System and method for dual mode air control in kettle grills

Abstract

An exemplary embodiment of a system and method for dual mode air control in a kettle grill is configured to be removably mounted to the exterior of a kettle grill, such as but not limited to a charcoal grill. When mounted to the kettle grill, an air chamber-like assembly directs air flow into the interior of the kettle of the grill via a lower body air vent hole of the kettle. A manually adjustable air intake damper in the air chamber assembly allows, limits, or prevents ambient air flow drawn into the air chamber assembly. Forced air flow generated by a fan can also be separately provided into the air chamber assembly. Adjustment of the air intake damper can also adjust damper blades within the kettle of the grill. Ash falling out of the vent hole of the kettle is dropped through the air chamber assembly and captured in an ash container removably mounted to the air chamber assembly.

Description

[0001] Divisional application information

[0002] This application is a divisional application of the application patent application with the application date of July 20, 2021, the application number of 202110817125.3, and the invention name of “System and method for dual mode air control in kettle grills”. TECHNICAL FIELD

[0003] The present invention relates to outdoor grilling and smoking solutions, and more particularly to a novel system for enabling dual mode air control in kettle grills designed for use with charcoal. BACKGROUND

[0004] Kettle grills designed for use with lump fuel sources, such as typical grills, are relatively inexpensive and ubiquitous in the market. As recognized by one of ordinary skill in the art of kettle grills, air flow is typically manually controlled through a lower damper located at the bottom of the kettle’s lid, and optionally, also through an upper damper located in the kettle’s lid. In addition to affecting air flow, the lower damper can also be configured in typical kettle grills to stir out ash from the kettle so that ash can be collected in an ash can assembly located below the kettle. With skill and knowledge, a user can periodically adjust and set the manual dampers (lower and / or upper) of a typical kettle grill to control cooking temperature and / or smoke retention within the grill.

[0005] The skill and knowledge required for a kettle grill user to effectively manipulate and control air flow using the manual dampers has led the industry to introduce various forced air “add-on” solutions designed to alleviate the need for the user to master the manual dampers. However, prior art solutions typically require modification of the kettle to have “cutouts” and / or prevent the user from selecting manual damper control.

[0006] Accordingly, there is a need in the art for a system and method that does not require modification of the kettle of the grill, and furthermore, enables the user to selectively alternate between manual and automatic modes for air control through the kettle. More specifically, there is a need in the art for a dual mode air control system in a kettle grill. SUMMARY

[0007] An exemplary embodiment of a system and method for dual mode air control in kettle grills is disclosed. Certain embodiments are configured to be removably installed to a kettle grill, such as but not limited to a the exterior of a kettle grill. When installed to the kettle grill, the air chamber-like assembly directs airflow into the interior of the kettle of the grill via the lower body air vent hole of the kettle. A manually adjustable air intake damper in the air chamber assembly allows, restricts, or prevents ambient airflow drawn into the air chamber assembly. Forced airflow generated by a fan can also be provided into the air chamber assembly separately. Ash falling out of the air vent hole of the kettle falls through the air chamber assembly and is captured in an ash container that is removably mounted to the air chamber assembly. In this way, embodiments of the solution require no significant modification of the kettle grill, if any, in order for the kettle grill to use a dual mode air control system. Embodiments can also include temperature cycle control of the fan.

[0008] An exemplary embodiment of a system for dual mode air control in a kettle grill having one or more air vent holes in the lower portion of its kettle includes: 1) one or more positionable damper vanes associated with the one or more air vent holes in the lower portion of the kettle, each damper vane operable to be positioned such that it opens, restricts, or closes its associated air vent hole; 2) a damper air chamber having an open top and an open bottom, the damper air chamber including a manually adjustable air intake damper and a forced air input port, wherein the manually adjustable air intake damper is mechanically connected to the one or more positionable damper vanes; 3) an ash container assembly removably attached to the damper air chamber; and 4) an air control unit including a variable speed fan.

[0009] The air control unit can further include a temperature sensor in electrical communication with an electronic controller configured to vary the speed of the fan. The electronic controller can be operable to apply a proportional-integral-derivative control algorithm, and can also be configured to wirelessly communicate with a remote user device.

