Cross Reference to Related Application

[0001] This application claims the benefit of U.S. Provisional Application No. 63/329,230, filed April 8, 2022 and entitled “Combi-Oven Adapters for Outdoor Grills and Smokers,” the disclosure of which is hereby incorporated by reference in its entirety.

Field

[0002] This invention relates to outdoor grills and smokers.

Background

[0003] Professional restaurant kitchens often include sophisticated cooking equipment that is unaffordable by ordinary household cooks. For example, so-called combi-ovens (sometimes called combi-steamers) typically include recirculating air, a steam generator, electronic controls and sensors, and are programmed to provide controlled recirculation of hot air and controlled delivery of steam in separate, sequential, or combined operating modes. Combi-oven or combi-steamer suppliers include Alto-Shaam, Axis, Blodgett, Convotherm, Rational, Vulcan, and other companies. Combi-oven prices may start at around $4,000 and typically may be several times that amount. Accessories including touch panel controls, recipe databases, cold smoking capability and other features can further increase the price.

[0004] Many home cooks already own or are contemplating purchasing a wood product- fired closeable outdoor grill or smoker equipped with a wood product combustion zone (for example, a chamber or other receptacle for lump charcoal, briquettes, or pellets) that when ignited will provide a directional flow of heated combustion products, such as heated air or smoke. During operation of the grill or smoker, the heated combustion products pass from the combustion zone through a typically co-located or adjacent cooking chamber that may include grates, stones, grill racks, trays or spits (e.g., rotisserie spits) to hold food during cooking or smoking. The heated combustion products (and potentially additional smoke, moisture or other emissions from the food) exit the cooking chamber and the grill or smoker via one or more vents that typically are physically located in or on the grill at a higher elevation than the combustion zone. A water pan may be included in or above the combustion zone or in the cooking chamber to provide moisture during cooking. An electrically-powered combustion air blower may be located upstream from the combustion zone to assist or accelerate combustion, and a temperature-sensing probe may be located downstream from the combustion zone (e.g., in the cooking chamber) to provide temperature feedback to an adjustable electronic controller so as to enable regulation of airflow delivery by the combustion air blower and assist in grill or smoker startup or cooking chamber temperature regulation.

Summary of the Invention

[00051 The above-mentioned wood product-fired closeable outdoor grills and smokers are popular, relatively low in cost, and capable of imparting tastes to foods that may not be attainable in a home oven. However, they typically do not provide the well-controlled cooking environments attainable in a combi-oven or combi-steamer, and the significant flow of heated combustion products through and then out of the cooking chamber may cause undesirable drying of the cooked food or undesirable lengthening of the required cooking time.

