Pellet-fired cooking apparatus

Abstract

A cooking apparatus, having a body defining an interior cooking chamber for cooking food, a pellet supply portion coupled to the body and including a hopper for storing fuel, a combustion chamber for burning the fuel and heating the cooking chamber, a feeding mechanism for supplying fuel from the hopper to the combustion chamber, and a removable collection receptacle located below the combustion chamber. The apparatus also includes an ash-shaker located between the collection receptacle and the combustion chamber, the ash-shaker including an external actuator that controls one or more moving elements located in the combustion chamber, wherein movement of the moving elements encourages unburned debris in the combustion chamber to fall into the receptacle, after which the collection receptacle can be removed and the unburned debris discarded.

Description

<DP=1>²Title: Pellet-Fired Cooking Apparatus²Related Applications ²

[0001] This application claims the benefit of U.S. Provisional Patent ²²Application Serial No. 62 / 639,777 filed March 7, 2018 and entitled Pellet-²Fired ² Cooking Apparatus, the entire contents of which are hereby incorporated by ²reference herein for all purposes.²Technical Field ²

[0002] The embodiments disclosed herein relate to cooking apparatus ²such ²as barbecues and smokers, and, in particular to pellet-fired cooking apparatus ²that² use pellet based fuel, such as wood pellets.²Introduction ²

[0003] US Patent No. 4,823,684 to Traeger is a Pellet-Fired Barbecue, ²and ²describes a pellet-fired barbecue including an elevated barbecue pan fired by ²a ²pellet-burning pot mounted below the bottom of the barbecue. A heat baffle ²plate is² disposed within the pan above the top of the pot, and forced-air mechanism ²produces movement of hearted air within the barbecue.²

[0004] US Patent No. 4,989,521 to Traeger is a Gravity Fed Pellet ²Burner, ²and describes a gravity operated burner for particulate fuel. Fuel held in a ²hopper ²drops downwardly through a fuel tube to fall on an inclined chute. The chute ²feeds a²shelf where burning takes place in a high heat zone. Material on the shelf ²stops ²unhindered flow of fuel down the chute.²

[0005] US Patent No 5,251,607 to Traeger is a Pellet-Fired Cooking ²Grill, and ²describes a pellet-fired cooking grill which includes a housing having a grill ²chamber ²defined within it. Tubular structure extends downwardly from the base of the²chamber and defined within this structure is a burning zone. A hopper holding ²pellet ²fuel disposed above and adjacent the burning zone supplied pellets through a ²gravity operated chute to the burning zone.²CA 303'6060 2019-03-07²<DP=2>²- 2 -²Brief Description of the Drawings ²

[0006] The drawings included herewith are for illustrating various ²examples of²articles, methods, and apparatuses of the present specification. In the ²drawings:²

[0007] FIG. 1 is a first perspective view of a pellet fired cooking ²apparatus ² according to one embodiment;²

[0008] FIG. 2 is a second perspective view of the pellet fired ²cooking ²apparatus of FIG 1;²

[0009] FIG. 3 is a left-side elevation view of the pellet fired ²cooking apparatus ²of FIG 1;²

[0010] FIG. 4 is a right-side elevation view of the pellet fired cooking ²²apparatus of FIG 1;²

[0011] FIG. 5 is a rear elevation view of the pellet fired cooking ²apparatus of ²FIG 1;²

[0012] FIG. 6 is a front elevation view of the pellet fired cooking ²apparatus of ² FIG 1;²

[0013] FIG. 7 is another perspective view of the pellet fired cooking ²apparatus ²of FIG 1 shown with the lid open;²

[0014] FIG. 8 is an exploded perspective view of the pellet fired ²cooking ²apparatus of FIG 1;²

[0015] FIG. 9 is an elevation view of the grease tray and pellet feeding ²auger²of the cooking apparatus of FIG 1 according to one embodiment;²

[0016] FIG. 10 is perspective view of the grease tray and pellet ²feeding auger ²of FIG. 9;²

[0017] FIG. ills a perspective view of the enclosed pellet feeding ²auger and²fire pot assembly of the cooking apparatus of FIG. 1 according to one ²embodiment;²

