Granulate hopper lining

Abstract

A pellet hopper for a pellet grill includes a first floor, a second floor, and a third floor. Each floor has an inner edge that partially defines a pellet discharge opening. The first, second, and third floors form a first non-zero angle, a second non-zero angle, and a third non-zero angle, respectively, with respect to a horizontal plane. In this way, each floor is angled downward toward the pellet discharge opening.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority to U.S. Patent Application No. 16 / 412,191, filed May 14, 2019, entitled “Pellet Hopper Liner”. Technical Field

[0003] This invention generally relates to systems, methods, and apparatus for baking and heating food. In particular, this disclosure relates to systems and apparatus for supplying fuel to a baking apparatus. Background Technology

[0004] Consumers use a variety of grilling devices to cook, grill, and heat food. Some grilling devices, including smokers and pellet grills, burn solid fuels. These solid fuels can be in the form of wood pellets or other granular solid fuel materials. Pellet grills and smokers burn solid fuels to generate heat and smoke, which enter the grilling cavity to cook the food inside. These grilling devices typically include an externally accessible cavity that holds and supplies the solid fuel pellets to the grilling device for combustion. Those skilled in the art generally refer to this externally accessible cavity as a hopper.

[0005] The hopper is typically connected to a screw conveyor system that slowly removes fuel pellets from the hopper and supplies them to the combustion chamber. In conventional roasting apparatus, one end of the screw conveyor system is connected to the bottom of the hopper and the other end to the combustion chamber. In this configuration, the screw conveyor system moves the pellets from the hopper to the combustion chamber located within the roasting apparatus. When the fuel pellets reach the combustion chamber, heating elements ignite them, thus providing heat for cooking and / or heating food.

[0006] Along these routes, the screw conveyor system can supply fuel pellets to the combustion chamber at different speeds according to the user's needs. For example, increasing the speed at which fuel pellets enter the combustion chamber results in higher cooking and smoke temperatures. Conversely, decreasing the speed at which fuel pellets enter the combustion chamber reduces cooking and smoke temperatures.

[0007] Therefore, for effective cooking using a pellet grill as described above, the screw conveyor system of the grilling apparatus must be able to maintain the necessary flow rate of fuel pellets from the hopper into the combustion chamber. However, in typical pellet grill and screw conveyor systems, numerous obstructions can cause fuel pellets to become clogged or stuck, resulting in backflow of fuel pellets within the system and hindering fuel flow.

[0008] When fuel pellets become stuck in the hopper of a typical pellet oven or screw conveyor system, users usually need to clear them themselves. This may require removing the fuel pellets, turning on the screw conveyor system, identifying the location of the stuck pellets, and manually clearing the system. Manually clearing the pellet oven in this way is time-consuming and inconvenient for users.

[0009] Ultimately, when the hopper and screw conveyor system fails to supply fuel pellets to the combustion chamber at the appropriate rate, the pellet grill cannot generate the necessary heat and smoke. Therefore, there are many solvable drawbacks in the grilling apparatus and system. Summary of the Invention

[0010] Embodiments of this disclosure include systems, methods, and apparatus for baking and heating food. In particular, this disclosure relates to systems and apparatus for supplying fuel to a baking apparatus. For example, in one embodiment of this disclosure, a pellet hopper includes a first bottom plate, a second bottom plate, and a third bottom plate. Each of the bottom plates includes an inner edge that at least partially defines a pellet discharge opening. Furthermore, the first plate, the second plate, and the third plate form a first angle, a second angle, and a third angle, respectively. The first angle, the second angle, and the third angle are non-zero angles relative to a horizontal plane, such that each plate is inclined downward toward the pellet discharge opening.

[0011] In another embodiment of this disclosure, the pellet hopper assembly includes a hopper bottom and wall plates. The hopper bottom includes a first plate, a second plate, and a third plate, the first plate being connected to the second plate at a first interface, and the third plate being connected to the second plate at a second interface. Each plate includes an inner edge that at least partially defines a pellet discharge opening. Furthermore, the first, second, and third plates form a first non-zero angle, a second non-zero angle, and a third non-zero angle relative to a horizontal plane. Thus, each plate is inclined downward toward the pellet discharge opening.

[0012] In this embodiment, the wall panel is connected to the second and third plates at the third and fourth interfaces, respectively. The wall panel includes a main surface and a bottom inclined surface, the bottom inclined surface including a fourth inner edge that also partially defines the particle discharge opening. The bottom inclined surface of the wall panel also forms a non-zero angle such that the bottom inclined surface slopes downward toward the particle discharge opening.

[0013] In another embodiment according to this disclosure, a particle discharge insert is configured to be placed inside the particle discharge opening of a particle hopper. In this embodiment, the particle discharge insert includes a first trapezoidal surface, a second trapezoidal surface, a third trapezoidal surface, and a fourth trapezoidal surface connected together. The inner edge of each trapezoidal surface at least partially defines a rectangular particle discharge insert opening. The particle discharge insert also includes a first surface, a second surface, a third surface, and a fourth surface extending downward from their inner edges, respectively. Each trapezoidal surface is disposed at a non-zero angle relative to a horizontal plane. In this way, each trapezoidal surface is inclined downward toward the particle discharge insert opening. Attached Figure Description

[0014] To describe how the above and other advantages and features of the invention can be obtained, a more specific description of the invention briefly described above will be presented with reference to specific embodiments of the invention shown in the accompanying drawings. It should be understood that these drawings depict only exemplary embodiments of the invention and are therefore not intended to limit the scope of the invention. The invention will be described and explained with additional features and details using the drawings, wherein:

[0015] Figure 1A A perspective view of a pellet hopper disposed within a pellet oven according to an embodiment of the present disclosure is shown;

[0016] Figure 1B An embodiment according to this disclosure is shown. Figure 1A Exploded view of the pellet hopper and pellet baking rack;

[0017] Figure 1C A schematic diagram of a screw conveyor system for feeding fuel pellets from a pellet hopper into a combustion chamber, according to an embodiment of the present disclosure, is shown.

