Refractory insert and smoker comprising such refractory insert

Abstract

The utility model relates to a fire-resistant insert and further relates to a smoker comprising the fire-resistant insert. A refractory insert for use within a combustion chamber of a smoker, the refractory insert comprising: a first set of opposing walls wherein a first wall of the first set of opposing walls comprises a first height and a second wall of the first set of opposing walls comprises a second height wherein the first height is different than the second height; and wherein a top edge of at least one wall of the first set of opposing walls is inclined. Embodiments of the disclosure relate to an improved refractory insert that reduces fuel bridging. In an embodiment, the improved refractory insert is composed of two or more pieces of refractory material of different heights. In some embodiments, the top edge of the refractory insert is inclined. The height variation and inclination of the top edge help significantly reduce fuel bridging on or within the refractory insert.

Description

Technical Field

[0001] The utility model relates to a refractory insert and also to a smoker comprising the refractory insert. Background Art

[0002] Refractory materials are often used in systems and applications involving extreme mechanical, chemical or thermal stresses. These types of materials are particularly useful in wood-burning kilns, fireplaces, grills and smokers because they can withstand high temperatures and maintain dimensional stability, thereby providing higher energy efficiency compared to non-refractory materials. Modern refractory materials used in grills and smokers are generally composed of ceramics and / or ceramic composites, and can generally be referred to as "fire bricks" or "fire mud bricks". As used herein, the terms "grill" or "smoker" each generally refer to any grill, smoker, kiln, fireplace, oven or other cooking equipment that can be used to cook one or more foods using heat and / or smoke. As used herein, the term "refractory insert" generally refers to any type of insert that can withstand high temperatures and maintain dimensional stability. As used herein, a "refractory insert" may include any material (e.g., ceramic, ceramic composite, metal) or design (e.g., in which a material that can withstand high temperatures is used as a liner and an insulating substance is disposed between the material and the combustion chamber, such as air, ceramic, or another type of insulating substance) now known or later discovered that can withstand high temperatures and maintain dimensional stability.

[0003] The use of refractory materials within the interior of barbecue grills and smokers allows the grill / smoker to withstand high heat and maintain greater energy efficiency during cooking. For example, one or more refractory materials may be positioned inside high temperature areas within a grill or smoker, such as within a cooking enclosure and / or a combustion chamber, to absorb and reflect heat in order to reduce heat loss during the cooking process. An example of a barbecue grill and smoker that may use refractory fire brick materials is disclosed in U.S. Patent No. 11,172,688, entitled "Gravity Fed Smoker," which is hereby incorporated by reference in its entirety as if fully set forth herein. In the patent, refractory materials (e.g., fire bricks) are used to line certain interior surfaces within a combustion chamber positioned below a feed hopper.

[0004] The feed hopper in the above-mentioned patent is configured to accommodate various fuel types (e.g., charcoal, lump charcoal, wood) and allow the fuel to be vertically fed into the combustion chamber. Once in the combustion chamber, the fuel ignites and burns to generate heat and / or smoke for the cooking process. When larger pieces of fuel are fed into the feed hopper, such as large pieces of wood or lump charcoal, one or more of the fuel pieces on the inside of the hopper may hinder the continuous feeding of fuel into the combustion chamber by gravity if they happen to fall on the top edge of the fire bricks on the inside of the combustion chamber, thereby forming a "bridge" above the combustion chamber that hinders or prevents the movement of fuel from the feed hopper into the combustion chamber. Such bridging of fuel on or above the combustion chamber may affect the ability of the grill to feed fuel into the combustion chamber from above, which in turn may cause large changes in temperature and affect the ability of the grill to both maintain a stable temperature during the cooking process and burn the fuel efficiently. Utility Model Content

[0005] Embodiments of the presently disclosed invention address the above-mentioned problem of "bridging" above the combustion chamber of grills and smokers that may occur when using refractory inserts. The improved refractory insert has a tuned geometry that allows fuel to move through the combustion chamber and minimizes fuel entrapment, for example, on or within the refractory insert. This improved geometry of the refractory insert in turn reduces changes in temperature during fuel combustion and improves fuel combustion efficiency.

[0006] Exemplary embodiments of the presently disclosed invention include a refractory insert for use within a combustion chamber of a grill or smoker. The refractory insert may generally include a first set of opposing walls. A first wall of the first set of opposing walls includes a first height, and a second wall of the first set of opposing walls includes a second height. The heights of the first wall and the second wall may be measured from any location along the length of the wall, and for example and without limitation, along one edge of the wall, along another edge of the wall, or along a midline of the wall. Preferably, the heights are measured at the same point on each of the walls. Additionally, as described and illustrated herein, the height of the first wall of the first set of opposing walls may be different than the height of the second wall of the first set of opposing walls.