[0010] The damper air chamber is configured to be installed to the kettle grill such that the open top establishes a seal around an exterior region of the kettle that includes the one or more air vent holes. The air control unit is attached to the damper air chamber such that forced airflow generated by the fan enters the damper air chamber through the forced air input port. And when the manually adjustable air intake damper is in an open state, ambient airflow drawn in enters the damper air chamber through the manually adjustable air intake damper.

[0011] Further to the exemplary embodiment, when the manually adjustable air intake damper is in an open state, the one or more positionable damper vanes are positioned in the kettle such that the one or more damper apertures are closed. Similarly, when the manually adjustable air intake damper is in a closed state, the one or more positionable damper vanes are positioned in the kettle such that the one or more damper apertures are fully open. And when the manually adjustable air intake damper is in a partially open state, the one or more positionable damper vanes are positioned in the kettle such that the one or more damper apertures are partially restricted. Ash exiting the kettle of the grill through the one or more damper apertures is captured in an ash container underneath the air chamber.

[0012] Another exemplary embodiment of a system for dual mode air control in a kettle grill having one or more damper apertures in a lower portion of a kettle thereof includes: 1) a means for opening, restricting, or closing each of the one or more damper apertures; 2) a means for adjusting an aspirated ambient airflow between a fully open, fully closed, and a partially open state; 3) a means for adjusting a forced airflow; and 4) a means for capturing ash exiting the kettle. The means for adjusting the aspirated ambient airflow operates concurrently to adjust the means for opening, restricting, or closing each of the one or more damper apertures. Both the aspirated ambient airflow and the forced airflow enter the kettle through the one or more damper apertures.

[0013] When the means for adjusting the aspirated ambient airflow between a fully open, fully closed, and a partially open state is in an open state, the means for opening, restricting, or closing each of the one or more damper apertures operates to close the one or more damper apertures. Similarly, when the means for adjusting the aspirated ambient airflow between a fully open, fully closed, and a partially open state is in a closed state, the means for opening, restricting, or closing each of the one or more damper apertures operates to open the one or more damper apertures. And when the means for adjusting the aspirated ambient airflow between a fully open, fully closed, and a partially open state is in a partially open state, the means for opening, restricting, or closing each of the one or more damper apertures operates to restrict the one or more damper apertures.

[0014] The means for adjusting a forced airflow includes a temperature sensor in electrical communication with an electronic controller configured to vary a speed of a fan. The electronic controller can be operable to apply a proportional-integral-derivative control algorithm, and can also be configured to wirelessly communicate with a remote user device. BRIEF DESCRIPTION OF DRAWINGS

[0015] Figure 1An exemplary embodiment of a dual mode air control system for a kettle grill according to the solution is illustrated;

[0016] Figure 2 is Figure 1 an exploded view of the exemplary embodiment shown in

[0017] Figure 3 illustrates an exemplary embodiment of the dual mode air control system shown installed to a kettle grill; Figure 1

[0018] Figure 4 is Figure 3 a cross-sectional view to illustrate an exemplary connection between the novel system and the lower damper of a kettle grill;

[0019] Figure 5 is a functional block diagram of the electrical components included in an exemplary embodiment of the solution for a dual mode air control system for a kettle grill; and

[0020] Figure 6 is a flowchart illustrating an exemplary method of implementing dual mode air control in a kettle grill using a dual mode air control system according to the solution. DETAILED DESCRIPTION

[0021] Various embodiments, aspects, and features of the present invention encompass systems and methods for dual mode air control in a kettle grill, such as a kettle grill designed for use with lump charcoal fuel. As will be understood and appreciated by one of ordinary skill in the art, kettle grills are primarily designed for manual manipulation of a damper to control airflow through the kettle.

