Method of grilling
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Solution Overview
Problem
Solid wood charcoal, considered an undesirable byproduct due to its brittleness and small, high-fixed-carbon outer portions, is not effectively utilized in traditional grilling apparatuses, leading to inefficiencies and flavor issues.
Innovation Solution
A fuel support system using a substantially flat, embossed metal screen or louvered perforated metal grid is introduced to support and maintain airflow for solid fuel, allowing consistent combustion and enabling uninterrupted refueling without lifting the food grate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If small chipped pieces of solid wood charcoal are used as fuel, then high heat generation and fast cooking are achieved, but the small pieces fall through traditional charcoal support structures
Solution Approach 1:
The support structure is segmented into multiple levels with varying mesh sizes. The first level has larger openings to support larger charcoal pieces, while the second level has smaller openings to support and retain the smaller chipped charcoal pieces, preventing them from falling through while still allowing airflow for combustion.
Solution Approach 2:
Different regions of the support structure have different properties - the first level is optimized for larger fuel pieces with larger openings, while the second level is optimized for smaller chipped pieces with smaller openings. This local differentiation allows each level to perform its specific function effectively.
2Reliability
If traditional charcoal support structures are used, then fuel retention is maintained, but airflow is restricted and combustion efficiency decreases
Solution Approach 1:
The support structure is divided into two levels with different mesh characteristics. The first level provides structural support with larger openings, while the second level provides fine retention with smaller openings. This segmentation allows airflow to pass through both levels efficiently while still retaining the small chipped charcoal pieces on the second level.
Solution Approach 2:
The second level of the support structure acts as an intermediary between the small chipped charcoal pieces and the airflow. It allows the small pieces to be retained while maintaining sufficient airflow passage, mediating between the conflicting requirements of fuel retention and combustion efficiency.
3Power
If solid wood charcoal is used instead of charcoal briquettes, then higher heat and neutral/wood smoke flavor are achieved, but cooking time increases and heat stability decreases
Solution Approach 1:
The invention merges the advantages of both large charcoal lumps and small chipped pieces by supporting both sizes on the multi-level structure. The larger pieces provide long-lasting heat, while the smaller chipped pieces burn hotter and faster, creating a combined fuel system that achieves both high heat intensity and extended cooking duration.
Solution Approach 2:
The invention changes the physical parameters of the fuel system by using a distribution of particle sizes rather than a single size. This parameter change allows different burn rates to coexist, with smaller pieces providing initial high heat and larger pieces sustaining the combustion over longer periods.
4Ease of operation
If the food grate is lifted to add fuel during grilling, then refueling is possible, but the grilling process is interrupted and heat loss occurs
Solution Approach 1:
The support structure is segmented into two levels, with the second level specifically designed to receive and retain small chipped charcoal pieces. This segmentation allows fuel to be added through the food grate opening without needing to lift the grate, as the small pieces can be deposited directly onto the second level where they will be retained and ignited.
Solution Approach 2:
The multi-level support structure with its specific mesh configuration enables self-service refueling - the structure itself guides and retains the small chipped charcoal pieces in the correct position for combustion without requiring manual intervention to lift or adjust the food grate.
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 efficient, high-heat cooking with natural wood charcoal, providing faster cooking times, enhanced flavor, and improved moisture retention without interrupting the grilling process.
Implementation Method 1
The solid fuel is ignited to generate heat from combustion of the solid fuel
Implementation Method 2
A fuel support system using a substantially flat, embossed metal screen or louvered perforated metal grid is introduced to support and maintain airflow for solid fuel
Data Source
AI summary
A method of grilling on a grill includes installing a fuel support for supporting solid fuel inside the grill, wherein the fuel support comprises a substantially flat, embossed, non-expanded formed metal screen. The grill is of a type intended for cooking or grilling food solely by combusting ignitable gas. A food-supporting grill-grate is placed over the support for solid fuel and solid fuel added onto the fuel support underlying the food-supporting grill grate. The solid fuel is ignited to generate heat from combustion of the solid fuel. Food is placed on the food-supporting grill grate; cooked using the heat from the combustion of the solid fuel.