Abstract: A cart suitable for supporting a grill, including a grill bowl. The cart has two union members with curved channels for receiving tubular, U-shaped frame members. The union members may be in the form of two similar (but not necessarily identical) halves joined together to enclose the frame members. The tubular channels of the union members resist movement (such as twisting and tilting) in at least two directions. The union members lock the frame members in place with internal protrusions that fit into mating depressions or holes in the frame members. Extra rigidity is added to the cart by one or more side tables which are structural members as well as functional tables. The side tables thus serve as cross-members between two frame assemblies. The grill's lid can easily be tilted back to rest in place on lid supports underneath the bottom edge and contact points on the side tables.

Abstract: A portable barbecue cooking apparatus is provided, the apparatus comprising a cooking chamber comprising a topside opening and a fire bowl with opposing ends; at least two handles, each handle attached to opposing ends of the fire bowl; and at least two shelves, each shelf being pivotally attached to each of the handles, and each shelf being foldable inwardly towards the topside opening of the cooking chamber during a stowage position and extendable outwardly away from the topside opening of the cooking chamber during a usage position.

Abstract: A quick-connect fitting for connecting a burner tube to a barbecue grill. The quick-connect includes a female connector and a male connector. In one embodiment, the female connector is attached to the burner tube and the male connector is connected upstream of the fuel supply. The female connector has an inwardly directed protrusion while the male connector has a corresponding longitudinal entry portion and circumferential groove. In the first step of assembly, the female connector is mated with the male connector by aligning the protrusion with the entry portion and urging the connectors together. In the second step of assembly, the female connector is rotated relative to the male connector such that the protrusion enters the groove to effectively prevent relative axial movement between the connectors.

Abstract: The present invention is directed to a control knob bezel plate for a barbecue grill. The preferred bezel plate assembly of the present invention comprises a bezel plate, a control knob, a control panel, a gas control valve, and two anchors. The preferred bezel plate includes a raised annular portion which serves as a frame for the control knob. Both the preferred bezel plate and the control panel include two parallel slots which are adapted to engage with the anchors. The two parallel slots in the bezel plate are aligned generally transverse to the two parallel slots in the control panel. The bezel plate is connected to the control panel by means of the anchors which are configured to slide within the slots. In this manner, the bezel plate can be adjusted in two dimensions with respect to the panel.

Abstract: The present invention provides a support frame assembly for a firebox for a built-in gas barbecue grill assembly having a work structure. The support frame assembly has a first end substantially adjacent the firebox and a second end substantially adjacent a floor supporting the built-in grill assembly. In one embodiment the support assembly has a first mating member for supporting the firebox, and a second mating member for mating with the work structure to connect the support frame assembly to the work structure.

Abstract: Various embodiments of a gas valve and a sear-zone gas burner are described and claimed herein. One embodiment described herein relates to a cooking chamber with a cooking surface, which has at least two portions including a first portion and a second portion. The first and second portions of the cooking surface each have at least one heat source disposed underneath. The at least one heat source for each cooking surface in turn has a highest setting such that a first maximum heat output is provided to the first portion of the cooking surface when set at the highest setting and a second maximum heat output is provided to the second portion of the cooking surface when set at highest setting, wherein the second maximum heat output provided to the second portion is greater than the first maximum heat output provided to the first portion of the cooking surface.

Abstract: The inventions disclosed herein relate to frame assemblies for gas barbecue grills which incorporate structures for preventing a consumer from storing replacement fuel tanks on the grill, in order to minimize fire and tipping hazards. Because it is known that many consumers never install or even remove prior art tank blockers, the tank blocker of the present invention is adapted to serve as a function of the grill (in addition to the function of blocking a tank) or to support a component of the grill. The preferred embodiment of the tank blocker described herein is adapted to support a component of the grease management system, namely the grease drip pan. Consequently, it is believed that consumers will be forced to install or will be prevented from removing the tank blocker, lest the grease management system become inoperable (or function improperly), causing grease to spill onto the cart.

Abstract: Two main embodiments of a heat shield for a barbecue grill are disclosed herein. Both are designed to reduce the transfer of heat from the heated volume of the cooking chamber to the handle of the barbecue grill. The first embodiment mounts to the exterior of the cooking chamber and is disposed between the cooking chamber and the handle. The first embodiment is contoured to interrupt the convective flow of heated air away from the handle. The second embodiment mounts to the interior of the cooking chamber opposite the handle. The second embodiment rests adjacent the inside surface of the cooking chamber to form a partially or substantially closed volume that serves as an insulating barrier for the handle.

