Curved Charcoal Grate Structure for Non-Rectangular Grill Fireboxes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing charcoal trays for barbecue grills are not optimally suited for non-rectangular grill shapes, such as dome-shaped or oval fireboxes, and lack efficient support mechanisms, especially in portable grills with complex designs like the Weber Q series, which reduces the usable space and requires multiple trays or complex support systems.
Innovation Solution
A charcoal grate made from sheet metal with apertures for air and ash flow, featuring side walls that conform to the grill's shape and engage with nesting targets for secure positioning, allowing for increased surface area and dual-purpose nesting features that facilitate stacking and support within the grill firebox.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If traditional rectangular charcoal trays with horizontal lips are used, then the trays can be easily manufactured and supported, but the surface area available for holding charcoal is reduced and they do not conform to non-rectangular firebox shapes
Solution Approach 1:
The charcoal tray is formed with a curved bottom surface that conforms to the dome-shaped or oval cross-section of the firebox. This curvature allows the tray to maximize the usable surface area within the non-rectangular firebox space while eliminating the need for complex support mechanisms, as the curved shape naturally nests within the firebox contours.
2Reliability
If multiple separate trays or complex support systems are used to accommodate non-rectangular shapes, then the charcoal can be held securely, but the device complexity increases and manufacturing cost rises
Solution Approach 1:
The support function and charcoal holding function are merged into a single integrated tray structure. The outwardly extending flanges are formed as an integral part of the tray body, eliminating the need for separate support components or multiple trays. This single-piece construction provides secure charcoal holding while maintaining simplicity in both design and manufacturing.
3Reliability
If the tray includes outwardly extending flanges for support, then the tray can be securely positioned in the firebox, but the manufacturing complexity increases
Solution Approach 1:
The tray is constructed from a plurality of formed metal pieces that are joined together to create the final structure with outwardly extending flanges. This segmentation allows each piece to be formed and reinforced independently, then assembled into the complete tray with integrated support flanges, making the manufacturing process more manageable while maintaining structural integrity and positioning stability.
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 enhances charcoal tray performance by maximizing usable space in non-rectangular grills, providing efficient combustion air access, ash disposal, and supporting the grate within the grill while allowing for efficient stacking and reduced shipping costs through integrated nesting features.
Implementation Method 1
The bottom wall is configured to hold charcoal briquettes and has a plurality of apertures which allow combustion air to reach the charcoal briquettes
Implementation Method 2
The bottom wall is configured to hold charcoal briquettes and has a plurality of apertures which allow combustion air to reach the charcoal briquettes
Implementation Method 3
The bottom wall is configured to hold charcoal briquettes and has a plurality of apertures which allow combustion air to reach the charcoal briquettes and allow ashes to fall therethrough
Data Source
AI summary
A charcoal fired barbecue grill is described and shown herein. In one embodiment, a charcoal grate is disclosed which is formed from a sheet metal material. The charcoal grate includes a bottom wall and a plurality of side walls, The bottom wall includes a plurality of apertures to allow combustion air to reach the charcoal and a plurality of embossments to increase the structural rigidity of the charcoal tray. At least some of the side walls include side wall extensions which are configured to engage with the barbecue grill firebox to support the charcoal grate underneath the cooking grate. In a second embodiment, a charcoal grill firebox is disclosed which includes a dual purpose nesting target on an inside surface. The nesting target is not only configured to support a grate, it is also configured to nest with a corresponding nesting feature which is positioned on an outside surface of the firebox.