegetables at the same time, on the same barbecue,
but at different
temperatures. If a sufficient air seal is achieved between zones 1 and 2 when
lid 22 is closed and
divider 136 is in place, then the effect of flavours and other aromas produced
by the cooking of
food in one zone may be reduced in the other zone, thus preserving flavours of
items cooked.
However, an air seal is not required for divider 136 to operate.
[00127] Divider 136 may be made of a material that resists the
transfer of thermal energy,
such as a ceramic. However, thermally conductive materials, including metals,
may be used
because such materials will also serve to inhibit thermal transfer between
zones 1 and 2. A
combination of materials such as insulation sandwiched between sheets of
metal, may also be
employed.
[00128] Divider 136 may conform to an inside perimeter of lid 22 and
base 24 when lid 22
is closed. In such configuration, divider 36 may divide or bifurcate the
volume enclosed by base
24 and closed lid 22. Divider 136 may divide such volume into two equal
volumes, or unequal
volumes depending on cooking needs, such as the grill 26 area required, and
the placement of
burners, such as burners 86, 88 and 90.
[00129] Figure 13 illustrates divider 136 in a plane generally
perpendicular to grill 26 and
generally perpendicular to a plane of the front of grill 20. Divider 136 may
alternatively be
placed in any other orientation that serves to thermally separate the internal
volume of grill 20.
Furthermore, multiple dividers 136 may be employed, for example, to thermally
separate each of
burners 86, 88 and 90. In the present embodiment, divider 136 may limit the
effect of different
temperatures in zones 1 and 2 on each other. For example, divider 136 may
limit the effect of a
temperature in zone 1 on zone 2 by not more than plus or minus 10 degrees
Fahrenheit. In a
further example, if the temperature of zone 1 is 300 degrees Fahrenheit, and a
desired
temperature of zone 2 is 200 degrees Fahrenheit, then zone 1 will generally,
at most, raise the
temperature of zone 2 to 210 degrees Fahrenheit with divider 136 in place. As
noted below, the
extent of this effect may depend on the material used for divider 136 and the
extent to which
divider 136 seals zone 1 from zone 2.
1001301 While divider 136 preferably conforms to an internal perimeter
of combined lid
22 and base 24, it needs not completely conform to such internal perimeter.
With reduced
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conforming to such internal perimeter, divider 136 may be less thermally
inhibiting.
Nevertheless, even a limited amount of thermal resistance by divider 136 to
the transfer of heat
between zones 1 and 2 may provide a suitable differentiation in cooking
temperature in each of
zones 1 and 2.
[00131] Divider 136 may be cut, stamped, moulded or otherwise formed as a
single sheet,
or as multiple sheets or pieces connected together. As noted, divider 136 may
be made of a
metal, a plastic, or some other substance that resists burning.
1001321 In an embodiment, divider 136 may be a single, generally
continuous, generally
planar sheet. Grill 26 may be formed of two separated grill parts (not shown).
Divider 136 may
then be placed between each grill part. The grill parts may serve to support
divider 136.
[00133] Divider 136 may alternatively be provided with one or more
rebates for avoiding
features of grill 20 that may inhibit placement of divider 136. For example,
divider 136 may be
provided with one or more grill rebates 138. Rebates 138 may be dimensioned
and located to
receive a portion of grill 26 that may inhibit placement of divider 136 as
shown in figure 13A.
Rebates 138 may each receive one or more of the steel members that form grill
26. The
positioning, number, and orientation of rebates, such as rebates 136, may be
determined by the
particular configuration of a given barbecue. For example, a barbecue may
additionally include
a warming rack 140. Accordingly, divider 136 may include a warming rack rebate
142 to
accommodate warming rack 140, as seen in figure 13A. Warming rack rebate 142
may be
configured to closely correspond to a portion of a perimeter of warming rack
140. As
mentioned, rebates such as rebate 142 may generally correspond to a feature
such as warming
rack 140, and may permit a limited amount of thermal transfer, including air,
to pass. The
rebates, such as rebate 142, may be made large enough for easy passage of
obstructions, such as
warming rack 140, therein. If a given barbecue configuration does not include
obstructions
inhibiting the placement of divider 136, then divider 136 need not be provided
with any rebates.