Abstract: In one embodiment, a barbecue grill assembly includes a cooking grate positioned in an upper portion of a cooking chamber, a heat and grease deflecting apparatus positioned in a lower portion of the cooking chamber, and a heat source positioned between the cooking grate and the heat and grease deflecting apparatus. The heat and grease deflecting apparatus not only reduces heat loss from the cooking chamber during the operation of the barbecue grill by slowing the travel of hot grease and ignited particles form the cooking grate to the grease collecting tray, but also reduces the occurrences of grease fires in the cooking chamber.

Abstract: A portable barbecue cooking apparatus is provided, the apparatus comprising a base; a fire bowl having a topside opening, and the fire bowl is mounted on the base, and the topside opening of the fire bowl is situated above the base; a grill situated within the fire bowl and is moveable within the fire bowl; and at least one shelf is pivotally attached to the base, and the shelf is foldable inwardly towards the topside opening of the fire bowl during a stowage position and extendable outwardly away from the topside opening of the fire bowl during a usage position.

Abstract: The inventions disclosed herein generally relate to isolating heat sensitive components from the heat source of a barbecue grill. In the preferred embodiment, ceramic bushings are used to isolate a glass-reinforced nylon grill stand from the cooking chamber of a barbecue grill. The bushing incorporates a beveled upper edge for engaging with lobes which downwardly depend from the cooking chamber. The bushing also incorporates a circular lower portion for engagement with an aperture in the grill stand. The bushing is locked into engagement with the cooking chamber using a threaded bolt and is locked into loose engagement with the grill stand using a spring clip. The combination of the beveled upper edge and the loose engagement with the grill stand allows the bushing to float with respect to both the grill stand and cooking chamber. As a result, manufacturing tolerance requirements can be relaxed.

Abstract: A retractable rotisserie driver which is used in connection with a barbecue grill is described and shown herein. In one embodiment, a retractable motor support apparatus is pivotably connected to a side shelf assembly of a barbecue grill, and is movable between a storage position, where the rotisserie motor is substantially enclosed by the side shelf assembly, and a usage position, where the motor is generally aligned for engagement with a rotisserie spit. The support apparatus includes a first wall and a second wall which are adjacent and generally transverse to one another. The first wall is configured to be aligned generally flush with an upper surface of the side shelf assembly when the support apparatus is moved to the storage position to increase the usable work area on the shelf. The second wall is provided with a power cord holder for compactly holding the motor's power cord when the apparatus is moved to the storage position.

Abstract: Various embodiments of a collapsible charcoal starter are shown, described and claimed herein. In one embodiment, the charcoal starter includes six panels being hingedly interconnected to form a closed loop. The charcoal starter is configured to have an expanded position and a collapsed position, and can be moved therebetween without any disassembly of the charcoal starter. In the expanded position, the six panels form four walls or boundaries, whereby the walls define a volume for receiving charcoal briquettes. In the collapsed position, the six panels are oriented generally parallel. Moreover, four of the panels are sandwiched in between the two remaining panels. In this manner, the depth of the charcoal starter can be significantly reduced as compared to the expanded position, while the width is substantially the same in both the collapsed and expanded positions.

Abstract: The present invention provides a shelf 300 for a barbecue grill frame assembly 302 of a barbecue grill. The shelf 300 has a perimeter that is cooperatively dimensioned with the interior space of the barbecue grill frame assembly 302 such that the shelf 300 is positioned within the interior space. The securing member 308 secures the shelf 300 to the barbecue grill frame assembly 302 in a first position. The securing member 308 adjusts to a second position to detach the shelf 300 from the barbecue grill frame assembly 302.

Abstract: The present invention provides a cooking grate for use within a barbecue grill assembly. The cooking grate is located within a cooking chamber of the barbecue grill and adjacent the heat source. The cooking grate has an energy receptor portion and cooking members depending therefrom. The energy reception portion of the cooking grate receives energy from the heat source. The energy received by the energy reception portion of the cooking grate is then conducted through the cooking grate to cooking members to cook food thereon. The present invention also provides a grease control structure for the grate to assist in directing the flow of grease away from the burners.

Abstract: A cart suitable for supporting a grill, including a firebox. The cart has four panels each of which has all four of its edges bent to form a flange that provides structural rigidity and a connection feature for facilitating the assembly of the cart. Two opposing side panels are carried by and preferably welded to a respective side frame. The side frames are joined by upper crossbars, one at the front of the cart and a second at the rear of the cart. A bottom panel fits into and is carried by troughs formed by upturned lips on the lower edges of the side panels. The structural integrity and racking strength of the cart is enhanced by the attachment of a rear panels, which has a lower lip that locks into engagement with the rear edge of the bottom panel. The top edge of the rear panel is fastened to the rear upper crossbar to complete the basic structure of the cart. Hooks welded to the side frames allow easy and secure attachment of side and front attachments to the cart.

Abstract: 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.