[0022] When a typical kettle grill is used as intended, charcoal is placed in the kettle of the grill and lit. A cooking grate is suspended above the top of the charcoal within the kettle. Heat energy produced by the burning charcoal radiates upward toward the grate and cooks any food placed thereon. To control temperature, burn rate, and smoke retention, kettle charcoal grills typically rely on somewhat crude manual damper-style control. Some kettle grills incorporate a damper on top of the lid that cooperates with and is above the lower kettle. However, other kettle grills, such as the grills commonly known as the Weber® brand, incorporate a damper at the bottom of the kettle (typically in addition to the damper on the lid of the kettle), providing a means for controlling air that enters directly into and through the burning charcoal.

[0023] As will be recognized by one of ordinary skill in the art, temperature, burn rate, and smoke retention are all critical parameters to control when using a kettle grill. Thus, the experience and skill of a user with a manual damper can directly impact the quality of the cooked food. To improve control of airflow in a kettle grill, the incorporation of an electric fan with temperature control cycling can be used in place of a manual damper.​​

[0024] Advantageously, embodiments of the solution are configured to be detachably integrated to a kettle grill having a lower damper in the kettle, without requiring modification of the kettle, and provide a dual mode option for the user to use the grill in a manual damper mode or an automatic damper mode. When in the manual damper mode, the solution allows the user to rely on manual setting and manipulation of the lower damper, while in the automatic damper mode, the user can rely on an electric fan to force air through the lower damper holes in response to a temperature control cycle. As can be better understood from the drawings and the following description, embodiments of the solution can be integrated to an existing kettle grill without requiring modification of the kettle (e.g., cutting holes in the kettle) or rendering the lower damper inoperable for ash removal and manual damper adjustment.

[0025] Turning now to the drawings, exemplary embodiments of a dual mode air control system 100 will be shown and described with common reference to the illustrations in Figures 1 to 5 . That is, each of the illustrations in Figures 1 to 5 will be described concurrently. Figure 1 Exemplary embodiments of a dual mode air control system 100 for a kettle grill according to the solution will be generally described, while Figure 2 exemplary embodiments thereof will be described. Figure 3 and 4 exemplary embodiments of the dual mode air control system 100 will be described. Figure 5 is a functional block diagram of the electrical components included in the control system of an exemplary embodiment of the solution for a dual mode air control system for a kettle grill.

[0026] As will be apparent from the figures, the system 100 can be configured to be mounted to the exterior of a kettle charcoal grill. The dual mode air control system 100 can cooperate / collocate with the kettle 210 (see, e.g., Figure 3 and 4 ) of the grill, such that the system 100 is positioned below and to the side of the kettle 210. The cooperating flange 125 of the damper plenum 107 can form a tight seal with the bottom side of the kettle.

[0027] The damper plenum 107 includes a manually adjustable air intake damper 115 that, when partially open, provides restricted air intake of ambient air drawn into the interior space of the damper plenum 107 (when the system 100 is in the manual damper mode), and when fully closed, prevents ambient air flow into the damper plenum 107 while preventing forced air flow injected into the plenum 107 by the fan 105 from flowing out (when the system is in the automatic damper mode). Whether from the drawn-in ambient air flow or the forced air flow generated by the fan 105 (or a combination of both), the air flow into the plenum 107 can exit the damper plenum 107 and enter the kettle 210 of the grill (see Figure 4 ) via the open lower damper holes 215.

[0028] It will be appreciated that manipulation of the adjustable air intake damper 115 position via the handle 119 corresponds to manipulation of the position of the damper vane 212 within the kettle 210 in order to open, restrict, or close the lower damper aperture 215 in the kettle. The air intake damper 115 can be mechanically connected to the damper vane 212 via the link 121 in order to adjust the air intake damper 115 to correspondingly cause adjustment of the damper vane 212. Generally, when the air intake damper 115 is fully closed, the lower damper aperture 215 can be fully open (due to the position of the damper vane 212), and the dual mode air control system 100 can be in the automatic damper mode such that the only air flow into the damper plenum 107 (and subsequently into the kettle 210 via the open lower damper aperture 215) is the forced air flow attributable to the electric fan 105. And when the air intake damper 115 is fully open, the lower damper aperture 215 can be fully closed (due to the position of the damper vane 212), and the dual mode air control system 100 can be in the off mode such that no air is allowed to flow from the damper plenum 107 into the kettle 210. When the air intake damper 115 is partially open, the lower damper aperture 215 can also be partially open (due to the position of the damper vane 212) in order to modulate the air flow into the kettle 210, and the dual mode air control system 100 can be in the manual damper mode. When the system 100 is in the manual damper mode, ambient air flow drawn in can be introduced into the damper plenum 107, and subsequently into the kettle 210. Depending on the embodiment of the solution, the fan 105 can provide supplemental forced air flow into the damper plenum 107 when the system 100 is in the manual damper mode.