[00134] Rebates 138 in turn define tongues 144 (additional tongues may
be defined such
as tongues 146 and 148). The tongues together serve to inhibit movement of
energy, air, fumes
and other matter between the zones.
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1001351 Divider 136 may include a stabilizer, attachment, or other
feature to maintain its
intended placement, and to permit divider 136 to resist movement when barbecue
20 is used. For
example, a stabilizer 150 may be included at one or both ends of divider 136.
Stabilizer 150 may
be configured to abut a corresponding feature of grill 26. Stabilizer 150 may
alternatively be
located at an intermediate portion of divider 136. For example, stabilizer 150
may be placed
adjacent to any part of rebate 142 to provide stabilization of divider 136
against warming rack
142. In the illustrated embodiment, 2 stabilizers 150 are provided to lie upon
grill 26 in a
direction transverse to a plane of divider 136. In this configuration,
stabilizer 150 may inhibit
lateral movement of divider 136. Stabilizer 150 is illustrated as being stick-
like. Alternatively,
stabilizer 150 may be provided at an angle less than 90 degrees relative to
divider 146, in order
to still impart stability to divider 136. Other protrusions from divider 136,
may also be included
so long as they provide a measure of support to divider 136 in order inhibit
its movement when
installed in barbecue 20. Alternatively, or additionally, divider 136 may be
made to have a
thickness approximating the spacing of grill 26. In this way, a friction fit
may be formed
between divider 136 and grill 26 when it is inserted therein.
[00136] Divider 136 may alternatively be permanently or temporarily
attached to one or
both of grill 26 and base 24. For example, divider 136 may be welded, caulked,
screwed, bolted,
or otherwise mounted to grill 26 or base 24, or both. Divider 136 may
alternatively be attached
to an inside surface of lid 22 so that it is moved in and out of place by
opening and closing lid
22. In such configuration, the shapes of one or more of rebates 138 and 142
may need to be
changed to accommodate this movement.
[00137] Support for divider 136 may alternatively, or additionally, be
provided by a
feature of base 24 (not shown). For example base 24 may include a receptacle
or groove for
receiving an edge of divider 136 in order to maintain its position. Such
groove preferably has a
width corresponding to, or marginally less than, a width of divider 136 to
provide a friction fit
when divider 136 is placed therein.
[00138] Divider 136 may alternatively constructed of two or more
separate pieces. For
example, a divider portion (not shown) may be installed below grill 26. A
second
complimentary portion may then be installed above grill 26. Such configuration
could serve to
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reduce the need for any rebates, such as rebates 138. This in turn could
reduce the extent to
which thermal energy, air, and other matter can pass between zone 1 and zone
2. In a further
alternative, divider 136 may be installed through a slot provided in base 24
(not shown). In this
configuration, divider 136 may be installed in a generally opposite direction
to the manner
illustrated in figure 13. A retainer or other feature may be provided to
prevent divider 136 from
falling out of the slot and base 24. A similar feature could also be provided
using a slot in lid 22.