[0007] The refractory insert may further include a second set of opposing side walls.A first wall of the second set of opposing walls may further include a third height and a second wall of the second set of opposing walls may include a fourth height, wherein the third height is different from the fourth height.

[0008] In addition, the top edge of at least one of the first set of opposing walls may be inclined (or angled). For example, in an embodiment, the top edge of at least one of the first set of opposing walls may be inclined at an angle of 5 to 20 degrees. The top edge of at least one of the second set of opposing walls may also be inclined. For example, in an embodiment, the top edge of at least one of the second set of opposing walls may be inclined at an angle of 5 to 20 degrees.

[0009] In some embodiments, the opposite walls of the first group can be coupled to the opposite walls of the second group. For example, the opposite walls of the first group and the opposite walls of the second group can be coupled together via brackets and fasteners positioned on the corners of the top edges of one or more of the opposite walls.

[0010] Alternative embodiments include grills and smokers, wherein the grills and smokers include a combustion chamber and a refractory insert positioned within the combustion chamber. The refractory insert may include a first set of opposing walls and a second set of opposing walls as previously described, and each set of opposing walls may be flush with the inner surface of the combustion chamber of the grill or smoker. Thus, the set of opposing walls may line the inner surface of the combustion chamber. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1A is a perspective view of a grill and smoker according to an exemplary embodiment of the presently disclosed invention.

[0012] Figure 1B is a side view of a grill and smoker according to an exemplary embodiment of the presently disclosed invention.

[0013] Figure 1C is a cross-sectional view of a grill and smoker according to an exemplary embodiment of the presently disclosed invention.

[0014] Figure 2 is a perspective view of a prior art refractory insert.

[0015] Figures 3A-3C are various views of a refractory insert according to an exemplary embodiment of the presently disclosed invention.

[0016] Figures 4A-4H A grill and smoker (such as Figures 1A-1C Various views of the refractory inserts positioned together (shown in FIG. ).

[0017] Figures 5A-5C A grill and smoker (such as Figures 1A-1C Various cross-sectional views of refractory inserts positioned together (shown in FIG. ).

[0018] Fig. 6Ais the use of prior art refractory inserts (such as Figure 2 ) is a graphical representation of the temperatures measured over time at several locations within the cooking chamber of a grill.

[0019] Figure 6B is the use of improved refractory inserts (such as Figures 3A-3C ) is a graphical representation of the temperatures measured over time at several locations within the cooking chamber of a grill. DETAILED DESCRIPTION

[0020] The following exemplary embodiments of the presently disclosed invention include improved configurations for use of fire bricks in grills and smokers. Advantageously, the improved fire brick configurations can reduce or eliminate bridging of fuel blocks that would otherwise prevent or impede fuel movement into or through a combustion chamber, depending on where the bridging occurs. In some embodiments, the inventive fire brick configurations can be deployed as inserts ("refractory inserts" or "refractory brick inserts") that can be positioned within or adjacent to the interior walls of a cooking enclosure and / or combustion chamber of a grill and smoker. The refractory brick insert can be comprised of a group of one or more fire brick blocks that can be individually positioned within a cooking enclosure or combustion chamber, or alternatively can be integrally incorporated into a single removable unit that can be placed within and removed from a cooking enclosure or combustion chamber.

[0021] In some disclosed embodiments, individual fire bricks within a refractory brick insert may be individually removable and / or replaceable. Additionally, in some disclosed embodiments, a refractory brick insert may be a single unit that may be positioned within and removed from a designated location within the interior of a grill or smoker. In such embodiments, a refractory brick insert may include one or more support structures upon which one or more fire bricks may be mounted. In other embodiments, a support structure for one or more fire bricks of a refractory brick insert may be located within or integrally incorporated into a cooking enclosure or combustion chamber of a grill or smoker.