[0018] FIG. 12 is a front elevation view of the enclosed pellet ²feeding auger ²and fire pot assembly of FIG. 11;²CA 3036060 2019-03-07²<DP=3>²- 3 -²

[0019] FIG. 13 is a left-side elevation view of the enclosed pellet ²feeding ²auger and fire pot assembly of FIG. 11;²

[0020] FIG. 14 is a right-side elevation view of the enclosed pellet ²feeding ²auger and fire pot assembly of FIG. 11;²

[0021] FIG. 15 is a perspective view of the enclosed pellet feeding auger ²and²fire pot assembly of FIG. 11 with the front cover removed;²

[0022] FIG. 16 is a front elevation view of the enclosed pellet ²feeding auger ²and fire pot assembly of FIG. 11 with the front cover removed;²

[0023] FIG. 17 is a left-side elevation view of the enclosed pellet ²feeding² auger and fire pot assembly of FIG. 11 with the front cover removed;²

[0024] FIG. 18 is a right-side elevation view of the enclosed pellet ²feeding ²auger and fire pot assembly of FIG. 11 with the front cover removed;²

[0025] FIG. 19 is a cut-away perspective view of the fire pot, auger ²and air fan ²of the cooking apparatus of FIG. 1 according to one embodiment;²

[0026] FIG. 20 is a cut-away perspective view of the fire pot of the ²cooking²apparatus of FIG. 1 according to one embodiment showing the ash-hole agitator;²

[0027] FIG. 21 is a front perspective view of the ash-hole agitator ²being ²activated by a tool, such as a grid lifter;²

[0028] FIG. 22 is a perspective view of a rotisserie apparatus of the ²cooking ²apparatus of FIG. 1 according to one embodiment;²

[0029] FIG. 23 is a detailed view of the control panel for the ²cooking ²apparatus of FIG. 1 according to one embodiment;²

[0030] FIG. 24 is a detailed exploded view of a first portion of the ²cooking ²apparatus of FIG. 1 according to one embodiment;²

[0031] FIG. 25 is a detailed exploded view of a second portion of the ²cooking²apparatus of FIG. 1 according to one embodiment;²CA 3036060 2019-03-07²<DP=4>²- 4 -²

[0032] FIG. 26 ²is a table showing a parts list with reference numerals²corresponding to the detailed exploded views shown in FIGS. 24 and 25.²Detailed Description ²

[0033] Referring ²to FIGS. 1 to 8 generally, illustrated therein is a cooking² apparatus 10.²

[0034] The ²cooking apparatus 10 includes a body 12 defining an interior²cooking chamber C for cooking food. As shown, the body 12 may be supported by ²a ²base 16, and the body 12 includes a lid 20 that encloses the cooking chamber ²C.²

[0035] The lid ²20 may be adapted to removably cover the cooking chamber C.²For example, as shown in FIG. 7, the lid 20 may be hingedly coupled to the ²chamber²bottom 21, and may have a handle 40 for pivoting the lid 20 between open and ²closed positions.²

[0036] The body ²12 also includes a chimney 26 for venting exhaust during²use. The chimney 26 may include an adjustable valve 27 (i.e., a rotatable ²plate) to ²control the amount of exhaust exiting the cooking chamber C (which may be ²particularly useful during a smoking operation, for example).²

[0037] In some ²embodiments, coupled to the body 12 may be a shelf 34. The²shelf 34 as shown is located on one side of the body 12, and can be used for²supporting items (i.e., food, sauces, etc.) prior to or during the cooking ²operation.²

[0038] In some ²embodiments, the cooking apparatus 12 may include a²rotisserie 39 (as shown in FIG. 22 for example) for cooking food. The ²rotisserie 39 ²may be driven by a motor 36 and may be supported at one or more ends of the ²body ²12.²

[0039] Turning ²now to FIG. 3 for example, in some embodiments the body 12²may include a grease trap 50 for catching grease and other debris that is ²generated²during use of the cooking apparatus 10.²