[0018] Figure 2A A perspective view of the bottom of the hopper according to an embodiment of the present disclosure is shown;

[0019] Figure 2B A front view of the bottom of the hopper according to an embodiment of the present disclosure is shown;

[0020] Figure 2C A side view of the bottom of the hopper according to an embodiment of the present disclosure is shown;

[0021] Figure 3A A perspective view of the bottom of the hopper according to this disclosure is shown;

[0022] Figure 3B A front view of the bottom of the hopper according to this disclosure is shown;

[0023] Figure 3C A left view of the bottom of the hopper according to this disclosure is shown;

[0024] Figure 4A A perspective view of a pellet hopper assembly according to an embodiment of the present disclosure is shown;

[0025] Figure 4B An embodiment according to this disclosure is shown. Figure 4A A perspective view of the vertical wall of the pellet hopper assembly shown in the figure;

[0026] Figure 5A A bottom perspective view of a pellet hopper assembly including a shelf according to an embodiment of the present disclosure is shown;

[0027] Figure 5B A perspective view of a shelf according to an embodiment of the present disclosure is shown;

[0028] Figure 5C A left-side view of a pellet hopper assembly according to an embodiment of the present disclosure is shown;

[0029] Figure 5D A rear view of a pellet hopper assembly according to an embodiment of the present disclosure is shown;

[0030] Figure 5E An embodiment according to this disclosure is shown. Figure 5A The top perspective view of the pellet hopper assembly shown in the figure;

[0031] Figure 6 A pellet hopper assembly with a horizontal surface surrounding its pellet discharge opening is shown;

[0032] Figure 7 A perspective view of a particle discharge insert located inside the bottom of a hopper having a horizontal surface surrounding the particle discharge opening is shown.

[0033] Figure 8A A perspective view of a particle discharge insert according to an embodiment of the present disclosure is shown;

[0034] Figure 8B A front view of a particle discharge insert according to an embodiment of the present disclosure is shown; and

[0035] Figure 8C A left view of a particle discharge insert according to an embodiment of the present disclosure is shown. Detailed Implementation

[0036] This invention generally relates to systems, methods, and apparatuses for baking and heating food. In particular, this disclosure relates to systems and apparatuses for supplying fuel to a baking apparatus. For example, in one embodiment of this disclosure, a pellet hopper includes a first base plate, a second base plate, and a third base plate. Each of the base plates includes an inner edge that at least partially defines a pellet discharge opening. Furthermore, the first plate, the second plate, and the third plate form a first angle, a second angle, and a third angle, respectively. The first angle, the second angle, and the third angle are non-zero angles relative to a horizontal plane that cause each plate to tilt downward toward the pellet discharge opening.

[0037] The pellet hopper disclosed herein includes a smooth pellet drop feature that improves the discharge efficiency of the pellet hopper, thereby reducing the incidence of pellet discharge failure. The embodiments disclosed herein can reduce the frequency of temperature loss during the baking and heating of food products. Therefore, users can use the pellet grill without having to carefully monitor the discharge status of fuel pellets into the screw conveyor system. Users can also avoid restarting the pellet grill in response to pellet discharge interruptions. Furthermore, in some instances, as described below, existing pellet grills can achieve the above benefits through aftermarket modifications.

[0038] Referring to the attached diagram, Figure 1A A perspective view of a pellet hopper 100 disposed within a pellet grill 10 according to an embodiment of the present disclosure is shown. The pellet hopper 100 is disposed inside a cavity 20 located on the side of the pellet grill 10. The pellet grill 10 also includes a hopper cover 30, which a user can open to selectively access the pellet hopper 100 inside the cavity 20.

[0039] Figure 1B An exploded view of the particle grill 10, including Figure 1A The pellet hopper 100, cavity 20, and hopper cover 30 are described. During use, the user opens the hopper cover 30 and introduces fuel, such as solid fuel pellets, into the cavity 20 of the pellet grill 10. The pellet hopper 100 guides the pellets downward through the pellet discharge opening 105 and into the screw conveyor feeder system 40 (see [link to system description]). Figure 1C Then, the screw conveyor feeder system supplies fuel particles to the combustion chamber for ignition and heat generation.

[0040] Along these routes, Figure 1CA schematic diagram of a pellet hopper 100, a screw conveyor feeder system 40, and a combustion chamber 50 inside a pellet grill 10 is shown. As shown, the pellet hopper 100 is positioned above the screw conveyor feeder system 40, which receives fuel pellets 60 through a pellet discharge opening 105 in the pellet hopper 100. The screw conveyor feeder system 40 then supplies the fuel pellets 60 into the combustion chamber 50 for combustion and heat generation inside the pellet grill 10.

[0041] Fuel pellets 60 pass through the pellet discharge opening 105 of the pellet hopper 100 and enter the screw conveyor feeder system 40 at the interface 110 therebetween. In one or more embodiments of this disclosure, the interface 110 between the pellet hopper 100 and the screw conveyor feeder system 40 may further include one or more interface fittings, such as gaskets, seals, connecting devices, etc. Reference will be made below. Figures 4A to 5E This interface accessory will be described in more detail. In the embodiments described in this disclosure, the interface 110 is substantially free of any obstructions that could interfere with the conveying of fuel pellets 60 from the pellet hopper 100 to the screw conveyor feeder system 40.