[0022] Figures 1A-1CAn example grill and smoker 100 is shown in which a refractory brick insert may be used according to a certain exemplary embodiment of the present disclosure. The grill and smoker 100 includes a food cooking enclosure 110 and an external chimney 120. The external chimney 120 may be connected to a side 112 of the food cooking enclosure 110. The external chimney 120 may be generally rectangular in shape and include a feed hopper 122 for receiving fuel, a combustion chamber 124 for receiving fuel from the feed hopper and burning the fuel during cooking, and a lower chimney portion 126 including an ash removal bin (not shown). In some disclosed embodiments, a fan 140 may be configured to force air into the combustion chamber 124 from an opening below a fire grate 125 within the combustion chamber 124. Additionally, in some disclosed embodiments, the speed of the fan 140 may be controlled by a digital controller 150 configured to monitor the temperature within the food cooking enclosure 110 and adjust the speed of the fan 140 to maintain, increase, or decrease the temperature within the food cooking enclosure 110 based on one or more user-selected preferences (including, for example, temperature settings).

[0023] exist Figures 1A-1C In an exemplary embodiment of the present invention, a feed hopper 122 is located near the top of the chimney 120 and is configured to receive solid fuel, such as charcoal, lump charcoal, and / or wood. The feed hopper 122 is also positioned above the combustion chamber 124 and connected to the top of the combustion chamber 124. The chimney 120 preferably has a top opening 128 for loading fuel into the feed hopper 122. The combustion chamber 124 includes a fire grate 125 on which the fuel can rest and burn when ignited. In some embodiments, ash generated from the spent fuel can fall through the fuel grate 125 and enter an ash collector (not shown). The combustion chamber 124 includes a smoke outlet that is substantially aligned with an inlet opening on the side 112 of the food cooking enclosure 110 so that heat and smoke generated in the combustion chamber 124 can flow through the smoke outlet of the combustion chamber, through the inlet on the side 112, and into the food cooking enclosure 110. In some embodiments, the smoke outlet can be covered by a smoke outlet grill and / or a spark arrestor, such as Figure 3A and Figure 4C An exemplary smoke outlet grille is shown in FIG.

[0024] Figure 2 Shown can be used for example Figures 1A-1C The prior art refractory brick insert in the exemplary grill and smoker 100 of FIG. Figure 2 As shown in , a prior art refractory brick insert includes four walls of refractory material such that the horizontal top edges of each wall in the insert are configured to be located at the same height and are substantially coplanar with each other. Figure 2 The exemplary prior art refractory brick insert in is configured to be positioned in the combustion chamber 124 (e.g., Figures 1A-1CEach of the four walls of refractory fire brick material lines the corresponding inner wall inside the combustion chamber 124. Figure 2 The exemplary prior art refractory brick insert in is constructed of three side walls of approximately equal height (e.g., 200 mm) and one shorter wall (e.g., 111 mm) so that it can be positioned on or above a smoke outlet grill that, when in use, allows smoke and heat to flow from the combustion chamber 124 into the food cooking enclosure 110. Because the horizontal top edges of the four walls of the prior art refractory brick insert are substantially in line with each other, the prior art refractory insert presents a greater risk of causing bridging, wherein one or more pieces of fuel may cross from the top surface of one wall to the top surface of another wall above the combustion chamber 124, resulting in undesirable and unpredictable temperature variability and reduced fuel efficiency.

[0025] Figures 3A-3C An exemplary refractory brick insert 300 according to an exemplary disclosed embodiment of the present invention is shown. The refractory brick insert 300 may be used, for example, Figures 1A-1C Refractory brick insert 300 includes four walls (310A, 310B, 310C, and 310D) of different heights. In some disclosed embodiments, the refractory brick insert includes two or more fire bricks that have different heights when they are inserted into the combustion chamber or food cooking enclosure. Figure 2 Unlike the prior art refractory brick insert shown in , the top edges (312A, 312B, 312C, and 312D) of the four walls (310A, 310B, 310C, and 310D) of the refractory brick insert 300 of the embodiment of the present disclosure are not substantially at the same height and are not coplanar, with some walls extending higher than others. For example, Figures 3A-3C As shown in FIG. 1 , one or more of the four walls 310A, 310B, 310C, and 310D may also have a sloped top edge. Figure 3A and Figure 3B In an exemplary embodiment of, wall 310D may have a maximum height, wall 310A may have a second maximum height, wall 310B may have a third maximum height, and wall 310C may have a fourth maximum height. Those skilled in the art will recognize that the relative heights of walls 310A, 310B, 310C, and 310D of refractory brick insert 300 may be configured differently in other disclosed embodiments, so long as, in this example, at least two of the walls have different heights within combustion chamber 124 when refractory brick insert 300 is positioned within combustion chamber 124. For example, at least two walls located at substantially opposite locations in refractory brick insert 300, such as a pair of walls 310A and 310B or a pair of walls 310C and 310D, have different heights when positioned in combustion chamber 124. Figure 3AIn an exemplary embodiment of the present invention, the shortest wall 310C may be mounted on or otherwise coupled to an exemplary smoke grill 322, which in some embodiments may be an angled smoke grill through which heat and smoke may exit the combustion chamber 124 through the smoke outlet 320 and enter the combustion chamber 124. Figures 1A-1C The food cooking enclosure 110 of the exemplary grill and smoker 100 is shown in FIG.