[0040] As also ²shown the body 12 is coupled to a pellet supply portion 14,²which as shown may include a hopper 22 for storing fuel (generally in chamber ²42²CA 303'6060 2019-03-07²<DP=5>²- 5 -²as shown in FIG. 8). Generally, the fuel will be in the form of combustible ²pellets ²(typically wood pellets), which may of different types of wood (hickory, ²mesquite, ²etc.) and which may have additives such as flavourings and so on. The pellet ²supply ²portion 14 may also include a control panel 24 for controlling the operation ²of the²cooking apparatus 10 (e.g., setting temperatures, pellet feed rates and so ²on). For ²example, in some cases the cooking apparatus 10 may be used for high heat ²cooking (i.e., grilling) or low heat cooking (i.e., smoking) and the ²temperature of the ²cooking chamber C can be selected accordingly.²

[0041] The pellet supply portion 14 may be powered by a power source, ²²which in some embodiments may be an electrical wall panel connected via a ²power ²cord 44.²

[0042] In some embodiments, the pellet supply portion 14 may include ²an ²actuator (shown schematically as 45) for effecting movement of the hopper 22 ²and / or chamber 42. In particular, fuel, particularly wood pellets, that are ²stored in the²chamber 42 of the hopper 22 may tend to become stuck or clogged. For instance, ²²some wood pellets may tend to stick to angled sides of the chamber 42, ²particularly ²in seams or other locations within the chamber 42. By using an actuator 45, ²the ²hopper 22 and / or chamber 42 can be moved to help dislodge pellets that are ²stuck ²in the chamber 42. For example, the actuator 45 could include a vibrating ²motor that.²At particular times (such as once every few minutes), the motor could vibrate ²the ²chamber 42 to help ensure the pellets flow smoothly and tend not to stick. In ²some ²embodiments, the actuator 45 could be actuated automatically, for example by ²the ²controller based on a time-based schedule. In some embodiments, the actuator ²45 ²may activate in response to a sensor, for example a sensor that monitors the ²flow of² pellets. In some embodiments, the actuator 45 could be capable of manual ²actuation, such as by an operator or user of the cooking apparatus 10.²

[0043] In some embodiments, the hopper 22 and / or chamber 42 may ²include ²one or more devices for measuring the quantity of pellets remaining in the ²hopper ²22. For example, one or more sensors could be used to measure the quantity of ²pellets. In one example, an optical sensor could be used. In one example, a ²weight²CA 3036060 2019-03-07²<DP=6>²- 6 -²sensor could be used. In one example, the actuator 45 could be pulsed, and a ²measured vibration response could be used to estimate the quantity of pellets ²in the ²hopper 22.²

[0044] In some embodiments, the hopper 22 and / or chamber 42 may ²include²one or more drain holes for selectively removing the fuel therefrom. For ²example, a ²user may desire to switch the type of fuel in the hopper 22 (i.e., switching ²from ²hickory to mesquite wood pellets), or to otherwise remove old fuel. One or ²more ²drain holes can be provided that, when opened, allow the fuel to be drained ²out of ²the hopper 22.²

[0045] The cooking apparatus 10 may also include one or more grates, such²as a main grate G and an upper grate UG for supporting food or cookware within ²the ²cooking chamber C (see for example FIG. 8). As shown, the body 12 may have a ²generally cylindrical shape. In other examples, the body 12 may have other ²shapes.²

[0046] Located below the grates G may be one or more grate plates 56, ²which ²may be angled to direct grease or other debris that is generated during use of ²the ²cooking apparatus 10 into the grease trap 50 via an outlet 58.²

[0047] The cooking apparatus 10 also includes a plurality of leg ²members 30 ²for supporting the body 22. As shown, there may be four legs 30, which may be ²located at four corners of the body 12. The legs 30 may help elevate the ²cooking²apparatus 10 above a support surface such as a ground surface, a deck, and so ²on. ²In some cases, one or more of the legs 30 may include wheels to allow the ²cooking ²apparatus 10 to be moved around more easily.²

[0048] In some embodiments, one of more of the legs 30 may be coupled ²²together by a lower shelf 38. The lower shelf 38 can provide for storage ²during use²of the cooking apparatus 10, and may also help stabilize the legs 30.²