[0042] For example, Figure 2A A perspective view of a hopper bottom 200 according to an embodiment of the present disclosure is shown. The hopper bottom 200 may be a component of a pellet hopper assembly. Figure 2A The hopper bottom 200 shown includes a first bottom plate 205a, a second bottom plate 205b, and a third bottom plate 205c. The first bottom plate 205a is connected to the second bottom plate 205b at a first interface 210a, and the second bottom plate 205b is connected to the third bottom plate 205c at a second interface 210b.

[0043] In one or more embodiments, the hopper bottom 200 may further include a fourth bottom plate ( Figure 2A (Not shown in the diagram) The fourth base plate is connected to the third base plate 205c at the third interface and to the first base plate 205a at the fourth interface. The fourth base plate may also form a non-zero angle with respect to the horizontal plane defined by the particle discharge opening 220. Like the other base plates 205a to 205c, the fourth base plate in the alternative embodiment may also include an inner edge that partially defines the particle discharge opening 220.

[0044] Furthermore, one or more embodiments of the hopper bottom 200 will be described below with reference to the accompanying drawings, for example... Figure 2A The hopper bottom 200 shown may also include one or more vertical walls extending vertically downward from one or more of the inner edges 215a to 215c of the bottom plate 205a to 205c. These vertical walls may extend downward or through... Figure 1CThe interface 110 between the pellet hopper 100 and the screw conveyor feeder system 40 is shown. Similarly, see below... Figures 7 to 8C More details are given regarding the inner edges 815a to 815d and the outer edges 825a to 825d. It is briefly noted here that... Figures 2A to 2C The embodiment of the hopper bottom 200 shown may also include these additional vertical walls.

[0045] Additionally, it is important to note that in one or more embodiments of the pellet hopper 100 described herein, one or more vertical surfaces 225 may extend upward from the outer edges of each base plate 205a to 205c. Figure 2A A vertical surface 225 extending upward from the first base plate 205a is shown. In one or more embodiments, a similar vertical surface may be used with... Figure 1A The interior of the cavity 20 of the grill 10 shown is connected via an interface. The vertical surface 225 may be formed separately from or integrally with one or more base plates 205a to 205c.

[0046] Furthermore, it should be noted that one or more base plates 205a to 205c of this disclosure may include secondary discharge openings 230 extending therethrough. Figure 2A This secondary discharge opening 230, extending through the third base plate 205c, is shown. When needed, a user can manipulate a door that removably covers the secondary discharge opening 230 to selectively discharge fuel particles 60 through the secondary discharge opening 230. In one or more embodiments, one or more secondary discharge openings 230 may also be used as overflow discharge openings.

[0047] Each base plate 205a to 205c includes a respective inner edge 215a to 215c that at least partially defines a particle discharge opening 220 located in a horizontal plane defined by the inner edges 215a to 215c. Furthermore, each base plate 205a to 205c is configured to form a non-zero angle relative to the horizontal plane. In this way, each of the base plates 205a to 205c is inclined downward toward the particle discharge opening 220.

[0048] The angle at which each base plate 205a to 205c is inclined downward toward the particle discharge opening 220 affects the conveying of fuel particles 60 from the cavity 20 through the particle discharge opening 220 and into the screw conveyor feeder system 40. For example, the smaller the angle of each base plate 205a to 205c relative to the horizontal plane defined by the inner edges 215a to 215c of each base plate 205a to 205c, the smaller the inclination at which the fuel particles travel along each base plate 205a to 205c toward the particle discharge opening 220 due to gravity.

[0049] Conversely, and along the same path, the greater the angle of each base plate 205a to 205c relative to the horizontal plane (i.e., the steeper the base plate), the more inclined the fuel particles will be, thus traveling along the base plates 205a to 205c toward the particle discharge opening 220. Therefore, the manufacturer can choose the angle of inclination of each base plate 205a to 205c to ensure efficient discharge of the fuel particles 60 through the particle discharge opening 220. When determining these angles, the manufacturer can consider many other factors that also affect the transport of the fuel particles 60 toward the particle discharge opening 220.

[0050] For example, one factor the manufacturer might consider is the frictional properties of the materials used to form the base plates 205a to 205c. The manufacturer may also consider the frictional properties of the fuel pellets 60 that the user might use to heat the pellet grill 10. Furthermore, the manufacturer may consider the environment in which the user uses the pellet grill 10 to grill food.

[0051] For example, moisture can affect the frictional properties of fuel pellets 60 and base plates 205a to 205c, making them more sticky. Therefore, when users may expose fuel pellets 60 and / or base plates 205a to 205c to water from outdoor sprinklers, rainwater, dew, moisture, etc., the manufacturer can form base plates 205a to 205c at a steeper angle.

[0052] In view of this, there are multiple angles and ranges for each base plate 205a to 205c that can facilitate the discharge of fuel particles. Figure 2B and 2C The diagram shows these non-zero angles of the base plates 205a to 205c. Figure 2B and 2C It shows Figure 2A The diagram shows a front view and a side view of the hopper bottom 200. For example, in one or more embodiments, such as... Figure 2B As shown, the first base plate 205a can form a first non-zero angle θ1 between approximately 40 and 60 degrees relative to the horizontal plane H. In one or more embodiments, the first non-zero angle θ1 can be between approximately 45 and 55 degrees, and preferably approximately 50 degrees.

