ENVIRONMENTALLY SAFE CHARCOAL-BASED HEAT SOURCE

RELATED APPLICATIONS [0001] This is a continuation-in-part of U.S. Patent Application No. 11/212,033, filed August

25, 2005 entitled, Environmentally Safe Charcoal-Based Heat Source. This application also claims priority of U.S. Patent Application No. 11/836,031 filed August 8, 2007 entitled, Environmentally Safe Charcoal-Based Heat Source filed August 8, 2007.

TECHNICAL FIELD OF THE DISCLOSURE

[0002] The subject matter relates generally to a heat source and a method of using the heat source that controls a prolonged and continuous burning of charcoal without the use of a lighting fluid or other igniting aid.

BACKGROUND OF THE DISCLOSURE

[0003] Backyard barbequing of meat and other foods provides an excellent way to enjoy the very best of smoked food preparation. One popular way to achieve the smoky flavor that barbequing makes possible uses lump charcoal or charcoal briquettes as a heat source. The heat sources are ignited and allowed to burn for a period of time after which the cooks use their embers to smoke the food.

Unfortunately, traditional methods for igniting charcoal require the use of an igniting fluid or similar aid to burn for a sufficiently long time for the charcoal to ignite.

[0004] The main problems with lighting fluids or other similar aids include the likelihood that the lighting fluid or at least fumes from the lighting fluid will penetrate into the cooking food. Also, lighting fluid is itself an environmental pollutant, releasing volatile organic compounds (VOCs) into the atmosphere. Still another frustrating aspect of lighting fluid is the user generally must be carrying the lighting fluid as a separate, dangerously combustible item.

[0005] Other methods of igniting charcoal for grilling include treating the charcoal briquettes during the manufacturing process with lighter fluid. These treated charcoal briquettes are commonly referred to as Instant Light Briquettes. However, treating the charcoal with lighter fluid means the charcoal still gives off the undesirable VOCs, as well as the fumes associated with lighter fluid. [0006] Yet another frustration occurs when the user applies either too much or too little lighting fluid. If too much fluid is used, a large, uncontrollable and dangerous fire may result. If too little is used, the charcoal may not begin a self-sustaining burn prior to depleting the applied fluid. Furthermore, if the user applies new fluid or fluid treated charcoal briquettes to an active fire or smoldering ember, a further uncontrollable combustion may result.

[0007] All these limitations suggest the need for a way to achieve the same igniting of charcoal for barbequing and the like without the need to use a lighting fluid.

[0008] Accordingly, there is the need for a way to light charcoal or similar substances for barbequing and the like that avoids the use of lighting fluid.

[0009] There is the need for a clean or non-polluting way to light charcoal or similar substances that does not affect the cooking food. [0010] Other methods of igniting charcoal includes the chimney starter, which is a metal cylinder with a grate near the bottom and a handle mounted at the side. Unlit charcoal is placed inside the cylinder and newspaper or other flammable material is placed under the grate and lit. The charcoal at the bottom of the cylinder lights first and the "chimney effect" ignites the remaining charcoal above. However, this method is time consuming and potentially dangerous as the consumer must pour the ignited charcoals onto the grilling grate. Additionally, the device must be cooled sufficiently before it can safely be stored. The hazard of transferring the ignited charcoal and requirement of a cooling period suggest an alternative method may be preferable.

[0011] Another method ignition uses an electric charcoal starter. A layer of charcoal is laid down, then the electric starter is placed on top and then an additional layer of charcoal is placed over the top of the starter. The electric charcoal starter is then plugged in and ignites the charcoal once it has heated up sufficiently. This process is also time consuming and has the restriction of requiring access to an electrical outlet. Just as the chimney starter, the electric charcoal starter must be allowed to cool before it can be safely stored. This method is most obviously limited by the necessity of an electrical outlet, which is not always available when barbequing, as well as the required cooling period. [0012] While these two methods forego the use of lighter fluid, they still have limitations suggesting that a disposable, portable ignition source would be more convenient and safer for the ignition of charcoal.

[0013] Others in the prior art have attempted in various ways to promote the uniform heating of charcoal through orienting the charcoal in a vertical stack within the combustible package. The combustible package in such applications is constructed to be vertically upstanding, thereby orienting the charcoal to be vertically stacked around a central flue. As the combustible is consumed, combustion gases flow up through the central flue, providing for the heating of the charcoal from the center. The central flue also promotes the self feeding of the charcoal into the center as the central flue is consumed by fire. However, the central flue concentrates the heat of the fire within the center of the charcoal stack only, thus neglecting the outer edges of the charcoal.