[0006] We have found that by introducing into the cooking chamber of a wood product- fired closeable outdoor grill or smoker one or both of (a) a recirculation blower and (b) moisture from a steam or water droplet generator controlled by a humidity sensor, we can impart combi-oven capabilities to the thus-modified grill or smoker at relatively modest cost. Doing so is especially effective when the grill or smoker already comes equipped with a combustion air blower, temperature-sensing probe and adjustable electronic controller, as the electronic controller can be reprogrammed to add regulation of one or both of a recirculation blower and a steam or water droplet generator, and the power source for the combustion air blower can also be used to power one of both of the recirculation blower and steam or water droplet generator. [0007] The present disclosure accordingly provides, in some embodiments, a wood product-fired closeable outdoor grill or smoker having a wood product combustion zone, a cooking chamber and one or more vents above or at a higher elevation than the combustion zone, wherein wood products ignited in the combustion zone provide a directional flow of heated combustion products that pass from the combustion zone through the cooking chamber and then exit the grill or smoker via the one or more vents, and wherein the grill or smoker further comprises an electrically-powered recirculation blower that redirects the flow of heated combustion products rising through the cooking chamber so that such heated combustion products are delayed in exiting the cooking chamber via the one or more vents. In some embodiments the grill or smoker also comprises a temperature-sensing probe (e.g., in the cooking chamber) that provides temperature feedback to an adjustable electronic controller that regulates operation of the recirculation blower. In some embodiments the redirection of heated combustion products is one or more of downwardly, laterally or otherwise different with respect to the normal flow of heated combustion products rising through the cooking chamber towards the one or more vents when the recirculation blower is not in operation. In some embodiments the recirculation blower is located outside the cooking chamber, is supplied with ambient air from outside the grill or smoker, and an outlet duct carries ambient air blown by the recirculation blower through one or more of the vents and into the cooking chamber so that such ambient air impinges upon and redirects the flow of heated combustion products rising through the cooking chamber. In some embodiments the recirculation blower is located outside the cooking chamber, a blower inlet duct draws heated combustion products from the cooking chamber through one or more of the vents (and optionally through a replaceable or cleanable inline filter that removes grease, smoke particles or other potential grime from the flow of heated combustion products) and into the recirculation blower, and an outlet duct carries heated combustion products blown by the recirculation blower through one or more of the vents and into the cooking chamber so that such heated combustion products impinge upon and redirect the flow of other heated combustion products rising through the cooking chamber. In other embodiments the recirculation blower is located inside (or at least partially inside) the cooking chamber, may or may not employ any ducts or filters, and the recirculation blower redirects the flow of heated combustion products rising through the cooking chamber. In some embodiments the recirculation blower is powered using direct current (e.g., from one or more batteries or from a 5V, 7.5 V, 12 V or other DC voltage power supply), and in other embodiments the recirculation blower is powered using alternating current (e.g., from a residential electrical circuit).

[0008] The present disclosure provides, in additional embodiments, a wood product-fired closeable outdoor grill or smoker having a wood product combustion zone, a cooking chamber and one or more vents above or at a higher elevation than the combustion zone, wherein wood products ignited in the combustion zone will provide a directional flow of heated combustion products that pass from the combustion zone through the cooking chamber and then exit the grill or smoker via the one or more vents, and wherein the grill or smoker further comprises a steam or water droplet generator controlled by a humidity sensor, wherein the steam or water droplet generator raises the level of moisture in the cooking chamber and the humidity sensor detects such moisture level and provides moisture level feedback to regulate operation of the steam or water droplet generator. In some embodiments the steam or water droplet generator is located between the combustion zone and cooking chamber, and introduces moisture into the flow of heated combustion products that pass from the combustion zone into the cooking chamber. In some embodiments the steam or water droplet generator is located outside the cooking chamber, is supplied with ambient air from outside the grill or smoker, and an outlet duct carries moisture generated by the steam or water droplet generator and the thus-moisturized ambient air through one or more of the vents and into the cooking chamber. In some embodiments the steam or water droplet generator is located outside the cooking chamber, an inlet duct draws heated combustion products from the cooking chamber through one or more of the vents (and optionally through a replaceable or cleanable inline filter that removes grease, smoke particles or other potential grime from the flow of heated combustion products) and to the steam or water droplet generator, and an outlet duct carries moisture generated by the steam or water droplet generator and the thus- moisturized heated combustion products through one or more of the vents and into the cooking chamber. In other embodiments the steam or water droplet generator is located inside (or at least partially inside) the cooking chamber, and may or may not employ any ducts or filters. In some embodiments the steam or water droplet generator is supplied with liquid water from a refillable water reservoir positioned outside the grill or smoker. In some embodiments the steam or water droplet generator comprises an electrically-heated surface and moisture is generated by supplying liquid water to such surface, boiling the liquid and converting it to steam. In some embodiments the steam or waterjet droplet generator comprises a spray orifice that atomizes droplets of liquid water. In some embodiments the steam or water droplet generator comprises an ultrasonic piezoelectric vaporizer or nebulizer, similar to that used in home humidifiers. In some embodiments the steam or water droplet generator is powered using direct current (e g., from one or more batteries or from a 5V, 7.5 V, 12 V or other DC voltage power supply y), and in other embodiments the steam or water droplet generator is powered using alternating current (e.g., from a residential electrical circuit).