[0053] Moreover, such as Figure 2C As shown, in one or more embodiments, the second base plate 205b may form a second non-zero angle θ2 between approximately 15 degrees and 35 degrees relative to the horizontal plane H. In one or more embodiments, the second non-zero angle θ2 may be between approximately 20 degrees and 30 degrees. In one or more embodiments, the second non-zero angle θ2 is preferably approximately 25 degrees.

[0054] like Figure 2BAs shown, in one or more embodiments, the third base plate 205c may form a third non-zero angle θ3 relative to the horizontal plane H, which is between approximately 15 degrees and 35 degrees or between approximately 20 degrees and 30 degrees. Preferably, in one or more embodiments, the third non-zero angle θ3 is preferably approximately 25 degrees.

[0055] Along these routes, Figures 3A to 3C It shows various other angles α relative to the horizontal plane H. 1-3 An embodiment of the hopper bottom 300 with base plates 305a to 305c. Figures 3A to 3C In the illustrated embodiment, the angles of the first plate, the second plate, and the third plate 305a to 305c can be less than [the angles of the three plates]. Figures 2A to 2C The angles of the various bottom plates 205a to 205c are shown. In this way, the volume inside the bottom 300 of the hopper can be maximized. This additional volume can be advantageous depending on the manufacturer's setting of the position of the pellet hopper 100.

[0056] For example, re-referencing Figure 1A In one or more embodiments, the manufacturer may position the cavity 20 and the pellet hopper 100 at the front of the pellet grill 10. In this front-mounted hopper configuration, reducing the horizontal depth of the cavity 20 and thus the volume of the cavity extending in front of the pellet hopper 100 may be advantageous and convenient for the user. It is understood that the volume of the cavity 20 may vary depending on the position in which the manufacturer places the cavity 20 and the pellet hopper 100 on the pellet grill 10.

[0057] The hopper bottom 300 (such as) inside the cavity 20 has a reduced volume. Figures 3A to 3C In the embodiments shown, the bottom plate 305a to 305c of the hopper bottom 300 can have a relative... Figures 2A to 2C The corresponding angle θ shown 1-3 The angle of decrease α 1-3 These reduced angles α 1-3 This results in a larger volume inside the cavity 20 that can be used to load the fuel particles 60.

[0058] For example, the first base plate 305a may form a first non-zero angle α1 of approximately 10 to 30 degrees relative to the horizontal plane H. In one or more embodiments, the first non-zero angle α1 may be between approximately 15 to 25 degrees. In one or more embodiments, the first non-zero angle α1 is preferably approximately 17 degrees.

[0059] Moreover, such as Figure 3CAs shown, the second base plate 305b can form a second non-zero angle α2 of approximately 15 to 35 degrees relative to the horizontal plane H. In one or more embodiments, the second non-zero angle α2 can be between approximately 20 and 30 degrees. In one or more embodiments, the second non-zero angle α2 is preferably approximately 25 degrees.

[0060] In one or more embodiments, Figure 3B The third base plate 305c shown can form a third non-zero angle α3 of approximately 10 to 30 degrees relative to the horizontal plane H. In one or more embodiments, the third non-zero angle α3 can be between approximately 15 and 25 degrees. In one or more embodiments, the third non-zero angle α3 is preferably approximately 17 degrees.

[0061] Similarly, as described above, one or more embodiments of the hopper bottom may include bottom plates 205a to 205c, 305a to 305c arranged at various different angles θ, α, or combinations thereof, as described herein. Manufacturers may determine these angles θ, α based on several factors discussed above to optimize the conveying of fuel pellets 60 from the pellet hopper 100 to the screw conveyor feeder system 40 in a variety of different environments and configurations.

[0062] Figure 4A A perspective view of another embodiment of a pellet hopper 400 according to another embodiment of the present disclosure is shown. Similar to that shown in other embodiments described herein, the pellet hopper 400 includes a first bottom plate 405a, a second bottom plate 405b, and a third bottom plate 405c. Additionally, the pellet hopper 400 includes a wall plate 410, which is connected to the first and third bottom plates 405a and 405c at third and fourth interfaces 415a and 415b, respectively.

[0063] In one or more embodiments, the wall panel 410 includes a main surface 420 and a bottom inclined surface 425. The main surface 420 of the wall panel 410 extends vertically upward from the first base plate 405a and the second base plate 405b and interfaces with the interior of the cavity 20 of the particle grill 10 (e.g., Figures 1A to 2C (As shown). The bottom inclined surface 425 of the wall panel 410 is connected to the main surface 420. In one or more embodiments, the bottom inclined surface 425 includes a fourth inner edge 430 that at least partially defines the particle discharge opening 435.

[0064] Similar to the bottom plates 405a to 405c of the pellet hopper 400 shown, the bottom inclined surface 425 of the wall plate 410 may also form a non-zero angle relative to the horizontal plane defined by the pellet discharge opening 435. In this way, the bottom inclined surface 425 of the wall plate 410 slopes downward toward the pellet discharge opening 435. Therefore, the bottom inclined surface 425 facilitates the conveyance of fuel pellets 60 from the pellet hopper 400 through the pellet discharge opening 435.

[0065] Along these routes, Figure 4B It shows Figure 4A The diagram shown is a perspective view of only wall panel 410. As shown, the bottom inclined surface 425 of wall panel 410 is connected to the main surface 420 and extends at a non-zero angle β relative to the horizontal plane H. The horizontal plane H is formed by... Figure 4A The particle discharge opening 435 shown is defined. (Refer to this document) Figures 2A to 3C Similar to the other non-zero angles α and θ described in the base plates 205a to 205c and 305a to 305c shown, the non-zero angle β can vary in different embodiments. For example, the non-zero angle β can be similar to any angles α and θ described above with reference to other embodiments.

