Ash Catcher Support Clip Design for Stable Grill-Leg Attachment
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Solution Overview
Problem
Existing ash catcher systems for charcoal grills are shallow, prone to ash being blown out by wind, and have limited capacity due to structural constraints, with spring clamps that are awkward to use and not strong enough to securely attach the pan, leading to instability and potential spills.
Innovation Solution
A deeper ash catcher pan with support clips that have a circular collar, squeeze arms with an angled grip, and a support flange, allowing for secure attachment to the grill legs without requiring complex internal clamping, providing improved stability and ease of use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If prior art spring clamps are used to secure the ash catcher pan, then the pan can be attached to the grill legs, but the clamps are awkward to use and not strong enough, resulting in instability and potential spills
Solution Approach 1:
The support clip inverts the traditional clamping approach by using a spring-loaded collar that expands outward to grip the leg, rather than squeezing inward. This inversion makes the clip easier to install by simply opening the collar and sliding it onto the leg, while the spring mechanism provides strong, reliable holding force without requiring awkward squeezing motions.
Solution Approach 2:
The support system is segmented into separate functional components: the collar portion for gripping the leg, the squeeze arms for adjustment, and the support flange for bearing the pan weight. This segmentation allows each component to be optimized independently, with the collar providing secure attachment and the flange providing stable support.
2Quantity of substance
If the ash catcher pan is made deeper to increase capacity, then more ash can be held and wind resistance improves, but the structural constraints of prior clamps limited the achievable pan size
Solution Approach 1:
The support clip is designed as a universal support mechanism that can accommodate various pan sizes and shapes. The circular collar portion can grip legs of different diameters, and the adjustable squeeze arms allow the support flange to position at different heights, enabling support for deeper, higher-capacity pans without requiring pan-specific clamp designs.
3Ease of manufacture
If the spring clamp structure is simplified for easier manufacture, then production costs decrease, but the clamping strength and reliability are reduced
Solution Approach 1:
The spring mechanism parameters are optimized to provide sufficient clamping force through material selection and geometric design rather than complex multi-component structures. By adjusting spring wire diameter, coil density, and overall dimensions, the desired holding strength is achieved with a simple, manufacturable single-piece construction for each support clip.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution results in a higher ash capacity that is less susceptible to wind-blowing ash, with a secure and easy-to-install support system that maintains the pan's levelness, enhancing user convenience and stability during ash disposal.
Implementation Method 1
a spring-loaded collar that expands to grip the leg
Implementation Method 2
a support flange that extends from the collar portion on a side opposite the squeeze arms
Data Source
AI summary
The present inventions are directed to an ash catcher system for use with a charcoal grill and having an ash catcher pan and a plurality of support clips.