[0009] The present disclosure provides, in additional embodiments, a wood product-fired closeable outdoor grill or smoker that includes both an embodiment of any of the above- mentioned recirculation blowers and an embodiment of any of the above-mentioned steam or water droplet generators controlled by a humidity sensor.

[0010] In some embodiments the disclosed wood product-fired closeable outdoor grill or smoker includes one or more of a removable ash receptacle, forced air intake, openable cooking chamber door or lid, or electronic control and sensor(s) to regulate cooking chamber temperature and to regulate one or both of the extent of heated combustion product recirculation and the level of moisture in the cooking chamber during grilling or smoking. [0011] The present disclosure provides, in additional aspects, an adapter for a wood product-fired closeable outdoor grill or smoker having a wood product combustion zone, a cooking chamber, and one or more vents above or at a higher elevation than the combustion zone, wherein the adapter comprises (a) one or both of i) an electrically-powered recirculation blower that is outside the cooking chamber and which redirects heated combustion products rising through the cooking chamber so that such heated combustion products are delayed in exiting the cooking chamber via the one or more vents, or ii) a steam or water droplet generator that is outside the cooking chamber, controlled by a humidity sensor, and which raises the level of moisture in the cooking chamber; (b) an outlet duct that carries ambient air or heated combustion products blown by the recirculation blower, or that carries moisture generated by the steam or water droplet generator, through one or more of the vents and into the cooking chamber; and (c) a bracket or hook for mounting element (a) of the adapter outside the grill or smoker. In some embodiments the bracket or hook suspends the adapter from one or more of the one or more vents. In some embodiments the adapter is supplied with ambient air from outside the grill or smoker. In some embodiments the adapter further comprises (d) an inlet duct that draws heated combustion products from the cooking chamber through one or more of the vents (and optionally through an inline filter that removes grease, smoke particles or other potential grime from the flow of heated combustion products) and to one or both of the recirculation blower or the steam or water droplet generator. In some embodiments the adapter includes a temperature-sensing probe to detect the temperature of heated combustion products flowing through the adapter or inside the cooking chamber. In some embodiments the adapter includes control electronics that operate or regulate one or both of the recirculation blower or the steam or water droplet generator. In some embodiments the adapter includes electrical cabling to connect one or both of the recirculation blower and steam or water droplet generator to an adjustable electronic controller on the grill or smoker. In some embodiments the adapter includes a refillable water reservoir positioned outside the cooking chamber.

[0012] The disclosed grills, smokers and adapters enable outdoor grilling or smoking with combi-oven-like control over cooking chamber recirculation, cooking chamber humidity, or both recirculation and humidity in separate, sequential, or combined operating modes. The disclosed adapters may be included as part of a new grill or smoker or sold as aftermarket accessories for an existing grill or smoker.

Brief Description of the Drawing

[0013] Fig. 1 is a front view of a temperature-controlled charcoal grill of the prior art. [0014] Fig. 2 is a perspective view of a temperature-controlled pellet grill of the prior art.

[0015] Fig. 3 is a front view of a temperature-controlled charcoal smoker of the prior art.

[0016] Fig. 4 is a perspective view of one embodiment of the disclosed adapter.

[0017] Fig. 5 is a perspective view of the Fig. 4 adapter mounted on the Fig. 2 grill.

[0018] Like reference symbols in the various figures of the drawing indicate like elements. The elements in the drawing are not to scale.

Detailed Description

[0019] The recitation of a numerical range using endpoints includes all numbers subsumed within that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, 5, etc.).

[0020] The terms “a,” “an,” “the,” “at least one,” and “one or more” are used interchangeably. Thus, for example, an adapter that includes “a” sensor means that the adapter includes “one or more” sensors.

[0021] The term “backside” when used in reference to the disclosed grills and smokers refers to a major (e g., rear) surface of the grill or smoker that will face away from a chef using the grill or smoker.