[0066] Furthermore, the non-zero angle β can be different from any angle α, θ described above with reference to other embodiments. For example, angle β can be between approximately 5 degrees and 15 degrees or between approximately 60 degrees and 80 degrees. Similarly, the manufacturer can form the bottom inclined surface 425 at any angle based on the above-mentioned friction and environmental factors to optimize the delivery of fuel particles 60.

[0067] Figure 5A A bottom perspective view of another embodiment of the pellet hopper 100, including a shelf 505, is shown. The shelf 505 may be disposed below the bottom plates 510a to 510c of the pellet hopper 100. In one or more embodiments, the shelf 505 is connected to at least one of the bottom plates 510a to 510c of the pellet hopper 100 and forms a horizontal surface 515 disposed below the bottom plates 510a to 510c. In one or more embodiments, the horizontal surface 515 may be parallel to the horizontal plane where the pellet discharge opening 520 is located. Additionally or optionally, in one or more embodiments, the horizontal surface 515 of the shelf 505 is parallel to and coplanar with the horizontal plane where the pellet discharge opening 520 is located.

[0068] Figure 5BA top perspective view of an embodiment of a shelf 505 according to the present disclosure is shown. In the illustrated embodiment, the shelf 505 includes a horizontal surface 515 extending around and at least partially defining a shelf opening 525. One or more vertical surfaces 530a to 530d extend upward from the horizontal surface 515. In one or more embodiments, the vertical surfaces 530a to 530d of the shelf 505 may extend upward from the horizontal surface 515 at different heights.

[0069] In one or more embodiments, the height of each vertical surface 530a to 530d may extend upward to the bottom surfaces of the respective bottom plates 510a to 510c of the pellet hopper 100. As described above, because each bottom plate 510a to 510c of the pellet hopper 100 may form different non-zero angles, each corresponding vertical surface 530a to 530d of the shelf 505 may necessary extend upward to different heights to extend between the horizontal surface 515 of the shelf 505 and the bottom surfaces of the respective bottom plates 510a to 510c. Therefore, it will be understood that the height of each vertical surface 530a to 530d of the shelf 505 may thus vary depending on the angle of the bottom plates 510a to 510c to which the shelf 505 is connected.

[0070] In one or more embodiments, a shelf 505 is connected to a pellet hopper 100, wherein the upper edge 535 of each vertical surface 530a to 530d of the shelf 505 contacts the bottom surface of the bottom plates 510a to 510c of the pellet hopper 100. Additionally or alternatively, the peripheral edge 540 of the shelf opening 525 may be connected to the inner edge 545 of the respective bottom plates 510a to 510c.

[0071] Figure 5C It shows Figure 5A The image shows a side view of the pellet hopper 100. In the illustrated embodiment, the vertical surface 530b of the shelf 505 extends from the bottom surface of the base plate 510b to the horizontal surface 515 of the shelf 505. Additionally, it will be noted that... Figure 5A , Figure 5C , Figure 5D An embodiment of the pellet hopper 100 shown includes a wall panel 550. In this embodiment, the vertical surface 530d of the shelf 505 can extend from the horizontal surface 515 of the shelf 505 to the main surface 555 of the wall panel 550.

[0072] Therefore, in one or more embodiments, such as Figure 5A As shown, the vertical surface 530d of the shelf 505 can span the vertical height of the bottom inclined surface 560 of the wall panel 550. Thus, as... Figure 5D As shown, the vertical surface 530d of the shelf 505 corresponding to the position of the wall panel 550 can be connected to the main surface 555 of the wall panel.

[0073] Additionally or alternatively, in one or more embodiments, the upper edge 535b of the vertical surface 530d of the shelf 505 corresponding to the position of the wall panel 550 may be connected to the interface 565 between the main surface 555 and the bottom inclined surface 560 of the wall panel 550.

[0074] The horizontal surface 515 of the shelf 505 provides a surface where the manufacturer can place gaskets or seals between the pellet hopper 100 and the screw conveyor system 40. In such a configuration, the horizontal surface 515 of the shelf 505 provides a flat, level surface to which gaskets or seals can effectively engage. This advantageously provides an improved watertight seal between the pellet hopper 100 and the screw conveyor system 40 of this disclosure. Therefore, moisture cannot enter the pellet hopper 100 and affect the frictional characteristics of the pellet hopper 100 with the fuel pellets 60, or negatively impact the pellet hopper 100 through material corrosion or the like.

[0075] Additionally, in one or more embodiments, the shelf opening 525 is at least as large as the pellet discharge opening 520 of the pellet hopper 100. In this way, the horizontal surface 515 of the shelf 505 extends around and away from the pellet discharge opening 520. Therefore, the shelf 505 will not block the pellet discharge opening 520 or impede the flow of fuel pellets 60 therethrough during use.

[0076] Figure 5E As shown Figure 5A The top perspective view of the pellet hopper 100 includes a shelf 505 disposed below the bottom plates 510a to 510c. However, as shown from the top perspective view, no part of the shelf 505 obstructs, extends into, or otherwise physically interferes with the pellet discharge opening 520.