[00139] Figure 15 illustrates barbecue 22 and an internal storage
system. The internal
storage system may include a container 152 slidably mounted to shelf 128, for
example via
conventional telescoping rails 154, and a nestable container 156. Container
152 may be made of
any suitable material, such as a plastic, and may be dimensioned to occupy a
suitable portion of a
volume defined by barbecue shelf 128, barbecue walls 158, doors 112 (see
figure 1) and back
(not shown). Storage 152 may have generally rectilinear dimensions, but may
also be rounded or
some other shape, as required. Container 152 may be slideably mounted to shelf
128 by
providing a complimentary indent (not shown) in shelf 128 for receiving the
bottom of container
152. Alternatively, container 152 may be mounted to a movable shelf (not
shown). Container
152 may be used to store grill 26, or parts of grill 26, or other components
of barbecue 20 or
tools or appliances used in conjunction with barbecue. Container 152 may
include a grip or
handle 159 attached or integrally formed in some convenient location of
container 152, such as a
top edge thereof
[00140] The storage system may also be provided with an insert, such as
insert container
156. Insert container 156 preferably includes a lip 160 for supporting insert
156 upon edges 162
of container 152. Container 156 may additionally include a grip or handle such
as an opening
164. Any other suitable handle may alternatively or additionally be applied.
[00141] Figures 16A to figure 16D illustrate various views of the
storage system.
[00142] Figure 17, 17A and figures 18A to 18A illustrate a receptacle 166
for receiving
grease, fat or other matter that may drip, fall or otherwise reside within
base 24. An opening (not
shown) within base 24 may permit the passage of such material into receptacle
166. Receptacle
166 may be any convenient size and shape to define a volume suitable for
receiving an
predetermined amount of material, such as fat or grease, that may be caught
therein. For
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example, receptacle 166 may have the following approximate dimensions: about 1
inch deep by
about 8 inches wide by about 5 inches long. In the preferred embodiment,
receptacle 166 has
dimensions of 1.1 inches deep by 7.785 inches wide by 5.315 inches long..
1001431 Receptacle 166 may be supported by a shelf 16A. Shelf 16A may
define an
1001441 Shelf 168 may be movable within a slot 174 of barbecue 20.
Other slidable
may also be conveniently provided with a grip or catch such as in the nature
of a handle 176.
[00145] Figures 19, 19A and 20A to 20D illustrate an infrared burner
178 that may be
included in addition to burners 86, 88 and 90. Alternatively, infrared burner
178 may be
25 [00146] The following focuses on the operation of the
programming of temperature
control apparatus 32, identifying aspects of the operation of the programmed
software as shown
in part in Figure 21.
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[00147] Software of temperature control apparatus 32 may be programmed
to include the
following functions described below. One or more of the evaluations made by
the software may
be done in a different order as set out below, or as shown in Figure 21, as
appropriate.
[00148] As illustrated in Figure 21, the operation of the following
disclosed aspects of the
software may begin at step 200, for example, by a user turning on temperature
control apparatus
32. At step 202, the software evaluates whether a condition exists in which an
alarm should be
activated due to barbeque 20 being too hot, or if the temperature measured
within barbeque 20
increases or decreases in temperature at higher than a predetermined rate.
1001491 Step 202 may also evaluate whether any other safety or alarm
condition exists. If
such a condition exists, then the software instructs temperature control
apparatus 32 to lower the
flow rate of a connected fuel flow control device, such as valve 38. For
example, valve 38
maybe set to a low flow rate following an alarm or error condition. This is
done to reduce the
amount of fuel provided in the event that something is wrong with the burning
of fuel. If control
valve 38 is configured to have an off state, then the software may cause valve
38 to turn off in
step 204.
[00150] In step 206, the software evaluates whether barbeque 20 is set
for manual
operation. For example, temperature control apparatus 32 may include an input
for a user to
select between manual or automatic operation. Alternatively, if no desired
temperature set point
is entered, then temperature control apparatus 32 may default to manual
operation. In such case,
in step 210 valve 38 (or other flow control device) may be set to permit fuel
flow, and is
preferably set to permit a high flow rate. In this manner, a user may manually
restrict fuel flow
using one or more of control knobs, such as control knobs 30.