[0022] The term “closeable” when used in reference to the disclosed grills and smokers refers to a cover or door, typically hingedly attached to the grill or smoker, which when removed or opened will provide access for the addition, removal, inspection or measurement of food items in the cooking chamber, and which when replaced or closed will substantially seal the cooking chamber so that its temperature can be raised and maintained for grilling or smoking.

[0023] The term “cooking” when used in reference to the disclosed grills and smokers refers to either grilling or smoking.

[0024] The term “grill” means a cooking device capable of a variety of cooking tasks including but not limited to grilling, baking, smoking and roasting.

[0025] The term “smoker” means a cooking device primarily intended for use in smoking meats, fish, vegetables, fruits and other foods. [0026] The term “vent” means a hole, slot or other opening in a wood product-fired grill or smoker through which a substantial portion and preferably the majority of heated combustion products exit the grill or smoker during grilling or smoking.

[0027] Turning now to Fig. 1, a temperature-controlled charcoal grill 100 of the prior art is shown in front view. Grill 100 includes a charcoal reservoir 102 that can be filled with briquette or lump charcoal for later ignition in combustion zone 104. A temperature- controlled fan (not shown in Fig. 1) blows heated combustion products from combustion zone 104 into cooking chamber 106. Chamber 106 includes sidewall 108 and hinged, openable cover 110 which is shown in an open position. When cover 110 is closed, a narrow slot (not shown in Fig. 1) between the backside edge of cover 110 and the backside upper edge of sidewall 108 provides a vent through which heated combustion products can escape during grill operation. Electronic controls 112 and a temperature-sensing probe (not shown in Fig. 1) in cooking chamber 106 provide feedback to the temperature-controlled fan to speed grill startup and regulate cooking chamber temperature during grilling. In normal use, heated combustion products from combustion zone 104 rise through cooking chamber 106 and exit via the vent.

[0028] Fig. 2 illustrates a temperature-controlled pellet grill 200 in perspective view. Grill 200 includes a wood pellet charcoal reservoir 202 that supplies pellets to an auger (not shown in Fig. 2) which feeds metered pellet quantities into a thimble-shaped receptacle (not shown in Fig. 2) inside combustion zone 204. A temperature-controlled fan (not shown in Fig. 2) blows heated combustion products from combustion zone 204 into cooking chamber 206. Chamber 206 includes insulated sidewall 208 and hinged, openable insulated cover 210 which is shown in an open position. When cover 210 is closed, a narrow slot 211 between the backside edge of cover 210 and the backside upper edge of sidewall 208 provides a vent through which heated combustion products can escape during grill operation. Electronic controls 212 and a temperature-sensing probe (not shown in Fig. 2) in cooking chamber 206 provide feedback to the temperature-controlled fan to speed grill startup and regulate cooking chamber temperature during grilling. In normal use, heated combustion products from combustion zone 204 rise through cooking chamber 206 and exit via vent 211. [0029] Fig. 3 illustrates a temperature-controlled charcoal smoker 300 in front view. Smoker 300 includes a charcoal reservoir 302 that can be filled with briquette or lump charcoal for later ignition in combustion zone 304. A temperature-controlled fan (not shown in Fig. 3) beneath reservoir 302 blows heated combustion products from combustion zone 304 into smoking chamber 306. Chamber 306 includes sidewall 308 and hinged, openable door 310 which is shown in an open position. A narrow slot 311 in the backside of sidewall 308 provides a vent through which heated combustion products can escape during smoker operation. Electronic controls 312 and a temperature-sensing probe (not shown in Fig. 3) in cooking chamber 306 provide feedback to the temperature-controlled fan to speed startup and regulate cooking chamber temperature during smoking. In normal use, heated combustion products from combustion zone 304 rise through smoking chamber 306 and exit via vent 311. [0030] Fig. 4 shows a perspective view of a combi-oven adapter 400 for installation on grills like those shown in Fig. 1 and Fig. 2. Adapter 400 has a housing 402 that can be hung on the backside of a grill. Adapter 400 includes inlet 404 which carries heated combustion products from the grill cooking chamber through duct 405 and into and through adapter 400. After travelling through adapter 400 (as discussed in more detail below), the heated combustion products are returned to the grill through duct 406 and reenter the grill through outlet 407. When adapter 400 is installed on a grill, inlet 404, outlet 407, and short nearby segments of ducts 405 and 406 reside inside the grill (viz., inside the grill cooking chamber), and the remainder of adapter 400 resides outside the grill, where it will be out of the way during use yet accessible as may be needed for cleaning, filter replacement or water addition, and where it will be shielded from grilling heat. Standoffs 408 can help maintain an air gap between the backside of the grill and housing 402, thereby reducing heat transfer from the grill to adapter 400. The hook-shaped bends in ducts 405 and 406 support adapter 400 and may suspend it from the lower edge of the grill vent. This is shown for example in Fig. 5, which shows adapter 400 hung from slot 211 in the Fig. 2 grill.