[0049] Turning now to FIGS. 8 to 21, the operation of the cooking ²apparatus ²10 will be described in reference to some specific internal components ²thereof. For ²instance, as shown in FIG. 8, the pellet supply portion 14 includes a ²combustion ²chamber 46 for burning pellets. The pellet supply portion 14 also includes a ²feeding²CA 3036060 2019-03-07²<DP=7>²- 7 -²mechanism for supplying pellets from the hopper 22 to the combustion chamber ²46, ²which in this example includes an auger 54. The auger 54 is controlled by a ²controller (typically by selections made on the control panel 24) and which ²ensures ²that a suitable amount of pellets are provided to the combustion chamber 46 to² obtain the desired operating temperatures for the cooking apparatus 10. In ²particular, a heating element (which may be an electric arc or other suitable ²heating ²element) in the combustion chamber. A fan 66 may also drive air into the ²combustion chamber 46 to encourage efficient combustion of the pellets ²therein, ²thus reducing the amount of unburned waste product.²

[0050] In some ²embodiments, the size and shape of the auger 54 may be²specially selected to ensure good pellet flow from the hopper 22 into the ²combustion ²chamber 46. For example, as shown the auger 54 in this example includes a ²generally elongate rod around which is wrapped a helical member, much like a ²screw. The angle and pitch of this helical member and the size of the rod can ²be²specifically selected to inhibit binding of the pellets as they travel to the ²combustion²chamber 46.²

[0051] In ²general, the auger 54 may be driven by one or more electric motors,²and may be coupled thereto by a gear 60 located in the hopper 22. As seen by ²inspection of FIG. 9, wood pellets in the hopper 22 can pass through an ²opening 62 ²to engage with the auger.²

[0052] One or ²the challenges with the operation of pellet-fired cooking²apparatuses generally is the generation of unburned waste product (i.e., ²unburned ²ash and other portions of the pellets). Although pellet-fired coking apparatus ²tend to ²be relatively efficient, their configuration can make this a problem. In ²particular, the²combustion chamber 46 tends to be cylindrical and of relatively small size. ²This ²helps to ensure efficient combustion. However, the small size means that any ²unburned waste products tends to accumulate in the combustion chamber 46, and ²can quickly interfere with the operation of the cooking apparatus 10. For ²example, ²some prior art cooking apparatuses require the combustion chamber to be ²regularly²CA 303'6060 2019-03-07²<DP=8>²- 8 -²cleaned by vacuuming it out, which often requires a substantial disassembly of ²all or ²a portion of such cooking apparatuses.²

[0053] Located below the combustion chamber 46 according to the ²present ²teachings, however, is an as collection receptacle 48. Located generally ²between² the receptacle 48 and the combustion chamber 46 is an ash-shaker. More ²specifically, the ash-shaker includes an external actuator 52 that controls ²one or ²more moving elements 64 in the bottom of the combustion chamber 46. As shown ²in ²FIG. 20 for example, the moving element 64 in this embodiment include a ²circular ²plate with several holes. These holes cooperated with holes in the bottom of ²the²combustion chamber 46. When ash or other unburned debris builds up in the ²combustion chamber 46, the actuator 52 can be moved, rotating or otherwise ²moving the moving element 64 and allowing the unburned debris to fall out of ²the ²combustion chamber and into the receptacle 48. The receptacle 48 can then be ²removed and the unburned debris discarded. In this manner, the combustion²chamber 46 can be cleaned out without needing to substantially dismantle the ²cooking apparatus 10.²

[0054] In some embodiments, the moving element 64 may have other ²shapes, ²and could for instance be rectangular.²

[0055] In some embodiments, the actuator 52 can be actuated by hand. ²In ²some embodiments, the actuator 52 is designed to be used with a tool T (such ²as a ²grid lifter ¨ see FIG. 21). This can help facilitate operation of the actuator ²52, ²particularly then the cooking apparatus 10 is hot.²

[0056] Turning now to FIG. 23, illustrated therein is a detailed view ²of the ²control panel 24 of the cooking apparatus 10.²