[00151] In step 220, the software assesses whether the measured
temperature of barbeque
20 is within a predetermined range of a desired set point. For example, the
software may
determine whether the measured temperature is with 2 F (for example, either 2
above or below
a desired temperature set point). If the measured temperature is within this
range then the
software does not change the present flow rate of fuel, whether such flow rate
is at a high rate, a
low rate, or otherwise.
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[00152] In step 222 the software assesses whether the measured
temperature is higher than
the temperature range described above. For example, it may evaluate whether
the measured
temperature is higher than the desired set point temperature plus a set
amount, such as 2 F. If the
measured temperature is above such total, the software may send an instruction
to lower or
otherwise restrict the flow rate of fuel (in some embodiments it may instruct
fuel flow to be
turned off). If the measured temperature is not higher than the predetermined
range, fuel flow is
maintained in step 226.
[00153] Additionally (not shown), a further step of evaluating whether
the measured
temperature is below the predetermined temperature range may be carried out.
If the measured
temperature is below such range then the flow of fuel may be increased, for
example, by setting
valve 38 to a high flow rate.
[00154] As can be seen from Figure 21, the ultimate result of any step
is a return to just
after start step 200. This permits the continuous evaluation of the various
states of barbeque 20.
Evaluation may be performed by the software at any interval, for example,
evaluation may be
done many times per second, or evaluation may be done intermittently, such as
every few
seconds, every minute, or after a series of minutes. Of course, evaluation may
be done at
varying intervals, depending on the stage of cooking. For example, at start
up, evaluation of the
temperature state of barbeque 20 may be done every minute, however, once a
temperature set
point is approached, then evaluation of various states of barbeque 20 may be
done more
frequently. For safety, evaluation is preferably done frequently.
[00155] It is also possible to change the ordering of one or more
steps. For example, the
assessment of the alarm condition in step 202 may occur after any other step
described. It is also
possible to evaluate one step more often than other steps. For example, the
measured
temperature comparison in step 220 may be conducted two or more times for
every one time that
the manual operation evaluation is conducted in step 206. Alternatively, the
alarm status
evaluation of step 202 may be conducted after each and every other step in the
flow chart.
1001561 The foregoing example has been described in the context of
controlling
temperature within a single area or volume of barbeque 20. As described,
barbeque 20 may have
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one or more zones that may require different temperature control. In such
case, additional zones
may be controlled using similar steps as described herein.
[00157] Further description and examples of the functionality
illustrated in Figure 21
follow.
[00158] In an embodiment, if a set point temperature is below a preset
minimum value
(for example, a predetermined temperature in the range of 110 C or 225 F), the
barbeque 20 may
enter a manual mode where the flow rate may be manually set by the user and
the temperature
control apparatus 32 will not operate to control the valve 38. Otherwise, if a
mode of the
temperature control apparatus 32 is set by a user to "preheat", a
predetermined preheat set point
may be used as the target temperature instead of a user inputted desired
temperature. Preheat
may be pre-determined or coded in temperature control apparatus 32 at 200 C or
400 F, or some
other value for getting barbeque 20 in a state ready for cooking.
[00159] A user may also set the temperature control apparatus 32 to a
keep warm setting.
If keep warm is set and the keep warm set point temperature is below the user
set point
temperature, the keep warm set point will be used as the target temperature by
the temperature
control apparatus 32. The keep warm set point may be any suitable temperature
that slows or
stops the rate of cooking of food placed within barbeque 20. The temperature
may be pre-
programmed. The keep warm temperature may also be activated when a timer (such
as
illustrated in figure 5B) reaches zero. In response to the timer completing,
the set point is
reduced to the keep warm set point temperature.
1001601 In an embodiment, if none of the above conditions is true, the
user inputted
desired temperature set point may be used as the target temperature.
[00161] If the measured temperature of barbeque 20 is generally above
about a desired
target temperature plus a predetermined amount or hysteresis, the temperature
control apparatus
32 changes the fuel flow rate to low flow rate. If the measured temperature is
below the target
temperature minus a predetermined amount or hysteresis, then the fuel flow
rate may be changed
to the higher flow rate.
