Detachable Bimodal Air Control Plenum for Kettle-Style Grills
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Solution Overview
Problem
Kettle-styled grills require manual skill to control air flow, which limits user flexibility and can be improved with a system that allows bimodal air control without modifying the grill, enabling both manual and auto-damper modes.
Innovation Solution
A detachable bimodal air control system that integrates with existing kettle-styled grills, using a plenum component with a manually adjustable intake damper and a forced-air fan, allowing for temperature loop control and ash capture without modifying the grill, and includes a variable speed fan with a proportional-integral-derivative control algorithm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual dampers are used to control air flow, then the grill structure remains simple and unmodified, but the user requires skill and knowledge to effectively control temperature and smoke retention
Solution Approach 1:
A plenum chamber is introduced as an intermediary component between the ambient air and the kettle interior. The plenum receives air from both manual dampers and a forced-air fan, then distributes it through damper holes in the kettle. This mediator allows automated temperature control without directly modifying the kettle structure or requiring user skill for air flow management.
Solution Approach 2:
The manual mechanical damper adjustment system is supplemented with an automated forced-air fan system controlled by a temperature sensor and controller. The fan provides automated air flow control based on temperature feedback, replacing the need for manual damper adjustment while preserving the original mechanical damper structure for ash removal.
2Ease of operation
If forced-air solutions are added to automate air flow control, then user skill requirements are reduced, but the kettle must be modified with cut-outs
Solution Approach 1:
The plenum chamber serves as an external intermediary that interfaces with the kettle through its existing damper holes rather than requiring cut-outs. Air is drawn through the plenum and delivered to the kettle interior through the original damper hole openings, preserving the kettle's structural integrity while enabling automated control.
Solution Approach 2:
The plenum chamber is designed to work with the existing damper holes that serve dual purposes: air flow control and ash removal. By utilizing this existing opening for both functions, the system avoids requiring separate cut-outs in the kettle, maintaining ease of manufacture while enabling automated air flow control.
3Adaptability or versatility
If manual dampers are used for ash removal, then the system remains simple, but the user cannot selectively alternate between manual and auto modes
Solution Approach 1:
The system is designed to be dynamically adjustable between two operational modes: manual mode where users directly control dampers, and automated mode where a temperature-controlled fan manages air flow. The plenum chamber and fan system can be selectively activated or deactivated, allowing users to switch between control methodologies based on their preference or cooking requirements.
Solution Approach 2:
The air flow control system is segmented into independent functional components: manual dampers for ash removal and mode selection, and an automated fan system for temperature control. This segmentation allows each subsystem to operate independently or in combination, providing versatility while keeping individual components relatively simple.
4Ease of manufacture
If the plenum component is detachably mounted, then the grill can remain unmodified, but the connection between air flows and kettle interior must be established through existing holes
Solution Approach 1:
The existing damper holes in the kettle are utilized for multiple functions: serving as air flow passages from the plenum to the kettle interior, and as pathways for ash removal. This multi-functional use of existing openings simplifies the overall system design by eliminating the need for dedicated air flow openings while maintaining a relatively simple air flow path through the plenum.
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
Enables users to seamlessly switch between manual and auto-damper modes, improving air flow control and temperature management without altering the grill, while capturing ash efficiently, thus enhancing cooking performance and user experience.
Implementation Method 1
a forced air flow generated by a fan may also be provided into the plenum component
Implementation Method 2
The air control unit may further comprise a temperature sensor in electrical communication with an electronic controller configured to vary the speed of the fan
Data Source
AI summary
Exemplary embodiments of a system and method for bimodal air control in a kettle-style grill are configured to be detachably mounted to the exterior of a kettle-styled grill such as, but not limited to, a Weber® charcoal grill. When mounted to the kettle-styled grill, a plenum-like component directs air flows to the interior of the grill's kettle via the kettle's lower body damper holes. A manually adjustable intake damper in the plenum component allows, restricts, or prevents a drawn ambient air flow into the plenum component. Separately, a forced air flow generated by a fan may also be provided into the plenum component. Adjustment of the intake damper may also adjust damper blades inside the grill's kettle. Ash that falls out of the kettle's damper holes falls through the plenum component and is captured in an ash receptacle that is removably mounted to the plenum component.