[0014] Another approach attempts to extend the flue across the width of the combustible package, thereby increasing the quantity of charcoal affected by the centrally concentrated heat. This approach provides a second department beneath the stack of charcoal for containing an igniter for igniting the fire. Again, this configuration's use of the combustion gases neglects the outer perimeter of the charcoal.

[0015] Yet another approach attempts, but fails to address the charcoal along an outer perimeter. Such a configuration provides a combustible package that includes a generally octagonal

platform, a centrally located chimney, a wall attached to the platform's perimeter, and an igniter. Along the platform's base are a number of holes that seek to draw air into the perimeter. While this configuration may provide modest improvement over prior art, it fails to either provide a sustainable or truly rapid heating of the charcoal. Because the package has no mechanism to assure that the package will sustain a flame for any period of time, the package may burn either completely or to a point where no further igniting combustion occurs. The result is simply hot, but unlit charcoal. In addition, because the holes at the platform base simply draw in ambient air into the charcoal peripheral chamber, the effect may, in fact, be to not provide the sought-after igniting at all. [0016] As can be appreciated the above, the prior art has not succeeded in providing a self- igniting combustion package which uses the full potential of the heat generated by the incipient flame for purposes of preheating a quantity of charcoal.

[0017] Therefore, what is needed is a simple, combustible package having a built-in igniter and which provides for the uniform heating of a quantity of charcoal by concentrating the combustion heat not only beneath and at the center of the quantity of charcoal, but also along the perimeter of the charcoal.

[0018] There is a further need for a way to ignite charcoal or similar substances for heating or cooking that provides for a sustained burning of the heating substance.

[0019] A need exists for a way to ignite charcoal or similar substances that avoids the need to also use a lighting fluid. [0020] A need exists for a way to ignite and burn charcoal and similar heating substances that provide a truly biodegradable or non-polluting alternative to polluting or contaminating situation which happens with the use of lighting fluid or similar substances.

BRIEF DESCRIPTION OF THE FIGURES

[0021] [0020] For a more complete understanding of the present disclosure, and the advantages thereof, reference is now made to the following brief descriptions taken in conjunction with the accompanying FIGUREs, in which like reference numerals indicate like features: [0022] FIGURE 1 is an illustration of an exemplary embodiment of the charcoal-based heat source of the disclosed subject matter.

[0023] FIGURES 2-10 depict the device in various stages in the initial use of the disclosed subject matter. [0024] FIGURE 11 portrays an exemplary full use of the embodiment of the disclosed subject matter.

[0025] Techniques for making and using an environmentally safe charcoal-based heat source are disclosed, which both techniques improve the cooking experience of barbequing. The apparatus and method here disclosed result in reduced environmental pollutants and a safer, more reliable charcoal burning experience for many types of barbeque cooking applications. [0026] The disclosed subject matter, therefore provides and environmentally- safe, disposable, and combustible charcoal-based heat source includes a first chimney structure, an inner chimney insert, and a second wall structure surrounding the chimney structure. An inner chimney flue receives air for igniting and burning the charcoal-based fuel and an outer chimney flue exhausts the combustion fumes from the charcoal-based fuel. A bottom wall member secures to the inner chimney to flue and the outer chimney flue and forms a combustible material to be consumed during the ignition of the charcoal-based fuel. The top of the device is left open to exhaust the combustion fumes from the outer chimney flue. An ignition ring establishes a sustained ignition of sufficient duration to ignite uniformly the charcoal- based fuel. There is also a removable, separable, combustible inner chimney insert, which can contain safety matches, striking paper, wood pellets for smoking, and promotional materials, that may be separated and used underneath the heat source to ensure airflow and promote combustion. The inner chimney flue, outer chimney flue, the open top, the ignition lattice, and the inner chimney insert cooperate to provide uniform and rapid burning of the charcoal-based fuel.

[0027] These and other advantages of the disclosed subject matter, as well as additional novel features, will be apparent from the description provided herein. The intent of this summary is not to be a comprehensive description of the Claimed subject matter, but rather to provide a short overview of some of the subject matter's functionality. Other systems, methods, features and advantages here provided will become apparent to one with skill in the art upon examination of the following FIGUREs and detailed description. It is intended that all additional systems, methods, features and advantages be included within this description, be within the scope of the accompanying Claims.

DETAILED DESCRIPTION

[0028] This disclosure provides a long-burning charcoal-based heat source that requires no lighting fluid or similar igniting aid for either initial or sustained burning.