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[00162] The hysteresis may be a pre-programmed (for example during
manufacture or
coding) at 1 C or 2 F, or some other higher or lower value suitable for
cooking. As noted, higher
numbers may lead to less accurate cooking, but may reduce the wear on any
movable parts such
as valve 38.
[00163] The software of temperature control device 32 may be pre-programmed
to include
the following features:
[00164] = Off/Manual Mode ¨ This mode permits a user to control
the fuel rate
manually.
[00165] = Preheat Mode ¨ The temperature control apparatus 32
controls the system
to a predefined preheat set point and may sound or otherwise indicate an
alert when the barbeque 20 is at a preheat temperature.
[00166] = Grill Temp Mode - The temperature control apparatus 32
controls the
barbeque 20 temperature to a user defined set point for each zone, when
more than one zone is employed.
[00167] = Timer Mode ¨ This mode is similar to Grill Temp Mode, except
that once
the settable timer expires, the set points may be automatically reduced to
the keep warm set points.
[00168] = Probe Cook Mode - This mode is similar to Grill Temp
Mode, except that
once the probe temperature has reached the set point, the fuel rates of both
zones may be reduced to minimum.
[00169] The software of temperature control device 32 may be pre-
programmed to include
one or more of the following safety features (the alarms may be auditory or
visual or both, and
may include a explanation of the nature of the alarm to be displayed on LCD
52):
[00170] 1. Normal Alarm ¨ this may be activated by temperature control
device 32 when
the measured temperature is not approaching the desired set point over time.
In this situation, the
software continues to control normally, but alerts the user with the display
and an alarm, such as
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an audible beep, to the possibility of an undesirable condition such cover
left open, or an out of
fuel condition.
[00171] 2. Overtemp Alarm - this may be activated by temperature
control device 32 when
the temperature, for example as measured by a thermocouple, exceeds a fixed
programmable
parameter. When this event occurs, an overtemp alarm may be triggered and the
fuel flow rate
reduced.
[00172] 3. OverAcceleration Alarm - this may be activated by
temperature control device
32 temperature, for example as measured by a thermocouple, increases or
decreases (for example
by ramping up or down) too quickly. In such case, an undesirable condition
such as a grease fire
may exist. The software of temperature control device 32 may then reduce the
fuel flow rate,
and may activate an alarm.
[00173] In an embodiment, temperature control device 32 may be
programmed to include
a probe cook mode. In the probe cook mode, a user may set the probe
temperature set point
based on the type of meat and the desired wellness. From the software, this is
a series of pre-
programmed set points used for each wellness state that may be selected (left
to right in degrees
Fahrenheit, the table illustrates the set point probe temperature for rare,
medium rare, medium
and well, respectively) :
[00174] {135,145,160,170}, I/ BEEF
{135,145,160,170}, // LAMB
{135,145,160,170},// VEAL
{180,180,180,180}, // CHICKEN
{180,180,180,180}, //TURKEY
{170,170,170,170}, // PORK
{160,160,160,160}, //FISH
{160,160,160,160} // HAMBURGER
1001751 In a yet further embodiment, the temperature control device
32 may be
programmed to collect data from a tank level sensor that may provide an
indication of the level
of fuel in the tank and the time remaining at the current cook rate. This is
done by monitoring
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the rate of change over time and predicting (extrapolating) the time when the
tank will be out of
fuel.
[00176] * * * * *
[00177] While the foregoing embodiments have been described in some detail
for
purposes of clarity and understanding, it will be appreciated by one skilled
in the art, that
numerous modifications, variations, and adaptations may be made to the
particular embodiments
described above without departing from the scope of the invention(s), which is
defined in the
following claims. In particular, many of the embodiments disclosed may be
applied to other gas
fueled devices and appliances with appropriate modification.
DOCSTOR. 1392511,1