[0077] However, in one or more embodiments of the pellet oven, the opening to the screw conveyor system 40 may be smaller than the pellet discharge opening connected to the screw conveyor system 40. Additionally or alternatively, one or more sealing elements, such as gaskets or other types of seals, may at least partially close the pellet discharge opening described herein. For example, Figure 6 An embodiment of a pellet hopper 100 with a partially closed pellet discharge opening 605 is shown.

[0078] As stated above, and as Figure 6 As shown, numerous obstructions may block the particle discharge opening 605. These obstructions may include sealing gaskets or other components connected to the screw conveyor feeder system 40 of the particle hopper 100. Additionally, in one or more embodiments, as... Figure 6As shown, the pellet grill may include a pellet hopper 100, which includes one or more horizontal features 610 extending from the inner edge 615 of the base plate 620.

[0079] exist Figure 6 In the illustrated embodiment, the horizontal feature 610 extends inward from the inner edge 615 of the base plate 620 to at least partially block the pellet discharge opening 605. In this embodiment, it may be advantageous that these horizontal features 610 can reduce the negative impact on the flow of fuel pellets 60 through the pellet discharge opening 605. For example, any other pellet discharge opening 605 with a horizontal feature 610 or a blocking feature (whether horizontal or not) can cause fuel pellets 60 to flow through the pellet discharge opening 605 and accumulate and become blocked within the pellet hopper 100.

[0080] Therefore, one or more embodiments of the pellet hopper 100 may include a pellet discharge insert 705. For example... Figure 7 As seen, the manufacturer or user can position the pellet discharge insert 705 inside the pellet hopper 100. The pellet discharge insert 705 can be located above and around the pellet discharge opening 710 and on the top side of the bottom of the base plate 715. The pellet discharge insert 705 can advantageously cover any obstruction to the pellet discharge opening 710, such as... Figure 6 The horizontal feature 610 shown in the figure provides a smooth, sloping surface extending from the base plate 715 to the particle discharge opening 710.

[0081] Along these routes, Figure 8A A top perspective view of an embodiment of the particle discharge insert 800 is shown. The particle discharge insert 800 includes a first insert plate 805a connected to a second insert plate 805b at a first interface 810a and a third insert plate 805c connected to the second insert plate 805b at the second interface 810b. Additionally, in one or more embodiments, the particle discharge insert 800 includes a fourth insert plate 805d connected to the third and first insert plates 805c and 805a at the third and fourth interfaces 810c and 810d, respectively.

[0082] Additionally, each insert panel 805a to 805d includes a corresponding inner edge 815a to 815d that at least partially defines the particle discharge insert opening 820. In one or more embodiments, each insert panel 805a to 805d is trapezoidal. Moreover, in one or more embodiments, the particle discharge insert opening 820 formed by the inner edges 815a to 815d is rectangular. It will be understood that the shape of the particle discharge insert opening 820 and the insert panels 805a to 805d can vary depending on the number of insert panels 805a to 805d included in the particle discharge insert 800.

[0083] Each insert plate 805a to 805d forms a non-zero angle relative to the horizontal plane containing its inner edges 815a to 815d. In this way, each insert plate 805a to 805d is inclined downward toward the pellet discharge insert opening 820 to facilitate the downward flow of fuel pellets 60 into the screw conveyor feeder system 40. When the pellet discharge insert 800 is positioned inside the pellet hopper 100, as... Figure 7 As shown, the outer edges 825a to 825d of the insertion plates 805a to 805d are in contact with the upper surface of the corresponding bottom plate 715 of the pellet hopper 100.

[0084] In this way, fuel particles 60 flowing downward along one of the base plates 715 can smoothly transition from the surface of the base plate 715 and pass through the upper surfaces of the insert plates 805a to 805d. The fuel particles 60 can then flow downward through the particle discharge insert opening 820 and thus through the particle discharge opening 710. To form a smooth transition between the base plate 715 and the insert plates 805a to 805d, the non-zero angle formed by the insert plates 805a to 805d must be smaller than the non-zero angle θ of the base plate 715.

[0085] For example, Figure 8B It shows Figure 8A The front view of the particle discharge insert 800 shown. Additionally, Figure 8B It shows Figure 7 The image shows a cross-sectional view of a base plate 715 on which a particle discharge insert 800 is disposed. Similar to... Figure 6 As shown, the base plate 715 (a, c) may further include a blocking feature of the horizontal feature 610, which at least partially blocks the particle discharge opening 605. In this configuration, the non-zero angles μ1 and μ3 of the first and third insertion plates 805a and 805c relative to the horizontal plane H are smaller than the non-zero angles θ1 and θ3 formed by the first base plate and the third base plate 715, respectively.

[0086] As a non-restrictive example, Figure 8B The embodiment shown may have a first base plate 715 set at a non-zero angle θ1 of 40 degrees. In this embodiment, the non-zero angle μ1 of the first insert plate 805a is less than 40 degrees. In this way, the first insert plate 805a of the particle discharge insert 800 may span the horizontal feature 610 of the particle discharge opening that blocks the particle hopper and provide a transition surface on which fuel particles 60 may flow into the particle discharge opening.

[0087] Similarly, as Figure 8B and Figure 8C As shown, the non-zero angles μ2-μ4 between the insertion plates 805b and 805d are smaller than the non-zero angle θ of the base plate 715 that contacts the insertion plates 805b and 805d. 2-4For example, in an embodiment where θ3 is 25 degrees, μ3 is less than 25 degrees. Similarly, for example, in an embodiment where θ2 is 30 degrees and θ4 is 50 degrees, μ3 is less than 30 degrees and μ4 is less than 50 degrees.