[0031] Although the disclosed adapters may be placed wholly or largely inside a grill, placing the adapter outside or largely outside a grill is desirable in order to avoid the high temperatures that may be present inside the grill cooking chamber (e.g., temperatures that may be more than 250°C, more than 315°C or more than 370°C, corresponding to more than about 482°F, more than about 600°F or more than about 700 °F). Such temperatures could damage or shorten the life of adapter 400 or its components.

[0032] The removal of heated combustion products from a grill via inlet 404 and their reintroduction into the grill via outlet 407 serves to redirect the normal upward flow of heated combustion products rising through the cooking chamber, and causes the both the thus- reintroduced heated combustion products, as well as other heated combustion products rising through the cooking chamber from beneath outlet 407, to remain longer in the cooking chamber (in other words, to be delayed in exiting the cooking chamber) before exiting the grill via the grill vent(s).

[0033] Turning now to the components inside adapter 400, heated combustion products entering adapter 400 via duct 405 preferably pass through an optional filter 409 that helps remove grease droplets, smoke particles and other debris from the heated combustion product stream. The heated combustion products next pass downwardly into a first plenum 410 on the inlet side of recirculation fan 412, and then into a second, horizontal plenum 414 on the outlet side of recirculation fan 412. The heated combustion products in plenum 414 are carried past steam or water droplet generator 416 where humidity may be added as needed. Steam or water droplet generator 416 is supplied with water via tubing 418 which is connected to an outlet at the bottom of water reservoir 420 containing liquid water 422. A removable cover 424 permits refilling of reservoir 420 as needed. The humidified heated combustion gases next pass upwardly through third plenum 426 and thence into duct 406, whereupon they are returned to the grill cooking chamber via outlet 407.

[0034] Control of recirculating fan 412 and steam or water droplet generator 416 may be accomplished in some embodiments of adapter 400 using onboard electronics 428 whose controls 429 and display 430 may be used to select operating conditions such as fan speed, operating cycle, humidity and other parameters available in combi-ovens. Temperature probe 432 and humidity sensor 424 supply feedback to onboard electronics 428, and may also provide safety limits such as preventing the operation of recirculation fan 412 when excessive temperatures are detected in the incoming heated combustion products. Cord 440 may be used to supply power to adapter 400. In some embodiments cord 440 may be used to couple adapter 400 to control electronics already supplied on the grill, such as electronic controls 112 in the Fig. 1 grill or electronic controls 212 in the Fig. 2 grill. In such embodiments it may be appropriate to omit one or more of control electronics 428, controls 429 or display 430 from adapter 400 and rely on the electronic controls that may already be supplied on the grill (for example, to regulate a combustion zone fan or to control cooking chamber temperatures) to also regulate the operation of adapter 400.