[0057] Control panel 24 in this embodiment includes a main display 70, ²which²can show details such as the desired or actual operating temperature of the ²cooking ²apparatus 10 (which may be measured by a probe installed in the cooking ²chamber ²C). Control panel 24 may also include a main control knob 72 for selecting the ²²desired operating temperature.²CA 303'6060 2019-03-07²<DP=9>²- 9 -²

[0058] Control panel 24 may also include probe ports 74, 76 for ²coupling to ²one or more probe thermometers (i.e., meat thermometers), which can be used to ²²measure the temperature of food products being cooked. The measured ²temperatures can be displayed on secondary displays 75, 77. Another display 78² may also show time information, such as elapsed time, a timer, and so one.²

[0059] The control panel 24 may also include a power button 80 for ²turning ²the cooking apparatus on and off).²

[0060] The control panel 24 may also include preset temperature ²buttons ²operable to select particular cooking temperatures, such as a first button 82 ²for ²smoking food, a second button 84 for poultry, and a third button 86 for high ²heat ²grilling.²

[0061] The control panel 24 may also include a settings button 88, ²which may ²allow a user to adjust one or more characteristics of the cooking apparatus ²10. This ²could include, for instance, adjusting the auger speed, activating the ²rotisserie 39, ²and so on.²

[0062] Turning lastly to FIGS. 24-25, illustrated therein are ²detailed exploded ²views of the various components of the cooking apparatus of FIG. 1 according ²to ²one embodiment, while FIG. 26 is a table showing a parts list with reference ²numerals corresponding to the detailed exploded views shown in FIGS. 24 and ²25.²

[0063] While the above description provides examples of one or more ²apparatus, methods, or systems, it will be appreciated that other apparatus, ²methods, or systems may be within the scope of the present description as ²interpreted by one of skill in the art.²CA 3036060 2019-03-07²

Claims

- 10 - Claims 1. A cooking apparatus, comprising: a body defining an interior cooking chamber for cooking food; a pellet supply portion coupled to the body and including a hopper for storing fuel; a combustion chamber for burning the fuel and heating the cooking chamber; a feeding mechanism for supplying fuel from the hopper to the combustion chamber; a removable collection receptacle located below the combustion chamber; and an ash-shaker located between the collection receptacle and the combustion chamber, the ash-shaker including an external actuator that controls one or more moving elements located in the combustion chamber, wherein movement of the moving elements encourages unburned debris in the combustion chamber to fall into the receptacle, after which the collection receptacle can be removed and the unburned debris discarded.

2. The cooking apparatus of claim 1, wherein the actuator is sized and shaped to be moved by hand.

3. The cooking apparatus of claim 1, wherein the actuator is sized and shaped to be moved using a tool.

4. The cooking apparatus of claim 1, wherein the moving element include a circular plate with one or more holes. ,, CA 3036060 2019-03-07 - 11 - 5. The cooking apparatus of claim 1, further comprising a control panel for controlling the cooking apparatus; 6. The cooking apparatus of claim 1, wherein the fuel includes combustible pellets.

7. The cooking apparatus of claim 1, wherein the fuel includes wood pellets.

8. The cooking apparatus of claim 1, wherein the feeding mechanism is controlled by a controller to ensure that a suitable amount of fuel is provided to the combustion chamber to obtain desired operating temperatures for the cooking apparatus.

9. The cooking apparatus of claim 1 wherein the pellet supply portion is powered by an electrical power source.

10. The cooking apparatus of claim 1 wherein the feeding mechanism comprises an auger.

11. The cooking apparatus of claim 1, further comprising a heating element in the combustion chamber for burning the fuel.

12. The cooking apparatus of claim 1, further comprising a fan that drives air into the combustion chamber to encourage efficient combustion of the fuel.

13. The cooking apparatus of claim 1, further comprising an actuator for effecting movement of the hopper. ,, CA 3036060 2019-03-07 - 12 - 14. The cooking apparatus of claim 13, wherein the actuator includes a vibrating motor.

15. The cooking apparatus of claim 14, wherein the vibrating motor is selectively activated to discourage fuel from sticking in the hopper.

16. The cooking apparatus of claim 1, further comprising a sensor for measuring a quantity of fuel in the hopper. CA 303"6 060 2019-03-07