[0088] The foregoing is not intended to be limiting in any way. Rather, the foregoing example is given to illustrate that the non-zero angles μ1-μ4 of each insert plate 805a to 805d are smaller than the angles θ1-θ4 of the corresponding base plate 715 on which the particle discharge insert 800 is located. In this way, the particle discharge insert can be configured such that each insert plate 805a to 805d contacts the upper surface of the corresponding base plate 715 of the particle hopper and crosses any physical obstruction of the horizontal feature 610 that blocks the particle discharge opening. Therefore, even if one or more obstructions of the horizontal feature 610 partially block the particle discharge opening, the particle discharge insert can advantageously facilitate the downward flow of fuel particles 60 into the screw conveyor feeder system 40.

[0089] It will be understood that the non-zero angles μ1 to μ4 of each insert panel 805a to 805d can vary between embodiments depending on the non-zero angles θ1 to θ4 and α1 to α4 of the base plates 715a to 715d. Because the non-zero angles θ1 to θ4 and α1 to α4 of the base plates 715a to 715d vary between the pellet hopper embodiments as described herein, the non-zero angles μ1 to μ4 of each insert plate 805a to 805d in the various embodiments of the pellet discharge insert 800 can also vary accordingly.

[0090] Moreover, such as Figures 8A-8C As shown, in one or more embodiments of the particle discharge insert 800, one or more vertical walls 830a to 830d extend from the inner edges 815a to 815d of the particle discharge insert 800, respectively. During use, the vertical walls 830a to 830d extend vertically downward into the particle discharge opening of the particle hopper. In one or more embodiments, each wall may extend through the particle hopper opening and into the screw conveyor feeder system 40 connected to the particle hopper 100. Alternatively, in one or more embodiments, the vertical walls 830a to 830d may extend only partially toward the screw conveyor feeder system 40 through the particle discharge opening.

[0091] Furthermore, in one or more embodiments, each vertical wall 830a to 830d may extend downward to varying degrees. In one or more embodiments, the vertical walls 830a to 830d may extend downward through the particle discharge opening to prevent the flowing fuel particles 60 from encountering any component between the particle hopper and the screw conveyor feeder system 40. Such components may include the shelves, screw conveyor feeder system openings, gaskets, or seals described herein. For example... Figure 1CAs shown, these interface components may be located at or near the interface 110 between the pellet hopper 100 and the screw conveyor system 40.

[0092] Interface components located at the interface can have sharp edges, cracks, or other uneven profiles through interface 110. These uneven features of any interface component may block the pellet discharge opening or otherwise obstruct the flow of fuel pellets 60 into the screw conveyor feeder system 40. Therefore, the vertical walls 830a to 830d of the pellet discharge insert 800 may extend at least partially through interface 110 and provide sidewalls with smooth surfaces extending through the interface. In this way, the vertical walls 830a to 830d of the pellet discharge insert 800 may further reduce the chance of fuel pellets 60 becoming clogged and backflowing as they flow through the pellet discharge opening of the pellet hopper 100.

[0093] Additionally, in one embodiment according to this disclosure, the manufacturer may form the pellet discharge insert 800 separately from the pellet hopper 100 described herein. In this embodiment, the user or manufacturer may separately and selectively incorporate the pellet discharge insert 800 into the pellet hopper 100 when needed. Alternatively, in one or more embodiments of the pellet hopper 100 described herein, the manufacturer may integrally form the pellet discharge insert with the pellet hopper 100 as a single part. In this way, the manufacturer can ensure an efficient flow of fuel pellets 60 provided by the pellet discharge insert 800 as described herein.

[0094] As will be understood from the above, in one or more embodiments, the vertical walls 830a to 830d of the particle discharge insert 800 may also extend from the inner edge of the base plate described herein, rather than from the separate particle discharge insert 800. This can occur, as described above, in embodiments where the particle discharge insert 800 is integrally formed with the particle hopper 100. In this embodiment, the vertical walls 830a to 830d extending from the inner edge of the base plate of the particle hopper 100 can serve the same function and provide the same advantages as the vertical walls 830a to 830d extending from the inner edges 815a to 815d of the respective insert plates 805a to 805d of the particle discharge insert 800.

[0095] In addition to the various embodiments described herein, the invention may be implemented in other specific forms without departing from its intended spirit or essential characteristics. The embodiments described herein should be considered illustrative rather than restrictive in all respects. Therefore, the scope of the invention is indicated by the appended claims rather than by the foregoing detailed descriptions. All modifications falling within the equivalent meaning and scope of the claims should be covered within their scope.

Claims

1. A pellet hopper for a pellet grill, the pellet hopper comprising: A first base plate, the first base plate having a first inner edge; A second base plate, having a second inner edge and connected to the first base plate at a first interface; as well as A third base plate, the third base plate having a third inner edge and connected to the second base plate at a second interface, and The secondary overflow discharge opening extends through the first base plate, the second base plate, or the third base plate. in: The first inner edge, the second inner edge, and the third inner edge of each base plate at least partially define the particle discharge opening; and The first base plate, the second base plate, and the third base plate form a first non-zero angle, a second non-zero angle, and a third non-zero angle relative to the horizontal plane, respectively, such that each base plate is inclined downwards toward the particle discharge opening. The first non-zero angle, the second non-zero angle, and the third non-zero angle are all different. The pellet hopper further includes: One or more horizontal features extend from one or more of the first inner edge, the second inner edge, and the third inner edge to at least partially block the particle discharge opening; and A particle discharge insert covering the one or more horizontal features, the particle discharge insert comprising: A first insertion plate and a second insertion plate, wherein the first insertion plate is connected to the second insertion plate at a first interface; and A third insertion plate is connected to the second insertion plate at the second interface. in: The first insertion plate, the second insertion plate, and the third insertion plate have a first inner edge, a second inner edge, and a third inner edge that at least partially define the particle discharge insertion opening; The first insertion plate, the second insertion plate, and the third insertion plate form a first non-zero angle, a second non-zero angle, and a third non-zero angle with respect to the horizontal plane, respectively, such that the first insertion plate, the second insertion plate, and the third insertion plate of the particle discharge insert are inclined downward toward the particle discharge insertion opening; and Each of the first insertion plate, the second insertion plate, and the third insertion plate includes an outer edge of the top surface of each of the first plate, the second plate, and the third plate that respectively contact the bottom of the hopper.