[0029] As will be appreciated by those of ordinary skill in the art of kettle grills, manipulation of the damper vane 212 within the kettle can stir and cause ash to exit the kettle through the lower damper aperture 215. The ash can fall through the damper plenum 107 under the force of gravity and collect in the ash can or container 109. The ash can 109 can be releasably connected to the lower portion of the damper plenum 107 via the latch 111 or other means. In this manner, a user of the system 100 can periodically empty the collected ash by simply disconnecting the ash can 109 without having to disconnect the damper plenum 107 and / or the entire system 100 from the grill.

[0030] Embodiments of the solution can utilize a controller 102 including a graphical user interface 101 or the like. The graphical user interface 101 can be local (as depicted in the attached figures) and / or can be displayed remotely on a wirelessly connected user device. The controller 102, along with the fan 105, can be included within an air control unit bounded by a housing 117 configured to mount on the outside of the damper plenum 107 and kettle 210. The controller 102 can include a processor, memory components, a wireless transceiver, a power source, and the like, as understood by one of ordinary skill in the art of electronic controllers. The controller 102 can store within its memory any one or more temperature control algorithms that, when executed by the processor, cause adjustments to the speed of the fan 105. That is, the controller 102 can be configured to receive a temperature setpoint specified by a user, or, depending on the embodiment, the temperature control algorithm can predefine the temperature setpoint without user input. The temperature setpoint signals the controller 102 to vary the speed of the fan in view of the temperature sensor 123. As understood by one of ordinary skill in the art of process control, the controller 102 can utilize a proportional-integral-derivative (“PID”) control algorithm. In this manner, the controller 102 can adjust the fan speed in response to temperature readings from the temperature sensor 123, and by extension, adjust the flow rate of the forced air into the damper plenum 107.

[0031] It is further contemplated that embodiments of the controller 102 can be configured to wirelessly communicate with a software application or the like running on a remote user device, such as but not limited to a smartphone or tablet device. In such embodiments, the user interface 101 can partially comprise a user interface on the remote user device. A user can utilize the remote user interface 101 and / or the local user interface 101 (as shown in the figures) to adjust the selection of temperature control algorithms and / or monitor feedback data points (e.g., temperature, cooking time, alarms, etc.), as understood by one of ordinary skill in the art.

[0032] One or more temperature control algorithms can rely on input from a temperature sensor 123 that can be placed on the cooking grate or elsewhere within the kettle 210. Depending on the particular embodiment, it is contemplated that the solution can utilize temperature sensor feedback from a plurality of temperature sensors positioned in a plurality of locations within and / or outside the kettle 210. The temperature sensor 123 provides feedback to the controller 102, which in turn controls the fan speed. By controlling the fan speed, the controller 102 can maintain the cooking temperature at a desired temperature setting, as the forced air entering the damper plenum through the input port 113 will enter the kettle 210 via the lower damper hole 215 and affect the cooking temperature.

[0033] Figure 6is a flowchart illustrating an exemplary method 300 of implementing dual mode air control in a kettle grill according to the solution using a dual mode air control system. From block 305, the controller 102 can recognize or determine the position of the intake damper 115. In some embodiments, the controller 102 can rely on user input to determine the intake damper 115 position, while in other embodiments, the controller 102 can be configured to receive position sensor input to determine the intake damper 115 position.