[0026] like Figure 3C , at least some of the top edges (312A, 312B, 312C, and 312D) of the four walls (310A, 310B, 310C, and 310D) of the refractory insert 300 may be inclined relative to the vertical side edges of the walls. One skilled in the art will recognize that in some embodiments, any one or more of the top edges 312A, 312B, 312C, and 312D may be inclined (angled) in accordance with the disclosed embodiments of the refractory brick insert 300 described herein. In some embodiments, for example, each of the top edges of the four walls may be inclined at the same angle. In other embodiments, one or more of the top edges of the four walls may be inclined at a different angle than the angle of inclination of the other top edges of the four walls. The angle of inclination of one or more of the top edges may be in the range of about 5 to 80 degrees, and in particular, in the range of 5 to 10 degrees, 10 to 15 degrees, 15 to 20 degrees, 20 to 25 degrees, 25 to 30 degrees, 30 to 35 degrees, 35 to 40 degrees, 40 to 45 degrees, 45 to 50 degrees, 50 to 55 degrees, 55 to 60 degrees, 60 to 65 degrees, 65 to 70 degrees, 70 to 75 degrees, 75 to 80 degrees. In some embodiments, the angle of inclination of one or more of the top edges may be at least 5 degrees, at least 10 degrees, at least 15 degrees, at least 20 degrees, at least 25 degrees, at least 30 degrees, at least 35 degrees, at least 40 degrees, at least 45 degrees, at least 50 degrees, at least 55 degrees, at least 60 degrees, at least 65 degrees, at least 70 degrees, and at least 75 degrees. In an exemplary embodiment, the angle of each of the top edges of the wall is in the range of about 7 to 10 degrees, preferably in the range of about 8 to 9 degrees.

[0027] In an exemplary embodiment, if Figure 3C As shown in FIG. 3 , the relative dimensions of each of the walls of the refractory brick insert 300 may be as follows:

[0028] Wall A: The side vertical walls have a height of 260 mm and 230 mm, and the bottom horizontal wall has a length of 187 mm;

[0029] • Wall B: The side vertical walls have heights of 140 mm and 170 mm, and the bottom horizontal wall has a length of 187 mm.

[0030] Wall C: the side vertical walls have heights of 51 mm and 81 mm, and the bottom horizontal wall has a length of 212 mm;

[0031] Wall D: the side vertical walls have a height of 260 mm and 230 mm, and the bottom horizontal wall has a length of 215 mm;

[0032] It will be appreciated that the relative size of each of the walls may be adjusted as desired based on, for example, how the refractory brick insert is used (e.g., in a grill, smoker, fireplace, or kiln), the relative size of the area in which the refractory brick insert is used, and other components (e.g., grates) located around and / or near the refractory brick insert.

[0033] Figures 4A-4H Shows how to use Figures 1A-1C Various views of the refractory insert 300 used in certain exemplary embodiments of the exemplary grill and smoker 100 of FIG. Figure 5A-5B FIG. 2 is a cross-sectional view of a grill and smoker 100 including a refractory brick insert 300 and also illustrates the positioning of the refractory brick insert 300 relative to other components of the grill and smoker 100. Figures 4A-5A , the refractory insert 300 may be positioned above the lower chimney portion 126 and within the combustion chamber 124. The refractory insert 300 preferably lines the inner wall (or at least a portion thereof) of the combustion chamber 124 and is preferably positioned above the combustion chamber grid 125. In some exemplary embodiments, for example, Figure 4F As shown in FIG. 1 , the walls of the refractory inserts ( 310A, 310B, 310C, and 310D) may be coupled together via one or more brackets 330 .