2. The pellet hopper according to claim 1, further comprising: A first vertical wall, a second vertical wall, and a third vertical wall are respectively connected to the first base plate, the second base plate, and the third base plate, and the first vertical wall, the second vertical wall, and the third vertical wall extend vertically downward from the innermost edge defining the particle discharge opening.

3. The pellet hopper according to claim 1, further comprising: A fourth base plate having a fourth inner edge and connected to the third base plate.

4. The pellet hopper according to claim 3, wherein, The fourth inner edge at least partially defines the particle discharge opening.

5. The pellet hopper according to claim 1, further comprising: A shelf is disposed below and connected to the first base plate, the second base plate and the third base plate, and the shelf forms a horizontal surface disposed below the first base plate, the second base plate and the third base plate.

6. The pellet hopper according to claim 5, wherein, The horizontal surface formed by the shelf is configured to face outward from the particle discharge opening so as not to block the particle discharge opening.

7. The pellet hopper according to claim 1, wherein, The first non-zero angle is between 40 and 60 degrees.

8. The pellet hopper according to claim 1, wherein, The second non-zero angle is between 15 and 35 degrees.

9. The pellet hopper according to claim 1, wherein, The third non-zero angle is between 15 and 35 degrees.

10. A pellet hopper assembly, comprising: The bottom of the hopper includes: A first plate, a second plate, and a third plate, wherein the first plate is connected to the second plate at a first interface, and the second plate is connected to the third plate at a second interface, wherein a first inner edge of the first plate, a second inner edge of the second plate, and a third inner edge of the third plate together define a particle discharge opening, and wherein: The first plate forms a first non-zero angle with respect to the horizontal plane, causing the first plate to tilt downward toward the particle discharge opening; The second plate forms a second non-zero angle relative to the horizontal plane, causing the second plate to tilt downwards toward the particle discharge opening; and The third plate forms a third non-zero angle with respect to the horizontal plane, causing the third plate to tilt downwards toward the particle discharge opening. The first non-zero angle, the second non-zero angle, and the third non-zero angle are all different; and A wall panel, wherein the wall panel is connected to the first plate and the third plate at a third interface and a fourth interface respectively, the wall panel comprising: Main surface; and A bottom inclined surface connected to the main surface, the bottom inclined surface including a fourth inner edge that at least partially defines the particle discharge opening, the bottom inclined surface forming a fourth non-zero angle relative to the horizontal plane such that the bottom inclined surface is inclined downward toward the particle discharge opening; One or more horizontal features extend from one or more of the first inner edge, the second inner edge, the third inner edge, and the fourth inner edge to at least partially block the particle discharge opening; and A particle discharge insert covering the one or more horizontal features, the particle discharge insert comprising: A first insertion plate and a second insertion plate, wherein the first insertion plate is connected to the second insertion plate at a first interface; and A third insertion plate is connected to the second insertion plate at the second interface. in: The first insertion plate, the second insertion plate, and the third insertion plate have a first inner edge, a second inner edge, and a third inner edge that at least partially define the particle discharge insertion opening; The first insertion plate, the second insertion plate, and the third insertion plate form a first non-zero angle, a second non-zero angle, and a third non-zero angle with respect to the horizontal plane, respectively, such that the first insertion plate, the second insertion plate, and the third insertion plate of the particle discharge insert are inclined downward toward the particle discharge insertion opening; and Each of the first insertion plate, the second insertion plate, and the third insertion plate includes an outer edge of the top surface of each of the first plate, the second plate, and the third plate that respectively contact the bottom of the hopper.

11. The pellet hopper assembly according to claim 10, further comprising: A shelf disposed below and connected to at least one of the first, second, and third plates, the shelf forming a horizontal surface disposed below the first, second, third, and fourth plates.

12. The pellet hopper assembly according to claim 11, wherein, The horizontal surface of the shelf is coplanar with the particle discharge opening.

13. The pellet hopper assembly according to claim 10, wherein, The main surface of the fourth plate is vertical.

14. The pellet hopper assembly according to claim 10, wherein, The particle discharge insert further includes a fourth insert plate having a fourth inner edge that at least partially defines the particle discharge insertion opening, the fourth insert plate forming a non-zero angle with respect to the horizontal plane such that the fourth insert plate of the particle discharge insert is inclined downward toward the particle discharge insertion opening.

15. The pellet hopper assembly according to claim 14, wherein, The first insertion plate, the second insertion plate, the third insertion plate, and the fourth insertion plate are planar trapezoids to form rectangular particle discharge insertion openings.

16. The pellet hopper assembly of claim 10, wherein the pellet discharge insert further comprises: A first vertical wall, a second vertical wall, and a third vertical wall, the first vertical wall, the second vertical wall, and the third vertical wall extending downward from the first inner edge, the second inner edge, and the third inner edge, respectively.

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