[0035] Adapter 400 can be installed by opening the grill cover (e.g., cover 210 in Fig. 2) and tipping adapter 400 while behind the grill so that heated combustion products inlet 404 and adapter outlet 407 can be inserted through the combustion products vent (e.g., vent 211 in Fig. 2) and into the cooking chamber. Adapter 400 may then be lowered into place, for example to straddle and be suspended from the upper backside edge of the cooking chamber sidewall (e.g., sidewall 206 in Fig. 2).

[0036] For use on a smoker such as smoker 300 in Fig. 3 with a small combustion products vent like the vertical vent 311, it typically will be desirable to modify the disclosed adapters so that the heated combustion products inlet and adapter outlet can fit through the vent 311. In other embodiments, the smoker may be modified to provide a larger vent or the disclosed adapter is placed largely inside the smoker.

[0037] For use with Kamado-style hinged covered grills, the disclosed adapters may be modified so that the heated combustion products inlet and adapter outlet can fit through the dome vent typically provided in the cover of such grills. In additional embodiments, the disclosed adapters may be modified so that the heated combustion products inlet and adapter outlet can fit through the spit opening in a wedge-shaped loeTisserie adapter like that shown in U.S. Patent Nos. 9,603,484 B2 and 10,925,435 B2.

[0038] The disclosed adapters may include a variety of alternative or additional features if desired. For example, magnets, clamps, auxiliary latches, screws or other fastening devices may also or instead be used to attach the disclosed adapters to a grill or smoker. The disclosed adapters may be made from a variety of materials including rolled or cast metals, ceramics, and composites. Exemplary metals include cold-rolled steel, hot-rolled steel, weathered steel (e.g. steel in an ASTM A588, A606-4, A847 or “Cor-Ten” finish), stainless steel, aluminum and laminates thereof. Exemplary ceramics include alumina, boron nitride, cordierite, mullite, silicon carbide, spinel, steatite, titanium carbide, Wollastonite, zirconia (including partially stabilized zirconia), glass-ceramics, porcelain, earthenware, reinforced ceramic composites and mixtures or combinations thereof. Foamed and other insulating ceramics may also be employed. Exemplary ceramic material suppliers or ceramic part manufacturers include Accuratus Corp., Applied Ceramics, Inc., Associated Ceramics and Technology, Inc., Bailey Ceramic Supply, BASF, Continental Clay, CoorsTek, Inc., McDaniel Advanced Ceramic Technologies, National Ceramic Co., Saint-Gobain Advanced Ceramics, Wunder Mold and other suppliers or manufacturers that will be familiar to persons having ordinary skill in the ceramic cooker art. The adapters may be unfinished or finished and may for example have an oxidized, anodized, painted, chromed, powder-coated, ceramic or glazed finish applied before or after the adapter has been fabricated. The disclosed adapters may include an insulation layer (for example one or more insulation layers of any desired construction), or a multifunctional layer (for example a layer having both insulation and an outer decorative surface). The disclosed adapters may include one or more reinforcing bars, flanges, corrugations or other stiffening members or shapes that strengthen the adapter overall as well as improving its structural integrity if subjected to sudden temperature changes, accidental droppage or other stresses or impacts. The disclosed adapters may also include labels, warning legends, instructions or other printed information on available adapter surfaces. [0039] The disclosed adapters may be used with grills form a variety of suppliers including Bayou Classic, Big Green Egg, Big Steel Keg, Blaze, California Kamado, Camp Chef, Char-Broil, Char-Griller, GourmetPot, Grill Dome, Imperial Kamado, Kamado Joe, Komodo Kamado, Masterbuilt, Meteor, Monolith Grill GmbH, Primo Grills and Smokers, Saffire, Traeger, and Weber-Stephen Products

[0040] Having thus described preferred embodiments of the present invention, those of skill in the art will readily appreciate that the teachings found herein may be applied to yet other embodiments within the scope of the claims hereto attached. The complete disclosure of all patents, patent documents, and publications are incorporated herein by reference as if individually incorporated.