[0034] Fig. 6A and Figure 6B is an exemplary illustration showing a refractory brick insert 300 (such as in Figure 3A Similar measurement results of the exemplary embodiment disclosed in Figure 6B ) compared to using Figure 2 Temperature measurements with respect to cooking time for a prior art refractory brick insert configuration disclosed in ( Fig. 6A In two test scenarios, a grill and a smoker (such as Figures 1A-1C The feed hopper of the grill and smoker (shown in Figure 1) was filled with lump charcoal of the same weight and size. The lump charcoal was then ignited and allowed to burn until all the charcoal was consumed. The grill temperature was set to 700°F during the test. Temperature measuring devices were placed at different locations within the cooking chamber of the grill and smoker (in Fig. 6A and Figure 6B TC1-TC8 in the figure and shown as different lines in the figure).

[0035] Fig. 6A The graph shown in is a representation of the temperature in the cooking chamber (measured in Fahrenheit and displayed on the y-axis) over time (measured in seconds). Fig. 6A The valleys shown in the figure represent the temperature drop in the cooking chamber at different points in time, which is believed to be due to the solid fuel crossing the Figure 2 The prior art refractory brick inserts are caused by bridging of the horizontal top edges. Figure 6B The drop in temperature due to the improved refractory brick insert 300 design and construction is shown to be significantly reduced, indicating that the temperature remained more stable throughout the tests performed to obtain the data in this figure.

[0036] In some embodiments, the refractory brick insert 300 may be constructed from one or more fire bricks. In other embodiments, the refractory insert may be constructed from ceramic or other refractory materials currently known or later discovered.

[0037] The foregoing description relates to specific exemplary embodiments. However, it will be apparent that other variations and modifications may be made to the described embodiments, wherein some or all of their advantages are obtained. For example, those skilled in the art will recognize that, in accordance with the description of the embodiments disclosed herein, the refractory brick inserts described in the exemplary disclosed embodiments can be used in various types of grills and smokers to avoid bridging of fuel blocks in the grill or smoker. Therefore, this description is intended only as an example and not to limit the scope of the embodiments herein.

Claims

1. A refractory insert for use in a combustion chamber of a smoker, the refractory insert comprising: a first set of opposing walls, wherein a first wall of the first set of opposing walls comprises a first height and a second wall of the first set of opposing walls comprises a second height, wherein the first height is different from the second height; and Wherein a top edge of at least one of the first set of opposing walls is inclined.

2. The refractory insert according to claim 1, wherein A top edge of at least one of the first set of opposing walls is inclined at an angle of 5 to 20 degrees.

3. The refractory insert of claim 1 further comprising a second set of opposing walls, wherein: a first wall of the second set of opposing walls comprises a third height and a second wall of the second set of opposing walls comprises a fourth height, wherein the third height is different from the fourth height; and Wherein a top edge of at least one of the second set of opposing walls is inclined.

4. The refractory insert according to claim 3, wherein A top edge of at least one of the second set of opposing walls is inclined at an angle of 5 to 20 degrees.

5. The refractory insert of claim 3, wherein: Opposing walls of the first set are coupled to opposing walls of the second set.

6. The refractory insert according to claim 5, wherein The first set of opposing walls and the second set of opposing walls are coupled together via brackets and fasteners positioned on corners of a top edge of one or more of the opposing walls.

7. A smoker comprising the refractory insert of claim 1, the smoker further comprising a combustion chamber in which the refractory insert is used.

8. The smoker according to claim 7, wherein: The top edge of at least one of the first set of opposing walls of the refractory insert is inclined at an angle of 5 to 20 degrees.

9. The smoker of claim 7 further comprising a second set of opposing walls, wherein: A first wall of the second set of opposing walls comprises a third height, and a second wall of the second set of opposing walls comprises a fourth height, wherein the third height is different from the fourth height; and wherein a top edge of at least one of the second set of opposing walls is inclined.

10. The smoker according to claim 9, wherein: A top edge of at least one of the second set of opposing walls is inclined at an angle of 5 to 20 degrees.

11. The smoker according to claim 9, wherein: Each of the first set of opposing walls and the second set of opposing walls is flush with an inner surface of a combustion chamber of the smoker.

12. The smoker according to claim 9, wherein: Opposing walls of the first set are coupled to opposing walls of the second set.

13. The smoker according to claim 12, wherein: The first set of opposing walls and the second set of opposing walls are coupled together via brackets and fasteners positioned on corners of a top edge of one or more of the opposing walls.

14. The smoker of claim 9, further comprising an angled grill for allowing smoke and heat to exit the combustion chamber.

15. The smoker of claim 14, wherein: The angled grille is positioned below at least one of the second set of opposing walls.

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