[0029] It is an object of the present disclosure to provide a simple, combustible package for facilitating the combustion of a quantity of charcoal or similar combustible material for the general purpose of outdoor cooking. This package is designed such that it may be folded flat to facilitate ease of transportation and assembly of final product.

[0030] It is the further object of this disclosure that such combustible package use the heat generated by the combustion to uniformly heat the quantity of charcoal to be burned, thereby encouraging combustion and minimizing the time required to ready the charcoal for cooking.

[0031] Yet a further object of the present disclosure is to provide a combustible package that includes a self-contained igniter for eliminating any need for petroleum-based flame accelerators. [0032] It is a further object of the present invention to provide a package of charcoal having a chimney therein where the chimney is so shaped that as the material thereof burns away, and in so doing the chimney will draw combustion air into the combustible package and exhaust the fumes from igniting the charcoal, while providing heated combustion air and flame for igniting the charcoal from around the inner chimney flue. At the bottom of the inner chimney flue an ignition ring, also of a non-polluting combustible material, maintains a flame that assures the charcoal will light during the burning of the combustion package. The inner chimney flue insert, also made of a non-polluting combustible material, may be placed under the package in circumstances where the barbeque grill or smoker does not allow sufficient airflow to the inner chimney flue. Additionally, the opening at top of the package forms a secondary exhaust chimney, resulting in a conductive path for the hot exhaust fumes generated by the igniting charcoal. This causes a more rapid and more reliable burning of the charcoal. [0033] Still another object of the present disclosure is the provision of a charcoal package in which charcoal will be fed automatically into the part of the burning assemblage which is the hottest, whereby to promote ignition of the charcoal.

[0034] FIGURE 1 is a picture of an exemplary embodiment of the portable heat source 10 of the disclosed subject matter. It also illustrates the bag top seal 11 that contains the charcoal-based fuel in the package. [0035] FIGURES 2- 6 depict the packaging as it would be when opened. FIGURE 2 shows the concept of a flat-packed bag embodying the outer wall portion of the portable heat source 10. FIGURE 3 illustrates how the bag is to be opened fully 12 to exhaust the fumes of the charcoal-based fuel, which is surrounded by the outer wall 18. FIGURE 4 shows the interior configuration of the heat source 10. A charcoal-based fuel would surround the inner chimney flue 16 and be enclosed by the outer wall 18. An ignition ring 22, consisting of a combustible material surrounds the inner chimney. The inner chimney insert 14 resides inside of the inner chimney 16 and possesses a safety match 23 and a match strike pad 15 at the top. The inner chimney insert 14 additionally provides structural support to the heat source 10

so that it may be stacked during transport. FIGURE 5 depicts the flaps 24 located at the base 26 of the heat source 10. The flaps 24 are meant to promote ignition of the inner chimney flue 16. The result, therefore, is an integrated and economical ignition system, including inner chimney 16, outer wall 18, ignition ring 22, inner chimney insert 14 with safety match 23 and strike pad 15, and flaps 24. [0036] FIGURE 6 shows the heat source 10 when disassembled, including the open top 12 bounded by the outer wall 18, with the inner chimney insert 14 removed and opened, revealing the included safety matches 23 meant to be used to ignite the heat source 10.

[0037] FIGURES 7-10 depict the heat source 10 as it is being prepared for use. FIGURE 7 shows the inner chimney insert 14 unfolded, complete with strike pad 15 at one end. FIGURE 8 illustrates how the inner chimney insert 14 is meant to be separated and used as two separate halves 17. FIGURE 9 shows a possible configuration of the heat source 10 before ignition. With the bag opening 12 fully extended, the ignition ring 22 surrounds the inner chimney flue 16, which is bounded by the outer wall 18. The package then rests on top of the inner chimney insert 14 to promote ignition and sustained burning of the charcoal-based fuel that is contained by the heat source 10. [0038] FIGURE 11 shows an exemplary use of one embodiment of the disclosed subject matter for heat source 10. In particular, in FIGURE 11, the heat source 10 filled with charcoal-based fuel 28 may be placed in a grill 30. Upon being ignited by the safety match 23, heat source 10 begins to catch flame. Thereafter, inner chimney 16 and ignition ring 22 begin to burn, which draws combustion air into the inner chimney 16 and exhausts combustion fumes from the bag opening 12. As heat source 10 continues to burn, the exterior walls 18 of the heat source burn away. As the heat source 10 finishes combusting, the stack of charcoal-based fuel 28 is exposed from the heat source 10. The final result of heat source 10 use is evenly and completely burned charcoal.