[0034] Returning to the method 300, at decision block 310, if the intake damper 115 is fully open, then the "yes" branch can be followed. With the intake damper 115 fully open, the lower damper hole 215 in the kettle 210 can be fully closed. Accordingly, the method 300 can reach block 325 and set the system 100 to an off mode. In the off mode, the controller 102 can stop actuation of the fan 105, or alternatively, can continue to force air through the input port 113 into the damper plenum 107 in order to improve heat energy dissipation from the kettle 210. The method 300 returns to block 305 to monitor for any changes in the position of the intake damper 115. However, if it is determined at decision block 310 that the intake damper 115 is not fully open, then the method 300 follows the "no" branch to decision block 315.

[0035] At decision block 315, if the intake damper 115 is fully closed, then the "yes" branch can be followed. With the intake damper 115 fully closed, the lower damper hole 215 in the kettle 210 can be fully open. Accordingly, the method 300 can reach block 330 and set the system 100 to an automatic damper mode. In the automatic damper mode, the controller 102 can modulate the speed of the fan 105 based on input from the temperature sensor 123, and in doing so, provide forced air flow through the input port 113 into the damper plenum 107. With the intake damper 115 closed, ambient air intake into the damper plenum 107 can be prevented. The forced air flow can pass through the fully open damper hole 215 into the kettle 210 in order to affect the burn and cooking temperatures. The method 300 returns to block 305 to monitor for any changes in the position of the intake damper 115. However, if it is determined at decision block 315 that the intake damper 115 is not fully closed, then the method 300 follows the "no" branch to decision block 320.

[0036] At decision block 320, if the air intake damper 115 is partially open, then the "yes" branch can be followed. With the air intake damper 115 partially open, the lower damper hole 215 in the kettle 210 can also be partially open. Thus, the method 300 can reach block 335 and set the system 100 to a manual damper mode. In the manual damper mode, the controller 102 can modulate the speed of the fan 105 based on input from the temperature sensor 123, and in doing so, provide a forced air flow through the input port 113 into the damper plenum 107 that supplements the suction air flow into the damper plenum 107 from the partially open air intake damper 115. Alternatively, the controller 102 can turn off the fan 105 so that the only air flow into the damper plenum 107 is the suction air flow through the partially open air intake damper 115. Air flow can enter the kettle 210 through the partially open damper hole 215 in order to affect the burn and cook temperatures. The method 300 returns to block 305 to monitor for any changes in the position of the air intake damper 115. However, if it is determined at decision block 320 that the air intake damper 115 is not partially open, then the method 300 follows the "no" branch and the method 300 returns.

[0037] A system and method for dual mode air control in kettle grills according to the solution has been described using the detailed description of its embodiments, which are provided by way of example and are not intended to limit the scope of the disclosure. The described embodiments include different features, not all of which are necessary in all embodiments of the dual mode air control system according to the solution. Some embodiments of the solution utilize only some of the described features or possible combinations of the described features. Variations of the described embodiments of the solution and embodiments of the solution including different combinations of the features mentioned in the described embodiments will occur to those skilled in the art.

[0038] Those skilled in the art will realize that the system and / or method for dual mode air control in kettle grills according to the solution is not limited by what has been specifically shown and described herein. In particular, the scope of the system and / or method for dual mode air control in kettle grills according to the solution is defined by the appended claims.

Claims

1. A dual mode air control system, the system comprising: an air damper chamber configured to be removably positioned underneath a kettle of a kettle grill, wherein the kettle grill comprises one or more air damper holes in a bottom side surface and one or more air damper vanes corresponding to the one or more air damper holes; a manually adjustable air intake damper in a side surface of the air damper chamber; a mechanical connection between the manually adjustable air intake damper and the one or more air damper vanes; an electric fan configured to create a positive air flow into the air damper chamber; and an ash can removably mounted to the air damper chamber and configured to capture ash exiting the kettle grill through the one or more air damper holes; wherein when the manually adjustable air intake damper is in a fully closed state, the one or more air damper vanes are positioned such that the one or more air damper holes are in an open state; and wherein when the manually adjustable air intake damper is in a partially open state, the one or more air damper vanes are positioned such that the one or more air damper holes are in a partially open state; and wherein when the manually adjustable air intake damper is in a fully open state, the one or more air damper vanes are positioned such that the one or more air damper holes are in a closed state.

