Double-Walled Grill Structure for Fuel-Saving Heat Control
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Solution Overview
Problem
Kamado type grills suffer from being heavy and fragile, inefficient heat transfer, fixed fuel grate positions leading to uneven cooking, and poor air flow, which results in increased fuel consumption and difficulty in temperature control.
Innovation Solution
A grill design featuring a double-walled construction with key-shaped air intake slots, a movable fuel grate, and a double-walled deflector plate that can be supported by an annular retaining member, allowing for flexible cooking modes and improved air flow, enabling efficient direct and indirect cooking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If ceramic materials are used for the grill body and lid, then heat retention and fuel efficiency are improved, but the grill becomes heavy and fragile
Solution Approach 1:
The patent employs a composite construction combining ceramic inner wall with an outer shell, creating a hybrid structure that retains the thermal benefits of ceramic while reducing overall weight and fragility. The ceramic layer provides heat retention while the outer shell provides structural support, achieving a balance between thermal efficiency and mechanical properties.
2Device complexity
If a fixed fuel grate position is used, then the grill structure is simple, but cooking uniformity deteriorates for different cooking modes
Solution Approach 1:
The fuel grate is designed to be movable rather than fixed, allowing users to adjust its position vertically within the combustion chamber. This dynamic adjustment capability enables optimization of heat distribution for different cooking modes (direct grilling, indirect roasting, smoking), achieving uniform cooking results without requiring complex multiple grate systems.
3Ease of manufacture
If standard air intake slots are used, then manufacturing is simple, but heat transfer efficiency and air flow deteriorate
Solution Approach 1:
The air intake slots are designed with an asymmetric key-shaped geometry rather than simple circular or rectangular openings. This asymmetric design creates optimized flow patterns that enhance combustion air intake efficiency and improve heat transfer from the combustion zone to the cooking chamber, while still being manufacturable using standard techniques.
4Device complexity
If a single-walled construction is used, then manufacturing is simple, but temperature control and heat distribution deteriorate
Solution Approach 1:
The grill body is segmented into multiple walls (inner ceramic wall and outer shell) creating a multi-layered construction. This segmentation allows for better thermal management by creating insulating air gaps and enabling controlled heat distribution throughout the cooking chamber, improving temperature uniformity and control without excessive complexity.
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 design provides improved temperature control, reduced fuel consumption, and enhanced cooking quality by allowing for optimal placement of the fuel grate and deflector plate, ensuring efficient heat dispersion and air flow for both direct and indirect cooking.
Implementation Method 1
air goes into the side draft door 3, is heated by the coals and circulates to the top vent 4 for discharge
Implementation Method 2
The ceramic components are thought to aid in the slow cooking and/or smoking process by retaining heat
Implementation Method 3
the heat from the coals is supposed to be deflected by the deflector plate 9 and rise around the exterior recessed edges of the deflector plate 9 to cook the food by convection
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
A grill (20) comprising: a lid (22), the lid having a hollow plenum (42) formed between an inner wall (41) and an outer wall (40); an exterior grill body (50) having a bottom and a plurality of elongated key shaped air intake slots (28) radiating from the center of the bottom of the body; an interior grill body member (51) within the exterior grill body, the interior body member having an open top portion (54), an intermediate portion (55) adapted to support an annular retaining member (36) and an open bottom portion (53) adapted to support a fuel grate (32), the open bottom portion in fluid communication with the plurality of air intake slots and wherein a hollow space (47) is created between the sides of the interior grill body member and the exterior grill body member.