[0039] The disclosed subject matter, therefore, provides an environmentally safe, disposable, and combustible charcoal-based heat source that includes a first combustible, inner, vertical, upright chimney structure and a second combustible, outer, vertical, upright, wall structure surrounding the chimney structure. An inner flue is defined by the chimney structure for receiving air for igniting and burning the charcoal-based fuel. An outer chimney flue is defined by the outer wall of the first combustible inner, vertical, upright, chimney structure and the inner wall of the second combustible, vertical, upright wall structure, the outer chimney for exhausting combustion fumes from the charcoal- based fuel.

[0040] A bottom wall member is secured to the inner chimney flue and the outer chimney flue and formed of a combustible material so as to be consumed during the ignition and burning of the charcoal-based fuel. An ignition ring associates the bottom of the inner chimney flue and the bottom of the outer chimney flue, the ignition ring for establishing a sustained ignition of sufficient duration to ignite uniformly the charcoal-based fuel. The inner chimney, outer chimney and the ignition lattice cooperate to provide uniform and rapid burning of the charcoal-based fuel.

[0041] The heat source 10 may be formed in its entirety of a biodegradable material, the ashes of which likewise may biodegrade. Heat source 10, therefore, improves on existing packaging, lighting and handling of bagged barbeque charcoal by implementing a single-use system that provides ease of use, added safety and a more environmentally sensitive product. Additionally, the package material is formed such that it can be folded flat for transport before charcoal fuel is added to the heat source 10. Heat source 10 works with most types of bagged charcoal including briquettes and lump charcoal. [0042] Heat source 10 may be made of a paper, paperboard material or any other economical material that provides the desired level of combustion so that it achieves the purposes of the present disclosure and such that it may fold into itself, collapsing the packaging to require less room for storage. The charcoal-based fuel provides a single -use amount of a charcoal material. The charcoal-based fuel may or may not be treated with a flammable substance to promote combustion. A safety match 23, enclosed within the inner chimney insert 14, will provide the ignition for the heat source 10. The inner chimney insert 14 will have a sulfur-based match striking surface 15 to be used in conjunction with the provided safety match in order to light said safety match 23. [0043] One particularly advantageous aspect of heat source 10 includes the ability to be formed from comparatively inexpensive materials using comparatively inexpensive and efficient manufacturing techniques. Thus, while prior combustible heat sources may include some of the novel features of the disclosed subject matter, none show the desirable attributes heat source 10 that may be formed of prefabricated paperboard or similar material from which the inner chimney 16 and inner chimney insert 14 are formed and the paper or similar material from which all the outer walls 18 may be formed.

Moreover, the novel ignition ring 22 may also be formed of an inexpensive, combustible, pre-fabricated material. The inner chimney 16 contains a horizontal fold so that it may be collapsed to ensure that the heat source 10 may be flat-packed following the initial assembly. This enables most of the assembly to take place prior to final assemblage at a charcoal distribution center, as well as creating a flat-packed bag that facilitates transport to said charcoal distribution center. However, since the inner chimney 16 lacks strong structural integrity due to the necessity of folding for the intermediate flat-packed bag, the inner chimney insert 14 provides the necessary structural support once final assembly has been completed. As a result of these advantages, the disclosed subject matter prorate a self-igniting combustible heat source 10 that may be competitively priced with all existing charcoal bags, all other modes of displaying and selling charcoal and with all the technical features here described. This technical advantage alone distinguishes the disclosed heat source 10 from all prior such devices. [0044] The use of the terms "a" and "an" and "the" and similar referents in the context of describing embodiments of the subject matter (especially in the context of the following Claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by the context. The terms "comprising", "having", "including" and "containing" are to be construed as open-ended terms (i.e., meaning "including, but not limited to,") unless otherwise noted. Recitations of ranges of values herein are merely intended to serve as a shorthand method for referring individually to each separate value falling within the range, unless otherwise indicated herein, and each

separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein and otherwise clearly contradicted by the context. The use of any and all examples, or exemplary language (e.g. "such as") provided herein, is intended mere to better illuminate embodiments of the subject matter and does not pose a limitation on the scope of the subject matter. No language in the specification should be construed as indicating any non-described element as essential to the practice of the subject matter. [0045] Preferred embodiments of this subject matter are described herein, including the best mode known to the inventors for carrying out the subject matter. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the subject matter to be practiced otherwise than as specifically described herein. Accordingly, this subject matter includes all modifications and equivalents of the subject matter as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the subject matter unless otherwise indicated herein or otherwise clearly contradicted by context.