2. The dual mode air control system of claim 1, further comprising an electronic controller in electrical communication with the electric fan.

3. The dual mode air control system of claim 2, further comprising a temperature sensor in electrical communication with the electronic controller, wherein the electronic controller is configured to change a speed of the electric fan based on a signal input from the temperature sensor.

4. The dual mode air control system of claim 3, wherein the electronic controller changes the speed of the electric fan in a proportional-integral-derivative control algorithm.

5. The dual mode air control system of claim 2, wherein the electronic controller is configured to wirelessly communicate with a remote user device.

6. The dual mode air control system of claim 2, wherein the electronic controller comprises a graphical user interface.

7. A dual mode air control system, the system comprising: means for removably mounting an air damper chamber underneath a kettle of a kettle grill, wherein the kettle grill comprises one or more air damper holes in a bottom side surface and one or more air damper vanes corresponding to the one or more air damper holes; means for manually adjusting an air intake damper in a side surface of the air damper chamber; means for adjusting the one or more air damper vanes while adjusting the air intake damper; electromechanical means for creating a positive air flow into the air damper chamber; and means for capturing ash exiting the kettle grill through the one or more air damper holes and falling from the air damper chamber; wherein when the air intake damper is in a fully closed state, the one or more air damper vanes are positioned such that the one or more air damper holes are in an open state; and wherein when the air intake damper is in a partially open state, the one or more air damper vanes are positioned such that the one or more air damper holes are in a partially open state; and wherein when the air intake damper is in a fully open state, the one or more air damper vanes are positioned such that the one or more air damper holes are in a closed state. ​ wherein when the intake damper is in a fully open state, the one or more damper vanes are positioned such that the one or more damper holes are in a closed state.

8. The dual mode air control system of claim 7, further comprising a means for controlling the electromechanical means to generate a positive airflow into the damper plenum.

9. The dual mode air control system of claim 8, wherein the means for controlling the electromechanical means is configured to change a speed of the electromechanical means for generating a positive airflow into the damper plenum based on a signal input from a temperature sensor.

10. The dual mode air control system of claim 9, wherein the means for controlling the electromechanical means changes a speed of the electromechanical means for generating a positive airflow into the damper plenum in a proportional-integral-derivative control algorithm.

11. The dual mode air control system of claim 8, wherein the means for controlling the electromechanical means is configured to wirelessly communicate with a remote user device.

12. The dual mode air control system of claim 8, wherein the means for controlling the electromechanical means comprises a graphical user interface.

13. A method of dual mode air control in a kettle grill, the method comprising: installing a damper plenum below a kettle of a kettle grill, wherein the damper plenum comprises an adjustable intake damper and the kettle grill comprises one or more damper holes in a bottom side surface and one or more damper vanes corresponding to the one or more damper holes; removably installing an ash can to the damper plenum to capture ash exiting the kettle grill through the one or more damper holes; providing a mechanical connection between a manually adjustable intake damper and the one or more damper vanes; configuring an electric fan to generate a positive airflow into the damper plenum; and manually adjusting the intake damper, wherein: when the intake damper is in a fully closed state, the one or more damper vanes are positioned such that the one or more damper holes are in an open state; and when the manually adjustable intake damper is in a partially open state, the one or more damper vanes are positioned such that the one or more damper holes are in a partially open state; and when the manually adjustable intake damper is in a fully open state, the one or more damper vanes are positioned such that the one or more damper holes are in a closed state.

14. The method of claim 13, further comprising an electronic controller in electrical communication with the electric fan.

15. The method of claim 14, further comprising providing a temperature sensor in electrical communication with the electronic controller, wherein the electronic controller is configured to change a speed of the electric fan based on a signal input from the temperature sensor.

16. The method of claim 15, wherein the electronic controller changes a speed of the electric fan in a proportional-integral-derivative control algorithm.

17. The method of claim 14, wherein the electronic controller is configured to wirelessly communicate with a remote user device.

18. The method of claim 14, wherein the electronic controller comprises a graphical user interface.

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